mix design for pumped concrete with ppc, opc, opc flyash
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Mix Design for Pumped Concrete with PPC, OPC,OPC+Flyash
A simple method of concrete mix design for pumpable concrete based on an
estimated weight of the concrete per unit volume is presented in the
article. The Tables and Figures included are worked out by the author from
a wide range of materials available in the country. The method is suitable
for normal weight concrete and with admixtures.
Kaushal Kishore, Materials Engineer, Roorkee, Uttaranchal
Pumped Concrete
Pumped concrete may be defined as concrete that is conveyed under pressure through either rigid
pipe or flexible hose and discharged directly into the desired location. Pumping may be used for
most all concrete construction, but is especially useful where space or access for construction
equipment is limited.
Pumping equipment consists of pumps which are of three types:
Piston type concrete pumpa.
Pneumatic type concrete pumpb.
Squeeze pressure type concrete pumpc.
Other accessories are rigid pipelines, flexible hose and couplings etc.
A pumpable concrete, like conventional concrete mixes, requires good quality control, i.e. properly
graded uniform aggregates, materials uniformly and consistently batched and mixed thoroughly.
Depending on the equipment, pumping rates may vary from 8 to 130 m3 of concrete per hour.
Effective pumping range varies from 90 to 400 meters horizontally, or 30 to 100 meters vertically.
Cases have been documented in which concrete has successfully been pumped horizontally upto
1400 meters and 430 meters vertically upward. New record values continued to be reported.
Pumping
For the successful pumping of concrete through a pipeline, it is essential that the pressure in the
pipeline is transmitted through the concrete via the water in the mix and not via the aggregate; in
effect, this ensures the pipeline is lubricated. If pressure is applied via the aggregate, it is highly
likely that the aggregate particles will compact together and against the inside surface of the pipe to
form a blockage; the force required to move concrete under these conditions is several hundred
times that required for a lubricated mix.
If, however, pressure is to be applied via the water, then it is important that the water is not blown
through the solid constituents of the mix; experience shows that water is relatively easily pushed
through particles larger than about 600 microns in diameter and is substantially held by particles
smaller than this.
In the same way, the mixture of cement, water and very fine aggregate particles should not be
blown through the voids in the coarse aggregate. This can be achieved by ensuring that the
aggregate grading does not have a complete absence of material in two consecutive sieve sizes
for example, between 10 mm and 2.36 mm. In effect any size of particle must act as a filter to
prevent excessive movement of the next smaller size of materia l.
Basic Considerations
Cement Content
Concretes without admixtures and of high cement content, (over about 460 kg/m3) are liable to
prove difficult to pump, because of high friction between the concrete and the pipeline. Cement
contents below 270 to 320 kg/m3 depending upon the proportion of the aggregate may also prove
difficult to pump because of segregation within the pipe line.
Workability
The workability of pumped concrete in general has an average slump of between 50 mm and 100
mm. A concrete of less than 50 mm slump is impractical for pumping, and slump above 125 mm
should be avoided. In mixtures with high slump, the aggregate will segregate from the mortar and
paste and may cause blocking in the pump lines.
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The mixing water requirements vary for different maximum sizes and type of aggregates. The
approximate quantity of water for a slump of 85 mm and 100 mm is given in Table 1. In high
strength concrete due to lower water/cement ratio and high cement content, workability is reduced
with the given quantity of water per cu.m. of concrete. In such cases, water reducing admixtures
are useful. In the addition to this type of admixtures at normal dosage levels, to obtain a higher
workability for a given concrete mix, there is no necessity to make any alteration to the mix design
from that produced for the concrete of the initial lower slump. There is generally no loss of cohesion
or excess bleeding even when the hydroxycarboxylic acid baset materials are used.
If this class of product is used to decrease the water/cement ratio, again no change in mix design
will be required, although small alterations in plastic and hardened density will be apparent and
should be used in any yield calculations.
