ABSTRACT:

The stresses induced in concrete pavements are mainly flexural. Therefore flexural strength is
more often specified than compressive strength in the design of concrete mixes for pavement
construction. A simple method of concrete mix design based on flexural strength for normal
weight concrete mixes is described in the paper.

INTRODUCTION:
Usual criterion for the strength of concrete in the building industry is the compressive strength,
which is considered as a measure of quality concrete. However, in pavement constructions, such
as highway and airport runway, the flexural strength of concrete is considered more important, as
the stresses induced in concrete pavements are mainly flexural. Therefore, flexural strength is
more often specified than compressive strength in the design of concrete mixes for pavement
construction. It is not perfectly reliable to predict flexural strength from compressive strength.
Further, various codes of the world specified that the paving concrete mixes should preferably be
designed in the laboratory and controlled in the field on the basis of its flexural strength.
Therefore, there is a need to design concrete mixes based on flexural strength.

The type of aggregate can have a predominant effect, crushed rock aggregate resulting in
concrete with higher flexural strength than uncrushed (gravel) aggregates for comparable mixes,
assuming that sound materials are used. The strength of cement influences the compressive and
flexural strength of concrete i.e. with the same water-cement ratio, higher strength cement will
produce concrete of higher compressive and flexural strength.

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MIX DESIGN DETAILS

IRC: 15-2011 specified that for concrete roads OPC should be used. This code also allowed PPC
as per IS: 1489 (Part-1) with flyash content not more than 20 percent by weight of PPC.
Accordingly OPC + fly ash may be used in concrete roads. Flyash shall be not more than 20
percent by weight of cementitious material. However, IS: 456-2000 specified that fly ash
conforming to grade-1 of IS” 3812 may be used as part replacement of OPC provided uniform
blended with cement is essential. The construction sites where batching plants are used this may
be practicable. In ordinary sites where mixer or hand mixing are done uniform blending of fly
ash with cement is not practicable. At such construction sites, PPC may be used. PPC should be
used with caution where rapid construction methods like slip form is being used. Joints cutting
also need early strength.
1 Characteristic Flexural Strength : 4.5 N/mm2
at 28 days
2 Cement : Three mixes are to be designed
MIX-A
With PPC (Flyash 18 percent based) conforming
to IS:1489-part-I-1991. 7 days strength 37.5
N/mm2. Specific Gravity : 3.00
MIX-B
With OPC-43- Grade conforming to IS: 8112-
1989. 7 days strength 40.5 n/mm2. Specific

3 Fly ash replacement
4 Maximum nominal size of
aggregates
5 Fine aggregate and coarse
aggregate grading
6 Minimum cement content for 4.5 : (a) OPC shall not be less than 360 kg/m3.
N/mm2 characteristic flexural
strength:
Gravity : 3.15
MIX-C
With OPC of Mix-B and Fly ash conforming to
IS:3812 (Part-I)-2003 Specific Gravity : 2.20
Note: Requirements of all the three mixes are
the same. Fine Aggregate, Coarse Aggregate and
Retarder Super plasticizer are the same for all
the three mixes.
: 20% Fly ash is required to be replaced with the
total cementitious materials.
: 31.5 mm Crushed aggregate
: Given in Table 1
(b) PPC shall not be less than 425 kg/m3. Fly ash
in it 20% maximum by weight of total
cementitious materials

(c) OPC + Fly ash mix OPC shall not be less

than 340 kg/m3. Fly ash 20% maximum by
weight of cementations material
7 Maximum free W/C Ratio : (a) For OPC 0.45
(b) For PPC 0.50
8 Workability : 40 mm slump at pour the concrete will be
transported from central batching plant through
transit mixer, at a distance of 15 Km during
June, July months. The average temperature last
year during these months was 300C.
9 Exposure condition : Moderate
10 Method of placing : Fully mechanised construction
11 Degree of supervision : Good
12 Maximum of cement content : (a) OPC 425 kg/m3
(b) PPC 425 kg/m3
13 Chemical admixture : Retarder Super plasticizer conforming to
IS:9103-1999. With the given requirements and
materials, the manufacturer of Retarder Super
plasticizer recommends dosages of 1% bw of
OPC, which will reduce 15% of water without
loss of workability. For fly ash included cement
dosages will be required to be adjusted by
experience/ trials.2% maximum by weight of
cementitious material
14 Values of Z x (for National : 1.96 x 0.40
Highway)
TEST DATA FOR MATERIALS AND OTHER DETAILS
1. The grading of fine aggregate, 1 & 2 aggregates are as given in Table. 1.
2. Properties of aggregates

