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MixDesignForConcreteRoadsAsPerIRC:152011

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MixDesignForConcreteRoadsAsPerIRC:152011
By
KaushalKishore,MaterialsEngineer,Roorkee
ABSTRACT:
Thestressesinducedinconcretepavementsaremainlyflexural.Thereforeflexuralstrengthismoreoften
specifiedthancompressivestrengthinthedesignofconcretemixesforpavementconstruction.Asimple
methodofconcretemixdesignbasedonflexuralstrengthfornormalweightconcretemixesisdescribedin
thepaper.
INTRODUCTION:
Usualcriterionforthestrengthofconcreteinthebuildingindustryisthecompressivestrength,whichis
consideredasameasureofqualityconcrete.However,inpavementconstructions,suchashighwayand
airportrunway,theflexuralstrengthofconcreteisconsideredmoreimportant,asthestressesinducedin
concretepavementsaremainlyflexural.Therefore,flexuralstrengthismoreoftenspecifiedthan
compressivestrengthinthedesignofconcretemixesforpavementconstruction.Itisnotperfectlyreliableto
predictflexuralstrengthfromcompressivestrength.Further,variouscodesoftheworldspecifiedthatthe
pavingconcretemixesshouldpreferablybedesignedinthelaboratoryandcontrolledinthefieldonthe
basisofitsflexuralstrength.Therefore,thereisaneedtodesignconcretemixesbasedonflexuralstrength.
Thetypeofaggregatecanhaveapredominanteffect,crushedrockaggregateresultinginconcretewith
higherflexuralstrengththanuncrushed(gravel)aggregatesforcomparablemixes,assumingthatsound
materialsareused.Thestrengthofcementinfluencesthecompressiveandflexuralstrengthofconcretei.e.
withthesamewatercementratio,higherstrengthcementwillproduceconcreteofhighercompressiveand
flexuralstrength.
MIXDESIGNDETAILS
IRC:152011specifiedthatforconcreteroadsOPCshouldbeused.ThiscodealsoallowedPPCasperIS:
1489(Part1)withflyashcontentnotmorethan20percentbyweightofPPC.AccordinglyOPC+flyashmay
beusedinconcreteroads.Flyashshallbenotmorethan20percentbyweightofcementitiousmaterial.
However,IS:4562000specifiedthatflyashconformingtograde1ofIS3812maybeusedaspart
replacementofOPCprovideduniformblendedwithcementisessential.Theconstructionsiteswhere
batchingplantsareusedthismaybepracticable.Inordinarysiteswheremixerorhandmixingaredone
uniformblendingofflyashwithcementisnotpracticable.Atsuchconstructionsites,PPCmaybeused.PPC
shouldbeusedwithcautionwhererapidconstructionmethodslikeslipformisbeingused.Jointscuttingalso
needearlystrength.
1

Characteristic
Flexural
Strengthat28
days

4.5N/mm2

Cement

Threemixesaretobedesigned

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MIXA
WithPPC(Flyash18percentbased)conformingtoIS:1489partI1991.7days
strength37.5N/mm2.SpecificGravity:3.00
MIXB
WithOPC43GradeconformingtoIS:81121989.7daysstrength40.5n/mm2.
SpecificGravity:3.15
MIXC
WithOPCofMixBandFlyashconformingtoIS:3812(PartI)2003Specific
Gravity:2.20
Note:Requirementsofallthethreemixesarethesame.FineAggregate,Coarse
AggregateandRetarderSuperplasticizerarethesameforallthethreemixes.
3

Flyash
replacement

20%Flyashisrequiredtobereplacedwiththetotalcementitiousmaterials.

Maximum
nominalsize
ofaggregates

31.5mmCrushedaggregate

Fine
aggregate
andcoarse
aggregate
grading

GiveninTable1

Minimum
cement
contentfor
4.5N/mm2
characteristic
flexural
strength:

(a)OPCshallnotbelessthan360kg/m3.