A loss of slump during pumping is normal and should be taken into consideration when proportioningthe concrete mixes. A slump loss of 25 mm per 300 meters of conduit length is not unusual, the
amount depending upon ambient temperature, length of line, pressure used to move the concrete,
moisture content of aggregates at the time of mixing, truck-haulage distance, whether mix is kept
agitated during haulage etc. The loss is greater for hose than for pipe, and is sometimes as high as
20 mm per 30 meter.
Aggregates
The maximum size of crushed aggregate is limited to one-third of the smallest inside diameter of
the hose or pipe based on simple geometry of cubical shape aggregates. For uncrushed (rounded)
aggregates, the maximum size should be limited to 40% of the pipe or hose diameter.
The shape of the coarse aggregate, whether crushed or uncrushed has an influence on the mix
proportions, although both shapes can be pumped satisfactorily. The crushed pieces have a larger
surface area per unit volume as compared to uncrushed pieces and thus require relatively more
mortar to coat the surface. Coarse aggregate of a very bad particle shape should be avoided.
Difficulties with pump have often been experienced whentoo large a proportion of coarse aggregate is used in an
attempt to achieve economy by reducing the amount of
cement; such mixes are also more difficult and costly to
finish. The grading of coarse aggregate should be as per
IS : 383-1970. If they are nominal single sized then 10
mm and 20 mm shall be combined in the ratio of 1:2 to
get a 20 mm graded coarse aggregate. In the same way,
10 mm, 20 mm and 40 mm aggregates shall be combined in the ratio of 1:1.5:3 to get a 40 mm
graded coarse aggregate.
Fine aggregate of Zone II as per IS: 383-1970 is generally suitable for pumped concrete provided
15 to 30% sand should pass the 300 micron sieve and 5 to 10 percent should pass the 150 micron
sieve. Fine aggregate of grading as given in Table 2 is best for pumped concrete. The proportion of
fine aggregate (sand) to be taken in the mix design is given in Table 3. However, the lowest
practical sand content should be established by actual trial mixes and performance runs.
In practice, it is difficult to get fine and coarse aggregates of a particular grading. In the absence of
fine aggregate of required grading they should be blended with selected sands to produce desiredgrading, and then combined with coarse aggregates to get a typed grading as per Table 4.
Uncrushed Aggregate (River Gravel)
It has become a custom that almost in all the construction sites crushed aggregates are being used.
To save environmental pollution as far as possible in ordinary construction works uncrushed
aggregates (River Gravel) including river sand should be used.
Production of crushed aggregates from crushers poses air and noise pollution problems.
Crusher & Air Pollution Problem
When the rocks and river bed boulders are crushed, dry surfaces are exposed and air borne dust
can be created. An inventory of sources of dust emissions usually begins with the first crusher and
continues with the conveyor transfer points to and including the succeeding crushers. Here the
aggregate is more finely grounded, and dust emission become greater. As the process continues,
dust emission are again prevalent from sources at conveyor transfer points and the final screens.
In the modern screening and washing plant in the production of uncrushed (gravel/shingle)
aggregate from the river bed they are not crushed, thus no dust is formed. Further aggregates are
washed to remove silt and clay like materials. Therefore, uncrushed (gravel/shingle) aggregates
produces in these plant arrive at site in a moist condition, hence do not present a dust problem.
Whereas the crushed aggregate leave crushing plant very dry and create considerable dust when
handled. To prevent dust in handling it is not possible to wet each load of crushed aggregate
thoroughly before it is dumped from the delivery truck. Attempts to spray the crushed aggregate as
it is being dumped have had very limited effectiveness.
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During crushing of aggregate particles less than 100 micron remains suspended in the air. The
suspension of a particle in the air follows a certain trajectory depending on its size, density, shape
and other physical properties. In air turbulence the dry crusher dust has long trajectories or
suspension time and settling distance to the ground. If a crushing plant is not properly designed and
operate without any efficient prevention system this fugitive dust may generate air pollution.
Air quality due to pollution should be monitored monthly.
