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Concrete Mix Design Report

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Department of Civil Technology Written By: Ahmed Zakaria 1 Summer Office Training Report 2015 AHMED ZAKARIa BS CIVIL TECHNOLOGY
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Page 1: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 1

Summer Office Training Report 2015

AHMED ZAKARIa

BS CIVIL TECHNOLOGY

Page 2: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 2

INTERNSHIP SUPERVISOR: Engr. Ahmed Yahya

AUTHOR: Ahmed Zakaria

(670-2013)

Hosting Organization: Al-Haramain Company of

Commerce and Contracting.

Commencement Date: September 1, 2015

Completion Date: September 20, 2015

Approved By:

Name of supervisor:Engr. Ahmed Yahya

Signature:

Name of mentor: Muhammad Munawwar Khan

Signature:

Hosting company stamp

Page 3: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 3

ACKNOWLEDGEMENT

I would like to thank Al-Haramain Company of Commerce and Contracting for giving me

the opportunity to undertake my three week training in their laboratory work area. I would

like to convey my heartiest thanks to Lab engineer Mohammad Munawwar Khan and the

project manager Engr. Ahmed Yahya for their immense support and cooperation which

made this experience very learning and worthwhile

Dated: September 25, 2015

Page 4: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 4

List of Tables

Table No. Title Page No.

Table 1 F.A Gradation 08

Table 2 L.A.A Test 12 Table 3 Grading of 3/4 Aggregate 16 Table 4 Grading of 3/8

Aggregate 16

Table 5 Aggregate Blend 17 Table 6 Sample for specific

gravity 18

Table 7-A Specific gravity of 3/4 19 Table 7-B Specific gravity of 3/8 20 Table 8 Specific gravity record 21 Table 9 Calculation of Ave.

specific gravity 21

Table 10 Nominal Max. Size

conversions 22

Table 11 Gradation standards C.A 23 Table 12 Gradation standards F.A 23 Table 13 Concrete Class

Designation 24

List of Figures

Figure No. Title Page No.

Fig 5

Collage of C.A

specific gravity

procedure

Fig 6 Recording weight of

sample on weighing

scale

Page 5: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 5

CONTENTS

Chapter Title Page No.

Chapter One

Introduction

Concrete Mix Design

Things Should Know

Before Designing

Concrete.

Precautions And Things To

Remember During Design

Concrete Mixes

03

04

05

06

Chapter Two

Fine Aggregate

Gradation Test.

Fine Aggregate Angularity

Test

Sand Equivalent Test

Fine Aggregate Specific

Gravity Test

07

08

09

09

10

Chapter Three

Coarse Aggregate

Los Angeles abrasion test.

Soundness Test of

Aggregate

Determination of Flakiness

index

Determination of

Elongation Index

Calculation of percentage

passing of aggregate 3/4 &

3/8 separately.

Making Blend of

Aggregate 3/4 & 3/8.

11

11

13

14

15

16

17

Chapter Four Concrete Mix Design 22

Chapter Five Asphalt 31

Pictorial Explanation 34

References 37

Page 6: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 6

CHAPTER ONE

INTRODUCTION

A wide range of problem associated with concrete mix design has to be faced during

graduation period. Keeping in view such difficulties it has been written in a way to gain

the complete knowledge of Concrete Mix Design before stepping into professional life.

The report is written on standards followed by KSA and its calculation, method will only

applicable in the kingdom. However report is written briefly and divided into five parts:

Fine Aggregate

Coarse Aggregate

Concrete Mix Design

Asphalt

Pictorial Explanation

Concrete:

Concrete is the most building material on earth it was the building block of the Roman Empire. Today

it’s the material for new generation. The raw ingredients that create this magic formula can nearly

found in every country on earth. The basic formula is simple, sand, crush rock aggregate, water and

cement.

Concrete can take nearly any shape that’s why it is being used in mega dam structures, sky scrapers or

bridges or any structure on earth.

Page 7: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 7

Concrete mix Design

Concrete mix design may be defines as the art of selecting suitable ingredients of concrete and

determining their relative proportions with the object of producing concrete of certain minimum

strength & durability as economically as possible.

