Mix Design With Superplasticizers

INTRODUCTION
Superplasticizers belongs to a class of water reducer chemically different from the normal water
reducers and capable of reducing water content by about 30%. The Superplasticizers are broadly
classified into four groups: sulfonated melamine formaldehyde condensate (SMF), sulphonated
naphthalene formaldehyde condensate (SNF), modified lignosulphonate (MLS) and others
including sulphonic acid ester, polyacrylates, polystryrene sulphonates, etc. The benefits
obtained by Superplasticizers in the reduction of water in the concrete mixes are best illustrated
by the following examples.

MIX DESIGN DETAILS

1 Grad of Concrete : M-40

2 Cement : Three mixes are to be designed
MIX-A

With PPC (Flyash based) conforming

to IS:1489-part-I-1991. 7 days strength
38.5 N/mm2. Specific Gravity : 3.00
MIX-B

With OPC-43- Grade conforming to IS:

8112-1989. 7 days strength 40.7
n/mm2. Specific Gravity : 3.15
MIX-C

With OPC of Mix-B and Fly ash

conforming to IS:3812 (Part-I)-2003
Specific Gravity : 2.25
Note: Requirements of all the three
mixes are the same. Fine Aggregate,
Coarse Aggregate and normal Super
plasticizer are the same for all the three
mixes.
3 Fly ash replacement : 30% Fly ash is required to be replaced
with the total cementitious materials.
4 Maximum nominal size of : 20 mm Crushed aggregate
aggregates
5 Fine aggregate : River sand of Zone-II as per IS:383-
1970
6 Minimum cement content : 360 kg/m3 including Fly ash
7 Maximum free W/C Ratio : 0.40
8 Workability : 50 mm slump
9 Exposure condition : Extreme for RCC work
10 Method of placing : Site mixing
11 Degree of supervision : Good
12 Maximum of cement content : 450 kg/m3
(Fly ash not included)
13 Chemical admixture : Super plasticizer conforming to
IS:9103-1999. With the given
requirements and materials, the
manufacturer of Normal Super
plasticizer recommends dosages of 20
gm per kg of OPC, which will reduce
28% of water without loss of
workability. For fly ash included
cement dosages will be required to be
adjusted by experience/ trials.

TEST DATA FOR MATERIALS

1. The grading of fine aggregate, 10 and 20 mm aggregates are as given in Table. 1. 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 10 mm aggregate 40 mm aggregate

Specific Gravity 2.65 2.65 2.65
Water Absorption % 0.8 0.5 0.5

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

fck = fck + 1.65 x S
40 + 1.65 x 5
= 48.3 N/mm2 at 28 days age

4. For Mix A and B free W/C ratio with crushed aggregate and required target strength of 48.3
N/mm2 at 28 days from Fig. 1 Curve D found to be 0.4 Taking into the consideration of water in
admixture,let it be 0.39. This is lower than specified maximum W/C ratio value of 0.4

Note:
In absence of cement strength, but cement conforming to IS Codes, assume from Fig. 1 and Fig.
2.
Curve A and B – OPC 33 Grade
Curve C and D – OPC 43 Grade
Curve E and F – OPC 53 Grade

Take curves C and D for PPC, as PPC is being manufactured in minimum of 43 Grade of
strength.
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 strength of 48.3 N/mm2 as worked out is 0.39.

b) Free water for 50 mm slump from Table 2 for 20 mm maximum size of aggregate.
2/3*180 + 1/3*210
= 190 kg/m3
From trials also it is found that Normal Super plasticizer at a dosages of 21gm/kg of cement may
reduce 28% water without loss of workability

Then water = 190 – (190 x 0.28) = 136.8 kg/m3

for trials say 137 kg/m3

c) PPC = 137/0.39 = 351 kg/m3 This is lower than minimum requirement of 360 kg/m3. Then
take 360 kg/m3.
Then W/C = 137/360 = 0.38

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 = Wight 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% for 40 mm maximum size of aggregate, 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)
=10 x 2.65 (100 – 1.5) + 360(1- 2.65/3.00) – 137 (2.65 -1)
2426 kg/m3

e)Aggregates = 2426 – 360 – 137 = 1929 kg/m3

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

20 mm maximum size of aggregate, W/C ratio = 0.39, 50 mm slump found to be for trial 33%.

