oor TENTATIVE GUIDELINES FOR CEMENT CONCRETE MI DESIGN FOR PAVEMENTS (FOR NON-AIR ENTRAINED AND: CONTINUOUSLY GRADED CONCRETE) (First Revision) Published by The Indian Roads Congress, Jamnagar House, Shabjaban Road, New Delhi-110011 1976 gh Price Rew (plus Packing & Postage)IRC: 44-1976 TENTATIVE GUIDELINES FOR CEMENT CONCRETE MIX DESIGN FOR PAVEMENTS (For Non-Aiv-Enivained and Continuously Graded Concéete) 1. INTRODUCTION Ll. The problem of designing a mix fora given purpose can be equated to obtaining a concrete of the required strength, durability and workability at lowest cost, by a suitable choice of materials and the proportions in which these may be combined. In doing so, the relative importance of the different factors that influence the quality of concrete should be understood. The strength of concrete depends upon many factors,.e.g. quality and quantity af cement, water and aggregates; batching; mixing; placing; compaction; curing; etc, The water-cement ratio is the principal controlling factor for strength of concrete, Since the quantity of water controls the workability for given materials, different workabilities can be obtained by changing the water content but keeping the water-cement ratio and hence strength the same. The choice of proportions is governed by the satisfactory condition of concrete in two states, namely, the plastic and the hardened. state. If the condition of the plastic concrete is not satisfactory, a fully compacted, dense and/or uniform concrete can not be obtained and its structural value will be-greatly reduced. The property of workability, therefore, becomes of vital importance, 1.2. Against this background, it is not possible to lay down any mathematical formulae that would enable us to obtain ihe best possible mix, The same holds true for the charts, tables or curves presented by Various organisations. These: provide only a means of arciving-at a reasonably satisizetory choice of proportions. Since the aggregates may have widely differing: characteristics, and the cement strength may also vary considerably from factory 10 factory; it is always desirable to get the mix designed in laboratory with the mate- rials proposed to he utilised in the work, Moreover, depending on process and control variances in the field,.one should also be prepa- red to make final adjustments in the mix.al the site, 1.3. These Guidelines da not debar adoption af any other uecepted method of mix design, 1.4. The Guidelines were prepared by the Cement Concrete Road Surfacing Committee (personnel given below), These were theni 4g 1976 scessed and approved by the Specifications and Standards Com- lee in their meeting held on the 18th and [9th November, 1971. ter, these were finally approved by the Executive Committée in ir meeting held on the 26th and 27th April, 1972and by the Coun- in their 78th meeting held at Nainital on the 10th July, 1972. PERSONNEL OF Tn Cemmnr ConceeTe ROAD, SumFacinG ComMInrEs 1. .K.K. Nambiar — Convenor 2, Dr. RK Ghosh — Menvber-Secverary Members “3. M_M Bose 1: 4. BUR. Chopiia 12, 3. Br, MP. Dhir ie 6& CLS. tyengar 14,8 7: MD. Kale 15, 8, Dr SK. Khanna 1G ALG, a 9, Col OP. Narula Vi. Br. H.C. Visvesvaraya 10, NL, Patel 1.4. The Guidlines were later amended by thé Cemeént Con- ste Road Surficing Committee In their meeting held at New ‘Iki on the 26th November 1974 and then processed ‘by the ecifications and Standards Committee, This publication contains ¢ revised Guidelines as finally approved for the se of the mem- rs_of the profession. 2) GUIDE ANES 2.1. Basic Bata for Mix Design 2.1, The following are required to be specified for design of cement conerete tm (a) Mitimum compressive strength/fexural strength of con- erete in the field al 28-davs. (b) Maximum size of aperegate tobe used and its type. (c) Degree ofworkability, rélated to the compaction equip- ment available. (d) Degree of quality control expected tobe exercised—very good, good.ar fait—and permissible coefficient of variation or standard dévi:tion, (e) Accepted tolerance level. 