Analysis of Use of Basalt Aggregate in Concrete Mixes With Granite Stone Under M-20 & M-25 Grades

ANALYSIS OF USE OF BASALT AGGREGATE IN CONCRETE MIXES WITH GRANITE STONE UNDER M-20 & M-25 GRADES
ABSTRACT
This study aims at environmentally assessing the most significant
input and output flows related to the production of concrete using
basalt aggregates.
An experimental program is set up to test the effect of basalt
aggregate content and its combinations with granite stone with
variation of percentages in concrete mixes. Different aggregate
percentage combinations were used in this study for basalt and granite
(0%,100%),(30%,70%),(50%,50%),(75%,25%),(90%,10%)
respectively.
Guided by: Dr. Ashad Ullah Qureshi

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CONTENTS
Chapter 1. Introduction 1 - 30
1.1 Aesthetics
1.2 Strength
1.3 Construction
1.4 Fire Resistance
1.5 Energy Efficiency
1.6 Thermal Comfort
1.7 Air Quality
1.8 Natural Light
1.9 Noise
1.10 Affordability
1.11 Study On Granite Waste Uses In India
1.12 Favorable Environment For Granite Industry In India
1.13 Properties Of Concrete
1.14 Grades Of Concrete
1.15 Compressive Strength Of Concrete
1.16 Characteristic Strength Of Concrete
1.17 Characteristic Strength Of Concrete In Flexural Member
1.18 Design Strength (Fd) And Partial Safety Factor For
Material Strength

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1.19 Tensile Strength Of Concrete
1.20 Creep in concrete
1.21 Shrinkage of Concrete
1.22Durability of concrete
1.23 Unit weight of concrete
Chapter 2. Literature Review 31 - 50
2.1 General
2.2 Literature Reviewed
2.3 Sieve Analysis For Grading Of Coarse Aggregates [Is

2368– (Part – I) 1963]
2.4 Fineness Modulus
2.5 Specific Gravity Of Aggregates[Is: 2386 – (Part – Iii) 1963]
2.6 Water Absorption Of Aggregate [Is: 2386 – (Part – Iii)

1963]
2.7 Flakiness And Elongation Index Of Coarse Aggregate: [Is:

2368 Part-1-1963]
2.8 Elongation Index
2.9 Impact Value Of Aggregate:[Is: 2386 Part-4-1963]
2.10 Crushing Value Of Coarse Agrgregate :[Is: 2386 Part-4-

1963]
2.11 Abrasion Test Of Aggregate:[Is 2386 (Part-Iv) –1963]

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Chapter 3. Concrete Mix Design 51 - 75
3.1 Introduction
3.2 Types of Mixes
3.3 Mix Proportion designations
3.4 Procedure
3.5 Design Parameters
Chapter 4. Results 76 - 80
Chapter 5. Conclusions 81 - 82
References

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CHAPTER 1
INTRODUCTION
India can be a more favorable and attractive industrial area for the development of granite
industry now a days and in future. India has been known for decades for its stone industry
and it is one of the biggest exporters of natural stone in the world. India uses natural stone as
building material more than many other countries. The researcher explores whether Indian
granite industries can increase their exports to world countries and how likely it is that stone
imports will increase there. Each country has unique soil and granite stones. Granite from
India is very different compared to world granite and it cannot be copied. The unique
appearance of Indian granite is definitely a competitive advantage that should be considered
when planning export strategies.
Many studies predict that India will grow economically in future and it will be one of Asia’s
giants. In that case Indian stone industries should start promoting their material in advance to
establish trade relations with world countries. The infrastructure has suffered from over usage
of the huge population and needs large scale investments for the improvement of granite
industry. In many Indian granite stone industries, Asia, especially China, plays an important
role. Chinese markets have been growing each year and many surveys predict that markets
will become mature at some point and then there would be other countries to replace and take
over that role.
The purpose of this thesis project is to explore and improve the concrete mix design in basalt
stone with the mix of granite stone in building technique as applied to sustainable housing.
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Design mix of granite with basalt construction refers to a specific style of steel and concrete
construction. It's a method that involves the use of steel reinforcement layers in the structure
and a concrete mix that includes granite stone with basalt in the coarse aggregate. The
resulting structure can be thinner than traditional reinforced concrete construction, while
retaining superior strength. Material costs are typically competitive with conventional
building techniques, but there is considerable manual labour involved in setting up the steel
reinforcement in the field and skilled labour is required for the manufacture of design mix of
m20& m25 with granite stone with basalt in coarse aggregate.
A major appeal of concrete mix design is that structure can become very strong in strength
and design for the long life as compare to normal mix design of concrete . Taking advantage
of shell shapes that naturally place the concrete in compression is a key part of designing with
concrete mix design with granite and basalt.. Shapes such as domes and catenary beams are
especially well suited. However, more complex shells are very difficult to analyze by hand
and therefore a computer tool such as Finite Element Analysis (FEA) can enable complex
designs. The term sustainable housing" has many aspects. For clarity, it is defined in this
paper as incorporating the following features:
1.1 Aesthetics
A beautiful building will be cherished and maintained for a long time, reducing the need for
new construction and increasing occupant comfort and building can be build by less material
use than other concrete mix design.

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1.2 Strength
The structure's strength to withstand natural disasters such as hurricanes and earthquakes is
key in many regions and avoids costly reconstruction and the strength of the structure is more
than the requirement for construction .
1.3 Construction
Minimal ecological footprint during construction, including the use of locally sourced
materials, renewable materials, minimizing energy use, minimizing waste, minimizing
disturbances to neighbors and avoiding the use of ecologically-sensitive land and mostly use
of the locally available material in the construction .
1.4 Fire resistance
Use of materials that give occupants time to evacuate. Preferably the structure should not be
flammable nor weaken considerably during a fire and it give the more fire resistant than the
other normal mix design. Granite will not be affected by exposure to ordinary sources of heat
in a household. To prevent possible damage, avoid extreme changes in temperature, such as
placing something cold on an area of a granite right after placing something hot on that area.
Granite is heat resistant up to between 150 ˚C and 200˚C temperature; damage may not be
noticed instantly if this is done regularly, however after some time hairline cracks may appear
which reduces the strength.

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1.5 Energy efficiency
Minimize the energy required to heat, cool and electrify the building. Includes strategies such
as passive solar heating, insulation, air heat recovery, heat pumps, efficient appliances and
smaller living spaces. Energy production To minimize the impact of external power plants,
the building should generate as much of its energy needs as possible. Strategies include solar
water heating, solar photovoltaics, biomass combustion and small wind turbines.as possible
as the buildind is so construction that is recuired minimum conventional soureses.
1.6 Thermal comfort
Stability of the interior temperature can be increased with thermal mass to balance changes in
the outdoor climate. Rounded building profiles reduce the surface area for a given volume,
which reduces thermal losses of the building envelope
1.7 Air quality
Fresh air should be ventilated constantly and preferably filtered to minimize CO2, dust and
other pollutants. Ventilation rates are compromised by maximizing energy efficiency. Air
quality also means minimizing materials which give off Volatile Organic Compounds
(VOCs) and other harmful gases to the occupants.emergency ventilation is essentially
provided in the building for any emergency condition for the flow of fresh air.
1.8 Natural light
Sunlight in the building increases occupant comfort, although maximizing glazing comes in
conflict with energy efficiency.

