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A SIMPLE TOOL FOR SELF COMPACTING CONCRETE MIX DESIGN

SCC can be made from any of the constituents that are generally used for structural concrete. In the mix design of SCC, the relative proportions of key components are generally considered by volume rather than by mass. On the basis of these proportions, a simple tool has been designed for self compacting concrete (SCC) mix design. In this paper, this tool has been evaluated with a SCC mix having 28% of coarse aggregate content, 35% replacement of cement with class F fly ash, 0.36 water/cementitious ratio (by weight) and 388 litre/m 3 of paste volume. Crushed granite stones of size 20mm and 10mm are used with a blending 60:40 by percentage weight of total coarse aggregate. Detailed steps used in this tool are discussed in this study. This tool can also be used for self compacting mortar (SCM) design. It is practically seen that this simple tool is very much useful for the mix design of SCC with or without blended cement and with or without coarse aggregate blending..

International Journal of Advances in Engineering & Technology, May 2012. ©IJAET ISSN: 2231-1963 A SIMPLE TOOL FOR SELF COMPACTING CONCRETE MIX DESIGN J. Guru Jawahar1, C. Sashidhar2, I.V. Ramana Reddy3 and J. Annie Peter4 1 2 Research Scholar, Department of Civil Engineering, JNTUACE, Anantapur, India Associate Professor, Department of Civil Engineering, JNTUACE, Anantapur, India 3 Professor, Department of Civil Engineering, SVUCE, Tirupati, India 4 Scientist, Advanced Materials Lab, SERC, Chennai, India ABSTRACT SCC can be made from any of the constituents that are generally used for structural concrete. In the mix design of SCC, the relative proportions of key components are generally considered by volume rather than by mass. On the basis of these proportions, a simple tool has been designed for self compacting concrete (SCC) mix design. In this paper, this tool has been evaluated with a SCC mix having 28% of coarse aggregate content, 35% replacement of cement with class F fly ash, 0.36 water/cementitious ratio (by weight) and 388 litre/m3 of paste volume. Crushed granite stones of size 20mm and 10mm are used with a blending 60:40 by percentage weight of total coarse aggregate. Detailed steps used in this tool are discussed in this study. This tool can also be used for self compacting mortar (SCM) design. It is practically seen that this simple tool is very much useful for the mix design of SCC with or without blended cement and with or without coarse aggregate blending.. KEYWORDS: Self compacting concrete, mix design, simple tool, self compacting mortar. I. INTRODUCTION According to ACI 237R-07, self compacting concrete (SCC) is highly flowable, non segregating concrete that can spread into place, fill the formwork and encapsulate the reinforcement without any mechanical consolidation [1]. Professor Okamura in Japan proposed a concept for a design of concrete independent of the need for compaction in 1986. Ozawa and Maekawa produced the first prototype of SCC at the university of Tokyo in 1988 [14] and [15]. The general purpose mix design method was first developed by Okamura and Ozawa [12]. Recommendations on the design and applications of SCC in construction have been developed by many professional societies like American Concrete Institute (ACI), American Society for Testing and Materials (ASTM), European Federation of National Trade Associations (EFNARC 2002) etc. Although SCC has passed from research stage to field applications, there are no systematic standards or specifications to be followed in its mixture proportioning [9]. In reviewing literature on the methods for proportioning SCC, numerous methods exist, most of which give only general guidelines and ranges of quantities of materials to be used in SCC proportioning. The emphasis of these methods is on the fresh properties