Department of

Civil
Technology

Summer Office Training Report 2015

AHMED ZAKARIa
BS CIVIL TECHNOLOGY

Written By: Ahmed Zakaria 1

 Department of
Civil
Technology

INTERNSHIP SUPERVISOR: Engr. Ahmed Yahya

AUTHOR: Ahmed Zakaria

(670-2013)

Hosting Organization: Al-Haramain Company of

Commerce and Contracting.

Commencement Date: September 1, 2015

Completion Date: September 20, 2015

Approved By:

Name of supervisor:Engr. Ahmed Yahya

Signature:

Name of mentor: Muhammad Munawwar Khan

Signature:

Hosting company stamp

Written By: Ahmed Zakaria 2

 Department of
Civil
Technology

ACKNOWLEDGEMENT

I would like to thank Al-Haramain Company of Commerce and Contracting for giving me
the opportunity to undertake my three week training in their laboratory work area. I would
like to convey my heartiest thanks to Lab engineer Mohammad Munawwar Khan and the
project manager Engr. Ahmed Yahya for their immense support and cooperation which
made this experience very learning and worthwhile

Dated: September 25, 2015

Written By: Ahmed Zakaria 3

 Department of
Civil
Technology

List of Tables

Table No. Title Page No.

Table 1 F.A Gradation 08
Table 2 L.A.A Test 12
Table 3 Grading of 3/4 Aggregate 16
Table 4 Grading of 3/8 16
Aggregate
Table 5 Aggregate Blend 17
Table 6 Sample for specific 18
gravity
Table 7-A Specific gravity of 3/4 19
Table 7-B Specific gravity of 3/8 20
Table 8 Specific gravity record 21
Table 9 Calculation of Ave. 21
specific gravity
Table 10 Nominal Max. Size 22
conversions
Table 11 Gradation standards C.A 23
Table 12 Gradation standards F.A 23
Table 13 Concrete Class 24
Designation

List of Figures

Figure No. Title Page No.

Collage of C.A
Fig 5 specific gravity
procedure
Fig 6 Recording weight of
sample on weighing
scale

Written By: Ahmed Zakaria 4

 Department of
Civil
Technology

CONTENTS
Chapter Title Page No.

Introduction 03

Concrete Mix Design 04

Things Should Know
Chapter One Before Designing 05
Concrete.
Precautions And Things To 06
Remember During Design
Concrete Mixes

Fine Aggregate 07

Gradation Test. 08
Chapter Two Fine Aggregate Angularity 09
Test 09
Sand Equivalent Test
Fine Aggregate Specific 10
Gravity Test

Coarse Aggregate 11

Los Angeles abrasion test. 11

13
Soundness Test of
Aggregate 14
Determination of Flakiness
Chapter Three index
Determination of 15
Elongation Index
Calculation of percentage
passing of aggregate 3/4 & 16
3/8 separately.
Making Blend of
17
Aggregate 3/4 & 3/8.

Chapter Four Concrete Mix Design 22

Chapter Five Asphalt 31

Pictorial Explanation 34

References 37

Written By: Ahmed Zakaria 5

 Department of
Civil
Technology

CHAPTER ONE
INTRODUCTION

A wide range of problem associated with concrete mix design has to be faced during

graduation period. Keeping in view such difficulties it has been written in a way to gain
the complete knowledge of Concrete Mix Design before stepping into professional life.
The report is written on standards followed by KSA and its calculation, method will only
applicable in the kingdom. However report is written briefly and divided into five parts:

Fine Aggregate
Coarse Aggregate
Concrete Mix Design
Asphalt
Pictorial Explanation

Concrete:
Concrete is the most building material on earth it was the building block of the Roman Empire. Today
it’s the material for new generation. The raw ingredients that create this magic formula can nearly
found in every country on earth. The basic formula is simple, sand, crush rock aggregate, water and
cement.
Concrete can take nearly any shape that’s why it is being used in mega dam structures, sky scrapers or
bridges or any structure on earth.