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Noise
External noise should be attenuated in the structure. Internal noise from occupants and
equipment should also be minimized and mix design is such that is reduce the noise in the
building and build the noise free environment
1.9 Affordability
The building technique should be as economically accessible as possible.
Building codes and practices typically cover only the bare minimum of sustainable building
ideology. For this reason, voluntary accreditation was created to help fill this gap. Examples
include the American LEED, British BREEAM and Swedish Miljobyggnad. Each takes a
different approach, where LEED focuses on lowering energy costs and site selection,
BREEAM focuses on minimizing greenhouse gas emissions in construction and operation
and Mil jobyggnad focuses on occupant comfort.
The target is to reach net-zero energy use for a typical family in a given year for any climate
in the continental india, while allowing for architectural flexibility and strength that's not
available in conventional house building methods.
Today, there are basic deficiencies of common assets in introduce situation. Creation of
cement and use of cement has quickly expanded, which brings about expanded utilization of
regular total as the biggest solid segment. A conceivable arrangement of these issues is to
utilize that misuse of stone industry create an option total for auxiliary cement along these
lines stone delivered by two phases cutting of stone in appropriate size and abatements

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vitality utilization and can give cost investment funds. Stone can be easily available from
stone industries and this stone can be crushed and get predominant size by suitable IS sieve
analysis after hammering or in available crushing machine and this graded cutting stone
called stone of required size for mixing in the concrete mix design say as 10mm,20mm &
40mm size.
Figure 1 shows the Stone waste converted into stone chips.
Stone chips were got from three distinct sorts of stone industries, for example, Granite stone
in this test examination. Blend of granite stone had been taken and isolate by strainer
investigation and get overwhelming size.
Concrete is the most utilized development material over the world and in solid greatest part is
coarse total. Subsequently, examination of these properties with characteristic basalt with
granite totals in M20 and M25 review blends. Fundamental changes in both kind of total if
rock stone utilized as in any event halfway supplant with coarse total than it will lessen cost

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of solid generation. Stone are required from the perspective of purpose of test protection and
compelling use of assets.
For the countries with a developed stone industry the waste generated in the natural stone
processing plants pose environmental and economic problems. The utilisation of stone
waste in various areas is still under research. In addition, there are only a limited number of
studies concerning the use of stone waste obtained from processing plants in the
stabilisation of clayey soil. Furthermore, none of the studies in the literature investigated
the effect of the characteristics of the stone on the stabilisation of the soil. This is the first
study that compares the efficiency of the waste calcitic marble, dolomitic marble and
granite powder as additives for the stabilisation of clayey soil. Artificial soil samples were
prepared in the laboratory using bentonite and kaolinite. Natural stone waste powder was
added to the soil samples at different percentages, and the index and compaction parameters
of the stabilised soil were analysed. The results showed that the types of waste powder used
in this study, like lime, could be used as stabilisers. As the percentage of additives
increased, the plasticity index of the clayey soil decreased and the physical properties of the
soil changed from clay to silt. In terms of compaction parameters, the use of all types of
natural waste powder in the study resulted in a decrease in the optimum water content and
an increase in the maximum dry unit weight. The lowest optimum water content and the
highest maximum dry unit weight were obtained from the dolomitic marble powder.
As in all industrial activities, waste production is also inevitable in natural stone quarries
and plants, and the negative environmental impact of this waste poses a problem. India is
among the first three economies in the world in terms of growth rate and the construction
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industry is a very important part of the economy. On the other hand, companies have a
social responsibility to protect the environment and ensure the sustainable use of natural
resources. Thus, for a sustainable economy, industrialisation and the use of natural
resources should be accompanied by environmental protection (Mymrin 1997). The most
important stage in achieving this balance is that waste produced in one area is reused either
within the same area, in another industry or for another purpose such as soil stabilisation,
concrete, aggregate source, new and binding materials (Gürer et al. 2004; Karaca 2009;
Zega et al. 2010; Güllü and Girisken 2012).
The continuing increase in world population results in a higher demand for new
construction such as housing, public buildings and roads, thus the need for construction
materials increases. Materials obtained by conventional methods are not sufficient to satisfy
this demand. To ensure the sustainability of geotechnical and building construction, it is
essential to utilise production waste as well as to create new sources of materials. Every
year a large part of recyclable materials is disposed of in landfills or arbitrarily discharged
to the environment. Therefore, researchers are interested in finding ways of eliminating the
negative impacts of waste and obtaining economic benefits from the recycled material
(Gürer et al. 2004; Karaca 2009; Edil 2011; Altuncu and Kasapseçkin 2011).
There were some difficulties experienced in india in terms of waste material utilisation,
which resulted in a significant economic loss. While the recycling rate of waste is
approximately 80 % in Western Europe and the USA, it is only about 15 % in india. Every
year, the reuse of aggregates in asphalt pavement is over 93 million tons. Considering that
the 90 % of the asphalt pavement materials consist of aggregates, it is obvious that the
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reuse of this material significantly contributes to the economy and reduces damage to the
environment. In addition, almost 50 % of the marble blocks obtained from marble quarries
become waste materials (Gürer et al. 2004; Karaca 2009).
Knowing which natural stone waste to use for the stabilisation of clayey soil and in what
amount will not only reduce the widely known environmental impacts of this waste but also
fulfil a social responsibility by ensuring the controlled use of non-renewable resources and
offer a way for the construction industry to meet its increasing demands for material. When
the soil, on which buildings, highways, airports, dams and tunnels are to be built, is soft,
loose or expansive and thus do not have the desired properties for construction, the best
solution is to stabilise or improve the soil. Therefore, the search for materials to be used in
soil stabilisation is one of the leading areas of interest for researchers to eliminate the
problems related to the swelling of expansive clayey soil, thus improving the soil bearing
capacity and consolidation in soft clayey soil, and the seepage properties of the materials
used in the construction of dams, cut-off walls and blankets.
In this regard, it is necessary to investigate the use of waste produced in natural stone
processing plants in soil stabilisation both in terms of the utilisation of these waste and the
elimination of their negative environmental impacts. Therefore, this study compares the
efficiency of the waste calcitic marble, dolomitic marble and granite as additives in the
stabilisation of bentonite and kaolinite clay soil with different levels of plasticity. The
results of this study show that selecting the type of natural stone waste that is most suitable
for the properties of the soil to be stabilised and determining the effect of these waste on the

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index and compaction parameters of clayey soil will contribute to the better utilisation of
waste generated in the natural stone industry
1.11 Study on granite waste uses in india
In India about 960 million tones of solid waste is generated annually as bi-product from
different industrial processes out of which approximately 350 million tones are from organic
agricultural sources, 290 million tones inorganic wastage from industrial mining and 4.5
million tones are hazardous waste. Part of the waste from different industries has been
recycled in construction industry as well as other industries [Ashokan et al., 2007]. The
granite saw dust comprises of calcium and iron which has the compatibility to acid soils,
granite waste powder is used as a suitable means to neutralize acid soils [Barral et al., 2005].
Use of granite and marble rock waste found to be effective in the production of concrete for
civil construction [Hanifi et al., 2008]. Use of municipal solid waste incinerated fly ash is
found to be effective up to 20%, as cement substitute [Lin et al., 2003].
The granite industry constitutes an important segment of the mineral based industries in
Indian economy in terms of its contribution to the country’s Gross Domestic Product (GDP),
reserves and resources, employment, industrial production, exports, imports and creation of
entrepreneurial base. The government established the Ministry of Mines, Indian Bureau of
Mines (IBM), Centre for Development of Stones (CDOS) in India, and also Department of
Mines and Geology at state level, as the nodal ministry for formulation of policies and central
sector programmes and schemes, their implementation and related coordination, to
supplement the efforts of the states for promotion and development of the granite industry in
India.
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• The role of the Ministry of Mines and that of Indian Bureau of Mines (IBM) is to
mainly assist the states in their efforts to promote growth and development of the
granite industry to enhance their competitiveness and to generate additional
employment opportunities in rural areas and semi-urban areas in India. In addition,
the ministry attempts to address issues of country-wide common concerns and also
undertake advocacy on behalf of the granite industries. The specific schemes and
programmes undertaken by organization of the Ministry of Mines and Indian Bureau
of Mines seek to facilitate one or more aspects for the care of granite industry. India
has one of the best granite deposits in the world. With a varied diversity of more than
110 shades, India accounts for over 20 per cent of the total granite reserves across the
world. The total granite reserves in the India are estimated around 13.87 Crore tonnes
and it is one of the largest exporters of granite and granite products in the world.
Geologically the Southern and Eastern belts of the nation are places where granite is
available in abundance such as those in Tamil Nadu, Andhra Pradesh, Karnataka,
Maharashtra, Assam, Bihar, Rajasthan, Orissa, Meghalaya and Madhya Pradesh.
Indian granite has become the most sought-after and extensively used stone material
in building construction and massive structural works throughout the world, and it is
well known in the international market, not only for its elegance and aesthetic quality,
but also for its durability. In India, the granite stone industry has received a wider
publicity and corporate importance, only in the last few years. It is emerging now as a
thrust-exportarea with several corporate houses, supported by expert professionals
trained in all aspects, entering the sector with sophisticated world-class machinery and
making it an organized one. In order to give a new thrust to granite industry and for
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better growth, the following aspects are to be taken care of. The steps taken by the
government in 11th five year plan for the development of granite industry are as
follows: Detailed exploration of the granite resources.
• Handing over prospecting data to prospective investor at a reasonable cost.
• To mention the need for establishing government cutting and polishing units in the
gamete belts for sample testing at low or reasonable rate
• More government incentives to attract investors.
• Single window system for time to and disposal of lease application.
• Development of internal market.
• Organized training to prospecting cutter and miner.
• Better infrastructural facilities.
An organized professional approach based on co-operation with investors will no doubt boost
the industry in the study area during the coming years. The CAPEXIL set up by the
Government of India under the aegis of Ministry of Commerce and Industry [formerly known
as the Chemicals and Allied Products Export Promotion Council] over the years has been
playing an important role in promoting exports of granite and granite based products. All
India Granites and Stone Association (Bangalore) has also been playing an equally important
role in promoting granite industry by organizing international trade fairs on granite and other
stones in India every four years. The leading exporters and importers have widely
participated in these trade fairs both from India and abroad. The interaction among the key
players in such gatherings help the industry to generate export orders and also acquire the
latest technical know-how about the developments in the granite industry in India.