of SCC [8]. From the review of previous research on SCC, it was found that the EFNARC method for proportioning SCC have been used extensively. SCC with low yield stress will be achieved by adding superplasticiser (SP), water, paste or some additives (fly ash or GGBS) [11]. Viscosity is controlled by changing water content, paste content or adding some additives (fly ash) or viscosity modifying agent (VMA) [10] and [11]. As SCC requires high cement content that leads to increase in cost and temperature rise during hydration, additives or mineral admixtures such as fly ash, limestone powder or slag can generally be used as partial replacement of cement to reduce the cost and heat of hydration [13]. 550 Vol. 3, Issue 2, pp. 550-558 International Journal of Advances in Engineering & Technology, May 2012. ©IJAET ISSN: 2231-1963 1.1 Selection of Mix Proportions In designing the SCC mix, it is most useful to consider the relative proportions of the key components by volume rather than by mass [7]. The following key proportions for the mixes listed below [12], [7], [10] and [6]: 1. Air content (by volume) 2. Coarse aggregate content (by volume) 3. Paste content (by volume) 4. Binder (cementitious) content (by weight) 5. Replacement of mineral admixture by percentage binder weight 6. Water/ binder ratio (by weight) 7. Volume of fine aggregate/ volume of mortar 8. SP dosage by percentage cementitious (binder) weight 9. VMA dosage by percentage cementitious (binder) weight 1.2. Research Significance A simple and user friendly tool has been developed for SCC mix design (“JGJ_SCCMixDesign.xls”) on the basis of key proportions of the constituents of SCC with or without blended cement and with or without coarse aggregate blending. 1.3. Outline of This Paper This paper includes the selection of mix proportions for SCC from the relevant literature, the experimental program, material properties, design of SCC mix design tool, calculation of key proportions for a given SCC scenario, evaluation of SCC mix design and conclusions. II. EXPERIMENTAL STUDY 2.1. Experimental Program Our objective was to develop a simple tool for SCC mix design with the available materials. In this study, this tool has been used to design a SCC mix having 28% of coarse aggregate content and 388 litre/m3 of paste volume, 35% replacement of cement with class F fly ash and 0.36 water/cementitious ratio (by weight). Crushed granite stones of size 20mm and 10mm are used with the blending 60:40 by percentage weight of total coarse aggregate. 2.2. Material Properties This section will present the chemical and physical properties of the ingredients. Bureau of Indian Standards (IS) and American Society for Testing and Materials (ASTM) procedures were followed for determining the properties of the ingredients in this investigation. 2.2.1. Cement Ordinary Portland Cement 53 grade was used corresponding to IS-12269(1987) [5]. The specific gravity of cement is 3.15. 2.2.2. Chemical Admixtures Sika Viscocrete 10R is used as high range water reducer (HRWR) SP and Sika Stabilizer 4R is used as VMA. Percentage of dry material in SP and VMA is 40%. 2.2.3. Additive or Mineral Admixture Class F fly ash produced from Rayalaseema Thermal Power Plant (RTPP), Muddanur, A.P is used as an additive according to ASTM C 618 [2]. As per IS-456(2000) [3], cement is replaced by 35% of fly ash by weight of cementitious material. The specific gravity of fly ash is 2.12. 2.2.4. Coarse Aggregate Crushed granite stones of size 20mm and 10mm are used as coarse aggregate. As per IS: 2386 (Part III)-1963 [4], the bulk specific gravity in oven dry condition and water absorption of the coarse aggregate are 2.6 and 0.3% respectively. The dry-rodded unit weight (DRUW) of the coarse aggregate with the coarse aggregate blending 60:40 (20mm and 10mm) as per IS: 2386 (Part III)-1963 [4] is 1646 kg/m3. 