Maximum
freeW/C
Ratio

Workability

(b)PPCshallnotbelessthan425kg/m3.Flyashinit20%maximumbyweight
oftotalcementitiousmaterials
(c)OPC+FlyashmixOPCshallnotbelessthan340kg/m3.Flyash20%
maximumbyweightofcementationsmaterial
(a)ForOPC0.45
(b)ForPPC0.50
40mmslumpatpourtheconcretewillbetransportedfromcentralbatchingplant
throughtransitmixer,atadistanceof15KmduringJune,Julymonths.The
averagetemperaturelastyearduringthesemonthswas300C.

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Exposure
condition

Moderate

10

Methodof
placing

Fullymechanisedconstruction

11

Degreeof
supervision

Good

12

Maximumof
cement
content

(a)OPC425kg/m3

13

Chemical
admixture

RetarderSuperplasticizerconformingtoIS:91031999.Withthegiven
requirementsandmaterials,themanufacturerofRetarderSuperplasticizer
recommendsdosagesof1%bwofOPC,whichwillreduce15%ofwaterwithout
lossofworkability.Forflyashincludedcementdosageswillberequiredtobe
adjustedbyexperience/trials.2%maximumbyweightofcementitiousmaterial

14

ValuesofZx
(forNational
Highway)

1.96x0.40

(b)PPC425kg/m3

TESTDATAFORMATERIALSANDOTHERDETAILS
1.Thegradingoffineaggregate,1&2aggregatesareasgiveninTable.1.
2.Propertiesofaggregates

