CHAPTER – 3

METHODOLOGY

3.0 METHODOLOGY:

The work methodology of the present thesis work contains collection

of raw materials, determining the physical properties of the collected
materials and confirming the test results to the standard values
mentioned in the relevant codes. Further, determining the proper mix
design by using obtained physical properties. With different trial mix
designs desired mix proportion is determined and further work was
continued using those proportions.

Few initial tests were conducted on the raw materials to determine the
their physical properties. based on these properties a suitable design
mix of required target strength is designed and tested for fresh and
hardened concrete. alternation are made to trail mixes so as to get
the final mix which should satisfy the EFNARC guidelines.

The finalized design-mix is tabulated. concrete cubes of

150x150x150mm and cylinders of 150x300mm will be casted and
their results are labeled.

3.1 COLLECTIONS OF MATERIALS

3.1.1 CEMENT The cement of OPC 53 is used in project of ultratech-

cement.

3.1.2. FINE AGGREGATE The river used for our investigations is

collected form SRIKAKULLAM of which is conforming to Zone III as per
Indian Specification 383-1970 codal provisions.

3.1.3 COARSE AGGREGATE The coarse aggregate of max10mm size

with an angular shape which is well graded.

3.1.4 MINERAL ADMIXTURES Fly ash, GGBS and silica fume were
used as mineral admixtures as partial replacement of cement.

3.1.5 CHEMICAL ADMIXTURES Fosroc (super plasticizer) and

Glenium stream 2 (VMA) are used.
3.2 DETERMINING THE PHYSICAL PROPERTIES OF MATERIALS:

3.2.1 CEMENT

The cement, used for this present study ultratech-cement (OPC 53)
grade cement conforming all conditions of IS 8112-1989.It is most
recently manufactured, is of uniform color and also free of lumps.
The physical property of the cement is determined considering codal
provisions. Fineness of cement, normal consistency, specific gravity,
setting time, and compressive strength of cement, is determined and
are shown below.

3.2.2 PHYSICAL TESTS OF CEMENTS

The following are usually conducted in the laboratory:

 Fineness Test
 Specific Gravity
 Standard Consistency Test
 Initial Setting Time & Final Setting Time
 Compressive Strength Test

3.2.2.1 Fineness Test

The fineness of cement has an important bearing on

the rate of hydration and, rate of gain of strength, evolution of heat.
Finer cement offers greater surface area. Fineness of cement is tested
by Sieving

Procedure

 Take 100 grams of cement on a standard sieve of size 90µ.

 Break down the air – set lumps and sieve it and then
weigh it.
 This weight shall not exceed 10% for ordinary cement.
 Fig 3.1 90µ IS SIEVE

observations

weight of cement retained w1=

weight of sample w2 =

calculations
fineness of cement = w2/w1 x 100

3.2.2.2 Specific Gravity of Cement

The specific gravity of the cement is the ratio of the weight of a

given volume of cement to the weight of an equal volume of water.
It is mere number and it denotes how many times a substance is
heavy as water.

To find the specific gravity of cement, it is required to find the

weight of a certain volume of cement to the weight an equal volume
of water.

Fig 3.2 DENSITY BOTTLE

Procedure

1. Take a sample of cement approximately 25 grams (W1).

2. Fill the flask with kerosene and record the weight as
the weight of the flask filled with kerosene (W2).
3. Place the sample of cement using funnel into the flask
and fill it with kerosene up to 90% of the pycnometer
capacity
4. Shake, roll and invert the flask manually until no of
bubbles remain.
5. Fill the flask with kerosene to the calibration line then
record the weight of pycnometer filled with cement and
kerosene (W3).
6. Empty, clean and dry the flask and then weight the
flask filled with water (W4).
7. Weight the empty flask (W5).

observations

weight of density bottle W1 = gms

weight of density bottle+ 1/3rd volume of cement W2 = gms

weight of density bottle+ 1/3rd volume of cement

+kerosene W3 = gms

weight of density bottle + weight of water W4 = gms

calculations

specific gravity of cement = w2-w1

( (w2-w1)-( w2-w1) )x0.79

3.2.2.3 Standard Consistency Test

 The standard consistency is also known as Normal

Consistency.
 The standard consistency of a cement is determined by Vicat
Apparatus.
 The standard consistency of a cement paste is defined as that
consistency which will permit a Vicat plunger having 10mm
and 50mm length to penetrate to a depth of 33 – 35 mm from
the top of the mould.

