VISVESVARAYA TECHNOLOGICAL UNIVERSITY

JNANA SANGAMA, BELAGAVI, KARNATAKA, INDIA -590018.

Project Work Phase1 (18CVP78) Report on

“ANALYZING CHALLENGES IN CONCRETE MIX DESIGN AND
CONSOLIDATION TECHNIQUES: A COMPREHENSIVE STUDY ON
VOLUME BATCHING AND WEIGH BATCHING PRACTICES.”

For the requirement of 7th Semester B.E in Civil Engineering

Submitted by

MOTI KR.SHA (1KT20CV003)

SUMESH KR.YADAV (1KT20CV008)
UJJWAL BHAGAT (1KT20CV009)
BIDISHA KAR (1KT21CV401)

Under the guidance of

Internal Guide Head of the Department

DEPARTMENT OF CIVIL ENGINEERING & SCIENCE

SRI KRISHNA INSTITUTE OF TECHNOLOGY
BENGALURU-560090.
 SRI KRISHNA INSTITUTE OF TECHNOLOGY
No.29, Chimney Hills, Hesaraghatta Main Road, Chikkabanavara Post
Bengaluru-560090.

Department of Civil Engineering & Science

CERTIFICATE

This is to certify that the project work entitled “ANALYZING CHALLENGES IN

CONCRETE MIX DESIGN AND CONSOLIDATION TECHNIQUES: A
COMPREHENSIVE STUDY ON VOLUME BATCHING AND WEIGH
BATCHING PRACTICES.” proposed by UJJWAL BHAGAT (1KT20CV009),
are bonafide students of SRI KRISHNA INSTITUTE OF TECHNOLOGY, have
successfully submitted the Project Work Phase-1 (18CVP78) report, in Partial
Fulfillment for 7th semester Bachelor of Engineering in Civil and Engineering of the
VISVESVARAYA TECHNOLOGY UNIVERSITY, Belgavi, during the year
2023-24. It is certified that all corrections/suggestions indicated for internal
assessment have been incorporated in the report and not been submitted to any other
University wholly or in part for award of any other degree.

Signature of the guide Signature of the HOD

 ABSTRACT
Batching of concrete is generally the proportioning of the different constituents of
concrete before mixing which could be by weight or volume. Mix-design justified by
trial test is the best method to achieve a concrete of desired properties. Standardized
prescribed concrete (SPC) mix-design is mostly adopted in mass concreting to high
strength concreting applications in most developing nations. British standards accept
volume batching for SPC only in mass concrete (20 MPa) recommended to be
batched by weight. Designs batched by volume have been identified as the most
commonly used method in concrete production in Nigeria and most developing
nations, especially by medium to small scale construction firms due to the very high
cost of employing batching plants.

This research work developed a modified volumetric batch mix-design that will be
equivalent to SPC design mix batched by weight in normal and higher strength
concrete. The physical properties of the constituent concrete materials, fine aggregate,
12 and 19 mm sized coarse aggregates were determined. The strength of SPC mix of
ST2, ST4, and ST5 to British standard were determined when batched by weight and
their volume equivalents mix-design batch determined.

The strengths of these SPC mixes were batched by volume and their weight equivalent batch-
design determined. A relationship was determined between both batching mixdesign methods
for all the prescribed mixes and strengths using the binder-aggregate and coarsefine aggregate
ratios, such that the preferred weight batching design mix could be achieved by a modified
mix-design batched by volume. This study concludes that concrete mix-design batched by
weight is superior to when batched by volume and the desired design batching by weight
could be achieved by generating a modified mix-design-batch by volume. This will improve
the quality of concrete storey buildings in most developing nations

I
 ACKNOWLEDGEMENT

We consider it is a special privilege to express a few word of gratitude and respect to all
those who have guided and inspired us in completing the first phase project work. The
success of the project depends largely on the encouragement and guideline of many
other. We take this opportunity to express our gratitude to the people who have been
instrumental in successful completion of the Project Work Phase 1.