Similarly the common method of expressing the proportions of ingredients of a concrete mix is

in the terms of parts or ratios of cement, fine and coarse aggregates. For e.g., a concrete mix of

proportions 1:2:4.

1. Standards for Mix design

ACI and other standards only serves as a guide, initial designs must be confirmed by

laboratory trial and plant trial, adjustments on the design shall be done during trial

mixes.

Initial design “on paper” is never the final design.

2. Trial Mixes

Always carry out trial mixes using the materials for actual use

3. Design Variation Tests

Carry out 2 or 3 design variations for every design target

4. Safety Factors

Consider always the factor of safety, (1.125, 1.2, 1.25, 1.3 X target strength)

5. Material Sources

Before proceeding to plant trials, always confirm the source of materials to be the

same as the one used in the laboratory trials.

6. Batching Plant Calibration

Check calibration of batching plant before trials

7. Tests at Batching Plant

Carry out full tests of fresh concrete at the batching plant, specially the air content

and yield which is very important in commercial batching plants

8. Quality Control

Correct quality control procedures at the plant will prevent future concrete problems

9. Admixture

Follow admixture recommendations from your supplier

10. Strength Development Check

Check and verify strength development, most critical stage is the 3 and 7 days strength

Technical knowledge is an advantage for batching plant staff, even if you have good concrete design but

uncommon or wrong procedures are practiced it will eventually result to failures

Page 8: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 8

Things should know before designing concrete.

1. What are the strength requirements?

Compressive (on cube or cylinder specimen) strength

Flexural strength

Tensile strength

2. What is the placing method?

By pump or direct pouring.

3. How far is the JOB SITE from the batching plant?

4. How many Transit Mixers are available on plant?

5. How much cubic meter concrete to be done in one working day?

6. Capacity of each Transit Mixer?

7. What is the capacity of Batching Plant?

8. What will be the expected temperature of site?

9. Which type of water is provided to use in concrete?

10. What type of cement is provided?

11. Fine and Coarse Aggregates quality test results.

12. Water temperature?

13. What is the structure for casting?

Pavement, foundation, elevated slab, etc.

14. What are the projects specifications?

Maximum or minimum cement contents

Maximum water/cement ratio

Slump or consistency limit

Minimum Strength requirement @28 days

Material specifications

15. Latest testing results of materials is needed in the preliminary selection of materials and

design calculation

Page 9: Concrete Mix Design Report

Department of

Civil

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Written By: Ahmed Zakaria 9

PRECAUTIONS AND THINGS TO REMEMBER DURING

DESIGN CONCRETE MIXES

1. Increasing the sand/totalaggregate ratio, increases the water requirement at the

same consistency.

2. Increasing the water/cement ratio decreases the strength of concrete at the same

cement content.

3. Remember that adding 5 liters of water per cubic meter increases the slump by

2.5cm.

4. Remember that adding 5 liters of water per cubic meter decreases strength by

approximately 4%.

5. Always follow recommended admixture dosage.

6. Always have “control” when performing trial mixes, always perform trial mixes with

another mix using the same materials. This data can be useful in diagnostics if a

problem occurs.

7. Always adjust batching quantities to the actual moisture condition of theaggregates.

8. Volume tolerance for 1m3 concrete is 1 ± 0.2 m3.

9. Range of normal weight concrete is from 2,200 kg/m3 to 2,400 kg/m3

10. Always take 3 samples for each test.

11. Calculate the average of all 3 samples for accuracy.

12. Complete all the required necessary tests before you start Concrete Mix Design

calculations and make a table of their resulted values.

Page 10: Concrete Mix Design Report

Department of

Civil

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Written By: Ahmed Zakaria 10

CHAPTER TWO

FINE AGGREGATE

Fine Aggregate Test Section

The tests are used to determine the material characteristics and properties of

aggregate materials for use in pavement construction. Test results are an important part

of mix design and can help predict pavement quality. Fine Aggregate tests are as

follows:

Gradation Test.