The ambient air quality standards as recommended byCentral Pollution Control Board (CPCB) India are given in
the following table.
Note:
SPm : Suspended particle matters
SO2 : Sulpher dioxide
CO : Carbon Mono oxide
NOx : Nitrogen Oxide
1.
The concentrations for the above pollutants shall be 95% of the time within the limits
prescribed.
2.
Category C sensitive areas are: Hill Stations, Tourist Resorts, Sanctuaries, National Part,
National Manuments etc.
3.
The air quality levels should be determined by sampling and brought down within specified
ambient air quality standards through use of various mitigation measures, modern pollution
free equipment and advance construction technology, such as giving preference in usinguncrushed (gravel/shingle) natural aggregate in the general civil engineering construction
work in place of crushed aggregate obtained from crusher.
4.
Pumping
Before the pumping of concrete is started, the conduit should be primed by pumping a batch of
mortar through the line to lubricate it. A rule of thumb is to pump 25 litres of mortar for each 15
meter length of 100 mm diameter hose, using smaller amounts for smaller sizes of hose or pipe.
Dump concrete into the pump-loading chamber, pump at slow speed until concrete comes out at the
end of the discharge hose, and then speed up to normal pumping speed. Once pumping has started,
it should not be interrupted (if at all possible) as concrete standing idle in the line is liable to cause a
plug. Of greater importance is to always ensure some concrete in the pump receiving hopper at all
times during operation, which makes necessary the careful dispatching and spacing of ready-mix
truck.
Testing for Pumpability: There is no recognized laboratory apparatus or precise piece of
equipment available to test the pumpability of a mix in the laboratory. The pumpability of the mix
therefore, should be checked at site under field conditions.
Field Practices: The pump should be as near the placing area as practicable and the entire
surrounding area must have adequate bearing strength to support the concrete delivery trucks, thus
assuring a continuous supply of concrete. Lines from the pump to the placing area should be laid out
with a minimum of bends. For large placing areas, alternate lines should be installed for rapid
connection when required.
When pumping downward 15 m or more, it is desirable to provide an air release valve at the middle
of the top bend to prevent vacuum or air buildup. When pumping upward, it is desirable to have a
valve near the pump to prevent the reverse flow of concrete during the fitting of clean up
equipment, or when working on the pump.
Illustration example on Concrete Mix Design.
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Test Data for Materials
The grading of fine aggregate, 10 & 20 mm aggregates are as given in Table. 5. Fine
aggregate is of zone-I of IS:383-1970. 10 and 20 mm crushed aggregate grading are single
sized as per IS: 383-1970.
1.
Properties of aggregates2.
Target strength for all A, B and C mixes
fck = fck + 1.65 x S40 + 1.65 x 5
= 48.3 n/mm2 at 28 days age
3.
For Mix A and B free W/C ratio with crushed aggregate and given strength for target strength
of 48.3 n/mm2 at 28 days from Fig. 1 Curve D found to be 0.40. This is lower than specified
maximum W/C ration value of 0.45
Note: In absence of cement strength, but cement conforming to IS Codes, assume from Fig.
1 and Fig. 2.
Curve A and B for OPC 33 Grade
Curve C and D for OPC 43 GradeCurve E and F for OPC 53 Grade
Take curves C and D for PPC, as PPC is being manufactured in minimum of 43 Grade of
strength.
4.
Other data: 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
determined. 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
5.
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aggregates are also adjusted accordingly.
Design of Mix-a with PPC
Free W/C ratio for the target strength of 48.3 n/mm2 from Fig. 1 curve D found to be 0.4a.
Free water for 100 mm slump from Table 1 for 20 mm maximum size of aggregate.
From trials, it is found that Retarder Superplasticizer at a dosages of 18 gm/kg of cement
water may be reduced 25% without loss of workabilityThen water = 200 (200 x 0.25) = 150 kg/m3
b.
PPC = 150/0.4 = 375 kg/m3c.
