Concrete Mix Design – M70 Grade of Concrete (OPC 53 Grade)
Concrete mix design – M70 grade of concrete provided here is for
reference purpose only. Actual site conditions vary and thus this should
be adjusted as per the location and other factors.
A. Design Stipulation:
Characteristic comprehensive Strength @ 28 days = 70 N/mm^{2}
Maximum size of aggregate = 20 mm
Degree of workability = Collapsible
Degree of quality control = Good
Type of exposure = Severe
Minimum cement content as per is 4562000
B. Test data for concrete ingredients
Specific gravity of cement = 3.15
Specific gravity of fly ash = 2.24
Specific gravity of microsilica = 2.21
Setting time of cement initial = 165 min, final = 270min
Cement compressive strength =
39.0 N/mm^{2} @ 3 days
51.0 N/mm^{2} @ 7 days
64.2 N/mm^{2} @ 28 days
Specific gravity of coarse aggregates (ca) and fine aggregates (fa)
20 mm 2.729
10 mm 2.747
R/sand 2.751
C/sand 2.697
Water absorption
20 mm 1.540, 10mm 1.780, R/sand 3.780, C/sand 4.490
Characteristic strength @ 28 days 70 N/mm^{2}
Target mean strength : Depend upon degree of quality control “good” and considering (std. Dev.As 5 N/mm^{2})
Characteristic strength given by the relation 70 +(1.65 *5 ) = 78.25 N/mm^{2}
C. Quantities of ingredients (By Absolute Volume Method )
Actual cement used = 486 kg/cum
Actual fly ash used = 90 kg/cum
Actual microsilica used = 24 kg/cum
W/C fixed = 0.26
Absolute volume of cement = 0.154
Absolute volume of air = 0.02
Absolute vol of water. = 0.156
Absolute vol of fly ash. = 0.040
Absolute vol of microsilica = 0.011
Total volume of CA and FA used = 1.00(0.155+0.044+0.022+0.02 +0.154)
= 0.619 Cum
D. Aggregate percent used.
20 Mm = 24, 10 mm = 36, r/sand = 20, c/sand = 20
(2.729*0.24) + (2.747*0.36) +(2.751* 0.20 )+(2.697*0.20) *0.619*1000
405+612+340+334=1691
Aggt: cement = 2.82 : 1
Mix proportion = 0.26:1:0.57:0.56:1.02:0.67
E. Abstract:
20 mm = 405 kg/cum
10 mm = 612 kg/cum
r/sand = 340 kg /cum
c/sand = 334 kg/cum
water = 154 kg/cum
Admixture 0.50 % BY WT OF (C+F+MS) ASTP1 OF BASF
Cube Compressive Strength (N/mm^{2})
3 days = 49.13
7 Days = 59.57
28 Days = 81.49
Note: Mix design is same for Crane bucket and Pump concrete only admixture dosage will fine tuned by 0.05 to 0.10%
We are thankful to Deshmukh D S for submitting this very useful mix design information to us.
Dear All
Again I am back with M20 Mix Designs as per IS102622009
Dear All
Again I am back with M25 Mix Designs as per IS102622009.
Dear All
Again I am back with M30 Mix Designs as per IS102622009
The mix design for M35 Grade Of Concrete for pile foundations provided here is for reference purpose only. Actual site conditions vary and thus this should be adjusted as per the location and other factors.
Grade of Concrete : M35
Characteristic Strength (Fck) : 35 Mpa
Standard Deviation : 1.91 Mpa*
Target Mean Strength : T.M.S.= Fck +1.65 x S.D.
(from I.S 4562000) = 35+ 1.65×1.91
= 38.15 Mpa
Test Data For Material:
Aggregate Type : Crushed
Specific Gravity
Cement : 3.15
Coarse Aggregate : 2.67
Fine Aggregate : 2.62
Water Absorption:
Coarse Aggregate : 0.5%
Fine Aggregate : 1.0 %
Select Water Cement Ratio = 0.43 for concrete grade M35
(From Fig 2. of I.S. 10262 1982)
Select Water Content = 172 Kg
(From IS: 10262 for 20 mm nominal size of aggregates Maximum Water Content = 186 Kg/ M^{3 })
Hence, Cement Content= 172 / 0.43 = 400 Kg / M^{3}
Formula for Mix Proportion of Fine and Coarse Aggregate:
1000(1a_{0})_{ }= {(Cement Content / Sp. Gr. Of Cement) + Water Content +(F_{a }/ Sp. Gr.* P_{f })}
1000(1a_{0})_{ }= {(Cement Content / Sp. Gr. Of Cement) + Water Content +C_{a }/ Sp. Gr.* Pc_{ })}
Where C_{a }= Coarse Aggregate Content
F_{a }= Fine Aggregate Content
P_{f } = Sand Content as percentage of total Aggregates
= 0.36
Pc = Coarse Aggregate Content as percentage of total Aggregates.
= 0.64
a_{0 }= Percentage air content in concrete (As per IS :10262 for 20 mm nominal size of
aggregates air content is 2 %) = 0.02
Hence, 1000(10.02)_{ }= {(400 /3.15) + 172 +(F_{a }/ 2.62 x 0.36)}
Fa = 642 Kg/ Cum^{ }
As the sand is of Zone II no adjustment is required for sand.
Sand Content = 642 Kg/ Cum
1000(10.02)_{ }= {(400 /3.15) + 172 +(C_{a }/ 2.67 x 0.64)}
Hence, Ca = 1165 Kg/ Cum^{ }
From combined gradation of Coarse aggregates it has been found out that the proportion of 53:47 of 20 mm & 10 mm aggregates produces the best gradation as per IS: 383.
Hence, 20 mm Aggregates = 619 Kg
And 10 mm Aggregates = 546 Kg
To obtain slump in the range of 150190 mm water reducing admixture brand SP430 from Fosroc with a dose of 0.3 % by weight of Cement shall be used.
Hence the Mix Proportion becomes:
Units – Kg/ M^{3}
A. Design Stipulation:
Characteristic comprehensive Strength @ 28 days = 70 N/mm^{2}
Maximum size of aggregate = 20 mm
Degree of workability = Collapsible
Degree of quality control = Good
Type of exposure = Severe
Minimum cement content as per is 4562000
B. Test data for concrete ingredients
Specific gravity of cement = 3.15
Specific gravity of fly ash = 2.24
Specific gravity of microsilica = 2.21
Setting time of cement initial = 165 min, final = 270min
Cement compressive strength =
39.0 N/mm^{2} @ 3 days
51.0 N/mm^{2} @ 7 days
64.2 N/mm^{2} @ 28 days
Specific gravity of coarse aggregates (ca) and fine aggregates (fa)
20 mm 2.729
10 mm 2.747
R/sand 2.751
C/sand 2.697
Water absorption
20 mm 1.540, 10mm 1.780, R/sand 3.780, C/sand 4.490
Characteristic strength @ 28 days 70 N/mm^{2}
Target mean strength : Depend upon degree of quality control “good” and considering (std. Dev.As 5 N/mm^{2})
Characteristic strength given by the relation 70 +(1.65 *5 ) = 78.25 N/mm^{2}
C. Quantities of ingredients (By Absolute Volume Method )
Actual cement used = 486 kg/cum
Actual fly ash used = 90 kg/cum
Actual microsilica used = 24 kg/cum
W/C fixed = 0.26
Absolute volume of cement = 0.154
Absolute volume of air = 0.02
Absolute vol of water. = 0.156
Absolute vol of fly ash. = 0.040
Absolute vol of microsilica = 0.011
Total volume of CA and FA used = 1.00(0.155+0.044+0.022+0.02 +0.154)
= 0.619 Cum
D. Aggregate percent used.
20 Mm = 24, 10 mm = 36, r/sand = 20, c/sand = 20
(2.729*0.24) + (2.747*0.36) +(2.751* 0.20 )+(2.697*0.20) *0.619*1000
405+612+340+334=1691
Aggt: cement = 2.82 : 1
Mix proportion = 0.26:1:0.57:0.56:1.02:0.67
E. Abstract:
20 mm = 405 kg/cum
10 mm = 612 kg/cum
r/sand = 340 kg /cum
c/sand = 334 kg/cum
water = 154 kg/cum
Admixture 0.50 % BY WT OF (C+F+MS) ASTP1 OF BASF
Cube Compressive Strength (N/mm^{2})
3 days = 49.13
7 Days = 59.57
28 Days = 81.49
Note: Mix design is same for Crane bucket and Pump concrete only admixture dosage will fine tuned by 0.05 to 0.10%
We are thankful to Deshmukh D S for submitting this very useful mix design information to us.
