Mix Design- M40 - Modified 28 Days Ccs

MIX DESIGN REPORT FOR M-40 GRADE OF CONCRETE CLIENT SIMPLEX INFRASTRUCTURES LIMITED

NAME OF WORK ADANI POWER SHANDONG JOB, MUNDRA

REPORT. NO GES /MD/GHD-8030/01, DATED: 03/05/2008

SIEVE ANALYSIS OF SAND : Material Taken 2000 Sieve Retained % Cum. % % OF Size Material Retained Retained PASSING mm gms 0 10mm 0 0.00 100.00 140.0 4.75mm 7.0 7.00 93.00 100.0 2.36mm 5.0 12.00 88.00 160.0 1.18mm 8.0 20.00 80.00 468.0 600µ 23.4 43.40 56.60 676.0 300µ 33.8 77.20 22.80 150µ 364.0 18.2 95.40 4.60 68.0 75µ 3.4 98.80 1.20 1976 FINENESS MODULUS : 2.55 ZONE : SIEVE ANALYSIS KAPACHI : 20mm GRIT : 10 mm Material Taken gms 5000 5000 Proportion 0.45 0.55 Sieve Retained % Of Retained % Of Size Material Passing Material Passing mm gms gms 0 0 80 100.00 100.00 0 0 63 100.00 100.00 0 0 40 100.00 100.00 480 0 20 90.40 100.00 4486 0 16 0.68 100.00 26 0 12.5 0.16 100.00 8 1368 10 0.00 72.64 0 3426 4.75 0.00 4.12 0 206 2.36 0.00 0.00 0 600µ 0 0.00 0.00 0 150µ 0 0.00 0.00 5000 5000 All-in-Aggregate Grit Metal Sieve Size Sand Kapachi 39.7% 27.1% 33.2% 0.0% 80mm 39.7% 27.1% 33.2% 0.0% 40mm 39.7% 27.1% 33.2% 0.0% 20mm 39.7% 24.5% 33.2% 0.0% 4.75mm 36.9% 0.0% 1.4% 0.0% 600µ 22.5% 0.0% 0.0% 0.0% 150µ 1.8% 0.0% 0.0% 0.0%

I.S. Requirement for Zone I 100 90-100 75-100 55-90 35-59 8-30 0-10

II

Silt Content

METAL : 40 mm 5000 0 Retained % Of Material Passing gms 0 100.00 0 100.00 0 100.00 0 100.00 0 100.00 0 100.00 0 100.00 0 100.00 0 100.00 0 100.00 0 100.00

Mix 100.0% 100.0% 100.0% 97.4% 38.3% 22.5% 1.8%

Sieve size mm

Graded Aggregate

I.S. Requirement

80 63 40 20 16 12.5 10 4.75 2.36 600µ 150µ

100 100 100.00 95.68 55.31 55.07 39.95 2.27 0.00 0.00 0.00

-

I.S. Requirement For 40mm 100 100 95-100 30-50 10-35 0-6

1.20

-

100 95-100 25-55 0-10 -

Page 3

CALCULATION SHEET OF M40 GRADE MIX DESIGN (BASED ON - I.S. : 10262-1982, I.S. : 456-2000 & SP-23)

Design Stipulation: 1

Cement:

Sanghi 53 grade OPC

2

Coarse Aggregate Source:

3

Fine Aggregate Source:

4

Characteristic Strength required in the field at 28 days, N/mm

40

5

Maximum Size of aggregate, mm

20

6

Entraped air, %

0.02

7

Degree of Workability

0.90

8

Degree of Quality control

Good

9

Exposure

2

Extreme

Test Data of Materials: 1

Specific Gravity of Cement

2

Req. Compressive Strength of cement at 28 days, N/mm2

Sr. No. 1

Tests Consistency

3.15

Parameter

53

I.S. Requirement (I.S. 8112 – 1990)

30.50%

--

Initial, min

165

Shall be more than 30 minutes

Final, min

285

Shall be less than 600 minutes

Setting time 2

Compressive strength of mortar cubes (70.6mm size), in N/mm2

3

3 days cured

25.51

Shall be more than 27 N/mm2

7 days cured

34.69

Shall be more than 37 N/mm2

Page 1

3

SPECIFIC GRAVITY

i

Coarse Aggregate, Metal

0.000

ii

Coarse Aggregate, Kapachi

2.810

iii

Coarse Aggregate, Grit

2.810

iv

Fine Aggregate

2.660

4

BULK DENSITY

i

Cement

Kg/m3

1440

ii

Metal

Kg/m

0

iii

Kapachi

Kg/m3

1401

iv

Grit

Kg/m3

1422

v

Sand

Kg/m3

1466

5

Water Absorption

i

Coarse Aggregate

%

0.19

ii

Fine Aggregate

%

1.05

6

Free Surface Moisture

i

Coarse Aggregate

%

Nil

ii

Fine Aggregate

%

1.0

7

Sieve Analysis-Sand

i

ZONE (1, 2, 3 or 4)

ii

Fineness Modulus

2.55

iii

Silt Content %

1.20

3

II

Page 2

12.50

25.51

17.00

34.69

A

Target Strength of Concrete

1

Tolerance Factor (Taking 1 in 20 acceptance of results)