We would like to profoundly thank the Management of Sri Krishna Institute of

Technology [SKIT] for providing such a working environment for successful
completionof the project report.

We express our sincere thanks to Dr. Mahesha K, Principal of Sri Krishna Institute
of Technology, for his courteous comments and valuable suggestions, which enabled
the successful completion of the Project Work Phase 1.

We express our gratitude to Dr. Roopa Bhandiwad, Head of the Department ofCivil
Engineering & Science, for her constant support, kind guidance and encouragement.

Our special thanks to Project coordinators Prof. Mohan K T, Asst. Professor,

Department of Civil Engineering & Science who inspired us in taking up this project
and guided with required necessities for carrying out of the Project Work Phase 1.

We are also thankful to our parents who have always been our mentors.

II
 TABLE OF CONTENTS

No. Description Page No.

CHAPTER 1 INTRODUCTION 1-5

1.1 Introduction of Topic 1
1.2 Problem Statement 2
1.3 Objectives of the project 2
1.4 Scope 3
3
CHAPTER 2 LITERATURE SURVEY 6-11

CHAPTER 3 REQUIREMENTS SPECIFICATION 12-15

CHAPTER 4 METHODOLOGY 16-18

REFERENCES 20

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CONSOLIDATION TECHNIQUES

CHAPTER 1

INTRODUCTION
1.1 Introduction
Batching of concrete refers to the process of measuring and combining the ingredients
required for making concrete. These ingredients typically include cement, aggregates
(such as sand, gravel, or crushed stone), water, and sometimes admixtures or additives.
The batching process plays a crucial role in ensuring the quality and consistency of the
resulting concrete. The choice of batching method depends on the size of the job,
production rate, and standards of batching performance.

TYPES OF BATCHING:

1. Volume Batching:

Volume batching is a traditional method of concrete batching where materials are

measured based on their volume rather than weight. In this approach, the proportions of
the various components, such as cement, aggregates, and water, are specified in terms of
volume (cubic meters or cubic feet). While widely used in smaller construction projects,
volume batching can be less precise than its weight-based counterpart, as it relies on the
assumption that the materials have consistent densities. Challenges may arise due to
variations in material properties and compaction, potentially affecting the overall quality
of the concrete mix.

Fig 1.1: Volume batching

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2. Weigh Batching:
Weigh batching is a modern and more precise method that measures materials based on
their weight rather than volume. Each component, including cement, aggregates, and
water, is weighed using calibrated scales. This method ensures a more accurate mix, as it
accounts for variations in material density and moisture content. Weigh batching is
commonly used in large-scale construction projects where precision and consistency are
crucial for meeting specific strength and durability requirements. While it requires more
sophisticated equipment, weigh batching offers improved control over the mix's
composition, contributing to better overall concrete quality.

Fig 1.1: weigh batching.

3. Continuous Batching:

Continuous batching is a method where materials are continuously fed into the mixer in
predetermined proportions, allowing for a steady and uninterrupted concrete production
process. This approach is particularly advantageous for large-scale projects with high
concrete demand. Continuous batching systems can enhance efficiency by reducing
downtime between batches and ensuring a constant flow of concrete. However, they
require careful monitoring and control to maintain accurate proportions and prevent
variations in the mix.

4. Discontinuous Batching:

Discontinuous batching, also known as batch batching, involves dividing the concrete
production process into distinct batches. Each batch consists of a predetermined quantity
of materials, which are mixed together before the next batch begins. This method is
common in smaller projects and provides more flexibility in adjusting mix proportions.

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However, discontinuous batching may lead to variations in concrete quality between
batches, and careful attention is needed to ensure consistency.

5. Low-Volume Batching:

Low-volume batching refers to a method suitable for smaller construction projects where
the overall demand for concrete is limited. It involves the precise measurement of
materials in relatively smaller quantities compared to high-volume batching systems.
While it may lack the scale efficiency of larger systems, low-volume batching offers
greater flexibility and cost-effectiveness for projects with lower concrete requirements.