Mix Design For Concrete Roads As Per IRC152002
ABSTRACT:
The stresses induced in concrete pavements are mainly flexural. Therefore flexural strength is more often specified than compressive strength in the design of concrete mixes for pavement construction. A simple method of concrete mix design based on flexural strength for normal weight concrete mixes is described in the paper.
INTRODUCTION:
Usual criterion for the strength of concrete in the building industry is the compressive strength, which is considered as a measure of quality concrete. however, in pavement constructions, such as highway and airport runway, the flexural strength of concrete is considered more important, as the stresses induced in concrete pavements are mainly flexural. Therefore, flexural strength is more often specified than compressive strength in the design of concrete mixes for pavement construction. It is not perfectly reliable to predict flexural strength from compressive strength. Further, various codes of the world specified that the paving concrete mixes should preferably be designed in the laboratory and controlled in the field on the basis of its flexural strength. Therefore, there is a need to design concrete mixes based on flexural strength.
The type of aggregate can have a predominant effect, crushed rock aggregate resulting in concrete with higher flexural strength than uncrushed (gravel) aggregates for comparable mixes, assuming that sound materials are used. The strength of cement influences the compressive and flexural strength of concrete i.e. with the same watercement ratio, higher strength cement will produce concrete of higher compressive and flexural strength.
MIX DESIGN DETAILS
IRC: 152002 specified that for concrete roads OPC should be used. This code also allowed PPC as per IS: 1489 may also be used. Accordingly OPC + fly ash may be used in concrete roads. However, IS: 4562000 specified that fly ash conforming to grade1 of IS3812 may be used as part replacement of OPC provided uniform blended with cement is essential. The construction sites where batching plants are used this may be practicable. In ordinary sites where mixer or hand mixing are done uniform blending of fly ash with cement is not practicable. At such construction sites, PPC may be used.
TEST DATA FOR MATERIALS AND OTHER DETAILS
1. The grading of fine aggregate, 10 and 20 mm aggregates are as given in Table. 1 ( given in the end). Fine aggregate is of zoneII as per IS:3831970. 10 and 20 mm crushed aggregate grading are single sized as per IS: 3831970.
2. Properties of aggregates
3. Target average flexural strength for all A, B and C mixes
S = S^{’}+ J_{a}o
= 4.5 + 1.65 x 0.5
= 5.3 N/mm^{2} at 28 days age
4. For Mix A and B free W/C ratio with crushed aggregate and required average flexural target strength of 5.3 N/mm^{2} at 28 days from Fig. 1 Curve D ( Figure shown in the end) found to be 0.42. This is lower than specified maximum W/C ratio value of 0.50
Note: In absence of cement strength, but cement conforming to IS Codes, assume from Fig. 1
Curve A and B  For OPC 33 Grade
Curve C and D  For OPC 43 Grade
Take curves C and D for PPC, as PPC is being manufactured in minimum of 43 Grade of strength.
5. Other data’s: The Mixes are to be designed on the basis of saturated and surface dry aggregates. At the time of concreting, moisture content of site aggregates are to be determine. If it carries surface moisture this is to be deducted from the mixing water and if it is dry add in mixing water the quantity of water required for absorption. The weight of aggregates are also adjusted accordingly.
DESIGN OF MIXA WITH PPC
a) Free W/C ratio for the target flexural strength of 5.3 N/mm^{2} as worked out is 0.42
b) Free water for 30 mm slump from Table 2 for 20 mm maximum size of aggregate.
2/3*165 + 1/3*195
= 175 kg/m^{3}
From trials it is found that Retarder Super plasticizer at a dosages of 15gm/kg of cement may reduce 15% water without loss of workability
Then water = 175 – (175 x 0.15) = 148.75 kg/m^{3}
For trials say 149 kg/m^{3}
c) PPC = 149/0.42 = 355 kg/m^{3}
This is higher than minimum requirement of 350 kg/m^{3}
d) Formula for calculation of fresh concrete weight in kg/m^{3}
U_{M } = 10 x G_{a} (100 – A) + C_{M}(1 – G_{a}/G_{c}) – W_{M} (G_{a} – 1)
Where,
U_{m} = Weight of fresh concrete kg/m^{3}
G_{a} = Weighted average specific gravity of combined fine and coarse aggregate bulk, SSD
G_{c} = Specific gravity of cement. Determine actual value, in absence assume 3.15 for OPC and 3.00 for PPC (Fly ash based)
A = Air content, percent. Assume entrapped air 1.5% for 20 mm maximum size of aggregate and 2.5% for 10mm maximum size of aggregate. There are always entrapped air in concrete. Therefore ignoring entrapped air value as NIL will lead the calculation of higher value of density.
W_{m} = Mixing water required in kg/m^{3}
C_{m} = Cement required, kg/m^{3}
Note: The exact density may be obtained by filling and fully compacting constant volume suitable metal container from the trial batches of calculated design mixes. The mix be altered with the actual obtained density of the mix.
U_{m} = 10 x G_{a} (100 – A) + C_{m} (1 – G_{a}/G_{c}) – W_{m} (G_{a} – 1)
= 10 x 2.65 (100 – 1.5) + 355(1 2.65/3.00) – 149 (2.65 1)
= 2405.9 kg/m^{3}
Say 2405 kg/m^{3}
e) Aggregates = 2405 – 355 – 149 = 1901 kg/m^{3}
f) Fine aggregate = From Table 3 for zoneII Fine aggregate and
20 mm maximum size of aggregate, W/C ratio = 0.42, 30 mm slump found to be 35%.
Fine aggregate = 1901 x 0.35 = 665 kg/m^{3}
Coarse aggregate = 1901 – 665 = 1236 kg/m^{3}
10 and 20 mm aggregate are single sized as per IS: 3831970. Let they be combined in the ratio of 1.2:1.8 to get 20 mm graded aggregate as per IS: 3831970
10 mm aggregate = 1236×1.2/3 = 494 kg/m^{3}
20 mm aggregate = 1236×1.8/3 = 742 kg/m^{3}
g) Thus for 4.5 N/mm^{2} flexural strength quantity of materials per cu.m. of concrete on the basis of saturated and surface dry aggregates:
Water = 149 kg/m^{3}
PPC = 355 kg/m^{3}
Fine Aggregate (sand) = 665 kg/m^{3}
10 mm Aggregate = 494 kg/m^{3}
20 mm Aggregate = 742 kg/m^{3}
Retarder Super Plasticizer = 5.325 kg/m^{3}
MIX B WITH OPC
a) Water = 175 – (175 x 0.15) = 149 kg/m^{3} say 149 kg/m^{3}
b) OPC = 149/0.42 = say 355 kg/m^{3}
c) Density: 10 x 2.65 (100 – 1.5) + 355 (1 – 2.65/3.15) – 149 (2.65 – 1)
= 2420.8 kg/m^{3} say 2420 kg/m^{3}
d) Total Aggregates = 2420 – 355 – 149 = 1916 kg/m^{3}
Fine Aggregate = 1916 x 0.35 = say 670 kg/m^{3}
Coarse aggregate = 1916 – 670 = 1246 kg/m^{3}
10 mm Aggregate = 1246×1.2/3 = 498 kg/m^{3}
20 mm Aggregate = 1246×1.8/3 = 748 kg/m^{3}
e) Thus for 4.5 N/mm^{2} flexural strength quantity of materials per cu.m of concrete on the basis of SSD aggregates are given below:
Water = 149 kg/m^{3}
OPC = 355 kg/m^{3}
Fine Aggregate (sand) = 670 kg/m^{3}
10 mm Aggregate = 498 kg/m^{3}
20 mm Aggregate = 748 kg/m^{3}
Retarder Super Plasticizer = 3.550 kg/m^{3}
MIX. C WITH OPC + FLYASH
With the given set of materials increase in cementitious materials = 10.7%
Total cementitious materials = 355×1.107 = 393 kg/m^{3}
Fine Aggregate = 0.6994 – 0.4702 = 0.2292
= 0.2292 x 2650 = 607 kg
Note:
1. Specific gravity of Normal Superplasticizer = 1.15
2. Addition of Flyash reduces 5% of water demand.
Note:
1. For exact W/C ratio the water in admixture should also be taken into account.
2. The W/C ratio of PPC and OPC is taken the same assuming that the strength properties of both are the same. If it is found that the PPC is giving the low strength then W/C ratio of PPC have to be reduce, which will increase the cement content. For getting early strength and in cold climate the W/C ratio of PPC shall also be required to be reduced.
3. PPC reduces 5% water demand. If this is found by trial then take reduce water for calculation.
4. If the trial mixes does not gives the required properties of the mix, it is then required to be altered accordingly. However, when the experiences grows with the particular set of materials and site conditions very few trials will be required, and a expert of such site very rarely will be required a 2^{nd} trial.
5. It may be noted that, for the fly ash concrete the total cementation material is greater but the OP cement content is smaller, the coarse aggregate content is deliberately, the same, the water is reduced and the density is reduced, because of the lower density of fly ash compared with OPC.
CONCLUSION
1. For 4.5 N/mm^{2} flexural strength concrete having same material and requirement, but without water reducer, the PPC and OPC required will be 175/0.42 = 417kg/m^{3}
2. With the use of superplasticizer the saving in cement is 62 kg/m^{3} and water 26 lit/m^{3} for PPC and OPC.
3. In the Fly ash concrete the saving in cement is 122 kg/m^{3} and water 33 lit/m^{3} including utilization of 98 kg/m^{3} of fly ash witch is a waste material.
4. In the financial year 20092010 India has produces 200 million tonnes of cement. In India one kg of cement produce emitted 0.93 kg of CO_{2}. Thus the production of 200 million tonnes of cement had emitted 200 x 0.93 = 186 million tonnes of CO_{2} to the atmosphere.
5. If 50 million tonnes cement in making concrete uses water reducers 7500000 tonnes of cement can be saved. 3750000 KL of potable water will be saved and the saving of Rs. 3300 crores per year to the construction Industry. 6975000 tonnes of CO_{2} will be prevented to be emitted to the atmosphere. The benefits in the uses of water reducers not limited to this. When water reduces shrinkage and porosity of concrete are reduces which provides the durability to concrete structures.
6. India is facing serious air, water, soil, food and noise pollution problems. Every efforts therefore are necessary to prevent pollution on top priority basis.
7. As the stress induced in concrete pavements are mainly flexural, it is desirable that their design is based on the flexural strength of concrete. The quality of concrete is normally assessed by measuring its compressive strength. For pavings, however, it is the flexural strength rather than the compression strength of concrete which determine the degree of cracking and thus the performance of road, and it is imperative to control the quality on the basis of flexural strength.
REFERENCES:
Table. 1: Grading of Aggregates
Table. 2: Approximate freewater content (kg/m^{3}) required to give various levels of workability for nonairentrained (with normal entrapped air) concrete.
Note: When coarse and fine aggregate of different types are used, the free water content is estimated by the expression.
2/3W_{f}+1/3W_{c}
Where,
W_{f} = Free water content appropriate to type of fine Aggregate
W_{c} = Free water content appropriate to type of coarse aggregate.
Table. 3: Proportion of fine aggregate (percent) with 10mm and 20mm maximum sizes of aggregates and slump 1545 mm.
Dear All,
Here i am giving the mix designs as per IS102622009 which gives to change the procedure for calculating the concrete ingredients
The stresses induced in concrete pavements are mainly flexural. Therefore flexural strength is more often specified than compressive strength in the design of concrete mixes for pavement construction. A simple method of concrete mix design based on flexural strength for normal weight concrete mixes is described in the paper.
INTRODUCTION:
Usual criterion for the strength of concrete in the building industry is the compressive strength, which is considered as a measure of quality concrete. however, in pavement constructions, such as highway and airport runway, the flexural strength of concrete is considered more important, as the stresses induced in concrete pavements are mainly flexural. Therefore, flexural strength is more often specified than compressive strength in the design of concrete mixes for pavement construction. It is not perfectly reliable to predict flexural strength from compressive strength. Further, various codes of the world specified that the paving concrete mixes should preferably be designed in the laboratory and controlled in the field on the basis of its flexural strength. Therefore, there is a need to design concrete mixes based on flexural strength.
The type of aggregate can have a predominant effect, crushed rock aggregate resulting in concrete with higher flexural strength than uncrushed (gravel) aggregates for comparable mixes, assuming that sound materials are used. The strength of cement influences the compressive and flexural strength of concrete i.e. with the same watercement ratio, higher strength cement will produce concrete of higher compressive and flexural strength.
MIX DESIGN DETAILS
IRC: 152002 specified that for concrete roads OPC should be used. This code also allowed PPC as per IS: 1489 may also be used. Accordingly OPC + fly ash may be used in concrete roads. However, IS: 4562000 specified that fly ash conforming to grade1 of IS3812 may be used as part replacement of OPC provided uniform blended with cement is essential. The construction sites where batching plants are used this may be practicable. In ordinary sites where mixer or hand mixing are done uniform blending of fly ash with cement is not practicable. At such construction sites, PPC may be used.
1  Characteristic Flexural Strength at 28 days  4.5N/mm^{2} 
2  Cement  Three mixes are to be designed 
MIXA With PPC (Flyash based) conforming to IS:1489partI1991. 7 days strength 37.5N/mm^{2}. Specific Gravity: 3.00 

