Unit-4 Special Concretes

Reference: Concrete technology Theory and Practice By M S Shetty

[soft copy attached]

Light Weight Concrete (LWC) – 504 to 513 (no design only theory)

Fiber reinforced concrete (FRC) – 526 to 534 (no design only theory)

Polymer concrete (PC) – 534 to 542 (no design only theory)

Self-compacted concrete (SCC) – 572 to 579 (no design only theory)

SCC test method - 579 to 585

DOE mix design – 474 to 488 (two examples in this notes)

IRC mix design – 489 to 498 (three examples in this notes)

Concrete Mix Design Procedure as per BIS 10262 –
2009
Procedure for concrete mix design requires following step by step process:

1. Calculation of target strength of concrete

2. Selection of water-cement ratio
3. Determination of aggregate air content
4. Selection of water content for concrete
5. Selection of cement content for concrete
6. Calculation of aggregate ratio
7. Calculation of aggregate content for concrete
8. Trial mixes for testing concrete mix design strength
Step 1: Calculation of Target Strength of Concrete
Target strength is denoted by ft which is obtained by characteristic compressive
strength of concrete at 28 days (fck) and value of standard deviation (s)
ft = fck + 1.65 s
Standard deviation can be taken from below table

Grade of concrete Standard deviation (N/mm2)

M10 3.5

M15 3.5

M20 4.0

M25 4.0

M30 5.0

M35 5.0

M40 5.0

M45 5.0
 M50 5.0

Step 2: Selection of Water-Cement Ratio

Ratio of the weight of water to weight of cement in the concrete mix is water-
cement ratio. It is the important consideration in concrete mix design to make the
concrete workable. Water cement ratio is selected from the below curve for 28
days characteristic compressive strength of concrete.

Fig: Selection of Water-Cement Ratio for Concrete Mix Design

Similarly, we can determine the water-cement ration from the 7-day concrete
strength, the curves are divided on the basis of strength from water cement ratio
is decided. Which is observed from the below graph.
Fig: Concrete Compressive Strength vs. Water Cement
Ratio
Step 3: Determination of Aggregate Air content
Air content in the concrete mix is determined by the nominal maximum size of
aggregate used. Below table will give the entrapped air content in percentage of
volume of concrete.

Nominal maximum size of aggregate Air content (% of volume of concrete)

10mm 5%
20mm 2%

40mm 1%

Step 4: Selection of Water Content for Concrete

Select the water content which is useful to get required workability with the help

of nominal maximum size of aggregate as given in below table. The table given

below is used when only angular shaped aggregates are used in concrete as well

as the slump should be 25 to 50mm.

Nominal maximum size of aggregate Maximum water content

10mm 208

20mm 186

40mm 165

If the shape of aggregate or slump value is differing from above, then some
adjustments are required as follows.

Condition Adjustment

Sub angular aggregate Reduce the selected value by 10%

Gravel with crushed stone Reduce the selected value by 20kg

Rounded gravel Reduce the selected value by 25kg

 Using plasticizer Decrease the selected value by 5-10%

Using superplasticizer Decrease the selected value by 20-30%

For every increment of 25mm slump Increase the selected value by 3%

Step 5: Selection of Cement Content for Concrete

Water – cement ratio is determined in step2 and quantity of water is determined
in step -4. So, we can easily calculate the quantity of cement from these two
conditions. But, the value obtained should satisfy the minimum conditions as
given in the below table. The greater of the two values is decided as quantity of
cement content.

Cement Content for Plain Cement Concrete

Plain Cement Concrete (P.C.C)
Exposure Minimum Cement Max Free Water – Minimum Grade of
Content Kg/m3 Cement Ratio Concrete
Mild 220 0.6 –
Moderate 240 0.6 M15
Severe 250 0.5 M20
Very
260 0.45 M20
severe
Extreme 280 0.4 M25

Cement Content for Reinforced Concrete

Reinforced Cement Concrete (RCC)
Exposure Minimum Cement Max Free Water – Minimum Grade of
Content Kg/m3 Cement Ratio Concrete
Mild 300 0.55 M20
Moderate 300 0.5 M25
Severe 320 0.45 M30
Very
340 0.45 M35
severe
Extreme 360 0.4 M40
Step 6: Calculation of Aggregate Ratio
For the given nominal maximum size of aggregate, we can calculate the ratio of
volumes of coarse aggregate and volume of total aggregates for different zones of
fine aggregates from the below table.

