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. % Size Material Retained Retained mm gms 0 10mm 0 0.00 140.0 4.75mm 7.0 7.00 100.0 2.36mm 5.0 12.00 160.0 1.18mm 8.0 20.00 600m 468.0 23.4 43.40 300m 676.0 33.8 77.20 150m 364.0 18.2 95.40 75m 3.4 98.80 68.0 1976 FINENESS MODULUS : 2.55

% OF PASSING 100.00 93.00 88.00 80.00 56.60 22.80 4.60 1.20 ZONE : II

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

Silt Content

1.20

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 0 480 20 90.40 100.00 0 4486 16 0.68 100.00 0 26 12.5 0.16 100.00 1368 8 10 0.00 72.64 3426 0 4.75 0.00 4.12 206 0 2.36 0.00 0.00 600m 0 0 0.00 0.00 150m 0.00 0.00 0 0 5000 5000 All-in-Aggregate Sieve Size Sand Kapachi Grit Metal 34.7% 29.4% 35.9% 0.0% 80mm 34.7% 29.4% 35.9% 0.0% 40mm 34.7% 29.4% 35.9% 0.0% 20mm 34.7% 26.5% 35.9% 0.0% 4.75mm 32.3% 0.0% 1.5% 0.0% 600m 19.7% 0.0% 0.0% 0.0% 150m 1.6% 0.0% 0.0% 0.0%

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 0 100.00 100.00 0

Sieve size mm 80 63 40 20 16 12.5 10 4.75 2.36 600m 150m

Graded Aggregate 100 100 100.00 95.68 55.31 55.07 39.95 2.27 0.00 0.00 0.00

I.S. Requirement
-

100 95-100 25-55 0-10 -

Mix 100.0% 100.0% 100.0% 97.2% 33.8% 19.7% 1.6%

I.S. Requirement For 40mm

100 100 95-100 30-50 10-35 0-6

Page 3

CALCULATION SHEET OF M40 GRADE MIX DESIGN

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

Design Stipulation: 1 2 3 4 5 6 7 8 9 Cement: Coarse Aggregate Source: Fine Aggregate Source: Characteristic Strength required in the field at 28 days, N/mm2 Maximum Size of aggregate, mm Entraped air, % Degree of Workability Degree of Quality control Exposure Sanghi 53 grade OPC
-

40 20 0.02 0.90 Good Extreme

Test Data of Materials: 1 2 Sr. No. 1 2 Specific Gravity of Cement Req. Compressive Strength of cement at 28 days, N/mm
2

3.15 53

Tests Consistency Setting time Initial, min Final, min

Parameter 30.50% 165 285 25.51 34.69

I.S. Requirement (I.S. 8112 1990) -Shall be more than 30 minutes Shall be less than 600 minutes 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

3 days cured 7 days cured

Page 1

3 i ii iii iv 4 i ii iii iv v 5 i ii 6 i ii 7 i ii iii

SPECIFIC GRAVITY Coarse Aggregate, Metal Coarse Aggregate, Kapachi Coarse Aggregate, Grit Fine Aggregate BULK DENSITY Cement Metal Kapachi Grit Sand Kg/m3 Kg/m Kg/m
3

0.000 2.810 2.810 2.660 1440 0 1401 1422 1466

% %

Kg/m3
3 3

Kg/m Water Absorption Coarse Aggregate Fine Aggregate Free Surface Moisture Coarse Aggregate Fine Aggregate Sieve Analysis-Sand ZONE (1, 2, 3 or 4) Fineness Modulus Silt Content %
% %

0.19 1.05 Nil 1.0 II 2.55 1.20

Page 2

12.50 17.00

25.51 34.69

A 1 2

Target Strength of Concrete Tolerance Factor (Taking 1 in 20 acceptance of results) 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 1.65 456 6.6 5.0 5.0

Target mean Strength after 28 days B C Selection of Water Cement Ratio Selection of Water & Sand content

N/mm

48.25 0.4

For 20mm max. size of aggregate and sand confirming to zone - IV i) ii) Water content Sand content Lit/m %
3

180 35

Sr. No. 1 2 3

Water Content % Change in Condition Adj. Req. Each 0.05 inc./ dec. in water cement ratio Inc./dec. in compacting Factor by 0.1 Zone confirmation for Sand 0 +/- 3% 0 Changes 0 3 0

