Code of practice for manufacture and use of lime-pozzolana concrete blocks for paving

Scope of IS 10359: Lime Pozzolana Concrete Blocks

• Applicable Standards: Definitions per

  • IS 3115:1992 (Specification for lime-based blocks)
  • IS 6508:1988 (Specification for building limes)

• Materials:

  • Lime conforming to IS 269:1989 or IS 1489 (Part 1 & 2):1991
  • Pozzolana as per IS specifications (calcined clay, fly ash, etc.)

• Mix Proportions (by mass) for Lime Pozzolana Concrete Blocks (Clause 4.1, Table 1):

• Note: Mix proportions are indicative and may be adjusted for desired performance.

Summary

• Lime-pozzolana blocks use lime and pozzolana in specified ratios for strength and durability.
• Water content varies between 10-11% by mass of total material.
• Aggregates graded with max 20 mm size are used.

flowchart LR
    A[Lime] --> B[Mixing]
    C[Pozzolana] --> B
    D[Fine Aggregate] --> B
    E[Coarse Aggregate (20mm)] --> B
    B --> F[Lime Pozzolana Concrete Blocks]

This ensures blocks meet strength and durability requirements per IS 10359.

IS 10359: Definitions & Key Specifications Summary

Clause 2.1: Definitions

• Definitions follow IS 3115-1978 (Lime-based blocks) and IS 6508-1972 (Building lime).
• Refer these for precise terminology on lime, pozzolana, aggregates, and blocks.

Key Tables: Mix Proportions for Lime Pozzolana Concrete Blocks (Clause 4.1)

Note: Mix proportions are indicative; adjust based on performance requirements.

Cement Specification (Clause 3.5)

• Cement shall conform to:
  • IS 269:1989 (Ordinary Portland Cement)
  • IS 1489 (Part 1 & 2):1991 (Portland Pozzolana Cement)

Mixing Procedure (Clause 5.1.1)

• Add part of total water first.
• Add coarse aggregate, lime, and pozzolana or lime-pozzolana mixture.
• Mix thoroughly.
• Add remaining water and mix for at least 2 minutes.

Summary Diagram: Lime-Pozzolana Concrete Block Mix Process

flowchart TD
    A[Start: Add part water] --> B[Add coarse agg + lime + pozzolana]
    B --> C[Mix thoroughly]
    C --> D[Add remaining water]
    D --> E[Final mixing (≥2 min)]
    E --> F[

IS 10359: Key Material Specifications & Mix Proportions

1. Recommended Mix Proportions for Lime Pozzolana Concrete Blocks (Clause 4.1)

Note: Water requirement is by mass of total material.

2. Storage of Materials (Clause 3.7)

• Materials must be stored as per IS 4082-1977 to maintain quality.

3. Curing (Clause 8.1)

• Initial curing: 72 hours.
• Final curing: Minimum 28 days with regular moistening.

Summary

• Mix design varies with lime grade and aggregate proportions.
• Water content is critical (10-11% by mass).
• Proper storage and curing ensure block quality.

flowchart TD
    A[Materials Storage] --> B[Mixing as per Table 1]
    B --> C[Initial Curing (72 hrs)]
    C --> D[Final Curing (28 days)]
    D --> E[Quality Lime Pozzolana Blocks]

For detailed manufacturing and testing, refer to IS 10359 and related IS codes (IS 3115, IS 6508).

IS 10359 - Mix Proportions for Lime-Pozzolana Concrete Blocks

Key Mix Proportions (by Mass) — Table 1 (Clause 4.1)

Notes:

• Water content is percentage by mass of total materials.
• Adjust water and mix based on workability and absorption (see IS 2185 Part 1).
• Proportions are guidelines; modify as needed for desired block performance.
• Storage of materials per IS 4082-1977.

