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REPORT. NOGES /MD/GHD-8030/01, DATED: 03/05/2008

MIX DESIGN REPORT FOR M-40 GRADE OF

CONCRETE

CLIENTSIMPLEX INFRASTRUCTURES LIMITED

NAME OF WORKADANI POWER SHANDONG JOB, MUNDRA

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Material Taken 2000

Sieve Retained % Cum. % % OF

Size Material Retained Retained PASSING

mm gms

10mm 0 0 0.00 100.00 100

4.75mm 140.0 7.0 7.00 93.00 90-100

2.36mm 100.0 5.0 12.00 88.00 75-100

1.18mm 160.0 8.0 20.00 80.00 55-90

600m 468.0 23.4 43.40 56.60 35-59

300m 676.0 33.8 77.20 22.80 8-30

150m 364.0 18.2 95.40 4.60 0-10

75m 68.0 3.4 98.80 1.20

1976

FINENESS MODULUS : 2.55 ZONE : II Silt Content 1.20

SIEVE ANALYSIS

Material Taken gms 5000

Proportion 0.45

Sieve Retained % Of Retained % Of Retained % Of Sieve

Size Material Passing Material Passing Material Passing size

mm gms gms gms mm

80 0 100.00 0 100.00 0 100.00 80 100 -

63 0 100.00 0 100.00 0 100.00 63 100 -

40 0 100.00 0 100.00 0 100.00 40 100.00 100

20 480 90.40 0 100.00 0 100.00 20 95.68 95-100

16 4486 0.68 0 100.00 0 100.00 16 55.31 -

12.5 26 0.16 0 100.00 0 100.00 12.5 55.07 -

10 8 0.00 1368 72.64 0 100.00 10 39.95 25-55

4.75 0 0.00 3426 4.12 0 100.00 4.75 2.27 0-10

2.36 0 0.00 206 0.00 0 100.00 2.36 0.00 -

600m 0 0.00 0 0.00 0 100.00 600m 0.00 -150m 0 0.00 0 0.00 0 100.00 150m 0.00 -

5000 5000

Sand Kapachi Grit Metal Mix

34.7% 29.4% 35.9% 0.0% 100.0%

80mm 34.7% 29.4% 35.9% 0.0% 100.0%

40mm 34.7% 29.4% 35.9% 0.0% 100.0%

20mm 34.7% 26.5% 35.9% 0.0% 97.2%

4.75mm 32.3% 0.0% 1.5% 0.0% 33.8%

600m 19.7% 0.0% 0.0% 0.0% 19.7%150m 1.6% 0.0% 0.0% 0.0% 1.6%

Page 3

I.S.

Requirement

SIEVE ANALYSIS OF SAND :

0-6

I.S. Requirement

For 40mmSieve Size

95-100

30-50

10-35

100

I.S.

Requirement

for Zone I

All-in-Aggregate

KAPACHI : 20mm

Graded

Aggregate

5000

0.55

5000

0

GRIT : 10 mm METAL : 40 mm

100

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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/mm2 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 Extreme

Test Data of Materials:

1 Specific Gravity of Cement 3.15

2 Req. Compressive Strength of cement at 28 days, N/mm2 53

1

Page 1

CALCULATION SHEET OF M40 GRADE MIX DESIGN

(BASED ON - I.S. : 10262-1982, I.S. : 456-2000 & SP-23)

Sr.

No.

I.S. Requirement

(I.S. 8112 1990)ParameterTests

2

Consistency

Setting time

Initial, min

Final, min

3 Shall be more than 27 N/mm2

Shall be more than 37 N/mm2

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

25.51

34.697 days cured

--

Shall be more than 30 minutes

Shall be less than 600 minutes

3 days cured

30.50%

285

165

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3 SPECIFIC GRAVITY

i Coarse Aggregate, Metal 0.000ii 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/m3 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

ii Fineness Modulus 2.55

iii Silt Content % 1.20

Page 2

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12.50 25.51

17.00 34.69

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A Target Strength of Concrete