Fig 3.2 Vicat’s apparatus

Procedure

1. Take about 400 grams of cement & water of 24% by weight

of cement.
2. Fill it in Vicat’s mould within 3-5 min.
3. After filling, shake the mould to expel air.
4. A standard plunger, 10mm diameter, 50mm long is
attached and brought down to touch the surface of the
paste and quickly released.
5. Note the reading according to the depth of penetration of
the plunger.
6. Conduct tails continuously by taking different water
cement ratios till the plunger penetrates for a depth of 33 -
35mm from top.
7. This particular percentage is known as percentage of water
required to produce cement paste of standard consistency.
8. This is usually denote by “P”.
3.2.2.4 Initial Setting Time & Final Setting Time

The time elapsed between the moment that the water is added to
the cement, tot the time that the paste starts losing its plasticity.
Normally a minimum of 30min has maintained for mixing & handling
operations. It should be less than 30 min. This process is called as
Initial Setting Time.

The time elapsed between the moment the water is added to the
cement, and the time when the paste completely losses its plasticity
and has attained sufficient firmness to resist certain definite pressure.
It should not exceed 10hours. So that it is avoided from least
vulnerable to damages from external activities. This process is called
Final Setting Time

Fig 3.3: Instrument for initial and final setting time

Procedure

1. Prepare a neat cement paste by gauging 300 grams of

cement with 0.85 times the water required to give a paste of
standard consistency.
2. Potable or distilled water shall be used in preparing the
paste.
 3. The paste shall be gauged in the manner and under the
conditions prescribed in determination of consistency of
standard cement paste.
4. Start a stop – watch at the instant when water is added to
the cement.
5. Fill the mould with the cement paste gauged as above the
moud resting on nonporous plate.
6. Fill the mould completely and smooth off the paste making
it level with the top of the mould.
7. The cement block thus prepared in the mould is the test
block.

Determination of Initial Setting Time

1. Place the test blocks confined in the mould and rest it on

the non – porous plate, under the rod bearing initial
setting needle, lower the needle gently in contact with the
surface of the test block and quickly release, allowing it to
penetrate into the test block.
2. In the beginning, the needle will completely pierce the test
block.
3. Repeat this procedure until, the needle when brought in
contact with the test block and released as described
above, fails to pierce the block to a point 5 to 7mm
measured from the bottom of the mould shall be the initial
setting time.

Determination of Final Setting Time

1. Replace the needle of the vicat apparatus by the needle with

an annular attachment.
2. The cement shall be considered as finally set when, upon
applying the needle gently to the surface of the test block,
the needle makes an impression there on, while the
attachment fails to do so.
3. The period elapsed between the time when water is added to
the cement and the time at which the needle makes an
impression on the surface of the test block while the
attachment fails to do so shall be the final setting time.
3.2.2.5 Compressive Strength Test

Compressive strength is the basic data required for mix design. By

this test the quality and quantity can be controlled and the degree
of adulteration can be checked.

Test Procedure:

1. The test specimens are 70.6 mm cubes having face area of

about 5000 sq. mm.
2. Large size specimen cubes cannot be made since cement
shrinks and cracks may develop.
3. The temperature of water and test room should be 27°± 2°C.
A mixture of cement and standard sand in the proportion 1:3
by weight is mixed dry with a trowel for one minute and then
with water until the mixture is of uniform colour.
4. Three specimen cubes are prepared and the material for each
cube is mixed separately.
5. The quantities of cement, standard sand and water are 185
g, 555 g and (P/4) + 3.5, respectively where P = percentage of
water required to produce a paste of standard consistency.
6. The mould is filled completely with the cement paste and is
placed on the vibration table.
7. Vibrations are imparted for about 2 minutes at a speed of
12000±400 per minute.
8. The cubes are then removed from the moulds and
submerged in clean fresh water and are taken out just prior
to testing in a compression testing machine.
9. Compressive strength is taken to be the average of the
results of the three cubes.
10. The load is applied starting from zero at a rate of 35 N/sq
mm/minute.
11. The compressive strength is calculated from the crushing
load divided by the average area over which the load is
applied.
12. The result is expressed in N/mm2.
 TEST REPORT OF CEMENT OPC 53 GRADE

