GRADATION CHART

SIEVE PERCENTAGE OF DIFFERENT

PERCENT PASSING
FRACTIONS
SIZE
I II III TOTAL
I II III
"mm" 98 % 2% 0% 100 %

4.75 95 91.8 0 93.1 1.836 0 94.936

2.36 90 67.67 0 88.2 1.3534 0 89.553
1.18 80 57.84 0 78.4 1.1568 0 79.557
600 65 47.13 0 63.7 0.9426 0 64.643
300 13 32.77 0 12.74 0.6554 0 13.395
150 3.45 21.18 0 3.381 0.4236 0 3.8046

Sieve analysis of Fine aggregate

SIEVE
PERCENT
LIMIT AS PER IS:383 (TABLE 4)
SIZE
PASSING REMARKS
ZONE I ZONE II ZONE III
1 1 1 4.75 mm 94.94 90 - 100 90 - 100 90 - 100
1 1 1 2.36 mm 89.55 60 - 95 75 - 100 85 - 100
0 1 1 1.18 mm 79.56 30 - 70 55 - 90 75 - 100 CONFORMING TO
0 0 1 600 mic. 64.64 15 - 34 35 - 59 60 - 79 GRADING ZONE-III

1 1 1 300 mic. 13.40 5 - 20 8 - 30 12 - 40

1 1 1 150 mic. 3.80 0 - 10 0 - 10 0 - 10
0 0 3 3
120
4.75 90 100 94.9

100
2.36 85 100 89.6
PERCENTAGE PASSING

1.18 75 100 79.6

80
0.6 60 79 64.6

60
0.3 12 40 13.4

0.15 0 10 3.8
40

20

0
0.1 1 10

SIEVE SIZE IN mm

LOWER LIMIT UPPER LIMIT COMBINED

 GRADATION CHART

SIEVE PERCENTAGE OF DIFFERENT

PERCENT PASSING
FRACTIONS
SIZE
I II III TOTAL
I II III
"mm" 40 % 60 % 0% 100 %

4.75 92.17 99.73 0 36.868 59.838 0 96.706

2.36 62.3 98.36 0 24.92 59.016 0 83.936
1.18 51.78 97.58 0 20.712 58.548 0 79.26
600 40.68 94.79 0 16.272 56.874 0 73.146
300 25.03 41.37 0 10.012 24.822 0 34.834
150 16.01 4.13 0 6.404 2.478 0 8.882

Sieve analysis of Fine aggregate

SIEVE
PERCENT
LIMIT AS PER IS:383 (TABLE 4)
SIZE
PASSING REMARKS
ZONE I ZONE II ZONE III
1 1 1 4.75 mm 96.71 90 - 100 90 - 100 90 - 100
1 1 0 2.36 mm 83.94 60 - 95 75 - 100 85 - 100
0 1 1 1.18 mm 79.26 30 - 70 55 - 90 75 - 100 NOT CONFORMING
TO ANY GRADING
0 0 1 600 mic. 73.15 15 - 34 35 - 59 60 - 79 ZONE
0 0 1 300 mic. 34.83 5 - 20 8 - 30 12 - 40
1 1 1 150 mic. 8.88 0 - 10 0 - 10 0 - 10
0 0 0 0
120
4.75 90 100 96.7

100
2.36 85 100 83.9
PERCENTAGE PASSING

1.18 75 100 79.3

80
0.6 60 79 73.1

60
0.3 12 40 34.8

0.15 0 10 8.88
40

20

0
0.1 1 10

SIEVE SIZE IN mm

LOWER LIMIT UPPER LIMIT COMBINED

 GRADATION CHART

SIEVE PERCENTAGE OF DIFFERENT

PERCENT PASSING BLENDING RESULT
FRACTIONS
SIZE
I II III TOTAL SIEVE PERCENT PERCENT PASSING
I II III
"mm" SIZE PASSING AS PER MOST
11 % 29 % 60 % 100 %

19 91.56 100 100 10.072 29 60 99.072 19.00 mm 99.072 100 - 100

13.2 44.59 99.85 100 4.9049 28.957 60 93.861 13.20 mm 93.861 79 - 100
9.5 10.19 92.02 100 1.1209 26.686 60 87.807 9.50 mm 87.807 70 - 88
4.75 0.03 0.24 96.02 0.0033 0.0696 57.612 57.685 4.75 mm 57.685 53 - 71
2.36 71.44 0 0 42.864 42.864 2.36 mm 42.864 42 - 58
1.18 61.94 0 0 37.164 37.164 1.18 mm 37.164 34 - 48
0.6 50.1 0 0 30.06 30.06 0.60 mm 30.060 26 - 38
0.3 37.36 0 0 22.416 22.416 0.30 mm 22.416 18 - 28
0.15 21.16 0 0 12.696 12.696 0.15 mm 12.696 12 - 20
0.075 11.22 0 0 6.732 6.732 0.075 mm 6.732 4 - 10

120
### ### ### ###
100

19 100 100 ###

PERCENTAGE PASSING

80
13.2 79 100 ###

9.5 70 88 ###
60
4.75 53 71 ###

2.3640 42 58 ###

1.18 34 48 ###
20
0.6 26 38 ###

0.3 0 18 28 ###

0.1 1 10 100
0.15 12 20 ###

SIEVE SIZE IN mm
0.08 4 10 ###

LOWER LIMIT UPPER LIMIT COMBINED

 PAGE 7 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
GRADE : M 25 DATED : 2/11/2006