21.2, The specific stipulations in respect of the above items ould conform to requirements laid down ih IRC: 15-1970*, if the struction of ConcreteTRE: 44-1976 work pertains to concrete pavement. For other works, stipulations of relevant specifications may be consulted. 2.2. ‘Tests for Materials For design of mix, it will be necessary to carry out the following ‘tesis on materials: (a) Cement; (i) Compressive strength ofcement at 7 days (1S: 269-1967"). (iW) Specific gravity of cerient (15: 269-1967*) (Assume a yalue of 3.15, if test isnot pos- sible}. (b) Aggregate: (i) Specific pravity (182386 Part I1-19637), (ii) Per cept water absorption (1S: 2386 Part 111-1963), (iil) Sieve-analysis (1S: 2386 Part 1-1963*+), 2.3. Selection of Aggregate Grading 23.1, The aggregate grading should conform to TS:383 — 1970, Tnsofaras the grading of coarse agerepates is concerned, there are to specific requirements laid down in the above Indian Standard. How- ever, to achieve good results with normal aperegaies at comparative ease. itis advisable to have suitable grading zones for coarse: “ppregates for the purpose of guidance, as exist in many international standards such a& British, German, American, Russian-ete. Of course, these grading should in no sense be regarded as “ideal gradings”, and it inay sometimes be necessary to make final adjustments in the gradings at site, though such adjustments generally involve only minor alterations in the ratio of fine to coarse uggrepate. The coarse agercgate gradings suggtsted by the Transport and Read Research Laboratary, U.K,,ate piven in Tablet. Out of the'three yones in Table 1, zone B is considered more suitable than zones A and C, sOrdinary, Rapid Hardening and Low Heat Partlund Cement. 4-Snecilic Gravity, Density, Voids, Absorption and Bulking. + | Particle Size-and Shape, @Couiwe and Fine Aggregates from Natural Sourees for Concrete, 3IRC: 44-1976 Taste 1: Sucorstrp Coarse AcarecArr Grapinas Per cent passing LS. sieve sizes (mm) Nominal maxim | Zane | _ ee eS sine of aggrcgate (mm) | 40 | 20 ru ans | A i100 ded | 6-18 0. 40 B 100 AD.ds. 18-20 De th | c 160 45-53 20-25) a A 100) LK) abo a 20 u 100 100 31-40 0 ra 100 | 100 ee ae ee Note: Allowance for oversize in the nominal maximuin size of aggregates stall be linvited to S per cent. 2.3.2. Sometimes it may be necessary to combine two or more coarse agerceate fractions to oblain & prading approximating to the one required. Among the several methods available for this purpose the trial method is simple and. convenient to apply. The same is described in dumexure f. 2.4, Design Strength for Concrete 2.4.1. In order to get the specified minimum compressive stren- gih in the field, the concrete mix has to be designed tor somewhat higher average compressive strength depending on the degree of qua- lity control (denoted through permissible coefficient of variation or standard deviation) and the tolerance level. The average atrength(S) at 28 days for whieh the mix might be designed isgiven by the equation: where S— minimum compressive strength (kg/sq- em.) in the field at 28 days. "4 i = factor (dimensionless) depending on specified tolerance jevel,-and cocfhicient of variation (per cent) specified, 2s The yalues of ¢ in equation (1) for different tolerance levels are given in Table 2.TRC + 44-1976 TABLE? : VALUES or TOLERANCE Factor Ww Ss | Tolerance level No. of samples 7 7 Jin 10 | bin 5 | Lis] finde | Lin 109 | { iar | 10 1.65 181 293 2.76 20 | 32 1.38 1.72 2,09 2.53 30 | ae 14 170 2.04 2.46 c= (Infinite) | vee | a8 | Led 1:96 233 Notes In case OF & major Gonereting job, where large number of Samples will be tested, it would be appropriate to adopt a toleranee factor corresponding to: Infiniic number of samples. 