2.2.5. Fine Aggregate Natural river sand is used as fine aggregate. As per IS: 2386 (Part III)-1963 [4], the bulk specific gravity in oven dry condition and water absorption of the sand are 2.6 and 1% respectively. 2.2.6. Water 551 Vol. 3, Issue 2, pp. 550-558 International Journal of Advances in Engineering & Technology, May 2012. ©IJAET ISSN: 2231-1963 Ordinary tap water is used. III. DESIGN OF SELF COMPACTING CONCRETE MIX DESIGN TOOL 3.1. Material Properties for SCC Mix Design Tool The following material properties for the SCC mix design tool are to be determined as shown in Table 1. 1. Specific gravity of cement, fly ash, coarse aggregate and fine aggregate. 2. Percentage of water absorption of coarse and fine aggregates. 3. Percentage of moisture content in coarse and fine aggregates. 4. Dry-rodded unit weight (DRUW) of coarse aggregate for the particular coarse aggregate blending. 5. Percentage of dry material in SP and VMA. Table 1. Material Properties Material Cement Additive – Fly Ash Coarse aggregate (CA1 20mm) Coarse aggregate (CA2 10mm) Fine aggregate (Sand) Material Data Specific Gravity 3.15 2.12 2.6 2.6 2.6 % Absorption N/A N/A 0.3 0.3 1.0 % Moisture N/A N/A 0 0 0 3.2. Detailed Steps for SCC Mix Design Tool The detailed steps for mix design are described as follows: 1. Assume air content by percentage of concrete volume. 2. Input the coarse aggregate blending by percentage weight of total coarse aggregate. 3. Input the percentage of coarse aggregate in DRUW to calculate the coarse aggregate volume in the concrete volume. 4. Adjust the percentage of fine aggregate volume in mortar volume. 5. Obtain the required paste volume. 6. Adopt suitable water/ binder ratio by weight. 7. Input the percentage replacement of fly ash by weight of cementitious material. 8. Input the dosage of SP and VMA (if required) by percentage weight of binder. 9. Adjust the binder (cementitious material) content by weight to obtain the required paste. The coarse aggregate optimization is shown in Table 2. The input parameters section is shown in Table 3. Table 2. Coarse Aggregate Optimization or Blending Coarse aggregate optimization Material % by weight CA1 20mm 60 CA2 10mm 40 Table 3. Input Parameters Section Input parameters Dry Rodded Unit Weight(kg/cum) % of CA in DRUW % of Sand in Mortar % of Fly ash Wt. Water/Binder Binder (kg/cum) SP (% wt.of binder) 552 1646 44.3 46.1 35 0.36 495 0.9 Vol. 3, Issue 2, pp. 550-558 International Journal of Advances in Engineering & Technology, May 2012. ©IJAET ISSN: 2231-1963 VMA (% wt. of binder) % of Air % of dry material in SP % of dry material in VMA 0.2 2 40 40 3.3. Output Constituent Materials for SCC After giving all the necessary data, the tool automatically calculates and shows the required out put. Concrete mix proportions by volume and total aggregate by weight are shown in Table 4. Table 4. Concrete Mix Proportions by Volume Coarse aggregate (kg/cum) 729.178 % of CA in concrete volume 28.04530769 Concrete Mix proprtions by volume (lit/cum) CA Mortar Sand Paste 280.4531 719.5469 331.7111 387.8357915 Sand (kg/cum) 862.448942 Total aggregates (kg/cum) 1591.626942 Paste composition is shown in Table 5. Constituent materials for SCC are shown in Table 6. Constituent materials for SCM are shown in Table 7. This tool also displays the constituent materials for the required volume of SCC or SCM as shown in Table 6 and Table 7. Aggregate proportions by volume and by weight are shown in Table 8. Table 5. Paste Composition Cement 321.75 Vol. Water/Powder Paste composition Kg/cum Fly ash Water SP 173.25 178.2 4.455 0.969191695 VMA 0.99 lit/cum Paste 387.5096 Table 6. Constituent Materials for SCC Material (kg/cum) Cement Fly Ash Water CA1 20mm CA2 10mm Sand SP (lit) VMA (lit) Unit Weight Constituent Materials for Concrete Required (cum) Initial Adjusted 0.0062 321.75 321.75 1.99485 173.25 173.25 1.07415 178.2 185.745 1.151619145 437.5068 437.5068 2.71254216 291.6712 291.6712 