Fine Aggregate Angularity Test

Sand Equivalent Test

Fine Aggregate Specific Gravity Test

Page 11: Concrete Mix Design Report

Department of

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Written By: Ahmed Zakaria 11

Gradation Test:

This test is performed to identify the size of particles in a sample.

Aggregate passing sieve # 4 is considered as F.A.

Take a sample of F.A from the stock pile after splitting properly.

Record the weight of sample, and soak it in water for 24 hours.

After 24 hours take the sample and wash it by sieve 200 unless all the dirt

particles are drained and clear water can be seen.

Record the weight, the difference of total weight and after wash weight should

not more than 5% of the total weight.

Clay lumps should not more than 1% in sample.

Perform sand equivalent test to measure clay presence.

Clay should not be more than 75% of the sample for Concrete and 45% for

Asphalt.

Perform Gradation trough sieves for further calculation and tests.

Sieve analysis %Passing by weight

Sieve Size % Passing Specifications

3/8 “ 100 100

No. 4 97 95 - 100

No. 8 84

No. 16 71 45 - 80

No. 30 45

No. 50 17 10 - 30

No. 100 8 2 - 10

No. 200 2.8 0 - 4

Table1: F.A Gradation

Fineness Modulus = 2.77

Page 12: Concrete Mix Design Report

Department of

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Written By: Ahmed Zakaria 12

Fine Aggregate Angularity Test:

I. The fine aggregate angularity (FAA) test is an indirect method of assessing the

angularity of fine aggregate.

II. Fine aggregate angularity is important because an excess of rounded fine

aggregate (in the form of natural sand) can lead to rutting.

III. The FAA test estimates fine aggregate angularity by measuring the loose

uncompact void content of a fine aggregate sample.

IV. The higher the void content, the higher the assumed angularity and rougher the

surface.

V. This test is used to ensure that the blend of fine aggregate has sufficient

angularity and texture to resist permanent deformation (rutting) for a given traffic

level

VI. The test can be found in AASHTO T 304.

Sand Equivalent Test:

I. This is a rapid field test to show the relative proportions of fine dust or clay-like materials in fine aggregate.

II. The term “sand equivalent” expresses the concept that most fine aggregates are mixtures of desirable coarse particles and generally undesirable clay or plastic fines and dust.

III. These materials can coat aggregate particles and prevent proper asphalt binder-aggregate bonding.

IV. The test can be found in AASHTO T 84.

Fig 1: F.A

Angularity Test

Fig 2: Sand

equivalent cylinder

with aggregate

sample

Page 13: Concrete Mix Design Report

Department of

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Written By: Ahmed Zakaria 13

Fine Aggregate Specific Gravity Test:

I. Thisis used to calculate the specific gravity of a fine aggregate sample by

determining the ratio of the weight of a given volume of aggregate to the weight

of an equal volume of water.

II. It is similar in nature to the coarse aggregate specific gravity test.

III. The fine aggregate specific gravity test measures fine aggregate weight under

three different sample conditions

Oven-dry (no water in sample)

Saturated surface dry (water fills the aggregate pores)

Submerged in water (underwater).

IV. Using these three weights and their relationships, a sample’s apparent specific

gravity, bulk specific gravity and bulk SSD specific gravity as well as absorption

can be calculated. V. The test can be found in AASHTO T 84.

Fig 3: F.A Specifiv gravity

sample and Pycnometer

Page 14: Concrete Mix Design Report

Department of

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Written By: Ahmed Zakaria 14

CHAPTER THREE

Coarse AGGREGATE

Coarse Aggregate Test Section

Los Angeles abrasion test.

Los Angeles Machine:

It consists of a hollow steel cylinder, closed at both the ends with an internal diameter of

700 mm and length 500 mm and capable of rotating about its horizontal axis. A removable

steel shaft projecting radially 88 mm into cylinder and extending full length (i.e.500 mm) is

mounted firmly on the interior of cylinder. The shelf is placed at a distance 1250 mm

minimum from the opening in the direction of rotation.

Abrasive charge:

Cast iron or steel balls, approximately 48mm in diameter and each weighing between 390 to

445g; six to twelve balls are required.

