Mix Design For Concrete Roads As Per IRC-15-2002

engineeringcivil.com/mix-design-for-concrete-roads-as-per-irc-15-2002.html

By
Er. Kaushal Kishore ,
Materials Engineer, Roorkee

Check out the Mix Design For Concrete Roads As Per IRC:15-2011

ABSTRACT:
The stresses induced in concrete pavements are mainly flexural. Therefore flexural
strength is more often specified than compressive strength in the design of concrete mixes
for pavement construction. A simple method of concrete mix design based on flexural
strength for normal weight concrete mixes is described in the paper.

INTRODUCTION:
Usual criterion for the strength of concrete in the building industry is the compressive
strength, which is considered as a measure of quality concrete. however, in pavement
constructions, such as highway and airport runway, the flexural strength of concrete is
considered more important, as the stresses induced in concrete pavements are mainly
flexural. Therefore, flexural strength is more often specified than compressive strength in
the design of concrete mixes for pavement construction. It is not perfectly reliable to
predict flexural strength from compressive strength. Further, various codes of the world
specified that the paving concrete mixes should preferably be designed in the laboratory
and controlled in the field on the basis of its flexural strength. Therefore, there is a need to
design concrete mixes based on flexural strength.

The type of aggregate can have a predominant effect, crushed rock aggregate resulting in
concrete with higher flexural strength than uncrushed (gravel) aggregates for comparable
mixes, assuming that sound materials are used. The strength of cement influences the
compressive and flexural strength of concrete i.e. with the same water-cement ratio,
higher strength cement will produce concrete of higher compressive and flexural strength.

MIX DESIGN DETAILS

IRC: 15-2002 specified that for concrete roads OPC should be used. This code also
allowed PPC as per IS: 1489 may also be used. Accordingly OPC + fly ash may be used in
concrete roads. However, IS: 456-2000 specified that fly ash conforming to grade-1 of IS-
3812 may be used as part replacement of OPC provided uniform blended with cement is
essential. The construction sites where batching plants are used this may be practicable.
In ordinary sites where mixer or hand mixing are done uniform blending of fly ash with
cement is not practicable. At such construction sites, PPC may be used.

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1 Characteristic 4.5N/mm2
Flexural
Strength at
28 days

2 Cement Three mixes are to be designed

MIX-A
With PPC (Flyash based) conforming to IS:1489-part-I-1991. 7
days strength 37.5N/mm2. Specific Gravity: 3.00

MIX-B
With OPC-43- Grade conforming to IS: 8112-1989. 7 days
strength 40.5N/mm2. Specific Gravity : 3.15

MIX-C
With OPC of Mix-B and Fly ash conforming to IS:3812 (Part-
I)-2003 Specific Gravity : 2.20

Note Requirements of all the three mixes are the same. Fine
Aggregate, Coarse Aggregate and Retarder Super plasticizer are
the same for all the three mixes.

3 Fly ash 25% Fly ash is required to be replaced with the total cementitious
replacement materials.

4 Maximum 20 mm Crushed aggregate

nominal size
of aggregates

5 Fine River sand of Zone-II as per IS:383-1970

aggregate

6 Minimum 350 kg/m3 including Fly ash

cement
content

7 Maximum 0.50
free W/C
Ratio

8 Workability 30 mm slump at pour the concrete will be transported from central

batching plant through transit mixer, at a distance of 20 Km during
June, July months. The average temperature last year during
these months was 400C.

9 Exposure Moderate
condition

10 Method of Fully mechanized construction

placing

11 Degree of Good
supervision

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 12 Maximum of 425 kg/m3
cement
content (Fly
ash not
included)

13 Chemical Retarder Super plasticizer conforming to IS:9103-1999. With the

admixture given requirements and materials, the manufacturer of Retarder
Super plasticizer recommends dosages of 10 gm per kg of OPC,
which will reduce 15% of water without loss of workability. For fly
ash included cement dosages will be required to be adjusted by
experience/ trials.

14 Values of 1.65 x 0.5 N/mm2

Jaxo-

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TEST DATA FOR MATERIALS AND OTHER DETAILS
1. The grading of fine aggregate, 10 and 20 mm aggregates are as given in Table. 1 ( given
in the end). Fine aggregate is of zone-II as per IS:383-1970. 10 and 20 mm crushed
aggregate grading are single sized as per IS: 383-1970.