1. DESIGN STIPULATIONS

1 Characteristic compressive strength required 25 Mpa D

2 Maximum size of aggregate 20 mm D

3 Degree of workability (compacting factor) 0.85 D

4 Degree of quality control Good D

5 Type of Structure (PCC, RCC, PSC) RCC D

6 Type of exposure (1 for Normal, 2 for Severe) 1 D

7 Type of Structure (1 for Major, 2 for Culverts) 2

2. TEST DATA FOR MATERIALS

1 Grade of Cement (OPC)) 43 D

2 Specific gravity of cement 3.15 D

3 Specific gravity of Coarse aggregate 2.738 D

4 Specific gravity of Fine aggregate 2.729 D

5 Water absorption of Coarse aggregate 0.53 % D

6 Water absorption of Fine aggregate 0.61 % D

7 Free (surface) moisture of Coarse aggregate 0.00 % D

8 Free (surface) moisture of Fine aggregate 0.00 % D

9 Sieve analysis of Coarse aggregate

SIEVE PERCENTAGE OF DIFFERENT

PERCENT PASSING D
FRACTIONS LIMIT AS
SIZE
I II III TOTAL
PER REMARKS
I II III IS:383
"mm" 70 % 30 % 0% 100 %

1 20 97.63 100 0 68.341 30 0 98.341 95-100

1 10 2.77 97.31 0 1.939 29.193 0 31.132 25-55 CONFORMING TO
1 4.75 0.09 1 0 0.063 0.3 0 0.363 0-10 TABLE 2 OF IS:383

1 2.36 0 0 0 0 0 0 0 0
4
120
20 95 100 98

10 25 55 31
100
4.75 0 10 0.36
PERCENTAGE PASSING

2.36 80 0 0 0

60

40

20

0
0 5 10 15 20 25

SIEVE SIZE IN mm

LOWER LIMIT UPPER LIMIT COMBINED

IRCON'S REPRESENTATIVE SWK'S REPRESENTATIVE

 PAGE 8 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
GRADE : M 25 DATED : 2/11/2006

10 Sieve analysis of Fine aggregate

SIEVE PERCENT
LIMIT AS PER IS:383 (TABLE 4) D
SIZE PASSING REMARKS
ZONE I ZONE II ZONE III D

1 1 1 4.75 mm 97.79 90 - 100 90 - 100 90 - 100

1 1 1 2.36 mm 92.76 60 - 95 75 - 100 85 - 100
0 1 1 1.18 mm 87.03 30 - 70 55 - 90 75 - 100 CONFORMING TO
0 0 1 600 mic. 73.18 15 - 34 35 - 59 60 - 79 GRADING ZONE-III

0 1 1 300 mic. 20.4 5 - 20 8 - 30 12 - 40

1 1 1 150 mic. 2.22 0 - 10 0 - 10 0 - 10
0 0 3 3
120

4.75 90 100 97.8

100
2.36 85 100 92.8
PERCENTAGE PASSING

1.18 75 100 87
80
0.6 60 79 73.2

600.3 12 40 20.4

0.15 0 10 2.22
40

20

0
0.1 1 10

SIEVE SIZE IN mm

LOWER LIMIT UPPER LIMIT COMBINED

3. TARGET MEAN STRENGTH OF CONCRETE

Current Margin for M 25 grade concrete as per MOST = 11.0

Therefore Target mean strength = 36.00 Mpa

IRCON'S REPRESENTATIVE SWK'S REPRESENTATIVE

 PAGE 9 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
GRADE : M 25 DATED : 2/11/2006

4. SELECTION OF WATER CEMENT RATIO

FIG. 1 OF IS:10262-1982
60
0 0.3 0.4 0

10 0.33 43.5 53.2 0.4 36

50
28 DAY COMPRESSIVE STRENGTH IN Mpa

0.64 17.8 0.35 41.1 50.6 0 36

0.59 20 0.4 35.3 43.4

0.46 30 0.45 30 36.9

40
0.37 40 0.5 25.1 31.5

0.31 50 0.55 21.5 26.6

0.3 51.1 0.6 18.4 22.4

30
60 0.64 16.3 19.7

20

10

0
0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65
WATER CEMENT RATIO

GENEREL FOR 43 GRADE CEMENT FOR 53 GRADE CEMENT W/C REQUIRED

From Fig. 1, the free water-cement ratio required for the target mean strength of
36 Mpa is = 0.4 D

As per MOST Specification, the max. water cement ratio = 0.45

And the water cement ratio adopted = 0.45 D

5. SELECTION OF WATER AND SAND CONTENT

From Table 4 & 5 (IS:10262), for 20 mm nominal max. size agg and Mix M 25
Water content per cubic metre of concrete = 186 kg
Sand content as percentage of total aggregate = 35 %
Required adjustment as per Table 6 (IS:10262):

ADJUSTMENT
CONDITION
WATER CONTENT " % " %SAND IN TOTAL AGG.

ZONE-III (SAND) 0.00 -1.50

FOR C F, (0.85-0.8) THAT IS 0.05 1.50 0.00

4 0.60 FOR DECREASE IN W/C RATIO

0.00 - 3.00
BY (0.6-0.45) THAT IS 0.15

IRCON'S REPRESENTATIVE SWK'S REPRESENTATIVE

 PAGE 10 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
GRADE : M 25 DATED : 2/11/2006

TOTAL 1.50 - 4.50

IRCON'S REPRESENTATIVE SWK'S REPRESENTATIVE

 PAGE 11 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
GRADE : M 25 DATED : 2/11/2006

Therefore required water content per cubic metre of concrete = 188.8 lit/cu. m
And required sand content as percentage of total aggregate = 30.5 %

6. DETERMINATION OF CEMENT CONTENT

Water Cement ratio = 0.45

Water = 188.8 lit
Cement = 420 kg/cu.m

But as per MOST, CL:1703.2 min. cement required = 310 kg

And max. cement content = 540 kg
Therefore cement content = 420 kg

7. DETERMINATION OF COARSE AND FINE AGGREGATE CONTENT

From Table-3, for the specified max. size of aggregate of 20 mm , the amount of
entrapped air in the wet concrete is = 2%

