IDAX CONSULTING & RESEARCH GROUP, BBSR JSPL Project, Angul

DESIGN MIX OF M-25 GRADE OF CONCRETE

FOR OATS BATCHING PLANT

Name of the Work: CONSTRUCTI ON OF CIVIL STRUCTURES FO R

JSPL PROJECT, ANGUL

Date: 09.05.2012
ODYSSEY ADVANCED TELEMATICS SYSTEMS (OATS)
JSPL Project, Angul.

CLIENT: JINDAL STEEL & POWER LTD., ANGUL

CONSULTANT: BVIL

TESTING AGENCY:
IDAX CONSULTING & RESEARCH GROUP
Plot No.- 50/6, Duplex-E, Brundaban Enclave, VSS Nagar,
Bhubaneswar-751007, Odisha (INDIA).
Tel: +91-674-3199991, 2360019, Fax: +91-674-2360019
E-mail: info@idaxconsulting.com
Web: www.idaxconsulting.com

Date of Test: 10.04.2012

Date of Submission of Report: 09.05.2012

Design Mix_M25_09.05.2012 Odyssey Advanced Telematics Systems (OATS)

 IDAX CONSULTING & RESEARCH GROUP, BBSR JSPL Project, Angul

Recommendations:

From the above 3 Trail Mixes it is concluded that the Trial Mix-I is fit for the concreting
purpose. So the Trial Mix-I can be adopted for the Building concreting work. The abstract of
the final Trial Mix-I is given separately.

The mix designed proportion of cement concrete (Mix-I) is based on the quality of the
ingredient materials such as water, cement, fine aggregate and coarse aggregates received
in this laboratory. More over as strength of concrete of the said Mix is directly related to the
strength of cement mentioned at A-1 (table- II), cement having the same strength must be
used while adopting the above Mix design of concrete. Aggregates are used in (S.S.D)
saturated surface dry condition in the above Mix-I

NB:
 The above test reports are based on the sample received by our laboratory.
 The test results relates only to the items tested.
 The report shall not be reproduced except in full without the approval of the testing
laboratory.

For IDAX CONSULTING & RESEARCH GROUP

(Sr. Scientist)

Design Mix_M25_09.05.2012 Odyssey Advanced Telematics Systems (OATS)

 IDAX CONSULTING & RESEARCH GROUP
(An ISO 9001:2008 Certified Company)
Plot No.- 50/6, Duplex-E, Brundaban Enclave, VSS Nagar, Bhubaneswar-751007, Odisha. www.idaxconsulting.com
DESIGN MIX / TRIAL MIX REPORT (IS 456:2000 & IS 10262:1999)

DETAILS OF PROJECT / TRIAL: TRAIL NO. : 001 DATE OF TRIAL : 10.04.2012

OATS BATCHING PLANT, JSPL PROJECT, ANGUL LOCATION : IDAX LAB, BATCHING TIME : 17:00
0
BHUBANESWAR AIR TEMPERATURE : 29 C

MIX PROPORTION (KG): BATCH SIZE = 0.025 M3

DESIGN
NAME OF SOURCE / SSD (KG) WATER ABSORPTION DRY MOISTURE QTY /
ADJUSTMENT REMARKS
MATERIAL TYPE BATCH WT.
PER 1M3 % QTY PER 1M
3
% QTY PER 1M
3

CEMENT JSPL 414 - - 414 - - 414 10.35

MINERAL ADM1 - - - - - - - -
MINERAL ADM2 - - - - - - - -
CA : 20MM JSPL 794 0.31 2.46 792 0.15 1.19 793 19.82 JAGANNATH CRUSHER
CA : 10MM JSPL 530 0.31 1.64 528 0.15 0.79 529 13.23 JAGANNATH CRUSHER
FA : SAND BRAHMANI 545 0.72 3.92 541 0.10 0.54 542 13.54 PRADHAN ENTERPRISES
FA : CRF - - - - - - - -
ADMIXTURE 1 SIKA 4 - - 4 - - 4 0.10 PLASTIMENT-R1
ADMIXTURE 2 - - - - - - - -
WATER JSPL 169 - - 177 - - 175 4.36
THEORETICAL PLASTIC DENSITY 2456 2456 2456 2456