6. High-Volume Batching:

High-volume batching is employed in large-scale construction projects where the demand

for concrete is substantial. This method is designed to handle significant quantities of
materials efficiently. High-volume batching systems often incorporate advanced
technologies and automation to ensure accurate measurements and consistent mixing.
While they may require more substantial initial investment, these systems contribute to
enhanced productivity and quality control in extensive construction endeavors.

COMPARISON BETWEEN VOLUME BATCHING AND WEIGH BATCHING:

Concrete production involves complex processes that require precise batching of ingredients t o
achieve optimal quality. Two primary methods of batching concrete are volume batching and
weigh batching. Volume batching involves measuring the ingredients based on their volume,
while weigh batching measures the ingredients based on their weight. Weigh batching is more
precise than volume batching and is commonly used in large-scale concrete production. The
selection of a batching method depends on several factors, including project requirements,
accuracy and precision, project size, concrete production rate, availability of skilled workers,
moisture content and aggregate characteristics, and equipment and technology. Proper batching
enhances the workability of concrete, reduces segregation or bleeding, and minimizes the wastage
of concrete ingredients. However, poorly batched concrete ingredients may result in porous
concrete, voids, and leakages in the house.

In volume batching, the challenge lies in maintaining consistent mix proportions, posing potential
risks to the structural integrity of the concrete. Material variations introduce an element of

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unpredictability, making it difficult to sustain a uniform mix. The complexities associated with
workability and rheology further complicate the process, influencing the ease with which concrete
can be handled, placed, and compacted during construction.

Moreover, the instruments used in volume batching systems, such as containers or buckets, can
introduce irregularities in shape and size, affecting the accuracy of mix proportions and thus
influencing mixed design calculations. Issues with these instruments may impact the overall
precision of the concrete mix.

Weigh batching, relying on precise measurements, faces challenges in quality control. Variations
in weighing accuracy can result in deviations from desired mix proportions, affecting the overall
strength and durability of the concrete. Additionally, the broader environmental impact of concrete
production raises sustainability concerns, demanding a closer examination of both volume and
weigh batching practices.

In the pursuit of refining concrete production, technological advancements present both

opportunities and challenges. While innovative technologies have the potential to address existing
issues, their adoption necessitates a comprehensive understanding of intricacies.

This study delves into the challenges inherent in volume and weighs batching methods, with a
specific focus on inconsistent mix proportions, material variability, workability and rheology
complexities, quality control issues, environmental considerations, and the impact of instruments
on mixed design calculations. Through meticulous examination, the study aims to unveil effective
solutions and establish best practices. The overarching goal is to ensure concrete quality and
structural performance while promoting sustainability within the construction industry,
specifically concentrating on volume and weigh batching.
1.2 PROBLEM STATEMENT:

Producing good concrete faces significant challenges, especially when using volume and
weigh batching methods. Inconsistencies in mixing proportions, uncertainties due to
material variations, complexities in workability and rheology, persistent quality control
issues, environmental concerns, and the need for embracing technological advancements
collectively create hurdles in refining concrete production. This emphasizes the urgent
requirement for a thorough study specifically focusing on volume and weigh batching
methods. The study aims to deeply investigate these challenges, carefully explore
practical solutions, and establish a guide of best practices. The ultimate objective is not
only to ensure concrete quality but also to enhance structural performance and encourage
sustainability in the construction industry, specifically within the context of volume and
weigh batching techniques.

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1.3 OBJECTIVES:

 Investigate the impact of instrument practices on concrete mix design in volume

and weigh batching methods.

 Identify challenges arising from instrument misuse and its consequences on the
quality and consistency of the concrete mix.

Volume Batching and Instrument Influence:

 Analyze the effect of instrument practices on volume batching, emphasizing

how inaccuracies impact mix ratios and material proportions.

 Investigate how instrument errors contribute to variations in concrete quality in

volume batching.