Summary:

• Use LP 20 or LP 40 lime-pozzolana mix or separate lime and pozzolana.
• Fine aggregate varies from 1 to 6 parts; coarse aggregate from 2 to 12 parts.
• Water content ranges from 10% to 11% by mass.

flowchart LR
    A[Lime-Pozzolana Mix] --> B[Fine Aggregate]
    A --> C[Coarse Aggregate (20 mm)]
    B --> D[Water Addition (10-11%)]
    C --> D
    D --> E[Mixing & Compaction]
    E --> F[Concrete Blocks Manufacture]

This ensures uniform mixing and proper hydration for durable lime-pozzolana concrete blocks.

IS 10359: Mixing - Key Formulas, Tables & Specifications

1. Mixing Requirements (Clauses 6.1.2 & 5.1)

• Uniform mixing is essential to ensure consistent quality.
• Allow for water absorption by aggregates; adjust water content based on compaction method.
• Preferably use mechanical concrete mixers for thorough mixing.

2. Storage of Materials (Clause 3.7)

• Follow IS 4082-1977 for proper storage to maintain material quality.

3. Recommended Mix Proportions (Clause 4.1, Table 1)

Note: Mix proportions are indicative and may be adjusted for desired performance.

4. Water Adjustment Formula

[ W_{adjusted} = W_{required} + W_{absorption} ]

• Where:
  • ( W_{required} ) = water % from table
  • ( W_{absorption} ) = water absorbed by aggregates (determined experimentally)

Summary:

• Use mechanical mixers for uniformity.
• Adjust water for aggregate absorption and compaction method.
• Follow

IS 10359 - Manufacture of Lime Pozzolana Concrete Blocks

Key Mix Proportions (Clause 4.1, Table 1)

Note: Mix proportions can be adjusted for desired block performance.

Manufacturing Procedure (Clause 5.1.1)

• Add part of total water first.
• Add coarse aggregate, lime, and pozzolana or lime-pozzolana mixture into the mixer.
• Mix thoroughly.
• Add remaining water and mix for minimum 2 minutes.

Curing (Clause 8.1)

• Initial curing: 72 hours.
• Final curing: Keep blocks moist by spraying water regularly for at least 28 days.

Storage (Clause 3.7)

• Follow IS 4082-1977 for proper storage of materials.

flowchart TD
    A[Add part water] --> B[Add coarse agg., lime, pozzolana]
    B --> C[Mix thoroughly]
    C --> D[Add remaining water]
    D --> E[Mix for >= 2 minutes]
    E --> F[Initial curing 72 hrs]
    F --> G[Final curing 28 days with moist spraying]

This ensures quality lime-pozzolana concrete blocks per IS 10359.

IS 10359: Initial Curing of Lime Pozzolana Concrete Blocks

Key Specifications (Clause 7.1)

• Immediately after molding, blocks must be released from the mold with the base plate.
• Blocks should be moved to a covered shed protecting from sun, strong wind, and rain.
• Cover blocks with polythene sheets to retain moisture.
• Minimum initial curing period: 72 hours to achieve sufficient hardness for handling without damage.

Purpose

• Ensures proper hydration and strength gain before handling.
• Prevents surface drying and cracking.

Curing Environment Requirements

• Shed must provide:
  • Shade from sunlight
  • Protection against wind and rain
• Maintain moisture retention by covering.

Summary Table for Curing Periods

Additional Notes

• Initial curing is critical before final curing (Clause 8.1).
• Final curing involves moist curing for at least 28 days to achieve full strength.

flowchart TD
    A[Molding of Block] --> B[Release from Mold + Base Plate]
    B --> C[Move to Covered Shed]
    C --> D[Cover with Polythene Sheets]
    D --> E[Initial Curing: 72 hrs minimum]
    E --> F[Stack Blocks for Final Curing]
    F --> G[Final Curing: 28 days moist curing]

Reference: IS 10359 Clauses 7.1 & 8.1

IS 10359 - Final Curing of Lime Pozzolana Concrete Blocks

Key Specifications (Clause 8.1)

• Initial curing: Minimum 72 hours after demoulding.
• Final curing: Minimum 28 days.
• Blocks must be stacked, covered, and kept moist by regular water spraying.
• Protect blocks from sun, wind, and rain during curing (Clause 7.1).