1.65

2

Assumed Standard Deviation (Insert 10262 or 456)

456

Accor. To I.S. 10262 (Table no.7)

6.6

Accor. To I.S. 456 (Table no. 5)

5.0

Hence, Standard Deviation for TMS

5.0

Target mean Strength after 28 days B

Selection of Water Cement Ratio

C

Selection of Water & Sand content

48.25

N/mm2

0.4

For 20mm max. size of aggregate and sand confirming to zone - IV i)

Water content

Lit/m3

174

ii)

Sand content

%

40

Sr. No.

Change in Condition

1

Each 0.05 inc./ dec. in water cement ratio

2

Inc./dec. in compacting Factor by 0.1

3

Zone confirmation for Sand

Water Content %

Sand %

Adj. Req.

Changes

Adj req.

Changes

0

0

+/- 1%

1.0

+/- 3%

3

0

0

0

0

+1.5% for Zone I

0

-1.5% for Zone III -3% for Zone IV

TOTAL

3

1.0

D

Sand required as % of total aggregate by absolute volume

0.41

E

Required Water Content, Kg/m3

179.22

F

Required Cement Content, Kg/m3

448.05

i

Determination of Metal Content

ii

Determination of Kapachi Content

iii

Determination of Grit Content

0.0

0.00

Kg

0.45

491.31

Kg

0.55

600.49 1091.8

G

Determination of Fine Aggregate Content

Kg

718.21

8.96 Bags

Page 4

H

MIX PROPORTIONS ARE: Proportion By weight

By Volume

Water

Cement

Sand

179.22

448.05

0.4 0.4

Coarse Aggregate Metal

Kapachi

Grit

718.21

0.00

491.3

600.49

1

1.60

0.00

1.10

1.34

1

1.57

0.00

1.13

1.36

For 1bag of Cement, the Quantities of Materials are : By weight

I

20

50

80.15

0.00

54.83

67.01 0.23

Extra quantity of water to be added for absorption in case of coarse aggregate, by mass

J

0.80

Quantity of water to be deducted for free moisture present in sand, by mass

K

Actual quantity of proportions required are :

19.43

50.00

80.95

0.00

54.72

66.88

By weight

0.389

1.00

1.62

0.00

1.09

1.34

By Volume

0.389

1.00

1.59

#DIV/0!

1.12

1.35

Page 5

Proportion

Water

Cement

Sand

Weight Batch

20.00

50

Density

---

Per M3

Coarse Aggregate Metal

Kapachi

Grit

80.15

0.00

54.83

67.01

0

1466

0

1401

1422

---

0.03

0.054

0.000

0.039

0.047

Per Ft3

---

1 Bag

1.92

0.00

1.37

1.65

Per Farma

---

---

1.53

0.00

1.10

1.32

(1 X 1 X 1.25)

---

---

---

---

---

---

38.6

4.04

4.05

DESIGN PROPORTION Design of Mix is based on the properties of individual materials. Three different trials with the adjustment in the W/C ratio and sand percentage are worked out and the result of the best mix is presented below. Parameters

S. N.

Cement Consumption

1

TM 1 Kg/m

448.05

bags

8.96

3

2

W.C. Ratio

0.4

3

Slump observed, mm

115

4

Water Content, lit/cum

179.22

5

Plasticizer, ml / Bag of Cement

400.00 COARSE AGGREGATE

PROPORTION TRIAL MIX BY 1

CEMENT

SAND

Grit-10mm DN

Kapchi20mm DN

WEIGHT

1

1.60

1.34

1.10

VOLUME

1

1.57

1.36

1.13

COMPRESSIVE STRENGTH OF 150 mm SIZE OF CUBE- 3 & 7 Days Curing Density, gm/cc

Observed Load, kN

Compressive Strength at 3 days, N/mm2

8.51

2.521

680.00

30.22

8.53

2.527

695.00

30.89

8.54

2.530

685.00

30.44

Weight in kg

Density, gm/cc

Observed Load, kN

Compressive Strength at 7 days, N/mm2

8.52

2.524

835.00

37.11

8.53

2.527

830.00

36.89

8.5

2.519

825.00

36.67

Weight in kg

Density, gm/cc

Observed Load, kN

Compressive Strength at 28 days, N/mm2

8.56

2.536

1130.00

50.22

8.55

2.533

1195.00

53.11

8.53

2.527

1180.00

52.44

Weight in TRIAL MIX kg

1

Note: 1 2 3

Design of Mix has been carried out with the materials supplied by the client. Cement consumption in field may vary as derived in design mix because of various factors like bulking of sand, compaction factor, change in gradation of aggregates etc. Design is based on the surface dry saturated fine aggregates and hence, adjustments for water absorption and free surface moisture (i.e. for bulking of sand) shall be applied at site.

