Sawla - Kako Road Construction Project

Contract 2: 70+400 - 122+768

Employer Consultant Contractor

Metaferia Consulting
Blue Nile Construction Share
Ethiopian Roads Authority Engineers in JV with Company
National Engineers

Trial One Mix Design for Class'C' concrete

Concrete Grade = Class'C' concrete (C - 20)

Mix design:- (for 1m3 of concrete)

Cement (OPC Maple Leaf) = 320.0 kg/m3
Fine Aggregate(Aluma Sand) = 814.38 kg/m3
Coarse aggregate (37.5mm) = 593.54 kg/m3
Coarse aggregate (10mm) = 475.30 kg/m3
Slump (consistency) = 25-75 mm
Sand saturated surface dry density (SSD) = 2.640
Fine Aggregate(Sand) bulk specific gravity = 2.580
Fine Aggregate(Sand) unit weight (loose) = 1510 kg/m3
Coarse Aggregate(37.5 mm) bulk specific gravity = 2.78
Coarse Agg.(37.5mm) Saturated surface dry den. (SSD) = 2.83
Coarse Aggregate(37.5 mm) unit weight (loose) = 1520 kg/m3
Coarse Aggregate(10mm) bulk specific gravity = 2.72
Coarse Agg.(10mm) Saturated surface dry den. (SSD) = 2.77
Coarse Aggregate(10mm) unit weight (loose) = 1470 kg/m3
Usual Specific gravity of cement = 3.15
Approximate water content = 206.6 kg/m3
Box Size Determination for Hand Mixing
Cement(OPC Maple Leaf Pakistan) 50.0 kg = 1 bag
3
Fine Aggregate(Aluma Sand) 127.25 kg = 0.0843 m 2 box of size(m)= 0.40 0.50 0.21
Coarse Aggregate(37.5mm) 92.74 0.061 2 box of size(m)= 0.40 0.50 0.16
Coarse Aggregate(10mm) 74.27 Kg = 0.051 m 3
1 box of size(m)= 0.40 0.50 0.25
Lab Batch Mix Dessign:-
Volume of cylinderical mold = 0.0053 m3
Total Volume of Concrete in the mold = 0.0424 m3
Requred Quantity of Ingredients of Concrete for Lab Batch Mix Design:-
Cement(OPC Maple Leaf) = 13.57 kg
Fine Aggregate(Aluma Sand) = 34.53 kg
Coarse Aggregate(37.5) = 25.17 kg
Coarse Aggregate(10) = 20.15 kg
Approximate water content = 8.76 Lt.

PREPARED BY CHECKED BY APPROVED BY

__________ ___________ ____________
Cont.Matr'l.Eng. Cons.Lab.Technician Cons.Matr'l.Eng.

Date__________ Date__________ Date__________

 Sawla - Kako Road Construction Project
Contract 2: 70+400 - 122+768

Employer Consultant Contractor

Metaferia Consulting
Blue Nile Construction Share
Ethiopian Roads Authority Engineers in JV with Company
National Engineers

Trial Two Mix Design forClass'C' concrete

Concrete Grade = Class'C' concrete(C - 20)

Mix design:- (for 1m3 of concrete)