Tests Fine Aggregate Aggregate

aggregate 1 2
Specific 2.65 2.65 2.65
Gravity
Water 0.8 0.5 0.5
Absorption
%
3. Target average flexural strength for all A, B and C mixes
S = S+ Zq
=4.5 + 1.96 x 0.40
= 5.3 N/mm2 at 28 days age
4. For Mix A, B and C free W/C ratio with crushed aggregate and required average flexural
target strength of 5.3 N/mm2 at 28 days from Fig. 1 Curve D found to be 0.42. This is lower than
specified maximum W/C ratio value of 0.45 for OPC and 0.50 for PPC.

Note:
In absence of cement strength, but cement conforming to IS Codes, assume from Fig. 1

Curve C and D for OPC 43 Grade

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

5. Other data’s: The Mixes are to be designed on the basis of saturated and surface dry
aggregates. At the time of concreting, moisture content of site aggregates are to be determine. If
it carries surface moisture this is to be deducted from the mixing water and if it is dry add in
mixing water the quantity of water required for absorption. The weight of aggregates are also
adjusted accordingly.

DESIGN OF MIX-A WITH PPC

a) Free W/C ratio for the target flexural strength of 5.3 N/mm2 as worked out is 0.42 for first
trial.

b) Free water for 40 mm slump from Table 2 for 31.5 mm maximum size of aggregate.
2/3×170 + 1/3×200= 180 kg/m3
From trials it is found that Retarder Super plasticizer at a dosages of 1.3% bw of PPC may
reduce 15% water without loss of workability
Then water = 180 – (180 x 0.15) = 153 kg/m3

c) PPC = 153/0.42 = 364 kg/m3 (Required minimum PPC is 425 kg/m3)

d) Formula for calculation of fresh concrete weight in kg/m3
Um = 10 x Ga (100 – A) + Cm(1 – Ga/Gc) – Wm (Ga – 1)
Where,
Um=Weight 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 for trial entrapped air 1.5%

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For 31.5 mm maximum size of aggregate

There is always entrapped air in concrete. Therefore ignoring entrapped air value as NIL will
lead the calculation of higher value of density. Take exact value of air as obtained in the test
Wm=Mixing water required in kg/m3
Cm=Cement required, kg/m3
Note:- The exact density may be obtained by filling and fully compacting constant volume
suitable metal container from the trial batches of calculated design mixes. The mix be altered
with the actual obtained density of the mix.

Um =10 x Ga (100 – A) + Cm (1 – Ga/Gc) – Wm (Ga – 1)

=10 x 2.65 (100 – 1.5) + 425(1- 2.65/3.00) – 153 (2.65 -1)
=2409 kg/m3

e) Aggregates = 2409 – 425 – 153 = 1831 kg/m3

f) Fine aggregate = 1831 x 0.45 = 824 kg/m3

Aggregate 1 = 1831 x 0.29 = 531 kg/m3
Aggregate 2 = 1831 x 0.26 = 476 kg/m3

g) Thus for 4.5 N/mm2 flexural strength quantity of materials per cu.m. of concrete on the basis
of saturated and surface dry aggregates:

Water = 153 kg/m3

PPC = 425 kg/m3
Fine Aggregate (sand) = 824 kg/m3
Aggregate (1) = 531 kg/m3
Aggregate (2) = 476 kg/m3
Retarder Super Plasticizer 1.3% bw of PPC = 5.525 kg/m3

MIX- B WITH OPC

a) Water = 180 – (180 x 0.15) = 153 kg/m3
b) OPC = 153/0.42 = 364 kg/m3
c) Density: 10 x 2.65 (100 – 1.5) + 364 (1 – 2.65/3.15) – 153 (2.65 – 1)= 2416 kg/m3
d) Total Aggregates = 2416 – 364 – 153 = 1899 kg/m3
Aggregate 1 = 1899 x 0.29 = 551 kg/m3
Aggregate 2 = 1899 x 0.26 = 494 kg/m3
Fine Aggregate = 1899 x 0.45 = 854 kg/m3
e) Thus for 4.5 N/mm2 flexural strength quantity of materials per cu.m of concrete on the basis of
SSD aggregates are given below:
Water = 153 kg/m3
OPC = 364 kg/m3
Fine Aggregate (sand) = 854 kg/m3
Aggregate (1) = 551 kg/m3
Aggregate (2) = 494 kg/m3
Retarder Super Plasticizer 1% bw OPC = 3.640 kg/m3

