180605: Project II

Project Report
On
'High-Strength Concrete Mix Design' Using
Various Admixtures and Evaluation of
Properties

As partial fulfillment of award of

Bachelor of Engineering in
Civil Engineering

Prepared by:
NAME ENROLLMENT NO.
Abhal Gudhka 120010106002
Satish Patel 120010106011
Nilesh Balasara 120010106021
Kalpesh Bhatti 130013106002
Team ID: 52645

Internal Guide
Prof. Sandip P. Mistry

A. D. Patel Institute of Technology

Gujarat Technological University
(April - 2016)

1
 Department of Civil Engineering
A. D. Patel Institute of Technology
Gujarat Technological University

CERTIFICATE

This is to certify that Abhal Gudhka (120010106002), Satish Patel

(120010106011), Nilesh Balasara (120010106021) and Kalpesh
Bhatti (130013106002) of final year Civil Engineering have
satisfactorily completed their project work 'High-Strength Concrete
Mix Design' Using Various Admixtures and Evaluation of
Properties for the subject 180605-Project-II in the 2nd semester of
academic year 2015-16 for the partial fulfillment of the award of the
Bachelor of Engineering in Civil Engineering at Gujarat
Technological University.

Date:

Project Guide
Prof. Sandip P. Mistry

Head of Department Principal of Institute

Dr. Rajiv Bhatt Dr. R. K. Jain

2
 ACKNOWLEDGEMENT

We would like to acknowledge the Institute A.D.I.T., Gujarat Technological

University for giving us the opportunity for the project work in 'High-Strength Concrete
Mix Design' Using Various Admixtures and Evaluation of Properties.

We express our gratitude towards our guide Prof. Sandip Mistry, Civil Engineering
Department, A.D.I.T., who has guided us throughout the tenure of project and has given his
suggestions to improve the quality of project at critical moments. We also thank Prof.
Kumarpal Trivedi, Associate Professor, Civil Engineering Department, A. D. I. T. for helping
us and giving valuable suggestions. We are thankful to Dr. Rajiv Bhatt, Head of Department
and our principal Dr. R. K. Jain for allowing us to work on this project.

3
 ABSTRACT

Concrete is a mixture of Portland cement, water, coarse and fine aggregates and
sometimes admixtures. Proportioning a concrete mix for a given purpose is the art of
obtaining a suitable ratio of various ingredients of concrete with the required properties at the
lower cost. The primary difference between high-strength concrete and normal-strength
concrete relates to the compressive strength.

High strength concrete has compressive strength of up to 100 MPa as against

conventional concrete which has compressive strengths of less than 40 MPa. Low water-
cement ratio is a crucial aspect which can be achieved by using chemical admixtures such as
plasticizers. A mineral admixture introduces favourable behaviour with respect to shrinkage
and high evolution of heat of hydration and enhances durability. The project revolves around
the development of high compressive strength using proper mix of ingredients.

4
 TABLE OF CONTENTS

ACKNOWLEDGEMENT ......................................................................................................... 3
ABSTRACT ............................................................................................................................... 4
LIST OF PHOTOGRAPHS ....................................................................................................... 6
LIST OF CHARTS .................................................................................................................... 6
LIST OF SYMBOLS, ABBREVIATIONS AND NOMENCLATURES ................................. 7
CHAPTER 1: INTRODUCTION .............................................................................................. 8
CHAPTER 2: LITERATURE REVIEW ................................................................................... 9
CHAPTER 3: AIM & OBJECTIVES ...................................................................................... 12
CHAPTER 4: METHODOLOGY ........................................................................................... 13
CHAPTER 5: INGREDIENTS OF HSC ................................................................................. 14
CHAPTER 6: IMPORTANCE OF ADMIXTURES ............................................................... 17
CHAPTER 7: TRAIL MIX - 1 ................................................................................................ 24
CHAPTER 8: TRAIL MIX - 2 ................................................................................................ 28
CHAPTER 9: ANALYSIS OF RESULTS .............................................................................. 33
CHAPTER 10: COST IMPLICATIONS AND APPLICATION ............................................ 35
CHAPTER 11: CONCLUSIONS ............................................................................................ 37
REFERENCES ........................................................................................................................ 39

5
 LIST OF PHOTOGRAPHS

No. Title Page No.