Tests
SpecificGravity

WaterAbsorption%

Fineaggregate

Aggregate1

Aggregate2

2.65

2.65

2.65

0.8

0.5

0.5

3.TargetaverageflexuralstrengthforallA,BandCmixes
S=S+Zq
=4.5+1.96x0.40
=5.3N/mm2at28daysage
4.ForMixA,BandCfreeW/Cratiowithcrushedaggregateandrequiredaverageflexuraltargetstrengthof
5.3N/mm2at28daysfromFig.1CurveDfoundtobe0.42.ThisislowerthanspecifiedmaximumW/Cratio
valueof0.45forOPCand0.50forPPC.
Note:
Inabsenceofcementstrength,butcementconformingtoISCodes,assumefromFig.1
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CurveCandDforOPC43Grade
TakecurvesCandDforPPC,asPPCisbeingmanufacturedinminimumof43Gradeofstrength.
5.Otherdatas:TheMixesaretobedesignedonthebasisofsaturatedandsurfacedryaggregates.Atthe
timeofconcreting,moisturecontentofsiteaggregatesaretobedetermine.Ifitcarriessurfacemoisturethis
istobedeductedfromthemixingwaterandifitisdryaddinmixingwaterthequantityofwaterrequiredfor
absorption.Theweightofaggregatesarealsoadjustedaccordingly.
DESIGNOFMIXAWITHPPC
a)FreeW/Cratioforthetargetflexuralstrengthof5.3N/mm2asworkedoutis0.42forfirsttrial.
b)Freewaterfor40mmslumpfromTable2for31.5mmmaximumsizeofaggregate.
2/3170+1/3200=180kg/m3
FromtrialsitisfoundthatRetarderSuperplasticizeratadosagesof1.3%bwofPPCmayreduce15%water
withoutlossofworkability
Thenwater=180(180x0.15)=153kg/m3
c)PPC=153/0.42=364kg/m3(RequiredminimumPPCis425kg/m3)
d)Formulaforcalculationoffreshconcreteweightinkg/m3
Um=10xGa(100A)+C m(1Ga/Gc)Wm(Ga1)
Where,
Um=Weightoffreshconcretekg/m3
Ga=Weightedaveragespecificgravityofcombinedfineandcoarseaggregatebulk,SSD
Gc=Specificgravityofcement.Determineactualvalue,inabsenceassume3.15forOPCand3.00forPPC
(Flyashbased)
A=Aircontent,percent.Assumefortrialentrappedair1.5%
For31.5mmmaximumsizeofaggregate
Thereisalwaysentrappedairinconcrete.ThereforeignoringentrappedairvalueasNILwillleadthe
calculationofhighervalueofdensity.Takeexactvalueofairasobtainedinthetest
Wm=Mixingwaterrequiredinkg/m3
Cm=Cementrequired,kg/m3
Note:Theexactdensitymaybeobtainedbyfillingandfullycompactingconstantvolumesuitablemetal
containerfromthetrialbatchesofcalculateddesignmixes.Themixbealteredwiththeactualobtained
densityofthemix.
Um=10xGa(100A)+C m(1Ga/Gc)Wm(Ga1)
=10x2.65(1001.5)+425(12.65/3.00)153(2.651)
=2409kg/m3
e)Aggregates=2409425153=1831kg/m 3
f)Fineaggregate=1831x0.45=824kg/m3
Aggregate1=1831x0.29=531kg/m3
Aggregate2=1831x0.26=476kg/m3
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g)Thusfor4.5N/mm2flexuralstrengthquantityofmaterialspercu.m.ofconcreteonthebasisofsaturated
andsurfacedryaggregates:
Water=153kg/m3
PPC=425kg/m3
FineAggregate(sand)=824kg/m3
Aggregate(1)=531kg/m3
Aggregate(2)=476kg/m3
RetarderSuperPlasticizer1.3%bwofPPC=5.525kg/m3
MIXBWITHOPC
a)Water=180(180x0.15)=153kg/m3
b)OPC=153/0.42=364kg/m3
c)Density:10x2.65(1001.5)+364(12.65/3.15)153(2.651)=2416kg/m3
d)TotalAggregates=2416364153=1899kg/m3
Aggregate1=1899x0.29=551kg/m3
Aggregate2=1899x0.26=494kg/m3
FineAggregate=1899x0.45=854kg/m3
e)Thusfor4.5N/mm2flexuralstrengthquantityofmaterialspercu.mofconcreteonthebasisofSSD
aggregatesaregivenbelow:
Water=153kg/m3
OPC=364kg/m3
FineAggregate(sand)=854kg/m3
Aggregate(1)=551kg/m3
Aggregate(2)=494kg/m3
RetarderSuperPlasticizer1%bwOPC=3.640kg/m3
MIXCWITHOPC+FLYASH
Withatotalcementitiousmaterialof430kg/m3,
OPC=430x0.80=344kg/m3
Flyash=430x0.20=86kg/m3
MixonthebasisofSSDAggregates,
(1)Waterasworkedoutearlier=153kg/m3
(2)OPC=344kg/m3
(3)Flyash=86kg/m3
Density=10x2.65(1001.5)+430(12.65/3.00)153(2.651)=2410kg/m3
TotalAggregates=241015334486=1827kg/m 3
(4)Fineaggregate0.45x1827=822kg/m3
(5)Aggregate(1)0.29x1827=530kg/m3
(6)Aggregate(2)0.26x1827=475kg/m3
(7)Retardersuperplasticizer1.5%bwofcementitiousmaterial=6.450kg/m3
Note:
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(1)CementitiousmaterialworkedoutasperIRC:152011,whichspecified:Incaseflyash(asperIS:3912
Part1)isblendedatsite,thequantityofflyashshallberestrictedto20percentbyweightofcementitious
materialandthequantityofOPCinsuchablendshallnotbelessthan340kg/m3.
(2)Afterthefirsttrialmix,itsactualdensityistobedetermined,asspecifiedelasewhereinthispaper.The
mixproportionsshallthenbeworkedoutaccordinglyincludingthewatercontent,thedosagesofRetarder
SPforrequiredworkabilitykeepingthefreew/cratiowithinthepermissiblelimitsandadjustingitaccording
totherequiredflexuralstrength.
(3)Themixproportionsgiveninthispaperareforfirsttrialandtobeadjustedasperactualsitematerials,
conditionsandrequirements.
For4.5N/mm2flexuralstrengthquantityofmaterialpercu.mofconcreteonthebasisofsaturated
andsurfacedryaggregatesofMixA,Bandcaregivenbelow:

Materials
Waterkg/m3

PPCkg/m3

OPCkg/m3

Flyashkg/m3

FineAgg.kg/m 3

Agg.(1)kg/m3

Agg.(2)kg/m3

RetarderSuperplasticizerkg/m3

W/Cementitiousratio

MIX.AwithPPC

Mix.BwithOPC

Mix.CwithOPC+Flyash

153

153

153

425

364

344

86

824

854

822

531

551

530

476

494

475

5.525

3.640

6.450

0.36

0.42

0.356

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Note:
1.ForexactW/Cratiothewaterinadmixtureshouldalsobetakenintoaccount.
2.PPCreduces5%waterdemand.Ifthisisfoundbytrialthentakereducewaterforcalculation.
3.Ifthetrialmixesdoesnotgivestherequiredpropertiesofthemix,itisthenrequiredtobealtered
accordingly.However,whentheexperiencesgrowswiththeparticularsetofmaterialsandsiteconditions
veryfewtrialswillberequired,andaexpertofsuchsiteveryrarelywillberequireda2ndtrial.
CONCLUSION
1.For4.5N/mm2flexuralstrengthconcretehavingsamematerialandrequirement,butwithoutwater
reducer,theOPCrequiredwillbe180/0.42=429kg/m3
2.WiththeuseofsuperplasticizerthesavinginOPCis65kg/m3andwater27lit/m3.
3.Inthefinancialyear20092010Indiahasproduces200milliontonnesofcement.InIndiaonekgof
cementproduceemitted0.93kgofCO2.Thustheproductionof200milliontonnesofcementhademitted
200x0.93=186milliontonnesofCO2totheatmosphere.
4.If50milliontonnescementinmakingconcreteusesWaterReducers7500000tonnesofcementcanbe
saved.3750000KLofpotablewaterwillbesavedandthesavingofRs.3300croresperyeartothe
constructionIndustry.6975000tonnesofCO2willbepreventedtobeemittedtotheatmosphere.The
benefitsintheusesofwaterreducersnotlimitedtothis.Whenwaterreducesshrinkageandporosityof
concretearereduceswhichprovidesthedurabilitytoconcretestructures.
5.Indiaisfacingseriousair,water,soil,foodandnoisepollutionproblems.Everyeffortsthereforeare
necessarytopreventpollutionontopprioritybasis.
6.Asthestressinducedinconcretepavementsaremainlyflexural,itisdesirablethattheirdesignisbased
ontheflexuralstrengthofconcrete.Thequalityofconcreteisnormallyassessedbymeasuringits
compressivestrength.Forpavings,however,itistheflexuralstrengthratherthanthecompressionstrength
ofconcretewhichdeterminethedegreeofcrackingandthustheperformanceofroad,anditisimperativeto
controlthequalityonthebasisofflexuralstrength.
7.AsperIRC:152011,incaseofsmallsizeprojects,wherefacilitiesfortestingbeamswiththreeprint
loadingarenotavailable,insuchcases,themixdesignmaybecarriedoutbyusingcompressivestrength
valuesandthereafterflexuralstrengthwillbedeterminedaspercorrelationbetweenflexuralstrengthwith
compressivestrengthgiventhefollowingequation.
WherefcristheflexuralstrengthinMPaorN/mm2andfckisthecharacteristiccompressivestrengthinMPa
orN/mm2asperIS:4562000.
REFERENCES:
1

IS:383
1970

Specificationsforcoarseandfineaggregatesfromnaturalsourcesforconcrete
(secondrevision)BIS,NewDelhi

IS:4562000

Codeofpracticeforplainandreinforcedconcrete(fourthrevision),BIS,New
Delhi

IS:9103

Specificationforadmixturesforconcrete(firstrevision)BIS,NewDelhi

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1999
4

IS:8112
1989

Specificationsfor43Gradeordinaryportlandcement(firstrevision)BIS,New
Delhi

IS:2386
(PartIII)
1963

methodoftestforaggregateforconcrete.Specificgravity,density,voids,
absorptionandbulking,BIS,NewDelhi