FREE W/C = 0.42 ADMIXTURE DOSAGE = 1.00 %

OBSERVATIONS:
0
CONCRETE TEMPERATURE : 32 C COHESIVE / SEGREGATING / BLEEDING
ACTUAL PLASTIC DENSITY : KG/M3 AIR CONTENT (%) : 2% YIELD :
SETTING TIME OF CONCRETE : Initial (hr:min) - 140 min Final (hr:min) - 255 min

INITIAL SLUMP - 135 mm

WORKABILITY SLUMP AFTER 30 MINS - 110 mm
SLUMP AFTER 60 MINS - 100 mm

DENSITY STRENGTH AVERAGE STRENGTH

VE STRENGTH DATA

DATE OF DATE OF WEIGHT

REF NO. AGE (DAYS) SIZE (M3) 3 LOAD (KN) 2
CAST TEST (KG.) (KG/M ) (N/MM ) (N/MM2)

7 0.15x0.15x 8.38 2483 519 23.07

OATS-JSPL 16.04.2012 7 0.15= 8.40 2489 521 23.16 23.01
PROJ- 7 0.003375 8.42 2495 513 22.80
10 04 2012
10.04.2012
COMPRESSIV

TM001-
M25 28 0.15x0.15x 8.28 2453 778 34.58
07.05.2012 28 0.15= 8.26 2447 785 34.89 34.64
28 0.003375 8.31 2462 775 34.44

COMMENTS :

NB:
1.This test report is based on the samples received by our laboratory.
2. The test result relates only to the items tested. Sign:
3. The report shall not be reproduced except in full without the approval. QC Engineer

SUB-CONTRACTOR CONTRACTOR CLIENT CONSULTANT

 IDAX CONSULTING RESEARCH GROUP JSPL Project, Angul

Test on materials for cement concrete Mix-Design for M25 grade.

I:-Water-The sample of water was tested As per IS:456-2000 and IS:3025

Name of Test Observed value Requirement as per I:S:456-2000

Determination of pH value 7.2 Not less than 6

A-1:- Cement: -

Brand: JINDAL
Sl. Requirement as per
Physical Properties Observed value
No. IS:-455 -1989

1 Type and grade PSC ----

2 Standard consistency 29.50% ----

3 Initial setting time 140 minutes Not less than 30 minutes

4 Final setting time 255 minutes Not more than 600 minutes

5 Specific gravity 3.15 ----

6 Compressive strength

Average
Compressive strength of Load Compressive Compressive Requirement as per
cement at in Ton strength in kg/cm² strength in IS:-455 -1989
kg/cm²

12.0 240
3-days 10.5 210 223.333 Min.-160
11.0 220
16.5 330
7-days 15.5 310 313.333 Min.-220
15.0 300
21.0 425
28-days 20.5 410 421.667 Min.-330
21.5 430

Above test results pertain to the samples received in this laboratory.

Design Mix_M25_09.05.2012 Odyssey Advanced Telematics Systems (OATS)

 IDAX CONSULTING RESEARCH GROUP JSPL Project, Angul

II:-Fine aggregates (sand):-

The sample of sand was tested as per IS:383-1970 and IS:2386-1963
1) Grading test:-
Weight of sample taken= 500 gms. Source: Brahmani
Cumulative % by
IS sieve Weight of Percentage Passing as per
% by Weight of % of Weight of
Size in material retained IS-383, 1970
material retained material material
mm. in gms
Retained Passing Zone-I Zone-II Zone-III
10 0.00 0.00 0.0 100 100 100 100
4.75 0.00 0.000 0.000 100 90--100 90--100 90--100
2.36 42.00 8.400 8.400 91.6 60--95 75--100 85--100
1.18 31.50 6.300 14.700 85.3 30--70 55--90 75--100
0.6 68.50 13.700 28.400 71.6 15--34 35--59 60--79
0.3 200.00 40.000 68.400 31.6 5--20 8--30 12--40
0.15 126.00 25.200 93.600 6.4 0--10 0--10 0--10
PAN 32.00 6.400 100.0 0 -- -- --
Fine Aggregate sample conforms to grading "Zone III" as per table 4 of IS: 383-1970
2)Fineness of Modullus = 2.04
3) Specific gravity = 2.70
4) Bulk density = 1630 kg/cum
5) Water Absorption = 0.72 %
III:-Coarse Aggregates :-
The sample of coarse aggregate was tested as per IS:383-1970 and IS: 2386-1963
1)Sieve analysis: (60% 20mm & 40% 10mm)
Weight of sample taken= 5000 gms. Source: Jagannath Crusher