Weigh Batching and Instrument Precision:

 Evaluate the influence of instrument precision on weigh batching, focusing on

how inaccuracies affect the final concrete mix.

 Examine the correlation between instrument errors and the reliability of

material proportions in weigh batching.

Comparison of Batching Instruments:

 Conduct a comparative analysis of instruments commonly used in both volume

and weigh batching.

 Identify specific challenges associated with each type of instrument and their
impact on mix design.

Quality Control in Mix Design:

 Emphasize the role of instrument practices in maintaining quality control

during concrete mix design.

 Provide recommendations for improving instrument calibration and usage to

enhance mix design accuracy.

Real-World Examples of Instrument Impact:

 Present real-world case studies illustrating how instrument practices influence

concrete mix design in construction projects.

 Highlight instances where instrument misuse led to challenges in achieving

desired mix properties.

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Recommendations for Instrument Optimization:

 Propose practical recommendations for optimizing the use of instruments in

both volume and weigh batching.

 Offer guidelines for proper instrument calibration, maintenance, and usage in

the context of mix design.

Understanding Material Variability and Instrument Impact:

 Investigate how variations in material properties, coupled with instrument

practices, impact the precision of concrete mix design.

 Discuss strategies for minimizing the combined impact of material variability

and instrument errors.

1.4 SCOPE:
Concrete Mix Design:

Explore challenges and considerations in contemporary concrete mix design practices.

Focus on how variations in batching methods (volume and weigh batching) impact the
final mix properties.

Volume Batching:

Investigate challenges specific to volume batching practices, including mix ratio

consistency and issues with material proportions.
Assess the influence of material density variations on concrete quality in volume batching.

Weigh Batching:

Examine challenges related to weigh batching, particularly the impact of instrument

inaccuracies on the final concrete mix.
Evaluate how material characteristics interact with instrument precision in weigh
batching.

Comparison of Batching Methods:

Conduct a detailed comparative analysis of commonly used instruments in both volume

and weigh batching.
Identify and highlight challenges associated with each type of instrument, considering
their impact on mix design.

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Instrument Influence on Mix Design:

Explore how instrument practices influence concrete mix design outcomes in both volume
and weigh batching.

Investigate the correlation between instrument errors and the reliability of material
proportions in mix design.

Quality Control in Mix Design:

Emphasize the role of instrument practices in maintaining quality control during concrete
mix design.

Provide practical recommendations for enhancing instrument calibration and usage for
improved mix design accuracy.

Real-World Examples:

Present real-world case studies illustrating the direct impact of instrument practices on
concrete mix design in construction projects.

Highlight instances where improper instrument use led to challenges in achieving desired
mix properties.

Recommendations for Optimization:

Propose actionable recommendations for optimizing the use of instruments in both

volume and weigh batching for mix design.

Offer guidelines for proper instrument calibration, maintenance, and usage to enhance mix
design precision.

Understanding Material Variability and Instrument Impact:

Investigate how variations in material properties, coupled with instrument practices,

impact the precision of concrete mix design.

Discuss strategies for minimizing the combined impact of material variability and
instrument errors on mix design.

By delving into these specific areas, the study aims to provide a comprehensive
understanding of how instrument practices affect concrete mix design, with a focus on
both volume and weigh batching methods.

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Chapter 2

LITERATURE SURVEY

 What is Literature survey in a project report?

A literature survey, often referred to as a literature review, is a critical and
systematic examination of existing literature, scholarly articles, books, and other
sources relevant to the subject or topic of a project. It is an integral component of a
project report and serves several purposes:

1. Understanding Existing Knowledge:

The literature survey provides a comprehensive overview of existing knowledge,

theories, and findings related to the project's subject matter. It helps the researcher
understand what has already been explored and documented in the chosen field.

2. Identifying Gaps and Research Questions:

By reviewing existing literature, the researcher can identify gaps, inconsistencies, or

unanswered questions in the current body of knowledge. This process guides the
formulation of specific research questions that the project aims to address.