Taking this into account and appling equations from 3.5.1, IS:10262 :
fa = 548 kg/cu. m
and, ca = 1252 kg/cu. m

The Mix proportion then becomes :

WATER CEMENT FINE AGG. COARSE AGG.
189.0 lit 420 kg 548 kg 1252 kg
0.45 1 1.30 2.98

8. ACTUAL QUANTITIES REQUIRED FOR THE MIX

1 CEMENT : = 420 kg

2 WATER :
(a) For water cement ratio of 0.45 quantity of water = 189.00 litres
(b)
Extra quantity of water for absorption of coarse aggregate, at 0.53 % by mass = 6.64 litres
(c) Quantity of water to be deducted for free moisture present in sand, at 0 % by
mass = 0.00 litres
(d) Actual quantity of water to be added = 195.64 litres

IRCON'S REPRESENTATIVE SWK'S REPRESENTATIVE

 PAGE 12 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
GRADE : M 25 DATED : 2/11/2006

3 SAND :
= 548.00 kg
Actual quantity of sand required after allowing for mass of free moisture

4 COARSE AGGREGATE :
Actual quantity of coarse aggregete required :
876 4.64 (a) Fraction 1, (876.4 - 4.64) = 871.76 kg
376 1.99 (b) Fraction 2, (375.6 - 1.99) = 373.61 kg
0 0 (c) Fraction 3, (0 - 0) = 0.00 kg

Therefore, the actual quantities of different constituents required for the mix are :

Rounded
Constituents FOR 1 cu.m Concrete FOR 1 bag Cement
Quantity

WATER __________ 195.6 lit 23.3 lit 23 lit

CEMENT __________ 420 kg 50 kg 50 kg

FINE AGG. ________ 548 kg 65 kg 65 kg

COARSE AGG. _____

Fraction 1 871.76 kg 103.78 kg 104 kg

Fraction 2 373.61 kg 44.48 kg 44 kg

Fraction 3 0.00 kg 0.00 kg 0 kg

TOTAL WEIGHT ______ 2409 kg/cu.m

IRCON'S REPRESENTATIVE SWK'S REPRESENTATIVE

 IMPORTANT TIPS FOR MIX SESIGN
ACTION REACTION
FIXED W/C RATIO 1 There would be one optimum combination of coarse and fine aggregate
resulting in the highest workability.

2 Strength of concrete increased with increase in Agg./Cement ratio.

3 There would always be an optimum cement content resulting in highest

28-days compressive strength.

4 Use of coarse aggregates of larger size and/or rounded aggregates

gives higher workability.

5 Use of fine sand gives lower workability.

WATER CEMENT FINE AGG. COARSE AGG.

INCRESE IN W/C RATIO BY No Effect Decrease Increase Increase

0.05 (From 0.3 to 0.55)
(8% to 3%) (3.4% to
(12% to 5%) -1.4%)
INCRESE IN COMPACTING Increase Increase Decrease Decrease
FACTOR BY 0.1
(+3%) (- (-
(+3%) 1.5%) 1.5%)
INCRESE Max. NOMINAL Decrease Decrease Decrease Increase
SIZE OF COARSE
AGGREGATE

FINER GRADING OF SAND No Effect Decrease Increase

(1.5%
to 3%)
 PAGE 14 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
DATED : 2/10/2006
GRADE : M 25

1. DESIGN STIPULATIONS

1 Characteristic compressive strength required 25 Mpa D

2 Maximum size of aggregate 20 mm D

3 Degree of workability (compacting factor) 0.80 D

4 Degree of quality control Good D

5 Type of Structure (PCC, RCC, PSC) RCC D

6 Type of exposure (1 for Normal, 2 for Severe) 1 D

7 Type of Structure (1 for Major, 2 for Culverts) 1

2. TEST DATA FOR MATERIALS

1 Grade of Cement (OPC)) 43 D

2 Specific gravity of cement 3.15 D

3 Specific gravity of Coarse aggregate 2.738 D

4 Specific gravity of Fine aggregate 2.660 D

5 Water absorption of Coarse aggregate 0.53 % D

6 Water absorption of Fine aggregate 0.62 % D

7 Free (surface) moisture of Coarse aggregate 0.00 % D

8 Free (surface) moisture of Fine aggregate 0.00 % D

9 Sieve analysis of Coarse aggregate

PERCENTAGE OF DIFFERENT
SIEVE PERCENT PASSING D
FRACTIONS LIMIT AS
SIZE
I II III TOTAL
PER REMARKS
I II III IS:383
"mm"
65 % 35 % 0% 100 %

1 20 95.73 100 0 62.2245 35 0 97.2245 95-100

1 10 10.37 93.54 0 6.7405 32.739 0 39.4795 25-55 CONFORMING TO
1 4.75 0.52 0.19 0 0.338 0.0665 0 0.4045 0-10 TABLE 2 OF IS:383

1 2.36 0 0 0 0 0 0 0 0
4
120
20 95 100 97

10 25 55 39
100
4.75 0 10 0.4
PERCENTAGE PASSING

2.3680 0 0 0

60

40

20

0
0 5 10 15 20 25

SIEVE SIZE IN mm

LOWER LIMIT UPPER LIMIT COMBINED

IRCON's REPRESENTATIVE SWK REPRESENTATIVE

 PAGE 15 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
DATED : 2/10/2006
GRADE : M 25

