CODE OF PRACTICE FOR PLAIN AND REINFORCED CONCRETE
2. Revisions in Section 2 : Materials, Workmanship, Inspection and Testing
2.1 Materials
2.1.1 Cement (Cl. 5.1) :
All three grades of OPC viz. 33, 43 & 53, Low Heat Portland cement and Sulphate resisting Portland cement have been included under various types of cement. In the manufacturing of concrete, the code also permits other combination of Portland cement with mineral admixtures of quality listed in Cl. 5.2.
2.1.2 Mineral Admixtures (Cl. 5.2) :
The mineral admixtures, which may be used as part replacement of cement, listed in the code are Pozzolanas (such as fly ash, silica fume, rice husk ash and metakaoline) and Ground Granulated Blast Furnace Slag.
2.1.3 Aggregates (Cl. 5.3) :
(i) Preference has been given to the use of natural aggregates as far as possible. Most of the zonal railway specifications permit use of only crushed aggregate for RCC structures. It is considered that this should be reviewed to generate greater use of natural aggregates. (ii) The limit of sulphate content in other types of aggregates such as slag etc. has been reduced from 1% to 0.5%. (iii) According to the revised code, 40 mm or larger size aggregates may be permitted where there is no restriction to the flow of concrete in the section. (iv) The code recommends considering use of 10 mm nominal maximum size aggregate for thin section, closely spaced reinforcement and smaller cover.
2.1.4 Water (Cl. 5.4)
(i) From durability considerations, permissible limits of solids in water have been reduced as under:
Sulphate - from 500 mg/l to 400 mg/l Chloride - from 1000 mg/l to 500 mg/l for RCC works
AN OVERVIEW OF REVISIONS IN IS 456 : 2000 CODE OF PRACTICE FOR PLAIN AND REINFORCED CONCRETE
(ii) The 1978 edition of the code allowed use of seawater under unavoidable circumstances in such RCC structures, which are permanently under seawater. But the present revision prohibits this.
2.1.5 Admixtures (Cl. 5.5)
The 1978 edition contained a single sentence permitting use of admixture conforming to IS-9103. Considering increase in the usage of several types of admixtures available in the market, the new revision has given following detailed guidelines on their use under sub clause 5.5.1 to 5.5.6.
Admixtures should not impair durability of concrete. Workability, compressive strength and slump of concrete should be checked for both with and without admixtures in trial mix. Relative density of liquid admixtures to be checked. Chloride content to be independently tested. If two or more admixtures are used simultaneously, data should be obtained to assess their interaction to ensure their compatibility.
2.1.6 Reinforcement (Cl. 5.6)
i) Use of hot rolled deformed bars conforming to IS 1139 has been withdrawn. ii) Use of structural steel conforming to Grade A of IS 2062 has been introduced in place of IS 226 as the latter code is superceded by the former. iii) Cleaning of reinforcement by sand blasting or other treatment has been recommended. iv) Reference to specialist literature has been recommended for special precautions like coating of reinforcement in exceptional cases.
2.2 Concrete (Cl. 6)
2.2.1 Grade of Concrete (Cl. 6.1)
i) Higher grade of concrete up to M 80 has been permitted (earlier revision was permitting maximum grade M 40). This is a progressive provision in line with recent trend for using high strength concrete in India and abroad. However, the code has cautioned that for high strength concrete (compressive strength greater than M 55), the design parameters given in this standard AN OVERVIEW OF REVISIONS IN IS 456 : 2000 CODE OF PRACTICE FOR PLAIN AND REINFORCED CONCRETE
may not be applicable and the values may be obtained from specialist literatures and experimental results.