Cement (OPC Maple Leaf) = 340 kg/m3
Fine Aggregate(Aluma Sand) = 710 kg/m3
Coarse aggregate (37.5mm) = 690 kg/m3
Coarse aggregate (10mm) = 460 kg/m3
Slump (consistency) = 25-75 mm
Sand saturated surface dry density (SSD) = 2.640
Fine Aggregate(Sand) bulk specific gravity = 2.580
Fine Aggregate(Sand) unit weight (loose) = 1510 kg/m3
Combined Coarse Aggregate(37.5 & 10) bulk specific gravity = 2.72
Combined Coarse Agg.(37.5 &10) Saturated surface dry den. (SSD) = 2.76
Combined Coarse Aggregate(37.5 & 10) unit weight (loose) = 1520 kg/m3
Usual Specific gravity of cement = 3.15
Approximate water content = 197.2 kg/m3
Box Size Determination for Hand Mixing
Cement(OPC Maple Leaf Pakistan) 50.0 kg = 1 bag
Fine Aggregate(Aluma Sand) 104.41 kg = 0.0691 m3 2 box of size(m)= 0.40 0.50 0.17
3
Combined Coarse Aggregate 169.12 Kg = 0.111 m 3 box of size(m)= 0.40 0.50 0.19
Lab Batch Mix Dessign:-
Volume of cylinderical mold = 0.0053 m3
Total Volume of Concrete in the mold = 0.0424 m3
Requred Quantity of Ingredients of Concrete for Lab Batch Mix Design:-
Cement(OPC Maple Leaf) = 14.42 kg
Fine Aggregate(Aluma Sand) = 30.10 kg
Coarse Aggregate(37.5) = 29.26 kg
Coarse Aggregate(10) = 19.50 kg
Approximate water content = 8.36 Lt.

PREPARED BY CHECKED BY APPROVED BY

__________ ___________ ____________
Cont.Matr'l.Eng. Cons.Lab.Technician Cons.Matr'l.Eng.

Date__________ Date__________ Date__________

 THE FEDERAL DEMOCRATIC REPUBLIC OF ETHIOPIA
ETHIOPIAN ROAD AUTHORITY
Sawla kako Gravel road projecct , Contract 2 From km (70+400 to 122+678.127)

Analysis of Trial Mix Design for Class'C' Concrete by Absolute Volume Basis
Concrete Grade = Class'C' (C-20)
Required average strength = 20.0MPa
Target average strength = 27.0MPa
Required Slump (consistency) = 25-75 mm
Combined maximum size aggregate = 37.5mm
Specific gravity of cement = 3.15
Dry Roaded mass of coarse agg(37.5mm) = 1660kg/m3
Dry Roaded mass of coarse agg(10mm) = 1530kg/m3
Bulk specific gravity of coarse aggregate(37.5mm) = 2.78
Saturated surface dry dens. (SSD) of coarse aggregate(37.5mm) = 2.83
Bulk specific gravity of coarse aggregate(10mm) = 2.72
Saturated surface dry dens. (SSD) of coarse aggregate(10mm) = 2.77
Bulk specific gravity of fine aggregate(sand) = 2.58
Saturated surface dry dens.(SSD) of fine aggregate(sand) = 2.64
Apsorption of coarse aggregate(37.5mm) = 1.60%
Apsorption of coarse aggregate(10mm) = 1.69%
Apsorption of fine aggregate(sand) = 2.03%
Moisture content of coarse aggregate(37.5mm) = 0.60%
Moisture content of coarse aggregate(10mm) = 0.70%
Moisture content of fine aggregate(sand) = 0.79%
Loose unit weight of blended coarse aggregate = 1520kg/m3
Loose unit weight of coarse aggregate(37.5mm) = 1450kg/m3
Loose unit weight of coarse aggregate(10mm) = 1470kg/m3
Loose unit weight of fine aggregate(sand) = 1510kg/m3
Finess moduless of fine aggrgate (sand) = 2.83
Estimate of Water and Cement Content
Approximate mixing water content for slump 25 to 75mm = 186Lt./m3
From ACI Table A1.5.3.3, (207+166) = 186Lt.
2
From ACI Table A1.5.3.4(A),
The water-cement ratio for non-air-entrained concrete with strength of 27.0MPa =0.58
The required cement for mixing = 186/0.58 = 320kg/m3
So, let we use a maple-leaf cement of 320kg for 1m3 of concrete

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 Blending of Coarse Aggregate and Fine Aggregate(Sand)
Coarse Aggregate = 50%
Coarse Aggregate(37.5mm size) = 50%
Coarse Aggregate(10mm size) = 40%
Fine Aggregate = 10%

