Chapter 6 Proposed Mix Design Method for HPC and Validity

Chapter 6
PROPOSED MIX DESIGN METHOD FOR HPC AND VALIDITY

6.1 INTRODUCTION
Concrete mix design is a process of proportioning the ingredients in right
proportions. Though it is based on sound technical principles and heuristics, the entire
process is not in the realm of science and precise mathematical calculations. This is
because of impreciseness, vagueness, approximations and tolerances involved.

The objective of any mix design method is to determine an appropriate and

economical combination of concrete ingredients that can be used for a first trial batch
to produce a certain concrete which is close to that can achieve a good balance
between various desired properties of concrete at the minimum cost. A mixture
proportioning only provides a starting mix design that will have to be more or less
modified to meet the desired concrete characteristics. In spite of the fact that mix
design is still something of an art, it is unquestionable that some essential scientific
principles can be used as a basis for calculations. Mix design of high performance
concrete (HPC) is different from that of usual concrete because of the following
reasons (Laskar and S. Talukdar, 2008):

Water-binder ratio is very low.

Concrete quite often contains cement replacement materials that drastically
change the properties of fresh and hardened concrete.
Slump or compaction factor can be adjusted using high range water reducing
admixture (HRWRA) without altering water content.

Concrete is required to exhibit performance in the given environment.

However, there has been no established method whereby the mixture proportions of
concrete can be optimized according to the required performance. The conventional
mix design methods are no longer capable of meeting the stringent multiple
requirements of HPC (Wong and Kwan, 2005). These methods are not directly
applicable to HPC mixes. Several methods have been proposed over the years for the
proportioning of mineral admixture based HPC mixes. The methods proposed by

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 Chapter 6 Proposed Mix Design Method for HPC and Validity

ACI, modified ACI, Mehta and Aitcin, DOE among other methods are popular and
are found to be suitable for designing HPC mixes especially in cold countries where
temperature hardly goes beyond 25oC (Kumbhar and Murnal,2011). These methods
have been in use successfully by the engineers over the years. However, the British or
American methods will not be applicable for our country, as the specific relationships
constituting figures and tables are based on their materials. Also the climatic
conditions of our country are different from the climates of these countries.

India, being a tropical country has different environment in its different parts.
Tropical countries usually receive significant rainfall during only some part of the
year leading to substantial variation in the level of humidity in many parts of the
tropics. High temperatures, low humidity and wind cause rapid evaporation of water
from the concrete mix during summer. This drying of concrete leads to cracking and
crazing of the surface (Gambhir, 2005). The variation in temperature and humidity
has profound effect on the properties of HPC such as strength and durability since the
mix proportions are usually decided at laboratory conditions. Therefore, a new
modified method of mix design procedure has been proposed and is discussed in
subsequent sections for design of HPC mixes taking into account the effect of
environmental conditions such as varying humidity and temperatures on the properties
of HPC mixes.

6.2 GENERAL INFORMATION

Based on the results of experimentation it is stated that the following material
specifications must meet to develop HPC mixes of desired workability and target
compressive strengths.

6.2.1 Cement:
The ordinary Portland cement (OPC) of 53 grade satisfying the IS
Specifications. The cement content obtained from the existing IS Code method of mix
design (IS10262-1982) works out to be more than the maximum specified limit of
450kg/m3 for mixes with low water-cement ratios. Hence, the quantity of cement
needs to be altered and should be used in combination with suitable mineral

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 Chapter 6 Proposed Mix Design Method for HPC and Validity

admixture such as micro silica. The total quantity of materials (called as binders) thus
will include both cement and desired quantity of mineral admixture (micro silica).

6.2.2 Fine Aggregates:

From the investigations carried out to study the effect of sand zones on various
properties of HPC mixes, it is recommended to use fine aggregates conforming to
Zone-I for obtaining better strength properties.

6.2.3 Coarse Aggregates:

The cubical shaped coarse aggregates of two fractions are recommended for
use in developing HPC mixes of grades M50-M90.
Fraction: I passing through 20mm IS sieve and retained on 12.5mm IS sieve (60%)
Fraction: I passing through 12.5mm IS sieve and retained on 10mm IS sieve (40%)

6.2.4 Mineral Admixtures:

Several mineral admixtures such as fly ash, micro silica, GGBS etc are being used in
making HPC mixes of different grades. However, micro silica is a highly pozzolanic
mineral admixtures and the addition it in concrete will start contributing to strength in
about 3 days (Bagade and Puttaswamy, 2007). A micro silica content of 5% to15 %
leads to an increase of concrete strength. However, the desirable content of micro
silica needed from point of view of workability and 28 day compressive strength is to
be determined by trials.