3. Establishing Relevance and Justification:

A literature survey helps establish the relevance and justification for the research
project. By showcasing the existing state of knowledge and emphasizing the gaps, it
clarifies why the proposed project is necessary and how it contributes to advancing the
field. Various papers are available that contain information on

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2.2 LITERATURE SURVEY:

[1]"On February 20, 2020, the authors of the article are Opeyemi Joshua, Kolapo O.
Olusola, David O. Nduka, Anthony N. Ede, Oluwarotimi M. Olofinnade, and Olorunmeye
F. Job. This paper introduces 'Modified mix design development specification batched by
volume from specified mix design by weight towards improved concrete production.”

The article "Modified mix design development specification batched by volume from
specified mix design by weight towards improved concrete production" presents a method
for deriving a mix design to be batched by volume from a specified mix design by weight
using a design chart. The study found that concrete mix designs batched by volume,
common in many developing countries, result in less durable concrete compared to
weight-batched mix designs. The study developed a method to address this disparity,
aiming to produce more durable concrete in developing countries. The method involves
using a design chart to derive a mix design to be batched by volume, which is equivalent
to a specified mix design by weight, as long as the target strength is not beyond 25 MPa.
The study recommends using the developed charts for deriving standardized prescribed
concrete mix designs by volume and suggests further research on other concrete
applications and aggregate sizes. The article does not explicitly mention the survey
method used in the study. Therefore, the specific survey method employed in the research
is not provided in the available information. If you have access to the full article, you may
find the details of the survey method within the document.

Predominantly, mix designs are batched by volume within the study area and most
developing countries which results to the production of less durable concrete than when
batched by weight. This practice is due to the higher cost of acquiring the batching plants
[6] employed in concrete production by medium to small scale construction firms.

This study developed a method of deriving a mix design to be batched by volume from
the specified mix designed by weight using a design chat developed from [4, 5]. Concrete
can then be produced with the derived mixed design and batched by volume as though it
was batched by weight from the specified mix design. This method eliminates the strength
disparity by both batching methods and production of more durable concrete in most
developing countries

[2] “On January 12, 2024, the study "Batching Methods and Their Influence on Properties
of Concrete – A Limited Study" was authored by Shodolapo Oluyemi Franklin and Philip
N. Kaboro. This paper describes "Batching Methods and Their Influence on Properties of
Concrete - A Limited Study" investigates the effect of mass and volume batching on the
fresh and hardened properties of concrete using a single mix proportion and water-cement
ratios of 0.5, 0.55, and 0.65. The study found that the workability increased with w/c
ratios for both methods of batching, although it was somewhat higher for mass
proportioning than for volume batching. In addition, higher compressive strengths were
obtained for concrete specimens proportioned by mass, for all w/c ratios. The coefficients
of variation of the compressive strength test results for the concrete batched by mass were
markedly lower than their equivalent counterparts produced by volume proportioning. The
article concludes that these findings were in broad agreement with the results of previous
research in the literature. The study used OPC 42.5N CEM Type 1 cement and the
specimens were cured in water for 7, 14 and 28 days as required. A total of one hundred

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and eight (108) concrete cubes of 150 mm sizes were cast for the compressive strength
tests.

Ordinary Portland cement of specification 42.5 N CEM 1 and manufactured by PPC Ltd.
was utilized for the study. This cement is suitable for the production of all reinforced
concrete work and mortars requiring high initial strength. It has ready application in a
great variety of reinforced and prestressed construction. The cement has an initial setting
time ≥ 60 minutes and final setting time of approximately 110 minutes, with a 7 day
compressive strength of 29 MPa and 28 day compressive strength of 42.5 MPa. The
coarse aggregate utilized was 13.2 mm maximum size silica stone, while the fine
aggregate employed was 4.75 mm maximum size crusher sand. The loose bulk densities
of the fine and coarse aggregates were approximately 1,600 kg/m3 and 1,440 kg/m3
respectively. The aggregates were sourced from Kgale Quarries in Gaborone.

