For Restricted use only

Project No: HCSCPL-219(Part I)-18/19

December, 2018

Design of Concrete Mixes of M45 Grade

Project Site
GAD Tower at Amaravati, Andhra Pradesh

Report Prepared for

M/s Nagarjuna Construction Company Ltd, Andhra Pradesh

Hitech Concrete Solutions Chennai Pvt. Ltd.,

#64, Galaxy Road, Ponniyamman Nagar,
Ayanambakkam, Chennai-600 095

AN ISO 9001:2015 CERTIFIED ORGANIZATION

&
NABL ACCEREDITED LABORATORY AS PER ISO/IEC 17025
 
 
Materials

The Materials – Cement – UltraTech OPC 43G, GGBS, 20 mm, 12.5 mm, River Sand
(R. Sand), and Admixture - MYK Remicrete PC20 were supplied from M/s NCC, Andhra
Pradesh and were used in the trial mix.

MATERIAL PROPERTIES

Materials Source
Material Description Source of Material
Coarse Aggregate – 20 mm Pericharla
Coarse Aggregate – 12.5 mm Pericharla
Fine Aggregate – River Sand Krishna River – Lingaia Palem
GGBS JSW

1. Cement

Property UltraTech OPC 43 Grade

Normal Consistency % 29
Initial Setting Time (min) 155
Final Setting Time (min) 295
Specific Gravity 3.15

2. GGBS

Property GGBS
Specific Gravity 2.84

3. Aggregates
(a) Sieve Analysis

Sieve Size % Passing

In
20 mm 12.5 mm R. Sand
(mm)
40 100 - -
20 96.20 - -
16 - 99.77 -
12.5 - 99.13 -
10 2.77 77.53 99.7
4.75 0.10 0.73 99.0
2.36 - - 96.8
1.18 - - 87.4
0.6 - - 57.7
0.3 - - 17.8
0.15 - - 2.3

R. Sand conforms to Grading Zone II

 (b) Specific Gravity, Density, Water Absorption

Specific Bulk Density Water Absorption

Type of Aggregate
Gravity kg/m3 %
20 mm 2.70 1661.4 0.45
12.5 mm 2.72 1737.4 0.62
R. Sand 2.58 1726.6 1.52

C) All in Aggregate – M45 Grade with 45% River Sand

CUM % PASSING IN MATERIAL CUM% IS 383

% % % % % % PASSING LIMITS
IS 16.5 38.5 45 ALL IN ALL IN
SIEVE AGG AGG
20 mm 12.5 mm R. Sand 20 mm 12.5 mm R. Sand
40.00 100 100 100 16.50 38.50 45.00 100.00 100
20.00 96.2 100 100 15.87 38.50 45.00 99.37 95 -100
4.75 0.1 0.73 99 0.02 0.28 44.55 44.85 30 - 50
0.60 0 0 57.7 0.00 0.00 25.97 25.97 10 - 35
0.15 0 0 2.3 0.00 0.00 1.04 1.04 0-6

3. Superplasticizer used
1. MYK Remicrete PC20 manufactured by M/s MYK SCOHOMBURG
4. Trial 1 – M45 Grade with GGBS

Step 1
Target strength for mix proportioning = 45 + 1.65 x 5.0 = 53.25 MPa
Step 2
For a M45 grade concrete, w/c required from experience is = 0.34
Step 3
From Table 2 of IS 10262:2009, water content for a slump of 25 to 50 mm for 20 mm
aggregates is 186 kg/m3.

Estimated Water content for a slump of around 175 mm = 186 + 186 *(15/100) = 214 kg/m3.
As Superplasticizer is used, water content can be reduced up to 20 per cent and above.