10 Sieve analysis of Fine aggregate

SIEVE PERCENT
LIMIT AS PER IS:383 (TABLE 4) D
SIZE PASSING REMARKS
ZONE I ZONE II ZONE III D

1 1 1 4.75 mm 95.7 90 - 100 90 - 100 90 - 100

1 1 1 2.36 mm 86.35 60 - 95 75 - 100 85 - 100
0 1 1 1.18 mm 80.65 30 - 70 55 - 90 75 - 100 CONFORMING TO
0 0 1 600 mic. 74.45 15 - 34 35 - 59 60 - 79 GRADING ZONE-III

0 0 1 300 mic. 38.4 5 - 20 8 - 30 12 - 40

1 1 1 150 mic. 8.14 0 - 10 0 - 10 0 - 10
0 0 3 3
120

4.75 90 100 95.7

100
2.36 85 100 86.4
PERCENTAGE PASSING

1.18 75 100 80.7

80
0.6 60 79 74.5

600.3 12 40 38.4

0.15 0 10 8.14
40

20

0
0.1 1 10

SIEVE SIZE IN mm

LOWER LIMIT UPPER LIMIT COMBINED

3. TARGET MEAN STRENGTH OF CONCRETE

Current Margin for M 25 grade concrete as per MOST = 11.0

Therefore Target mean strength = 36.00 Mpa

4. SELECTION OF WATER CEMENT RATIO

As per MOST Specification water cement ratio required = 0.45

Therefore water cement ratio adopted = 0.45 D

IRCON's REPRESENTATIVE SWK REPRESENTATIVE

 PAGE 16 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
DATED : 2/10/2006
GRADE : M 25

5. SELECTION OF WATER AND SAND CONTENT

From Table 4 & 5 (IS:10262), for 20 mm nominal max. size agg and Mix M 25
Water content per cubic metre of concrete = 186 kg
Sand content as percentage of total aggregate = 35 %
Required adjustment as per Table 6 (IS:10262):

ADJUSTMENT
CONDITION
WATER CONTENT " % " %SAND IN TOTAL AGG.

ZONE-III (SAND) 0.00 -1.50

FOR C F, (0.8-0.8) THAT IS 0 0.00 0.00

4 0.60 FOR DECREASE IN W/C RATIO

0.00 - 3.00
BY (0.6-0.45) THAT IS 0.15

TOTAL 0.00 - 4.50

Therefore required water content per cubic metre of concrete = 186.0 lit/cu. m
And required sand content as percentage of total aggregate = 30.5 %

6. DETERMINATION OF CEMENT CONTENT

Water Cement ratio = 0.45

Water = 186.0 lit
Cement = 413 kg/cu.m

But as per MOST, CL:1703.2 min. cement required = 310 kg

And max. cement content = 540 kg
Therefore cement content = 413 kg

7. DETERMINATION OF COARSE AND FINE AGGREGATE CONTENT

From Table-3, for the specified max. size of aggregate of 20 mm , the amount of
entrapped air in the wet concrete is = 2%

Taking this into account and appling equations from 3.5.1, IS:10262 :
fa = 538 kg/cu. m
and, ca = 1261 kg/cu. m

The Mix proportion then becomes :

WATER CEMENT FINE AGG. COARSE AGG.
186.0 lit 413 kg 538 kg 1261 kg
0.45 1 1.30 3.05

IRCON's REPRESENTATIVE SWK REPRESENTATIVE

 PAGE 17 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
DATED : 2/10/2006
GRADE : M 25

8. ACTUAL QUANTITIES REQUIRED FOR THE MIX

1 CEMENT : = 413 kg

2 WATER :
(a) For water cement ratio of 0.45 quantity of water = 186.00 litres
(b)
Extra quantity of water for absorption of coarse aggregate, at 0.53 % by mass = 6.68 litres
(c) Quantity of water to be deducted for free moisture present in sand, at 0 % by
mass = 0.00 litres
(d) Actual quantity of water to be added = 192.68 litres

3 SAND :
= 538.00 kg
Actual quantity of sand required after allowing for mass of free moisture

4 COARSE AGGREGATE :
Actual quantity of coarse aggregete required :
820 4.34 (a) Fraction 1, (819.65 - 4.34) = 815.31 kg
441 2.34 (b) Fraction 2, (441.35 - 2.34) = 439.01 kg
0 0 (c) Fraction 3, (0 - 0) = 0.00 kg

Therefore, the actual quantities of different constituents required for the mix are :

Rounded
Constituents FOR 1 cu.m Concrete FOR 1 bag Cement
Quantity

WATER __________ 192.7 lit 23.3 lit 23 lit

CEMENT __________ 413 kg 50 kg 50 kg

FINE AGG. ________ 538 kg 65 kg 65 kg

COARSE AGG. _____

Fraction 1 815.31 kg 98.71 kg 99 kg

Fraction 2 439.01 kg 53.15 kg 53 kg

Fraction 3 0.00 kg 0.00 kg 0 kg

TOTAL WEIGHT ______ 2398 kg/cu.m

IRCON's REPRESENTATIVE SWK REPRESENTATIVE

 PAGE 18 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
DATED : 2/10/2006
GRADE : M 30

1. DESIGN STIPULATIONS

1 Characteristic compressive strength required 30 Mpa D

2 Maximum size of aggregate 20 mm D

3 Degree of workability (compacting factor) 0.90 D

4 Degree of quality control Good D

5 Type of Structure (PCC, RCC, PSC) RCC D

6 Type of exposure (1 for Normal, 2 for Severe) 1 D

2. TEST DATA FOR MATERIALS

1 Grade of Cement (OPC)) 43 D

2 Specific gravity of cement 3.15 D

3 Specific gravity of Coarse aggregate 2.738 D

4 Specific gravity of Fine aggregate 2.660 D

5 Water absorption of Coarse aggregate 0.53 % D

6 Water absorption of Fine aggregate 0.62 % D

7 Free (surface) moisture of Coarse aggregate 0.00 % D

8 Free (surface) moisture of Fine aggregate 0.00 % D

9 Sieve analysis of Coarse aggregate

PERCENTAGE OF DIFFERENT
SIEVE PERCENT PASSING D
FRACTIONS LIMIT AS
SIZE
I II III TOTAL
PER REMARKS
I II III IS:383
"mm"
65 % 35 % 0% 100 %