MIX-C WITH OPC + FLY ASH

With a total cementitious material of 430 kg/m3,
OPC = 430 x 0.80 = 344 kg/m3
Fly ash = 430 x 0.20 = 86 kg/m3
Mix on the basis of SSD Aggregates,
(1) Water as worked out earlier = 153 kg/m3
(2) OPC = 344 kg/m3
(3) Fly ash = 86 kg/m3
Density = 10 x 2.65 (100 – 1.5) + 430 (1 – 2.65/3.00) – 153 (2.65 – 1) = 2410 kg/m3

Total Aggregates = 2410 – 153 – 344 – 86 = 1827 kg/m3

(4) Fine aggregate 0.45 x 1827 = 822 kg/m3
(5) Aggregate (1) 0.29 x 1827 = 530 kg/m3
(6) Aggregate (2) 0.26 x 1827 = 475 kg/m3
(7) Retarder super plasticizer 1.5% bw of cementitious material = 6.450 kg/m3

Note:
(1) Cementitious material worked out as per IRC : 15-2011, which specified: In case fly ash (as
per IS: 3912 Part 1) is blended at site, the quantity of fly ash shall be restricted to 20 percent by
weight of cementitious material and the quantity of OPC in such a blend shall not be less than
340 kg/m3 .

(2) After the first trial mix, its actual density is to be determined, as specified elase where in this
paper. The mix proportions shall then be worked out accordingly including the water content, the
dosages of Retarder SP for required workability keeping the free w/c ratio with in the
permissible limits and adjusting it according to the required flexural strength.

(3) The mix proportions given in this paper are for first trial and to be adjusted as per actual site
materials, conditions and requirements.

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For 4.5 N/mm2 flexural strength quantity of material per cu.m of concrete on the basis of
saturated and surface dry aggregates of Mix ‘A’, ‘B’ and ‘c’ are given below:
Materials MIX. ‘A’ Mix. ‘B’ Mix. ‘C’ with OPC+Flyash
with PPC with OPC
Water kg/m3 153 153 153
PPC kg/m3 425 — —
OPC kg/m 3
— 364 344
Flyash kg/m 3
— — 86
Fine Agg. kg/m3 824 854 822
Agg. (1) kg/m3 531 551 530
Agg. (2) kg/m 3
476 494 475
Retarder Super- plasticizer 5.525 3.640 6.450
kg/m3
W/ Cementitious ratio 0.36 0.42 0.356
Note:-
1. For exact W/C ratio the water in admixture should also be taken into account.
2. PPC reduces 5% water demand. If this is found by trial then take reduce water for calculation.
3. If the trial mixes does not gives the required properties of the mix, it is then required to be
altered accordingly. However, when the experiences grows with the particular set of materials
and site conditions very few trials will be required, and a expert of such site very rarely will be
required a 2nd trial.

CONCLUSION
1. For 4.5 N/mm2 flexural strength concrete having same material and requirement, but without
water reducer, the OPC required will be 180/0.42 = 429 kg/m3

2. With the use of superplasticizer the saving in OPC is 65 kg/m3 and water 27 lit/m3.

3. In the financial year 2009-2010 India has produces 200 million tonnes of cement. In India one
kg of cement produce emitted 0.93 kg of CO2. Thus the production of 200 million tonnes of
cement had emitted 200 x 0.93 = 186 million tonnes of CO2 to the atmosphere.

4. If 50 million tonnes cement in making concrete uses Water Reducers 7500000 tonnes of
cement can be saved. 3750000 KL of potable water will be saved and the saving of Rs. 3300
crores per year to the construction Industry. 6975000 tonnes of CO2 will be prevented to be
emitted to the atmosphere. The benefits in the uses of water reducers not limited to this. When
water reduces shrinkage and porosity of concrete are reduces which provides the durability to
concrete structures.

5. India is facing serious air, water, soil, food and noise pollution problems. Every efforts
therefore are necessary to prevent pollution on top priority basis.

6. As the stress induced in concrete pavements are mainly flexural, it is desirable that their
design is based on the flexural strength of concrete. The quality of concrete is normally assessed
by measuring its compressive strength. For pavings, however, it is the flexural strength rather
than the compression strength of concrete which determine the degree of cracking and thus the
performance of road, and it is imperative to control the quality on the basis of flexural strength.

7. As per IRC: 15-2011, in case of small size projects, where facilities for testing beams with
three print loading are not available, in such cases, the mix design may be carried out by using
compressive strength values and there after flexural strength will be determined as per
correlation between flexural strength with compressive strength given the following equation.