IS:3812
(PartI)2003

Specificationforpulverizedfuelash:PartIforuseaspozzolanaincement,
cementmortarandconcrete(secondrevision)BIS,NewDelhi

IS:1489
PartI1991

Specificationsforportlandpozzolanacement(PartI)Flyashbased.(Third
revision),BIS,NewDelhi

IRC:152011Standardspecificationsandcodeofpracticeforconstructionofconcreteroad
(Fourthrevision)

KishoreKaushal,ConcreteMixDesignBasedonFlexuralstrengthforAirEntrainedConcrete,
Proceedingof13thConferenceonourWorldinConcreteandStructures,2526,August,1988,
Singapore.

10

KishoreKaushal,MethodofConcreteMixDesignBasedonFlexuralStrength,Proceedingofthe
InternationalConferenceonRoadandRoadTransportProblemsICORT,1215December,1988,
NewDelhi,pp.296305.

11

KishoreKaushal,MixDesignBasedonFlexuralStrengthofAirEntrainedConcrete.TheIndian
ConcreteJournal,February,1989,pp.9397.

12

KishoreKaushal,ConcreteMixDesignContainingChemicalAdmixtures,JournaloftheNational
BuildingOrganization,April,1990,pp.112.

13

KishoreKaushal,ConcreteMixDesignforRoadBridges,INDIANHIGHWAYS,Vol.19,No.11,
November,1991,pp.3137

14

KishoreKaushal,MixDesignforPumpedConcrete,JournalofCentralBoardofIrrigationand
Power,Vol.49,No.2,April,1992,pp.8192

15

KishoreKaushal,ConcreteMixDesignwithFlyAsh,IndianConstruction,January,1995,pp.16
17

16

KishoreKaushal,HighStrengthConcrete,BulletinofIndianConcreteInstituteNo.51,AprilJune,
1995,pp.2931

17

KishoreKaushal,ConcreteMixDesignSimplified,IndianConcreteInstituteBulletinNo.56,July
September,1996,pp.2530.

18

KishoreKaushal,ConcreteMixDesignwithFlyAsh&Superplasticizer,ICIBulletinNo.59,April
June1997,pp.2930

19

KishoreKaushal.MixDesignforPumpedConcrete,CE&CROctober,2006,pp.4450.

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Table.1:GradingofAggregates
ISSieve
Designation

Percentageofpassingbymass
Fine
aggregate
fromriver

26.50mm

19.0mm

9.50mm

4.75mm

600micron

150micron

75micron

Combined
gradingof
mix

IRC:152011recommendedgradingofcombined
aggregatesforpavementqualityconcrete(PQC)

(1)

(2)

29%

26%

100

100

100

100

100

100

100

98

99

8595

100

100

25

81

6888

100

46

58

4565

94

44

3055

42

19

830

10

515

05

45%

31.50mm

Crushed
aggregate

Table.2:Approximatefreewatercontent(kg/m3)requiredtogivevariouslevelsofworkabilityfor
nonairentrained(withnormalentrappedair)concrete.
Maximumsizeofaggregate(mm)

Typeofaggregate

Slump(mm)

Uncrushed

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25+10

40+1031.5

160

170
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Crushed

190

200

Note:Whencoarseandfineaggregateofdifferenttypesareused,thefreewatercontentisestimatedby
theexpression.
2/3Wf+1/3Wc
Where,
Wfsub>=FreewatercontentappropriatetotypeoffineAggregate
AndWc=Freewatercontentappropriatetotypeofcoarseaggregate.

Weatengineeringcivil.comarethankfultoEr.KaushalKishoreforsubmittingtherevisedmixdesignasper
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IRC:152011.Thiswillbeofgreathelptoallcivilengineeringstudentsandfacultywhoareseeking
informationonmixdesignbasedonrevisedIRC.

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