Written By: Ahmed Zakaria 6

 Department of
Civil
Technology

Concrete mix Design

Concrete mix design may be defines as the art of selecting suitable ingredients of concrete and
determining their relative proportions with the object of producing concrete of certain minimum
strength & durability as economically as possible.

Similarly the common method of expressing the proportions of ingredients of a concrete mix is
in the terms of parts or ratios of cement, fine and coarse aggregates. For e.g., a concrete mix of
proportions 1:2:4.

1. Standards for Mix design

ACI and other standards only serves as a guide, initial designs must be confirmed by
laboratory trial and plant trial, adjustments on the design shall be done during trial
mixes.
Initial design “on paper” is never the final design.
2. Trial Mixes
Always carry out trial mixes using the materials for actual use
3. Design Variation Tests
Carry out 2 or 3 design variations for every design target
4. Safety Factors
Consider always the factor of safety, (1.125, 1.2, 1.25, 1.3 X target strength)
5. Material Sources
Before proceeding to plant trials, always confirm the source of materials to be the
same as the one used in the laboratory trials.
6. Batching Plant Calibration
Check calibration of batching plant before trials
7. Tests at Batching Plant
Carry out full tests of fresh concrete at the batching plant, specially the air content
and yield which is very important in commercial batching plants
8. Quality Control
Correct quality control procedures at the plant will prevent future concrete problems
9. Admixture
Follow admixture recommendations from your supplier
10. Strength Development Check
Check and verify strength development, most critical stage is the 3 and 7 days
strength

Technical knowledge is an advantage for batching plant staff, even if you have good concrete design but
uncommon or wrong procedures are practiced it will eventually result to failures

Written By: Ahmed Zakaria 7

 Department of
Civil
Technology

Things should know before designing concrete.

1. What are the strength requirements?

Compressive (on cube or cylinder specimen) strength
Flexural strength
Tensile strength

2. What is the placing method?

By pump or direct pouring.

3. How far is the JOB SITE from the batching plant?

4. How many Transit Mixers are available on plant?

5. How much cubic meter concrete to be done in one working day?

6. Capacity of each Transit Mixer?

7. What is the capacity of Batching Plant?

8. What will be the expected temperature of site?

9. Which type of water is provided to use in concrete?

10. What type of cement is provided?

11. Fine and Coarse Aggregates quality test results.

12. Water temperature?

13. What is the structure for casting?

Pavement, foundation, elevated slab, etc.

14. What are the projects specifications?

Maximum or minimum cement contents
Maximum water/cement ratio
Slump or consistency limit
Minimum Strength requirement @28 days
Material specifications

15. Latest testing results of materials is needed in the preliminary selection of materials and
design calculation

Written By: Ahmed Zakaria 8

 Department of
Civil
Technology

PRECAUTIONS AND THINGS TO REMEMBER DURING

DESIGN CONCRETE MIXES

1. Increasing the sand/totalaggregate ratio, increases the water requirement at the

same consistency.

2. Increasing the water/cement ratio decreases the strength of concrete at the same
cement content.

3. Remember that adding 5 liters of water per cubic meter increases the slump by
2.5cm.

4. Remember that adding 5 liters of water per cubic meter decreases strength by
approximately 4%.

5. Always follow recommended admixture dosage.

6. Always have “control” when performing trial mixes, always perform trial mixes with
another mix using the same materials. This data can be useful in diagnostics if a
problem occurs.

7. Always adjust batching quantities to the actual moisture condition of theaggregates.

8. Volume tolerance for 1m3 concrete is 1 ± 0.2 m3.

9. Range of normal weight concrete is from 2,200 kg/m3 to 2,400 kg/m3

10. Always take 3 samples for each test.

11. Calculate the average of all 3 samples for accuracy.

12. Complete all the required necessary tests before you start Concrete Mix Design
calculations and make a table of their resulted values.

Written By: Ahmed Zakaria 9

 Department of
Civil
Technology

CHAPTER TWO
FINE AGGREGATE

Fine Aggregate Test Section

The tests are used to determine the material characteristics and properties of
aggregate materials for use in pavement construction. Test results are an important part
of mix design and can help predict pavement quality. Fine Aggregate tests are as
follows:

 Gradation Test.
 Fine Aggregate Angularity Test
 Sand Equivalent Test
 Fine Aggregate Specific Gravity Test

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 Department of
Civil
Technology

Gradation Test:

 This test is performed to identify the size of particles in a sample.