1.80836144 862.4489 862.4489 5.34718344 4.455 4.455 0.027621 0.99 0.99 0.006138 2270.272 Total (kg) 14.12246519 Litres 6.12075648 g/ml 1994.85 1074.15 1151.619 2712.542 1808.361 5347.183 27.621 6.138 14122.47 Table 7. Constituent Materials for SCM Material (kg/cum) Cement Fly Ash Water Sand SP (lit) 553 Constituent Materials for Mortar Required (cum) Initial Adjusted 0.0008 321.75 321.75 0.2574 173.25 173.25 0.1386 178.2 183.5575 0.146845992 862.4489 862.4489 0.689959154 4.455 4.455 0.003564 g/ml 257.4 138.6 146.846 689.9592 3.564 Vol. 3, Issue 2, pp. 550-558 International Journal of Advances in Engineering & Technology, May 2012. ©IJAET ISSN: 2231-1963 VMA (lit) Unit Weight 0.99 1541.094 0.99 Total (kg) Litres 0.000792 1.237161145 0.563662541 0.792 1237.161 Table 8. Aggregate Proportions by Volume and by Weight Aggregate Proportions % by Material Vol % by Weight CA1 20mm 27.48802 27.48802426 CA2 10mm 18.32535 18.32534951 Sand 54.18663 54.18662623 Total 100 100 IV. CALCULATION OF KEY PROPORTIONS The detailed steps for calculation of key proportions are presented below with an example. The interface of SCC mix design tool for the mix 28_60:40 is shown in Figure 1. SCC Mix Scenario: A SCC mix with 28% coarse aggregate content of concrete volume with a paste volume of 388 litre/m3 have been designed for water/ binder ratio 0.36 (by weight). Cement has been replaced with 35% of Class F fly ash by percentage weight of cementitious material. Coarse aggregate of sizes 20mm and 10mm with coarse aggregate blending 60:40 by percentage weight of total aggregate are used in this mix. SP and VMA are used. All the material properties and input parameters are shown in Table 1 and Table 3. Air content assumed as 2% of concrete volume. 4.1. Calculation of Coarse Aggregate Content in Concrete Volume Coarse aggregate blending Specific gravity of 20mm & 10mm DRUW of coarse aggregate % of Coarse aggregate in DRUW Coarse aggregate weight Coarse aggregate volume : : : : : : 60:40 2.6 1646 kg/m3 44.3 1646*(44.3/100) = 729.18 kg/m3 [(729.18*(60/100))/2.6] + [(729.18*(60/100))/2.6] =280.45 litre/m3 or 28.05% : : Concrete volume-coarse aggregate volume 1000-280.45 = 719.55 litre/m3 : : 46.1 719.55*(46.1/100) = 331.71 litre/m3 : : Mortar volume-sand volume 719.55-331.71 = 387.84 litre/m3 4.2. Calculation of Mortar Volume Mortar Volume 4.3. Calculation of Sand Volume % of sand in Mortar volume Sand Volume 4.4. Calculation of Paste Volume Paste Volume 4.5. Calculation of Paste Composition Specific gravity of cement Specific gravity of fly ash Air content Water/ binder ratio (by weight) % of fly ash by weight of binder % of SP by weight of binder % of VMA by weight of binder Binder Fly ash Cement Water 554 : : : : : : : : : : : 3.15 2.12 2% = 20 litre/m3 0.36 35 0.9 0.2 495 kg/m3 495*(35/100) = 173.25 kg/m3 495-173.25 = 321.75 kg/m3 495*0.36 = 178.2 litre/m3 Vol. 3, Issue 2, pp. 550-558 International Journal of Advances in Engineering & Technology, May 2012. ©IJAET ISSN: 2231-1963 321.75/3.15 = 102.14 litre/m3 173.25/2.12 = 81.72 litre/m3 495*(0.9/100) = 4.46 litre/m3 495*(0.2/100) = 0.99 litre/m3 Volume of (cement+fly ash+Water+SP+VMA+Air) 102.14+81.72+178.2+4.46+0.99+20=387.51 litre/m3 In the tool, the binder has been adjusted to 495 kg/m3 in order to obtain the required paste volume of about 387.51 litre/m3 (say 388 litre/m3). Volume of cement Volume of fly ash SP VMA Total Paste volume : : : : : 4.6. Calculation of Constituent Materials for Concrete Specific gravity of sand : 2.6 % of absorption of 20mm : 0.3 % of absorption of 10mm : 0.3 % of absorption of sand : 1.0 % of moisture in 20mm : 0.0 % of moisture in 10mm : 0.0 % of moisture in sand : 0.0 % of dry material in SP : 40 % of dry material in VMA : 40 Cement : 321.75 kg/m3 Fly ash : 173.25 kg/m3 Initial water content : 178.2 litre/m3 Coarse aggregate : 729.18 kg/m3 20mm coarse aggregate (CA1) : 729.18*(60/100) = 437.51 kg/m3 