1 20 95.73 100 0 62.2245 35 0 97.2245 95-100

1 10 10.37 93.54 0 6.7405 32.739 0 39.4795 25-55 CONFORMING TO
1 4.75 0.52 0.19 0 0.338 0.0665 0 0.4045 0-10 TABLE 2 OF IS:383

1 2.36 0 0 0 0 0 0 0 0
4
120
20 95 100 97

10 25 55 39
100
4.75 0 10 0.4
PERCENTAGE PASSING

2.3680 0 0 0

60

40

20

0
0 5 10 15 20 25

SIEVE SIZE IN mm

LOWER LIMIT UPPER LIMIT COMBINED

IRCON's REPRESENTATIVE SWK REPRESENTATIVE

 PAGE 19 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
DATED : 2/10/2006
GRADE : M 30

10 Sieve analysis of Fine aggregate

SIEVE PERCENT
LIMIT AS PER IS:383 (TABLE 4) D
SIZE PASSING REMARKS
ZONE I ZONE II ZONE III D

1 1 1 4.75 mm 95.7 90 - 100 90 - 100 90 - 100

1 1 1 2.36 mm 86.35 60 - 95 75 - 100 85 - 100
0 1 1 1.18 mm 80.65 30 - 70 55 - 90 75 - 100 CONFORMING TO
0 0 1 600 mic. 74.45 15 - 34 35 - 59 60 - 79 GRADING ZONE-III

0 0 1 300 mic. 38.4 5 - 20 8 - 30 12 - 40

1 1 1 150 mic. 8.14 0 - 10 0 - 10 0 - 10
0 0 3 3
120

4.75 90 100 95.7

100
2.36 85 100 86.4
PERCENTAGE PASSING

1.18 75 100 80.7

80
0.6 60 79 74.5

600.3 12 40 38.4

0.15 0 10 8.14
40

20

0
0.1 1 10

SIEVE SIZE IN mm

LOWER LIMIT UPPER LIMIT COMBINED

3. TARGET MEAN STRENGTH OF CONCRETE

Standard deviationn for M 30 grade concrete = 6.0

Therefore Target mean strength = 39.90 Mpa

4. SELECTION OF WATER CEMENT RATIO

From Fig. 1, the free water-cement ratio required for the target mean strength of 39.9 M = 0.45
Therefore water cement ratio adopted = 0.45 D

IRCON's REPRESENTATIVE SWK REPRESENTATIVE

 PAGE 20 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
DATED : 2/10/2006
GRADE : M 30

5. SELECTION OF WATER AND SAND CONTENT

From Table 4 & 5 (IS:10262), for 20 mm nominal max. size agg and Mix M 30
Water content per cubic metre of concrete = 186 kg
Sand content as percentage of total aggregate = 35 %
Required adjustment as per Table 6 (IS:10262):

ADJUSTMENT
CONDITION
WATER CONTENT " % " %SAND IN TOTAL AGG.

ZONE-III (SAND) 0.00 -1.50

FOR C F, (0.9-0.8) THAT IS 0.1 3.00 0.00

4 0.60 FOR DECREASE IN W/C RATIO

0.00 - 3.00
BY (0.6-0.45) THAT IS 0.15

TOTAL 3.00 - 4.50

Therefore required water content per cubic metre of concrete = 191.6 lit/cu. m
And required sand content as percentage of total aggregate = 30.5 %

6. DETERMINATION OF CEMENT CONTENT

Water Cement ratio = 0.45

Water = 191.6 lit
Cement = 426 kg/cu.m

But as per MOST, CL:1703.2 min. cement required = 310 kg

And max. cement content = 540 kg
Therefore cement content = 426 kg

7. DETERMINATION OF COARSE AND FINE AGGREGATE CONTENT

From Table-3, for the specified max. size of aggregate of 20 mm , the amount of
entrapped air in the wet concrete is = 2%

Taking this into account and appling equations from 3.5.1, IS:10262 :
fa = 530 kg/cu. m
and, ca = 1243 kg/cu. m

The Mix proportion then becomes :

WATER CEMENT FINE AGG. COARSE AGG.
192.0 lit 426 kg 530 kg 1243 kg
0.45 1 1.24 2.92

IRCON's REPRESENTATIVE SWK REPRESENTATIVE

 PAGE 21 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
DATED : 2/10/2006
GRADE : M 30

8. ACTUAL QUANTITIES REQUIRED FOR THE MIX

1 CEMENT : = 426 kg

2 WATER :
(a) For water cement ratio of 0.45 quantity of water = 192.00 litres
(b)
Extra quantity of water for absorption of coarse aggregate, at 0.53 % by mass = 6.59 litres
(c) Quantity of water to be deducted for free moisture present in sand, at 0 % by
mass = 0.00 litres
(d) Actual quantity of water to be added = 198.59 litres

3 SAND :
= 530.00 kg
Actual quantity of sand required after allowing for mass of free moisture

4 COARSE AGGREGATE :
Actual quantity of coarse aggregete required :
808 4.28 (a) Fraction 1, (807.95 - 4.28) = 803.67 kg
435 2.31 (b) Fraction 2, (435.05 - 2.31) = 432.74 kg
0 0 (c) Fraction 3, (0 - 0) = 0.00 kg