 Aggregate passing sieve # 4 is considered as F.A.
 Take a sample of F.A from the stock pile after splitting properly.
 Record the weight of sample, and soak it in water for 24 hours.
 After 24 hours take the sample and wash it by sieve 200 unless all the dirt
particles are drained and clear water can be seen.
 Record the weight, the difference of total weight and after wash weight should
not more than 5% of the total weight.
 Clay lumps should not more than 1% in sample.
 Perform sand equivalent test to measure clay presence.
 Clay should not be more than 75% of the sample for Concrete and 45% for
Asphalt.
 Perform Gradation trough sieves for further calculation and tests.

Sieve analysis %Passing by weight

Sieve Size % Passing Specifications

3/8 “ 100 100
No. 4 97 95 - 100
No. 8 84

No. 16 71 45 - 80
No. 30 45

No. 50 17 10 - 30
No. 100 8 2 - 10
No. 200 2.8 0-4

Table1: F.A Gradation

Fineness Modulus = 2.77

Written By: Ahmed Zakaria 11

 Department of
Civil
Technology

Fine Aggregate Angularity Test:

I. The fine aggregate angularity (FAA) test is an indirect method of assessing the
angularity of fine aggregate.
II. Fine aggregate angularity is important because an excess of rounded fine
aggregate (in the form of natural sand) can lead to rutting.
III. The FAA test estimates fine aggregate angularity by measuring the loose
uncompact void content of a fine aggregate sample.
IV. The higher the void content, the higher the assumed angularity and rougher the
surface.
V. This test is used to ensure that the blend of fine aggregate has sufficient
angularity and texture to resist permanent deformation (rutting) for a given traffic
level
VI. The test can be found in AASHTO T 304.

Fig 1: F.A
Angularity Test

Sand Equivalent Test:

I. This is a rapid field test to show the relative proportions of fine dust or clay-like
materials in fine aggregate.
II. The term “sand equivalent” expresses the concept that most fine aggregates are
mixtures of desirable coarse particles and generally undesirable clay or plastic
fines and dust.
III. These materials can coat aggregate particles and prevent proper asphalt binder-
aggregate bonding.
IV. The test can be found in AASHTO T 84.

Fig 2: Sand
equivalent cylinder
with aggregate
sample

Written By: Ahmed Zakaria 12

 Department of
Civil
Technology

Fine Aggregate Specific Gravity Test:

I. Thisis used to calculate the specific gravity of a fine aggregate sample by

determining the ratio of the weight of a given volume of aggregate to the weight
of an equal volume of water.
II. It is similar in nature to the coarse aggregate specific gravity test.
III. The fine aggregate specific gravity test measures fine aggregate weight under
three different sample conditions
 Oven-dry (no water in sample)
 Saturated surface dry (water fills the aggregate pores)
 Submerged in water (underwater).
IV. Using these three weights and their relationships, a sample’s apparent specific
gravity, bulk specific gravity and bulk SSD specific gravity as well as absorption
can be calculated.
V. The test can be found in AASHTO T 84.

Fig 3: F.A Specifiv gravity

sample and Pycnometer

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 Department of
Civil
Technology

CHAPTER THREE
Coarse AGGREGATE

Coarse Aggregate Test Section

Los Angeles abrasion test.

Los Angeles Machine:

It consists of a hollow steel cylinder, closed at both the ends with an internal diameter of
700 mm and length 500 mm and capable of rotating about its horizontal axis. A removable
steel shaft projecting radially 88 mm into cylinder and extending full length (i.e.500 mm) is
mounted firmly on the interior of cylinder. The shelf is placed at a distance 1250 mm
minimum from the opening in the direction of rotation.

Abrasive charge:

Cast iron or steel balls, approximately 48mm in diameter and each weighing between 390 to
445g; six to twelve balls are required.

