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. % % OF I.S.
Size Material Retained Retained PASSING Requirement
mm gms for Zone I
10mm 0 0 0.00 100.00 100
4.75mm 140.0 7.0 7.00 93.00 90-100
2.36mm 100.0 5.0 12.00 88.00 75-100
1.18mm 160.0 8.0 20.00 80.00 55-90
600µ 468.0 23.4 43.40 56.60 35-59
300µ 676.0 33.8 77.20 22.80 8-30
150µ 364.0 18.2 95.40 4.60 0-10
75µ 68.0 3.4 98.80 1.20
1976
FINENESS MODULUS : 2.55 ZONE : II Silt Content 1.20

SIEVE ANALYSIS
KAPACHI : 20mm GRIT : 10 mm METAL : 40 mm
Material Taken gms 5000 5000 5000
Proportion 0.45 0.55 0
Sieve Retained % Of Retained % Of Retained % Of Sieve
Graded I.S.
Size Material Passing Material Passing Material Passing size
Aggregate Requirement
mm gms gms gms mm
80 0 100.00 0 100.00 0 100.00 80 100 -
63 0 100.00 0 100.00 0 100.00 63 100 -
40 0 100.00 0 100.00 0 100.00 40 100.00 100
20 480 90.40 0 100.00 0 100.00 20 95.68 95-100
16 4486 0.68 0 100.00 0 100.00 16 55.31 -
12.5 26 0.16 0 100.00 0 100.00 12.5 55.07 -
10 8 0.00 1368 72.64 0 100.00 10 39.95 25-55
4.75 0 0.00 3426 4.12 0 100.00 4.75 2.27 0-10
2.36 0 0.00 206 0.00 0 100.00 2.36 0.00 -
600µ 0 0.00 0 0.00 0 100.00 600µ 0.00 -
150µ 0 0.00 0 0.00 0 100.00 150µ 0.00 -
5000 5000
All-in-Aggregate
I.S. Requirement
Sieve Size Sand Kapachi Grit Metal Mix
For 40mm
39.7% 27.1% 33.2% 0.0% 100.0%
80mm 39.7% 27.1% 33.2% 0.0% 100.0% 100
40mm 39.7% 27.1% 33.2% 0.0% 100.0% 100
20mm 39.7% 24.5% 33.2% 0.0% 97.4% 95-100
4.75mm 36.9% 0.0% 1.4% 0.0% 38.3% 30-50
600µ 22.5% 0.0% 0.0% 0.0% 22.5% 10-35
150µ 1.8% 0.0% 0.0% 0.0% 1.8% 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 Cement: Sanghi 53 grade OPC
2 Coarse Aggregate Source: -
3 Fine Aggregate Source: -
4 Characteristic Strength required in the field at 28 days, N/mm 2
40
5 Maximum Size of aggregate, mm 20
6 Entraped air, % 0.02
7 Degree of Workability 0.90
8 Degree of Quality control Good
9 Exposure Extreme

Test Data of Materials:

1 Specific Gravity of Cement 3.15
2 Req. Compressive Strength of cement at 28 days, N/mm2 53

Sr. I.S. Requirement

Tests Parameter
No. (I.S. 8112 – 1990)
1 Consistency 30.50% --
Setting time
2 Initial, min 165 Shall be more than 30 minutes
Final, min 285 Shall be less than 600 minutes
Compressive strength of mortar cubes (70.6mm size), in N/mm2
3 3 days cured 25.51 Shall be more than 27 N/mm2
7 days cured 34.69 Shall be more than 37 N/mm2