ii) The grades of concrete have been classified in following three groups:
a) Ordinary Grade M 10 to M 20 b) Standard concrete M 25 to M 55 c) High strength concrete M 60 to M 80
iii) The minimum grade of concrete for plain and reinforced concrete in various exposures conditions have been revised as under:- Minimum grade of concrete Exposure condition Plain Cement Concrete Reinforced Cement Concrete Mild - M 20 Moderate M 15 M 25 Severe M 20 M 30 Very Severe M 20 M 35 Extreme M 25 M 40
2.2.2 Properties of concrete (Cl. 6.2)
(i) IS 456 : 1978 allowed increase in compressive strength of concrete up to 20% depending upon the age of concrete where it could be shown that a member would not receive its full design load/stress within a period of 28 days. The new revision though acknowledges the increase in compressive strength with age but recommends design based on 28 days strength only unless there is evidence to justify higher strength for concrete of a particular structure. This is because the increase in strength depends upon the grade and type of cement, curing, environment conditions, etc. For concrete of Grade M 30 and above, the rate of increase of compressive strength with age should be based on actual investigation. (ii) The value of Modulus of elasticity has been reduced from 5700f ck to 5000f ck ,
which means that the deformation of the structure will be more.
2.3 Workability of concrete (Cl. 7)
IS 456 : 1978 specified workability in terms of compacting factor, vee-bee time and slump. But the new revision specifies workability only in terms of slump; except in case of very low and very high degree of workability, where compaction factor and flow determination method respectively have been AN OVERVIEW OF REVISIONS IN IS 456 : 2000 CODE OF PRACTICE FOR PLAIN AND REINFORCED CONCRETE
specified. This is probably because of the absence any correlation between the three test methods.
2.4 Durability of concrete (Cl. 8)
Major thrust/emphasis has been given on durability aspects. The durability clause has been enlarged to a great extent to include guidance on concerning factors. Detailed clause covering various requirements for durability of concrete structures has been incorporated.
2.4.1 Shape and size of member (Cl. 8.2.1)
For the first time, importance has been given to shape and design detailing to enhance durability of exposed concrete structures. Specific mention has been made regarding good drainage arrangement, adequate curing, cover to steel, chamfering of corners, surface coating, member profiling and design detailing of member intersections to ensure easy flow of concrete.
2.4.2 Exposure conditions (Cl. 8.2.2) 2.4.2.1 General Environment (Cl. 8.2.2.1)
Table 3 on environmental exposure conditions has been modified to include very severe and extreme exposure conditions. Five environmental exposure conditions (viz. Mild, moderate, severe, very severe and extreme) have been defined in this table. 2.4.2.2 Abrasive action (Cl. 8.2.2.2)
Reference to specialist literature has been recommended for durability requirements of concrete surface exposed to abrasive action. 2.4.2.3 Freezing and thawing (Cl. 8.2.2.3)
Use of suitable air entraining admixtures has been suggested for obtaining enhanced durability in case of freezing and thawing actions under wet conditions. For concrete lower than grade M 50, the mean total air content has been specified for such cases. Since air entrainment reduces the strength of concrete, suitable adjustment in the mix design may be required. 2.4.2.4 Exposure to sulphate attack (Cl. 8.2.2.4)
Table 4 (on requirements for concrete exposed to sulphate attack) has been modified to include two more classes of sulphate attack viz. Class 4 and 5. For very high sulphate concentration in class 5, use of lining with polyethylene or polychloroprene sheet or suitable surface coating has been recommended.
2.4.3 The cover to embedded steel (Cl. 8.2.3) AN OVERVIEW OF REVISIONS IN IS 456 : 2000 CODE OF PRACTICE FOR PLAIN AND REINFORCED CONCRETE
The nominal cover to embedded steel required from durability consideration has been related with exposure conditions vide Table 16. Tolerances for concrete cover have also been specified. In addition, minimum cover is also specified to meet different specified period of fire resistance from 0.5 hour to 4 hours.
Nominal cover has been defined as the depth of concrete cover to all steel reinforcement, including links.
2.4.4 Concrete mix proportions (Cl. 8.2.4)
From durability considerations appropriate values for minimum cement content and the maximum free water-cement ratio applicable to 20 mm nominal maximum size aggregate have been specified in Table 5 for different exposure conditions. Adjustment for minimum cement content for other aggregate size has been given in Table 6.