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/m
3
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 2.75 (100 1.5) + 375(1- 2.75/3.00) 150 (2.75 -1)
Density = 2477 kg/m3
d.
aggregates = 2477 375 150 = 1952 kg/m 3e.
Fine aggregate = From Table 3 for zone-I Fine aggregate and 20 mm maximum size of
aggregate, W/C ratio = 0.4 found to be 44 53%. For consideration of grading of Table 4 let
it be 45% Fine aggregate = 1952 x 0.45 = 878 kg/m3 Coarse aggregate = 1952 878 =
1074 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
10 mm aggregate = 358 kg/m3
20 mm aggregate = 716 kg/m3
With the consideration of grading of Table 5 let Fine aggregate, 10 and 20 mm aggregate
combine in the ratio of 45%, 19% and 36% and check with the required grading of Table. 5.
Thus,
Fine aggregate = 878 kg/m3
10 mm = 1952 x 0.19 = 371 kg/m 3
20 mm = 1952 x 0.36 = 703 kg/m 3
f.
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 = 150 kg/m3
PPC = 375 kg/m3
Fine Aggregate (sand) = 878 kg/m3
10 mm Aggregate = 371 kg/m3
20 mm Aggregate = 703 kg/m3
Retarder Super Plasticizer = 6.75 kg/m3
g.
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Mix-B with OPC
Water = 200 (200 x 0.25) = 150 kg/m3a.
OPC = 150/0.4 = 375 kg/m3b.
Density:
10 x 2.75 (100 1.5) + 375 (1 2.75/3.15) 150 (2.75 1)
= 2495 kg/m3
c.
Total Aggregates = 2495 150 375 = 1970 kg/m3
Fine Aggregate = 1970 x 0.45 = 887 kg/m3
10 mm Aggregate = 1970 x 0.19 = 374 kg/m3
20 mm Aggregate = 1970 x 0.36 = 709 kg/m3
d.
Thus for M-40 Grade of concrete with OPC per cu.m of concrete on the basis of saturated and
surface dry aggregates.
Water = 150 kg/m3
OPC = 375 kg/m3
Fine Aggregate (sand) = 887 kg/m3
10 mm Aggregate = 374 kg/m3
20 mm Aggregate = 709 kg/m3
Retarder Super Plasticizer = 5.625 kg/m3
e.
Mix. C with OPC + Flyash
With the given set of materials increase in cementitious
materials = 13%
Total cementitious materials = 375 x 1.13 = 424 kg
Note:-
Specific gravity of Retarder Superplasticizer = 1.151.
Addition of Flyash reduces 5% of water demand.2.
Note:-
For exact W/C ratio the water in admixture should also be taken into account.1.
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 reduced, 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.
2.
PPC reduces 5% water demand. If this is found by trial then take reduce water for
calculation.
3.
Conclusion
Pumped concrete may be used for most/all concrete construction, but is especially useful where
space or access for construction equipment is limited.
Although the ingredients of mixes placed by pump are the same as those placed by other methods,
quality control, batching, mix ing, equipment and the services of personnel with knowledge and
experience are essential for successful pumped concrete.
The properties of the fine normal weight aggregates (sand) play a more prominent role in theproportioning of pumpable mixes than do those of the coarse aggregates. Sands having a fineness
modulus between 2.4 and 3.0 are generally satisfactory provided that the percentage passing the
300 and 150 micron sieves meet the previously stated requirements. Zone-II sand as per IS:
383-1970 meets these requirements, and is suitable for pumped concrete.
For pumped concrete, there should be no compromise in quality. A high level of quality control for
assurance of uniformity must be maintained.
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T ER MS & C OND IT IO NS P RIVAC Y PO LIC Y C ANCE LLAT IO N/R EFU ND P OLIC Y DISCL AIM ER
A simple method of concrete mix design with normal weight aggregates and with admixtures for
pumped concrete is described in the article. The author has worked out the Tables and Figures for
materials available in the country by numerous trials. Therefore, the proportions worked out with
the help of these Tables and Figures will have quite near approach to the mix design problems in the
field.