10mm coarse aggregate (CA2) : 729.18*(40/100) = 291.67 kg/m3 Sand : 331.71*2.6 = 862.46 kg/m3 Adjusted water content = Initial water - [CA1*(% of moisture - % of absorption)/100] - [CA2*(% of moisture - % of absorption)/100] - [sand*(% of moisture - % of absorption)/100] - [SP*(100-%of dry material in SP)/100] - [VMA*(100-%of dry material in VMA)/100] = 178.2 - [437.51*(0-0.3)/100]-[291.67*(0-0.3)/100] - [862.46*(0-1)/100]-[4.46*(100-40)/100]-[0.99*(100-40)/100] = 185.75 litre/m3 Adjusted 20mm coarse aggregate : CA1*[1+(% of moisture/100)] 437.51*[1+(0/100)] = 437.51 kg/m3 Adjusted 10mm coarse aggregate : Adjusted sand : CA2*[1+(% of moisture/100)] 291.67*[1+(0/100)] = 291.67 kg/m3 sand*[1+(% of moisture/100)] 862.46*[1+(0/100)] = 862.46 kg/m3 4.7. Calculation of Constituent Materials for Mortar Coarse aggregate contribution should not be considered in the adjustment of water. The remaining constituents are already discussed in the section 4.6. Initial water content : 178.2 litre/m3 Adjusted water content = Initial water - [sand*(% of moisture - % of absorption)/100] - [SP*(100-%of dry material in SP)/100] - [VMA*(100-%of dry material in VMA)/100] = 178.2 - [862.46*(0-1)/100]-[4.46*(100-40)/100]-[0.99*(100-40)/100] = 183.56 litre/m3 4.8. Mix Proportions Mix types with percentage relative proportions and mix proportions of constituent materials are shown in Table 9 and Table 10. 555 Vol. 3, Issue 2, pp. 550-558 International Journal of Advances in Engineering & Technology, May 2012. ©IJAET ISSN: 2231-1963 Mix Type 28_60:40 a Table 9. Percentage Relative Proportions of SCC Mix w/cm – 0.36 Cementitious Material – OPC+35%Fly Ash Percentage Percentage Percentage Percentage Coarse Aggregate of of of of Blending Percentage Sand in Coarse Mortar Paste By Weight aggregate Mortar (20 mm and 10 mm) By Volume 60 40 28.05 71.95 46.1 38.8 a 28_60:40: where 28 is the percentage of coarse aggregate volume in a concrete mix 60:40 is the coarse aggregate blending by percentage weight of 20mm and 10mm resp. Mix Type 28_60:40 V. Binder kg/m3 495 Table 10. Mix Proportions of Constituent Materials Cement Fly Ash Water 20mm 10mm Kg/m3 Kg/m3 l/m3 Kg/m3 kg/m3 321.75 173.25 178.2 437.51 291.67 Sand kg/m3 862.46 SP l/m3 4.46 VMA l/m3 0.99 EVALUATION OF SCC MIX DESIGN The SCC mix designed by the SCC mix design tool has been evaluated by conducting the SCC fresh properties tests on the 28_60:40 SCC mix. 5.1. SCC Fresh Properties SCC fresh properties i.e., slump flow, T50cm at initial and at 60 minutes, V-Funnel time, V-Funnel time at 5 minutes (T5min) and L-Box ratio (h2/h1) are presented in the Table11 for the SCC mix 28_60:40. Table 11. Fresh Properties of SCC Slump Flow (mm) Mix Type 28_60:40 Initial At 60 min 696 657 T50cm (sec) V-Funnel Time (sec) Initial At 60 min Initial T5min 3.12 4.28 6.23 7.59 L-Box Ratio (h2/h1) 0.81 As it can be seen from the above results, the mix 28_60:40 has met the SCC acceptance criteria mentioned by EFNARC [7]. Hence, it is practically seen that SCC mix design tool is very much useful in designing any SCC mix. The only challenge in getting successful SCC mix is the adjusting the key proportions of the constituents. VI. CONCLUSIONS The following conclusions can be drawn on the basis of SCC mix design tool: Self compacting concrete mix design tool is developed based on the key proportions of the constituents. This tool is very simple and user friendly for the self compacting concrete mix design. This tool can be used for the SCC mix with or without blended cement and coarse aggregate with or without coarse aggregate blending. This tool can also be enhanced for multi blended cements with more additives. This tool is also useful for Self compacting mortar design. It displays all necessary data for SCC mix design and also displays constituent materials for SCC or SCM for the required volume. 