EE Engineering Construction Services

An ISO 9001:2000 Certified Company

Project: Concrete Mix Design from Recycled Waste Material

CONCRETE MIX DESIGN

GRADE: M25 RCC
(75% R.A +25% N.A)

By the Guide lines of hand book on Concrete Mixes (Based on Indian Standard)
SP-23 & IS: 10262-2009

A) Design Stipulations

1 Characteristic Compressive 25 N/mm2 As per IS 10262:2009

Strength and IS 456:2000
2 Target Mean Strength 31.6 N/mm2
3 Maximum Size of Aggregate 20mm
4 Degree of Quality of Concrete Good
5 Type of Exposure Normal
6 Minimum Cement Content 310Kg/m3 As per MORTH Table
1700-2
7 Method of Concreting Pumping/Dumping
8 Maximum Water Concrete 0.45 As per MORTH Table
Ratio 1700-2
9 Type of Aggregate Crushed Angular
Aggregate and
50 % Recycled
Aggregate
10 Chemical Admixture Used SUPER Specific Gravity = 1.105
PLASTICIZER
(Mid PC)
 EE Engineering Construction Services
An ISO 9001:2000 Certified Company

A) Test Data for Materials

1.
Properties of Cement as Obtained from Tests
Brand of Cement UltraTech
Type of Cement Ordinary Portland Cement
Grade of Cement 53 Grade
Specific Gravity of Cement 3.14
Normal Consistency (%) 29
Initial Setting Time (minutes) 110
Final Setting Time (minutes) 320
Fineness of Cement (On 90 Micron) (by 2
Sieve) %
Soundness of Cement by Le-Chatelier 2
(mm)
Compressive Strength of Cement (7 days) 34N/mm2

2.
Properties of Coarse Aggregate as 20mm Aggregate 10mm Aggregate
Obtained
Compacted Bulk Density/ Unit 1540 1515
Weight of Dry Aggregate (Kg/m3)
Loose Bulk Density 1434 1420
Specific Gravity of Coarse Aggregate 2.90 2.66
Flakiness Index % 13.1 -
Elongation Index % 12.1 -
Fineness Modulus 7.12 6.08
Water Absorption (%) 0.95 0.81
Free Surface Moisture nil nil
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An ISO 9001:2000 Certified Company

3. GRADATION OF COARSE AGGREGATES

a) FINENESS MODULUS OF AGGREGATES 20mm WEIGHT = 5000 grams

S.No IS Sieve No Weight % Weight Cumulative % Passing

Retained retained % retained
grams
1 40mm 0 0 0 100
2 20mm 386 12.4 12.4 92.28
3 10mm 4614 87.6 100 0
4 4.75mm 0 0 100 0
5 2.36mm 0 0 100 0
6 1.18mm 0 0 100 0
7 600 mic 0 0 100 0
8 300 mic 0 0 100 0
9 150 mic 0 0 100 0

Fineness Modulus: 7.12

b) FINENESS MODULUS OF AGGREGATES 10mm WEIGHT = 5000 grams

S.No IS Sieve No Weight % Weight Cumulative % Passing

Retained retained % retained
grams
1 40mm 0 0 0 100
2 20mm 0 0 0 100
3 10mm 297 8.5 8.5 91.5
4 4.75mm 4703 91.5 100 0
5 2.36mm 0 0 100 0
6 1.18mm 0 0 100 0
7 600 mic 0 0 100 0
8 300 mic 0 0 100 0
9 150 mic 0 0 100 0

Fineness Modulus: 6.08

 EE Engineering Construction Services
An ISO 9001:2000 Certified Company

c) . Combined Gradation of Coarse Aggregates (Theoretical)

Sieve % % Mix % of Specified Limits as

Size passing passing Proportion passing per IS:383
in for 20mm for 10mm 20mm 10mm
mm Aggregate Aggregate 50% 50% LOWER UPPER
40 100 100.00 50.00 50.00 100 100 100
20 91.10 100.00 45.55 50.00 95.55 95 100
10 12.45 88.48 6.23 44.24 50.47 25 55
4.75 0.63 16.58 0.32 8.29 8.61 0 10

d) Combined Gradation of Coarse Aggregate (Actual)

Sieve Size in % of Passing Specified limits as per

(mm) IS:383
40 100 100
20 96.5 95-100
10 51.4 25-55
4.75 0 0-10

4.
a) Properties of Fine Aggregate Recycled Sand 50%
as Obtained Coarse + 50% Fine
(Ramky Plant)
Compacted Bulk Density/ Unit 1855
Weight of Dry Aggregate (Kg/m3)
Loose Bulk Density 1720
Specific Gravity of Fine Aggregate 2.68
Water Absorption (%) 2.31
Free Surface Moisture nil
 EE Engineering Construction Services
An ISO 9001:2000 Certified Company

b) Gradation (50% Coarse Sand + 50% Fine Sand)