5.1 Ingredients of High Strength Concrete 15, 16

7.1 Photographs of Casted Elements & Results 22, 23

8.1 Photographs of Casted Elements & Results 26, 27

LIST OF CHARTS

No. Title Page No.

Chart 1 Compressive Strength: Trial Mix - 1 21

Chart 2 Compressive Strength: Trial Mix - 2 25

Chart 3 Comparison of Strength 28

Chart 4 % Strength Gain 28

6
 LIST OF SYMBOLS, ABBREVIATIONS AND
NOMENCLATURES

Symbols/ Meaning
Abbreviations/
Nomenclatures

MPa Mega Pascal (unit of pressure) = N/mm2

Mm Millimeter

Cm Centimeter

w/c Ratio of Water to Powder Content

Powder Cement + Fly Ash

HSC High Strength Concrete

ASTM American Standard for Testing and Materials

7
 CHAPTER 1: INTRODUCTION

 What is High Strength Concrete?

 As name suggests, it is concrete of high strength.

 It has compressive strengths of up to 100 MPa.
 Concrete designed by conventional methods have strengths up to 40 MPa.
 Certain admixtures are used to produce high strength concrete.
 There are two crucial aspects to be considered:
o Low water-cement ratio
o Dense particle packing
 So approach is to achieve concrete mix of high strength by using admixtures.

8
 CHAPTER 2: LITERATURE REVIEW

Sr. Title Name Of Name Of Review

Journal Author
No.

1 Partial Replacement International Prof. P.A. The Compressive strength

of Cement with Journal Of Shirulea, of Cubes are increased with
Marble Dust Powder Advanced Ataur addition of waste marble
Engineering Rahmanb , powder up to 10% replace
Research And Rakesh D. by weight of cement and
Studies Gupta further any addition of
waste marble powder the
compressive strength
decreases

2 Strength and International Er. Amritpal The replacement of cement

Duriabilty Properties Journal of Kaur, Er. with 9%MK and 10% MP,
of Concrete with Engineering Rajwinder give better results better for
Partial Replacement Research & Singh Bansal strength.
of Cement with Technology
Metakaolin and (IJERT)
Marble Dust

3 Experimental Study Int. Journal of Aalok D. The compressive strength of

on Use of Waste Engineering Sakalkale , concrete is increased with
Marble Dust in Research and G. D. addition of waste marble
Concrete Applications Dhawale , R. powder up to 50% by
S. Kedar weight in place of sand and
further any addition of
waste marble powder the
compressive strength
decreases.

9
Sr. Title Name Of Name Of Review
Journal Author
No.

4 Fly Ash Concrete: International Dr S L Patil, Fly ash can be successfully

A Technical Journal of J N Kale, S used in the cement concrete in
Analysis for Advanced Suman minor amount as an additive.
Compressive Engineering
Strength Research and
Studies

5 Analysis of Fly Ash International Tomas U. Fly ash has a lower unit
Cement Concrete Journal of Ganiron Jr weight which means the
for Road Advanced greater the percentage of fly
Construction Science and ash in the paste, the better
Technology lubricated the aggregates are
and the better the concrete
flows and continues to
combine with the lime in
cement, increasing
compressive strength over
time.

6 Effect Of Article Online Saeed Use of Superplasticizer shows

Superplasticizers Id: 100030014 Ahmad, increase in the compressive
On Workability Muhammad strength, workability, water
And Strength Of Nawaz, Ayub reduction, cement saving
Concrete Elahi requirements of concretes.