Test application:

The aggregate used in surface course of the highway pavements are subjected to
wearing due to movement of traffic. When vehicles move on the road, the soil particles
present between the pneumatic tyres and road surface cause abrasion of road
aggregates. The principle of Los Angeles abrasion test is to produce abrasive action by
use of standard steel balls which when mixed with aggregates and rotated in a drum for
specific number of revolutions also causes impact on aggregates. This test gives more
accurate value of the strength and hardness of aggregates. This test is mechanical
rather than manual where accuracy is doubtful.

Written By: Ahmed Zakaria 14

 Department of
Civil
Technology

PROCEDURE:

The test sample consists of clean aggregates dried in oven at 105° – 110°C. The sample
should conform to any of the grading.

I. Select the grading to be used in the test such that it conforms to the grading to be used
in construction, to the maximum extent possible.

II. Take 5 kg of sample for grading A, B, C & D and 10 kg for gradings E, F & G.

III. Choose the abrasive charge as per Table depending on grading of aggregates.

IV. Place the aggregates and abrasive charge on the cylinder and fix the cover.

V. Rotate the machine at a speed of 30 – 33 revolutions per minute. The number of

revolutions is 500 for grading’s A, B, C & D and 1000 for grading’s E, K & S. The
machine should be balanced and driven such that there is uniform peripheral speed.

VI. The machine is stopped after the desired number of revolutions and material is
discharged to a tray.

VII. The entire stone dust is sieved on 1.70 mm IS sieve.

VIII. The material coarser than 1.7mm size is weighed correct to one gram.

Table 2: L.A.A Test

Written By: Ahmed Zakaria 15

 Department of
Civil
Technology

Soundness Test of Aggregate:

This test is intended to study the resistance of coarse and fine aggregates to weathering
action and to judge the durability of the coarse aggregate.

1. Take individual samples in a wire mesh basket and immerse it in the solution of
sodium sulphate or magnesium sulphate for 5 days and change chemical every 24
hours, in such a manner that the solution covers them to a depth of at least 15 mm.
2. After completion remove the sample from solution and allow it to drain for 15
minutes
3. Then dry it in oven at 110oCtemperature.

Now sieve the material and weight it in a balance.

For Fine Aggregate the loss material should be less than 10% of the total material.
For Coarse Aggregate the loss material should not more than 12% o the total material
weight.

Flakiness and Elongation Index of Aggregate

One of the important properties of coarse aggregate is determination of its flakiness and
elongation index value for this test the required equipment’s are:

 Set of sieve
 Thickness Gauge
 Length Gauge
 Enamel Tray
 Pan & Scoop
 Weighing balance
 3 Aggregate sample
 Observation sheet.

Weighing Balance

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 Department of
Civil
Technology

Determination of Flakiness index:

 Measure the weight of aggregate sample after proper quartering
 Sieve it manually or by shaker, so that fraction of different sizes will retain on
different size of sieve.
 All the particles retained on first sieve i.e 16mm sieve will be tested in thickness
gauge scale on marked 20mm – 16mm slots.
 Width of slot corresponding to 20mm & 16 mm sieve can be calculated as :

( )

 The particle passing through 10.8mm thickness slot will be collected for weight
and record this weight in observation sheet.
 Same procedure is followed for aggregate passing through 16mm sieve and
retain on 12.5mm sieve.
 This time the aggregate are passing from the corresponding thickness slot are
collected and weight.

Flakiness Index =

 Flakiness Index in excess of 35 to 40% is considered undesirable.

Fig 4: Thickness Gauge

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 Department of
Civil
Technology

Determination of Elongation Index:

 Take minimum 200 pieces of aggregate from the sample and note down its
weight.
 Perform the sieve test with same set of sieve use in flakiness test.
 Different sizes of aggregate are retain on different sieve.
 Aggregate passing 20mm & retain 16mm is taken for test and passed through
the mentioned sieve slots of length gauge.
 Its important particle retain on slot are collected, weight and reading is recorded
 Length of slot corresponding to 20mm & 16mm slot is calculates as:

( )

 The particles retain on 32.4mm

 All the particles retain are weight and reading recorded in observation sheet.