Fine aggregate = 1929 x 0.33 = 637 kg/m3

Coarse aggregate = 1929 – 637 = 1292 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 = 517 kg/m3
20 mm aggregate = 775 kg/m3

g) Thus for M-40 Grade of concrete quantity of materials per cu.m.

of concrete on the basis of saturated and surface dry aggregates:

Water=137 kg/m3
PPC = 360 kg/m3
Fine Aggregate (sand) = 637 kg/m3
10 mm Aggregate = 517 kg/m3
20 mm Aggregate = 775 kg/m3
Normal Super Plasticizer = 7.560 kg/m3

MIX- B WITH OPC

a) Water = 190 – (190 x 0.28) = 136.8 kg/m3 say 137 kg/m3

b) OPC = 137/0.39 = 351 kg/m3
Minimum content specified = 360 kg/m3
Then take 360 kg/m3
c) Density:
10 x 2.65 (100 – 1.5) + 360 (1 – 2.65/3.15) – 137 (2.65 – 1)
= 2442 kg/m3

d) Total Aggregates = 2442 – 137 – 360 = 1945 kg/m3

Fine Aggregate = 1945 x 0.33 = 642 kg/m3
Coarse aggregate = 1945 – 642 = 1303 kg/m3
10 mm Aggregate = 1303×1.2/3 = 521 kg/m3
20 mm Aggregate = 1303×1.8/3 = 782 kg/m3

e) Thus for M-40 Grade of concrete quantity of materials per cu.m of concrete on the basis of
SSD aggregates are given below:
Water = 137 kg/m3
PPC = 360 kg/m3
Fine Aggregate (sand) = 642 kg/m3
10 mm Aggregate = 521 kg/m3
20 mm Aggregate = 782 kg/m3
Normal Super Plasticizer = 7.2 kg/m3

MIX. C WITH OPC + FLYASH

With the given set of materials increase in cementitious materials = 12%
Total cementitious materials = 360 x 1.12 = 403 kg/m3

Materials Weight (kg/m3) Volume (m3)

OPC = 403 x 0.70 282/3150 0.0895
Flyash = 403 x 0.30 121/2250 0.0538
Free Water = 137 x 0.95 130/1000 0.13
Normal Super Plasticizer = 8.2kg 8.2/1150 0.0071
Air = 1.5% 0.015
Total 0.2954
Total Aggregates = 1 – 0.2954 0.7046
1.00
Coarse Aggregate 1303/2650 0.4917

Fine Aggregate = 0.7046 – 0.4917 = 0.2129

= 0.2129 x 2650 = 564 kg
Note:-
1. Specific gravity of Normal Superplasticizer = 1.15
2. Addition of Flyash reduces 5% of water demand.

M-40 Grade of concrete 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:

MIX. ‘A’ with Mix. ‘B’ with Mix. ‘C’ with

Materials
PPC OPC OPC+Flyash
3
Water kg/m 137 137 130
3
PPC kg/m 360 – –
3
OPC kg/m – 360 282
3
Flyash kg/m – – 121
Fine Agg. kg/m3 637 642 564
10mm Agg. kg/m3 517 521 521
3
20 mm Agg. kg/m 775 782 782
Normal Super- 7.560 7.2 8.2
plasticizer kg/m3
W/Cementations ratio 0.38 0.38 0.323
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.
Table. 1: Grading of Aggregates

Percentage Passing
IS Sieve Designation Crushed Aggregate
Fine Aggregate
10 mm 20 mm
40 mm – – 100
20 mm – – 100
12.5 mm – 100 –
10 mm 100 85 4
4.75 mm 99 5 0
2.36 mm 88 0
1.18 mm 74
600 Micron 43
300 Micron 24
150 Micron 6

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 Type of Slump 25-75 50-100 100-180

size of aggregate (mm)
aggregate Degree of — … … …
(mm) workability
vary low Low Medium High
10 Uncrushed 150 205 220 240
Crushed
180 235 250 265
20 Uncrushed 140 180 195 210
Crushed
170 210 225 245
40 Uncrushed 120 160 175 190
Crushed
155 190 205 220
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 and 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 with different workability.