2.4.5 Maximum cement content (Cl. 8.2.4.2)
A new clause 8.2.4.2 has been added specifying that cement content not including fly ash and ground granulate blast furnace slag in excess of 450 kg/m 3 should not be used unless special consideration has been given to the increased risk of cracking due to drying shrinkage in thin sections or to early thermal cracking and to increased risk of damage due to alkali silica reactions.
This provision may lead to increased use of mineral admixtures as a part replacement of cement particularly for higher grade of concrete leading to likely enhancement of durability.
2.4.6 The type and quality of mix constituents (Cl. 8.2.5)
For concrete to be durable, careful selection of the mix and materials is necessary so that the presence of deleterious constituents do not exceed the prescribed limits.
2.4.6.1 Chloride in concrete (Cl. 8.2.5.2)
Chloride in concrete is harmful and there is an increased risk of embedded steel being corroded. To minimize the chances of deterioration, the maximum total acid soluble Chloride content in the concrete at the time of placing for different type/use of concrete has been limited vide Table 7. As per the new code, the maximum Chloride content is 0.6 kg/m 3 for RCC works; while the earlier edition limited the chloride content to 0.15% by mass of cement. Thus the new provision AN OVERVIEW OF REVISIONS IN IS 456 : 2000 CODE OF PRACTICE FOR PLAIN AND REINFORCED CONCRETE
is more lenient in this respect for concrete having cement content up to 400 kg/m 3 .
2.4.6.2 Sulphate in concrete (Cl. 8.2.5.3)
Sulphates are present in most cement and in some aggregates. Excessive amount of water-soluble sulphate can cause expansion and disruption of concrete. To prevent this, the total water-soluble sulphate content of the concrete mix expressed as SO 3 has been limited to 4% by mass of cement; which is same as was provided in IS 456 : 1978.
2.4.6.3 Alkali-aggregate reaction (Cl. 8.2.5.4)
Some aggregates containing particular varieties of silica may be susceptible to attack by alkalies (Na 2 O and K 2 O) originating from cement or other sources and may produce an expansive reaction which can cause cracking and disruption of concrete. The new code has suggested taking one or more of the following precautionary measures when the service records of the particular cement/aggregate combination is not well established:
Use of non-reactive aggregate from alternative sources. Use of low alkali OPC having total alkali content not more than 0.6% as Na 2 O equivalent. Measures to reduce the degree of saturation of concrete during service such as use of impermeable membranes. Limiting the cement content in the mix and thereby limiting the total alkali content.
2.4.7 Concrete in aggressive soils and water (Cl. 8.2.6)
The code has suggested that at sites where the alkali concentration are high or may become very high, the ground water should be lowered by drainage so that it does not come into direct contact with the concrete. It has also suggested additional protection like the use of chemically resistant stone facing or a layer of plaster of Paris covered with suitable fabric, such as jute thoroughly impregnated with bituminous material.
2.4.8 Concrete in Sea-water (Cl. 8.2.8)
From durability considerations, the minimum grade of concrete in sea- water or exposed directly along sea-coast has been increased from M 15 to M 20 in the case of PCC and from M 20 to M 30 in the case of RCC works.
2.5 Concrete mix proportioning (Cl. 9) AN OVERVIEW OF REVISIONS IN IS 456 : 2000 CODE OF PRACTICE FOR PLAIN AND REINFORCED CONCRETE
Salient revised provisions under this clause are highlighted hereunder:
i) In the list of information required in specifying a particular grade of concrete, the following new items have been added:
Exposure conditions as per Table 4 and 5 of the standard. Maximum temperature of concrete at the time of placing. Method of placing. Degree of supervision.
ii) As the guarantor of quality of concrete used in the construction, the constructor shall carry out the mix design and the mix so designed (not the method of design) shall be approved by the employer within the limitations of parameters and other stipulations laid down in this standard.
