REPORT ON CONCRETE MIX DESIGN

Date: 17.03.2020
Testing done for : L&T GeoStructure
Mount Poonamalle Road, Manapakkam,
P.B. No.979, Chennai-600089
Letter Ref. No: : LTGS/SUB/PKG-II,III,IV/FPW/001 dated 13.02.2020
Name of work : Flood protection Measures on the River with Flood Walls, Sheet Piles
including Embankment strengthening and Bank Protection Works on
Riverside in the district of Howrah and Hooghly-Package-II/III/IV
Name of Project : West Bengal Major Irrigation and Flood management Project
(WBMIFMP)

STIPULATION FOR PROPORTIONING

a) Grade designation : M-25
b) Type of Cement : OPC 43 (RAMCO)
c) Maximum nominal size of aggregate 20 mm
d) Exposure condition : Moderate
e) Minimum cement content 300 kg/m³
f) Maximum water-cement ratio : 0.50
g) Workability 100 mm After 3 Hrs.
h) Method of concrete placing : Pumping
i) Degree of supervision : Good
j) Type of coarse aggregate : Crushed angular aggregate (Source : Panchami)
k) Chemical admixture type : BASF Masterpolyheed 8127
l) Sand : Source Illambazar, Birbhum
m) Water : Source Garh Bhawanipur, Howrah

TEST DATA FOR MATERIALS

a) Cement used : OPC 43 (RAMCO)
b) Specific gravity of cement : 3.10
c) Specific gravity of Chemical admixture : 1.09
d) Chemical admixture Superplasticizer conforming to IS 9103
e) Specific gravity of :
1. Coarse aggregate : 2.88
2. Fine aggregate : 2.66
f) Water absorption
1. Coarse aggregate : 0.62 percent
2. Fine aggregate : 1.20 percent

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 g) Sieve analysis
1. Coarse aggregate
Individual Grading (% Finer)
Sieve Combined
for Different Sizes of Permissible
Size Grading % Remarks
Aggregates Limit (% Finer)
(mm) Finer
20.0mm 10.0mm
The combined
40.00 100.00 100.00 100.00 100 grading satifies the
20.00 90.92 100.00 95.46 95-100 requirement of
16.00 52.92 100.00 76.46 - graded aggregate of
12.50 16.50 98.67 57.59 - nominal size
10.00 3.50 54.25 28.88 25-55 20.0mm as per
Table 7 of IS 383-
4.75 0.33 0.42 0.38 0-10 2016
20.0mm & 10.0mm aggregates are to be mixed in proportion of 50 : 50 by weight.

2. Fine aggregate
Sieve Size Permissible
%Finer Remarks
(mm) Limit
10.00 100.00 100
4.75 91.81 90-100
Conforms to
2.36 88.34 75-100
grading Zone-II
1.18 75.60 55-90
as per IS:383-
0.60 38.51 35-59
2016.
0.30 8.87 8-30
0.15 2.55 0-10

The Mix Design has been carried out as per IS: 10262-2019

TARGET STRENGTH FOR MIX PROPORTIONING

Or

where
f’ ck = target average compressive strength at 28 days,
f ck = characteristic compressive strength at 28 days, and
s = standard deviation
X = factor based on grade of concrete

From Table 2, standard deviation, s = 4 N/mm²

From Table 1, factor based on grade of concrete, X = 5.5

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Therefore, target strength using both equations, that is,

a)
= 25 + 1.65 x 4 = 31.6 N/mm²
b)
= 25 + 5.5 = 30.5 N/mm²

The higher value is to be adopted. Therefore, target strength will be 31.6 N/mm²
as 31.6N/mm² > 30.5N/mm².

APPROXIMATE AIR CONTENT

From Table 3, the approximate amount of entrapped air to be expected in normal (non-air-
entrained) concrete is 1 percent for 20mm nominal maximum size of aggregate.