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1.12 FAVORABLE ENVIRONMENT FOR GRANITE INDUSTRY IN INDIA
The availability of a considerable wealth of geologic resources both in terms of quantity and
quality constitutes a good starting base for the Indian granite producers, but, on the other
hand, maintaining and strengthening a top position among the world leader countries implies
also the presence of a series of suitable conditions to be met or created, concerning the
extraction of raw materials, the production of finished stone elements and their trade and
application for a the variety of possible uses. To this purpose, the Indian granite industry can
benefit from some positive factors such as the relatively low cost of labour and cheaper prices
of energy. India has an abundance of port facilities for export of granite products to other
countries. This helps to increase the overall commercial strength of the granite industry,
especially in the foreign market. Domestic market is also an important 34 outlet, constituting
for many countries an extremely relevant area of stone demand and consumption, to the
obvious advantage of granite stone entrepreneurs. However, a number of initiatives are now
in progress, particularly the startup of the newly established Granite Technological Centers.
Institutional support and sector association should also be building up and fortified as high
profile marketing and promotion emerges as a key tool in penetrating the main mature and
demanding consumption markets.
• While production in the granite industry has increased dramatically in the last decade,
the decline in prices has also been impressive.
• Reduction in the cost of production as a result of technological improvement.
• New granite quarries are being opened every day with new sources of granite are
being discovered everywhere and all the time in India.

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• The access to raw materials has become a key aspect of competitive advantage in
granite industry. In this regard Indian granite industry has been getting raw granite
easily when compared to other competing countries. This is due to more of the
existing forest areas with plentiful granite resources.
• Some of the granite industries are setting up their own warehouses in the different
cities in India.
• One of the most positive and favourable developments for the improvement of granite
industry is greater awareness. So its popularity is growing in the major projects and
construction sector.
• The option of exporting granite products becomes favourable for granite exporters
after new economic reforms in India.
In addition to the above some of the efforts made by the government in order to create the
favorable conditions for a sounder development of the granite industry, include the training of
manpower, aiming at increasing the quarry recovery that is a factor of capital importance in
controlling the production cost and the profitability of quarrying activity. For this purpose
some of the following policies and strategies taken by the central and state governments.
1.13 Properties of Concrete

properties of concrete are influenced by many factors mainly due to mix proportion of
cement, sand, aggregates and water. Ratio of these materials control the various concrete
properties which are discussed below.

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Properties of Concrete
Different properties of concrete:
• Grades (M20, M25, M30 etc.)

• Compressive strength
• Characteristic Strength
• Tensile strength
• Durability
• Creep
• Shrinkage
• Unit weight
1.14 Grades of concrete
Concrete is known by its grade which is designated as M15, M20 etc. in which letter M refers
to concrete mix and number 15, 20 denotes the specified compressive strength (fck) of
150mm cube at 28 days, expressed in N/mm2.
Thus, concrete is known by its compressive strength. M20 and M25 are the most common
grades of concrete, and higher grades of concrete should be used for severe, very severe and
extreme environments.
1.15 Compressive strength of concrete
Like load, the strength of the concrete is also a quality which varies considerably for the same
concrete mix. Therefore, a single representative value, known as characteristic strength is
used.

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1.16 Characteristic strength of concrete
It is defined as the value of the strength below which not more then 5% of the test results are
expected to fall (i.e. there is 95% probability of achieving this value only 5% of not achieving
the same)
1.17 Characteristic strength of concrete in flexural member
The characteristic strength of concrete in flexural member is taken as 0.67 times the strength
of concrete cube
1.18 Design strength (fd) and partial safety factor for material strength
The strength to be taken for the purpose of design is known is known as design strength and
is given by
Design strength (fd) = characteristic strength/ partial safety factor for material strength
The value of partial safety factor depends upon the type of material and upon the type of limit
state. According to IS code, partial safety factor is taken as 1.5 for concrete and 1.15 for steel.
Design strength of concrete in member = 0.45fck
1.19 Tensile strength of concrete
The estimate of flexural tensile strength or the modulus of rupture or the cracking strength of
concrete from cube compressive strength is obtained by the relations
fcr = 0.7 fck N/mm2
The tensile strength of concrete in direct tension is obtained experimentally by split cylinder.
It varies between 1/8 to 1/12 of cube compressive strength.

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1.20 Creep in concrete
Creep is defined as the plastic deformation under sustain load. Creep strain depends primarily
on the duration of sustained loading. According to the code, the value of the ultimate creep
coefficient is taken as 1.6 at 28 days of loading.
1.21 Shrinkage of Concrete
The property of diminishing in volume during the process of drying and hardening is termed
Shrinkage. It depends mainly on the duration of exposure. If this strain is prevented, it
produces tensile stress in the concrete and hence concrete develops cracks.
1.22 Durability of concrete
Durability of concrete is its ability to resist its disintegration and decay. One of the chief
characteristics influencing durability of concrete is its permeability to increase of water and
other potentially deleterious materials.
The desired low permeability in concrete is achieved by having adequate cement, sufficient
low water/cement ratio, by ensuring full compaction of concrete and by adequate curing
1.23 Unit weight of concrete
The unit weight of concrete depends on percentage of reinforcement, type of aggregate,

amount of voids and varies from 23 to 26 kN/m2. The unit weight of plain and reinforced
concrete as specified by IS:456 are 24 and 25KN/m3 respectively.

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CHAPTER 2
LITERATURE REVIEW
2.1 GENERAL
This chapter presents the literature reviewed on the effect of using crushed rock material,
granite stone with partial replace with basalt stone in the preparation of concrete. Some of the
experimental investigations on the strength and durability behaviour of concrete on the use of
other products partial replace in the place of natural basalt stone are listed here.
In addition to crushed rock material, the granite stone may be used as an alternative material
for coarse aggregate . To increase the workability and strength of concrete super plasticizer
may also be used. These criteria viewed from different literature are listed in this chapter.
2.2 LITERATURE REVIEWED
B.Vidivelli et.al., [2] had studied on fly ash material in concrete using SEM analysis as
partial replacement to cement and had reported a significant increase of 20% compressive
strength of concrete mix respectively.
Lalit Gamashta et.al., developed the concrete strength by using masonry waste material in
concrete mix deaign in construction to minimize the environmental damages due to
quarrying. It is highly desirable that the waste materials of concrete and bricks are further
reutilized after the demolition of old structures or buliding in an effective manner especially
realizing that it will help in reducing the environmental damages caused by excessive
reckless quarrying for earth materials and stones. Secondly, this will reduce pressure on