10
Sr. Title Name Of Name Of Review
Journal Author
No.

7 Effect of International Rahul Dubey, With incorporation of SP

Superplasticizer Journal of Civil Pardeep Kumar up to 4%, there was
Dosages on and Structural significant increase of
Compressive Engineering compressive strength of
Strength Of Self- SCC mix with increase of
Compacting age.
Concrete

8 Behaviour of Pak. J. Engg. & S N R Shah, Dosage of superplasticizer

Normal Concrete Appl. Sci. Vol. Muhammad equal to 0.5% has been
Using 15 Aslam, S A observed to be optimum in
Superplasticizer Shah, Raja terms of enhancement in
under Different Oad the compressive strength.
Curing Regimes

9 Exploring Posibility International Rakesh Kumar Out of fifteen mixes only

of Developing High Journal of Sahu & Dr. S. one mix has achieved 28
Strength Concrete Advanced P. Mishra days strength more than 50
Using Locally Engineering MPa the proportion of the
Available Materials Research and mix is 1:1.17:1.88.
Studies

10 Experimental Study International Mr. Amol P. Increment in fly ash

Report on Use of Journal of Titarmare, Prof. content up to 15% given
Fly Ash In High Scientific & Shri best result in terms of
Grade Ready Mixed Engineering R.S.Deotale, compressive strength.
Concrete Research Mr. Sanjay B From 20% and above it can
Volume 3 Bachale be increase the percentage
for up to 30% but high
precautions required
during mixing.

11
 CHAPTER 3: AIM & OBJECTIVES

 Aim:
 Our aim is to produce a concrete mix of high strength – greater than 40 MPa by
using proper proportion of materials and various admixtures.
 Following are the objectives to reach our aim.

 Objectives:
 To learn the developments in materials, production method and mechanical
properties and their uses.
 To study the functions of admixtures.
 To learn the important aspects of high strength concrete.
 To achieve a concrete mix of strength greater than 40 MPa.

12
 CHAPTER 4: METHODOLOGY

 Method Used:
 Trial and error method
 Target strength: 50 MPa

 Important Criteria:

High Strength Concrete

Mix

Low Water-Binder Ratio Proper Mix For

(0.30-0.45) Minimum Voids

Rich Mix with Addition of

Use of Plasticizers Mineral Binder

 High strength is achieved if the particle packing is dense with minimum voids. For
this high paste volume is essential.
 A rich mix is used.
 Mineral and chemical admixtures are used.
 Two batches of concrete were prepared: one without superplasticizer, one with
superplasticizer.

13
 CHAPTER 5: INGREDIENTS OF HSC

 Apart from conventional ingredients of concrete, chemical and mineral admixtures

are used.
 Ingredient materials are as follows:

Ingredient Size/ Grade

Cement OPC 53 Grade

Fly Ash Class-F

Fine Aggregates 2.36 mm

Coarse Aggregates 10 mm

Coarse Aggregates 20 mm

Water Potable

Plasticizer Auramix-400

Marble Dust 2.36 mm

14
5.1: INGREDIENTS OF HIGH STRENGTH CONCRETE

OPC 53 Grade Fly Ash

Sand-1 (2.36 mm) Sand-2 (finer)

15
C. A. (10 mm) C. A. (20 mm)

Marble Dust Superplasticizer

Water
16
 CHAPTER 6: IMPORTANCE OF ADMIXTURES

 Admixtures:
 Admixtures are used to modify the properties of fresh and hardened concrete.
 Types of admixtures:

Chemical
Admixtures
Admixtures Reactive
Mineral
Admixtures
Inert

 Admixtures Used:

Chemical Admixtures Mineral Admixtures

Superplasticizer Fly Ash

Marble Dust

17
 Superplasticizer:
 Name: Auramix-400 (FOSROC)
 Auramix 400 is a combination of the latest generation superplasticisers, based on
a polycarboxylic ether polymer with long lateral chains.
 It allows water reduction and also gives good workability.

 Fly Ash:
 Class-F fly ash
 It is a byproduct resulting from burning of anthracite and bituminous coals. So use
of fly ash leads to cost and energy savings.
 It has pozzolonic properties; hence it is used as replacement of cement.
 It increases late compressive strength of the concrete.
 Also gives good durability due to decreased permeability.

 Marble Dust:
 It is free of cost material.
 It is used as filler. It increases density by filling voids.
 5 to 10% of cement content by weight is recommended to add in mix.