Nominal Ratio of volume of coarse aggregate and volume of

maximum size of total aggregate for different zones of fine aggregate
aggregate Zone – 1 Zone – 2 Zone – 3 Zone – 4
10mm 0.44 0.46 0.48 0.50
20mm 0.6 0.62 0.64 0.66
40mm 0.69 0.71 0.73 0.75
Step 7: Calculation of Aggregate Content for Concrete
We already determine the coarse aggregate volume ratio in the total aggregate
volume. So, it is very easy that, 1 – volume of coarse aggregate will give the
volume of fine aggregate. Alternatively, there are some formulae to find the
volume of fine and coarse aggregates as follows.

Mass of fine aggregate is calculated from below formula

Similarly, mass of coarse aggregate is calculated from below formula.

Where, V = volume of concrete

W = water content
C = cement content
Gc = sp. Gravity of cement
P = aggregate ration obtained in step6
F.A & C.A = masses of fine and coarse aggregates
Gf & Gca = sp. Gravities of fine and coarse aggregates.
Step 8: Trial Mixes for Testing Concrete Mix Design
Strength
Based on the values obtained above, conduct a trail test by making at least 3
cubes of 150mm size as per above standards. Test that cubes and verify whether
the required strength is gained or not. If not, redesign the mix with proper
adjustments until required strength of cube occurs.
The Department of Environment’s Design Method (DOE Method):
The DOE method of mix design is an improvement over Road Note No. 4 method. This
method of concrete mix design or proportioning mainly is based on the extensive field and
laboratory experiments carried out by Road Research laboratory U.K. The Road Note 4
method was published for the first time in 1950. This method of mix design was most
popular and widely used upto 1970 all over the world. Most of the Indian Concrete roads
and air fields were designed by this method, but it is obsolete now.

The DOE method was first published in 1975 and revised in 1988. The DOE method of mix
design is applicable to all types of concrete mixes including roads, while Road Note No. 4
was applicable to roads and air fields only. This method can also be used for concrete
containing fly ash. DOE method is a standard method of mix design in U.K. now. This
method used the relationship between water/cement ratio and compressive strength
depending on the type of cement and aggregate used.

The water contents required to give various levels of workability, as very low, low, medium
and high expressed in term of slumps or Vee Bee time or compacting factor, are determined
for the two types of aggregates as crushed aggregate and gravel. This method is suitable
for mix design of normal concrete mixes having 28 days cube compressive strength upto 75
MPa for non-air entrained concrete.

The step by step procedure of mix design is given below:

Procedure:
Step 1:
Determine the target mean strength from the specified characteristic strength. Target mean
strength = specified characteristic strength + standard deviation x Risk factor.

(Risk factor is taken on the assumption that 5% of results are allowed to fall below the
specified characteristic strength).

Step 2:
Calculate the water/cement ratio from Fig. 20.10. From table 20.46 the approximate
compressive strength of concrete made with free water/cement ratio 0.5 is obtained.

From table 20.46, find out the 28 days strength for the type of cement and type of C.A. Now
mark a point on the y-axis of the Fig. 20.10 equal to the compressive strength read from
table 20.46, which is at w/c ratio 0.5.
From this point draw a parallel dotted curve nearest to the point of intersection using this
curve, read off the w/c ratio as against target mean strength. The method will be more clear
from the example below.

Step 3:
Determine the water content for the required workability, taking into account the size of
aggregate and its type from table 20.47 and 20.48.
Step 4:
Determination of cement content ― The amount of cement can be determined from the total
water content and w/c ratio.

i.e., Cement content = [(Weight of water)/(w/c ratio)]

The quantity of cement obtained by the above relation should be compared with the
minimum cement content specified from 2800 durability. The higher of the two quantities
should be adopted. If maxi 2600 mum cement content is specified, then the calculated
cement content should be less than the specified maximum cement content.