556 Vol. 3, Issue 2, pp. 550-558 International Journal of Advances in Engineering & Technology, May 2012. ©IJAET ISSN: 2231-1963 Figure 1. SCC Mix Design Tool Interface REFERENCES [1]. American Concrete Institute. “Self-Consolidating Concrete”, ACI 237R-07. [2]. American Society for Testing and Materials. “Standard specification for coal fly ash and raw or calcined natural pozzolan for use in concrete”, ASTM C 618 (2003). [3]. Bureau of Indian Standards. “Plain and reinforced concrete code for practice”, IS-456 (2000), New Delhi. [4]. Bureau of Indian Standards. “Methods of test for aggregates for concrete. Specific gravity, Density, Voids, Absorption and Bulking”, IS-2386 (Part III, 1963). [5]. Bureau of Indian Standards. “Specification for 53 grade ordinary Portland cement”, IS-12269 (1987), New Delhi. [6]. Domone PLJ. 2006b. “Self-compacting concrete: An analysis of 11 years of case studies”. Cement and Concrete Composites 28(2):197-208. [7]. EFNARC. “Specification and guidelines for self-compacting concrete. European Federation of Producers and Applicators of Specialist Products for Structures”, 2002. [8]. Ghazi F Kheder, Rand S Al Jaidiri. 2010. “New Method for Proportioning Self-Consolidating Concrete Based on Compressive Strength Requirements”. ACI Materials 107(5):490-497. [9]. Goodier C. 2001. “Self-Compacting Concrete”. European Network of Building Research Institutes (ENBRI). 17:6 [10]. Khayat KH. 1998. Viscosity-enhancing admixtures for cement-based materials - An overview. Cement and Concrete Composites, No.20, 2-3: 171-188. [11]. Newman J, Choo BS. Advanced concrete technology concrete properties. Elsevier Butterworth Heinemann, 2003. [12]. Okamura H, Ozawa K. 1995. “Mix design for self-compacting concrete”. Concrete Library of Japanese Society of Civil Engineers 25(6):107-120. [13]. Okamura H, Ouchi M. 1999. “Self-compacting concrete development, present use and future”. In: The 1st International RILEM Symposium on Self-Compacting Concrete. Skarendahl A, Petersson O, editors, RILEM Publications. S.A.R.L, France. 3-14. [14]. Ozawa K, Maekawa K, Kunishima M, Okamura H. 1989. “Development of high performance concrete based on the durability design of concrete structures”. 445-450. [15]. RILEM TC 174 SCC. “Self compacting concrete State-of-the-art report of RILEM technical committe 174-SCC”. Skarendahl A, Petersson O, editors, RILEM Publications S.A.R.L., France, 2000. 557 Vol. 3, Issue 2, pp. 550-558 International Journal of Advances in Engineering & Technology, May 2012. ©IJAET ISSN: 2231-1963 Authors J. Guru Jawahar is a research scholar in JNTUA College of Engineering, Anantapur. He did his M.Tech in JNTUA, Anantapur. He has 12 years of Industry experience and 2 years of teaching experience. He is Six Sigma Green Belt Certified. C. Sashidhar is an Associate Professor and HOD in the department of Civil Engineering, JNTUA, Anantapur. He received M.Tech and Ph.D from J.N.T. University, Hyderabad. His research interests include FRC, SIFCON, HPC, Non Destructive Test Evaluation and Earth Quake Engineering. He has co – authored more than 30 scientific and technical publications. He has more than 15 years of teaching experience and guiding research scholars. He was an active member of AICTE, New Delhi. I.V. Ramana Reddy is Professor in the department of Civil Engineering, SVUCE, Tirupati. He received his Ph.D from S.V. University, Tirupati. He has more than 20 years of teaching experience and guiding research scholars. His research interests include SCC, HPC, advanced materials. He has more than 30 scientific and technical publications. He is an esteemed Civil and Structural consultant in Tirupati. J. Annie Peter is Chief Scientist in Advanced Materials Lab, SERC, Chennai. Her research interests are Self Compacting Concrete, High Performance Concrete, Advanced Cement Composites. She is an esteemed advisor for research activities. She acquired Indo-Polish Fellowship Award in 1993. 558 Vol. 3, Issue 2, pp. 550-558