Test application:

The aggregate used in surface course of the highway pavements are subjected to

wearing due to movement of traffic. When vehicles move on the road, the soil particles

present between the pneumatic tyres and road surface cause abrasion of road

aggregates. The principle of Los Angeles abrasion test is to produce abrasive action by

use of standard steel balls which when mixed with aggregates and rotated in a drum for

specific number of revolutions also causes impact on aggregates. This test gives more

accurate value of the strength and hardness of aggregates. This test is mechanical

rather than manual where accuracy is doubtful.

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Department of

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Written By: Ahmed Zakaria 15

PROCEDURE:

The test sample consists of clean aggregates dried in oven at 105° – 110°C. The sample should conform to any of the grading.

I. Select the grading to be used in the test such that it conforms to the grading to be used in construction, to the maximum extent possible.

II. Take 5 kg of sample for grading A, B, C & D and 10 kg for gradings E, F & G.

III. Choose the abrasive charge as per Table depending on grading of aggregates.

IV. Place the aggregates and abrasive charge on the cylinder and fix the cover.

V. Rotate the machine at a speed of 30 – 33 revolutions per minute. The number of revolutions is 500 for grading’s A, B, C & D and 1000 for grading’s E, K & S. The machine should be balanced and driven such that there is uniform peripheral speed.

VI. The machine is stopped after the desired number of revolutions and material is discharged to a tray.

VII. The entire stone dust is sieved on 1.70 mm IS sieve.

VIII. The material coarser than 1.7mm size is weighed correct to one gram.

Table 2: L.A.A Test

Page 16: Concrete Mix Design Report

Department of

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Written By: Ahmed Zakaria 16

Soundness Test of Aggregate:

This test is intended to study the resistance of coarse and fine aggregates to weathering

action and to judge the durability of the coarse aggregate.

1. Take individual samples in a wire mesh basket and immerse it in the solution of

sodium sulphate or magnesium sulphate for 5 days and change chemical every 24

hours, in such a manner that the solution covers them to a depth of at least 15 mm.

2. After completion remove the sample from solution and allow it to drain for 15

minutes

3. Then dry it in oven at 110oCtemperature.

Now sieve the material and weight it in a balance.

For Fine Aggregate the loss material should be less than 10% of the total material.

For Coarse Aggregate the loss material should not more than 12% o the total material

weight.

Flakiness and Elongation Index of Aggregate

One of the important properties of coarse aggregate is determination of its flakiness and

elongation index value for this test the required equipment’s are:

Set of sieve

Thickness Gauge

Length Gauge

Enamel Tray

Pan & Scoop

Weighing balance

3 Aggregate sample

Observation sheet.

Weighing Balance

Page 17: Concrete Mix Design Report

Department of

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Written By: Ahmed Zakaria 17

Determination of Flakiness index:

Measure the weight of aggregate sample after proper quartering

Sieve it manually or by shaker, so that fraction of different sizes will retain on

different size of sieve.

All the particles retained on first sieve i.e 16mm sieve will be tested in thickness

gauge scale on marked 20mm – 16mm slots.

Width of slot corresponding to 20mm & 16 mm sieve can be calculated as :

(

)

The particle passing through 10.8mm thickness slot will be collected for weight

and record this weight in observation sheet.

Same procedure is followed for aggregate passing through 16mm sieve and

retain on 12.5mm sieve.

This time the aggregate are passing from the corresponding thickness slot are

collected and weight.

Flakiness Index =

Flakiness Index in excess of 35 to 40% is considered undesirable.

Fig 4: Thickness Gauge

Page 18: Concrete Mix Design Report

Department of

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Written By: Ahmed Zakaria 18

Determination of Elongation Index:

Take minimum 200 pieces of aggregate from the sample and note down its

weight.

Perform the sieve test with same set of sieve use in flakiness test.

Different sizes of aggregate are retain on different sieve.

Aggregate passing 20mm & retain 16mm is taken for test and passed through

the mentioned sieve slots of length gauge.