2.4.3. In Table 3.are worked out the average desien strengths for concrete for different combinations of specified minimum stren- gth, tolerince level and coeffictent of variation corresponding to an infinite number of samples. On smaller jobswhere only a finite number of sainples will be tested, the corresponding average design strengths can be obtained by application of appropriate tolerance factors from Table 2 in equation (1), TABLE 3; AVERAGE DESIGN STRENGTHS FOR CONCRETE FOR DIFFERENT DEGREES OF QuaLITy CONTROL AND TOLERANCE LEVELS OO Degree of qua- | Minimum specified concrete strength at 28 days (kgfeis) lity control z 200 Tis 350 gia le |= e(a k a |e (9 Fi 2 |3 & SG ee ld Be |e fe Bloc itea| = @ |e lee 3 Bee| o a) Ye lb es & |62 legs] € & | é3 282 Very good Lin 13) 10 235 |i in 15) jn 20} 7 | 400 Good tin 250 [1 in 15} | in 15} 10 | 415 Pair Vin 10] 20 i Beg bees lio Notes; 1. Tho average design strengths given in the lable are for 1ole tance factors corresponding to infinite number of samples as aiven in Table 2. 2s Accordingite IRC; 15-1970, the tolerance level and permis- sible coellicient of varintion for paving concrete are 1 in 15 and 10 per cent respectively. 3IRC 244-1976 2,5. Selection of Water-Cement Ratio 9.5.1. As the cement strength may vary widely from factory to factory, itis not possible to have asinglé curve of correlation between water-cement ratioand compressive strength of concrete. A set of such curves with 7-days compressive strength of cement the third parameter is given in Fig 1 for purpose of guidance, Thes curves are the same as those under Appendix A of IS: 456-1964* but drawn in different'form, From Fig.l, for a particular cement S00 ™E 5 = 400 al z $00 7-0: Compyeréive Strength dt cement Uylene® ‘ayia THIew Reareaed ‘ Gi] 200 3 é 3 Z| boo al al ol ° O4 O8 O08 KO WATER = CEMENT RA Ww WT. Fig, 1, Design curve for cement concrete mixes in relation to F-days compressive strength of cement the compressive strength at 7days, of which is known, the water- cement ratio for the average Compressive strength (S of equation 1). of conerete for which the mix is to be designed can be selected. Where design is based _on flexural strength of concrete, ihe approxi- mate relationship between compressive and flexural strength of concrete may be cbtained from Anexure Ty * Code of Practice for Plain and Reinfored'Concrete &Scott W, APPA, Mia ‘Mtiure son Kinky, Coppa: 1 Pee, Ded. Baraca Siiion Dds Sew Delte-tinogy. TRC: 44-1975, 2.6, Selection of Water and Sand Content 2.6.1, To design the mix, water and sand contents per unit volume of concrete are to be-estimated in the first instance and this depends upon the maximum sizeof agereeate, moisture content in the aggregate, workability, type of aggrépare, cte. The values. of water and sand contents for different maximum sizes of crushed (angular) ageregate are given in Table 4 for a particular water-cement ratia of 0.50, slump of 25 mm-and fineness modulus of 2.60 for sand. TABLE 4! APPROXIMATE SAND AND WATER CONTENTS PER Curie Mire or CONCRETE (FOR W/c 0.50, SLuMP = 25 wi AND SAND Fim. = 2.60) ] Maximum size of Wiiter'eontent oy saturated Send in per cent aggregate (mm) surface dey, Basis: per cusn, of Local agar, by of eonerete (kg)! abs, Vol. (54) 80mm ia") 28.0 40 ium (18°) 325 25 mm (17) 38.0 2 mm") 40.0 “Note: By saturated surface dey condition, it is understood that the aggregates are fully ‘saturated but there is no fiee moisture present at the surface, Ifthe aggregates dre‘not in this condition, water to be-added in the mixer shall be required to be mercased or decreased 1@ make up the difference depending on whether the aggregates are dry or wel. 2.6.2, For other conditions of water-cemenl. ratio, slump and. fineness modulus.of sand,and for rounded aggregate, certain adjust- ments in the water and sand contents are necessary. which are given in Table 5, Tasce 5: ApsUSTMENT OF VALUES IN WATER AND SAND. CONTENTS FOR OTHER CONDITIONS SS ee er —— anges in conditions stipulated a in Tables Water conteat Sand cantent Each 0.09 inerease or decrease 1 m £195 im w/e ratio. Each 01 increase oF decresse in FM, of sand ett 20.5% Each 25 nin increase or decrease ; r slump 4% 0 Rounded aggregate —15 lire — 10 8%, (ad hoc) 7IRC : 44-1976 2.7. Determination of Aggresate-Coment Raila Knowing the water-cement falio, water requirement, cement content (fram Water-cement ratio.and water requirement) and proportion of sand in total aggregate by absolute volume, thé sand and course aggregate contents per unit yolume of concrete may be calculated separately from vs (we + 4 - a ) we (2) and rm (ie =< ip) hr reve (3) where, ¥ = absolute volume af’ the wet mix = ross volume (1 cu, in.) minus the-volume ofcntrapped aly (see elanse 2.7.2) Wr = we. of water in kg (=litre) per Cain, of concrete wl. of cement.in kg per cuum, of conerete we. of sand in ke per cu,m, of conerete wh. of coarse aggregate in kg per cu.m. of concrete P= proportion (in decimal fraction)’ ef sand in total agere- gite determined on the basis of absolute volume, and S.,5:,8s, = specific gravities of'cement, sand and coarse aggregate: respectively, The quantities of sand, coarse ageregate, cement and water required to determine the mix proportions ofa concrete mix are thus known, ee Approximate amounts of enteapped air in the wet con- crete mix for different maximum sizes of ageregate are indicated in Table 6. TABLE 6: APPROXIMATE AMOUNTS OF ENTRAPPED AIK IN NON-Aik-ENTRAINED CONCRETE Maximum size 10 1-20 2540 308) of aggregate (mm) Enirapped. air 3 iy 2 Us 10 0 On a {approximate) (% by i volume) t Volume ofentta- 0.030 0.625 0.020 D10IS 0.010" 0.005 0003-0.002 pped air per cum. gross volume of conerete (ciim.) ————— eee 8IRE : 44.1976 2.8, Trial Mix With the above mix proportions, the mix.is prepared and the workability measured. Tfthe workability is diferent from the stipu- lated yalue (workwbility is usually ‘very low’ for paving concrete), the water content may be adjusted in accordance with Table 5 for increasing or decreasing the slump, The mix proportions are there- after recalculated with adjusted water content.as per equations (2) and (3) for three water-cement ratios comprising the pre-selected water-cement ratio and two other values, one higher and the other lower than the pre-selected ratio by 0,05. Since the design adopted is on absolute volume basis, the yield for the three cases will remain the same, The strength of concrete (compressive and flexural streng- ths in case of paving conercle and compressive strength for othér structural conéretes) with the three water-cement ratios is then determined jn accordance with IS; 516-1969+. The values of strength obtained are then plotted against water-cement ratios and the appropriate water-Coment ratio chosen from the plot for the required strength, The final mix proportions are then recalculated for this water-cement ratio, other parameters rémaining the same. Notes Incase of pavitig concrete the edrrelition betyreen (lexural and com- pressive. sirengih may: be established, if quality comttrol in ihe field i§ proposed 10 be exercised on the basis of compressive strength only: 2.9, Worked-oul Example on Mix Design An example illustrating the mix design procedure is worked out in Annexure HHT. ++ Methoxls of Tost for Strength of Conerete 2IRC +-44-1976 Annexure f TRIAL METHOD TOR COMBINING AGGREGATES OF DIFFERENT GRADINGS. ‘The individual sieve analyses for the diflerent aggregate: fractions ‘are. first arranged in a tabular form and the: optimum percentage ef each tor combination worked out on trial and error basis. This 1s done by visual inspec- tion of the individual analyses and comparison between stipulated grading and combined grading on Iria. A few trials may he necessary. A typical example tabular form is given below to illustrate. ihe procedure using two different 6 Of coarse aggregate. EXAMPLE : COMBINATION OF TO COARSE AGGREGATE FRACTIONS Percent of different fractions Per cent passing ench sieve ist trial | 2nd trial Grading of agere- | Stipu- | 1 | 1 | €o 1 | at | Com: gate fmetions | laieé | 70%] 30% | bined | 68% | 32% | bined as available | com. 100% 100% bined prading| 10TRC: 44-1976 Annexure IT URAL AND COMPRESSIVE 1 Guidanee Only) CORRELATION BETWEEN FT) RENGTH OF CONCR = eS SHED! STONE AL GRAVEL s 28-DAY FLEXURAL STRENGTH-Kg/cm™ » 8 2 3 & 20-DAY COMPRESSIVE STRENGTH -KG/ cm orao O48 MATER-CEMENT RATIO (BY WT) (For “very low to “low! workability corresponding $02 Glump 0-25 mm)TRG 3 44-1976 Aunexttre HT WORKED-OUT EXAMPLE FOR CEMENT CONCRETE MIX DESIGN Ay Design Stipulations : 1) Minimom compressive strength required in the Feld at 28 days : 280 ka/em* 2) Maxinuiny size of ageregater 40 mm (angular aggregate) 3) Degree of Warkability + 25 mm shimp 4) Degree of