Curing Process Summary

Important Notes

• Immediate removal from mould after preparation.
• Maintain moisture to ensure proper hydration and strength gain.
• Proper curing ensures good bond between layers (Clause 6.3.2).

Quick Reference Table: Final Curing Requirements

flowchart TD
    A[Block Preparation] --> B[Demoulding]
    B --> C[Initial Curing (≥72 hrs)]
    C --> D[Stack & Cover Blocks]
    D --> E[Final Curing (≥28 days)]
    E --> F[Moisture Maintenance (Water Spray)]
    F --> G[Ready for Handling/Use]

For detailed mix proportions and curing practices, refer to Clause 4.1 and Table 1 of IS 10359.

Contact BIS offices for further clarifications or standards updates.

IS 10359: Storage of Materials - Key Points

• Storage Standard: As per Clause 3.7, storage of materials shall follow IS 4082:1996, which covers recommendations on stacking and storage of construction materials at site.

• Storage Conditions (Clause 7.1):

  • Blocks must be removed from molds and placed on base plates in a covered shed.
  • Shed must protect against sun, strong wind, and rain.
  • Blocks should be covered with polyethylene sheets to retain moisture.
  • Minimum storage/curing period before handling: 72 hours.

Recommended Mix Proportions for Lime-Pozzolana Concrete Blocks (by mass) - Table Extract (Clause 4.1)

Note: Mix proportions may be adjusted for desired block performance.

flowchart TD
    A[Materials Stored as per IS 4082:1996] --> B[Blocks removed from mould]
    B --> C[Placed on base plate in covered shed]
    C --> D[Covered with polyethylene sheets]
    D --> E[Minimum 72 hours curing before handling]

Summary: Proper storage involves protection from weather, moisture retention, and minimum curing time to ensure block strength and durability.

IS 10359: Quality Control Key Points

1. Mix Proportions (Clause 4.1, Table 1)

Note: Mix proportions can be adjusted to achieve desired block performance.

2. Curing Requirements (Clause 8.1)

• Initial curing: 72 hours.
• Final curing: Minimum 28 days.
• Blocks must be kept moist by regular water spraying during curing.

3. Storage (Clause 3.7)

• Follow IS 4082-1977 for storage of raw materials.

Summary Diagram of Quality Control Process

flowchart TD
    A[Raw Material Storage] --> B[Mixing as per Table 1]
    B --> C[Initial Curing (72 hrs)]
    C --> D[Stacking & Moisture Maintenance]
    D --> E[Final Curing (≥ 28 days)]
    E --> F[Quality Testing & Inspection]

References:

• IS 10359 for mix and curing.
• IS 4082 for storage.
• Adjust water content and aggregates as per site conditions for quality control.

IS 10359: Use of Lime-Pozzolana Concrete Blocks for Paving

Key Specifications (Clause 6.1)

• Block Size: 300 mm × 300 mm × 100 mm (thickness)
• Layer Composition:
  • Lower layer: 90 mm thick lime-pozzolana concrete
  • Wearing course: 10 mm thick cement-sand layer

Mix Proportions (Clause 4.1, Table 1)

Note: Mix proportions may be adjusted to achieve desired performance.

Summary:

• Use 300×300×100 mm blocks with a 90 mm base + 10 mm wearing layer.
• Follow mix proportions as per Table 1 for durability and strength.
• Water content ranges 10-11% by mass of total materials.

flowchart TD
    A[Raw Materials] --> B[Lime-Pozzolana Mix]
    B --> C[Mix with Aggregates]
    C --> D[Block Moulding (300x300x100 mm)]
    D --> E[Lower Layer (90 mm)]
    D --> F[Wearing Layer (10 mm)]
    E --> G[Drying & Curing]
    F --> G

This ensures durable, standardized paving blocks as per IS 10359.