Sieve Size in % of passing Specified Limits IS:383-2016

mm (Average) Zone-1 Zone-2 Zone-3
10.0 100 100 100 100
4.75 95.4 90-100 90-100 90-100
2.36 87.4 60-95 75-100 85-100
1.18 65.4 30-70 55-90 75-100
0.600 48.5 15-34 35-59 60-79
0.300 19.5 5-20 8-30 12-40
0.150 6.7 0-10 0-10 0-10

c) All in Aggregate – (Theoretical Blending )

Sieve % of Passing (Average) % of Ingredients % of Specified

Size in 29.00% 29.00% 21.00% 21% Passing limits as

(mm) 20mm 10mm River M 20mm 10mm Coarse Fine per

Sand Sand
Sand Sand IS:383

40mm 100 100 100 100 29.00 29.00 21.00 21.00 100.00 100

20mm 91.10 100 100 100 26.42 29.00 21.00 21.00 97.42 95-100

4.75mm 0.63 16.59 99.73 94.65 0.18 4.81 20.94 19.88 45.81 30-50

600mic 0 0 88.73 21.90 0.00 0.00 18.63 4.60 23.23 10-35

150mic 0 0 2.85 5.88 0.00 0.00 0.60 1.23 1.83 0-6

d) All in Aggregate – Actual Blending

Sieve Size in (mm) % of Passing Specified limits as per IS:383
40mm 100.00 100
20mm 97.1 95-100
4.75mm 48.5 30-50
600 mic 24.2 10-35
150 mic 2.20 0-6
 EE Engineering Construction Services
An ISO 9001:2000 Certified Company

5) Target Mean Strength of Concrete

 As per IS 10262 -2009,IS 456- 2000 and MORTH

Table 1700-5

F'ck= Fck+1.65(S)

where

ck f/ck = target average compressive strength at 28 days

f ck = characteristic Compressive strength at 28 days , and s

= standard deviation

 From table 1, standard deviation s = 5 N/mm 2

 Therefore, target strength =25+1.65 X 5 = 31.65 N/mm2 (as per IS

456 - 2000)

 Adopted Target mean Strength = 31.65 N/mm 2

(MORTH ->Table-1700-5)

Current margin = 6.65 Mpa

6)Selection of Water- Cement Ratio:

 As per MORT&H 1700-3 A specifications, the maximum W/C ratio

prescribed as 0.45.

 Based on experience, adopt water-cement 0.43

 Entrapped air content in the wet concrete is 1% (As per IS 10262 -2009)

 That means 1m3 of concrete is having 0.01m 3 of air content

 Total Aggregate Volume = 1 - 0.01 = 0.99m3

 EE Engineering Construction Services
An ISO 9001:2000 Certified Company

7) Selection of Water-Content:

1 Maximum Water Content (10262 – table-2) 186 Litres

2 Estimated Water Content for 50 - 75 mm Slump 138 Litres
3 Superplasticiser Used (1.1% by weight of 3.85 Kg
Cementitious Material)

8) Calculation of Cement Content:

1 Water Cement Ratio 0.43

2 Cement Content (138/0.43) 320 Kg/m3
Which is greater then
340Kg/m3

9) Proportion of Volume of Coarse Aggregate and Fine Aggregate Content

1 Volume of CA as per table 3 of IS 10262 62.00%

2 Adopted Volume of Coarse Aggregate 62.00%

3 Adopted Volume of Fine Aggregate 38.00%

 EE Engineering Construction Services
An ISO 9001:2000 Certified Company

10) Determination of Coarse and Fine Aggregate Content

The mix calculations per unit volume of coarse aggregates shall be as follows:

a) Volume of Concrete : 0.99m3

b) Volume of Cement : (Mass of Cement/Specific Gravity of Cement) x (1/1000)

(320/3.14) X 1/1000 = 0.1019

c) Volume of Water : (Mass of Water/Specific Gravity of Water) X 1/1000

(138/1) X (1/1000) = 0.138

d) Volume of Admixture : 0.0035

e) Volume of All Aggregate : (0.99 – 0.0859 - 0.135) = 0.7311m3

f) Volume of Coarse Aggregate : 0.402m3

g) Volume of Fine Aggregate : 0.3289m3

11) Mix Proportions for one Cum of Concrete (SSD Condition)

1 Mass of Cement in Kg/m3 320

2 Mass of Water Kg/m3 138

3 Mass of Fine Aggregate in Kg/m3 921.48

4 Mass of Coarse Aggregate in Kg/m3 1180.537

5 Mass of 20mm in Kg/m3 867.13

6 Mass of 10mm in Kg/m3 313.407

7 Mass of Admixture in Kg 3.85

8 Water Cement Ratio 0.43

 EE Engineering Construction Services
An ISO 9001:2000 Certified Company

12) Summary of Cube Test Results:

Batch Date of Date of Stren Average Date of 28 Days Average

No Casting Testing gth at Strength Testing Strength Strength
7
Days
21.8 21.56 32.2 32.266
Batch
1 20.8 31.9

22.1 32.7

22.0 21.46 32.6 32.36

Batch
2 17.06.2020 23.06.2020 21.5 24.06.2020 32.1
(Accelerated
Curing Tank
20.9 Used)
32.4

21.1 21.533 32.1 32.23

Batch
3 21.6 32.1

21.9 32.5