SELECTION OF WATER-CEMENT RATIO

From Fig.1, the free water-cement ratio required for the target strength of 31.6 N/mm² is 0.48 for
OPC 43 grade curve. This is lower than the maximum value of 0.5 prescribed for ‘Moderate’
exposure for reinforced concrete as per Table 5 of IS 456.
0.48 <0.50
Water-cement ratio seclected = 0.45

Trial Mix.I

SELECTION OF WATER CONTENT

From Table 4, water content = 186.0 kg
(for 50 mm slump) for 20 mm aggregate

Estimated water content for 100mm slump

= 186 + (( 6 x 186)/ 100)
= 197.2 kg

As superplasticizer is used, the water content may be reduced. Based on trial data, the water
content reduction of 18 percent is considered for the type of superplasticizer used.

Hence, the water content

= 197.16 x 0.82
= 162 kg

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CALCULATION OF CEMENT CONTENT
Water-cement ration = 0.45
Cemenet content = = 162 / 0.45 = 360 kg

From Table 5 of IS 456, minimum cement content for “Moderate “ exposure condition =300 kg
360 kg/m³ > 300 kg/m³, hence, OK

Cement content selected = 370.0 kg

Therefore, revised water content = 167.0 kg

PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE AGGREGATE

CONTENT
From Table 5, the proportionate volume of coarse aggregate corresponding to 20mm size
aggregate and fine aggregate (Zone-II) for water-cement ratio of 0.50 = 0.62

In the present case water-cement ration is 0.45. Therefore, volume of coarse aggregate is required
to be increased to decrease the fine aggregate content.
As the water-cement ratio is lower by 0.05, the proportion of volume of coarse, aggregate is
increased by 0.01 (at the rate of ≠ 0.01 for every ± 0.05 change in water-cement ratio).
Therefore, corrected proportion of volume of coarse aggregate for the water-cement ratio of
0.45 = 0.62 + 0.01 = 0.63

Therefore volume of coarse aggregate = 0.630

Volume of fine aggregate content = 1 – 0.63 = 0.37

MIX CALCULATIONS
The mix calculations per unit volume of concrete shall be as follows
a) Volume of concrete : 1.0 m³
b) Volume of entrapped air in wet concrete : 0.01 m³
c) Volume of cement : 0.119 m³
d) Volume of water : 0.167 m³
e) Volume of chemical admixture : 0.0027 m³
(Super-plasticizer) @ 0.8% by mass of cement
f) Volume of all in aggregate : 0.701 m³
g) Mass of coarse aggregate : 1271.8 kg
h) Mass of fine aggregate : 689.9 kg

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MIX PROPORTIONS FOR TRIAL MIX I
Cement : 370 kg/m³
Water : 167.0 litre
Fine aggregate : 690 kg/m³
Coarse aggregate : 1272 kg/m³
Chemical admixture : 2.96 kg/m³
Water-cement ratio : 0.45

The mix proportions are to be adjusted for free moisture of fine aggregate and moisture absorption

Six Cubes were cast at the laboratory.

The characteristics of fresh mix are as follows
Slump : 100 mm After 3 Hrs.
Colour : Whitish grey
Consistency : Less-Cohesive slight bleeding is observed.
Average 7 day cube compressive strength = 25.1 MPa was obtained.
Average 28 day cube compressive strength = 35.3 MPa was obtained.