PHYSICAL PROPERTIES OF CEMENT

Properties Permissible limits as Results

per IS:12269- 1987

Fineness of cement Shall not be less than 6%

10 %

Normal consistency 28%-32% 32%

Specific gravity 3.15 3.12

Setting time:

Initial Should not be less 40 MIN

than 30 min

Final
Should not be more
than 600 min 330 MIN
Compressive
Strength of
Cement :

Motor cubes for

Should not be less 29
3 days than 23 N/mm2

Should not be less 37.80

7 days than 33N/mm2

Should not be less 53.6

than 53 N/mm2
28 days
3.2.2 FINE AGGREGATE (RIVER SAND)

The sand which is used is comes under Zone –III as per IS 383-1970.
The physical properties like zoning of sand, specific gravity are
determined according to the Codal provision

3.2.3 TESTS OF FINE AGGREGATE

These are the following tests conducted. They are

 Fineness modulus of fine aggregate

 Specific gravity of fine aggregate and water absorption
 Bulking of sand

3.2.3.1 Fineness modulus of Fine aggregate

 Fineness modulus is generally used to get an idea of how
coarse or fine the aggregate is more fineness modulus value
indicates that the aggregate is coarser and small value of
fineness modulus indicates that the aggregate is finer.

Fig 3.4 IS SIEVES

Procedure

1. Sieve the aggregate using the appropriate sieves (80

mm, 40 mm, 20 mm, 10 mm, 4.75 mm, 2.36 mm, 1.18
mm, 600 micron, 300 micron & 150 micron)
2. Record the weight of aggregate retained on each sieve.
3. Calculate the cumulative weight of aggregate retained
on each sieve.
4. Calculate the cumulative percentage of aggregate
retained.
5. Add the cumulative weight of aggregate retained and
divide the sum by 100.
6. This value is termed as fineness modulus

Fine Aggregate Sieve Analysis

Size Retained Cumulative Retained%

of sieve weight retained cumulative %passi
(gms) weight weight ng
(gms) (gms)
4.75mm
2.36mm
1.18mm
600 µ
300 µ
150 µ
Pan
∑F =

Calculation

Fineness Modulus = (∑F)/100

Result:

Fineness modulus of fine aggregate = (∑cumulative % weight

retained)/100 = 243/100 = 2.43
3.2.3.2 Specific Gravity of fine aggregate

 Specific gravity of fine aggregate (sand)  is the ratio of the

weight of given volume of aggregates to the weight of equal
volume of water.
 The specific gravity of fine aggregate is considered to be
2.65.

Fig 3.5 PYCNOMETER

Procedure

1. Weigh the empty pycnometer and note it as W1

2. Take about 500g of sample and place it in the
pycnometer
3. Pour distilled water into it until it is full.
4. Eliminate the entrapped air by rotating the pycnometer
on its side, the hole in the apex of the cone being
covered with a finger.
5. Wipe out the outer surface of pycnometer and weigh
it (W2).
 6. Transfer the contents of the pycnometer into a tray, care
being taken to ensure that all the aggregate is
transferred.
7. Refill the pycnometer with distilled water to the same
level.
8. Find out the weight (W3).
9. Drain water from the sample through a filter paper.
10. Place the sample in oven in a tray at a temperature
of 100ºC to 110º C for 24±0.5 hours, during which
period, it is stirred occasionally to facilitate drying.
11. weigh the pycnometer with water to full level (W4).
12. The recommended value of specific gravity of sand
is 2.6-2.8

Calculations

specific gravity = (Weight of dry sample/Weight of equal volume of

water)

= W2-W1/(( W2-W1)-(W3-W4))

3.2.3.3 Water Absorption

 It is amount of water absorbed by the sand.

 It should be more than 0.6 by unit weight of sand.