Step 5:
Determination of total aggregate content ― For determining the total aggregate content, the
estimation of wet density of fully compacted concrete is required. This can be obtained from
Fig. 20.11 for approximate water content and known specific gravity of aggregate. If the
specific gravity of aggregate is not known its value for un crushed aggregate may be taken
as 2.6 and 2.7 for crushed aggregate may be assumed as shown on curves A and B of the
Fig. 20.11. The aggregate content is determined by subtracting the weights of cement and
water content from the weight of fresh concrete read from the Fig. 20.11.
Step 6:
Determination of fine aggregate ― The proportion of fine aggregate in the total aggregate is
determined from Fig. 20.12. Fig. 20.12 (a) is for 10 mm size, 20.12 (b) for 20 mm size, Fig.
20.12 (c) is for 40 mm size coarse aggregate. The parameters involved in Fig. 20.12 are
max. size of aggregate, the water content, degree of workability and the percentage of fine
aggregate passing through 600 micron sieve.
Knowing the proportion of fine aggregate from Fig. 20.12, the weight of fine aggregate may
be obtained by multiplying the total weight of aggregate by this proportion. Knowing the fine
aggregate, the weight of coarse aggregate can be found. The coarse aggregate can further
be divided into different fractions depending upon the shape of aggregate. Generally figures
given in Table 20.49 may be adopted.
Note:
1. From the proportions so obtained trial mix may be prepared and samples should be
prepared and tested to confirm its suitability for the proposed concrete structure.

2. If fly ash is used along with cement, then water content may be reduced as shown in
Table 20.48.

Example 2:
Design a concrete mix for targeted 28 days cube strength of 45 MPa by DOE method
from the following data:
1. Max. size of uncrushed aggregate to be used = 20 mm
2. Low workability, slump = 10-30 mm
3. Specific gravity of aggregate = 2.65
4. The aggregate percentage passing 600 micron = 50%
5. Exposure to concrete is moderate
6. The cover to the reinforcement to be provided is 25 mm.
Design:
Step 1:
Determine the target strength from the relation.
Target strength = specified characteristic strength + standard deviation x Risk factor In this
case the target strength is directly given as 45 MPa at 28 days.

Step 2:
Find out the water/cement ratio for targeted strength 45 MPa.
(a) For finding out the w/c ratio, refer to table 20.46. From this table for ordinary port-land
cement and uncrushed 20 mm aggregate the 28 days strength is 42 MPa.

(b) From Fig. 20.12 find the point of inter section of 42 MPa at 0.5 water/cement ratio.
Through this point draw a dotted line curve parallel to the neighboring curve. Now draw a
strength line from the desired strength on y-axis, where this line cuts the curve, draw a
perpendicular on x-axis which will give w/c ratio for the targeted strength i.e., 45 MPa.

From this curve for 45 MPa strength the water/cement ratio comes out 0.54.

For uncrushed aggregate of 20 mm max. size aggregate approximate water content from
table 20.47, is 160 kg/m3.
For moderate exposure and 25 mm cover maximum w/c ratio from durability consideration
is permitted as 0.5. Actually the lower value of the two should be adopted. Hence adopt w/c
ratio as 0.5 water content for 10 to 30 mm slump from table 20.47 is 160 kg/m 3.
Cement Content:
From w/c ratio 0.5 and water content 160 kg, 160

Cement content = 160/0.5 = 320.4 kg.

From Durability consideration, the quantity of cement should be used as 350 kg/m 3. Thus
adopt greater cement content as 350 kg/m3.
Determination of Density of Fresh Concrete:
From Fig. 20.11, for water content of 160 kg/m 3, 20 mm uncrushed, the wet density of
concrete = 2490 kg/m3
Determination of total weight of aggregate.

Total weight of aggregate = Total weight of concrete-weight of water-weight of cement.