Table. 4: Proportion of fine aggregate (percent) with 40 mm maximum sizes of Aggregates

and with different workability.

Grading Zone 40 mm aggregate Workability

W/C Ratio
of F.A VL L M H
I 0.3 27-33 29-35 33-39 38-46
0.4 29-35 31-38 35-42 41-49
0.5 31-38 33-41 37-44 43-52
0.6 33-41 36-43 39-47 45-54
 0.7 36-44 38-46 42-50 47-57
0.3 22-27 23-29 27-33 31-28
0.4 24-29 25-31 28-35 32-41
II 0.5 25-31 27-33 30-37 34-43
0.6 27-33 29-36 32-39 36-45
0.7 29-36 31-38 34-42 38-47
0.3 18-22 20-23 22-27 26-31
0.4 20-24 21-25 24-28 27-32
III 0.5 21-25 23-27 25-30 29-34
0.6 23-27 24-29 27-32 30-36
0.7 24-29 26-31 29-34 32-36
0.3 16-18 18-20 19-22 22-26
0.4 17-20 19-21 20-24 24-27
IV 0.5 18-21 20-23 22-25 25-29
0.6 20-23 22-24 23-27 26-30
0.7 21-24 23-26 25-29 28-32

VL = Very low workability.

L = Low workability – slump 25-75 mm
M = medium workability – slump 50-100 mm
H = High workability- slump 100-180 mm
Figures From Experimental Data
Click on the picture to zoom it.
REFERENCES
1 IS : 383-1970 Specifications for coarse and fine aggregates from natural sources for concrete
(second revision) BIS, New Delhi
2 IS: 456-2000-Code of practice for plain and reinforced concrete (fourth revision), BIS, New
Delhi
3 IS: 9103-1999 Specification for admixtures for concrete (first revision) BIS, New Delhi
4 IS: 8112-1989 Specifications for 43 Grade ordinary portland cement (first revision) BIS, New
Delhi
5 IS: 2386 (Part-III) 1963 method of test for aggregate for concrete. Specific gravity, density,
voids, absorption and bulking, BIS, New Delhi
6 IS: 3812 (Part-I) 2003 Specification for pulverized fuel ash: Part-I for use as pozzolana in
cement, cement mortar and concrete (second revision) BIS, New Delhi
7 IS: 1489-Part-I 1991 Specifications for portland pozzolana cement (Part-I) Flyash based.
(Third revision), BIS, New Delhi
8 Kishore Kaushal, “Design of Concrete Mixes with High-Strength Ordinary Portland Cement”.
The Indian Concrete Journal, April, 1978, PP. 103-104
9 Kishore Kaushal, “Concrete Mix Design”. A manual published for Structural Engineering
Studies, Civil Engineering Department, University of Roorkee, 1986.
10 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.
11 Kishore Kaushal, “Concrete Mix Design”, Indian Concrete Institute Bulletin September,
1988, pp. 27-40 and ICI Bulletin December, 1988, pp. 21-31.
12 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.
13 Kishore Kaushal, “Mix Design Based on Flexural Strength of Air-Entrained Concrete”. The
Indian Concrete Journal, February, 1989, pp. 93-97.
14 Kishore Kaushal, “Concrete Mix Design”, VIII All India Builders Convention 29-31, January,
1989, Hyderabad, organized by Builders Association of India, Proceeding Volume pp. 213-260.
15 Kishore Kaushal, “Concrete Mix Design Containing Chemical Admixtures”, Journal of the
National Building Organization, April, 1990, pp. 1-12.
16 Kishore Kaushal, “Concrete Mix Design for Road Bridges”, INDIAN HIGHWAYS, Vol. 19,
No. 11, November, 1991, pp. 31-37
17 Kishore Kaushal, “A Concrete Design”, Indian Architect and Builder, August, 1991, pp. 54-
56
18 Kishore Kaushal, “ Mix Design for Pumped Concrete”, Journal of Central Board of Irrigation
and Power, Vol. 49, No.2, April, 1992, pp. 81-92
19 Kishore Kaushal, “Concrete Mix Design with Fly Ash”, Indian Construction, January, 1995,
pp. 16-17
20 Kishore Kaushal, “High-Strength Concrete”, Civil Engineering and Construction Review,
March, 1995, pp. 57-61.
21 Kishore Kaushal, “High-Strength Concrete”, Bulletin of Indian Concrete Institute No. 51,
April-June, 1995, pp. 29-31
22 Kishore Kaushal, “Mix Design of Polymer-Modified Mortars and Concrete”, New Building
Materials & Construction, January, 1996, pp. 19-23.
23 Kishore Kaushal, “Concrete Mix Design Simplified”, Indian Concrete Institute Bulletin No.
56, July-September, 1996, pp. 25-30.
24 Kishore Kaushal, “Concrete Mix Design”, A Manual Published by M/S Roffe Construction
Chemicals Pvt. Ltd., Mumbai, pp. 1-36
25 Kishore Kaushal, “Concrete Mix Design with Fly Ash & Superplasticizer”, ICI Bulletin No.
59, April-June 1997, pp. 29-30
26 Kishore Kaushal. “Mix Design for Pumped Concrete”, CE & CR October, 2006, pp. 44-50.
We are thankful to Er. Kaushal Kishore, Materials Engineer, Roorkee for submitting this very
useful research to us so that other civil engineering students can take guidance from it.