Cumulative % by Required percent passing of

IS sieve Weight of
% by Weight of % of Weight of Aggregate as per IS:383-1970
Size in material retained
material retained material material
mm. in gms
Retained Passing
40mm 20mm 10mm
40 0.0 0.00 0.0 100 95-100 100 ----
20 85.0 1.70 1.7 98.30 30-70 95-100 ----
12.5 ---- ---- ---- ---- ---- ---- 100
10 510.0 10.20 11.9 88.10 10-35 25-55 85-100
4.75 4200.0 84.00 95.9 4.10 0-5 0-10 0-20
PAN 145.0 2.90 98.8 1.20 ---- ---- 0-5

The coarse aggregate sample conforms to 20mm graded aggregate as per Table-2 of IS:383-1970
2) Bulk density = 1680 kg/cum
3) Water absorption = 0.31 %
6) Specific gravity = 2.80
4) Crushing value = 17.5 % Max : 30% by wt. for wearing surfaces such as runway, railways &
5) Impact value = 17 % pavements and 45% by wt. for other concrete as per IS:383-1970.
Max : 30% by wt. for wearing surfaces such as runway, railways &
7) Abrasion Value = 22.6 % pavements and 50% by wt. for other concrete as per IS:383-1970.

Above test results pertain to the samples received in this laboratory

Design Mix_M25_09.05.2012 Odyssey Advanced Telematics Systems (OATS)

TRIAL MIX - I
 IDAX CONSULTING RESEARCH GROUP JSPL Project, Angul

Trial Mix-I
A-2-Design Stipulations of M25 grade cement concrete as per IS: 10262-1982 & IS: 456-2000

a) Characteristic compressive strength after 28 days 25 N/mm²

b) Maximum size of aggregate 20 mm (angular)
c) Degree of workability (slump) 100-135 mm
d) Degree of quality control Good
e) Type of exposure "Moderate"
f) Compressive strength of cement at 28days 421.667 kg/cm²

A-3-Target Mean strength of concrete:-

For a tolerance factor of 1.65 and using table-8 of IS:456-2000, the target mean strength
for M-25 grade concrete is = 25 + 1.65 x 4.0 = 31.6 N/mm²

A-4-Selection of water cement Ratio: - (W/C)

From Fig.2 of IS:10262-1982, the free water cement ratio required for the target mean
strength of 31.6 N/mm² is 0.42 which is less than the maximum value of 0.6
as prescribed "Moderate" for exposure at table-5 of IS:456-2000.

A-5-Selection of water & Sand content:-

From Table-4 of IS:10262-1982,
for 20mm maximum size aggregate and sand conforming to grading "Zone III"
Water content per cubic metre of concrete = 174 kg/m³ (Source: Jindal Tanker)
Admixture Dose = 4 kg/m³ (Make: SIKA-Plastiment R1)
And sand content as percentage of total aggregate by absolute volume= 35 %

For change in W/C & value for fine aggregate (sand) conforming to "Zone III" the
following adjustments are required.

Adjustment required in percentage (%) sand in total aggregate

I) For decrease in W/C ratio=
0.6 - 0.42 = 0.18
0.18 x 20 3.6

ii) For sand conforming to zone III of table-4 of IS:383-1970 1.50

Total 5.10
Therefore required sand content as percentage (%) of total aggregate by absolute volume=
35 - 5.10 = 29.90 %
Coarse aggregate =
100 - 29.90 = 70.10 %
Required water content = 174 kg/m³

Design Mix_M25_09.05.2012 Odyssey Advanced Telematics Systems (OATS)

 IDAX CONSULTING RESEARCH GROUP JSPL Project, Angul

A-6-Determination of cement content:-

Water cement ratio (W/C) = 0.42

Water requirement = 174 kg/cum
Cement requirement = 414.29 kg/cum
Or, say= 414.00 kg/cum
A-7-Determination of Fine and Coarse aggregate content:-

From Table 3 for the specified maximum size of aggregate of 20mm, the amount of entrapped
air in the wet concrete is= 2 (%) percent.