Page 1
3 SPECIFIC GRAVITY
i Coarse Aggregate, Metal 0.000
ii Coarse Aggregate, Kapachi 2.810
iii Coarse Aggregate, Grit 2.810
iv Fine Aggregate 2.660
4 BULK DENSITY
i Cement Kg/m3 1440
ii Metal Kg/m 3
0
iii Kapachi Kg/m3 1401
iv Grit Kg/m3 1422
v Sand Kg/m3 1466
5 Water Absorption
i Coarse Aggregate % 0.19
ii Fine Aggregate % 1.05
6 Free Surface Moisture
i Coarse Aggregate % Nil
ii Fine Aggregate % 1.0
7 Sieve Analysis-Sand
i ZONE (1, 2, 3 or 4) II
ii Fineness Modulus 2.55
iii Silt Content % 1.20
Page 2
12.50 25.51
17.00 34.69
A Target Strength of Concrete
1 Tolerance Factor (Taking 1 in 20 acceptance of results) 1.65
2 Assumed Standard Deviation (Insert 10262 or 456) 456
Accor. To I.S. 10262 (Table no.7) 6.6
Accor. To I.S. 456 (Table no. 5) 5.0
Hence, Standard Deviation for TMS 5.0

Target mean Strength after 28 days N/mm2 48.25

B Selection of Water Cement Ratio 0.4
C Selection of Water & Sand content
For 20mm max. size of aggregate and sand confirming to zone - IV
i) Water content Lit/m3 174
ii) Sand content % 40

Water Content % Sand %

Sr.
Change in Condition
No.
Adj. Req. Changes Adj req. Changes

1 Each 0.05 inc./ dec. in water cement ratio 0 0 +/- 1% 1.0

2 Inc./dec. in compacting Factor by 0.1 +/- 3% 3 0 0
3 Zone confirmation for Sand 0 0 +1.5% for Zone I 0
-1.5% for Zone III

-3% for Zone IV

TOTAL 3 1.0

D Sand required as % of total aggregate by absolute volume 0.41

E Required Water Content, Kg/m3 179.22

F Required Cement Content, Kg/m3 448.05 8.96 Bags
i Determination of Metal Content 0.0 0.00
ii Determination of Kapachi Content Kg 0.45 491.31
iii Determination of Grit Content Kg 0.55 600.49
1091.8
G Determination of Fine Aggregate Content Kg 718.21
 Page 4
H MIX PROPORTIONS ARE:
Coarse Aggregate
Proportion Water Cement Sand
Metal Kapachi Grit
By weight 179.22 448.05 718.21 0.00 491.3 600.49
0.4 1 1.60 0.00 1.10 1.34
By Volume 0.4 1 1.57 0.00 1.13 1.36
For 1bag of Cement, the Quantities of Materials are :
By weight 20 50 80.15 0.00 54.83 67.01

I Extra quantity of water to be added for absorption in case of coarse 0.23

aggregate, by mass
J Quantity of water to be deducted for free moisture present in sand, 0.80
by mass

K Actual quantity of proportions required are :

19.43 50.00 80.95 0.00 54.72 66.88

By weight 0.389 1.00 1.62 0.00 1.09 1.34
By Volume 0.389 1.00 1.59 #DIV/0! 1.12 1.35
 Page 5

Coarse Aggregate
Proportion Water Cement Sand
Metal Kapachi Grit
Weight Batch 20.00 50 80.15 0.00 54.83 67.01
Density --- 0 1466 0 1401 1422
Per M3 --- 0.03 0.054 0.000 0.039 0.047
Per Ft3 --- 1 Bag 1.92 0.00 1.37 1.65
Per Farma --- --- 1.53 0.00 1.10 1.32
(1 X 1 X 1.25) --- --- --- --- --- ---
38.6
4.04

4.05
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. Parameters TM 1
Cement Kg/m 3
448.05
1
Consumption bags 8.96
2 W.C. Ratio 0.4
3 Slump observed, mm 115
4 Water Content, lit/cum 179.22
5 Plasticizer, ml / Bag of Cement 400.00
COARSE AGGREGATE
PROPORTION
TRIAL MIX CEMENT SAND Grit-10mm Kapchi-
BY
DN 20mm DN
WEIGHT 1 1.60 1.34 1.10
1
VOLUME 1 1.57 1.36 1.13
COMPRESSIVE STRENGTH OF 150 mm SIZE OF CUBE- 3 & 7 Days Curing
Compressive
Weight in Density, Observed
TRIAL MIX Strength at 3 days,
kg gm/cc Load, kN
N/mm2
8.51 2.521 680.00 30.22
8.53 2.527 695.00 30.89
8.54 2.530 685.00 30.44