Trial Mix.II

Water-cement ratio changed to = 0.48

Cement content selected = 370.0 kg
Therefore, revised water content = 178.0 kg

From Table 5, the proportionate volume of coarse aggregate corresponding to 20mm size
aggregate and fine aggregate (Zone-II) for water-cement ratio of 0.50 = 0.62

In the present case water-cement ration is 0.48. Therefore, volume of coarse aggregate is required
to be increased to decrease the fine aggregate content.
As the water-cement ratio is lower by 0.02, the proportion of volume of coarse, aggregate is
increased by 0.004 (at the rate of ≠ 0.01 for every ± 0.05 change in water-cement ratio).
Therefore, corrected proportion of volume of coarse aggregate for the water-cement ratio of
0.48 = 0.62 + 0.004 = 0.624

Therefore volume of coarse aggregate = 0.624

Volume of fine aggregate content = 1 – 0.624 = 0.376

MIX CALCULATIONS
The mix calculations per unit volume of concrete shall be as follows
a) Volume of concrete 1.0 m³
b) Volume of entrapped air in wet concrete 0.01 m³
c) Volume of cement 0.119 m³
d) Volume of water 0.178 m³

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e) Volume of chemical admixture 0.0025 m³
(Super-plasticizer) @ 0.75% by mass of cement
f) Volume of all in aggregate 0.690 m³
g) Mass of coarse aggregate 1240.2 kg
h) Mass of fine aggregate 690.2 kg

MIX PROPORTIONS FOR TRIAL MIX II

Cement 370 kg/m³
Water 178.0 litre
Fine aggregate 690 kg/m³
Coarse aggregate 1240 kg/m³
Chemical admixture 2.78 kg/m³
Water-cement ratio 0.48

The mix proportions are to be adjusted for free moisture of fine aggregate and moisture absorption

Six Cubes were cast at the laboratory.

The characteristics of fresh mix are as follows
Slump : 115 mm After 3 Hrs.
Colour : Whitish grey
Consistency : Less-Cohesive slight bleeding is observed.
Average 7 day cube compressive strength = 22.5 MPa was obtained.
Average 28 day cube compressive strength = 30.4 MPa was obtained.

Trial Mix.III

Water-cement ratio changed to = 0.42

Cement content selected = 370.0 kg
Therefore, revised water content = 155.0 kg

From Table 5, the proportionate volume of coarse aggregate corresponding to 20mm size
aggregate and fine aggregate (Zone-II) for water-cement ratio of 0.50 = 0.62

In the present case water-cement ration is 0.42. Therefore, volume of coarse aggregate is required
to be increased to decrease the fine aggregate content.
As the water-cement ratio is lower by 0.08, the proportion of volume of coarse, aggregate is
increased by 0.016 (at the rate of ≠ 0.01 for every ± 0.05 change in water-cement ratio).
Therefore, corrected proportion of volume of coarse aggregate for the water-cement ratio of
0.42 = 0.62 + 0.016 = 0.636

Therefore volume of coarse aggregate = 0.636

Volume of fine aggregate content = 1 – 0.636 = 0.364

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MIX CALCULATIONS
The mix calculations per unit volume of concrete shall be as follows
a) Volume of concrete 1.0 m³
b) Volume of entrapped air in wet concrete 0.01 m³
c) Volume of cement 0.119 m³
d) Volume of water 0.155 m³
e) Volume of chemical admixture 0.0025 m³
(Super-plasticizer) @ 0.9% by mass of cement
f) Volume of all in aggregate 0.713 m³
g) Mass of coarse aggregate 1306.2 kg
h) Mass of fine aggregate 690.5 kg

MIX PROPORTIONS FOR TRIAL MIX III

Cement 370 kg/m³
Water 155.0 litre
Fine aggregate 690 kg/m³
Coarse aggregate 1306 kg/m³
Chemical admixture 3.33 kg/m³
Water-cement ratio 0.42

The mix proportions are to be adjusted for free moisture of fine aggregate and moisture absorption

Six Cubes were cast at the laboratory.

The characteristics of fresh mix are as follows
Slump : 95 mm After 3 Hrs.
Colour : Whitish grey
Consistency : Less-Cohesive slight bleeding is observed.
Average 7 day cube compressive strength = 30.8 MPa was obtained.
Average 28 day cube compressive strength = 42.1 MPa was obtained.
The Mix-I is suggested for the M-25 grade concrete.
Note :Admixture dose may vary depending on climatic condition

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