Therefore, the actual quantities of different constituents required for the mix are :

Rounded
Constituents FOR 1 cu.m Concrete FOR 1 bag Cement
Quantity

WATER __________ 198.6 lit 23.3 lit 23 lit

CEMENT __________ 426 kg 50 kg 50 kg

FINE AGG. ________ 530 kg 62 kg 62 kg

COARSE AGG. _____

Fraction 1 803.67 kg 94.33 kg 94 kg

Fraction 2 432.74 kg 50.79 kg 51 kg

Fraction 3 0.00 kg 0.00 kg 0 kg

TOTAL WEIGHT ______ 2391 kg/cu.m

IRCON's REPRESENTATIVE SWK REPRESENTATIVE

 PAGE 22 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
GRADE : M 15 DATED : 2/11/2006

1. DESIGN STIPULATIONS

1 Characteristic compressive strength required 15 Mpa D

2 Maximum size of aggregate 20 mm D

3 Degree of workability (compacting factor) 0.30 D

4 Degree of quality control Good D

5 Type of Structure (PCC, RCC, PSC) PCC D

6 Type of exposure (1 for Normal, 2 for Severe) 1 D

7 Type of Structure (1 for Major, 2 for Culverts) 2

2. TEST DATA FOR MATERIALS

1 Grade of Cement (OPC)) 43 D

2 Specific gravity of cement 3.15 D

3 Specific gravity of Coarse aggregate 2.738 D

4 Specific gravity of Fine aggregate 2.660 D

5 Water absorption of Coarse aggregate 0.53 % D

6 Water absorption of Fine aggregate 0.62 % D

7 Free (surface) moisture of Coarse aggregate 0.00 % D

8 Free (surface) moisture of Fine aggregate 5.70 % D

9 Sieve analysis of Coarse aggregate

PERCENTAGE OF DIFFERENT
SIEVE PERCENT PASSING D
FRACTIONS LIMIT AS
SIZE
I II III TOTAL
PER REMARKS
I II III IS:383
"mm"
65 % 35 % 0% 100 %

1 20 95.73 100 0 62.2245 35 0 97.2245 95-100

1 10 10.37 93.54 0 6.7405 32.739 0 39.4795 25-55 CONFORMING TO
1 4.75 0.52 0.19 0 0.338 0.0665 0 0.4045 0-10 TABLE 2 OF IS:383

1 2.36 0 0 0 0 0 0 0 0
4
120
20 95 100 97

10 25 55 39
100
4.75 0 10 0.4
PERCENTAGE PASSING

2.3680 0 0 0

60

40

20

0
0 5 10 15 20 25

SIEVE SIZE IN mm

LOWER LIMIT UPPER LIMIT COMBINED

IRCON's REPRESENTATIVE SWK REPRESENTATIVE

 PAGE 23 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
GRADE : M 15 DATED : 2/11/2006

10 Sieve analysis of Fine aggregate

SIEVE PERCENT
LIMIT AS PER IS:383 (TABLE 4) D
SIZE PASSING REMARKS
ZONE I ZONE II ZONE III D

1 1 1 4.75 mm 95.7 90 - 100 90 - 100 90 - 100

1 1 1 2.36 mm 86.35 60 - 95 75 - 100 85 - 100
0 1 1 1.18 mm 80.65 30 - 70 55 - 90 75 - 100 CONFORMING TO
0 0 1 600 mic. 74.45 15 - 34 35 - 59 60 - 79 GRADING ZONE-III

0 0 1 300 mic. 38.4 5 - 20 8 - 30 12 - 40

1 1 1 150 mic. 8.14 0 - 10 0 - 10 0 - 10
0 0 3 3
120

4.75 90 100 95.7

100
2.36 85 100 86.4
PERCENTAGE PASSING

1.18 75 100 80.7

80
0.6 60 79 74.5

600.3 12 40 38.4

0.15 0 10 8.14
40

20

0
0.1 1 10

SIEVE SIZE IN mm

LOWER LIMIT UPPER LIMIT COMBINED

3. TARGET MEAN STRENGTH OF CONCRETE

Current Margin for M 15 grade concrete as per MOST = 10.0

Therefore Target mean strength = 25.00 Mpa

4. SELECTION OF WATER CEMENT RATIO

As per MOST Specification, the max. water cement ratio = 0.50

Therefore water cement ratio adopted = 0.50 D

IRCON's REPRESENTATIVE SWK REPRESENTATIVE

 PAGE 24 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
GRADE : M 15 DATED : 2/11/2006

5. SELECTION OF WATER AND SAND CONTENT

From Table 4 & 5 (IS:10262), for 20 mm nominal max. size agg and Mix M 15
Water content per cubic metre of concrete = 186 kg
Sand content as percentage of total aggregate = 35 %
Required adjustment as per Table 6 (IS:10262):

ADJUSTMENT
CONDITION
WATER CONTENT " % " %SAND IN TOTAL AGG.