Elongation Index =

Fig 5: Length Gauge

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 Department of
Civil
Technology

Calculation of percentage passing of aggregate 3/4 & 3/8 separately.

 Aggregate Sample : 3/4

 Total Weight : 2334.3 Kg
 Percentage Passing =
*cumulative weight is retained weight of sample on each sieve.

Sieve No Cumulative Weight Percentage Passing

3/4 325.9 86.03 %
1/2 2205.3 6%
3/8 2308.0 1.1 %
4 2313.4 1.0 %
8 2313.8 1.0 %
16 2314.4 1.0 %
30 2315.0 1.0 %
50 2315.5 1.0 %
100 2316.5 1.0 %
200 2318.0 1.0 %
PAN 2324.8 0.4 %
Table 3: Grading of 3/4 Aggregate

 C.AggregateSample : 3/8
 Total Weight : 2475.5 Kg
 Percentage Passing =
*cumulative weight is retained weight of sample on each sieve.

Sieve No Cumulative Weight Percentage Passing

3/4 0 100 %
1/2 90.5 96 %
3/8 829.3 66 %
4 2387.5 4.0 %
8 2464.0 0.4 %
16 2465.0 0.4 %
30 2465.4 0.4 %
50 2465.7 0.3 %
100 2466.6 0.3 %
200 2467.8 0.3 %
PAN 2474.8 0.02 %
Table 4: Grading of 3/8 Aggregate

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 Department of
Civil
Technology

Making Blend of Aggregate 3/4 & 3/8.

 In concrete design an engineer should make at least 5 blend.
 To make blend, make the ratio of 3/4 & 3/8 aggregate by dividing them into
100%.
 For Example, take aggregate 3/4=40%, & aggregate 3/8=60% which equals to
100% on adding ratio's
 Similarly calculate 3/4 @ 60% & 3/8 @ 40% unless your results match the
specification table try five different ratios.
 In this report we will take ratio's 3/4 @40%& 3/8 @ 60%.
 The blend result will gives to match the specification chart of concrete strength
for further calculation and concrete mix design competition.
 To calculate blend value use formula:
&

 Use each sieve percentage passing value separately from table# 5 for 3/4
aggregate & table# 6 for 3/8 aggregate.
 For combine blend value add 3/4 and 3/8 blend value.
 Percentage passing value of each sieve from Table# 5 & 6 will be use in the
below table # 7 in separate sieve respectively
 .

3/4 @40% 3/8 @ 60% Combine

Sieve no. Blend
[ Percentage Passing x 0.4 ] [Percentage Passing x 0.6 ] 3/4 + 3/8
1" 100 100 100
3/4 " 34.4 60 94.4
1/2 " 2.4 57.7 60
3/8 " 0.44 39.8 40.2
4" 0.4 2.4 2.8
8" 0.4 0.24 0.64
16 " 0.4 0.24 0.64
30 " 0.4 0.24 0.64
50 " 0.4 0.18 0.58
100 " 0.4 0.18 0.58
200 " 0.4 0.18 0.58
PAN 0.16 0.012 0.172
Table 5:Aggregate Blend

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 Department of
Civil
Technology

Specific Gravity &Percentage Absorption Aggregates

To calculate specific gravity of aggregate follow the below procedure:

I. Take a sample of aggregate 3/4 & 3/8 separately from the same stock pile (which
we have used above in grading and blend) after proper quartering.
II. Record the weight of both aggregate of 3/4 and 3/8 respectively.
III. Soak the sample in water and record the weight which will be "Weigh. inWater".
IV. Drain out the water, and dry the sample with the help of towel or a piece of cloth
and record its weight, which will be "Saturated Surface Dry Weight".
V. Put the sample in oven at Temp. 110o C for 24 hrs.
VI. After oven dry, record its weight which will be "Oven Dry Weight".
VII. Calculate absorption of sample.
VIII. Calculate %age absorption of sample.