Mix Design With Superplasticizers

INTRODUCTION
Superplasticizers belongs to a class of water reducer chemically different from the normal water
reducers and capable of reducing water content by about 30%. The Superplasticizers are broadly
classified into four groups: sulfonated melamine formaldehyde condensate (SMF), sulphonated
naphthalene formaldehyde condensate (SNF), modified lignosulphonate (MLS) and others
including sulphonic acid ester, polyacrylates, polystryrene sulphonates, etc. The benefits
obtained by Superplasticizers in the reduction of water in the concrete mixes are best illustrated
by the following examples.

MIX DESIGN DETAILS

1 Grad of Concrete : M-40

2 Cement : Three mixes are to be designed
MIX-A

With PPC (Flyash based) conforming

to IS:1489-part-I-1991. 7 days strength
38.5 N/mm2. Specific Gravity : 3.00
MIX-B

With OPC-43- Grade conforming to IS:

8112-1989. 7 days strength 40.7
n/mm2. Specific Gravity : 3.15
MIX-C

With OPC of Mix-B and Fly ash

conforming to IS:3812 (Part-I)-2003
Specific Gravity : 2.25
Note: Requirements of all the three
mixes are the same. Fine Aggregate,
Coarse Aggregate and normal Super
plasticizer are the same for all the three
mixes.
3 Fly ash replacement : 30% Fly ash is required to be replaced
with the total cementitious materials.
4 Maximum nominal size of : 20 mm Crushed aggregate
aggregates
5 Fine aggregate : River sand of Zone-II as per IS:383-
1970
6 Minimum cement content : 360 kg/m3 including Fly ash
7 Maximum free W/C Ratio : 0.40
8 Workability : 50 mm slump
9 Exposure condition : Extreme for RCC work
10 Method of placing : Site mixing
11 Degree of supervision : Good
12 Maximum of cement content : 450 kg/m3
(Fly ash not included)
13 Chemical admixture : Super plasticizer conforming to
IS:9103-1999. With the given
requirements and materials, the
 manufacturer of Normal Super
plasticizer recommends dosages of 20
gm per kg of OPC, which will reduce
28% of water without loss of
workability. For fly ash included
cement dosages will be required to be
adjusted by experience/ trials.