Based on trials with MYK Remicrete PC20, Water contents (a reduction of nearly 25.23 %)
for a slump of 175 mm at the time of production is arrived as 160 kg/m3.
Step 3
Water Binder ratio = 0.34
Binder content = 470 kg/ m3
 Cement content (40 %) = 190 kg/ m3
GGBS content (60 %) = 280 Kg/ m3
Water content = 470 x 0.34 = 160 kg/m3
Step 4

For pumping concrete and based on experience, volume of the coarse aggregate content
to achieve a cohesive and pumping mix = 0.55

Therefore, volume of the fine aggregate content is 1-0.55 = 0.45

Step 5
The mix calculations per unit volume of concrete are as follows;

Volume of Cement = 190/ (3.15 x 1000) = 0.060

Volume of GGBS = 280/ (2.84 x 1000) = 0.098
Volume of water = 0.160
Volume of Admixture (@1.2 % by the mass of Binder) = (5.64/ (1.09*1000)) = 0.005
Note: the maximum dosage is considered in the design mix for the volume calculation
Volume of all in aggregate = 1-(0.060+0.098+0.160+0.005) = 0.677
Mass of Coarse aggregate 20 mm = 0.677 x 2.70 x 0.165 x 1000 = 302 kg/m3
Mass of Coarse aggregate 12.5 mm = 0.677 x 2.72 x 0.385x 1000 = 709 kg/m3
Mass of Fine Aggregate R. Sand = 0.677 x 2.58 x 0.45 x 1000 = 786 kg/m3
Step 6
a) Final Mixture Proportions in kg/m3

Binder Content Coarse Aggregate Fine MYK Remicrete

Free
Grade of Aggregate PC20
W/C Cement GGBS 20mm 12.5mm Water
Concrete (R. Sand) admixture
kg/m3 kg/m3 kg/m3 kg/m3 kg/m3
3.76 (0.8 % by
M45 0.34 190 280 302 709 786 160
the weight of
Binder)
Note: Dosage of the admixture can be fixed anywhere in the range of 0.5 – 1.2%
based on field trials and weather conditions for workability retention

b) Flow Test Result

Time Period Flow Value in (mm)

Initial Flow, Ti Bleeding
30 minutes, T30 640
60 minutes, T60 580
120 minutes, T120 500
 c) Compression Test Result

Date of Casting Age Date Avg. Compressive strength in N/mm2

ACT 28/11/2018 57.0
3 days 30/11/2018 32.1

27/11/2018 7 days 04/12/2018 39.9

28 days 25/12/2018 56.0
56 days 24/01/2019 69.0

 
 
 
 
 
 
Notes on Design Mix

1. The Design Mix has been carried out using the raw materials supplied by M/s NCC,
Andhra Pradhesh. If there is any change in the source of the materials during the actual
production other than that supplied to M/s Hitech Concrete Solutions Chennai Private
Limited, the proportion of the aggregates may be suitably changed to obtain a cohesive
and pumping mix.

2. Mix indicates adequate flow retention and concrete may be placed in position within
120 minutes from the time of batching/production at the plant/site

3. The water content given in the design mix is free water, based on saturated surface dry
(SSD) condition. The total water may be obtained after deducting for moisture in the
aggregates and adding for the absorption of the aggregates

4. Corrections for moisture in the aggregate may be made on a daily basis and at frequent
intervals during rainy season

5. Suitable corrections for the absorption of the aggregates may be carried out before
batching/production

6. Specific gravities of the materials may be evaluated from time to time to avoid any
issues relating to yield of concrete

7. The dosage of the Superplasticizer may be varied as per the range given in the notes of
the design mix as per the environmental condition prevailing at the time of
batching/production

8. A trial mix may be conducted at the site using the proportions given in the report and
workability ascertained immediately after production.

9. In a project of longer duration, the properties of the constituent materials are likely to
change from time to time. In such cases, minor modification in the course and fine
aggregate contents may be made to ensure a cohesive and pumping mix. However, the
cement content and water to cement ratio are expected to be maintained constant
throughout to ensure the correct strength and long-term durability.