Note:- When coarse and fine aggregate of different types are used, the free-water content is
estimated by the expression,
Where, Wf = Free-water content appropriate to type of fine aggregate.and, Wc= Free-water content appropriate to type of coarse aggregate.
Note:- The above combined obtained grading is for PPC and OPC mixes. For OPC + Flyash Mix fine
aggregate is about 43%, 10 mm 20% and 20 mm is 37%. This is also within the permissible limits
of recommended grading for pumped concrete.
References:
IS : 383-1970 Specifications for coarse and fine aggregates from natural sources for concrete
(second revision) BIS, New Delhi
IS: 456-2000 Code of practice for plain and reinforced concrete (fourth revision), BIS, New
Delhi
IS: 9103-1999 Specification for admixtures for concrete (first revision) BIS, New Delhi
IS: 8112-1989 Specifications for 43 Grade ordinary portland cement (first revision) BIS, New
Delhi
IS: 2386 (Part-III) 1963 method of test for aggregate for concrete. Specific gravity, density,voids, absorption and bulking, BIS, New Delhi
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
IS: 1489-Part-I 1991 Specifications for portland pozzolana cement (Part-I) Flyash based.
(Third revision), BIS, New Delhi
Kishore Kaushal, Design of Concrete Mixes with High-Strength Ordinary Portland Cement.
The Indian Concrete Journal, April, 1978, PP. 103-104
Kishore Kaushal, Concrete Mix Design. A manual published for Structural Engineering
Studies, Civil Engineering Department, University of Roorkee, 1986.
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.
Kishore Kaushal, Concrete Mix Design, Indian Concrete Institute Bulletin September, 1988,
pp. 27-40 and ICI Bulletin December, 1988, pp. 21-31.
Kishore Kaushal, Method of Concrete Mix Design Based on Flexural Strength, Proceeding ofthe International Conference on Road and Road Transport Problems ICORT, 12-15 December,
1988, New Delhi, pp. 296-305.
Kishore Kaushal, Mix Design Based on Flexural Strength of Air-Entrained Concrete. The
Indian Concrete Journal, February, 1989, pp. 93-97.
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.
Kishore Kaushal, Concrete Mix Design Containing Chemical Admixtures, Journal of the
National Building Organization, April, 1990, pp. 1-12.
Kishore Kaushal, Concrete Mix Design for Road Bridges, INDIAN HIGHWAYS, Vol. 19, No.
11, November, 1991, pp. 31-37
Kishore Kaushal, A Concrete Design, Indian Architect and Builder, August, 1991, pp. 54-56
Kishore Kaushal, Mix Design for Pumped Concrete, Journal of Central Board of Irrigation
and Power, Vol. 49, No.2, April, 1992, pp. 81-92
Kishore Kaushal, Concrete Mix Design with Fly Ash, Indian Construction, January, 1995, pp.16-17
Kishore Kaushal, High-Strength Concrete, Civil Engineering and Construction Review,
March, 1995, pp. 57-61.
Kishore Kaushal, High-Strength Concrete, Bulletin of Indian Concrete Institute No. 51,
April-June, 1995, pp. 29-31
Kishore Kaushal, Mix Design of Polymer-Modified Mortars and Concrete, New Building
Materials & Construction, January, 1996, pp. 19-23.
Kishore Kaushal, Concrete Mix Design Simplified, Indian Concrete Institute Bulletin No. 56,
July-September, 1996, pp. 25-30.
Kishore Kaushal, Concrete Mix Design, A Manual Published by M/S Roffe Construction
Chemicals Pvt. Ltd., Mumbai, pp. 1-36
Kishore Kaushal, Concrete Mix Design with Fly Ash & Superplasticizer, ICI Bulletin No. 59,
April-June 1997, pp. 29-30
Kishore Kaushal. Mix Design for Pumped Concrete, CE & CR October, 2006, pp. 44-50.
NBMCW September 2010
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