Aggregate Size Weight In Water Saturated Surface Dry Oven Dry Weight
Weight
3/4 1297.7 2016.5 1996
3/8 656.2 1026.6 1023.5
Table 6:Sample for specific gravity

Adding water Recording weight of

Surface drying Towel use for Oven dry material
material
in material soaked in water of aggregate surface dry @ 110oC

Fig 5: Collage of
C.A specific gravity
procedure

Fig6 :Recording weight of sample on weighing scale

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 Department of
Civil
Technology

Below is the given specific gravity calculation of sample step by step in table# 7-A and
7-B.

Coarse Aggregate : 3/4

LINE 1 Weight of saturated surface dry 2016.5

sample
LINE 2 Weight of oven dry sample in air 1996

LINE 3 Weight of sample in water 1297.7

LINE 4 Absorption of sample 2016.5 - 1996

(LINE 1 - LINE 2) = 20.5

LINE 5 % Absorptions

= 1.027 %

Moisture Content
LINE 6
= 1.01

Specific Gravity

Bulk, oven dry

a 2.77

Bulk, saturated
Surface dry
b 2.805

Apparent,

c 2.858

Table 7-A :Specific gravity of 3/4

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 Department of
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Technology

Coarse Aggregate : 3/8

LINE 1 Weight of saturated surface dry 1026.6

sample
LINE 2 Weight of oven dry sample in air 1023.5
LINE 3 Weight of sample in water 656.2
LINE 4 Absorption of sample 3.1
(LINE 1 - LINE 2)
% Absorptions
LINE 5 0.30 %

Moisture Content
LINE 6 0.30

Specific Gravity

Bulk, oven dry

a 2.76

Bulk, saturated
Surface dry
b 2.77

Apparent,
2.78
c

Table 7-B: Specific gravity of 3/8

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 Department of
Civil
Technology

Calculate Average Specific Gravity

 Average Sp. gravity can be calculate by adding sp. gravity of both aggregates 3/4& 3/8.
 Make a table of both aggregate sp. gravity.
 The calculation can be seen in table # 11.

Material Size % used SPECIFIC GRAVITY

Oven Dry Saturated Apparent % Absolute Moisture
Surface Dry Content
C.A – 3/4” 40% 2.77 2.805 2.858 1.027% 1.01
C.A – 3/8” 60% 2.76 2.77 2.78 0.30% 0.30
Table: 8

Average Specific Gravity:

Ave. Oven Dry 2.763

Ave. Saturated Surface

Dry 2.783

Ave. Apparent 2.811

% Absolute 0.584

Moisture Content 0.584

Table: 9 - Calculation of Ave. specific gravity

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 Department of
Civil
Technology

CHAPTER FOUR
CONCRETE MIX DESIGN

Concrete Design Section

In concrete design section we will calculate the aggregate weight, blend and specific
gravity and the outcome result will be matched with the given specification of concrete
design classes.

Before we begin the below test is done following the method of American Association
of State Highway and Transportation Officials (AASHTO) and quality test is done
according to American Society for Testing and Materials (ASTM).
These standards are following in Kingdom of Saudi Arabia and in the Middle Eastern
countries.

Every reading, units, measurements, specifications and sieve size number are
applicable for AASHTO standard concrete mix design test.

Nominal Aggregate size

mm inches

62.5 mm 21/2 inch

50 mm 2 inch
37.5 mm 11/2 inch
25 mm 1 inch
19 mm ¾ inch
12.5 mm ½ inch
9.5 mm 3/8 inch
4.75 mm No. 4
2.36 No. 8
1.18 mm No. 16
0.300 mm No. 50
0.150 mm No. 100
0.075 mm No. 200
Table 10:Nominal Max. Size conversions

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 Department of
Civil
Technology

Concrete Coarse Aggregate Gradation,Percentage Passing.

