REPORT ON CONCRETE MIX DESIGN

Date: 12.05.2020
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-20
b) Type of Cement : PSC (JSW)
c) Maximum nominal size of aggregate : 20 mm
d) Exposure condition : Mild
e) Minimum cement content : 300 kg/m³
f) Maximum water-cement ratio : 0.55
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 : SikaPlast 5202 NS 2 Batch No KB20000636
l) Sand : Source West Medinipur
m) Water : Source Garh Bhawanipur, Howrah

TEST DATA FOR MATERIALS

a) Cement used : PSC (JSW)
b) Specific gravity of cement : 2.98
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 Permissible
for Different Sizes of
Size Grading % Limit (% Remarks
Aggregates
(mm) Finer 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
20.0mm as per
10.00 3.50 54.25 28.88 25-55
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)
= 20 + 1.65 x 4 = 26.6 N/mm²
b)
= 20 + 5.5 = 25.5 N/mm²

The higher value is to be adopted. Therefore, target strength will be 26.6 N/mm²
as 26.6N/mm² > 25.5N/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 26.6 N/mm² is 0.54 for
OPC 43 grade curve. This is lower than the maximum value of 0.55 prescribed for ‘Mild’
exposure for reinforced concrete as per Table 5 of IS 456.
0.54 <0.55
Water-cement ratio seclected = 0.47

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 = 0.47
Cemenet content = = 162 / 0.47 = 345 kg

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

Cement content selected = 350.0 kg

Therefore, revised water content = 165.0 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 0.47. Therefore, volume of coarse aggregate is required
to be increased to decrease the fine aggregate content.
As the water-cement ratio is lower by 0.03, the proportion of volume of coarse, aggregate is
increased by 0.0061 (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
0.47 = 0.62 + 0.0061 = 0.6261

Therefore volume of coarse aggregate = 0.626

Volume of fine aggregate content = 1 – 0.6261 = 0.3739

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 : 0.117 m³
d) Volume of water :: 0.165 m³
e) Volume of chemical admixture : 0.0019 m³
(Super-plasticizer) @ 0.6% by mass of cement
f) Volume of all in aggregate : 0.706 m³
g) Mass of coarse aggregate : 1272.4 kg
h) Mass of fine aggregate : 701.8 kg

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MIX PROPORTIONS FOR TRIAL MIX : I
Cement : 350 kg/m³
Water : 165.0 litre
Fine aggregate : 702 kg/m³
Coarse aggregate : 1272 kg/m³
(20.0mm & 10.0mm aggregates are to be mixed in proportion of 50 : 50 by weight.)
Chemical admixture : 2.10 kg/m³
Water-cement ratio : 0.47

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

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 = 19.1 MPa was obtained.
Average 28 day cube compressive strength = 27.0 MPa was obtained.

Trial Mix.II : :

Water-cement ratio changed to = 0.50

Cement content selected = 350.0 kg
Therefore, revised water content = 175.0 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 0.5. Therefore, volume of coarse aggregate is required
to be increased to decrease the fine aggregate content.
Therefore, corrected proportion of volume of coarse aggregate for the water-cement ratio of
0.5 = 0.62 + 0 = 0.62

Therefore volume of coarse aggregate = 0.620

Volume of fine aggregate content = 1 – 0.62 = 0.38

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 0.117 m³
d) Volume of water 0.175 m³
e) Volume of chemical admixture 0.0016 m³

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(Super-plasticizer) @ 0.5% by mass of cement
f) Volume of all in aggregate 0.696 m³
g) Mass of coarse aggregate 1242.7 kg
h) Mass of fine aggregate 703.5 kg

MIX PROPORTIONS FOR TRIAL MIX II

Cement 350 kg/m³
Water 175.0 litre
Fine aggregate 703 kg/m³
Coarse aggregate 1243 kg/m³
(20.0mm & 10.0mm aggregates are to be mixed in proportion of 50 : 50 by weight.)
Chemical admixture 1.75 kg/m³
Water-cement ratio 0.50

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

Six Cubes were cast at the laboratory.

The characteristics of fresh mix are as follows
Slump : 120 mm After 3 Hrs.
Colour : Whitish grey
Consistency : Less-Cohesive slight bleeding is observed.
Average 7 day cube compressive strength = 17.2 MPa was obtained.
Average 28 day cube compressive strength = 24.9 MPa was obtained.

Trial Mix.III

Water-cement ratio changed to = 0.45

Cement content selected = 350.0 kg
Therefore, revised water content = 158.0 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 0.45. 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

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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 0.117 m³
d) Volume of water 0.158 m³
e) Volume of chemical admixture 0.0016 m³
(Super-plasticizer) @ 0.7% by mass of cement
f) Volume of all in aggregate 0.713 m³
g) Mass of coarse aggregate 1293.6 kg
h) Mass of fine aggregate 701.7 kg

MIX PROPORTIONS FOR TRIAL MIX III

Cement 350 kg/m³
Water 158.0 litre
Fine aggregate 702 kg/m³
Coarse aggregate 1294 kg/m³
(20.0mm & 10.0mm aggregates are to be mixed in proportion of 50 : 50 by weight.)
Chemical admixture 2.45 kg/m³
Water-cement ratio 0.45

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

Six Cubes were cast at the laboratory.

The characteristics of fresh mix are as follows
Slump : 90 mm After 3 Hrs.
Colour : Whitish grey
Consistency : Less-Cohesive slight bleeding is observed.
Average 7 day cube compressive strength = 24.2 MPa was obtained.
Average 28 day cube compressive strength = 34.6 MPa was obtained.
The Mix-I is suggested for the M-20 grade concrete.
Note :Admixture dose may vary depending on climatic condition

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