Taking this into account and applying equation from 3.5.1 of IS:10262-1982 .

Determination of fine aggregate (fa):

0.98 ={174+(414/3.15)+(1/0.299)x(fa/2.70)}x1/1000
fa= 544.582 Kg
Or, say= 545 Kg

Determination of Coarse aggregate (Ca)

0.98 ={174+(414/3.15)+(1/0.701)x(Ca/2.80)}x1/1000
Ca= 1324.049 Kg
Or, say= 1324 Kg

Water Cement Fine aggregate Coarse aggregate Remarks

174 Kg 414 Kg/cum 545 Kg/cum 1324 Kg/cum

% wt. w.r.t
0.420 1 1.316 3.198
Cement

21.01 Kg 50 Kg(1Bag) 65.82 Kg 159.90 Kg By weight

21.01 Kg 50 Kg(1Bag) 1.43 Cft 3.36 Cft By Volume

Admixture Dose = 4 Kg/cum

Design Mix_M25_09.05.2012 Odyssey Advanced Telematics Systems (OATS)

 IDAX CONSULTING RESEARCH GROUP JSPL Project, Angul

A-9-Observation of Trial Mix:-

a)Slump= 110mm (Satisfactory as per design)

b) Compressive strength of M25 grade preliminary cement concrete (15cm) cubes.

Compressive Average
Sl.No. Reference Age in days Load in M T Strength in compressive
kg/cm² strength in kg/cm²

1 Mix1 51.9 230.667

2 Mix1 7-days 52.1 231.556 230.074

3 Mix1 51.3 228.000

4 Mix1 778.0 3457.778

5 Mix1 28-days 785.0 3488.889 3463.704

6 Mix1 775.0 3444.444

Remarks:- The mix designed proportion of cement concrete (Mix-I) is based on the quality of the
ingredient materials such as water, cement, fine aggregate and coarse aggregates
received in this laboratory. More over as strength of concrete of the said Mix is directly
related to the strength of cement mentioned at A-1 (table- II), cement having the same
strength must be used while adopting the above Mix design of concrete.
2:-Aggregates are used in (S.S.D) saturated surface dry condition in the above Mix-I

Above test results pertain to the samples received in this laboratory.

For IDAX CONSULTING & RESEARCH GROUP

Design Mix_M25_09.05.2012 Odyssey Advanced Telematics Systems (OATS)

TRIAL MIX - II
 IDAX CONSULTING RESEARCH GROUP JSPL Project, Angul

Trial Mix-II
A-2-Design Stipulations of M25 grade cement concrete as per IS: 10262-1982 & IS: 456-2000

a) Characteristic compressive strength after 28 days 25 N/mm²

b) Maximum size of aggregate 20 mm (angular)
c) Degree of workability (slump) 150-180 mm
d) Degree of quality control Good
e) Type of exposure "Moderate"
f) Compressive strength of cement at 28days 421.667 kg/cm²

A-3-Target Mean strength of concrete:-

For a tolerance factor of 1.65 and using table-8 of IS:456-2000, the target mean strength
for M-25 grade concrete is = 25 + 1.65 x 4.0 = 31.6 N/mm²

A-4-Selection of water cement Ratio: - (W/C)

( Varying the pre-selected free W/C by(+) 10%as per IS : 10262 - 1982 )
From Fig.2 of IS:10262-1982, the free water cement ratio required for the target mean
strength of 31.6 N/mm² is 0.50 which is less than the maximum value of 0.6
as prescribed "Moderate" for exposure at table-5 of IS:456-2000.

A-5-Selection of water & Sand content:-

From Table-4 of IS:10262-1982,
for 20mm maximum size aggregate and sand conforming to grading "Zone III"
Water content per cubic metre of concrete = 200 kg/m³ (Source: Jindal Tanker)
Admixture Dose = 4 kg/m³ (Make: SIKA-Plastiment R1)
And sand content as percentage of total aggregate by absolute volume= 35 %

For change in W/C & value for fine aggregate (sand) conforming to "Zone III" the
following adjustments are required.