2. Properties of aggregates

Tests Fine aggregate 10mm aggregate 40mm aggregate

Specific Gravity 2.65 2.65 2.65

Water Absorption % 0.8 0.5 0.5

3. Target average flexural strength for all A, B and C mixes

S = S’+ Jao-
= 4.5 + 1.65 x 0.5
= 5.3 N/mm2 at 28 days age

4. For Mix A and B free W/C ratio with crushed aggregate and required average flexural
target strength of 5.3 N/mm2 at 28 days from Fig. 1 Curve D ( Figure shown in the end)
found to be 0.42. This is lower than specified maximum W/C ratio value of 0.50
Note: In absence of cement strength, but cement conforming to IS Codes, assume from
Fig. 1

Curve A and B – For OPC 33 Grade

Curve C and D – For OPC 43 Grade

Take curves C and D for PPC, as PPC is being manufactured in minimum of 43 Grade of
strength.

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5. Other data’s: The Mixes are to be designed on the basis of saturated and surface dry
aggregates. At the time of concreting, moisture content of site aggregates are to be
determine. If it carries surface moisture this is to be deducted from the mixing water and
if it is dry add in mixing water the quantity of water required for absorption. The weight of
aggregates are also adjusted accordingly.

DESIGN OF MIX-A WITH PPC

a) Free W/C ratio for the target flexural strength of 5.3 N/mm2 as worked out is 0.42

b) Free water for 30 mm slump from Table 2 for 20 mm maximum size of aggregate.
2/3*165 + 1/3*195
= 175 kg/m3

From trials it is found that Retarder Super plasticizer at a dosages of 15gm/kg of cement
may reduce 15% water without loss of workability
Then water = 175 – (175 x 0.15) = 148.75 kg/m3
For trials say 149 kg/m3

c) PPC = 149/0.42 = 355 kg/m3

This is higher than minimum requirement of 350 kg/m3

d) Formula for calculation of fresh concrete weight in kg/m3

UM = 10 x Ga (100 – A) + CM(1 – Ga/Gc) – WM (Ga – 1)

Where,
Um = Weight of fresh concrete kg/m3

Ga = Weighted average specific gravity of combined fine and coarse aggregate bulk, SSD

Gc = Specific gravity of cement. Determine actual value, in absence assume 3.15 for OPC
and 3.00 for PPC (Fly ash based)

A = Air content, percent. Assume entrapped air 1.5% for 20 mm maximum size of
aggregate and 2.5% for 10mm maximum size of aggregate. There are always entrapped air
in concrete. Therefore ignoring entrapped air value as NIL will lead the calculation of
higher value of density.

Wm = Mixing water required in kg/m3

Cm = Cement required, kg/m3

Note:- The exact density may be obtained by filling and fully compacting constant volume
suitable metal container from the trial batches of calculated design mixes. The mix be
altered with the actual obtained density of the mix.

Um = 10 x Ga (100 – A) + Cm (1 – Ga/Gc) – Wm (Ga – 1)

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= 10 x 2.65 (100 – 1.5) + 355(1- 2.65/3.00) – 149 (2.65 -1)
= 2405.9 kg/m3
Say 2405 kg/m3

e) Aggregates = 2405 – 355 – 149 = 1901 kg/m3

f) Fine aggregate = From Table 3 for zone-II Fine aggregate and

20 mm maximum size of aggregate, W/C ratio = 0.42, 30 mm slump found to be 35%.

Fine aggregate = 1901 x 0.35 = 665 kg/m3

Coarse aggregate = 1901 – 665 = 1236 kg/m3

10 and 20 mm aggregate are single sized as per IS: 383-1970. Let they be combined in the
ratio of 1.2:1.8 to get 20 mm graded aggregate as per IS: 383-1970

10 mm aggregate = 1236×1.2/3 = 494 kg/m3

20 mm aggregate = 1236×1.8/3 = 742 kg/m3

g) Thus for 4.5 N/mm2 flexural strength quantity of materials per cu.m. of concrete on the
basis of saturated and surface dry aggregates:

Water = 149 kg/m3

PPC = 355 kg/m3
Fine Aggregate (sand) = 665 kg/m3
10 mm Aggregate = 494 kg/m3
20 mm Aggregate = 742 kg/m3
Retarder Super Plasticizer = 5.325 kg/m3

MIX- B WITH OPC

a) Water = 175 – (175 x 0.15) = 149 kg/m3 say 149 kg/m3

b) OPC = 149/0.42 = say 355 kg/m3

c) Density: 10 x 2.65 (100 – 1.5) + 355 (1 – 2.65/3.15) – 149 (2.65 – 1)

= 2420.8 kg/m3 say 2420 kg/m3

d) Total Aggregates = 2420 – 355 – 149 = 1916 kg/m3

Fine Aggregate = 1916 x 0.35 = say 670 kg/m3
Coarse aggregate = 1916 – 670 = 1246 kg/m3
10 mm Aggregate = 1246×1.2/3 = 498 kg/m3
20 mm Aggregate = 1246×1.8/3 = 748 kg/m3

e) Thus for 4.5 N/mm2 flexural strength quantity of materials per cu.m of concrete on the
basis of SSD aggregates are given below:

Water = 149 kg/m3

OPC = 355 kg/m3
Fine Aggregate (sand) = 670 kg/m3

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10 mm Aggregate = 498 kg/m3
20 mm Aggregate = 748 kg/m3
Retarder Super Plasticizer = 3.550 kg/m3

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MIX. C WITH OPC + FLYASH
With the given set of materials increase in cementitious materials = 10.7%
Total cementitious materials = 355×1.107 = 393 kg/m3

Materials Weight (kg/m3) Volume (m3)

OPC = 393 x 0.75 295/3150 0.0937

Flyash = 393 x 0.25 98/2200 0.0445

Free Water = 149 x 0.95 142/1000 0.142

Retarder Super Plasticizer = 6.2 kg 6.2/1150 0.0054

Air = 1.5% 0.015

Total 0.3006

Total Aggregates = 1 – 0.3006 0.6994

Coarse Aggregate 1246/2650 0.4702

Fine Aggregate = 0.6994 – 0.4702 = 0.2292

= 0.2292 x 2650 = 607 kg

Note:-
1. Specific gravity of Normal Superplasticizer = 1.15
2. Addition of Flyash reduces 5% of water demand.

For 4.5 N/mm2 flexural strength quantity of material per cu.m of concrete on
the basis of saturated and surface dry aggregates of

Mix ‘A’, ‘B’ and ‘C’ are given below:

Materials MIX. ‘A’ with Mix. ‘B’ with Mix. ‘C’ with
PPC OPC OPC+Flyash

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 Water kg/m3 149 149 142

PPC kg/m3 355 — —

OPC kg/m3 — 355 295

Flyash kg/m3 — — 98

Fine Agg. kg/m3 665 670 607

10mm Agg. kg/m3 494 498 498

20 mm Agg. kg/m3 742 748 748

Retarder Super- plasticizer 5.325 3.550 6.2

kg/m3

W/Cementations ratio 0.42 0.42 0.361

Note:-

1. For exact W/C ratio the water in admixture should also be taken into account.

2. The W/C ratio of PPC and OPC is taken the same assuming that the strength properties
of both are the same. If it is found that the PPC is giving the low strength then W/C ratio
of PPC have to be reduce, which will increase the cement content. For getting early
strength and in cold climate the W/C ratio of PPC shall also be required to be reduced.

3. PPC reduces 5% water demand. If this is found by trial then take reduce water for
calculation.

4. If the trial mixes does not gives the required properties of the mix, it is then required to
be altered accordingly. However, when the experiences grows with the particular set of
materials and site conditions very few trials will be required, and a expert of such site very
rarely will be required a 2nd trial.

5. It may be noted that, for the fly ash concrete the total cementation material is greater
but the OP cement content is smaller, the coarse aggregate content is deliberately, the
same, the water is reduced and the density is reduced, because of the lower density of fly
ash compared with OPC.

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CONCLUSION
1. For 4.5 N/mm2 flexural strength concrete having same material and requirement, but
without water reducer, the PPC and OPC required will be 175/0.42 = 417kg/m3

2. With the use of superplasticizer the saving in cement is 62 kg/m3 and water 26 lit/m3
for PPC and OPC.

3. In the Fly ash concrete the saving in cement is 122 kg/m3 and water 33 lit/m3 including
utilization of 98 kg/m3 of fly ash witch is a waste material.

4. In the financial year 2009-2010 India has produces 200 million tonnes of cement. In
India one kg of cement produce emitted 0.93 kg of CO2. Thus the production of 200
million tonnes of cement had emitted 200 x 0.93 = 186 million tonnes of CO2 to the
atmosphere.

5. If 50 million tonnes cement in making concrete uses water reducers 7500000 tonnes of
cement can be saved. 3750000 KL of potable water will be saved and the saving of Rs.
3300 crores per year to the construction Industry. 6975000 tonnes of CO2 will be
prevented to be emitted to the atmosphere. The benefits in the uses of water reducers not
limited to this. When water reduces shrinkage and porosity of concrete are reduces which
provides the durability to concrete structures.

6. India is facing serious air, water, soil, food and noise pollution problems. Every efforts
therefore are necessary to prevent pollution on top priority basis.

7. As the stress induced in concrete pavements are mainly flexural, it is desirable that
their design is based on the flexural strength of concrete. The quality of concrete is
normally assessed by measuring its compressive strength. For pavings, however, it is the
flexural strength rather than the compression strength of concrete which determine the
degree of cracking and thus the performance of road, and it is imperative to control the
quality on the basis of flexural strength.