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finding new dumping ground for these wastes products, thus further saving the natural
environment and eco-systems. Durability, reliability and adequate in service performance of
these reused waste materials over the stipulated design life of designed structures are of
paramount importance to Structural Designers. This paper critically examines such properties
in reused concrete and brick masonry waste materials and suggests suitable recommendations
for further enhancing life of such structures, thereby resulting in sufficient economy to the
cost of buildings.
M.L.V. Prasad et.al., [4] had studied mechanical properties of fiber reinforced concretes
produced from building demolished waste products and observed that target mean strength
had been achieved in 100% recycled concrete aggregate replacement.
M. Mageswari et.al., [5] using the combination of waste Sheet Glass Powder (SGP) as fine
aggregate in concrete and Portland cement with 20% optimum replacement of fly ash
products as cementations binder offers an economically viable technology for high value
utilization of industrial waste. Use of SGP in concrete mix is an interesting possibility for
economy on waste disposal sites and conservation of natural available resources. Natural
sand was partially replace (10%, 20%, 30%, 40% and 50%) with SGP and 20% optimum
replacement of fly ash in Portland cement. Compressive strength, Tensile strength (cubes and
cylinders) and Flexural strength of mixture up to 180 days of age were compared with those
of concrete made with natural fine aggregates. Fineness modulus, Specific gravity, Moisture
content, Water absorption, Bulk density, Percentage of voids, Percentage of porosity (loose
and compact) state for sand and SGP were also studied for product construction. Test results
indicate that it is possible to manufacture low cost concrete containing SGP with
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characteristics similar to those of natural available sand aggregate concrete provided that the
percentage of SGP as fine aggregate up to 30% along with fly ash material 20% optimum in
partial cement replacement can be used respectively.
Ustev.J et.al., [6] determined the performance of concrete made with coconut shell as a
replacement of cement in concrete mix design. Cement was replaced with coconut shell in
steps of 0%, 10%, 15%, 20%, 25% and 30%. The results obtained for compressive strength
was increased from 12.45 N/mm2 at 7days to31.28 N/mm2 at 28 days curing and it meet the
requirement for use in both heavy weight and light weight concreting.
Amitkumar D. Raval et.al., [7] explained the compressive strength by replacing cement
with ceramic waste materials and utilizing the same material in construction industry.
Dr. G.Vijayakumar et.al., [8] had found that use of glass powder as partial replacement to
cement was effective in the construction industry as a concrete.
Ankit Nileshchandra Patel et.al., [9] examined the possibility of using stone waste product
as replacement of Pozzolana Portland Cement in the range of 5%, 10%, 30%, 40% and 50%
by weight of M 25 grade concrete mix design. They reported that stone waste product of
marginal quantity as partial replacement to the cement had beneficial effect on the
mechanical properties such as compressive strength values of concrete for 7, 14, 28 days
were less than the portand pozolana cement.

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Venkata Sairam Kumar et.al., [10] investigated the effect of using quarry dust as a possible
substitute for cement in concrete mixture. Partial replacement of cement in mixture with
varying percentage of quarry dust (0%, 10%, 15%, 20%, 25%, 30%, 35%, 40%) by weight of
M 20, M 30 and M 40 grade of concrete cubes were made for conducting compressive
strength test. From the experimental studies 25% partial replacement of cement in mix with
quarry dust showed improvement in hardeness of concrete.
Jayesh kumar et.al., [11] studied the performance of fly ash product as partial replacement
of cement. The values of compressive strength and split tensile strength are found by partial
replacement of cement in the mixture with varying percentage of 0%, 10%, 20%, 30% and
40% by weight of cement of M 25 and M 40 mix design. The compressive strength of the
samples was recorded at the curing age of 7, 14, 28 days and for split tensile strength of the
sample were conducted test on age of 56 days. It was observed that the compressive strength
was better on age of 14 days than the other proportions of concrete.
2.3 SIEVE ANALYSIS FOR GRADING OF COARSE AGGREGATES [IS 2368–
(PART – I) 1963]
Heap up the mass specimen got in cone shaped frame till cone smoothes. Get the example for
screening by strategy for quartering with the goal that appropriate weight for test testing is
accessible. Air dries the example at room temperature or by warming at 100˚C –110˚C.
Measure the air dried example. Place the arrangement of strainers in dropping request of their
sizes on skillet. Place the example in top coarse sifter and fit the cover. Shake entire get
together every which way for at the very least 2 minutes by hand developments/on shaking

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stage. Expel the top and measure the deposit painstakingly held on each strainer. Classify the
outcomes on execution. Furthermore, choose review of total from Table No 2, IS 383-1970
2.4 FINENESS MODULUS:
Take 1 kg. of total from research center example of 10 kg. Orchestrate the strainer arranged
by the size numbers. Fix them in strainer shaker with the container at the base and coffer at
top, discover the heaviness of each sifter. After this procedure ascertain aggregate of all %
weight of held on specific strainer and partition by 100.Hence, estimation of Fineness
Modulus which unit is in number. Which demonstrates the quantity of strainer from base to
top and that sifter estimate is the greatest size of the total.
2.5 SPECIFIC GRAVITY OF AGGREGATES[IS: 2386 – (PART – III) 1963]
Wash the thoroughly two kg. of aggregate sample to remove fines, drain and then place in
the wire basket and immerse in water at a temperature between 22˚C to 30˚C with a cover of
at least 5 cm of water above top of basket. Immediately after immersion, remove the
entrapped air from the sample by lifting the basket containing it, 25 mm above the base of
tank and allowing it to drop 25 times at about 1 drop/second. Keep the basket and aggregate
completely immersed in water for a period of 2 hours afterward. Weigh the basket and
sample while suspended in water to Remove the basket and aggregate from water. Allow to
drain few minutes after which gently empty the aggregate from the basket on the dry cloth.
Return the empty basket to the water and weigh in water (A-2)Place the aggregate on the dry
cloth and gently surface dry with the cloth and transfer it to the second dry cloth, when the
first will remove no further moisture. Weigh surface dried aggregates.(B)Place the aggregate

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in a shallow tray and keep it in oven for 24 hours at a temperature 100˚C to 110˚C. Remove
it from oven, cool in an air tight container and weigh (C).Calculate the Specific Gravity By =
C/ (B-A) Where, A=A1-A2
2.6 WATER ABSORPTION OF AGGREGATE [IS: 2386 – (PART – III) 1963]
Wash thoroughly two kg. of aggregate sample to remove fines, drain and then place in wire
basket and immerse in water at temperature between 22˚C to 30˚C with a cover of at least 5
cm of water above top of basket. Immediately after immersion, remove the entrapped air
from the sample by lifting the basket containing it, 25 mm above the base of tank and
allowing it to drop 25 times at about 1 drop/second. Keep the basket and aggregate
completely immersed in water for period of 2 hours afterwards. Weigh the basket and sample
while suspended in the water to(A-1)Remove the basket and aggregate from water. Allow to
drain few minutes after which gently empty the aggregate from the basket on dry cloth.
Return the empty basket to the water and weigh in water (A-2)Place the aggregate on the dry
cloth and gently surface dry with the cloth and transfer it to second dry cloths, when the first
will be remove no further moisture. Weigh surface dried aggregate.(B)Place the aggregate in
a shallow tray and keep it in oven for 24 hours at temperature of 100˚C to 110˚C, remove it
from oven, cool in an air tight container and weigh (C).Calculate water absorption =[100-(B-
C)]/C

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2.7 FLAKINESS AND ELONGATION INDEX OF COARSE AGGREGATE: [IS: 2368
part-1-1963]
FLAKINESS INDEX: Take adequate amount of total to give no less than 200 bits of any
portion to be tried. Strainer the example through sifter as appeared in perception Tables.
Isolate particles held on the recommended the sifter Try to go every molecule through the
relating opening of thickness gage. The total piece going through 50 mm and hold on 40 mm
ought to be go from ((50 +40)/2)*0.6) =27 mm space. On the off chance that the totals went
through this space than it considered as flaky. Measure every one of the pieces, which go
through this space. Compute the flakiness list as proportion of the heaviness of the material
going through the thickness gage to add up to weight of the specimen. This proportion is to
be increased 100 to change over in %
2.8 ELONGATION INDEX:
Strainer the specimen through IS Sieve as indicated In Observation table. Isolate the total
pieces held on sifters. Endeavor to pass each total piece through the comparing opening of
length gage, if the length gage. In the event that length of the molecule is ((50+40)/2)*1.8)
=81 mm, it is said to have held on length gage Weight every single such piece Calculate
lengthening Index as proportion of the heaviness of the material hold by the length gage to
add up to weight of the specimen the proportion is to be increased by 100 to change over in
%This prolongation And Flaky molecule ought not be more than 40-45%