Where fcr is the flexural strength in MPa or N/mm2 and fck is the characteristic compressive
strength in MPa or N/mm2 as per IS: 456-2000.

REFERENCES:

1 IS : 383-1970 Specifications for coarse and fine aggregates from

natural sources for concrete (second revision) BIS,
New Delhi
2 IS: 456-2000 Code of practice for plain and reinforced concrete
(fourth revision), BIS, New Delhi
3 IS: 9103-1999 Specification for admixtures for concrete (first
revision) BIS, New Delhi
4 IS: 8112-1989 Specifications for 43 Grade ordinary portland cement
(first revision) BIS, New Delhi
5 IS: 2386 (Part-III) method of test for aggregate for concrete. Specific
1963 gravity, density, voids, absorption and bulking, BIS,
New Delhi
6 IS: 3812 (Part-I) 2003 Specification for pulverized fuel ash: Part-I for use as
pozzolana in cement, cement mortar and concrete
(second revision) BIS, New Delhi
7 IS: 1489-Part-I 1991 Specifications for portland pozzolana cement (Part-I)
Flyash based. (Third revision), BIS, New Delhi
8 IRC: 15-2011 – Standard specifications and code of practice for construction of
concrete road (Fourth revision)
9 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.
10 Kishore Kaushal, “Method of Concrete Mix Design Based on Flexural
Strength”, Proceeding of the International Conference on Road and Road
Transport Problems ICORT, 12-15 December, 1988, New Delhi, pp. 296-305.
11 Kishore Kaushal, “Mix Design Based on Flexural Strength of Air-Entrained
Concrete”. The Indian Concrete Journal, February, 1989, pp. 93-97.
12 Kishore Kaushal, “Concrete Mix Design Containing Chemical Admixtures”,
Journal of the National Building Organization, April, 1990, pp. 1-12.
13 Kishore Kaushal, “Concrete Mix Design for Road Bridges”, INDIAN
HIGHWAYS, Vol. 19, No. 11, November, 1991, pp. 31-37
14 Kishore Kaushal, “ Mix Design for Pumped Concrete”, Journal of Central
Board of Irrigation and Power, Vol. 49, No.2, April, 1992, pp. 81-92
15 Kishore Kaushal, “Concrete Mix Design with Fly Ash”, Indian Construction,
January, 1995, pp. 16-17
16 Kishore Kaushal, “High-Strength Concrete”, Bulletin of Indian Concrete
Institute No. 51, April-June, 1995, pp. 29-31
17 Kishore Kaushal, “Concrete Mix Design Simplified”, Indian Concrete Institute
Bulletin No. 56, July-September, 1996, pp.25-30.
18 Kishore Kaushal, “Concrete Mix Design with Fly Ash & Superplasticizer”, ICI
Bulletin No. 59, April-June 1997, pp. 29-30
19 Kishore Kaushal. “Mix Design for Pumped Concrete”, CE & CR October,
2006, pp. 44-50.
Table. 1: Grading of Aggregates

IS Sieve Percentage of passing by mass

Designation Fine Crushed Combined IRC: 15-2011
aggregate aggregate grading of recommended
from (1) (2) mix grading of
river 29% 26% combined
45% aggregates
for pavement
quality
concrete
(PQC)
31.50 mm 100 100 100 100 100
26.50 mm 100 100 98 99 85 – 95
19.0 mm 100 100 25 81 68 – 88
9.50 mm 100 46 0 58 45 – 65
4.75 mm 94 5 44 30 – 55
600 micron 42 0 19 8 – 30
150 micron 10 5 5 – 15
75 micron 2 1 0–5
Table. 2: Approximate free-water content (kg/m3) required to give various levels of
workability for non-air-entrained (with normal entrapped air) concrete.

Maximum size of Type of aggregate Slump 25 + 10 40 + 1031.5

aggregate (mm) (mm)
Uncrushed 160 170
Crushed
190 200
Note:- When coarse and fine aggregate of different types are used, the free water content is
estimated by the expression.
2/3Wf+1/3Wc
Where,
Wfsub>= Free water content appropriate to type of fine Aggregate
And Wc= Free water content appropriate to type of coarse aggregate.
We at engineeringcivil.com are thankful to Er. Kaushal Kishore for submitting the revised mix
design as per IRC:15-2011. This will be of great help to all civil engineering students and faculty
who are seeking information on mix design based on revised IRC.