MIXB With OPC43 Grade conforming to IS: 81121989. 7 days strength 40.5N/mm^{2}. Specific Gravity : 3.15 

MIXC With OPC of MixB and Fly ash conforming to IS:3812 (PartI)2003 Specific Gravity : 2.20 

Note Requirements of all the three mixes are the same. Fine Aggregate, Coarse Aggregate and Retarder Super plasticizer are the same for all the three mixes.  
3  Fly ash replacement  25% Fly ash is required to be replaced with the total cementitious materials. 
4  Maximum nominal size of aggregates  20 mm Crushed aggregate 
5  Fine aggregate  River sand of ZoneII as per IS:3831970 
6  Minimum cement content  350 kg/m^{3} including Fly ash 
7  Maximum free W/C Ratio  0.50 
8  Workability  30 mm slump at pour the concrete will be transported from central batching plant through transit mixer, at a distance of 20 Km during June, July months. The average temperature last year during these months was 40^{0}C. 
9  Exposure condition  Moderate 
10  Method of placing  Fully mechanized construction 
11  Degree of supervision  Good 
12  Maximum of cement content (Fly ash not included)  425 kg/m^{3} 
13  Chemical admixture  Retarder Super plasticizer conforming to IS:91031999. With the given requirements and materials, the manufacturer of Retarder Super plasticizer recommends dosages of 10 gm per kg of OPC, which will reduce 15% of water without loss of workability. For fly ash included cement dosages will be required to be adjusted by experience/ trials. 
14  Values of J_{a}x_{o}  1.65 x 0.5 N/mm^{2} 
TEST DATA FOR MATERIALS AND OTHER DETAILS
1. The grading of fine aggregate, 10 and 20 mm aggregates are as given in Table. 1 ( given in the end). Fine aggregate is of zoneII as per IS:3831970. 10 and 20 mm crushed aggregate grading are single sized as per IS: 3831970.
2. Properties of aggregates
Tests

Fine aggregate

10mm aggregate

40mm aggregate

Specific Gravity 
2.65

2.65

2.65

Water Absorption % 
0.8

0.5

0.5

S = S^{’}+ J_{a}o
= 4.5 + 1.65 x 0.5
= 5.3 N/mm^{2} at 28 days age
4. For Mix A and B free W/C ratio with crushed aggregate and required average flexural target strength of 5.3 N/mm^{2} at 28 days from Fig. 1 Curve D ( Figure shown in the end) found to be 0.42. This is lower than specified maximum W/C ratio value of 0.50
Note: In absence of cement strength, but cement conforming to IS Codes, assume from Fig. 1
Curve A and B  For OPC 33 Grade
Curve C and D  For OPC 43 Grade
Take curves C and D for PPC, as PPC is being manufactured in minimum of 43 Grade of strength.
5. Other data’s: The Mixes are to be designed on the basis of saturated and surface dry aggregates. At the time of concreting, moisture content of site aggregates are to be determine. If it carries surface moisture this is to be deducted from the mixing water and if it is dry add in mixing water the quantity of water required for absorption. The weight of aggregates are also adjusted accordingly.
DESIGN OF MIXA WITH PPC
a) Free W/C ratio for the target flexural strength of 5.3 N/mm^{2} as worked out is 0.42
b) Free water for 30 mm slump from Table 2 for 20 mm maximum size of aggregate.
2/3*165 + 1/3*195
= 175 kg/m^{3}
From trials it is found that Retarder Super plasticizer at a dosages of 15gm/kg of cement may reduce 15% water without loss of workability
Then water = 175 – (175 x 0.15) = 148.75 kg/m^{3}
For trials say 149 kg/m^{3}
c) PPC = 149/0.42 = 355 kg/m^{3}
This is higher than minimum requirement of 350 kg/m^{3}
d) Formula for calculation of fresh concrete weight in kg/m^{3}
U_{M } = 10 x G_{a} (100 – A) + C_{M}(1 – G_{a}/G_{c}) – W_{M} (G_{a} – 1)
Where,
U_{m} = Weight of fresh concrete kg/m^{3}
G_{a} = Weighted average specific gravity of combined fine and coarse aggregate bulk, SSD
G_{c} = Specific gravity of cement. Determine actual value, in absence assume 3.15 for OPC and 3.00 for PPC (Fly ash based)
A = Air content, percent. Assume entrapped air 1.5% for 20 mm maximum size of aggregate and 2.5% for 10mm maximum size of aggregate. There are always entrapped air in concrete. Therefore ignoring entrapped air value as NIL will lead the calculation of higher value of density.
W_{m} = Mixing water required in kg/m^{3}
C_{m} = Cement required, kg/m^{3}
Note: The exact density may be obtained by filling and fully compacting constant volume suitable metal container from the trial batches of calculated design mixes. The mix be altered with the actual obtained density of the mix.
U_{m} = 10 x G_{a} (100 – A) + C_{m} (1 – G_{a}/G_{c}) – W_{m} (G_{a} – 1)
= 10 x 2.65 (100 – 1.5) + 355(1 2.65/3.00) – 149 (2.65 1)
= 2405.9 kg/m^{3}
Say 2405 kg/m^{3}
e) Aggregates = 2405 – 355 – 149 = 1901 kg/m^{3}
f) Fine aggregate = From Table 3 for zoneII Fine aggregate and
20 mm maximum size of aggregate, W/C ratio = 0.42, 30 mm slump found to be 35%.
Fine aggregate = 1901 x 0.35 = 665 kg/m^{3}
Coarse aggregate = 1901 – 665 = 1236 kg/m^{3}
10 and 20 mm aggregate are single sized as per IS: 3831970. Let they be combined in the ratio of 1.2:1.8 to get 20 mm graded aggregate as per IS: 3831970
10 mm aggregate = 1236×1.2/3 = 494 kg/m^{3}
20 mm aggregate = 1236×1.8/3 = 742 kg/m^{3}
g) Thus for 4.5 N/mm^{2} flexural strength quantity of materials per cu.m. of concrete on the basis of saturated and surface dry aggregates:
Water = 149 kg/m^{3}
PPC = 355 kg/m^{3}
Fine Aggregate (sand) = 665 kg/m^{3}
10 mm Aggregate = 494 kg/m^{3}
20 mm Aggregate = 742 kg/m^{3}
Retarder Super Plasticizer = 5.325 kg/m^{3}
MIX B WITH OPC
a) Water = 175 – (175 x 0.15) = 149 kg/m^{3} say 149 kg/m^{3}
b) OPC = 149/0.42 = say 355 kg/m^{3}
c) Density: 10 x 2.65 (100 – 1.5) + 355 (1 – 2.65/3.15) – 149 (2.65 – 1)
= 2420.8 kg/m^{3} say 2420 kg/m^{3}
d) Total Aggregates = 2420 – 355 – 149 = 1916 kg/m^{3}
Fine Aggregate = 1916 x 0.35 = say 670 kg/m^{3}
Coarse aggregate = 1916 – 670 = 1246 kg/m^{3}
10 mm Aggregate = 1246×1.2/3 = 498 kg/m^{3}
20 mm Aggregate = 1246×1.8/3 = 748 kg/m^{3}
e) Thus for 4.5 N/mm^{2} flexural strength quantity of materials per cu.m of concrete on the basis of SSD aggregates are given below:
Water = 149 kg/m^{3}
OPC = 355 kg/m^{3}
Fine Aggregate (sand) = 670 kg/m^{3}
10 mm Aggregate = 498 kg/m^{3}
20 mm Aggregate = 748 kg/m^{3}
Retarder Super Plasticizer = 3.550 kg/m^{3}
MIX. C WITH OPC + FLYASH
With the given set of materials increase in cementitious materials = 10.7%
Total cementitious materials = 355×1.107 = 393 kg/m^{3}
Materials