Procedure
 1. Take the sample and make it free from moisture
content by oven drying
2. Now, take 1kg sample (say W1)of sand and immerse in
water for 24 hours.
3. Transfer the sand to tray and clean with dry cloth and
then weigh it W2

Calculation

water absorption of sand = w2/ w1 x 100

TEST REPORT OF SAND OF ZONE III

Physical Properties Of Fine Aggregate

Properties RECOMMENED Test results

Specific gravity 2.6-2.8 2.6

Fineness modulus 2.2-3.2 2.43

WATER ABSORPTION 0.1-2.3 0.4

3.2.3 Coarse Aggregate:

The coarse aggregate used is from well-established quarry, satisfying

the code IS 383:1970. The mixture of coarse aggregates is used of only
10 mm .the material is of uniform color and has good angular shape.
The physical properties like fineness modulus, specific-gravity , water-
absorption.

3.2.4 TESTS ON COARSE AGGREGATE

 Fineness modulus of Coarse Aggregate

 Specific Gravity of Coarse Aggregate
 Water absorption of coarse aggregate

3.2.4.1 Fineness modulus of Coarse Aggregates

  Grading refers to the determination of the particle-size
distribution for aggregate.
 Grading limits and maximum aggregate size are
specified because grading and size affect the amount of
aggregate used as well as cement and water
requirements, workability, pumpability, and durability
of concrete.
 In general, if the water-cement ratio is chosen correctly,
a wide range in grading can be used without a major
effect on strength.
 When gap-graded aggregate are specified, certain
particle sizes of aggregate are omitted from the size
continuum.
 Gap-graded aggregate are used to obtain uniform
textures in exposed aggregate concrete.
 Close control of mix proportions is necessary to avoid
segregation.

Procedure

1. The sample shall be brought to an air-dry condition

before weighing and sieving.
2. This may be achieved either by drying at room
temperature or by heating at a temperature of 100º to
110°C.
3. The air-dry sample shall be weighed and sieved
successively on the appropriate sieves starting with the
largest.
4. Care shall be taken to ensure that the sieves are clean
before use.
5. Each sieve shall be shaken separately over a clean tray
until not more than a trace passes, but in any case for
a period of not less than two minutes.
6. The shaking shall be done with a varied motion,
backward sand forwards, left to right, circular
clockwise and anti-clockwise, and with frequent jarring,
so that the material is kept moving over the sieve
surface in frequently changing directions.
7. Material shall not be forced through the sieve by hand
pressure.
8. Lumps of fine material, if present, may be broken by
gentle pressure with fingers against the side of the
sieve.
 9. On completion of sieving, the material retained on each
sieve, together with any material cleaned from the
mesh, shall be weighed.

Calculations

Sieve analysis of coarse aggregate

Sieve size in Weight Cumulative Percentage Percentage

mm retained weight cumulative cumulative
(gm) retained weight weight
(gm) retained passed
12.5 0 0 0 100
10 128 128 6.4 93.6
4.75 1872 2000 100 0
2.36 0 0 0 0
Pan 0 0 0 0

Fineness modulus = (∑F+500)/100

= (106.4+500)/100

= 6.064

3.2.4.2 Specific gravity of coarse aggregate

 Specific gravity of coarse aggregate (sand)  is the ratio of the

weight of given volume of aggregates to the weight of equal
volume of water.
 Fig 3.5 PYCNOMETER

Procedure

1. Weigh the empty pycnometer say w1

2. Now take 1/3rd volume of aggregates by the volume of
pycnometer and weigh it say w2
3. Fill the pycnometer with water to a full level and weigh it
say w3
4. Empty the pycnometer and then fill it with water to a full
level and weigh it say w4

Calculations

specific gravity = (Weight of dry sample/Weight of equal volume of

water)

= W2-W1/(( W2-W1)-(W3-W4))

3.2.4.3 Water Absorption

 It is amount of water absorbed by the coarse aggregate.
 Fig 3.7 WATER ABSORPTION

Procedure

4. Take the sample and make it free from moisture

content by oven drying
5. Now, take 1kg sample (say W1)of sand and immerse in
water for 24 hours.
6. Transfer the sample to tray and clean with dry cloth
and then weigh it W2

Calculation

water absorption of sand = w2/ w1 x 100

Determined Physical Compositions Of Coarse Aggregate

Properties RECOMMENED Test values

Specific gravity 2.8 2.72
Water absorption 0.1-2.0 0.5
Fineness modulus 5-8 6.064

3.3. MIX DESIGN:

Mix Design Principles for SCC:

To achieve the required combination of properties in fresh SCC mixes:

The fluidity and viscosity of the paste is adjusted and balanced by

careful selection and proportioning of the cement and additions, by
limiting the water/powder ratio and then by adding a super plasticizer
and (optionally) a viscosity modifying admixture. Correctly controlling
these components of SCC, their compatibility and interaction is the
key to achieving good filling ability passing ability and resistance to
segregation.