This provision is very important as the responsibility of quality assurance and carrying out the mix design has been rightly entrusted to the constructor. Also what is more important is that the results of mix rather than the method of its design has been insisted upon as the basis for finalising the mix proportion. In this context it is worth mentioning that the earlier version of this code mentioned that the procedure given in IS : 10262-1982, Recommended Guidelines for Concrete Mix Design (which was under preparation at that time), may be followed. But the new IS : 456 does not refer to the above standard either in the body of the code or in the list of referred Indian Standards appearing in Annex A.
iii) The target mean strength of the concrete mix should be equal to the characteristic strength plus 1.65 times the standard deviation.
iv) The provision regarding necessity for revision of concrete mix has been modified. The mix design done earlier not prior to one year has been considered adequate for later works provided there is no change in source and the quality of the materials.
v) When sufficient test results for a particular grade of concrete are not available, the value of standard deviation given in Table 8 is to be taken for design of mix in the first instance. The values of assumed standard deviation given in the above table correspond to the site control having proper storage of cement; weigh batching of all materials; controlled addition of water; regular checking of all materials, aggregate grading and moisture content; and periodical checking of workability and strength. Where there is deviation from AN OVERVIEW OF REVISIONS IN IS 456 : 2000 CODE OF PRACTICE FOR PLAIN AND REINFORCED CONCRETE
the above, the values given in the table shall be increased by 1N/mm 2 . The revised code further stipulates that as soon as the results of samples are available, actual calculated standard deviation shall be used and the mix be designed properly.
2.6 Production of concrete (Cl. 10)
2.6.1 Quality Assurance Measures (Cl. 10.1)
Some important aspects on quality assurance measures have been added. These include:
Quality assurance to proper design, use of adequate materials and components to be supplied by producers, proper workmanship in the execution and timely maintenance and repair during service. Development and implementation of a general Quality Assurance Plan (QAP) to identify the key elements necessary to provide fitness of the structure and the means by which they are to be provided and measured. The quality assurance would involve quality audit of inputs such as materials of concrete; workmanship in all stages of batching, mixing, transportation, placing, compaction and curing; and related plant, machinery and equipment.
The QAP shall define the task and responsibility of all persons involved, adequate control and checking procedure and maintenance of adequate documentation, which should generally include:
* Test reports and manufacturers certificate for materials, concrete mix design details;
* Pour cards for site organization and clearance for concrete placement;
* Record of site inspection of workmanship, field tests;
* Non-conformance reports, change orders;
* Quality control charts; and
* Statistical analysis
2.6.2 Batching (Cl. 10.2)
The following important additions have been made: AN OVERVIEW OF REVISIONS IN IS 456 : 2000 CODE OF PRACTICE FOR PLAIN AND REINFORCED CONCRETE
To avoid confusion and error in batching, consideration should be given to using the smallest practical number of different concrete mixes on any site or in any one plant.
Ready-mixed concrete supplied by ready-mixed concrete plant has been given preference. For large and medium project sites, the concrete should be sourced from ready-mixed concrete plants or from on site or off site batching and mixing plants.
The accuracy of measuring equipment should be within 2% of the quantity of cement being measured and within 3% of the quantity of aggregate, admixtures and water being measured.
Volume batching may be allowed only when weigh batching is not practical and provided accurate bulk densities of materials to be actually used in concrete have earlier been established. The mass volume relationship should be checked as frequently as necessary.
2.6.3 Mixing (Cl. 10.3)
The mixers are required to be fitted with water measuring (metering) devices.
Dosages of retarders, plasticisers and superplasticisers have been restricted to 0.5, 1.0 and 2.0 percent respectively by weight of cementitious materials.
2.7 Formwork (Cl. 11)
The minimum period before striking vertical formwork to columns, walls, beams, etc. has been reduced to 16-24 hours from 24-48 hours.
2.8 Assembly of reinforcement (Cl. 12)
Re-bending or straightening of high strength deformed bars without prior approval has been prohibited.