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2.9 IMPACT VALUE OF AGGREGATE:[IS: 2386 part-4-1963]
Get test which should go entirely through 12.5 mm I.S. Strainer, and held on 10 mm sifter.
Dry example in a broiler for a time of 4 hours at a temperature of 100˚C to 110˚C and enable
cooling to room-temperature Fill the tube shaped metal in three equivalent layers, each layer
being given 25 consistently conveyed strokes of the adjusted end of the packing pole.
Measure the total in the measure to the closest gram (A).Fix the glass solidly in position on
the base of effect machine, put entire of the test in it and conservative by single packing of 25
strokes of the packing bar. Enable the sledge of Impact machine to fall unreservedly of total.
The test might be subjected to aggregate of 15 such blows, each being conveyed at an interim
of at the very least one moment. Expel the squashed total from the glass, and strainer on the
2.36 mm IS sifter. Measure the part going to a precision of 0.1 gm. (B) Calculate Impact
esteem = B/A *100<10% incredibly solid 10-20% Strong 20-30% Satisfactory for street
surfacing > 35% Weak for street surfacing. According to Seems to be: 383-1970. Cl. 3.4-45%
for concrete and 30% for wearing surface
2.10 CRUSHING VALUE OF COARSE AGRGREGATE :[IS: 2386 part-4-1963]
Strainer the total for gathering fitting measured specimen for testing. Dry the example for 24
hours in a stove at 100˚C to 110˚C temp. Furthermore, put in desiccator in impermeable tins
and enable it to cool. Measure the material (A) Place barrel on level base plate Fill the
material to profundity of 70 mm in the chamber and pack with packing pole. Rehash by
including layers till profundity of material in barrel is at 200 mm; the highest point of plunger
spine agreeing precisely with best of chamber. Measure the materials left finished assuming
any (B). Weight of sample=(A-B)Place contraption in pressure testing machine and apply
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heap of 160 M.T. consistently and continuously achieving greatest in 10 minutes. Discharge
head, evacuate the device and precisely expel entire of materials to be sieved through 10 mm
strainer. Measure the portion going through sifter (C) Repeat utilizing same weight of test (A-
B)Crushing Value = B/A *100As per IS: 383-1970. Cl. 3.3 - 45% for concrete and 30% for
wearing surface
2.11 ABRASION TEST OF AGGREGATE:[IS 2386 (Part-IV) –1963]
Sifter the total for gathering proper measured specimen for testing. Dry the example for 24
hours in a stove at 100˚C to 100˚C temp. What's more, placed in desiccators in water/air
proof tins and enable it to cool. Place pre-measured (W1) test materials and grating charge in
testing machine. Pivot machine at speed of 20 to 33 Revolutions/minute for 500
transformations. In the wake of finishing pivot, release the specimen totally and sifter it on
1.70 mm strainer for preparatory partition. Sifter the better segment later on through 1.70
mm, 1.18 m, 850 and 600 micron strainers as specified for squashing test. Wash coarser
material > 1.70 mm, dry in broiler at 105˚ C to 110˚C to steady weight and weigh precisely
(W2)Calculate (W1-W2)/W1*100As per IS: 383-1970. Cl. 3.4,45% for concrete and 30% for
wearing surface.

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CHAPTER 3
Concrete Mix Design
3.1 Introduction
The process of selecting suitable ingredients of concrete and determining their relative
amounts with the objective of producing a concrete of the required, strength, durability, and
workability as economically as possible, is termed the concrete mix design. The
proportioning of ingredient of concrete is governed by the required performance of concrete
in 2 states, namely the plastic and the hardened states. If the plastic concrete is not workable,
it cannot be properly placed and compacted. The property of workability, therefore, becomes
of vital importance.
The compressive strength of hardened concrete which is generally considered to be an index
of its other properties, depends upon many factors, e.g. quality and quantity of cement, water
and aggregates; batching and mixing; placing, compaction and curing. The cost of concrete is
made up of the cost of materials, plant and labour. The variations in the cost of materials arise
from the fact that the cement is several times costly than the aggregate, thus the aim is to
produce as lean a mix as possible. From technical point of view the rich mixes may lead to
high shrinkage and cracking in the structural concrete, and to evolution of high heat of
hydration in mass concrete which may cause cracking.
The actual cost of concrete is related to the cost of materials required for producing a
minimum mean strength called characteristic strength that is specified by the designer of the
structure. This depends on the quality control measures, but there is no doubt that the quality

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control adds to the cost of concrete. The extent of quality control is often an economic
compromise, and depends on the size and type of job. The cost of labour depends on the
workability of mix, e.g., a concrete mix of inadequate workability may result in a high cost of
labour to obtain a degree of compaction with available equipment.
Requirements of concrete mix design
The requirements which form the basis of selection and proportioning of mix ingredients are :
a ) The minimum compressive strength required from structural consideration
b) The adequate workability necessary for full compaction with the compacting equipment
available.
c) Maximum water-cement ratio and/or maximum cement content to give adequate durability
for the particular site conditions
d) Maximum cement content to avoid shrinkage cracking due to temperature cycle in mass
concrete.
3.2 Types of Mixes
1. Nominal Mixes
In the past the specifications for concrete prescribed the proportions of cement, fine and
coarse aggregates. These mixes of fixed cement-aggregate ratio which ensures adequate
strength are termed nominal mixes. These offer simplicity and under normal circumstances,
have a margin of strength above that specified. However, due to the variability of mix
ingredients the nominal concrete for a given workability varies widely in strength.

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2. Standard mixes
The nominal mixes of fixed cement-aggregate ratio (by volume) vary widely in strength and
may result in under- or over-rich mixes. For this reason, the minimum compressive strength
has been included in many specifications. These mixes are termed standard mixes.
IS 456-2000 has designated the concrete mixes into a number of grades as M10, M15, M20,
M25, M30, M35 and M40. In this designation the letter M refers to the mix and the number
to the specified 28 day cube strength of mix in N/mm 2. The mixes of grades M10, M15, M20
and M25 correspond approximately to the mix proportions (1:3:6), (1:2:4), (1:1.5:3) and
(1:1:2) respectively.
3. Designed Mixes
In these mixes the performance of the concrete is specified by the designer but the mix
proportions are determined by the producer of concrete, except that the minimum cement
content can be laid down. This is most rational approach to the selection of mix proportions
with specific materials in mind possessing more or less unique characteristics. The approach
results in the production of concrete with the appropriate properties most economically.
However, the designed mix does not serve as a guide since this does not guarantee the correct
mix proportions for the prescribed performance.
For the concrete with undemanding performance nominal or standard mixes (prescribed in
the codes by quantities of dry ingredients per cubic meter and by slump) may be used only
for very small jobs, when the 28-day strength of concrete does not exceed 30 N/mm 2. No
control testing is necessary reliance being placed on the masses of the ingredients.

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Factors affecting the choice of mix proportions

The various factors affecting the mix design are:
1. Compressive strength
It is one of the most important properties of concrete and influences many other describable
properties of the hardened concrete. The mean compressive strength required at a specific
age, usually 28 days, determines the nominal water-cement ratio of the mix. The other factor
affecting the strength of concrete at a given age and cured at a prescribed temperature is the
degree of compaction. According to Abraham’s law the strength of fully compacted concrete
is inversely proportional to the water-cement ratio.
2.Workability
The degree of workability required depends on three factors. These are the size of the section
to be concreted, the amount of reinforcement, and the method of compaction to be used. For
the narrow and complicated section with numerous corners or inaccessible parts, the concrete
must have a high workability so that full compaction can be achieved with a reasonable
amount of effort. This also applies to the embedded steel sections. The desired workability
depends on the compacting equipment available at the site.
3. Durability
The durability of concrete is its resistance to the aggressive environmental conditions. High
strength concrete is generally more durable than low strength concrete. In the situations when
the high strength is not necessary but the conditions of exposure are such that high durability
is vital, the durability requirement will determine the water-cement ratio to be used.
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4. Maximum nominal size of aggregate
In general, larger the maximum size of aggregate, smaller is the cement requirement for a
particular water-cement ratio, because the workability of concrete increases with increase in
maximum size of the aggregate. However, the compressive strength tends to increase with the
decrease in size of aggregate.
IS 456:2000 and IS 1343:1980 recommend that the nominal size of the aggregate should be
as large as possible.
5. Grading and type of aggregate
The grading of aggregate influences the mix proportions for a specified workability and
water-cement ratio. Coarser the grading leaner will be mix which can be used. Very lean mix
is not desirable since it does not contain enough finer material to make the concrete cohesive.
The type of aggregate influences strongly the aggregate-cement ratio for the desired
workability and stipulated water cement ratio. An important feature of a satisfactory
aggregate is the uniformity of the grading which can be achieved by mixing different size
fractions.
6. Quality Control
The degree of control can be estimated statistically by the variations in test results. The
variation in strength results from the variations in the properties of the mix ingredients and
lack of control of accuracy in batching, mixing, placing, curing and testing. The lower the