6.2.5 Chemical Admixtures:

The research and the experience indicate that the admixtures based on the poly
carboxylic ethers (PCE) are the best suited as they have a water reducing capacity of
18%-40% in reference to the control concrete. These admixtures assist in achieving
higher slump at much lesser w/c ratios (< 0.30).

6.3 PROPOSED MIX DESIGN METHOD FOR HPC

The proposed mix design method for HPC mixes is based on the principles of
existing IS Code method of mix design (IS 10262-1982 and IS 10262-2009). In the
development of this proposed method, the basic mix proportions were obtained for

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 Chapter 6 Proposed Mix Design Method for HPC and Validity

making HPC mixes using w/c ratios worked out by extrapolating the established
relationships between free water cement ratio and concrete strength for different
cement strengths as shown in figure 6.1 (IS:10262-1982). Different curves indicating
28 day strength range of cement, when tested according to IS 4031-1968 is given
Table 6.1. The curves indicating relationship between free water-cement ratio and 28
days compressive strength for different cement strengths were extrapolated and
modified to generate smooth curves (figure 6.2). The equations used in developing
the smooth curves are given in Table 6.2. The quantities of fine aggregate and coarse
aggregate were determined using the equation given in IS Code method (IS: 10262-
1982). The basic mix proportions thus obtained by following the guidelines of
existing IS Code method were used in making trial HPC mixes by incorporating
desirable contents of micro silica and superplasticizer in view of achieving the desired
workability and strength properties.

100
90
F-Curve
28 Days Comp St., MPa

80
E-Curve
70
D-Curve
60
C-Curve
50 B-Curve
40 A-Curve
30
20
10
0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6
Water-Cement Ratio
Figure 6.1: Relation between free Water-Cement Ratio and Concrete
strength for different cement strengths (Extrapolated curves-original)

Table 6.1: 28 days strength of cement, tested according to IS: 4031-1968

A=31.9-36.8 N/mm2 D=46.6-51.5 N/mm2
B=36.7 41.7 N/mm2 E=51.5 -56.4 N/mm2
C=41.7 46.6 F=56.4-61.3 N/mm2

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100
90 F-Curve

28 Day Comp St., MPa

80 E-Curve
70
D-Curve
60 C-Curve
50 B-Curve
40 A-Curve
30
20
10
0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6
Water-Cement Ratio

Figure 6.2: Relation between free W/C Ratio and Concrete St. for
different cement strengths (Modified Extrapolated-smooth curves)

Table 6.2: Equations used in developing smooth curves for relationship

between free water-cement ratio and concrete strength
Curve Exponential Equation of curve
A y = 92.85e-3.05x
B y = 107.6e-3.09x
C y = 119.5e-3.07x
D y = 131.8e-3.06x
E y = 145.0e-3.02x
F y = 159.1e-3.06x
Where, y= Comp. St., in MPa and x= w/c ratio

Further, based on experimental observations and the results of compressive

strengths of various grades of HPC mixes, the curves given in IS Code method are
modified so as to arrive at water-binder ratios best suited to different grades of HPC
mixes (Figure 6.3 to 6.5). The curve indicating generalized relationship between free
water cement ratio and compressive strength of concrete is also extrapolated and
modified so as to arrive at water-binder ratios best suited to different grades of HPC
mixes (Figure 6.6 to 6.8). The equations used to develop smooth curves for the
relationship between free water-binder ratio and compressive strength of concrete and

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 Chapter 6 Proposed Mix Design Method for HPC and Validity

also to arrive at water-binder ratios best suited for different grades of HPC mixes are
given in Table 6.3 and Table 6.4 respectively.