[3] On 17 April 2018 The Authors Published by Opeyemi Joshua; Olabosipo I. Fagbenle;
Olusola Kolapo; Shunanum Shamaki, the paper introduce "A Comparative Analysis of
Batching by Weight and Volume towards Improved Concrete Production".

Batching of concrete is generally the proportioning of the different constituents of

concrete before mixing which could be by weight or volume. Mix-design justified by trial
test is the best method to achieve a concrete of desired properties. Standardized prescribed
concrete (SPC) mix-design is mostly adopted in mass concreting to high strength
concreting applications in most developing nations. British standards accept volume
batching for SPC only in mass concrete (<15 MPa) but batching by weight for normal and
higher strength concrete. Structural concrete like in storey buildings requires at least a
normal strength concrete (>20 MPa) recommended to be batched by weight. Designs
batched by volume have been identified as the most commonly used method in concrete
production in Nigeria and most developing nations, especially by medium to small scale
construction firms due to the very high cost of employing batching plants. This research
work developed a modified volumetric batch mix-design that will be equivalent to SPC
design mix batched by weight in normal and higher strength concrete.

The materials used in this study are Dangote Portland cement grade 42.5N CEM II A-L
that conforms to BS EN 197-1:2011 which was obtained from the local market; river
dredged fine aggregate sharp sand that was air-dried and sieved with the #4 sieve
(4.76mm) that conform to BS EN 12620:2002 +A1 (2008); 12mm and 19mm sized quarry
crushed coarse aggregate obtained from Odeda quarry in Abeokuta, Ogun State; and bore
hole drinkable water that is locally sourced. The data in this study are experimental. Sieve
analysis was performed on all the aggregates (both fine and the coarse samples) to
determine their gradation which will be the main physical property of the aggregate that
was tested. Standardized Prescribed Concrete (SPC) conforming to ST2, ST4 and ST5
(1:3:6, 1:2:4 and 1:1.5:3 respectively) as specified in BS 8500-2:2002 were batched by
weight with the 12mm and 19mm aggregate size and the volumetric equivalent of the
batches were determined before they were mixed with water and cast into 150mm cube
molds. The expected strengths were not to be less than 15MPa, 20MPa and 25MPa
respectively. This was repeated with the 19mm aggregates. This whole process was
repeated, but in this case batched by volume and the weight equivalent mix-design of the
volumetric design batch was determined before there were mixed with water and cast into
150mm molds. Three (3) of every set was cast with a total of thirty-six (36) cubes cast.

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The cubes were cured by immersion in a water tank for twenty-eight days and their 28-
day strengths were determined.

[4] On 17 April 2020,Kolapo O. Olusola 1, Adewumi J. Babafemi 1,*, Akaninyene A.

Umoh2 & Babatunde J. Olawuyi3.This paper investigated the effect of batching by mass
and volume on concrete’s compressive strength and workability. Influence of mix
proportion at five levels and various water-cement ratios were also studied. All samples
were cured by complete immersion in water and tested up to 28 days. The results
indicated higher workability’s for concrete batched by mass than concrete batched by
volume at all w/c ratios and mix proportions investigated. The workability increased with
increase in w/c ratios in both methods. The compressive strength results showed that for
rich structural mixes (1:1:2 and 1:1.5:3), concrete batched by mass had 20 % and 6 %
strength increases respectively over the concrete batched by volume. Ordinary structural
mix (1:2:4) had 14 % increase while non-structural mixes (1:3:6 and 1:4:8) had 8 % and 6
% increases respectively. In all cases, concrete batched by mass had better fresh and
hardened properties of concrete.