Specified
Sieve Size (mm) Percentage Passing (%) Limit
L.env U.env
Test No.1 Test No.2 Average
37.50 100.00 100.00 100.00 100.0 100.0
25.00 92.93 91.02 91.97 80.0 100.0
20.00 74.59 71.03 72.81 55.0 100.0
9.50 59.19 52.84 56.01 45.0 75.0
4.75 49.32 47.92 48.62 35.0 60.0
2.36 42.49 41.98 42.24 27.0 45.0
1.18 30.73 31.53 31.13 20.0 35.0
0.60 20.22 21.32 20.77 12.0 25.0
0.30 7.85 8.01 7.93 5.0 15.0
0.15 1.60 1.78 1.69 1.0 5.0

Estimate of Coarse Aggregate and Fine Aggregate(Sand) content

Volume of coarse aggregate per unit volume of concrete =0.71 (from ACI Table A1.5.3.6)
The required dry mass of coarse aggregate = 0.71*1660 = 1180kg/m3
But we are going to use blended coarse aggregate of 60% from Agg(37.5mm) and 40% from Agg(10mm)
to produce 1m3 of concrete
i.e. Coarse aggregate(10mm size) = 40%*1180 = 472kg
Coarse aggregate(37.5mm size) = 50%*1180 = 590kg
Fine aggregate = 10*1180 = 118kg
Estimate of Fine Aggregate(Sand) content
The required fine aggregate will be determined on the basis of absolute volume as shown below:-
To calculate the mass of Fine Aggregate(Sand) we need first to
calculate the volume of all other ingredients:-
Volume of water = 186/1000 = 0.186m3
Volume of cement = 320/(3.15*1000) = 0.102m3
Volume of coarse aggregate(10) = 472/(2.72*1000) = 0.174m3
Volume of coarse aggregate(37.5) = 590/(2.78*1000) = 0.212m3
Volume of fine aggregate = 118/(2.58*1000) = 0..046m3
Volume of entrapped air = 1/100 = 0.01m3
Hence, total volume of ingredients except Fine Aggregate(Sand) = 0.73m3
Therefore, the required ingredients of fine Aggregate(sand) = 1 - 0.730 = 0.270m3
The required dry mass of fine Aggregate(Sand) = 0.272*(2.58*1000) = 690kg

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From the various steps, we can list the estimated mass of each of
the ingredients in kilograms per cubic meter of concrete as follows:-
Cement(OPC Maple-Leaf ) = 320.0kg
Fine Aggregate (Sand) = 808.0kg
Coarse Aggregate(37.5mm) = 590.0kg
Coarse Aggregate(10mm) = 472.0kg
Approximate water content = 186.0Lt.

Adjusted Aggregate masses for Moisture content

Coarse aggregate(37.5mm) = 590.0+ Wt. of moisture
= 590.0+(590.0*0.60/100) = 593.54kg
Coarse aggregate(10mm) = 472.0+ Wt. of moisture
= 472.0+ (472.0*0.34/100) = 475.30kg
Fine aggregate(sand) = 808.0+ Wt. of moisture
= 808.0+ (808.0*0.79/100 = 814.38kg
Water Absorbed by Aggregates
Water Absorbed by aggregates(37.5) = 1.60 - 0.6 = 1.0%
Water Absorbed by aggregates(10) = 1.69 - 0.70 = 0.99%
Water absorbed by fine aggregate(sand) = 2.03 - 0.79 = 1.24%
The estimated requirment for added water, therefore, becomes
186 + 590(0.01) + 472(0.0099) + 808(0.0124) = 206.6Lt.

The estimated mass of each of required ingredients in kilograms

per cubic meter of concrete as follows:-
Cement(OPC Maple-Leaf ) = 320.0kg
Fine Aggregate (Sand) = 814.38kg
Coarse Aggregate(37.5mm) = 593.54kg
Coarse Aggregate(10mm) = 475.30kg
Approximate water content = 206.6Lt.