ZONE-III (SAND) 0.00 -1.50

FOR C F, (0.3-0.8)
-15.00 0.00
THAT IS -0.5

4 0.60 FOR DECREASE IN W/C RATIO

0.00 - 2.00
BY (0.6-0.5) THAT IS 0.1

TOTAL -15.00 - 3.50

Therefore required water content per cubic metre of concrete = 158.1 lit/cu. m
And required sand content as percentage of total aggregate = 31.5 %

6. DETERMINATION OF CEMENT CONTENT

Water Cement ratio = 0.5

Water = 158.1 lit
Cement = 316 kg/cu.m

But as per MOST, CL:1703.2 min. cement required = 250 kg

And max. cement content = 540 kg
Therefore cement content = 316 kg

7. DETERMINATION OF COARSE AND FINE AGGREGATE CONTENT

From Table-3, for the specified max. size of aggregate of 20 mm , the amount of
entrapped air in the wet concrete is = 2%

Taking this into account and applying equations from 3.5.1, IS:10262 :
fa = 605 kg/cu. m
and, ca = 1353 kg/cu. m

The Mix proportion then becomes :

WATER CEMENT FINE AGG. COARSE AGG.
158.0 lit 316 kg 605 kg 1353 kg
0.50 1 1.91 4.28

IRCON's REPRESENTATIVE SWK REPRESENTATIVE

 PAGE 25 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
GRADE : M 15 DATED : 2/11/2006

8. ACTUAL QUANTITIES REQUIRED FOR THE MIX

1 CEMENT : = 316 kg

2 WATER :
(a) For water cement ratio of 0.5 quantity of water = 158.00 litres
(b)
Extra quantity of water for absorption of coarse aggregate, at 0.53 % by mass = 7.17 litres
(c) Quantity of water to be deducted for free moisture present in sand, at 5.7 % by
mass = -34.49 litres
(d) Actual quantity of water to be added = 130.69 litres

3 SAND :
= 639.49 kg
Actual quantity of sand required after allowing for mass of free moisture

4 COARSE AGGREGATE :
Actual quantity of coarse aggregate required :
879 4.66 (a) Fraction 1, (879.45 - 4.66) = 874.79 kg
474 2.51 (b) Fraction 2, (473.55 - 2.51) = 471.04 kg
0 0 (c) Fraction 3, (0 - 0) = 0.00 kg

Therefore, the actual quantities of different constituents required for the mix are :

Rounded
Constituents FOR 1 cu.m Concrete FOR 1 bag Cement
Quantity

WATER __________ 130.7 lit 20.7 lit 21 lit

CEMENT __________ 316 kg 50 kg 50 kg

FINE AGG. ________ 639 kg 101 kg 101 kg

COARSE AGG. _____

Fraction 1 874.79 kg 138.42 kg 138 kg

Fraction 2 471.04 kg 74.53 kg 75 kg

Fraction 3 0.00 kg 0.00 kg 0 kg

TOTAL WEIGHT ______ 2432 kg/cu.m

9. OBSERVATIONS :

IRCON's REPRESENTATIVE SWK REPRESENTATIVE

 PAGE 26 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
GRADE : M 25 DATED : 2/11/2006

1. DESIGN STIPULATIONS

1 Characteristic compressive strength required 25 Mpa D

2 Maximum size of aggregate 20 mm D

3 Degree of workability (compacting factor) 0.80 D

4 Degree of quality control Good D

5 Type of Structure (PCC, RCC, PSC) RCC D

6 Type of exposure (1 for Normal, 2 for Severe) 1 D

7 Type of Structure (1 for Major, 2 for Culverts) 2

2. TEST DATA FOR MATERIALS

1 Grade of Cement (OPC)) 43 D

2 Specific gravity of cement 3.15 D

3 Specific gravity of Coarse aggregate 2.738 D

4 Specific gravity of Fine aggregate 2.660 D

5 Water absorption of Coarse aggregate 0.53 % D

6 Water absorption of Fine aggregate 0.62 % D

7 Free (surface) moisture of Coarse aggregate 0.00 % D

8 Free (surface) moisture of Fine aggregate 0.00 % D

9 Sieve analysis of Coarse aggregate

PERCENTAGE OF DIFFERENT
SIEVE PERCENT PASSING D
FRACTIONS LIMIT AS
SIZE
I II III TOTAL
PER REMARKS
I II III IS:383
"mm"
65 % 35 % 0% 100 %

1 20 95.73 100 0 62.2245 35 0 97.2245 95-100

1 10 10.37 93.54 0 6.7405 32.739 0 39.4795 25-55 CONFORMING TO
1 4.75 0.52 0.19 0 0.338 0.0665 0 0.4045 0-10 TABLE 2 OF IS:383

1 2.36 0 0 0 0 0 0 0 0
4
120
20 95 100 97

10 25 55 39
100
4.75 0 10 0.4
PERCENTAGE PASSING

2.3680 0 0 0

60

40

20

0
0 5 10 15 20 25

SIEVE SIZE IN mm

LOWER LIMIT UPPER LIMIT COMBINED

IRCON's REPRESENTATIVE SWK REPRESENTATIVE

 PAGE 27 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
GRADE : M 25 DATED : 2/11/2006

10 Sieve analysis of Fine aggregate

SIEVE PERCENT
LIMIT AS PER IS:383 (TABLE 4) D
SIZE PASSING REMARKS
ZONE I ZONE II ZONE III D

1 1 1 4.75 mm 95.7 90 - 100 90 - 100 90 - 100

1 1 1 2.36 mm 86.35 60 - 95 75 - 100 85 - 100
0 1 1 1.18 mm 80.65 30 - 70 55 - 90 75 - 100 CONFORMING TO
0 0 1 600 mic. 74.45 15 - 34 35 - 59 60 - 79 GRADING ZONE-III

0 0 1 300 mic. 38.4 5 - 20 8 - 30 12 - 40

1 1 1 150 mic. 8.14 0 - 10 0 - 10 0 - 10
0 0 3 3
120

4.75 90 100 95.7

100
2.36 85 100 86.4
PERCENTAGE PASSING

1.18 75 100 80.7

80
0.6 60 79 74.5

600.3 12 40 38.4

0.15 0 10 8.14
40

20

0
0.1 1 10

SIEVE SIZE IN mm

LOWER LIMIT UPPER LIMIT COMBINED

3. TARGET MEAN STRENGTH OF CONCRETE

Current Margin for M 25 grade concrete as per MOST = 11.0

Therefore Target mean strength = 36.00 Mpa

4. SELECTION OF WATER CEMENT RATIO

As per MOST Specification, the max. water cement ratio = 0.45

Therefore water cement ratio adopted = 0.45 D

IRCON's REPRESENTATIVE SWK REPRESENTATIVE

 PAGE 28 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
GRADE : M 25 DATED : 2/11/2006

5. SELECTION OF WATER AND SAND CONTENT

From Table 4 & 5 (IS:10262), for 20 mm nominal max. size agg and Mix M 25
Water content per cubic metre of concrete = 186 kg
Sand content as percentage of total aggregate = 35 %
Required adjustment as per Table 6 (IS:10262):

ADJUSTMENT
CONDITION
WATER CONTENT " % " %SAND IN TOTAL AGG.