quality control : good (co-elliciont of variation 10%) 5) Accepted tolerance level: 1 in 15 6) Type ef job: Major work involving testing of a large number of samples, ic, t=1.50 B) Test Data for Malerials : 1) Compressive strength of cement with single-sized siandard sand-at Tdays 210 kefem® 2) Specific. gravity of cement : 3,15 3} Specific gravity of beth coarse aggregate and fine aggregate: 2.65 4) Water-absorption: i) Coarse aggregate > 04% ) Fine aggregate : 0.6%, 3) Free (surface) moisture z i) Coarse aggregate ; nil (absorbed moisture also nily if) Fine aggregate : 29, 6) Sieve analysis: ee Coarse aggregate Fine aggregate fractions: Ls. Pet cent passing Per cent) Cumulative | Fine- sieve passing | percent | ness size reiained modulus (mm) Fraction | Fraction 1 i 40 100 100 ‘475mm | 100 0 20 14 100 236mm | 98 | 2 10) | 8 34 Li8nm | 90 10 | 2,48. ae: || 2 6 600 $0 \] 50 12IRC 7 44:1976 (C) Combination of Coarse Aggregate Fractions + SS i Rer-cent passing (individeal) | Per cent passing (combined grading) size (mm) Grading of aggre | Combined Ast trial 2nd trial Batedvailable | grading fequired | —7—— Mable} ) of | a | eamb- IComb- 1 i 70% | 30% | “ined ined aradl- srad- ing ing 40 | 100 100 100 | 70.0 | 30.0 | 100.0 100.0 20 14 100. 40. 98 | 30.0 | 39.8 ans lo 8 a4 18 5.6 | 002°] 15.8 16.3 495 2 6 0 la] te) 32 33 Aperegates may, therefore, be cambined ‘in the proportion 68:32 (by weight), E) Selection of Water-Cement Rat From Fig, 1, using curve £ cerresponding to.7 days cement strength of 210 ke/em!. for design strength of.conerete of 330 kg/m, the water-coment ratio required =0.43, FE) Seb jon of Water and Sand Content From Table 4, for water-cement ratio of 0.50, slimp of 25 mm, F-M, of sand of 2.00 and angular aggregate, of 40 mm taximum Sige, water content per cum, of concrete=175 kg and sand content as per cent (of total aggregate by absolute volume=33.5 per cent, " For changes in-the values of water-cement: ratio; fineness moduluy 13TRC + 44-1976 ofsand and slump, the adjustoaents required inthemix are t Changes in condition Adjustment required in Water content Sand content (ea) (%) (i) decrease in aw, 3 030-04, a 4 0 —0.6 Gi) Slump (25mm—25im)=0 0 | 0 Total o 20%. ——— ee Therefore, required water content per’ cui, ofconcrete=175 kg ant sand content as percent of total aggregate by absolute volun =(33,5 2.00% 515%, (G) Determination of Cement Content: ‘Water-cement ratio= 0.43, but W175 ke (from step Fy; or 178 =a26 0.43. A C=A0T ke (A) Determination of Aggrcgate From Table 6, for the specified maximum size of dagregate of 40 ri’ the amount of entrapped airin the wet concrete is 1 per ‘cel ‘Taking this factor into account and applying equation 2, ad 5 I 099 cum= (195 535+ gare) ees) Toe 72S hes ‘ement Ratio: s= Applying equation 3, 0.99 ct.in= (teh 0.685 * 2 A= DS ‘The mix proport ng are therefore t ; Water Cement Sand | | Goarsé dgpregate Total tigeregal, W5ike 407 ke 572.5 ker 1244.9 kp 1817.4 ke or, O43" ¢ qT i Lar ; 306 4.47 +. Aggregaté—cement ratio= 4.47 + 1 14IRC: 44-1976 (2) Actual Quantities Required for the- Mix per Hay of Cement: The mix 5-043 (1,413.06 (by wt) 1, Cement = 50 kg 2, Asgregate=(witboar moisture adjustment) (i) Fine aggrepato= 50x 141 70.5 ke (ii) Coarse ageregate = 152.0 kg (a) Fraction 1 (68%) = 104.0 ke (b) Fraction I 2%) = 49.0 ke 9, Water () For watercemént fatio of 42/water required — 21.5 Hire (ii) Extra’ water to be added for absorption in case of coarse hgprerate, at 0.4% by woight = 0.4% of 153.0=0.61 lire (iii) Water to be deducted for free moisture present in fine aggregate, at 28, by weight = 2% af 70,S—141 litre (iv) Actual quantity of Water to be added =21.5 4,61 —1.41 20.70 litre 4. Actual quantity of fine aggregate required afier-allowing for weight of free moisture = 70:5 + 141 = 71.91 ke. 5, Actual quantity of coarse agercgale required {i) Braction [= (104,00—0.42) ke = 103.58 ke (i) Fraction [C= (49.00-0.19) ke = 48:81 kg _ Therefore the actual quantities of different constituents required for the mix are: Water = 20,96 fitre Cement = 0,00 kg Fine agercyate = 71.91 ke Coarse aggregate Fraction 1 = 103,58 ke Fraction I = 48,81 ke 15