Weight (kg/m^{3})

Volume (m^{3})

OPC = 393 x 0.75 
295/3150

0.0937

Flyash = 393 x 0.25 
98/2200

0.0445

Free Water = 149 x 0.95 
142/1000

0.142

Retarder Super Plasticizer = 6.2 kg 
6.2/1150

0.0054

Air = 1.5% 
0.015


Total

0.3006


Total Aggregates = 1 – 0.3006 
0.6994




Coarse Aggregate 
1246/2650

0.4702

= 0.2292 x 2650 = 607 kg
Note:
1. Specific gravity of Normal Superplasticizer = 1.15
2. Addition of Flyash reduces 5% of water demand.
For 4.5 N/mm^{2} flexural strength quantity of material per cu.m of concrete on the basis of saturated and surface dry aggregates of
Mix ‘A’, ‘B’ and ‘C’ are given below:
Materials

MIX. ‘A’ with PPC

Mix. ‘B’ with OPC

Mix. ‘C’ with OPC+Flyash

Water kg/m^{3} 
149

149

142

PPC kg/m^{3} 
355

–

–

OPC kg/m^{3} 
–

355

295

Flyash kg/m^{3} 
–

–

98

Fine Agg. kg/m^{3} 
665

670

607

10mm Agg. kg/m^{3} 
494

498

498

20 mm Agg. kg/m^{3} 
742

748

748

Retarder Super plasticizer kg/m^{3} 
5.325

3.550

6.2

W/Cementations ratio 
0.42

0.42

0.361

1. For exact W/C ratio the water in admixture should also be taken into account.
2. The W/C ratio of PPC and OPC is taken the same assuming that the strength properties of both are the same. If it is found that the PPC is giving the low strength then W/C ratio of PPC have to be reduce, which will increase the cement content. For getting early strength and in cold climate the W/C ratio of PPC shall also be required to be reduced.
3. PPC reduces 5% water demand. If this is found by trial then take reduce water for calculation.
4. If the trial mixes does not gives the required properties of the mix, it is then required to be altered accordingly. However, when the experiences grows with the particular set of materials and site conditions very few trials will be required, and a expert of such site very rarely will be required a 2^{nd} trial.
5. It may be noted that, for the fly ash concrete the total cementation material is greater but the OP cement content is smaller, the coarse aggregate content is deliberately, the same, the water is reduced and the density is reduced, because of the lower density of fly ash compared with OPC.
CONCLUSION
1. For 4.5 N/mm^{2} flexural strength concrete having same material and requirement, but without water reducer, the PPC and OPC required will be 175/0.42 = 417kg/m^{3}
2. With the use of superplasticizer the saving in cement is 62 kg/m^{3} and water 26 lit/m^{3} for PPC and OPC.
3. In the Fly ash concrete the saving in cement is 122 kg/m^{3} and water 33 lit/m^{3} including utilization of 98 kg/m^{3} of fly ash witch is a waste material.
4. In the financial year 20092010 India has produces 200 million tonnes of cement. In India one kg of cement produce emitted 0.93 kg of CO_{2}. Thus the production of 200 million tonnes of cement had emitted 200 x 0.93 = 186 million tonnes of CO_{2} to the atmosphere.
5. If 50 million tonnes cement in making concrete uses water reducers 7500000 tonnes of cement can be saved. 3750000 KL of potable water will be saved and the saving of Rs. 3300 crores per year to the construction Industry. 6975000 tonnes of CO_{2} will be prevented to be emitted to the atmosphere. The benefits in the uses of water reducers not limited to this. When water reduces shrinkage and porosity of concrete are reduces which provides the durability to concrete structures.
6. India is facing serious air, water, soil, food and noise pollution problems. Every efforts therefore are necessary to prevent pollution on top priority basis.
7. As the stress induced in concrete pavements are mainly flexural, it is desirable that their design is based on the flexural strength of concrete. The quality of concrete is normally assessed by measuring its compressive strength. For pavings, however, it is the flexural strength rather than the compression strength of concrete which determine the degree of cracking and thus the performance of road, and it is imperative to control the quality on the basis of flexural strength.
REFERENCES:
1  IS : 3831970  Specifications for coarse and fine aggregates from natural sources for concrete (second revision) BIS, New Delhi  
2  IS: 4562000  Code of practice for plain and reinforced concrete (fourth revision), BIS, New Delhi  
3  IS: 91031999  Specification for admixtures for concrete (first revision) BIS, New Delhi  
4  IS: 81121989  Specifications for 43 Grade ordinary portland cement (first revision) BIS, New Delhi  
5  IS: 2386 (PartIII) 1963  method of test for aggregate for concrete. Specific gravity, density, voids, absorption and bulking, BIS, New Delhi  
6  IS: 3812 (PartI) 2003  Specification for pulverized fuel ash: PartI for use as pozzolana in cement, cement mortar and concrete (second revision) BIS, New Delhi  
7  IS: 1489PartI 1991  Specifications for portland pozzolana cement (PartI) Flyash based. (Third revision), BIS, New Delhi  
8  IRC: 152002 – Standard specifications and code of practice for
construction of concrete road (third revision) 

9  Kishore Kaushal, “Concrete Mix Design Based on Flexural Strength for AirEntrained Concrete”, Proceeding of 13^{th} Conference on our World in Concrete and Structures, 2526, August, 1988, Singapore.  
10  Kishore Kaushal, “Method of Concrete Mix Design Based on Flexural Strength”, Proceeding of the International Conference on Road and Road Transport Problems ICORT, 1215 December, 1988, New Delhi, pp. 296305.  
11  Kishore Kaushal, “Mix Design Based on Flexural Strength of AirEntrained Concrete”. The Indian Concrete Journal, February, 1989, pp. 9397.  
12  Kishore Kaushal, “Concrete Mix Design Containing Chemical Admixtures”, Journal of the National Building Organization, April, 1990, pp. 112.  
13  Kishore Kaushal, “Concrete Mix Design for Road Bridges”, INDIAN HIGHWAYS, Vol. 19, No. 11, November, 1991, pp. 3137  
14  Kishore Kaushal, “ Mix Design for Pumped Concrete”, Journal of Central Board of Irrigation and Power, Vol. 49, No.2, April, 1992, pp. 8192  
15  Kishore Kaushal, “Concrete Mix Design with Fly Ash”, Indian Construction, January, 1995, pp. 1617  
16  Kishore Kaushal, “HighStrength Concrete”, Bulletin of Indian Concrete Institute No. 51, AprilJune, 1995, pp. 2931  
17  Kishore Kaushal, “Concrete Mix Design Simplified”, Indian Concrete Institute Bulletin No. 56, JulySeptember, 1996, pp. 2530. 