Coarse aggregate shall meet the following gradation requirements when tested:

Sieve Size Size A Size B Size C Size D

Aggregate Aggregate Aggregate Aggregate
2 inch 21/2 inch 1 inch ¾ inch
21/2 ---- 100 --- ---
2 inch 100 95-100 --- ---
11/2 inch 95-100 --- --- ---
1 inch --- 35-70 100 ----
¾ inch 35-70 --- 95-100 100
½ inch --- 10-30 --- 90-100
3/8 inch 10-30 --- 20-55 40-70
No. 4 0–5 0–5 0-10 0-15
No. 8 --- --- 0–5 0–5
No. 200 0-1 0-1 0-1 0-1
Table 11:Gradation standards C.A

Concrete Fine Aggregate Gradation, Percentage Passing.

Fine aggregate shall meet the following gradation requirements when tested:

Sieve Size Percentage Passing by Weight

9.5 mm (3/8 inch) 100

4.75 mm (No. 4) 95 - 100

1.18 mm (No. 16) 45 - 80

0.300 mm (No. 50) 10 - 30

0.150 mm (No. 100) 2 - 10

0.075 mm (No. 200) 0-4

Table 12: Gradation standards F.A

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 Department of
Civil
Technology

Concrete Class Designations:

Minimum Minimum Designated Alternate
Cement Content Compressive Coarse Coarse
Specified Class (Kg. Per Cu. M) Strength at 28 Aggregate Size Aggregate Size
Days
A 335 210 Kg./sq. cm A- (2 in) B
B 310 170 Kg./sq. cm B- (2 ½ in) A
C 375 250 Kg./sq. cm C- (1 in) D
D 375 250 Kg./sq. cm D- (¾ in)
E 375 280 Kg./sq. cm D- (¾ in)
K 390 315 Kg./sq. cm D-(¾ in)
S 410 350 Kg./sq. cm D- (¾ in)

Table 13:Concrete Class Designation

Table No 11 & 12 are the standards set by the Ministry of Transport Materials
Research and Testing Department KSA. After the gradation process of F.A & C.A
the % Passing should meet the specifications as given in table. If the aggregate
fails the ministry will not approve the project. KSA has set their standards as per
AASHTO and ASTM systems, they can vary with different countries or region.

Table No 13 is designed as reference classification chart by the material

engineer of Al-Haramain Company after all the calculations and following
instructions for future projects. However the concrete mix design is done on
every new project in the begging for accuracy. Table No13 is also approved by
ministry and consultant of the kingdom and has set as standard for the required
strength at 28 days till date September 2015.

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 Department of
Civil
Technology

Concrete Mix Design Calculation

According to M.O.C Saudi Arabia.
The below calculation is numerical calculation based on 15 steps with Fifteen different
equation used in each step. The following calculation is only applicable in Middle East.

STEP 1:
% Passing No. 200

= (Eq.1)

STEP 2: Required Water:

Water, KG./Cu.m of concrete

= (Eq. 2)

= 188.76 189 Kg/m3

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 Department of
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Technology

STEP 3: Water/Cement Ratio:

W/C = (Eq. 3)

Where A =

A=

A = 0.467293

W/C =

W/C =

W/C = 0.40 we will take w/c = 0.45

Cement Weight =

Used Cement Factor = 473Kg./m3

STEP 4: Estimated Strength of Concrete:

= 1028 – 1280 (Eq. 4)

= 1028 – 1280

= 377 Kg./cm2

Water Content = 410 x 0.45

= 185 L/m3

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 Department of
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Technology

STEP 5: Percentage Air Content:

% air = 4.4 x 0.3475 Nominal Max. Size in inches (Eq. 5)

= 4.4
% non-air entrained = 1.529 %

STEP 6: Volume of Cement:

Volume of Cement = (Eq. 6)

= 0.1301

STEP 7: Volume of Water& Admixtures:

Volume of water = (Eq. 7)

= 0.1850 L

Volume of Admixtures =

= 0.0025 L

Written By: Ahmed Zakaria 30

 Department of
Civil
Technology

STEP 8: Dry Rrodded volume of C.A:

= (Eq. 8)

= 0.6739 m3

STEP 9: Weight of C.A in KG:

Wt. in Kg of coarse aggregate = Dry rodded Vol. of C.A x Dry rodded unit wt. of C.A (Eq.9)