Adjustment required in percentage (%) sand in total aggregate

I) For decrease in W/C ratio=
0.6 - 0.5 = 0.1
0.1 x 20 2

ii) For sand conforming to zone III of table-4 of IS:383-1970 1.50

Total 3.50
Therefore required sand content as percentage (%) of total aggregate by absolute volume=
35 - 3.50 = 31.50 %
Coarse aggregate =
100 - 31.50 = 68.50 %
Required water content = 200 kg/m³

Design Mix_M25_09.05.2012 Odyssey Advanced Telematics Systems (OATS)

 IDAX CONSULTING RESEARCH GROUP JSPL Project, Angul

A-6-Determination of cement content:-

Water cement ratio (W/C) = 0.5

Water requirement = 200 kg/cum
Cement requirement = 400.00 kg/cum
Or, say= 400.00 kg/cum
A-7-Determination of Fine and Coarse aggregate content:-

From Table 3 for the specified maximum size of aggregate of 20mm, the amount of entrapped
air in the wet concrete is= 2 (%) percent.

Taking this into account and applying equation from 3.5.1 of IS:10262-1982 .

Determination of fine aggregate (fa):

0.98 ={200+(400/3.15)+(1/0.315)x(fa/2.70)}x1/1000
fa= 555.390 Kg
Or, say= 555 Kg

Determination of Coarse aggregate (Ca)

0.98 ={200+(400/3.15)+(1/0.685)x(Ca/2.80)}x1/1000
Ca= 1252.484 Kg
Or, say= 1252 Kg

Water Cement Fine aggregate Coarse aggregate Remarks

200 Kg 400 Kg/cum 555 Kg/cum 1252 Kg/cum

% wt. w.r.t
0.500 1 1.388 3.130
Cement

25.00 Kg 50 Kg(1Bag) 69.38 Kg 156.50 Kg By weight

25.00 Kg 50 Kg(1Bag) 1.50 Cft 3.29 Cft By Volume

Admixture Dose = 4 Kg/cum

Design Mix_M25_09.05.2012 Odyssey Advanced Telematics Systems (OATS)

 IDAX CONSULTING RESEARCH GROUP JSPL Project, Angul

A-9-Observation of Trial Mix:-

a)Slump= 160mm (Not fit for Pile Concrete)

b) Compressive strength of M25 grade preliminary cement concrete (15cm) cubes.

Compressive Average
Sl.No. Reference Age in days Load in M T Strength in compressive
kg/cm² strength in kg/cm²

1 Mix1 44.0 195.556

2 Mix1 7-days 42.5 188.889 194.815

3 Mix1 45.0 200.000

4 Mix1 65.5 291.111

5 Mix1 28-days 62.0 275.556 290.370

6 Mix1 68.5 304.444

Remarks:- The mix designed proportion of cement concrete (Mix-II) is based on the quality of the
ingredient materials such as water, cement, fine aggregate and coarse aggregates
received in this laboratory. More over as strength of concrete of the said Mix is directly
related to the strength of cement mentioned at A-1 (table- II), cement having the same
strength must be used while adopting the above Mix design of concrete.
2:-Aggregates are used in (S.S.D) saturated surface dry condition in the above Mix-II

Above test results pertain to the samples received in this laboratory.

For IDAX CONSULTING & RESEARCH GROUP

Design Mix_M25_09.05.2012 Odyssey Advanced Telematics Systems (OATS)

TRIAL MIX - III
 IDAX CONSULTING RESEARCH GROUP JSPL Project, Angul

Trial Mix-III
A-2-Design Stipulations of M25 grade cement concrete as per IS: 10262-1982 & IS: 456-2000

a) Characteristic compressive strength after 28 days 25 N/mm²

b) Maximum size of aggregate 20 mm (angular)
c) Degree of workability (slump) 80-110 mm
d) Degree of quality control Good
e) Type of exposure "Moderate"
f) Compressive strength of cement at 28days 421.667 kg/cm²

A-3-Target Mean strength of concrete:-

For a tolerance factor of 1.65 and using table-8 of IS:456-2000, the target mean strength
for M-25 grade concrete is = 25 + 1.65 x 4.0 = 31.6 N/mm²

A-4-Selection of water cement Ratio: - (W/C)

( Varying the pre-selected free W/C by(-) 10%as per IS : 10262 - 1982 )
From Fig.2 of IS:10262-1982, the free water cement ratio required for the target mean
strength of 31.6 N/mm² is 0.40 which is less than the maximum value of 0.6
as prescribed "Moderate" for exposure at table-5 of IS:456-2000.