TEST DATA FOR MATERIALS

1. The grading of fine aggregate, 10 and 20 mm aggregates are as given in Table. 1. 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 10 mm aggregate 40 mm aggregate

Specific Gravity 2.65 2.65 2.65
Water Absorption % 0.8 0.5 0.5

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

fck = fck + 1.65 x S
40 + 1.65 x 5
= 48.3 N/mm2 at 28 days age

4. For Mix A and B free W/C ratio with crushed aggregate and required target strength of 48.3
N/mm2 at 28 days from Fig. 1 Curve D found to be 0.4 Taking into the consideration of water in
admixture,let it be 0.39. This is lower than specified maximum W/C ratio value of 0.4

Note:
In absence of cement strength, but cement conforming to IS Codes, assume from Fig. 1 and Fig.
2.
Curve A and B – OPC 33 Grade
Curve C and D – OPC 43 Grade
Curve E and F – OPC 53 Grade

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

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 strength of 48.3 N/mm2 as worked out is 0.39.
b) Free water for 50 mm slump from Table 2 for 20 mm maximum size of aggregate.
2/3*180 + 1/3*210
= 190 kg/m3
From trials also it is found that Normal Super plasticizer at a dosages of 21gm/kg of cement may
reduce 28% water without loss of workability

Then water = 190 – (190 x 0.28) = 136.8 kg/m3

for trials say 137 kg/m3

c) PPC = 137/0.39 = 351 kg/m3 This is lower than minimum requirement of 360 kg/m3. Then
take 360 kg/m3.
Then W/C = 137/360 = 0.38

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 = Wight 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% for 40 mm maximum size of aggregate, 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)

=10 x 2.65 (100 – 1.5) + 360(1- 2.65/3.00) – 137 (2.65 -1)
2426 kg/m3

e)Aggregates = 2426 – 360 – 137 = 1929 kg/m3

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

20 mm maximum size of aggregate, W/C ratio = 0.39, 50 mm slump found to be for trial 33%.

Fine aggregate = 1929 x 0.33 = 637 kg/m3

Coarse aggregate = 1929 – 637 = 1292 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 = 517 kg/m3
20 mm aggregate = 775 kg/m3

g) Thus for M-40 Grade of concrete quantity of materials per cu.m.

of concrete on the basis of saturated and surface dry aggregates:

Water=137 kg/m3
PPC = 360 kg/m3
Fine Aggregate (sand) = 637 kg/m3
10 mm Aggregate = 517 kg/m3
20 mm Aggregate = 775 kg/m3
Normal Super Plasticizer = 7.560 kg/m3

MIX- B WITH OPC

a) Water = 190 – (190 x 0.28) = 136.8 kg/m3 say 137 kg/m3

b) OPC = 137/0.39 = 351 kg/m3
Minimum content specified = 360 kg/m3
Then take 360 kg/m3
c) Density:
10 x 2.65 (100 – 1.5) + 360 (1 – 2.65/3.15) – 137 (2.65 – 1)
= 2442 kg/m3

d) Total Aggregates = 2442 – 137 – 360 = 1945 kg/m3

Fine Aggregate = 1945 x 0.33 = 642 kg/m3
Coarse aggregate = 1945 – 642 = 1303 kg/m3
10 mm Aggregate = 1303×1.2/3 = 521 kg/m3
20 mm Aggregate = 1303×1.8/3 = 782 kg/m3

e) Thus for M-40 Grade of concrete quantity of materials per cu.m of concrete on the basis of
SSD aggregates are given below:
Water = 137 kg/m3
PPC = 360 kg/m3
Fine Aggregate (sand) = 642 kg/m3
10 mm Aggregate = 521 kg/m3
20 mm Aggregate = 782 kg/m3
Normal Super Plasticizer = 7.2 kg/m3