= 0.6739 x 1596
= 1076

STEP 10: Abs. Vol. C.A:

Absolute volume of C.A = (Eq.10)

= 0.3892

STEP 11: Specific Gravity:

Already calculated before. (Eq. 11)

STEP 12: Volume of air:

Volume of air in 1m3 of concrete = (Eq. 12)

= 0.0153

Written By: Ahmed Zakaria 31

 Department of
Civil
Technology

STEP 13: Wt. of F.A: (Eq.13)

Absolute volume of F.A = 1- [Eq6 + Eq7 + Eq10 + Eq12]

1 – [0.1301+0.6739+0.3892+0.0153]
= 0.2779 m3

Weight of F.A = F.A volume X (1000 X specific gravity on oven dry basis)
= 0.2779 X 1000 X 2.680
= 745 Kg./m3

STEP 14: Adjusted wt. C.A:

Adjusted wt. of C.A = Design wt. of C.A X (Eq.14)
= 1076 X ( )

= 1082 Kg

3/4 C.A = = 433 Kg

3/8 C.A = = 649 Kg

STEP 15: Adjusted wt. F.A:

Adjusted wt. of F.A = Design wt. of F.A X (Eq.15)

=745 X ( )

= 747 Kg

Written By: Ahmed Zakaria 32

 Department of
Civil
Technology

STEP 16: Adjusted wt. Water:

Adjusted wt. of water = Design wt. of water (Eq.16)

+ C.A wt. X ( % absorption - % moisture) / 100

+ F.A wt. X ( % absorption - % moisture) / 100

= + 1076 x (0.5908 – 0.584) / 100

= 7.3168
= + 745 (1.8 -0.30 ) / 100

= 11.175

Adjusted wt. of water= 185 + 7.3168 + 11.175

= 204 Kg.

Material required for 1 cu.ft concrete

Compressivestrength of concrete at 28 377 Kg/cm2
days
Cement 410 KG
Water 204 Kg
Fine Aggregate 747 Kg
3/4 = 430 Kg
Coarse Aggregate 3/8 = 649 Kg

The above specifications fulfill our Class-S concrete design.

Following this design we will perform trial of cylinders and cube
for compression test and accuracy.

Written By: Ahmed Zakaria 33

 Department of
Civil
Technology

CHAPTER FIVE
Asphalt

Asphalt Test Procedure:

1. Take a ready hot sample from Asphalt Paver after quartering.

2. Record its weight observation sheet.

3. Put in the extraction machine bowl.

4. Add Triclone chemical or Petrol continuously for washing its bitumen.

5. Let the machine complete its process.

6. Do not stop the machine unless the drain Triclone or Petrol is clearly
visible without any bitumen.

7. Stop the machine and check if all the bitumen has removed from the
aggregates.

8. Record the weight.

9. Put it in oven for drying 24 hours.

10. Weight to get the bitumen content that was present in aggregates.

11. Wash the aggregate with fresh water.

12. Leave sample for drying.

13. Perform sieve analysis

14. Record the gradation weight on every sieve.

15. Calculate %passing and specific gravity (same as performed above).

Written By: Ahmed Zakaria 34

 Department of
Civil
Technology

Pictorial Explanation

Preparation of trial mix for compression test and filling of cylinders and
cubes.

Slump Test is performed before filling of cubes and cylinders.

Written By: Ahmed Zakaria 35

 Department of
Civil
Technology

Cylinders and cube sample are kept under direct sunlight and water
respectively for compression test at 3 7 and 28 days.

Cylindrical and cubical compression are in progress in respective test

machines.

The LCD shows the result.

Written By: Ahmed Zakaria 36

 Department of
Civil
Technology

Batching Plant and transit mixer.

Type of aggregate separated after flakiness and elongation index test.

Written By: Ahmed Zakaria 37

 Department of
Civil
Technology

References

http://www.pavementinteractive.org/article/fine-aggregate-specific-gravity/
http://www.pavementinteractive.org/article/fine-aggregate-angularity/
http://www.pavementinteractive.org/article/sand-equivalent/

Written By: Ahmed Zakaria 38