Several methods have been reported for specifying concrete mixes. The five principal
ones are designated concretes, designed concretes, prescribed concretes, standardized
prescribed concretes and proprietary concretes [1]. Concrete works are commonly carried
out on most Nigerian construction sites for housing and similar construction where
concrete is site-batched on a small site using standardized prescribed concretes which are
batched by volume.Though Neville and Brooks [2] reiterated that volume batching is a
bad practice, it is the usual practice on construction sites in Nigeria because it is easier,
simpler and faster when compared to batching by mass. Most concrete specifications
require that concrete be batched by mass and structural design is based on strength of
concrete from such mix specifications and durability of concrete. Though volume
batching is said to be generally restricted to non-structural works [3] where supervision
could be poor, in the minor Nigerian construction environment, the practice is used for
both structural and non-structural works which is in accordance with [1]. Traditionally,
nominal mix which is now known as standardized prescribed concrete is batched in ratios
(e.g. 1:1:2, 1:1½:3, 1:2:4 etc.) using head-pan or wheelbarrow measures. When batching
by volume is used, possible sources of error could lead to variation in the amount of
aggregate in a specific volume and errors in measured volume [3]. These errors often lead
to variations in the fresh and hardened properties of concrete as against specified
characteristics properties.

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CHAPTER 3

REQUIREMENTS SPECIFICATION

INTRODUCTION TO REQUIREMENT:
Requirement can be defined as a necessary condition or specification that must be met in
order to achieve the desired outcome in concrete mix design and consolidation techniques.
Requirements analysis is the process of determining the needs and expectations of a new
product or service. The stages of requirement analysis include drawing the context
diagram, gathering and categorizing requirements, interpreting and recording
requirements, and finalizing and documenting the features and functionalities required of
the end product.

Key objective of requirement:

Material Requirements:

The materials required for concrete mix design, such as cement, fine and coarse
aggregates, water, and admixtures, must be selected based on their performance and
durability requirements

Mix Design Principles:

The principles of concrete mixture design must be followed to determine the relative
proportions of the materials required to produce concrete with the desired properties of
strength and durability

Compliance with Standards:

The concrete mix design and consolidation techniques must comply with the relevant
standards, such as the ACI 211.1 standard, which provides guidelines for designing
concrete mixes for normal, heavyweight, and mass concrete

Quality Control:

Rigorous quality control measures must be enforced during construction to minimize

consolidation problems and ensure the desired outcome

Precision:

Accurate measurement and combination of materials is crucial for producing high-quality

concrete. Weigh batching is more precise than volume batching, but it requires skilled
workers

Adjustments:

Adjustments to the concrete mix, such as the addition of water, cement, or admixtures at
The job site, must be made as necessary and documented on the Weekly Concrete Report

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Material Requirements
The materials required for concrete mix design and consolidation techniques include:

Cement:

A fine powder that binds the other ingredients together and provides strength to the
concrete.

Fine Aggregate:

Small particles, such as sand, that fill the gaps between the larger aggregate particles and
help to improve the workability of the concrete.

Coarse Aggregate:

Larger particles, such as gravel or crushed stone, that provide strength and stability to the
concrete.

Water:

Used to hydrate the cement and help the other ingredients mix together.

Admixtures:

Chemicals added to the concrete mix to improve its properties, such as workability,
strength, or durability.

Instruments Required
The instruments required for volume batching and weigh batching practices include:

Gauge Boxes (Farmas):

These are constructed boxes used to measure materials based on volume in volume
batching. They are generally wooden and have known volumes

Weigh Batching Machine/Plant:

This equipment is used to measure and combine materials based on weight in weigh
batching. It can be manual, semi-automatic, or fully automatic

Moisture Content Measuring Device:

In fully automatic weigh batching, this device measures the moisture content present in
the aggregate and corrects the required quantity of water

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ANALYZING CHALLENGES IN CONCRETE MIX DESIGN AND CONSOLIDATION
CONSOLIDATION TECHNIQUES

CHAPTER 4

METHODOLOGY

Understanding Concrete Mix Design:

Familiarize yourself with the process of selecting suitable ingredients and determining the
relative proportions to produce concrete with specific performance and durability
requirements