1 Tolerance Factor (Taking 1 in 20 acceptance of results)

2 Assumed Standard Deviation (Insert 10262 or 456)

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

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

Hence, Standard Deviation for TMS

Target mean Strength after 28 days N/mm2

B Selection of Water Cement Ratio

C Selection of Water & Sand content

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

i) Water content Lit/m3

ii) Sand content %

Adj. Req. Changes

1 Each 0.05 inc./ dec. in water cement ratio 0 0

2 Inc./dec. in compacting Factor by 0.1 +/- 3% 3

3 Zone confirmation for Sand 0 0

TOTAL 3

D Sand required as % of total aggregate by absolute volume

E Required Water Content, Kg/m3

F Required Cement Content, Kg/m3 9.27 Bags

i Determination of Metal Content 0.0

ii Determination of Kapachi Content Kg 0.45

iii Determination of Grit Content Kg 0.55

G Determination of Fine Aggregate Content Kg

Page 4

1.65

456

6.6

5.0

0

Sand %

Adj req. Changes

+/- 1%

0 0

1.0

1.0

+1.5% for Zone I

-1.5% for Zone III

-3% for Zone IV

5.0

48.25

0.4

180

35

620.00

0.36

185.40

463.50

0.00

1164.4

Change in ConditionSr.

No.

523.97

640.41

Water Content %

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H MIX PROPORTIONS ARE:

Metal Kapachi Grit

By weight 185.40 463.50 620.00 0.00 524.0 640.41

0.4 1 1.34 0.00 1.13 1.38

By Volume 0.4 1 1.31 0.00 1.16 1.40

By weight 20 50 66.88 0.00 56.52 69.08

I Extra quantity of water to be added for absorption in case of coarse 0.24

aggregate, by mass

J Quantity of water to be deducted for free moisture present in sand, 0.67

by mass

K Actual quantity of proportions required are :

19.57 50.00 67.55 0.00 56.42 68.95

0.391 1.00 1.35 0.00 1.13 1.38

0.391 1.00 1.33 #DIV/0! 1.16 1.40

Page 5

By Volume

Coarse Aggregate

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

Water Cement Sand

By weight

Proportion

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Metal Kapachi Grit

20.00 50 66.88 0.00 56.52 69.08

--- 0 1466 0 1401 1422

--- 0.0345 0.045 0.000 0.040 0.048

--- 1 Bag 1.60 0.00 1.41 1.70

--- --- 1.28 0.00 1.13 1.36

--- --- --- --- --- ---

Cement SandCoarse Aggregate

Proportion

(1 X 1 X 1.25)

Water

Weight Batch

Density

Per M3

Per Ft3

Per Farma

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38.6

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3.85

3.86

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DESIGN PROPORTION

S. N.

2

3

4

5

Note:

1

For GEO ENGINEERING SERVICES

Authorized Signatory

1.38WEIGHT

1

115

Density,

gm/cc

2.521

TRIAL

MIX

8.51

CEMENTPROPORTION

BY

Slump observed, mm

Cement

Consumption

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.

Grit-10mm

DN

Kapchi-

20mm DN

SAND

Parameters

W.C. Ratio

TM 1

Water Content, lit/cum

bags

463.50

9.27

0.4

Plasticizer, ml / Bag of Cement 400.00

185.40

Kg/m3

TRIAL

MIX

4

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

a lied at site.

The gradation requirement of single size aggregate and all in aggregate shall be

checked on site to match the design criteria.

11

1

1.34 1.13

COARSE AGGREGATE

1.161.40

8.53

VOLUME

COMPRESSIVE STRENGTH OF 150 mm SIZE OF CUBE- 3 & 7 Days Curing

Weight in

kg

5This 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

Design of Mix has been carried out with the materials supplied by the client.emen consump on n e may vary as er ve n es gn m x ecause o var ous

factors like bulking of sand, compaction factor, change in gradation of aggregates2