100
90 F-Curve
28 days Comp St., MPa

80 E-Curve
70 D-Curve
60 C-Curve
50 B-Curve
40 A-Curve
30
20
10
0.2 0.25 0.3 0.35 0.4 0.45 0.5
Water- Cement Ratio
Figure 6.3: Relationship between free W/C Ratio and Concrete St. for
different Cement Strengths (Extrapolated to suit HPC)

120
110 F-Curve
28 Day Comp St., MPa

100 E-Curve (y = 235.4e-4.15x)

90
80 D-Curve
C-Curve
70
B-Curve
60
A-Curve
50
40
30
20
10
0.2 0.225 0.25 0.275 0.3 0.325 0.35 0.375 0.4 0.425 0.45 0.475 0.5
Water-Binder Ratio
F-CURVE E-CURVE
D-CURVE C-CURVE
B-CURVE A-CURVE

Figure 6.4: Relationship between free W/C Ratio and Concrete St. for
different Cement Strengths (Extrapolated-Smooth Curves)

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 Chapter 6 Proposed Mix Design Method for HPC and Validity

Table 6.3: Equations used in developing smooth curves for relationship

between free water-cement ratio and concrete strength
Curve Exponential Equation of curve
A y = 156.8e-4.28x
B y = 176.5e-4.26x
C y = 195.0e-4.22x
D y = 216.1e-4.19x
E y = 235.4e-4.15x
F y = 267.4e-4.25x
Where, y= Comp. St., in MPa and x= w/c ratio

130
120
110
F-Curve
28 Days Comp St., MPa

100
90 E-Curve (y = 235.4e-3.85x)
80 D-Curve
70 C-Curve
60 B-Curve
50 A-Curve
40
30
20
10
0.2 0.225 0.25 0.275 0.3 0.325 0.35 0.375 0.4 0.425 0.45 0.475 0.5
Water-Binder Ratio
F-CURVE E-CURVE
D-CURVE C-CURVE
B-CURVE A-CURVE
Figure 6.5: Relationship between free W/C Ratio and Concrete St. for
different Cement Strengths (Extrapolated Modified Curves to Suit HPC)

Table 6.4: Equations used in developing curves for relationship between

free w/b ratio and concrete St. best suited to HPC
Curve Exponential Equation of curve
A y=156.8e-4.28x
B y=176.5e-4.26x
C y =195e-4.22x
D y =216.1e-4.19x
E y = 235.4e-3.85x
F y = 267.4e-4.025x
Where, y= Comp. St., in MPa and x= w/c ratio

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80
y = 146.3e-3.46x
70

28 Days Comp St., MPa

60
50
40
30
20
10
0.2 0.225 0.25 0.275 0.3 0.325 0.35 0.375 0.4 0.425 0.45 0.475 0.5
Water-Cement Ratio

Figure 6.6: Extrapolated Generalized Relation between free W/C ratio

and Comp. St. of Concrete (Original Curve as per IS: 10262-1982)

130
y = 297e-4.84x
28 days Comp St., MPa

110

90

70

50

30

10
0.2 0.225 0.25 0.275 0.3 0.325 0.35 0.375 0.4 0.425 0.45 0.475 0.5
Water-Binder Ratio

Figure 6.7: Extrapolated Modified (1st) generalized relation between free

W/C ratio and Comp. St. of Concrete to suit HPC mixes

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 Chapter 6 Proposed Mix Design Method for HPC and Validity

120
y = 297e-4.84x
110

28 days Comp St., MPa

100
90
80
70
60
50 y = 146.3e-3.46x
40
30
20
10
0.2 0.225 0.25 0.275 0.3 0.325 0.35 0.375 0.4 0.425 0.45 0.475 0.5
Water-Binder Ratio

Figure 6.8: Extrapolated Generalized relation between free W/C ratio and
Comp St. of Concrete to suit HPC Mixes (Original & Modified)

From the experimental observations, the basic mix proportions adopted for
making trial HPC mixes were modified by altering coarse aggregate to fine aggregate
ratio and incorporating appropriate micro silica and superplasticizer contents so as to
get desired workability and compressive strengths for different combinations of
humidity and temperature. The proposed mix design method for HPC thus provides
the final mix proportions taking into account the parameters or variables necessary to
be incorporated in achieving the desired workability and strength properties for
different grades of HPC mixes. The various variables or parameters considered in the
proposed mix design method for HPC mixes are as given below:
1. Grade of the HPC mix under consideration
2. Desired workability for the mix
3. Prevailing Relative Humidity in the atmosphere
4. Prevailing Temperature in the atmosphere
5. Total binder content
6. Total cement content
7. Desired micro silica content
8. Desired water-binder ratio
9. Desired coarse aggregate to fine aggregate ratio
10. Desired superplasticizer dose (by weight of cement)

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 Chapter 6 Proposed Mix Design Method for HPC and Validity

The stepwise procedure for the proposed method of mix design is outlined in
the following sections.