A-5-Selection of water & Sand content:-

From Table-4 of IS:10262-1982,
for 20mm maximum size aggregate and sand conforming to grading "Zone III"
Water content per cubic metre of concrete = 165 kg/m³ (Source: Jindal Tanker)
Admixture Dose = 4 kg/m³ (Make: SIKA-Plastiment R1)
And sand content as percentage of total aggregate by absolute volume= 35 %

For change in W/C & value for fine aggregate (sand) conforming to "Zone III" the
following adjustments are required.

Adjustment required in percentage (%) sand in total aggregate

I) For decrease in W/C ratio=
0.6 - 0.4 = 0.2
0.2 x 20 4

ii) For sand conforming to zone III of table-4 of IS:383-1970 1.50

Total 5.50
Therefore required sand content as percentage (%) of total aggregate by absolute volume=
35 - 5.50 = 29.50 %
Coarse aggregate =
100 - 29.50 = 70.50 %
Required water content = 165 kg/m³

Design Mix_M25_09.05.2012 Odyssey Advanced Telematics Systems (OATS)

 IDAX CONSULTING RESEARCH GROUP JSPL Project, Angul

A-6-Determination of cement content:-

Water cement ratio (W/C) = 0.40

Water requirement = 165 kg/cum
Cement requirement = 412.50 kg/cum
Or, say= 413.00 kg/cum
A-7-Determination of Fine and Coarse aggregate content:-

From Table 3 for the specified maximum size of aggregate of 20mm, the amount of entrapped
air in the wet concrete is= 2 (%) percent.

Taking this into account and applying equation from 3.5.1 of IS:10262-1982 .

Determination of fine aggregate (fa):

0.98 ={165+(413/3.15)+(1/0.295)x(fa/2.70)}x1/1000
fa= 544.718 Kg
Or, say= 545 Kg

Determination of Coarse aggregate (Ca)

0.98 ={165+(413/3.15)+(1/0.705)x(Ca/2.80)}x1/1000
Ca= 1349.997 Kg
Or, say= 1350 Kg

Water Cement Fine aggregate Coarse aggregate Remarks

165 Kg 413 Kg/cum 545 Kg/cum 1350 Kg/cum

% wt. w.r.t
0.400 1 1.320 3.269
Cement

19.98 Kg 50 Kg(1Bag) 65.98 Kg 163.44 Kg By weight

19.98 Kg 50 Kg(1Bag) 1.43 Cft 3.44 Cft By Volume

Admixture Dose = 4 Kg/cum

Design Mix_M25_09.05.2012 Odyssey Advanced Telematics Systems (OATS)

 IDAX CONSULTING RESEARCH GROUP JSPL Project, Angul

A-9-Observation of Trial Mix:-

a)Slump= 90mm (Not fit for Pile Concrete)

b) Compressive strength of M25 grade preliminary cement concrete (15cm) cubes.

Compressive Average
Sl.No. Reference Age in days Load in M T Strength in compressive
kg/cm² strength in kg/cm²

1 Mix1 59.5 264.444

2 Mix1 7-days 61.0 271.111 267.407

3 Mix1 60.0 266.667

4 Mix1 85.0 377.778

5 Mix1 28-days 84.5 375.556 377.778

6 Mix1 85.5 380.000

Remarks:- The mix designed proportion of cement concrete (Mix-III) is based on the quality of the
ingredient materials such as water, cement, fine aggregate and coarse aggregates
received in this laboratory. More over as strength of concrete of the said Mix is directly
related to the strength of cement mentioned at A-1 (table- II), cement having the same
strength must be used while adopting the above Mix design of concrete.
2:-Aggregates are used in (S.S.D) saturated surface dry condition in the above Mix-III

Above test results pertain to the samples received in this laboratory.

For IDAX CONSULTING & RESEARCH GROUP

Design Mix_M25_09.05.2012 Odyssey Advanced Telematics Systems (OATS)