3

Observed

Load, kN

Compressive

Strength at 3 days,

N/mm2

1.31

680.00 30.22

2.530

8.52 2.524 835.00 37.11

2.527 695.00

685.00

30.89

30.44

36.89

36.67

1

Compressive

Strength at 7 days,

N/mm2

Weight in

kg

Density,

gm/cc

Observed

Load, kN

8.5 2.519 825.00

8.54

2.527 830.008.53

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TABLE NO. 1 Where Freezing & Thawing action prevailsNominal Max. Size o Nominal Max. Size of

Note : Suitable Air - Entering Agent to be used

TABLE NO. 3

Min cement Max w/c Minimum Min cement Max w/c Minimum

content ratio Grade of content ratio Grade of

Kg/m Concrete Kg/m Concrete

MILD 220 0.6 ---- 300 0.55 M 20

MODERATE 240 0.6 M 15 300 0.5 M 25

SEVERE 250 0.5 M 20 320 0.45 M 30

VERY SEVERE 260 0.45 M 20 340 0.45 M 35

EXTREME 280 0.4 M 25 360 0.4 M40

Surface of members in tidal

zone. Members in direct

contact with liquid/solid

aggressive chemicals.

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.

Reinforced concretePlain concrete

Exposure

Concrete surfaces exposed to

sea water spray, corrosive

fumes or severe freezingconditions whilst wet. Concrete

in contact with or buried under

aggressive sub-soil/ground

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

Aggregate. mm of concrete

10 3

trapped Air, as % of vo

Aggregate. mm of concrete

5 + 1

ntrapped Air, as % of vol.

4 + 1

20

40

Concrete surfaces protected

against weather or gressive

conditions, except those

situated in coastal area.

20 2

40 1

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TABLE NO. 6 Approximate sand & water contents per m3 of concrete

for grades upto M35

Nominal maximum Water content / m3 Sand as % of total agg.

size of aggregate, m of concrete by absolute volume

10 208 40

20 186 35

40 165 30

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TABLE NO. 2 : WORKABILITY OF CONCRETE TABLE

C.F. Slump

mm

0.75--0.8 ----

0.8--0.85 25 - 75

M 5M7.5

M 10

M 15

M 20

0.85--0.92 50 - 100

75 - 100

Above .92 100 - 150

By Flow Value

TABLE NO. 4 TABLE NO. 5Grade of

Concrete

M10 3.5

M15 3.5

10 M20 4.0

20 M25 4.0

40 M30 5.0

M35 5.0

M40 5.0

TABLE NO. 7

SUGGESTED VALUES OF STANDARD DEVIATION

GRADE OF DIFFERENT DEGREE OF CONTROL

CONCRETE VERY GOOD GOOD FAIR

M10 2.0 2.3 3.3

M15 2.5 3.5 4.5

M20 3.6 4.6 5.6

M25 4.3 5.3 6.3

M30 5.0 6.0 7.0

M35 5.3 6.3 7.3

M40 5.6 6.6 7.6

M45 6.0 7.0 8.0

M50 6.4 7.4 8.4M55 6.7 7.7 8.7

M60 6.8 7.8 8.8

Nominal

Maximum

Aggregate Size

Adjustments to Minimum

Cement Contents in Table -

3 kg/sq.cm

+40

0

-30

Grade of

ConcreteDegree of Workability Values of Workability

Assumed Standard

Deviation, N/mm2

Placing Conditions

Very Low

High

Blinding concrete; Shallow

sections; Pavements using pavers

Mass concrete; Lightly reinforced

sections in slabs, beams, walls,columns; Floors; Hand placed

pavements; Canal lining; Strip

footings

beams, walls, columns; slipform

work; Pumped concrete

Trench fill; In situ piling

Heavily reinforced sections in

slabs,

Low

Medium

Very HighTremie concrete

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O. 6 : Proportions for Nominal Mix Concrete

800 60625 45

480 34

330 32

250 30

Generally 1 : 2 but

subject to an upper

limit of 1 : 1.5 and a

lower limit of 1 : 2.5

Total Quantity of Dry

Aggregates by Mass per

50kg of Cement, to be taken

as the Sum of the Individual

Masses of Fine and Coarse

Aggregates, kg (Max)

Proportions of Fine

Aggregate to Coarse

Aggregate (by mass)

Quantity of Water per

50kg of Cement,

Max