ACI Mix Design Standard:

Study the ACI 211.1 standard, which provides guidelines for designing concrete mixes for
normal, heavyweight, and mass concrete. This standard is essential for understanding the
principles of concrete mixture design

Material Requirements:

Gain knowledge of the material requirements for concrete mix design, including cement,
fine and coarse aggregates, water, and admixtures. Different materials and proportions can
significantly impact the properties of strength and durability of the concrete

Batching Methods:

Understand the two primary methods of batching concrete: volume batching and weigh
batching. Weigh batching is considered more precise than volume batching and is
essential for ensuring the accuracy of material proportions

Instruments Used in Volume Batching:

Learn about the instruments used in volume batching, such as gauge boxes (farmas) for
measuring the quantity of each solid ingredient by loose volume using a standard gauge
box

Instruments Used in Weigh Batching:

Gain knowledge of the instruments used in weigh batching, such as weighing scales, load
cells, and weigh modules, which are placed under a tank or from suspension points to
measure the gain and loss of the batching solution

Challenges and Considerations:

Be aware of the challenges and considerations associated with each batching method and
the instruments used. For example, weigh batching is more precise and can lead to higher
compressive strength, but it requires skilled workers. On the other hand, volume batching
is less precise but may not require skilled workers

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 ANALYZING CHALLENGES IN CONCRETE MIX DESIGN AND CONSOLIDATION
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Quality Control and Adjustments:

Learn about the importance of quality control in the batching process and the need for
adjustments to the concrete mix based on factors such as aggregate moisture content.
Understanding how to make and document these adjustments is crucial for ensuring the
quality of the concrete mix

REFERENCES

[1]S. Mindess, J.F. Young and D. Darwin “Concrete”, 2nd Edition, Prentice Hall/Pearson
Education Inc., New Jersey, USA, 2003, 657 pp.

[2] F.K. Kong and R.H. Evans, “Reinforced and Prestressed Concrete”, 3rd Edition e-
book, CRC Press, London, U. Kingdom, 2017, 528 pp.

[3] M.S. Shetty and A.K. Jain, “Concrete Technology – Theory and Practice”, 8th Revised
Edition, S. Chand and Co. Ltd., New Delhi, India, 2019, 664 pp.

[4] P.K. Mehta and P.J.M Monteiro, “Concrete: Microstructure, Properties and Materials”,
3rd Edition ebook, McGraw-Hill, New York, USA, 2006, 684pp.

[5] J. Kellerman, “Manufacture and Handling of Concrete”, In: Fulton’s Concrete

Technology, 9th Edition, G. Owens (Ed.), Cement and Concrete Institute, Midrand, South
Africa, 2009.

[6] S.T. Orumu, “Modified Volume Batching Method of Concrete”, Journal of Civil
Engineering, Vol. 11, No. 1, 2016, pp. 1-9.

[7] British Standards Institution, “Concrete –Complementary British Standard to BS EN

206-1 – Part 1: Method of Specifying and Guidance for the Specifier, BS 8500-1: 2002”,
BSI, London, U. Kingdom, 2003.

[9] A.T. Goldbeck and J.E. Gray, “A Method of Proportioning Concrete for Strength,
Workability and Durability”, National Crushed Stone Association, Engineering Bulletin
No. 11, 1968, 37 pp.

[10] B. Addis and J. Goodman, “Concrete Mix Design”, In: Fulton’s Concrete
Technology, 9th Edition, G. Owens (Ed.), Cement and Concrete Institute, Midrand, South
Africa, 2009.

[11] South African Bureau of Standards, “Concrete Tests – Compressive Strength of

Hardened Concrete, SANS 5863: 2006”, SABS Division, Groenkloof, Pretoria, South
Africa, 2002.

[12] British Standards Institution, “Concrete – Part 1: Specification, Performance,

Production and Conformity, BS EN 206-1: 2000”, BSI, London, U. Kingdom, 2003.

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