18  Kishore Kaushal, “Concrete Mix Design with Fly Ash & Superplasticizer”, ICI Bulletin No. 59, AprilJune 1997, pp. 2930  
19  Kishore Kaushal. “Mix Design for Pumped Concrete”, CE & CR October, 2006, pp. 4450. 
IS Sieve Designation

Percentage Passing


Fine Aggregate

Crushed Aggregate


10 mm

20 mm


40 mm 
–

–

100

20 mm 
–

–

100

12.5 mm 
–

100

–

10 mm 
100

89

0

4.75 mm 
98

6


2.36 mm 
86

0


1.18 mm 
71



600 Micron 
40



300 Micron 
21



150 Micron 
5



Maximum size of aggregate(mm) 
Type of aggregate

Slump(mm)

1545

10

Uncrushed Crushed  185 215  
20  Uncrushed Crushed  165 195 
2/3W_{f}+1/3W_{c}
Where,
W_{f} = Free water content appropriate to type of fine Aggregate
W_{c} = Free water content appropriate to type of coarse aggregate.
Table. 3: Proportion of fine aggregate (percent) with 10mm and 20mm maximum sizes of aggregates and slump 1545 mm.
Grading Zone of F.A 
W/C Ratio

10 mm aggregate

20 mm aggregate

I

0.3

4757

3745

0.4

4959

3947


0.5

5161

4149


II

0.3

3948

3037

0.4

4150

3239


0.5

4352

3441


III

0.3

3238

2530

0.4

3440

2732


0.5

3642

2934


IV

0.3

2832

2226

0.4

3034

2428


0.5

3236

2630

M 15 Mix Designs as per IS102622009
Dear All,
Here i am giving the mix designs as per IS102622009 which gives to change the procedure for calculating the concrete ingredients
M15 CONCRETE MIX DESIGN


As per IS 102622009 & MORT&H


A1

Stipulations for Proportioning  
1

Grade Designation  M15 
2

Type of Cement  OPC 53 grade confirming to IS122691987 
3

Maximum Nominal Aggregate Size  20 mm 
4

Minimum Cement Content (MORT&H 17003 A)  250 kg/m^{3 } 
5

Maximum Water Cement Ratio (MORT&H 17003 A)  0.5 
6

Workability (MORT&H 17004)  25 mm (Slump) 
7

Exposure Condition  Normal 
8

Degree of Supervision  Good 
9

Type of Aggregate  Crushed Angular Aggregate 
10

Maximum Cement Content (MORT&H Cl. 1703.2)  540 kg/m^{3 } 
11

Chemical Admixture Type  Superplasticiser Confirming to IS9103 
A2

Test Data for Materials  
1

Cement Used  Coromandal King OPC 53 grade 
2

Sp. Gravity of Cement  3.15 
3

Sp. Gravity of Water  1.00 
4

Chemical Admixture  Not Used 
5

Sp. Gravity of 20 mm Aggregate  2.884 
6

Sp. Gravity of 10 mm Aggregate  2.878 
7

Sp. Gravity of Sand  2.605 
8

Water Absorption of 20 mm Aggregate  0.97% 
9

Water Absorption of 10 mm Aggregate  0.83% 
10

Water Absorption of Sand  1.23% 
11

Free (Surface) Moisture of 20 mm Aggregate  nil 
12

Free (Surface) Moisture of 10 mm Aggregate  nil 
13

Free (Surface) Moisture of Sand  nil 
14

Sieve Analysis of Individual Coarse Aggregates  Separate Analysis Done 
15

Sieve Analysis of Combined Coarse Aggregates  Separate Analysis Done 
15

Sp.Gravity of Combined Coarse Aggregates  2.882 
16

Sieve Analysis of Fine Aggregates  Separate Analysis Done 
A3

Target Strength for Mix Proportioning  
1

Target Mean Strength (MORT&H 17005)  25N/mm^{2} 
2

Characteristic Strength @ 28 days  15N/mm^{2} 
A4

Selection of Water Cement Ratio  
1

Maximum Water Cement Ratio (MORT&H 17003 A)  0.5 
2

Adopted Water Cement Ratio  0.5 
A5

Selection of Water Content  
1

Maximum Water content (10262table2)  186 Lit. 
2

Estimated Water content for 25 mm Slump  135 Lit. 
3

Superplasticiser used  nil 
A6

Calculation of Cement Content  
1

Water Cement Ratio  0.5 
2

Cement Content (135/0.5)  270 kg/m^{3 } 

Which is greater then 250 kg/m^{3}  
A7

Proportion of Volume of Coarse Aggregate & Fine Aggregate Content  
1

Vol. of C.A. as per table 3 of IS 10262  62.00% 
2

Adopted Vol. of Coarse Aggregate  65.00% 

Adopted Vol. of Fine Aggregate ( 10.65)  35.00% 
A8

Mix Calculations  
1

Volume of Concrete in m^{3}  1.00 
2

Volume of Cement in m^{3}  0.09 

(Mass of Cement) / (Sp. Gravity of Cement)x1000  
3

Volume of Water in m^{3}  0.135 

(Mass of Water) / (Sp. Gravity of Water)x1000  
4

Volume of Admixture @ 0% in m^{3}  nil 

(Mass of Admixture)/(Sp. Gravity of Admixture)x1000  
5

Volume of All in Aggregate in m^{3}  0.779 

Sr. no. 1 – (Sr. no. 2+3+4)  
6

Volume of Coarse Aggregate in m^{3}  0.507 

Sr. no. 5 x 0.65  
7

Volume of Fine Aggregate in m^{3}  0.273 

Sr. no. 5 x 0.35  
A9

Mix Proportions for One Cum of Concrete (SSD Condition)  
1

Mass of Cement in kg/m^{3}  270 
2

Mass of Water in kg/m^{3}  135 
3

Mass of Fine Aggregate in kg/m^{3}  711 
4

Mass of Coarse Aggregate in kg/m^{3}  1460 

Mass of 20 mm in kg/m^{3}  1051 

Mass of 10 mm in kg/m^{3}  409 
5

Mass of Admixture in kg/m^{3}  nil 
6

Water Cement Ratio  0.5 

M20 Mix Designs as per IS102622009
Dear All
Again I am back with M20 Mix Designs as per IS102622009
M20 CONCRETE MIX DESIGN