In order to control temperature rise and thermal shrinkage cracking

as well as strength, the fine powder content may contain a significant
proportion of type l or ll additions to keep the cement content at an
acceptable level.

The paste is vehicle for the transport of the aggregate; therefore the
volume of the paste must be greater than the void volume in the
aggregate so that all individual aggregate particles are fully coated and
lubricated by a layer of paste. This increases fluidity and 42 reduces
aggregate friction.

The coarse to fine aggregate ratio in the mix is reduced so that

individual coarse aggregate particles are fully surrounded by a layer of
mortar. This reduces aggregate interlock and bridging when the
concrete passes through narrow openings or gaps between
reinforcement and increases the passing ability of the SCC.

These mix design principles result in concrete that, compared to

traditional vibrated concrete, normally contains:

 Lower coarse aggregate content.

 Increased paste content.
 Low water/powder ratio.
 Increased super plasticizer.
 Sometimes a viscosity modifying admixture.

There is NO standard method for SCC mix design and many

academic institutions, admixture, ready-mixed, precast and
contracting companies have developed their own mix proportioning
methods.

Mix designs often use volume as a key parameter because of the

importance of the need to over fill the voids between the aggregate
particles. Some methods try to fit available constituents to an
optimized grading envelope. Another method is to evaluate and
optimize the flow and stability of first the paste and then the mortar
fractions before the coarse aggregate is added and the whole SCC mix
tested. Further information on mix design and on methods of
evaluating the properties of SCC can be found in the EFNARC
Guidelines for SCC.

These Guidelines are not intended to provide specific advice on mix

design but table given below shows an indication of the typical range
of constituents in SCC by weight and by volume. These proportions
are in no way restrictive and many SCC mixes will fall outside this
range for one or more constituents.

3.4 MIX DESIGN APPROACH

Laboratory trials should be used to verify properties of the initial mix

composition with respect to the specified characteristics and classes.
If necessary, adjustments to the mix composition should then be
made. Once all requirements are fulfilled, the mix should be tested at
full scale in the concrete plant and if necessary at site to verify both
the fresh and hardened properties.

The mix design is generally based on the approach outlined below:

 Evaluate the water demand and optimize the flow and stability
of the paste
 Determine the proportion of sand and the dose of admixture to
give the required robustness
 Test the sensitivity for small variations in quantities (the
robustness)
 Add an appropriate amount of coarse aggregate
 Produce the fresh SCC in the laboratory mixer, perform the
required tests

Test the properties of the SCC in the hardened state produce trial
mixes in the plant mixer.

3.5 Working procedure:

The grade of concrete depends up on the mix design of the concrete.

Whereas the mix above M40 is designed mix. The mix design is based
in strength criteria and durability criteria used for moderate
environment. The ratios by weight of Cement, fine aggregate and
coarse aggregate are obtained using the specifications given in
EFNARC guidelines are given below. These proportions are maintained
strictly same throughout the casting process to obtain a uniform
standard and workable concrete mix. Normally Cubes, Prisms, were
tested for compressive strength, flexural strength after 7 and 28 days
curing. In this thesis work the age of curing at 3, 7, 28, are
conducted.

The compressive strength of hardened concrete which is generally

considered to be an index of its other properties, depending upon
many factors, e.g. w/c ratio quality and quantity of Cement, water,
aggregate, exposure conditions, material properties, mixing, placing,
compaction and soaked condition. In this project we consider the
design specifications such as,

Grade of concrete = M 40

Exposure condition = severe

W/C = 0.35-0.4

Required quantity of Cement, fine aggregate and coarse aggregate is

designed and final mix proportion is obtained. By considering the
above design specifications and by considering the codal provisions in
EFNARC norms the obtained mix design for M40 is obtained.

3.6 MIX DESIGN PROCEDURE