MIX. C WITH OPC + FLYASH

With the given set of materials increase in cementitious materials = 12%
Total cementitious materials = 360 x 1.12 = 403 kg/m3

Materials Weight (kg/m3) Volume (m3)

OPC = 403 x 0.70 282/3150 0.0895
Flyash = 403 x 0.30 121/2250 0.0538
Free Water = 137 x 0.95 130/1000 0.13
Normal Super Plasticizer = 8.2kg 8.2/1150 0.0071
Air = 1.5% 0.015
Total 0.2954
Total Aggregates = 1 – 0.2954 0.7046
1.00
Coarse Aggregate 1303/2650 0.4917

Fine Aggregate = 0.7046 – 0.4917 = 0.2129

= 0.2129 x 2650 = 564 kg
Note:-
1. Specific gravity of Normal Superplasticizer = 1.15
2. Addition of Flyash reduces 5% of water demand.

M-40 Grade of concrete 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:

MIX. ‘A’ with Mix. ‘B’ with Mix. ‘C’ with

Materials
PPC OPC OPC+Flyash
3
Water kg/m 137 137 130
3
PPC kg/m 360 – –
3
OPC kg/m – 360 282
3
Flyash kg/m – – 121
3
Fine Agg. kg/m 637 642 564
10mm Agg. kg/m3 517 521 521
3
20 mm Agg. kg/m 775 782 782
Normal Super- 7.560 7.2 8.2
plasticizer kg/m3
W/Cementations ratio 0.38 0.38 0.323

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.
Table. 1: Grading of Aggregates
 Percentage Passing
IS Sieve Designation Crushed Aggregate
Fine Aggregate
10 mm 20 mm
40 mm – – 100
20 mm – – 100
12.5 mm – 100 –
10 mm 100 85 4
4.75 mm 99 5 0
2.36 mm 88 0
1.18 mm 74
600 Micron 43
300 Micron 24
150 Micron 6

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 Type of Slump 25-75 50-100 100-180

size of aggregate (mm)
aggregate Degree of — … … …
(mm) workability
vary low Low Medium High
10 Uncrushed 150 205 220 240
Crushed
180 235 250 265
20 Uncrushed 140 180 195 210
Crushed
170 210 225 245
40 Uncrushed 120 160 175 190
Crushed
155 190 205 220

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 and 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 with different workability.
Table. 4: Proportion of fine aggregate (percent) with 40 mm maximum sizes of Aggregates
and with different workability.

Grading Zone 40 mm aggregate Workability

W/C Ratio
of F.A VL L M H
0.3 27-33 29-35 33-39 38-46
0.4 29-35 31-38 35-42 41-49
I 0.5 31-38 33-41 37-44 43-52
0.6 33-41 36-43 39-47 45-54
0.7 36-44 38-46 42-50 47-57
0.3 22-27 23-29 27-33 31-28
0.4 24-29 25-31 28-35 32-41
II 0.5 25-31 27-33 30-37 34-43
0.6 27-33 29-36 32-39 36-45
0.7 29-36 31-38 34-42 38-47
III 0.3 18-22 20-23 22-27 26-31
0.4 20-24 21-25 24-28 27-32
 0.5 21-25 23-27 25-30 29-34
0.6 23-27 24-29 27-32 30-36
0.7 24-29 26-31 29-34 32-36
0.3 16-18 18-20 19-22 22-26
0.4 17-20 19-21 20-24 24-27
IV 0.5 18-21 20-23 22-25 25-29
0.6 20-23 22-24 23-27 26-30
0.7 21-24 23-26 25-29 28-32

VL = Very low workability.

L = Low workability – slump 25-75 mm
M = medium workability – slump 50-100 mm
H = High workability- slump 100-180 mm

Figures From Experimental Data

Click on the picture to zoom it.
REFERENCES
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We are thankful to Er. Kaushal Kishore, Materials Engineer, Roorkee for submitting this very
useful research to us so that other civil engineering students can take guidance from it.