Its important particle retain on slot are collected, weight and reading is recorded

Length of slot corresponding to 20mm & 16mm slot is calculates as:

(

)

The particles retain on 32.4mm

All the particles retain are weight and reading recorded in observation sheet.

Elongation Index =

Fig 5: Length Gauge

Page 19: Concrete Mix Design Report

Department of

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Written By: Ahmed Zakaria 19

Calculation of percentage passing of aggregate 3/4 & 3/8 separately.

Aggregate Sample : 3/4

Total Weight : 2334.3 Kg

Percentage Passing =

*cumulative weight is retained weight of sample on each sieve.

Sieve No Cumulative Weight Percentage Passing

3/4 325.9 86.03 %

1/2 2205.3 6 %

3/8 2308.0 1.1 %

4 2313.4 1.0 %

8 2313.8 1.0 %

16 2314.4 1.0 %

30 2315.0 1.0 %

50 2315.5 1.0 %

100 2316.5 1.0 %

200 2318.0 1.0 %

PAN 2324.8 0.4 % Table 3: Grading of 3/4 Aggregate

C.AggregateSample : 3/8

Total Weight : 2475.5 Kg

Percentage Passing =

*cumulative weight is retained weight of sample on each sieve.

Sieve No Cumulative Weight Percentage Passing

3/4 0 100 %

1/2 90.5 96 %

3/8 829.3 66 %

4 2387.5 4.0 %

8 2464.0 0.4 %

16 2465.0 0.4 %

30 2465.4 0.4 %

50 2465.7 0.3 %

100 2466.6 0.3 %

200 2467.8 0.3 %

PAN 2474.8 0.02 % Table 4: Grading of 3/8 Aggregate

Page 20: Concrete Mix Design Report

Department of

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Written By: Ahmed Zakaria 20

Making Blend of Aggregate 3/4 & 3/8.

In concrete design an engineer should make at least 5 blend.

To make blend, make the ratio of 3/4 & 3/8 aggregate by dividing them into

100%.

For Example, take aggregate 3/4=40%, & aggregate 3/8=60% which equals to

100% on adding ratio's

Similarly calculate 3/4 @ 60% & 3/8 @ 40% unless your results match the

specification table try five different ratios.

In this report we will take ratio's 3/4 @40%& 3/8 @ 60%.

The blend result will gives to match the specification chart of concrete strength

for further calculation and concrete mix design competition.

To calculate blend value use formula:

&

Use each sieve percentage passing value separately from table# 5 for 3/4

aggregate & table# 6 for 3/8 aggregate.

For combine blend value add 3/4 and 3/8 blend value.

Percentage passing value of each sieve from Table# 5 & 6 will be use in the

below table # 7 in separate sieve respectively

.

Sieve no.

3/4 @40%

[ Percentage Passing x 0.4 ]

3/8 @ 60%

[Percentage Passing x 0.6 ]

Combine Blend 3/4 + 3/8

1 " 100 100 100

3/4 " 34.4 60 94.4

1/2 " 2.4 57.7 60

3/8 " 0.44 39.8 40.2

4 " 0.4 2.4 2.8

8 " 0.4 0.24 0.64

16 " 0.4 0.24 0.64

30 " 0.4 0.24 0.64

50 " 0.4 0.18 0.58

100 " 0.4 0.18 0.58

200 " 0.4 0.18 0.58

PAN 0.16 0.012 0.172 Table 5:Aggregate Blend

Page 21: Concrete Mix Design Report

Department of

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Written By: Ahmed Zakaria 21

Specific Gravity &Percentage Absorption Aggregates

To calculate specific gravity of aggregate follow the below procedure:

I. Take a sample of aggregate 3/4 & 3/8 separately from the same stock pile (which

we have used above in grading and blend) after proper quartering.

II. Record the weight of both aggregate of 3/4 and 3/8 respectively.

III. Soak the sample in water and record the weight which will be "Weigh. inWater".

IV. Drain out the water, and dry the sample with the help of towel or a piece of cloth

and record its weight, which will be "Saturated Surface Dry Weight".