4

The gradation requirement of single size aggregate and all in aggregate shall be checked on site to match the design criteria.

5

This report shall not be reproduced in full or in part unless written permission for the publication has been obtained from the Geo Engineering Services, Gandhidham

For GEO ENGINEERING SERVICES Authorized Signatory

Where Freezing & Thawing action prevails TABLE NO. 1 Nominal Max. Size of Entrapped Air, as % of vol. Nominal Max. Size of Entrapped Air, as % of vol. Aggregate. mm of concrete Aggregate. mm of concrete 10 3 20 2 20 5+1 40 1 40 4+1 Note : Suitable Air - Entering Agent to be used

TABLE NO. 3 Exposure MILD Concrete surfaces protected against weather or gressive conditions, except those situated in coastal area.

Plain concrete Reinforced concrete Min cement Max w/c Minimum Min cement Max w/c Minimum content ratio Grade of content ratio Grade of Kg/m3 Concrete Kg/m3 Concrete 220 0.6 ---300 0.55 M 20

MODERATE Concrete surfaces sheltered from severe rain or freezing whilst wet. Concrete exposed to condensation and rain. Concrete continuously under water. Concrete in contact or buried under non aggressive soil/ground water. Concrete surfaces sheltered from s

240

0.6

M 15

300

0.5

M 25

SEVERE Concrete surfaces exposed to severe rain, alternate wetting and dryng or occasional freezing whilst wet or severe condensation. Concrete completely immersed in sea water. Concrete exposed to coastal environment.

250

0.5

M 20

320

0.45

M 30

VERY SEVERE Concrete surfaces exposed to sea water spray, corrosive fumes or severe freezing conditions whilst wet. Concrete in contact with or buried under aggressive sub-soil/ground water.

260

0.45

M 20

340

0.45

M 35

EXTREME Surface of members in tidal zone. Members in direct contact with liquid/solid aggressive chemicals.

280

0.4

M 25

360

0.4

M40

TABLE NO. 6 Approximate sand & water contents per m3 of concrete for grades upto M35 Nominal maximum Water content / m3 size of aggregate, mm of concrete 10 208 20 186 40 165

Sand as % of total agg. by absolute volume 40 35 30

TABLE NO. 2 : WORKABILITY OF CONCRETE Placing Conditions

Degree of Workability

Blinding concrete; Shallow sections; Pavements using pavers

Very Low

Mass concrete; Lightly reinforced sections in slabs, beams, walls, columns; Floors; Hand placed pavements; Canal lining; Strip footings

Low

Heavily reinforced sections in slabs, beams, walls, columns; slipform work; Pumped concrete

Medium

0.8--0.85

0.85--0.92

High

Above .92

Very High

100 - 150 By Flow Value

Grade of Concrete M10 M15 M20 M25 M30 M35 M40

+40 0 -30

TABLE NO. 7 SUGGESTED VALUES OF STANDARD DEVIATION

M10 M15 M20 M25 M30 M35 M40 M45 M50 M55 M60

50 - 100

TABLE NO. 5

Nominal Adjustments to Minimum Maximum Cement Contents in Table Aggregate Size 3 kg/sq.cm 10 20 40

DIFFERENT DEGREE OF CONTROL VERY GOOD GOOD FAIR 2.0 2.5 3.6 4.3 5.0 5.3 5.6 6.0 6.4 6.7 6.8

Grade of Concrete

25 - 75

75 - 100

TABLE NO. 4

GRADE OF CONCRETE

Values of Workability C.F. Slump mm 0.75--0.8 ----

M5 M7.5 M 10 M 15 M 20

Trench fill; In situ piling Tremie concrete

TABLE NO. 6 : Propor

2.3 3.5 4.6 5.3 6.0 6.3 6.6 7.0 7.4 7.7 7.8

3.3 4.5 5.6 6.3 7.0 7.3 7.6 8.0 8.4 8.7 8.8

Assumed Standard Deviation, N/mm2 3.5 3.5 4.0 4.0 5.0 5.0 5.0

LE NO. 6 : Proportions for Nominal Mix Concrete Total Quantity of Dry Proportions of Fine Quantity of Water per Aggregates by Mass per Aggregate to Coarse 50kg of Cement, 50kg of Cement, to be taken Aggregate (by mass) Max as the Sum of the Individual Masses of Fine and Coarse Aggregates, kg (Max) 800 625 480 330 250

Generally 1 : 2 but subject to an upper limit of 1 : 1.5 and a lower limit of 1 : 2.5

60 45 34 32 30