REFERENCES:

1 IS : 383- Specifications for coarse and fine aggregates from natural

1970 sources for concrete (second revision) BIS, New Delhi

2 IS: 456- Code of practice for plain and reinforced concrete (fourth
2000 revision), BIS, New Delhi

3 IS: 9103- Specification for admixtures for concrete (first revision) BIS, New
1999 Delhi

4 IS: 8112- Specifications for 43 Grade ordinary portland cement (first

1989 revision) BIS, New Delhi

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5 IS: 2386 method of test for aggregate for concrete. Specific gravity,
(Part-III) density, voids, absorption and bulking, BIS, New Delhi
1963

6 IS: 3812 Specification for pulverized fuel ash: Part-I for use as pozzolana
(Part-I) in cement, cement mortar and concrete (second revision) BIS,
2003 New Delhi

7 IS: 1489- Specifications for portland pozzolana cement (Part-I) Flyash

Part-I based. (Third revision), BIS, New Delhi
1991

8 IRC: 15-2002 – Standard specifications and code of practice for

construction of concrete road (third

revision)

9 Kishore Kaushal, “Concrete Mix Design Based on Flexural Strength for Air-
Entrained Concrete”, Proceeding of 13th Conference on our World in Concrete
and Structures, 25-26, August, 1988, Singapore.

10 Kishore Kaushal, “Method of Concrete Mix Design Based on Flexural Strength”,

Proceeding of the International Conference on Road and Road Transport
Problems ICORT, 12-15 December, 1988, New Delhi, pp. 296-305.

11 Kishore Kaushal, “Mix Design Based on Flexural Strength of Air-Entrained

Concrete”. The Indian Concrete Journal, February, 1989, pp. 93-97.

12 Kishore Kaushal, “Concrete Mix Design Containing Chemical Admixtures”,

Journal of the National Building Organization, April, 1990, pp. 1-12.

13 Kishore Kaushal, “Concrete Mix Design for Road Bridges”, INDIAN

HIGHWAYS, Vol. 19, No. 11, November, 1991, pp. 31-37

14 Kishore Kaushal, “ Mix Design for Pumped Concrete”, Journal of Central Board
of Irrigation and Power, Vol. 49, No.2, April, 1992, pp. 81-92

15 Kishore Kaushal, “Concrete Mix Design with Fly Ash”, Indian Construction,
January, 1995, pp. 16-17

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 16 Kishore Kaushal, “High-Strength Concrete”, Bulletin of Indian Concrete Institute
No. 51, April-June, 1995, pp. 29-31

17 Kishore Kaushal, “Concrete Mix Design Simplified”, Indian Concrete Institute

Bulletin No. 56, July-September, 1996, pp.
25-30.

18 Kishore Kaushal, “Concrete Mix Design with Fly Ash & Superplasticizer”, ICI
Bulletin No. 59, April-June 1997, pp. 29-30

19 Kishore Kaushal. “Mix Design for Pumped Concrete”, CE & CR October, 2006,
pp. 44-50.

Table. 1: Grading of Aggregates

IS Sieve Designation Percentage Passing

Fine Aggregate Crushed Aggregate

10 mm 20 mm

40 mm — — 100

20 mm — — 100

12.5 mm — 100 —

10 mm 100 89 0

4.75 mm 98 6

2.36 mm 86 0

1.18 mm 71

600 Micron 40

300 Micron 21

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 150 Micron 5

Table. 2: Approximate free-water content (kg/m3) required to give various

levels of workability for non-air-entrained (with normal entrapped air)
concrete.

Maximum size of aggregate(mm) Type of aggregate Slump(mm) 15-45

10 Uncrushed Crushed 185

215

20 Uncrushed Crushed 165

195

Note:- When coarse and fine aggregate of different types are used, the free water content
is estimated by the expression.
2/3Wf+1/3Wc
Where,
Wf = Free water content appropriate to type of fine Aggregate
Wc = Free water content appropriate to type of coarse aggregate.

Table. 3: Proportion of fine aggregate (percent) with 10mm and 20mm

maximum sizes of aggregates and slump 15-45 mm.

Grading Zone of F.A W/C Ratio 10 mm aggregate 20 mm aggregate

I 0.3 47-57 37-45

0.4 49-59 39-47

0.5 51-61 41-49

II 0.3 39-48 30-37

0.4 41-50 32-39

0.5 43-52 34-41

III 0.3 32-38 25-30

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 0.4 34-40 27-32

0.5 36-42 29-34

IV 0.3 28-32 22-26

0.4 30-34 24-28

0.5 32-36 26-30

I am thankful to Sir Kaushal

Kishore for publishing his
research work here on
engineeringcivil.com. I am sure,
this research paper will help
many civil engineers around the
world in understanding how to
do mix design for concrete
roads as per IRC-15-2002.

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