6.3.1 Stepwise Procedure of Proposed Mix Design Method for HPC

The mix design procedure consists of a series of steps, which when completed
provide a mixture meeting strength and workability requirements based on the
properties of selected and proportioned ingredients. Following are the necessary steps.

6.3.1.1 Step I: Test data for Materials

The test data of ingredients of HPC mixes namely specific gravity, fineness
modulus; water absorption, moisture content etc. should be obtained.

6.3.1.2 Step II: Target Mean Compressive Strength of HPC

The target mean compressive strength at 28 days curing period for HPC mix is
determined using the relationship given below:

where,
f'ck = target mean compressive strength ,
fck = characteristic strength of concrete (grade of concrete) and
S = standard deviation (as per IS 456-2000)

As the strict quality control is necessary in making HPC mixes, the standard
deviation (SD) is not likely to exceed 5 MPa (Mullick, 2006). Hence, a standard
deviation value of 5MPa (as per IS 456 code) is assumed for arriving at target mean
strength.
6.3.1.3 Step III: Determination of Water-Binder Ratio
The determination of water-binder ratio is done by referring to the plotted
relationships between the 28 day compressive strength of concrete and water-binder
ratios for different humidity and temperature conditions as given in the figure 6.9 to
6.11. The w/b ratios for specific compressive strengths (grades of HPC mixes) and for
different humidity levels at 30oC, 35oC, 40oC temperature along with the equations
used for development of curves indicating relationship between w/b ratio and
corresponding compressive strengths are given in Table 6.5 to 6.10.

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115

RH-30%
105 RH-40%

RH-50%
28 Day Comp St, MPa

95
RH-60%

RH-70%
85
RH-80%

75 RH-90%

65

55

45
0.15 0.2 0.25 0.3 0.35 0.4 0.45
W/B Ratio
Figure 6.9: Relation between 28 day Comp St and Water-Binder for different humidity at 30OC Temp

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 Chapter 6 Proposed Mix Design Method for HPC and Validity

Table 6.5: Comp St. and W/B ratio for different RH at 30OC Temp
28 Day Comp Humidity Levels,% (Temp-30oC)
St., MPa 30 40 50 60 70 80 90
58.25 0.382 0.374 0.365 0.365 0.357 0.354 0.350
68.25 0.338 0.331 0.324 0.318 0.311 0.306 0.302
78.25 0.300 0.294 0.289 0.278 0.271 0.264 0.261
88.25 0.267 0.261 0.258 0.242 0.236 0.227 0.225
98.25 0.237 0.232 0.230 0.211 0.204 0.195 0.193

Table 6.6: Equations used for development of curves for relationship

between Comp St. and W/B ratio for different RH at 30OC Temp
Rh Exponential Equations (Temp 30oc)
30 y = 230.7e-3.6x
40 y = 230.1e-3.67x
50 y = 239.8e-3.88x
60 y = 201.2e-3.4x
70 y = 198e-3.43x
80 y = 186.5e-3.29x
90 y = 186.3e-3.32x
Where,
y =Compressive Strength in MPa,
x = w/b ratio and
e =exponent, the approximate value of e is 2.718282

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115 RH-30%

RH-40%

RH-50%
105
28 Day Comp St. MPa

RH-60%

RH-70%
95
RH-80%

RH-90%
85

75

65

55
0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45
W/B Ratio
Figure 6.10: Relation between 28 day Comp St and Water-Binder for different humidity at 35OC Temp

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Table 6.7: Comp St. and W/B ratio for different RH at 35OC Temp
28 Day Comp Humidity Levels,% (Temp-35oC)
St., MPa 30 40 50 60 70 80 90
58.25 0.404 0.404 0.403 0.402 0.393 0.391 0.390
68.25 0.347 0.342 0.336 0.334 0.327 0.321 0.316
78.25 0.298 0.289 0.277 0.275 0.270 0.262 0.253
88.25 0.254 0.243 0.226 0.224 0.220 0.209 0.197
98.25 0.216 0.201 0.181 0.178 0.175 0.162 0.147