Bar bending schedule is required to be prepared for all reinforcement work.
As per IS 456 : 1978, the reduction in concrete cover was permitted up to one-third of specified cover or 5 mm whichever is less. But the new code specifies tolerance of cover as +10 mm and 0 mm. AN OVERVIEW OF REVISIONS IN IS 456 : 2000 CODE OF PRACTICE FOR PLAIN AND REINFORCED CONCRETE
Thus, no reduction in actual cover from the specified cover has been permitted.
Types of cover-blocks acceptable (concrete of same strength or PVC) have been mentioned. This may pave the way for use of PVC cover blocks.
2.8.1 Welded Joints or mechanical connections (Cl. 12.4)
Only up to 12 mm for high strength deformed steel bars and up to 16 mm for mild steel bars are permitted to bend aside at construction joints which can afterwards be bent back to original position.
Reinforcement should be placed and tied in such a way that concrete placement be possible without segregation and allow compaction by immersion vibrator.
Within concrete mass, different types of metal in contact should be avoided to ensure that bimetal corrosion does not take place.
2.9 Transportation, placing, compaction and curing (Cl. 13)
Maximum permissible free fall of concrete has been stipulated as 1.5m. Construction joints should comply with IS 11817. The earlier practice of introducing a cement slurry/mortar layer between old and new concrete has been discontinued. It has now been recommended to roughen the surface of the previously poured concrete to expose the aggregate and the prepared surface should be in a clean surface dry condition when the fresh concrete is placed against it. Fresh concrete should be thoroughly vibrated near construction joint so that mortar from fresh concrete flows between large aggregates and develops proper bond with old concrete. Provision of shear keys has been recommended where high shear resistance is required at construction joints. The earlier code made a general statement that the curing period should not be less than 7 days from the date of placing concrete. But the new code has specified different period of curing for concrete where mineral admixtures or blended cements are used and also for concrete exposed to dry and hot weather conditions. As per the new code, the minimum curing period of concrete made with OPC is 7 days for normal conditions and 10 days for dry and AN OVERVIEW OF REVISIONS IN IS 456 : 2000 CODE OF PRACTICE FOR PLAIN AND REINFORCED CONCRETE
hot weather conditions. The same for concrete where mineral admixtures or blended cements are used, are 10 days for normal conditions and 14 days for dry and hot weather conditions. Impermeable membrane such as polyethylene sheeting to provide effective barrier against evaporation may be used as an alternative to moist curing.
2.10 Concreting under special conditions (Cl. 14)
2.10.1 Under-Water Concreting (Cl. 14.2)
Some fundamental conceptual changes have been made in provisions on under-water concreting. The 1978 edition stated that under-water concrete should in no case be considered as Design mix concrete and recommended to provide at least 10% extra cement than that required for the same mix placed in dry. The new edition envisages that design mix concrete alone will be used for under-water concreting and the requirement of 10% extra cement has been deleted. However, the code has further specified that the minimum cement content shall be 350 kg/m 3 , which would take care of possible loss of cement during under-water concreting.
Direct placement with pump has been added as one of the methods to be used for depositing concrete under water.
2.11 Sampling and strength of designed concrete mix (Cl. 15)
The heading of this clause should have been Sampling and strength test of concrete as per the earlier code since the details of sampling and testing is related to work site concrete and not to design mix concrete.
IS : 456 1978 exempted strength tests at the discretion of engineer-in-charge for concrete of quantity less than 15 m 3 in unimportant building and works.
Both 1978 and 2000 editions have specifically mentioned that in all cases, the 28 days compressive strength shall alone be the criteria for acceptance or rejection of concrete. But the 1978 edition permitted relaxation in the frequency in 28 days compressive strength provided a satisfactory relation between 28 days compressive strength and the modulus of rupture at 722 hrs or 7 days or compressive strength at 7 days is established for a AN OVERVIEW OF REVISIONS IN IS 456 : 2000 CODE OF PRACTICE FOR PLAIN AND REINFORCED CONCRETE
reasonably long period. This relaxation has been deleted from the 2000 edition.
