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CHAPTER 5
EXPERIMENTAL WORK
CONCRETE MIX DESIGN (M25 GRADE)
Mix proportions are calculated as per the design guidelines of IS 10262:2009 using a
W/C of 0.45.
Characteristic compressive strength = 25 N/mm2
Type of cement = OPC 53 grade
Maximum size of aggregate = 20 mm
Degree of workability = 0.9 (compaction factor)
Type of exposure = mild
Specific gravity of cement = 3.125
Specific gravity of fine aggregate = 2.69
Specific gravity of coarse aggregate = 2.72
Sieve analysis:
Fine aggregate –zone 111 (Refer table 4 of IS 383)
STEP 1: TARGET STRENGTH FOR MIX
f 'ck = fck +1.65 s
= 25+1.65x4 (s=4N/mm2, refer table 1)
f 'ck = 31.6N/mm2
STEP 2: SELECTION OF WATER CEMENT RATIO
For M25 concrete mix water cement ratio = 0.45(Refer Table 5 of IS456:2000)
STEP 3: SELECTION OF WATER CONTENT
Maximum water content for 20mm aggregate = 186lit (for 25mm to 50 mm slump)
Increase 3% of water content for every 25mm slump range
To attain maximum of 100 mm slump range = 6% increase in water content
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Estimated water content for 100 mm slump = 186+ 6 x 186
100
= 197 litre
STEP 4: CALCULATION OF CEMENT CONTENT
Water cement ratio = 0.45
197
Cement content =
0.45
Cement content = 437.7kg/m3
For table 5 is 456, minimum cement content for mild exposure condition = 300kg/m3
Above calculated cement content values > 300kg/m3
Hence ok
In present case water cement ratio is 0.45 (w/c) adjustment = 0.65
+/- for every 0.05 change in water cement ratio
Water cement ratio 0.45
Volume of coarse aggregate = 0.65
Volume of fine aggregate =0.35
STEP 5: MIX CALCULATIONS
Mix calculations per unit volume of concrete shall be as follows.
Volume of concrete = 1m3
Volume of cement = mass of cement x 1
Sp-gravity of cement 1000
= 437.7 x 1
3.125 1000
= 0.140 m3
Volume of water = mass of water x 1
Sp-gravity of water 1000
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= 197 x 1
1 1000
= 0.197 m3
Volume of all in aggregate = (1-(0.158+0.197))
= 0.663m3
Mass of coarse aggregate = 0.663 x 0.65 x 2.72 x 1000
= 1172 kg
Mass of fine aggregate = 0.663 x 0.35 x 2.69 x 1000= 624 kg
STEP 6: MIX PROPORTION FOR M25 GRADE CONCRETE
Table 3.4 - Mix Proportion for M25 Grade Concrete
Cement Water content Fine aggregate Coarse aggregate Water
Kg/m3 Kg/m3 Kg/m3 Kg/m3 cement
ratio
437.7 197 624 1172 0.45
1 0.45 1.43 2.68 0.45
4.6 PREPARATION OF SPECIMENS
4.6.1 Preparation of Conventional Concrete
Preparation of test specimen includes the following procedure:
Batching
The quantity of ingredients (Cement, Fine aggregate, Coarse aggregate and water)
were arrived by conducting proper weigh batching and stored separately for mixing.
Preparation of mould
The mould for prism was collected and they are properly checked for their
dimensions. Crude Oil can be applied to inner side of the moulds for the smooth replace.
Mixing
The Cement and Sand in the specified proportions are mixed throughly. Then this
mixture is spread evenly on a coarse aggregate.
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The mixture is turned over twice in a dry state. Then the measured quantity of water is
added and the mixture throughly to get an uniform mix.
Compacting
Compacting is done by using steel rod. All fresh concrete contains tiny bubbles of
air. The process of removal of entrapped air and uniform placement of concrete to form
homogeneous dense mass is termed as Compaction.
Curing
Water curing is used for conventional concrete. Curing concrete can be defined as
a chemical process that ensures the hydration of cement in newly placed concrete. The
curing process is part of the chemical reaction between Portland cement and water to
hydrate the product, creating a gel that can be laid down only in water-filled space. It
usually involves the control of moisture loss and the temperature affecting the hydration
process.
Demoulding
The casted specimens are demoulded in such a way that there is no possibilities of
damaging of specimens.
3.6.2 Preparation of Hypo Sludge Concrete
Preparation of test specimen includes the following procedure:
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Figure 4.1 Material collection
Batching
The quantity of ingredients (Cement, sikacrete, Fine aggregate, coarse aggregate
Hypo Sludge and water) were arrived by conducting proper weigh batching and stored
separately for mixing.
Preparation of mould
The mould for prism, cube and cylinders were collected and they are properly
checked for their dimensions. Crude Oil can be applied to inner side of the moulds for the
smooth replace.
Mixing
The Cement and Sand in the specified proportions are mixed throughly. Then this
mixture is spread evenly on a coarse aggregate.The mixture is turned over twice in a dry
state. Then the measured quantity of water is added and the mixture throughly to get an
uniform mix.
Figure 4.2 Mixing of materials
Compacting
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Specimen each one set were casted. Specimen was prepared by various
proportion of Hypo Sludge in 5%, 10%, 15%, and 20%.
Figure 4.3 casting of cube
Figure 4.2 Packing of Concrete
Demoulding
The casted specimens are demoulded in such a way that there is no possibilities of
damaging of specimens.
Figure 4.4 Demoulding of beams
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Curing
28 days curing achive strength.Water curing is used for recycled course concrete.
Curing concrete can be defined as a chemical process that ensures the hydration of
cement in newly placed concrete. The curing process is part of the chemical reaction
between Portland cement and water to hydrate the product, creating a gel that can be laid
down only in water-filled space. It usually involves the control of moisture loss and the
temperature affecting the hydration process.
Figure 4.5 Curing of Specimen.
TESTING OF CONCRETE CUBES:
Out of many test applied to the concrete, this is the utmost important which gives an idea
about all the characteristics of concrete. By this single test one judge that whether Concreting has
been done properly or not.
Compressive strength of concrete depends on many factors such as water-cement ratio, cement
strength, quality of concrete material, quality control during production of concrete etc.
Test for compressive strength is carried out either on cube or cylinder. Various standard codes
recommend concrete cylinder or concrete cube as the standard specimen for the test. American
Society for Testing Materials ASTM C39/C39M provides Standard Test Method
for Compressive Strength of Cylindrical Concrete Specimens.