As per IS 102622009 & MORT&H


A1

Stipulations for Proportioning  
1

Grade Designation  M20 
2

Type of Cement  OPC 53 grade confirming to IS122691987 
3

Maximum Nominal Aggregate Size  20 mm 
4

Minimum Cement Content (MORT&H 17003 A)  250 kg/m^{3 } 
5

Maximum Water Cement Ratio (MORT&H 17003 A)  0.5 
6

Workability (MORT&H 17004)  25 mm (Slump) 
7

Exposure Condition  Normal 
8

Degree of Supervision  Good 
9

Type of Aggregate  Crushed Angular Aggregate 
10

Maximum Cement Content (MORT&H Cl. 1703.2)  540 kg/m^{3 } 
11

Chemical Admixture Type  Superplasticiser Confirming to IS9103 
A2

Test Data for Materials  
1

Cement Used  Coromandal King OPC 53 grade 
2

Sp. Gravity of Cement  3.15 
3

Sp. Gravity of Water  1.00 
4

Chemical Admixture  Not Used 
5

Sp. Gravity of 20 mm Aggregate  2.884 
6

Sp. Gravity of 10 mm Aggregate  2.878 
7

Sp. Gravity of Sand  2.605 
8

Water Absorption of 20 mm Aggregate  0.97% 
9

Water Absorption of 10 mm Aggregate  0.83% 
10

Water Absorption of Sand  1.23% 
11

Free (Surface) Moisture of 20 mm Aggregate  nil 
12

Free (Surface) Moisture of 10 mm Aggregate  nil 
13

Free (Surface) Moisture of Sand  nil 
14

Sieve Analysis of Individual Coarse Aggregates  Separate Analysis Done 
15

Sieve Analysis of Combined Coarse Aggregates  Separate Analysis Done 
15

Sp. Gravity of Combined Coarse Aggregates  2.882 
16

Sieve Analysis of Fine Aggregates  Separate Analysis Done 
A3

Target Strength for Mix Proportioning  
1

Target Mean Strength (MORT&H 17005)  30N/mm^{2} 
2

Characteristic Strength @ 28 days  20N/mm^{2} 
A4

Selection of Water Cement Ratio  
1

Maximum Water Cement Ratio (MORT&H 17003 A)  0.5 
2

Adopted Water Cement Ratio  0.5 
A5

Selection of Water Content  
1

Maximum Water content (10262table2)  186 Lit. 
2

Estimated Water content for 25 mm Slump  145 Lit. 
3

Superplasticiser used  nil 
A6

Calculation of Cement Content  
1

Water Cement Ratio  0.5 
2

Cement Content (145/0.5)  290 kg/m^{3 } 

Which is greater then 250 kg/m^{3}  
A7

Proportion of Volume of Coarse Aggregate & Fine Aggregate Content  
1

Vol. of C.A. as per table 3 of IS 10262  62.00% 
2

Adopted Vol. of Coarse Aggregate  65.00% 

Adopted Vol. of Fine Aggregate ( 10.65)  35.00% 
A8

Mix Calculations  
1

Volume of Concrete in m^{3}  1.00 
2

Volume of Cement in m^{3}  0.09 

(Mass of Cement) / (Sp. Gravity of Cement)x1000  
3

Volume of Water in m^{3}  0.145 

(Mass of Water) / (Sp. Gravity of Water)x1000  
4

Volume of Admixture @ 0% in m^{3}  nil 

(Mass of Admixture)/(Sp. Gravity of Admixture)x1000  
5

Volume of All in Aggregate in m^{3}  0.763 

Sr. no. 1 – (Sr. no. 2+3+4)  
6

Volume of Coarse Aggregate in m^{3}  0.496 

Sr. no. 5 x 0.65  
7

Volume of Fine Aggregate in m^{3}  0.267 

Sr. no. 5 x 0.35  
A9

Mix Proportions for One Cum of Concrete (SSD Condition)  
1

Mass of Cement in kg/m^{3}  290 
2

Mass of Water in kg/m^{3}  145 
3

Mass of Fine Aggregate in kg/m^{3}  696 
4

Mass of Coarse Aggregate in kg/m^{3}  1429 

Mass of 20 mm in kg/m^{3}  1029 

Mass of 10 mm in kg/m^{3}  400 
5

Mass of Admixture in kg/m^{3}  nil 
6

Water Cement Ratio  0.5 
M25 Mix Designs as per IS102622009
Dear All
Again I am back with M25 Mix Designs as per IS102622009.
M25 CONCRETE MIX DESIGN


As per IS 102622009 & MORT&H


A1

Stipulations for Proportioning  
1

Grade Designation  M25 
2

Type of Cement  OPC 53 grade confirming to IS122691987 
3

Maximum Nominal Aggregate Size  20 mm 
4

Minimum Cement Content (MORT&H 17003 A)  310 kg/m^{3 } 
5

Maximum Water Cement Ratio (MORT&H 17003 A)  0.45 
6

Workability (MORT&H 17004)  5075 mm (Slump) 
7

Exposure Condition  Normal 
8

Degree of Supervision  Good 
9

Type of Aggregate  Crushed Angular Aggregate 
10

Maximum Cement Content (MORT&H Cl. 1703.2)  540 kg/m^{3 } 
11

Chemical Admixture Type  Superplasticiser Confirming to IS9103 
A2

Test Data for Materials  
1

Cement Used  Coromandal King OPC 53 grade 
2

Sp. Gravity of Cement  3.15 
3

Sp. Gravity of Water  1.00 
4

Chemical Admixture  BASF Chemicals Company 
5

Sp. Gravity of 20 mm Aggregate  2.884 
6

Sp. Gravity of 10 mm Aggregate  2.878 
7

Sp. Gravity of Sand  2.605 
8

Water Absorption of 20 mm Aggregate  0.97% 
9

Water Absorption of 10 mm Aggregate  0.83% 
10

Water Absorption of Sand  1.23% 
11

Free (Surface) Moisture of 20 mm Aggregate  nil 
12

Free (Surface) Moisture of 10 mm Aggregate  nil 
13

Free (Surface) Moisture of Sand  nil 
14

Sieve Analysis of Individual Coarse Aggregates  Separate Analysis Done 
15

Sieve Analysis of Combined Coarse Aggregates  Separate Analysis Done 
15

Sp. Gravity of Combined Coarse Aggregates  2.882 
16

Sieve Analysis of Fine Aggregates  Separate Analysis Done 
A3

Target Strength for Mix Proportioning  
1

Target Mean Strength (MORT&H 17005)  36N/mm^{2} 
2

Characteristic Strength @ 28 days  25N/mm^{2} 
A4

Selection of Water Cement Ratio  
1

Maximum Water Cement Ratio (MORT&H 17003 A)  0.45 
2

Adopted Water Cement Ratio  0.43 
A5

Selection of Water Content  
1

Maximum Water content (10262table2)  186 Lit. 
2

Estimated Water content for 5075 mm Slump  138 Lit. 
3

Superplasticiser used  0.5 % by wt. of cement 
A6

Calculation of Cement Content  
1

Water Cement Ratio  0.43 
2

Cement Content (138/0.43)  320 kg/m^{3 } 

Which is greater then 310 kg/m^{3}  
A7

Proportion of Volume of Coarse Aggregate & Fine Aggregate Content  
1

Vol. of C.A. as per table 3 of IS 10262  62.00% 
2

Adopted Vol. of Coarse Aggregate  62.00% 

Adopted Vol. of Fine Aggregate ( 10.62)  38.00% 
A8

Mix Calculations  
1

Volume of Concrete in m^{3}  1.00 
2

Volume of Cement in m^{3}  0.10 

(Mass of Cement) / (Sp. Gravity of Cement)x1000  
3

Volume of Water in m^{3}  0.138 

(Mass of Water) / (Sp. Gravity of Water)x1000  
4

Volume of Admixture @ 0.5% in m^{3}  0.00134 

(Mass of Admixture)/(Sp. Gravity of Admixture)x1000  
5

Volume of All in Aggregate in m^{3}  0.759 

Sr. no. 1 – (Sr. no. 2+3+4)  
6

Volume of Coarse Aggregate in m^{3}  0.471 

Sr. no. 5 x 0.62  
7

Volume of Fine Aggregate in m^{3}  0.288 

Sr. no. 5 x 0.38  
A9

Mix Proportions for One Cum of Concrete (SSD Condition)  
1

Mass of Cement in kg/m^{3}  320 
2

Mass of Water in kg/m^{3}  138 
3

Mass of Fine Aggregate in kg/m^{3}  751 
4

Mass of Coarse Aggregate in kg/m^{3}  1356 

Mass of 20 mm in kg/m^{3}  977 

Mass of 10 mm in kg/m^{3}  380 
5

Mass of Admixture in kg/m^{3}  1.60 
6

Water Cement Ratio  0.43 
M30 Mix Designs as per IS102622009
Dear All
Again I am back with M30 Mix Designs as per IS102622009
M30 CONCRETE MIX DESIGN