= 2490 – 160 – 350

= 2490 – 510 = 2180 kg/m3

Fine aggregate from Fig. 20.12 (b) for slump 10-30 and aggregate passing through 600
micron as 50% for w/c ratio 0.5

F.A. = 27%

∴ weight of fine aggregate = (2180 x 27)/100 = 588.6 = 589 kg/m 3

weight of coarse aggregate = 2180 – 5886 = 1591.4 kg/m 3
Estimated quantities in kg/m3 are:
(a) Cement = 350 kg/m3
(b) F.A. = 588.6 kg/m3
(c) C.A. = 1591.4 kg/m3
(d) Water = 160 kg/m3
(e) Wet density = 2490 kg/m3
From these quantities the trial mix is prepared, samples cast and tested at 28 days to judge
the suitability of concrete for the desired work. If need arises, adjustment in quantities be
made.
2. Concrete Mix Design by DOE Method using Fly Ash:
The use of fly ash as a part substitute of cement is fast gaining popularity throughout the
world. Thus one should be acquainted with the procedure of concrete mix design containing
fly ash. The method of design of mix is illustrated by the following example.

Example 3:
Design a concrete mix using fly ash by DOE method from the following data:
(a) Characteristic 28 days mean strength = 25 MPa
(b) Risk factor may be taken =1.65
(c) Standard deviation = 5.0
(d) The max. size of coarse, aggregate C.A. = 20 mm
(e) 40% F.A. passes through 600 micron sieve.
(f) Slump range = 30-60 mm
(g) Cover to reinforcement = 25 mm
(h) Specific gravity of F.A. and C.A. = 2.6 and 2.7 respectively
(i) Percentage of fly ash to be used = 30%
Design Procedure:
By DOE method of mix design using fly ash.

Cement content is given by the relation:

where, F is the quantity of fly ash and it is given as:

where, P is the percentage of fly ash in the total cementitious material:

W = Free water content W

... W/(C + 0.3F) is the free water Cementitious ratio for the design strength Fig. 20.12
Specified targeted strength = 25 + 5 x 1.65 = 25 + 8.25 = 33.25 MPa

Taking 33 MPa as the target strength we proceed as follows:

From table 20.46 for 0.50 w/c ratio {Here W/(C + 0.3F)}, the 28 days compressive strength
of concrete with ordinary cement is 42 MPa. For target mean strength of 33MPa, from Fig.
20.10, the value of free water W/(C + 0.3F) is 0.65.
Note:
This value is not to be compared with maximum value from durability consideration of table
17.3 it is to be used for strength purpose only. From table 20.47, for crushed 20 mm max.
size aggregate and 60 mm slump, the quantity of water is 210 kg/m 3. In the present case,
the fly ash used is 30%. Hence reduce water content as partable 20.48. From this table
reduction for 30% fly ash is 20 kg/m3.
Hence water content to be used = 210 – 20 = 190 kg/m 3

From table 17.3 Cement content satisfy the durability requirements, but water/cementitious
material ratio does not satisfy this durability condition. Hence adopt w/cementitious material
ratio as 0.50 instead of 0.51.

Then water content = 370 x 0.5 = 185 kg/m3

For water content of 185 kg/m3, and average specific gravity of 2.65, the density of fresh
concrete from Fig. 20.11 = 2420 kg/m3
Total weight of aggregate = 2420 – (259 + 111 + 185)

= 2420 – 555 = 1865 kg/m3

From Fig. 20.12 (b) for free water/cementitious material as 0.5 and for 40% F.A. passing
through 600 micron sieve and for slump 30-60 mm is 38%.

∴ weight of F.A. = 38/100 x 708.7 kg. say 709 kg.

weight of C.A. = 1865 – 709 = 1156 kg.

Hence estimated quantities of materials on the basis of saturated surface dry

condition are as follows:
The weight of aggregates may be adjusted according to free moisture content and
absorption characteristics of the aggregates.

The trial mix may be prepared to determine its characteristic strength which should satisfy
the desired requirements.