Compressive
Weight in Density, Observed
Strength at 7 days,
kg gm/cc Load, kN
N/mm2

8.52 2.524 835.00 37.11

1 8.53 2.527 830.00 36.89
8.5 2.519 825.00 36.67

Compressive
Weight in Density, Observed
Strength at 28
kg gm/cc Load, kN
days, N/mm2

8.56 2.536 1130.00 50.22

8.55 2.533 1195.00 53.11
8.53 2.527 1180.00 52.44
Note:
1 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
2 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
3 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
4
checked on site to match the design criteria.
This report shall not be reproduced in full or in part unless written permission for
5
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
Plain concrete Reinforced concrete
Min cement Max w/c Minimum Min cement Max w/c Minimum
Exposure
content ratio Grade of content ratio Grade of
Kg/m3 Concrete Kg/m3 Concrete
MILD 220 0.6 ---- 300 0.55 M 20
Concrete surfaces protected
against weather or gressive
conditions, except those
situated in coastal area.

MODERATE 240 0.6 M 15 300 0.5 M 25

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

SEVERE 250 0.5 M 20 320 0.45 M 30

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 260 0.45 M 20 340 0.45 M 35

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
water.
EXTREME 280 0.4 M 25 360 0.4 M40
Surface of members in tidal
zone. Members in direct
contact with liquid/solid
aggressive chemicals.
TABLE NO. 6 Approximate sand & water contents per m3 of concrete
for grades upto M35

Nominal maximum Water content / m3 Sand as % of total agg.

size of aggregate, mm
of concrete by absolute volume
10 208 40
20 186 35
40 165 30
TABLE NO. 2 : WORKABILITY OF CONCRETE TABLE NO. 6 : Propor
Placing Conditions Degree of Workability Values of Workability Grade of
C.F. Slump Concrete
mm
Blinding concrete; Shallow Very Low 0.75--0.8 ----
sections; Pavements using pavers

Mass concrete; Lightly reinforced Low 0.8--0.85 25 - 75

sections in slabs, beams, walls, M5
columns; Floors; Hand placed M7.5
pavements; Canal lining; Strip M 10
footings M 15
M 20
Heavily reinforced sections in Medium 0.85--0.92 50 - 100
slabs,
beams, walls, columns; slipform 75 - 100
work; Pumped concrete

Trench fill; In situ piling High Above .92 100 - 150

Tremie concrete Very High By Flow Value

TABLE NO. 4 TABLE NO. 5

Nominal Adjustments to Minimum Grade of Assumed Standard
Maximum Cement Contents in Table - Concrete Deviation, N/mm2
Aggregate Size 3 kg/sq.cm M10 3.5
M15 3.5
10 +40 M20 4.0
20 0 M25 4.0
40 -30 M30 5.0
M35 5.0
M40 5.0
TABLE NO. 7
SUGGESTED VALUES OF STANDARD DEVIATION

GRADE OF DIFFERENT DEGREE OF CONTROL

CONCRETE VERY GOOD GOOD FAIR

M10 2.0 2.3 3.3

M15 2.5 3.5 4.5
M20 3.6 4.6 5.6
M25 4.3 5.3 6.3
M30 5.0 6.0 7.0
M35 5.3 6.3 7.3
M40 5.6 6.6 7.6
M45 6.0 7.0 8.0
M50 6.4 7.4 8.4
M55 6.7 7.7 8.7
M60 6.8 7.8 8.8
LE 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 60
625 Generally 1 : 2 but 45
subject to an upper
480 34
limit of 1 : 1.5 and a
330 lower limit of 1 : 2.5 32
250 30