18
 Fly Ash Types and Benefits:

 What is Pozzolon?

The American Society for Testing and Materials (ASTM) defines pozzolan as
“a siliceous or siliceous and aluminous material, which in itself possesses little or no
cementitious value, but will, in finely divided form and in the presence of moisture,
chemically reacts with calcium hydroxide at ordinary temperatures to form
compounds possessing cementitious properties.”

Fly ash is the best known “pozzolan” in the world – and one of the most
commonly used.

 Class F and Class C fly ash are products of the combustion of coal in large power
plants.

 Class F Fly Ash:

 Class F fly ash is available in the largest quantities. Class F is generally low in
lime, usually under 15%, and contains a greater combination of silica, alumina
and iron (greater than 70%) than Class C fly ash.

 Most effectively moderates heat gain during concrete curing and is therefore
considered an ideal cementitious material in mass concrete and high strength
mixes. For the same reason, Class F is the solution to a wide range of summer
concreting problems.

 Provides sulphide and sulphate resistance equal or superior to Type V cement.

Class F is often recommended for use where concrete may be exposed to sulphate
ions in soil and ground water.

19
 Class C Fly Ash:

 Class C fly ash normally comes from coals which may produce an ash with higher
lime content, generally more than 15% often as high as 30%. Elevated CaO may
give Class C unique self-hardening characteristics.

 Most useful in “performance” mixes, prestressed applications, and other situations

where higher early strengths are important.

 Especially useful in soil stabilization, since Class C may not require the addition
of lime.

 Benefits of Using Fly Ash:

 Fly ash will result in a more predictable and consistent finished product that will
ensure customer acceptance.
 Fly ash improves the flowability of the concrete, which translates into less wear
and tear on all the producer’s equipment, from batching facilities to trucks.
 Fly ash produces a high strength concrete that accommodates the design of thinner
sections.
 Fly ash contributes to the aesthetic appearance of the concrete.
 Since fly ash concrete is not as vulnerable to deterioration or disintegration as
rapidly as concrete without fly ash, it ensures low-maintenance buildings that will
retain their value over the long-term.

20
 Chemical Composition of Class-F Fly Ash:

Chemical Analysis Class-F ASTM C 618

Fly Ash Class F

SiO2 (silicon dioxide), % 52.98

Al2O3 (aluminium oxide), % 28.96

Fe2O3 (iron oxide), % 8.24

SiO2 + Al2O3 + Fe2O3, % 90.18 70 Min

CaO (calcium oxide), % 1.46

MgO (magnesium oxide), % 0.91

SO3 (sulphur trioxide), % 0.03 5.0 Max

Na2O (sodium oxide) 0.14

K2O (potassium oxide), % 2.57

Moisture content, % 0.05 3.0 Max

Loss On Ignition (LOI), % 2.54 6.0 Max

21
 Superplasticizer: Why it is used and how it works…

 Addition of water to improve workability results in weak concrete mix and

reducing water content may result in stiffer mix which would be less workable.
 So care should be taken while determining water content. Reducing water content
in a concrete mix should be done in such a way so that complete hydration process
may take place and sufficient workability is maintained for placement.
 Superplasticizers, also known as ‘High Range Water Reducers’ are used to
improve workability of the concrete while not affecting strength of the concrete.

 Working of Superplasticizer:

 Cement particles form flocs and water gets trapped in these flocs.
 If this trapped water could be released, it would improve flowability of concrete.
 Superplasticizer does the same. Superplasticizer gets adsorbed by cement particles
and forms a thin film around these cement particles.
 Now negatively charged particles impart repulsive forces on each other.
 Hence there will be deflocculation of the cement particles and entrapped water
will be released. This water will improve flow characteristics of the concrete.
 Superplasticizer allows water reduction this way.