V. Put the sample in oven at Temp. 110o C for 24 hrs.

VI. After oven dry, record its weight which will be "Oven Dry Weight".

VII. Calculate absorption of sample.

VIII. Calculate %age absorption of sample.

Aggregate Size Weight In Water Saturated Surface Dry

Weight Oven Dry Weight

3/4 1297.7 2016.5 1996

3/8 656.2 1026.6 1023.5 Table 6:Sample for specific gravity

Fig6 :Recording weight of sample on weighing scale

Recording weight of material

soaked in water

Surface drying of aggregate

Adding water in material

Towel use for surface dry

Oven dry material @ 110oC

Fig 5: Collage of

C.A specific gravity

procedure

Page 22: Concrete Mix Design Report

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Written By: Ahmed Zakaria 22

Below is the given specific gravity calculation of sample step by step in table# 7-A and

7-B.

Coarse Aggregate : 3/4

LINE 1 Weight of saturated surface dry sample

2016.5

LINE 2 Weight of oven dry sample in air 1996

LINE 3 Weight of sample in water 1297.7

LINE 4

Absorption of sample

(LINE 1 - LINE 2)

2016.5 - 1996

= 20.5

LINE 5

% Absorptions

= 1.027 %

LINE 6

Moisture Content

= 1.01

Specific Gravity

a

Bulk, oven dry

2.77

b

Bulk, saturated Surface dry

2.805

c

Apparent,

2.858

Table 7-A :Specific gravity of 3/4

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Coarse Aggregate : 3/8

LINE 1 Weight of saturated surface dry sample

1026.6

LINE 2 Weight of oven dry sample in air 1023.5

LINE 3 Weight of sample in water 656.2

LINE 4 Absorption of sample

(LINE 1 - LINE 2)

3.1

LINE 5

% Absorptions

0.30 %

LINE 6

Moisture Content

0.30

Specific Gravity

a

Bulk, oven dry

2.76

b

Bulk, saturated Surface dry

2.77

c

Apparent,

2.78

Table 7-B: Specific gravity of 3/8

Page 24: Concrete Mix Design Report

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Calculate Average Specific Gravity

Average Sp. gravity can be calculate by adding sp. gravity of both aggregates 3/4& 3/8.

Make a table of both aggregate sp. gravity.

The calculation can be seen in table # 11.

Material Size % used SPECIFIC GRAVITY

Oven Dry Saturated Surface Dry

Apparent % Absolute Moisture Content

C.A – 3/4” 40% 2.77 2.805 2.858 1.027% 1.01 C.A – 3/8” 60% 2.76 2.77 2.78 0.30% 0.30

Table: 8

Average Specific Gravity:

Ave. Oven Dry

2.763

Ave. Saturated Surface Dry

2.783

Ave. Apparent

2.811

% Absolute

0.584

Moisture Content

0.584

Table: 9 - Calculation of Ave. specific gravity

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Written By: Ahmed Zakaria 25

CHAPTER FOUR

CONCRETE MIX DESIGN

Concrete Design Section

In concrete design section we will calculate the aggregate weight, blend and specific

gravity and the outcome result will be matched with the given specification of concrete

design classes.

Before we begin the below test is done following the method of American Association

of State Highway and Transportation Officials (AASHTO) and quality test is done

according to American Society for Testing and Materials (ASTM).

These standards are following in Kingdom of Saudi Arabia and in the Middle Eastern

countries.

Every reading, units, measurements, specifications and sieve size number are

applicable for AASHTO standard concrete mix design test.

Nominal Aggregate size

mm inches

62.5 mm 21/2 inch

50 mm 2 inch

37.5 mm 11/2 inch

25 mm 1 inch

19 mm ¾ inch

12.5 mm ½ inch

9.5 mm 3/8 inch

4.75 mm No. 4

2.36 No. 8

1.18 mm No. 16

0.300 mm No. 50

0.150 mm No. 100

0.075 mm No. 200 Table 10:Nominal Max. Size conversions

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Concrete Coarse Aggregate Gradation,Percentage Passing.