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difference between the mean and minimum strengths of the mix lower will be the cement-
content required. The factor controlling this difference is termed as quality control.
3.3 Mix Proportion designations
The common method of expressing the proportions of ingredients of a concrete mix is in the
terms of parts or ratios of cement, fine and coarse aggregates. For e.g., a concrete mix of
proportions 1:2:4 means that cement, fine and coarse aggregate are in the ratio 1:2:4 or the
mix contains one part of cement, two parts of fine aggregate and four parts of coarse
aggregate. The proportions are either by volume or by mass. The water-cement ratio is
usually expressed in mass
Factors to be considered for mix design
ð The grade designation giving the characteristic strength requirement of concrete.
ð The type of cement influences the rate of development of compressive strength of concrete.
ð Maximum nominal size of aggregates to be used in concrete may be as large as possible
within the limits prescribed by IS 456:2000.
ð The cement content is to be limited from shrinkage, cracking and creep.
ð The workability of concrete for satisfactory placing and compaction is related to the size
and shape of section, quantity and spacing of reinforcement and technique used for
transportation, placing and compaction.
3.4 Procedure
1. Determine the mean target strength f t from the specified characteristic compressive
strength at 28-day fck and the level of quality control.

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ft = fck + 1.65 S
where S is the standard deviation obtained from the Table of approximate contents given after
the design mix.
2. Obtain the water cement ratio for the desired mean target using the emperical relationship
between compressive strength and water cement ratio so chosen is checked against the
limiting water cement ratio. The water cement ratio so chosen is checked against the limiting
water cement ratio for the requirements of durability given in table and adopts the lower of
the two values.
3. Estimate the amount of entrapped air for maximum nominal size of the aggregate from the
table.
4. Select the water content, for the required workability and maximum size of aggregates (for
aggregates in saturated surface dry condition) from table.
5. Determine the percentage of fine aggregate in total aggregate by absolute volume from
table for the concrete using crushed coarse aggregate.
6. Adjust the values of water content and percentage of sand as provided in the table for any
difference in workability, water cement ratio, grading of fine aggregate and for rounded
aggregate the values are given in table.
7. Calculate the cement content form the water-cement ratio and the final water content as
arrived after adjustment. Check the cement against the minimum cement content from the
requirements of the durability, and greater of the two values is adopted.
8. From the quantities of water and cement per unit volume of concrete and the percentage of
sand already determined in steps 6 and 7 above, calculate the content of coarse and fine
aggregates per unit volume of concrete from the following relations:

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where V = absolute volume of concrete
= gross volume (1m3) minus the volume of entrapped air
Sc = specific gravity of cement
W = Mass of water per cubic metre of concrete, kg
C = mass of cement per cubic metre of concrete, kg
p = ratio of fine aggregate to total aggregate by absolute volume
fa, Ca = total masses of fine and coarse aggregates, per cubic metre of concrete, respectively,
kg, and
Sfa, Sca = specific gravities of saturated surface dry fine and coarse aggregates, respectively
9. Determine the concrete mix proportions for the first trial mix.
10. Prepare the concrete using the calculated proportions and cast three cubes of 150 mm size
and test them wet after 28-days moist curing and check for the strength.
11. Prepare trial mixes with suitable adjustments till the final mix proportions are arrived at.
3.5 Design Parameters
Data Recuired for mix design
(i) Concrete Mix Design Stipulation
(a) Characteristic compressive strength required in the field at 28 days grade designation - M
20
(b) Nominal maximum size of aggregates - 20 mm

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(c) Shape of CA - Angular

(d) Degree of workability required at the site 50-75 mm (slump)
(e) Degree of quality control at site - As per IS:456
(f) Types of exposure the structure will be subjected to (as defined IS: 456) - Mild
(g) Type of cement: PSC conforming IS:455
(h) Method of concrete placing: pump able concrete
(ii) Test data of materials (to be determined in the laboratory)

(a) Specific gravity of cement - 2.90
(b) Specific gravity of FA - 2.65
(c) Specific gravity of CA - 2.74
(d) Specific gravity of Granite - 2.79
(e) Aggregate are assumed to be in saturated surface dry condition.
(f) Fine aggregates confirm to Zone III of IS – 383
Procedure for Concrete Mix Design of M20 Concrete
Step 1 - Determination Of Target Strength

Himsworth constant for 5% risk factor is 1.65. In this case standard deviation is taken from
the IS:456 against M 20 is 4.0.
ftarget = fck + 1.65 x S
= 20 + 1.65 x 4.0 = 26.66 N/mm2
Where,
S = standard deviation in N/mm2 = 4 (as per table no 1 of IS 10262- 2009)

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Step 2 - Selection of water to cement ratio:-

From Table 5 IS 456, (page no 20)

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Maximum water-cement ratio for Mild exposure condition = 0.47

Based on experience, adopt water-cement ratio as 0.47.
0.47<0.55, hence OK.
Step 3 - Selection of Water Content

From Table 2 of IS 10262- 2009,

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Maximum water content = 186 Kg (for Nominal maximum size of aggregate - 20 mm)
Estimated water content = 186+ (.01/100) x 186 = 186 kg /m 3
Step 4 - Selection of Cement Content

Water-cement ratio = 0.47
Corrected water content = 186 kg /m3
Cement content =186/.47=395.74kg/m3
From Table 5 of IS 456,
Minimum cement Content for mild exposure condition = 300 kg/m 3
395.74 kg/m3 > 300 kg/m3, hence, OK.
This value is to be checked for durability of requirement from IS: 456.
In the present example against mild exposure and for the case of reinforced concrete the
minimum cement content is 300 kg/m 3 which is less than 395.74 kg/m3. Hence cement
content adopted = 395.74kg/m3.
As per clause 8.2.4.2 of IS: 456

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Maximum cement content = 450 kg/m3.
Step 5: Estimation of Coarse Aggregate proportion:-
For Nominal maximum size of aggregates = 20 mm,
Zone of fine aggregate = Zone III
And For w/c = 0.47
Volume of coarse aggregates per unit volume of total aggregate = 0.64
For every ±0.05 change in water-cement ratio, the coarse aggregate proportion is to be
changed by 0.01. If the water to cement is less than 0.5 (standard value), volume of coarse
aggregate is required to be increased to reduce the fine aggregate content. If the water to
cement is more than 0.5, volume of coarse aggregate is to be reduced to increase the fine
aggregate content. If coarse aggregates is not angular, volume of coarse aggregates may be
required to be increased suitably, based on experience.