Table 6.8: Equations used in development of curves indicating relationship

between Comp St. and W/B ratio for different RH at 35OC Temp
Rh Exponential Equations (Temp 35oC)
30 y = 179e-2.78x
40 y = 165.1e-2.58x
50 y = 150.2e-2.35x
60 y = 148.8e-2.335x
70 y = 149.5e-2.40x
80 y = 142.5e-2.29x
90 y = 134.7e-2.15x

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145
RH-30

RH-40
125
28 Day Comp St., MPa

RH-50

RH-60

105 RH-70

RH-80

RH-90
85

65

45
0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45
W/B Ratio
Figure 6.11: Relation between 28 day Comp St and Water-Binder for different humidity at 40OC Temp

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 Chapter 6 Proposed Mix Design Method for HPC and Validity

Table 6.9: Comp St. and W/B ratio for different RH at 40OC Temp
28 Day Comp Humidity Levels,% (Temp-40oC)
St., MPa 30 40 50 60 70 80 90
58.25 0.378 0.371 0.372 0.369 0.369 0.363 0.348
68.25 0.339 0.331 0.323 0.312 0.310 0.302 0.290
78.25 0.305 0.297 0.281 0.262 0.258 0.249 0.240
88.25 0.275 0.267 0.244 0.218 0.213 0.203 0.196
98.25 0.249 0.240 0.210 0.179 0.172 0.162 0.156

Table 6.10: Equations used in development of curves for relationships

between Comp. St. and W/B ratio for different RH at 40OC Temp
Rh Exponential Equations (Temp 40 OC)
30 y = 269.9e-4.06x
40 y = 256.8e-4.00x
50 y = 193.8e-3.23x
60 y =160.9e-2.75x
70 y =155e-2.65x
80 y =149.6e-2.6x
90 y = 150.6e-2.73x

i. Selection of Water-Binder Ratio

The maximum w/b ratio for different exposure conditions from view point of
durability is to be adopted as per IS 456-2000. The values of w/b ratio obtained from
the developed relationships taking into account the ambient RH and Temperature is
compared with the values specified in IS 456-2000 for different exposure conditions
and the value whichever is smaller is selected for designing the HPC mixes.

6.3.1.4 Step IV: Determination of Binder Content

From the w/b ratio obtained for the target mean compressive strength and for
the specified humidity and temperature condition, the required binder content is
determined based on the proposed relationship between binder content (cement +
micro silica) and w/b ratio (Figure 6.12).

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850
y = -1665x + 1078

Binder Content, Kg/m3

800
750
700
650
600
550
500
450
400
0.15 0.2 0.25 0.3 0.35 0.4
W/B Ratio
Figure 6.12: Proposed Relationship between Binder Content and W/B ratio
(Linear equation: y = -1665x + 1078, where y=binder content and x =w/b ratio)

From the selected w/b ratio and the obtained binder content, the total water content is
calculated using the following relationship:

100
Micro Silica Content, Kg/m3

90 y = 1.146x - 33.80

80
70
60
50
40
30
20
50 55 60 65 70 75 80 85 90 95 100 105
28 Days Comp. St. of HPC, MPa

Figure 6.13: Proposed variation of Micro Silica content with 28 days

Comp. St. of HPC

6.3.1.5 Step V: Determination of Desirable Contents of Mineral Admixture (Micro

Silica) and Cement Content
The desirable contents of micro silica required for making different grades of
HPC mixes can be obtained from the established relationship of micro silica content

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 Chapter 6 Proposed Mix Design Method for HPC and Validity

and compressive strength of HPC (Figure 6.13). Thus, knowing the micro silica
content, the required quantity of cement can be worked out by subtracting the micro
silica content from the total binder content.

6.3.1.6 Step VI: Determination of Desirable Contents of Superplasticizer (SP)

The type and desired dosage of superplasticizer needs to be decided by trials
to produce and maintain reasonable workability and enhance the strength of concrete
when micro silica is used as a mineral admixture. Though, in market different
varieties or brands of superplasticizers are available, the research and experience have
indicated that the admixtures based on the poly carboxylic ethers (PCE) are the best
suited as they have a water reducing capacity of 18%-40% in reference to the control
concrete.