Coarse aggregate shall meet the following gradation requirements when tested:

Sieve Size Size A

Aggregate

2 inch

Size B

Aggregate

21/2 inch

Size C

Aggregate

1 inch

Size D

Aggregate

¾ inch

21/2 ---- 100 --- ---

2 inch 100 95-100 --- --- 11/2 inch 95-100 --- --- ---

1 inch --- 35-70 100 ---- ¾ inch 35-70 --- 95-100 100

½ inch --- 10-30 --- 90-100

3/8 inch 10-30 --- 20-55 40-70

No. 4 0 – 5 0 – 5 0-10 0-15 No. 8 --- --- 0 – 5 0 – 5

No. 200 0 - 1 0 - 1 0 - 1 0 - 1 Table 11:Gradation standards C.A

Concrete Fine Aggregate Gradation, Percentage Passing.

Fine aggregate shall meet the following gradation requirements when tested:

Sieve Size Percentage Passing by Weight

9.5 mm (3/8 inch) 100

4.75 mm (No. 4) 95 - 100

1.18 mm (No. 16) 45 - 80

0.300 mm (No. 50) 10 - 30

0.150 mm (No. 100) 2 - 10

0.075 mm (No. 200) 0 - 4

Table 12: Gradation standards F.A

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Written By: Ahmed Zakaria 27

Concrete Class Designations:

Specified Class

Minimum

Cement Content

(Kg. Per Cu. M)

Minimum

Compressive

Strength at 28

Days

Designated

Coarse

Aggregate Size

Alternate

Coarse

Aggregate Size

A

B

C

D

E

K

S

335

310

375

375

375

390

410

210 Kg./sq. cm

170 Kg./sq. cm

250 Kg./sq. cm

250 Kg./sq. cm

280 Kg./sq. cm

315 Kg./sq. cm

350 Kg./sq. cm

A- (2 in)

B- (2 ½ in)

C- (1 in)

D- (¾ in)

D- (¾ in)

D-(¾ in)

D- (¾ in)

B

A

D

Table 13:Concrete Class Designation

Table No 11 & 12 are the standards set by the Ministry of Transport Materials

Research and Testing Department KSA. After the gradation process of F.A & C.A

the % Passing should meet the specifications as given in table. If the aggregate

fails the ministry will not approve the project. KSA has set their standards as per

AASHTO and ASTM systems, they can vary with different countries or region.

Table No 13 is designed as reference classification chart by the material

engineer of Al-Haramain Company after all the calculations and following

instructions for future projects. However the concrete mix design is done on

every new project in the begging for accuracy. Table No13 is also approved by

ministry and consultant of the kingdom and has set as standard for the required

strength at 28 days till date September 2015.

Page 28: Concrete Mix Design Report

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Written By: Ahmed Zakaria 28

Concrete Mix Design Calculation

According to M.O.C Saudi Arabia.

The below calculation is numerical calculation based on 15 steps with Fifteen different

equation used in each step. The following calculation is only applicable in Middle East.

STEP 1:

% Passing No. 200

=

(Eq.1)

STEP 2: Required Water:

Water, KG./Cu.m of concrete

=

(Eq. 2)

=

= 188.76 189 Kg/m3

Page 29: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 29

STEP 3: Water/Cement Ratio:

W/C =

(Eq. 3)

Where A =

A =

A = 0.467293

W/C =

W/C =

W/C = 0.40 we will take w/c = 0.45

Cement Weight =

Used Cement Factor = 473Kg./m3

STEP 4: Estimated Strength of Concrete:

= 1028 – 1280

(Eq. 4)

= 1028 – 1280

= 377 Kg./cm2

Water Content = 410 x 0.45

= 185 L/m3

Page 30: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 30

STEP 5: Percentage Air Content:

% air = 4.4 x 0.3475 Nominal Max. Size in inches (Eq. 5)

= 4.4

% non-air entrained = 1.529 %

STEP 6: Volume of Cement:

Volume of Cement =

(Eq. 6)

=

= 0.1301

STEP 7: Volume of Water& Admixtures:

Volume of water =

(Eq. 7)

=

= 0.1850 L

Volume of Admixtures =

=

= 0.0025 L

Page 31: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 31

STEP 8: Dry Rrodded volume of C.A:

=

(Eq. 8)

=

= 0.6739 m3

STEP 9: Weight of C.A in KG:

Wt. in Kg of coarse aggregate = Dry rodded Vol. of C.A x Dry rodded unit wt. of C.A (Eq.9)

= 0.6739 x 1596

= 1076

STEP 10: Abs. Vol. C.A:

Absolute volume of C.A =

(Eq.10)

=

= 0.3892

STEP 11: Specific Gravity:

Already calculated before. (Eq. 11)

STEP 12: Volume of air:

Volume of air in 1m3 of concrete =

(Eq. 12)

=

= 0.0153

Page 32: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 32

STEP 13: Wt. of F.A: (Eq.13)

Absolute volume of F.A = 1- [Eq6 + Eq7 + Eq10 + Eq12]

1 – [0.1301+0.6739+0.3892+0.0153]

= 0.2779 m3

Weight of F.A = F.A volume X (1000 X specific gravity on oven dry basis)

= 0.2779 X 1000 X 2.680

= 745 Kg./m3

STEP 14: Adjusted wt. C.A:

Adjusted wt. of C.A = Design wt. of C.A X

(Eq.14)

= 1076 X (

)

= 1082 Kg

3/4 C.A =

= 433 Kg

3/8 C.A =

= 649 Kg

STEP 15: Adjusted wt. F.A:

Adjusted wt. of F.A = Design wt. of F.A X

(Eq.15)

=745 X (

)

= 747 Kg

Page 33: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 33

STEP 16: Adjusted wt. Water:

Adjusted wt. of water = Design wt. of water (Eq.16)

+ C.A wt. X ( % absorption - % moisture) / 100

+ F.A wt. X ( % absorption - % moisture) / 100

= + 1076 x (0.5908 – 0.584) / 100

= 7.3168

= + 745 (1.8 -0.30 ) / 100

= 11.175

Adjusted wt. of water= 185 + 7.3168 + 11.175

= 204 Kg.

Material required for 1 cu.ft concrete

Compressivestrength of concrete at 28

days

377 Kg/cm2

Cement 410 KG Water 204 Kg

Fine Aggregate 747 Kg

Coarse Aggregate 3/4 = 430 Kg

3/8 = 649 Kg

The above specifications fulfill our Class-S concrete design.

Following this design we will perform trial of cylinders and cube

for compression test and accuracy.

Page 34: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 34

CHAPTER FIVE

Asphalt

Asphalt Test Procedure:

1. Take a ready hot sample from Asphalt Paver after quartering.

2. Record its weight observation sheet.

3. Put in the extraction machine bowl.

4. Add Triclone chemical or Petrol continuously for washing its bitumen.

5. Let the machine complete its process.

6. Do not stop the machine unless the drain Triclone or Petrol is clearly visible without any bitumen.

7. Stop the machine and check if all the bitumen has removed from the aggregates.

8. Record the weight.

9. Put it in oven for drying 24 hours.

10. Weight to get the bitumen content that was present in aggregates.

11. Wash the aggregate with fresh water.

12. Leave sample for drying.

13. Perform sieve analysis

14. Record the gradation weight on every sieve.

15. Calculate %passing and specific gravity (same as performed above).

Page 35: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 35

Pictorial Explanation

Preparation of trial mix for compression test and filling of cylinders and

cubes.

Slump Test is performed before filling of cubes and cylinders.

Page 36: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 36

Cylinders and cube sample are kept under direct sunlight and water

respectively for compression test at 3 7 and 28 days.

Cylindrical and cubical compression are in progress in respective test

machines.

The LCD shows the result.

Page 37: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 37

Batching Plant and transit mixer.

Type of aggregate separated after flakiness and elongation index test.

Page 38: Concrete Mix Design Report

Department of

Civil

Technology

Written By: Ahmed Zakaria 38

References

http://www.pavementinteractive.org/article/fine-aggregate-specific-gravity/

http://www.pavementinteractive.org/article/fine-aggregate-angularity/

http://www.pavementinteractive.org/article/sand-equivalent/


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