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Note 2: For pumpable concrete or congested reinforcement the coarse aggregates proportion
may be reduced up to 10%.
Hence,
Volume of coarse aggregate per unit volume of total aggregate = 0.64 x (0.01/0.05)x0.03 =
0.646
Volume of fine aggregate = 1 – 0.646 = 0.354
Step 6: Estimation of the mix ingredients
a) Volume of concrete = 1 m3
b) Volume of cement = [mass of cement / specific gravity of cement] x (1/100)
= (395.74/2.90) x (1/1000) = 0.136 m3
c) Volume of water = [mass of water / specific gravity of water] x (1/1000)
= (186/1) x (1/1000) = 0.186 m3
d) Volume of total aggregates = a – (b + c ) = 1 – (0.136 + 0.186) = 0.677 m3
e) Mass of coarse aggregates = 0.677x0.646 x 2.84 x 1000 = 1219.23 kg/m3
f) Mass of fine aggregates = 0.677 x 0.354 x 2.64 x 1000 = 632.69kg/m3
Mass of ingredients reuired will be calculated for 4 no’s of cube.
So assuming 25% wastage
Volume of concrete required for 4 cubes=4x(0.153x1.25)=0.016878m3
Cement = (395.74x0.016878)=6.67kg
Water=(186x0.016878)=3.13kg
Coarse aggregate=(1219.23x0.016878)=20.57kg
Fine aggregate=(633.35x0.016878)=10.68kg

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Procedure for Concrete Mix Design of M25 Concrete
Step 1 - Determination Of Target Strength

Himsworth constant for 5% risk factor is 1.65. In this case standards deviation is taken from
IS:456 against M 25 is 4.0.
ftarget = fck + 1.65 x S
= (25+1.65 x 4.0) = 31.6 N/mm2
Where,
S = standard deviation in N/mm2 = 4 (as per table no 1 of IS 10262- 2009)
Step 2 - Selection of water to cement ratio:-

From Table 5 IS 456, (page no 20)

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Maximum water-cement ratio for Mild exposure condition = 0.45

Based on experience, adopt water-cement ratio as 0.45.
0.45<0.55, hence OK.
Step 3 - Selection of Water Content


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Maximum water content = 186 Kg (for Nominal maximum size of aggregate - 20 mm)
Estimated water content = 186+ (.01/100) x 186 = 186 kg /m 3
Step 4 - Selection of Cement Content

Water-cement ratio = 0.47
Corrected water content = 186 kg /m3
Cement content =186/.45=413.33kg/m3
From Table 5 of IS 456,
Minimum cement Content for mild exposure condition = 300 kg/m3
413.33 kg/m3 > 300 kg/m3, hence, OK.
This value is to be checked for durability of requirement from IS: 456.
In the present example against mild exposure and for the case of reinforced concrete the
minimum cement content is 300 kg/m3 which is less than 413.33 kg/m3. Hence cement
content adopted = 413.33kg/m3.
As per clause 8.2.4.2 of IS: 456

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Maximum cement content = 450 kg/m3.
Step 5: Estimation of Coarse Aggregate proportion:-

For Nominal maximum size of aggregates = 20 mm,
Zone of fine aggregate = Zone III
And For w/c = 0.45
Volume of coarse aggregate per unit volume of total aggregates = 0.64
For every ±0.05 change in water to cement, the coarse aggregate proportion is to be changed
by 0.01. If the water to cement is less than 0.5 (standard value), volume of coarse aggregate is
required to be increased to reduce the fine aggregate content. If the water to cement is more
than 0.5, volume of coarse aggregates is to be reduced to increase the fine aggregates content.
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If coarse aggregates is not angular, volume of coarse aggregates may be required to be
increased suitably, based on experience =
Note 2: For pumpable concrete or congested reinforcement the coarse aggregates proportion
may be reduced up to 10%.
Hence,
Volume of coarse aggregate per unit volume of total aggregate = 0.64 x (0.01/0.05)x0.05 =
0.65
Volume of fine aggregates = 1 – 0.65 = 0.35
Step 6: Estimation of the mix ingredients
a) Volume of concrete = 1 m3
b) Volume of cement = (Mass of cement / Specific gravity of cement) x (1/100)
= (413.33/2.90) x (1/1000) = 0.1425m3
c) Volume of water = (Mass of water / Specific gravity of water) x (1/1000)
= (186/1) x (1/1000) = 0.186 m3
d) Volume of total aggregates = a – (b + c ) = 1 – (0.136 + 0.186) = 0.677 m3
e) Mass of coarse aggregates = 0.6715x0.65 x 2.84 x 1000 = 1216.44kg/m3
f) Mass of fine aggregates = 0.6715x 0.35 x 2.64 x 1000 = 620.46kg/m3
Mass of ingredients reuired will be calculated for 4 no’s of cube.
So assuming 25% wastage
Volume of concrete required for 4 cubes=4x(0.153x1.25)=0.016878m3
Cement = (413.33x0.016878)=6.97kg
Water=(186x0.016878)=3.13kg

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Coarse aggregate=(1216.44x0.016878)=20.53kg
Fine aggregate=(622.75x0.016878)=10.51kg
Step 7: Correction due to absorbing or moist aggregates:-
Since the aggregates is saturated surface dry condition hence no correction is required.

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CHAPTER 4
RESULTS
Workability Slump Test
Slump test results
for M 20 grade concrete mix in N/mm2
0% 30%
basalt/100% basalt/70% 50% basalt/50% 75% basalt/25% 90% basalt/10%
Specimen Granite Granite Granite Granite Granite
M 20 70 80 95 95 100
M 25 80 90 100 100 110
160
140
120
100
80 M 20
60 M 25
40
20
0
0 2 4 6

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M20 GRADE MIX
7 days compressive strength test results for M 20 grade concrete mix in N/mm2
0% 30% 50% 75% 90% 100%
basalt/100% basalt/70% basalt/50% basalt/25% basalt/10% basalt/0%
Specimen Granite Granite Granite Granite Granite granite
1 23.66 21.32 20.23 19.68 18.62 17.65
2 23.89 22.65 19.85 19.25 19.68 18.12
3 24.25 21.45 20.95 21.79 18.12 18.45
0% 30% 50% 75% 90% 100%
basalt/100% basalt/70% basalt/50% basalt/25% basalt/10% basalt/0%
1 28.36 27.58 26.62 26.69 27.56 24.95
2 29.12 26.35 25.63 26.31 27.45 25.26
3 29.45 26.44 26.74 26.45 26.81 24.99
Figure: Graph showing results for 7 days Compressive strength

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25
20
15 Series1
10 Series2
Series3
5
0
0 2 4 6 8
30
25
20
Series1
15
Series2
10
Series3
5
0
0 2 4 6 8
By comparing the basalt stone concrete with granite-basalt mix concrete we see that the
strength of partially reaplaced basalt with granite concrete get higher strength than the basalt
mix concrete and we can reduce much amount of granite waste which obtain from the
industry waste stone and get higher strength concrete mix.

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M25 GRADE MIX
0% 30% 50% 90% 100%
basalt/100% basalt/70% basalt/50% 75% basalt/25% basalt/10% basalt/0%
1 27.45 25.64 26.31 23.45 22.52 20.96
2 26.34 24.58 24.45 24.61 23.89 21.26
3 27.31 25.69 24.05 23.96 24.28 21.78
0% 30% 50% 90% 100%
basalt/100% basalt/70% basalt/50% 75% basalt/25% basalt/10% basalt/0%
Granite Granite Granite Granite Granite granite
1 31.24 29.86 29.75 29.32 28.99 27.98
2 34.35 30.54 28.56 28.74 29.01 28.56
3 33.226 30.96 29.78 28.86 27.98 28.23

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By comparing the basalt stone concrete with granite-basalt mix concrete we see that the
strength of partially reaplaced basalt with granite concrete get higher strength than the basalt
mix concrete and we can reduce much amount of granite waste which obtain from the
industry waste stone and get higher strength concrete mix.
50
40
30 Series3
20 Series1
10 Series2
0
1 2 3 4 5 6
Figure: Graph showing results for 28 days
Compressive strength
50
40
30 Series1
20 Series2
Series3
10
0
0 2 4 6 8