In the present research work, HPC mixes have been developed using PCE
based superplasticizers. The dosage of superplasticizer was determined by weight of
the cement used for the HPC mix. In the proposed mix design method the
approximate superplasticizer dosages for different grades of HPC mixes (M50-M90)
corresponding to different water-binder ratios can be obtained using the plotted
relationship between superplasticizer content and the cement content required for the
specified grade of HPC mix (Figure 6.14).

5
4.5
y = 0.012x - 2.83
SP Content, Kg/m3

4
3.5
3
2.5
2
1.5
1
0.5
400 425 450 475 500 525 550 575 600
Cement Content, Kg/m3
Figure 6.14: Proposed variation of SP for different Cement contents

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 Chapter 6 Proposed Mix Design Method for HPC and Validity

6.3.1.7 Step VII: Determination of Coarse and Fine Aggregate Contents

Taking into account the adopted volume of coarse aggregate in the total
aggregate volume during the experimentation, a relationship between ratio of volume
of coarse aggregate to the volume of total aggregate per unit volume of concrete
(figure 6.15) is established for corresponding 28 days compressive strengths obtained.
From the established relationship the ratio of volume of coarse aggregate to the
volume of total aggregate is determined for the specified 28 days compressive
strength of the concrete.

0.8
Ratio of Vol of Coarse Aggt to

y = 0.433e0.004x
0.75
Vol. of Total Aggt, m3

0.7
0.65
0.6
0.55
0.5
0.45
50 55 60 65 70 75 80 85 90 95 100
28 Days Comp St, MPa

Figure 6.15: Ratio of Volume of Coarse to Total Aggregate and 28 days

Compressive Strength (Exponential Eq.)

Thus, the following variables required for mix design process are determined:
1) Water-Binder Ratio
2) Binder content = ( Cement + Micro silica) content, Kg/m3
3) Water Content = (water-binder ratio x total binder content), kg/m3
4) Superplasticizer (by weight of cement)
5) Total Aggregate Content
= Volume of Concrete (water + binder + superplasticizer) content
6) CA / FA Ratio
7) Volume of Fine and Coarse aggregate

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6.4 ILLSUTRATIVE EXAMPLE FOR MIX DESIGN OF M50 GRADE

HPC MIX
An illustrative example for mix proportioning of M50 grade HPC mix using
the Proposed Mix Design Method is presented below.

6.4.1 STIPULATIONS FOR MIX PROPORTIONING

Characteristic comp. strength : 50 N/mm2
Maximum size of aggregate : 20mm (angular)
Degree of workability (slump) : 50-100
Degree of quality control : Good
Type of Exposure : Severe
Temperature : 30oC
Relative humidity : 50%

6.4.2 TEST DATA OF MATERIALS

Cement : OPC 53 Grade
Specific gravity of cement : 3.15
Specific gravity of coarse aggt : 2.90
Specific gravity of fine aggt : 2.80

Water absorption,%
Coarse aggregate : 2.03
Fine aggregate : 1.48
Free (surface) moisture,%
Coarse aggregate : 1.98
Fine aggregate : 1.33 (Confirming to grading zone I of table 4
of IS: 383-1970)

6.4.3 TARGET STRENGTH FOR MIX PROPORTIONING

Where,
=target average compressive strength at 28 days
= characteristic compressive strength at 28 days,

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 Chapter 6 Proposed Mix Design Method for HPC and Validity

= Standard deviation (Table 8 of IS456-2000)

= 5 N/mm2,
Therefore, target strength,
= 50 + 1.65 x 5 = 58.25 N/mm2

6.4.4 SELECTION OF WATER-BINDER RATIO

Referring to the plotted relationship between the 28 day compressive strength
of concrete and water-binder ratio (Figure 6.9), for a target mean compressive
strength of 58.25MPa and for specified humidity level of 50% and 30oC temperature a

waterbinder ratio of 0.371 is obtained.