Page 6 of 9
 Box Size Determination
Box size for sand
Loose unit weight of sand = 15100kg/m3
Volume of sand = Mass of sand = 814.38 = 0.539m3
Density of sand 1510.0
Hence, the total volume of wet sand to produce 1m3 of concrete = 0.539m3
Mix proportion for one bag (50kg) of cement:-
0.539m3 of sand = for 320kg of cement
X = for 50kg of cement
X = 0.539*50/320 = 0.084m3
Hence, the total volume of sand for one bag (50kg) of cement = 0.084m3
V = L*W*H

W
L
0.084 = 0.4*.05*H
H = 0.421m (For two boxes H = 0.21m)
Hence, we need two boxes of sand of size(40*50*21cm) for one bag(50kg) of cement

Box size for Coarse Aggregate(37.5mm)

Loose unit weight of Combined Coarse Aggregate = 1520kg/m3
Volume of Combined Coarse Agg= Mass of Corse Agg = 593.54 = 0.390m3
Density of Corse Agg 1520.0
Hence, the total volume of combined corse agg to produce 1m3 of concrete = 0.390m3

Mix proportion for one bag (50kg) of cement:-

0.390m3 of combined coarse Agg = for 320kg of cement
X = for 50kg of cement
X = 0.390*50/320 = 0.061m3
Hence, the total volume of combined coarse agg for one bag (50kg) of cement =0.061m3
V = L*W*H
0.061 = 0.4*.05*H
H = 0.31m ( For three boxes, H = 0.16m)
Hence, we need three boxes of combined coarse agg) of size(40*50*16cm) for one bag(50kg) of cement
Similarly, by using loose unit weight of Coarse Aggregate (10mm size) = 1470kg/m3,
The total volume of Coarse Agg(10mm) for one bag(50kg) of cement = 0.051m3
then, V = L*W*H
0.051 = 0.4*.05*H

Page 7 of 9
 H = 0.25m
For one bag of cement 2 box of size(cm)= 40.0 50.0 21.0 Fine aggregate(Sand)
2 box of size(cm)= 40.0 50.0 16.0 coarse Aggregate(37.5mm)
we need box size of :- 1 box of size(cm)= 40.0 50.0 25.0 coarse Aggregate(10mm)

Laboratory Batching Mix Design:-

Total volume of cylinderical mold = 0.0053m3
Total volume of concrete in the mold = 0.0424m3

Cylinder of size(Dia.= 15cm,H=30cm)

Required Quantity of Ingridients of Concrete for Lab Batch Mix Design

Estimate of Cement content

320kg cement = 1m3 of concrete
X = 0.0424m3 of concrete
X 0.0424*320 = 13.57kg
Estimate of Fine Aggregate(Sand)
814.38kg cement = 1m3 of concrete
X = 0.0424m3 of concrete
X = 0.0424*814.38 =34.53kg
Estimate of coarse aggregate(37.5mm size)
593.54kg cement = 1m3 of concrete
X = 0.0424m3 of concrete
X = 0.0424*593.54 =25.17kg
Estimate of Coarse Aggregate(10mm size)
475.30kg cement = 1m3 of concrete
X = 0.0424m3 of concrete
X = 0.0424*475.30 =20.15kg
Estimate of approximate water content
206.6kg cement = 1m3 of concrete
X = 0.0424m3 of concrete
X 0.0424*206.6= 8.73Lt.
Required ingredients to produce 0.0424m3 of concrete as follows:-

Cement(OPC Maple) = 13.57kg

fine Aggregate(Sand) = 34.53kg
Coarse Aggregate(37.5) = 25.17kg

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Coarse Aggregate(10) = 20.15kg
Approximate water content = 8.76Lt.

Note:- for the other trial mix designs exactly the same procedures are made to produce 1m 3 of concrete
within the required specification.

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