22
 Working of Superplasticizer

Figure 1: Adsorption of Superplasticizer on Cement Particle

Figure 2: Flocculation and Dispersion of Cement Particles

23
 CHAPTER 7: TRAIL MIX - 1
(Date: 05/03/2016)

Proportion Of Key Ingredients:

Powder Fine Aggregates Coarse Aggregates
(Cement+Fly Ash)
1 1.25 1.65

 Water to Powder Ratio:

Water/Powder

0.42

 Mineral Admixture Content:

Admixture Quantity

Fly Ash 10% replacement of cement

Marble Dust 10% of binder content

24
 Quantity of Materials:
No. Material Quantity (kg)

1 OPC 21.6

2 Fly Ash 2.4

3 Sand-1 (2.36 mm) 15

4 Sand-2 (1.18 mm) 15

5 C. A. (10 mm) 20

6 C. A. (20 mm) 20

7 Marble Dust 2.4

8 Water 10

 Results:

Chart 1: Compressive Strength

Trail Mix-1
50
Compressive Strength (MPa)

44.63
45 42
40.2 41.16
40 36.67
34.83 33.56
35
28.99 29.32 28.01 29.14
30 25.72
25
20
15
10
5
0
3 Day 7 Day 28 Day
Days

Cube 1 Cube 2 Cube 3 Average

25
7.1: PHOTOGRAPHS OF CASTED ELEMENTS & RESULTS

Compaction by Vibration Casted Elements

Casted Elements

26
3 Day Highest Strength

7 Day Highest Strength

28 Day Highest Strength

27
 CHAPTER 8: TRAIL MIX - 2
(Date: 11/03/2016)

 Proportion of Key Ingredients:

Powder Fine Aggregates Coarse Aggregates
(Cement + Fly Ash)
1 1.30 1.70

 Water to Powder Ratio:

Water/Powder

0.32

 Mineral Admixture Content:

Admixture Quantity

Fly Ash 10% replacement of cement

Marble Dust 10% of binder content

Superplasticizer 1% of binder content

28
 Quantity of Materials:
No. Material Quantity (kg)

1 OPC 35.3

2 Fly Ash 3.9

3 Sand-1 (2.36 mm) 25.5

4 Sand-2 (1.18 mm) 25.5

5 C. A. (10 mm) 33

6 C. A. (20 mm) 33

7 Marble Dust 3.9

8 Superplasticizer 0.39

9 Water 12.68

 Results:
CHART 2: Compressive Strength
Trail Mix - 2
60
Compressive Strength (MPa)

52.9
48.88 49.64 50.47
50
43.37
39.32 40.2 40.96
40

30 26.07 26.32 25.01

22.64
20

10

0
3 Day 7 Day 28 Day
Days

Cube 1 Cube 2 Cube 3 Average

29
 8.1:PHOTOGRAPHS OF CASTED ELEMENTS & RESULTS

Compaction by Vibration Casted Elements

ctio
E
on

Broken Element Casted Elements

30
3 Day Highest Strength

7 Day Highest Strength

28 Day Highest Strength

31
  Strength Gain After 28 Days:

 WHY IT IS IMPORTANT?
 It is not always the case that concrete would gain its 100% strength within 28
days.
 Strength gain after 28 days can be beneficial with respect to cost of construction.
 If there is considerable increase in strength after 28 days, saving in cost is
possible.
 For example, if concrete mix of M40 grade gives strength of 65 MPa after 56
days; the mix can be used instead of M60 grade mix. This will result in cost
saving because M60 grade concrete mix would require richer mix.

56 DAY COMPRESSIVE STRENGTH (MIX-2)

56
55.57
Compressive Strength (MPa)

55.5 55.26
55 54.70
54.5

54

53.5 53.25
53

52.5

52
Days

Cube 1 Cube 2 Cube 3 Average

 There was little increase in strength – 8.4%

 Strength gain is not significant to be considered for saving in cost.