The 1978 edition had given values of the modulus of rupture at 722 hrs and 7 days as well as compressive strength at 7 days for various grades of concrete in order to get a relatively quicker idea of the quality of concrete and possible compressive strength at 28 days. The new edition has not given these values and has rightly stated that these values should be arrived at based on actual testing because several factors may affect it.
The new revised standard recognizes the use of ready-mixed concrete and states that the frequency of sampling for such concrete may be decided mutually by supplier and purchaser.
2.11.1 Test results of sample (Cl. 15.4)
Both 1978 and 2000 editions state that test result of no individual specimen should vary more than 15% of the average strength of the sample. The 2000 edition further clarifies that the test results of such sample will be invalid.
2.12 Acceptance criteria (Cl. 16)
The acceptance criteria has been fully modified and made simpler for implementation. As per the new code the concrete shall be deemed to comply with strength requirements when both the following conditions are met:
a) The mean strength determined from any group of four non- overlapping consecutive test results gives concrete strength greater than or equal to:
(i) f ck + 0.825 x established standard deviation (rounded off to nearest 0.5 N/mm 2 )
or
(ii) f ck + 3 N/mm 2 (for M15) or f ck + 4 N/mm 2 (for M20 and above) as the case may be
Whichever of (i) and (ii) is greater.
AN OVERVIEW OF REVISIONS IN IS 456 : 2000 CODE OF PRACTICE FOR PLAIN AND REINFORCED CONCRETE
b) Any individual test result should be greater than equal to f ck - 3 N/mm 2 (for M15) or f ck - 4 N/mm 2 (for M20 and above) as the case may be.
Thus, as long as standard deviation is less than about 5 N/mm 2
(which can be achieved with good quality control), the criteria is satisfied when a margin of 4 N/mm 2 for the mean strength over the characteristic strength is maintained. Or in other words for concrete of grade M 20 to M 50, about 85 to 93 percent of target mean strength of design mix is to be achieved at site.
A new clause 16.2 has been added on the requirements of flexural strength.
Vide new additional clause 16.3, the quantity of concrete represented by strength test results has been clarified.
2.13 Inspection and testing of structures (Cl. 17)
The thrust is now more for a quality of inspection system than the inspection of final product. The following important additions have been made:
An inspection procedure should be set up covering materials, records and workmanship to ensure that the construction complies with the design.
Tests should be made on reinforcement and the constituent materials of concrete in accordance with relevant standard.
A suitable quality assurance plan should be made to see that:
* Design and detail are capable of being executed to a suitable standard, with due allowance for dimensional tolerance;
* There are clear instructions on inspection standards;
* There are clear instructions on permissible deviations;
* Elements critical to workmanship, structural performance, durability and appearance are identified; and
* There is a system to verify that the quality is satisfactory in individual parts of the structure, specially the critical ones. AN OVERVIEW OF REVISIONS IN IS 456 : 2000 CODE OF PRACTICE FOR PLAIN AND REINFORCED CONCRETE
2.13.1 Load tests for flexural members (Cl. 17.6)
The heading of this clause has been rightly changed from Load tests on parts of structure (as per cl. 16.5 of IS : 456 1978) to Load tests for flexural members as it describes detailed requirements of load tests for flexural members.
2.13.2 Members other than flexural members (Cl. 17.7)
This is a new provision, which states that members other than flexural members should be preferably investigated by analysis.
2.13.3 Non destructive tests (Cl. 17.8)
The earlier provision regarding non-destructive tests has been extended and non-destructive test methods like Ultrasonic Pulse Velocity and Rebound Hammer, Probe Penetration, Pullout and Maturity has been recognized to obtain estimation of the properties of concrete in the structure. Any of these methods may be adopted, in which case the acceptance criteria may be agreed upon prior to testing.
However, an important provision that the non-destructive tests should be done under expert guidance contained in the earlier code has not been mentioned here.