As per IS 102622009 & MORT&H


A1

Stipulations for Proportioning  
1

Grade Designation  M30 
2

Type of Cement  OPC 53 grade confirming to IS122691987 
3

Maximum Nominal Aggregate Size  20 mm 
4

Minimum Cement Content (MORT&H 17003 A)  310 kg/m^{3 } 
5

Maximum Water Cement Ratio (MORT&H 17003 A)  0.45 
6

Workability (MORT&H 17004)  5075 mm (Slump) 
7

Exposure Condition  Normal 
8

Degree of Supervision  Good 
9

Type of Aggregate  Crushed Angular Aggregate 
10

Maximum Cement Content (MORT&H Cl. 1703.2)  540 kg/m^{3 } 
11

Chemical Admixture Type  Superplasticiser Confirming to IS9103 
A2

Test Data for Materials  
1

Cement Used  Coromandal King OPC 53 grade 
2

Sp. Gravity of Cement  3.15 
3

Sp. Gravity of Water  1.00 
4

Chemical Admixture  BASF Chemicals Company 
5

Sp. Gravity of 20 mm Aggregate  2.884 
6

Sp. Gravity of 10 mm Aggregate  2.878 
7

Sp. Gravity of Sand  2.605 
8

Water Absorption of 20 mm Aggregate  0.97% 
9

Water Absorption of 10 mm Aggregate  0.83% 
10

Water Absorption of Sand  1.23% 
11

Free (Surface) Moisture of 20 mm Aggregate  nil 
12

Free (Surface) Moisture of 10 mm Aggregate  nil 
13

Free (Surface) Moisture of Sand  nil 
14

Sieve Analysis of Individual Coarse Aggregates  Separate Analysis Done 
15

Sieve Analysis of Combined Coarse Aggregates  Separate Analysis Done 
15

Sp. Gravity of Combined Coarse Aggregates  2.882 
16

Sieve Analysis of Fine Aggregates  Separate Analysis Done 
A3

Target Strength for Mix Proportioning  
1

Target Mean Strength (MORT&H 17005)  42N/mm^{2} 
2

Characteristic Strength @ 28 days  30N/mm^{2} 
A4

Selection of Water Cement Ratio  
1

Maximum Water Cement Ratio (MORT&H 17003 A)  0.45 
2

Adopted Water Cement Ratio  0.42 
A5

Selection of Water Content  
1

Maximum Water content (10262table2)  186 Lit. 
2

Estimated Water content for 5075 mm Slump  160 Lit. 
3

Superplasticiser used  0.5 % by wt. of cement 
A6

Calculation of Cement Content  
1

Water Cement Ratio  0.42 
2

Cement Content (160/0.42)  380 kg/m^{3 } 

Which is greater then 310 kg/m^{3}  
A7

Proportion of Volume of Coarse Aggregate & Fine Aggregate Content  
1

Vol. of C.A. as per table 3 of IS 10262  62.00% 
2

Adopted Vol. of Coarse Aggregate  62.00% 

Adopted Vol. of Fine Aggregate ( 10.62)  38.00% 
A8

Mix Calculations  
1

Volume of Concrete in m^{3}  1.00 
2

Volume of Cement in m^{3}  0.12 

(Mass of Cement) / (Sp. Gravity of Cement)x1000  
3

Volume of Water in m^{3}  0.160 

(Mass of Water) / (Sp. Gravity of Water)x1000  
4

Volume of Admixture @ 0.5% in m^{3}  0.00160 

(Mass of Admixture)/(Sp. Gravity of Admixture)x1000  
5

Volume of All in Aggregate in m^{3}  0.718 

Sr. no. 1 – (Sr. no. 2+3+4)  
6

Volume of Coarse Aggregate in m^{3}  0.445 

Sr. no. 5 x 0.62  
7

Volume of Fine Aggregate in m^{3}  0.273 

Sr. no. 5 x 0.38  
A9

Mix Proportions for One Cum of Concrete (SSD Condition)  
1

Mass of Cement in kg/m^{3}  380 
2

Mass of Water in kg/m^{3}  160 
3

Mass of Fine Aggregate in kg/m^{3}  711 
4

Mass of Coarse Aggregate in kg/m^{3}  1283 

Mass of 20 mm in kg/m^{3}  924 

Mass of 10 mm in kg/m^{3}  359 
5

Mass of Admixture in kg/m^{3}  1.90 
6

Water Cement Ratio  0.42 
Mix Design For M35 Grade Of Concrete
The mix design for M35 Grade Of Concrete for pile foundations provided here is for reference purpose only. Actual site conditions vary and thus this should be adjusted as per the location and other factors.
Grade of Concrete : M35
Characteristic Strength (Fck) : 35 Mpa
Standard Deviation : 1.91 Mpa*
Target Mean Strength : T.M.S.= Fck +1.65 x S.D.
(from I.S 4562000) = 35+ 1.65×1.91
= 38.15 Mpa
Test Data For Material:
Aggregate Type : Crushed
Specific Gravity
Cement : 3.15
Coarse Aggregate : 2.67
Fine Aggregate : 2.62
Water Absorption:
Coarse Aggregate : 0.5%
Fine Aggregate : 1.0 %
MIX DESIGN
Take Sand content as percentage of total aggregates = 36%Select Water Cement Ratio = 0.43 for concrete grade M35
(From Fig 2. of I.S. 10262 1982)
Select Water Content = 172 Kg
(From IS: 10262 for 20 mm nominal size of aggregates Maximum Water Content = 186 Kg/ M^{3 })
Hence, Cement Content= 172 / 0.43 = 400 Kg / M^{3}
Formula for Mix Proportion of Fine and Coarse Aggregate:
1000(1a_{0})_{ }= {(Cement Content / Sp. Gr. Of Cement) + Water Content +(F_{a }/ Sp. Gr.* P_{f })}
1000(1a_{0})_{ }= {(Cement Content / Sp. Gr. Of Cement) + Water Content +C_{a }/ Sp. Gr.* Pc_{ })}
Where C_{a }= Coarse Aggregate Content
F_{a }= Fine Aggregate Content
P_{f } = Sand Content as percentage of total Aggregates
= 0.36
Pc = Coarse Aggregate Content as percentage of total Aggregates.
= 0.64
a_{0 }= Percentage air content in concrete (As per IS :10262 for 20 mm nominal size of
aggregates air content is 2 %) = 0.02
Hence, 1000(10.02)_{ }= {(400 /3.15) + 172 +(F_{a }/ 2.62 x 0.36)}
Fa = 642 Kg/ Cum^{ }
As the sand is of Zone II no adjustment is required for sand.
Sand Content = 642 Kg/ Cum
1000(10.02)_{ }= {(400 /3.15) + 172 +(C_{a }/ 2.67 x 0.64)}
Hence, Ca = 1165 Kg/ Cum^{ }
From combined gradation of Coarse aggregates it has been found out that the proportion of 53:47 of 20 mm & 10 mm aggregates produces the best gradation as per IS: 383.
Hence, 20 mm Aggregates = 619 Kg
And 10 mm Aggregates = 546 Kg
To obtain slump in the range of 150190 mm water reducing admixture brand SP430 from Fosroc with a dose of 0.3 % by weight of Cement shall be used.
Hence the Mix Proportion becomes:
Cem

W/C

Water

Sand

20mm

10mm

Admix

400

0.43

172

635

619

564

1.2

1


0.43

1.6

1.547

1.36

0.003

Cement : Sand: Coarse Aggregates = 1 : 1.6 : 2.907
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