32
 CHAPTER 9: ANALYSIS OF RESULTS

 Comparison of Results of Two Mixes:

Chart 3: Comparison of Strength

Compressive Strength (MPa)

60 50.47
50
40.96
40 42
28.01
30 33.56
20 25.01
10
0
3 Day 7 Day 28 Day
Days

W/C=0.42 W/C=0.32

 % Strength Gain:

Chart 4: % Strength Gain

120.00%
99%
100.00%
80%
% Strength

80.00% 65%
60.00% 79%

40.00% 50%
20.00%
0.00%
3 Day 7 Day 28 Day
Days

W/C 0.42 W/C 0.32

33
 Analysis of Results: Trail Mix - 1
 Water to cement ratio: 0.42
 Superplasticizer was not used.
 28 day compressive strength: 42 MPa
 Cubes tested : 3 for each test
 65% strength was gained within 3 days.

 Analysis of Results: Trial Mix 2

 Water to cement ratio: 0.32
 Superplasticizer was used.
 28 day compressive strength: 50.47 MPa
 Cubes tested: 3 for each test
 Almost 50% strength was gained within 3 days.
 Reduction of w/c ratio from 0.42 to 0.32 resulted in 20% increase in compressive
strength.

34
 CHAPTER 10: COST IMPLICATIONS AND
APPLICATION

 Comparison of Concrete Quantities for A 275 M Chimney

HEIGHT M25 (m3) HIGH STRENGTH CONCRETE OF VARYING
(m) STRENGTH (m3)

M70 M50 M40 M25

0-130 7130 3680

130-190 1665 - 1255 - -

190-240 950 - - 895 -

240-275 525 - - - 515

TOTAL 10270 6345

Data from: Concrete Technology - Oxford

 From above table, it is evident that use of concrete mixes of high strengths reduces
quantity considerably.
 Here reduction is nearly 40%, which will reduce cost of construction.
 So, it is better to use various grades of high strength concrete or single grade of high
strength concrete instead of concrete of low strength for high rise structures.

35
 Application of High Strength Concrete:

 High strength concrete is used for structures which are supposed to carry large
loads.
 The mix we produced can be used for following types of structures.

INDUSTRY DESIGN STRENGTH (MPa)

Railway Bridges 50-80

Diaphragm Walls 50-55

Abrasion-resistant Concrete 40-80

High-rise RC Buildings 40-80

RC Piles 50

Centrifuged RC Piles 50-80

Railway Sleepers 40-50

36
 CHAPTER 11: CONCLUSIONS

 After testing two batches of concrete mix, we came down to

these conclusions:

1. By using certain admixtures, we achieved concrete of high strength.

2. Fly ash and marble dust should be used as partial replacement of cement.
3. To achieve high strength, more paste volume is required. Rich mix should be used,
i. e. more binder content and fine aggregates.
4. Reduction in w/c ratio resulted in increased compressive strength.
5. Superplasticizer allows reduction of water content.
6. This mix gives high early strength. About 50% strength is gained after only 3
days.
7. Formworks can be removed earlier and member can be loaded earlier.
8. Good surface finishing due to high paste volume.
9. Collapse was observed in slump test. Hence good self-compaction.
10. The results justify the importance of low w/c ratio and dense particle packing.
11. We designed high strength concrete of M50 grade by trial and error method.
12. This design can be used to produce M50 grade concrete, which will also have
good durability.

37
 M50 Grade Concrete Mix – Proportion:
Binder Fine Aggregates Coarse Aggregates
(Cement + Fly Ash)
1 1.30 1.70

Water/Binder Ratio 0.32

Fly Ash 10% replacement of cement content

Marble Dust 10% of binder content

Superplasticizer 1% of binder content

 M50 Grade Concrete Mix Design for 1 Cubic Metre:

INGREDIENT QUANTITY

Cement 540 kg

Fly Ash (Class-F) 60 kg

Sand-1 (2.33 mm) 390 kg

Sand-2 (1.18 mm) 390 kg

C. A. (10 mm) 510 kg

C. A. (20 mm) 510 kg

Water (Potable) 192 litre

Superplasticizer (Auramix 400) 6 kg

Marble Dust 60 kg

38
 REFERENCES

1. Concrete Technology – Oxford

2. www.engineeringcivil.com
3. http://www.ceratechinc.com/content/pdfs/patel-paper-final-5-10-12-2.pdf
4. www.applechemie.com
5. www.engr.psu.edu
6. FOSROC Constructive Solutions

39