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CHAPTER 5
CONCLUSION
Concrete construction is an exciting alternative to conventional design mixing methods. In
the context of sustainable housing, aspects such as strength, durability, architectural freedom,
occupant comfort, affordability and energy efficiency align well with sufficient strength
qualities. This project explores its rich history and structure types, including water tanks,
houses, boats and large public areas. Various options are explored to reduce construction
labour costs, which is the biggest reason for its low adoption in today's buildings. There are
many modern improvements possible, including new materials, innovative fabric forming
methods, computer modeling and analysis, among others.
Traditional concrete mixing large labour requirements can be reduced. Computer-generated,
projected layouts allow for required strength mixing design with experiment, which is only
assembled on-site.. The use of flexible, non-metallic materials such as basalt increases
durability and with the use of granite greater strength is found which makes the mesh easier
to handle and shape. Mortar composition can be improved with water cement ratio for
quicker shotcrete application.
Based on limited experiment Investigation of properties of aggregate on granite with basalt
following observation can be concludes: The laboratory test results in compressive strength,
seems to indicate that initially when we use basalt metal only for concrete we get 18.07
N/mm2 avg strength in 7days and 25.06N/mm2 avg strength in 28 days in m20 mix design
.similarly when we use basalt metal only we get 21.33 N/mm2 avg strength in 7days and
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28.25 N/mm2 avg strength in 28 days in m25 mix design and when we replace basalt partially
with granite we
get 23.93,21.80,20.34,20.24,18.80N/mm2 avg strength in 7days and
28.97,26.79,26.33,26.48,27.27 N/mm2 avg strength in 28days in m20 mix design. similarly
we get 27.03,25.30,24.93,24.00,23.56 avg strength in 7days and
32.93,30.45,29.36,28.97,28.66 N/mm2 avg strength in 28day in m25 mix design.
By comparing both concrete result we found that the result of partially replace basalt with
granite is much higher than basalt mix concrete and we found better concrete mix and the
increase in granite percentage with basalt enhances the mix strength over the conventional
mix . This is due to the fact that granite is stronger & denser than basalt and more durable and
less water absorbing & same goes to basalt. Also higher workability is obtained for more
basalt aggregate with granite content mix which reduces the cost of labour.
As basalt aggregate is a natural aggregate also available in plenty at low cost, an
economical and relatively high strength concrete is obtained by using basalt aggregate with
granite as coarse aggregate in concrete mixes.
As we found that when granite percentage increase the strength of concrete mix design of
M20 and M25 is increase and by partial replacement of basalt with granite give the strength
more than the target strength of concrete so it is very economical for construction industry.
By the experiment we found that in the overall granite waste about 30-40% waste stone
we can reduce 25-30% granite waste stone which are produce during the production of
granite stone products.so it is the most economical for the environment condition.
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References
[1] 1000days.net. Boatbuilding Shooner Anne.
http://1000days.net/home/media/boatbuilding/boat uilding.htm. [Accessed 2013-03-07].
[2] Airpacks Ltd. KORE Passive Slab. http://www.kore-system.com/oor-insulation-kore-
passive-slab. [Accessed 2013-03-11].
[3] Am-cor Inc. Ferrocement Homes & Building Kits. http://www.am-cor.com/. [Accessed
2013-03-05].
[4] ArchPoint. Wooden Frame House. http://archpointcity.com. [Accessed 2013-03-01].
[5] ColoradoENERGY.org. R-Value Tables. http://www.coloradoenergy.org/procorner/stu/r-
values.htm. [Accessed 2013-03-13].
[6] Commercial Building Consortium. Zero Energy. http://www.zeroenergycbc.org.
[Accessed 2013-02-27].
[7] Concrete Canvas Ltd. Concrete Canvas Rapidly Deployable Infrastructure.
http://concretecanvas.co.uk/. [Accessed 2013-03-02].
[8] Associated Press. Marysville, Indiana Tornado Completely Destroys Town As Twisters
Sweep Across State . Hungton Post (March 2012).

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[9] Ammary, B., 2007. Clean cutting stone industry. International Journal of Environment
and Waste Management, 1 (2/3): 106-112.
[10] Arslan E. I Il , Aslan Sibel, Ipek Ubeyde, Altun Samet, Yazicio lu Salih, 2005, Physico-
chemical treatment of marble processing wastewater and the recycling of its sludge, Waste
Management & Research, 23( 6): 550-559.
[11] Balasubramanian J., Sabumon C., john U. Lazar ,And ilangovanR.,1995, Reuse of textile
effluent treatment plant sludge in buildingmaterials, journal of materials processing
technology 48 (1-4) : 379– 384.Weng, C., Lin, D. and Chiang, P., 2003. Utilization of sludge
as brick materials. Advances in Environmental Research, 7 (3): 679-685
[12] Colangelo F., Marroccoli M., and Cioffi R., Properties of self-leveling concrete made
with industrial wastes. Conference on use of building materials in building structures,
November,2004, Barcelona , Spain
[13] Colombo A. , Tunesi A., Barberini V., Galimberti L., Cavallo A.,chemical and
mineralogical characterization of cutting process sludge ,exploitation of sludge from stone
working synthesis of the research,accessed 2008,
http://www.aigt.ch/download/rapporto_INTERREGen.pdf .
[14] Dr.T.Sekar, N.Ganesan & Dr.NVN.Nampoothiri (2011),“Studies on strength
characteristics on utilization of waste materials as coarse aggregate in concrete”, International
Journal of Engineering Science and Technology,Volume 3 No 7, 2011.

Contact: 6260651575, 9179357477
[15] G.Murali, K.R.Jayavelu, N.Jeevitha, M.Rubini and N.R.Saranya “Experimental
Investigation On Concrete With Partial Replacement Of Coarse Aggregate” International
Journal of Engineering Research and ApplicationsVol. 2, Issue 2,Mar-Apr 2012, pp.314-319.
[16] Hansen, T. C. and Begh, E., „Elasticity and drying shrinkage of recycled aggregate
concrete‟, Journal of American Concrete Institute, 82

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Analysis of Use of Basalt Aggregate in Concrete Mixes With Granite Stone Under M-20 &amp; M-25 Grades

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Analysis of Use of Basalt Aggregate in Concrete Mixes With Granite Stone Under M-20 &amp; M-25 Grades

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ANALYSIS OF USE OF BASALT AGGREGATE IN CONCRETE MIXES WITH GRANITE STONE UNDER M-20 & M-25 GRADES

This study aims at environmentally assessing the most significant

input and output flows related to the production of concrete using

An experimental program is set up to test the effect of basalt

aggregate content and its combinations with granite stone with

variation of percentages in concrete mixes. Different aggregate

Guided by: Dr. Ashad Ullah Qureshi

1.4 Fire Resistance

1.5 Energy Efficiency

1.6 Thermal Comfort

1.7 Air Quality

1.8 Natural Light

1.11 Study On Granite Waste Uses In India

1.12 Favorable Environment For Granite Industry In India

1.13 Properties Of Concrete

1.14 Grades Of Concrete

1.15 Compressive Strength Of Concrete

1.16 Characteristic Strength Of Concrete

1.17 Characteristic Strength Of Concrete In Flexural Member

1.18 Design Strength (Fd) And Partial Safety Factor For

Guided by: Dr. Ashad Ullah Qureshi

1.19 Tensile Strength Of Concrete

1.20 Creep in concrete

1.21 Shrinkage of Concrete

1.23 Unit weight of concrete

Chapter 2. Literature Review 31 - 50

2.2 Literature Reviewed

2.3 Sieve Analysis For Grading Of Coarse Aggregates [Is

2.4 Fineness Modulus

2.5 Specific Gravity Of Aggregates[Is: 2386 – (Part – Iii) 1963]

2.6 Water Absorption Of Aggregate [Is: 2386 – (Part – Iii)

2.7 Flakiness And Elongation Index Of Coarse Aggregate: [Is:

2.8 Elongation Index

2.9 Impact Value Of Aggregate:[Is: 2386 Part-4-1963]

2.10 Crushing Value Of Coarse Agrgregate :[Is: 2386 Part-4-

2.11 Abrasion Test Of Aggregate:[Is 2386 (Part-Iv) –1963]

Guided by: Dr. Ashad Ullah Qureshi

Chapter 3. Concrete Mix Design 51 - 75

3.2 Types of Mixes

3.3 Mix Proportion designations

3.5 Design Parameters

Guided by: Dr. Ashad Ullah Qureshi

appearance of Indian granite is definitely a competitive advantage that should be considered

when planning export strategies.

over that role.

m20& m25 with granite stone with basalt in coarse aggregate.

paper as incorporating the following features:

use than other concrete mix design.

Guided by: Dr. Ashad Ullah Qureshi

than the requirement for construction .

materials, renewable materials, minimizing energy use, minimizing waste, minimizing

of the locally available material in the construction .

1.4 Fire resistance

in a household. To prevent possible damage, avoid extreme changes in temperature, such as

which reduces the strength.

Guided by: Dr. Ashad Ullah Qureshi

1.5 Energy efficiency

as the buildind is so construction that is recuired minimum conventional soureses.

1.6 Thermal comfort

which reduces thermal losses of the building envelope

1.7 Air quality

(VOCs) and other harmful gases to the occupants.emergency ventilation is essentially

1.8 Natural light

conflict with energy efficiency.

Analysis of Use of Basalt Aggregate in Concrete Mixes With Granite Stone Under M-20 & M-25 Grades

Analysis of Use of Basalt Aggregate in Concrete Mixes With Granite Stone Under M-20 & M-25 Grades