Sand % Adj req. +/- 1% 0

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

Changes 1.0 0 0

TOTAL

1.0

D E F i ii iii G

Sand required as % of total aggregate by absolute volume Required Water Content, Kg/m3 Required Cement Content, Kg/m3 Determination of Metal Content Determination of Kapachi Content Determination of Grit Content Determination of Fine Aggregate Content Kg Kg Kg 0.0 0.45 0.55

0.36 185.40 463.50 0.00 523.97 640.41 1164.4 620.00

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9.27 Bags

MIX PROPORTIONS ARE:

Coarse Aggregate Proportion
By weight

Water

Cement

Sand Metal Kapachi Grit

185.40 0.4

463.50 1 1

620.00 1.34 1.31

0.00 0.00 0.00

524.0 1.13 1.16

640.41 1.38 1.40

By Volume

0.4

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

By weight

20

50

66.88

0.00

56.52

69.08

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

0.24 0.67

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

Actual quantity of proportions required are :

19.57 By weight By Volume 0.391 0.391

50.00 1.00 1.00

67.55 1.35 1.33

0.00 0.00 #DIV/0!

56.42 1.13 1.16

68.95 1.38 1.40

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Proportion

Water

Cement

Sand

Coarse Aggregate Metal Kapachi Grit

Weight Batch Density Per M

3

20.00 -----------

50 0 0.0345 1 Bag -----

66.88 1466 0.045 1.60 1.28 ---

0.00 0 0.000 0.00 0.00 ---

56.52 1401 0.040 1.41 1.13 ---

69.08 1422 0.048 1.70 1.36 ---

Per Ft3 Per Farma (1 X 1 X 1.25)

38.6

3.85

3.86

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.
S. N. 1 2 3 4 5

Parameters
Cement Consumption W.C. Ratio Slump observed, mm Water Content, lit/cum Plasticizer, ml / Bag of Cement PROPORTION BY WEIGHT VOLUME CEMENT 1 1 Kg/m bags
3

TM 1
463.50 9.27 0.4 115 185.40 400.00
COARSE AGGREGATE

TRIAL MIX 1

SAND 1.34 1.31

Grit-10mm DN 1.38 1.40

Kapchi20mm DN 1.13 1.16

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

TRIAL MIX Weight in kg 8.51 8.53 8.54 1 Weight in kg 8.52 8.53 8.5 Density, gm/cc 2.521 2.527 2.530 Density, gm/cc 2.524 2.527 2.519 Observed Load, kN 680.00 695.00 685.00 Observed Load, kN 835.00 830.00 825.00 Compressive Strength at 3 days, N/mm2 30.22 30.89 30.44 Compressive Strength at 7 days, N/mm2 37.11 36.89 36.67

Note:
1 2 3 4 5

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

TABLE NO. 1 Where Freezing & Thawing action prevails 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. 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 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 Kg/m3 Concrete Concrete 220 0.6 ---300 0.55 M 20

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

250

0.5

M 20

320

0.45

M 30

260

0.45

M 20

340

0.45

M 35

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

TABLE NO. 6 : Proportions

Grade of Concrete

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 Heavily reinforced sections in slabs, beams, walls, columns; slipform work; Pumped concrete Trench fill; In situ piling Tremie concrete

Very Low

Low

0.8--0.85

25 - 75 M5 M7.5 M 10 M 15 M 20

Medium

0.85--0.92

50 - 100 75 - 100

High Very High

Above .92

100 - 150 By Flow Value

TABLE NO. 4
Nominal Adjustments to Minimum Maximum Cement Contents in Table Aggregate Size 3 kg/sq.cm 10 20 40 +40 0 -30

TABLE NO. 5
Grade of Concrete M10 M15 M20 M25 M30 M35 M40 Assumed Standard Deviation, N/mm2 3.5 3.5 4.0 4.0 5.0 5.0 5.0

TABLE NO. 7
SUGGESTED VALUES OF STANDARD DEVIATION GRADE OF CONCRETE M10 M15 M20 M25 M30 M35 M40 M45 M50 M55 M60 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 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

TABLE 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 60 45 34 32 30

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