6.4.5 DETERMINATION OF BINDER CONTENT, MICRO SILICA AND

CEMENT
From the proposed relationship between binder content and w/b ratio (Figure
6.12), for a compressive strength of 58.25 MPa binder content (cement + micro silica)
of 460.28 Kg/m3 is obtained. Also, referring to the established relationship between
micro silica and 28 days compressive strength of HPC mixes (Figure 6.13), a micro
silica content of 32.94 kg/m3 (7.71%) is obtained. Thus, knowing the total binder
content and the amount of micro silica in it, the quantity of cement required can be
calculated by subtracting the micro silica content from the total binder content. Thus,
the quantity of cement is calculated as given below:

6.4.6 DETERMINATION OF DESIRABLE CONTENTS OF

SUPERPLASTICIZER (SP)
The desirable content of superplasticizer required for the desired workability is
determined by weight of cement. The superplasticizer dosage is obtained from the
established relationship between superplasticizer dosage and the cement content
required to attain the specified compressive strength under given humidity and
temperature conditions (Figure 6.14). Thus, from the calculated quantity of cement a

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superplasticizer dose of 0.54% is determined. The quantity of superplasticizer per m3

of concrete is obtained as given below:

6.4.7 DETERMINATION OF WATER CONTENT

From the obtained w/b ratio and binder content, the required water content is
calculated as given below:

6.4.8 PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE

AGGREGATE CONTENT
The estimation of volume of coarse aggregate in the volume of total
aggregates is determined using the established relationship between 28 days
compressive strength and ratio of volume of coarse aggregate to the volume of total
aggregate per unit volume of concrete (Figure 6.15). Thus, for M50 grade HPC the
ratio of volume of coarse aggregate to the volume of total aggregate per unit volume
of concrete as obtained from the established relation is 0.55m3. Hence the volume of
fine aggregate is obtained as given below:
Volume of fine aggregate = (1- 0.55) = 0.45m3

6.4.9 MIX CALCULATION

Mix Calculations per unit volume of concrete shall be as follows:

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6.4.9.2 Final Quantities of Ingredients and Mix Proportion

Cement = 427.34 kg/m3
Micro Silica = 32.94kg/m3
Water = 170.76 kg/m3
Fine Aggregate = 856.80 kg/m3
Coarse Aggregate =1084.60 kg/m3
Superplasticizer = 2.56 kg/m3

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Mix Proportion obtained is : 0.37:1 (0.93: 07):1.86:2.36

The mix proportions so obtained are adjusted for field conditions as per usual
procedure before preparing trial mix.

6.5 EXPERIMENTAL VALIDATION OF PROPOSED MIX

PROPORTIONING METHOD FOR HPC
The mix proportions for different grades of HPC mixes are obtained by using
the established relationships (curves) developed through experimental studies. The
proposed method of mix proportioning of HPC mixes provides the mix proportions
for different levels of humidity and temperature combinations for the grades of M50
to M90 HPC mixes. To verify the validity of the proposed mix design method, a trial
HPC mix of M50 grade was prepared using the mix proportion obtained by the
proposed method. The mix was designed for a slump range of 75-100mm considering
a humidity of 80% with a temperature of 30oC. The mix proportion, expressed as parts
of water : binder content (cement+micro silica) : fine aggregate : coarse aggregate,
adopted for making the HPC mix was 0.36:1(0.93:0.07):1.81:2.29. A superplasticizer
content of 0.56% by weight of cement was used as obtained from the mix design.

The trial mix produced using the above proportion showed a very good quality
with a slump of 90mm and a flow value of 23.67% and a compressive strength of
54.07MPa at 28 days curing. The slump test and the flow test conducted on the trial
mix are shown in figures 6.17(a) and 6.17(b) respectively. Since the trial HPC mix
prepared was found to give satisfactory workability with good flow property and also
in a single trial for the mix proportion obtained by the proposed method, it can be
stated that the proposed method of mix design is valid for proportioning HPC mixes
for specified humidity and temperature conditions.

Figure (a): Slump Test Figure (b: Flow Test

mixture
Figure 6.16: Workability of Trial HPC Mix (M50)

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The Software based on the Artificial Neural Network (ANN) approach is also
developed to get the mix proportions for the given grade of HPC and any given
humidity and temperature conditions. In order to check the validity of the software, a
trial mix of M50 grade of HPC was prepared for the ambient humidity (80%) and
temperature (30OC) conditions by adopting the mix proportion provided by the
developed software (ANN). The prepared trial HPC mix showed good results in
respect of workability (slump & flow values) and compressive strength. The results of
the slump (210mm) and compressive strength test (56.70MPa) were found to be close
to the expected results for the mix. The figure 6.18 shows the various stages during
slump test. The flow of the trial mix concrete indicating the spread on the table is
shown in figure 6.19.

(a) (b) (c) (d)

Figure 6.17: Stages in the Slump Test on Trial Mix of HPC

Figure 6.18: Flow Test on Trial HPC mix

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