ZONE-III (SAND) 0.00 -1.50

FOR C F, (0.8-0.8)
0.00 0.00
THAT IS 0

4 0.60 FOR DECREASE IN W/C RATIO

0.00 - 3.00
BY (0.6-0.45) THAT IS 0.15

TOTAL 0.00 - 4.50

Therefore required water content per cubic metre of concrete = 186.0 lit/cu. m
And required sand content as percentage of total aggregate = 30.5 %

6. DETERMINATION OF CEMENT CONTENT

Water Cement ratio = 0.45

Water = 186.0 lit
Cement = 413 kg/cu.m

But as per MOST, CL:1703.2 min. cement required = 310 kg

And max. cement content = 540 kg
Therefore cement content = 413 kg

7. DETERMINATION OF COARSE AND FINE AGGREGATE CONTENT

From Table-3, for the specified max. size of aggregate of 20 mm , the amount of
entrapped air in the wet concrete is = 2%

Taking this into account and applying equations from 3.5.1, IS:10262 :
fa = 538 kg/cu. m
and, ca = 1261 kg/cu. m

The Mix proportion then becomes :

WATER CEMENT FINE AGG. COARSE AGG.
186.0 lit 413 kg 538 kg 1261 kg
0.45 1 1.30 3.05

IRCON's REPRESENTATIVE SWK REPRESENTATIVE

 PAGE 29 OF 31

IRCON INTERNATIONAL LIMITED (UPSRP-01)

CONCRETE MIX DESIGN
TRAIL No.
GRADE : M 25 DATED : 2/11/2006

8. ACTUAL QUANTITIES REQUIRED FOR THE MIX

1 CEMENT : = 413 kg

2 WATER :
(a) For water cement ratio of 0.45 quantity of water = 186.00 litres
(b)
Extra quantity of water for absorption of coarse aggregate, at 0.53 % by mass = 6.68 litres
(c) Quantity of water to be deducted for free moisture present in sand, at 0 % by
mass = 0.00 litres
(d) Actual quantity of water to be added = 192.68 litres

3 SAND :
= 538.00 kg
Actual quantity of sand required after allowing for mass of free moisture

4 COARSE AGGREGATE :
Actual quantity of coarse aggregate required :
820 4.34 (a) Fraction 1, (819.65 - 4.34) = 815.31 kg
441 2.34 (b) Fraction 2, (441.35 - 2.34) = 439.01 kg
0 0 (c) Fraction 3, (0 - 0) = 0.00 kg

Therefore, the actual quantities of different constituents required for the mix are :

Rounded
Constituents FOR 1 cu.m Concrete FOR 1 bag Cement
Quantity

WATER __________ 192.7 lit 23.3 lit 23 lit

CEMENT __________ 413 kg 50 kg 50 kg

FINE AGG. ________ 538 kg 65 kg 65 kg

COARSE AGG. _____

Fraction 1 815.31 kg 98.71 kg 99 kg

Fraction 2 439.01 kg 53.15 kg 53 kg

Fraction 3 0.00 kg 0.00 kg 0 kg

TOTAL WEIGHT ______ 2398 kg/cu.m

9. OBSERVATIONS :

IRCON's REPRESENTATIVE SWK REPRESENTATIVE

 % PASSING (AVE) ZONE I ZONE II ZONE III ZONE I ZONE II
sieve 20 mm ZONE I ZONE II ZONE III 63.5-36.5 65-35 66.5-33.5 CUM. % RETAIN
20 97.50 100.00 100.00 100.00 98.41 98.38 98.34 1.59 1.63
10 40.00 100.00 100.00 100.00 61.90 61.00 60.10 38.10 39.00
4.75 5.00 95.00 95.00 95.00 37.85 36.50 35.15 62.15 63.50
2.36 0.00 77.50 87.50 92.50 28.29 30.63 30.99 71.71 69.38
1.18 0.00 50.00 72.50 87.50 18.25 25.38 29.31 81.75 74.63
600 0.00 24.50 47.00 69.50 8.94 16.45 23.28 91.06 83.55
300 0.00 12.50 19.00 26.00 4.56 6.65 8.71 95.44 93.35
150 0.00 5.00 5.00 5.00 1.83 1.75 1.68 98.18 98.25

% PASSING (AVE) ZONE I ZONE II ZONE III ZONE I ZONE II ZONE III
sieve ZONE I ZONE II ZONE III CUM. % RETAIN % RETAIN
4.75 95.00 95.00 95.00 5.00 5.00 5.00 5.00 5.00 5.00
2.36 77.50 87.50 92.50 22.50 12.50 7.50 17.50 7.50 2.50
1.18 50.00 72.50 87.50 50.00 27.50 12.50 27.50 15.00 5.00
600 24.50 47.00 69.50 75.50 53.00 30.50 25.50 25.50 18.00
300 12.50 19.00 26.00 87.50 81.00 74.00 12.00 28.00 43.50
150 5.00 5.00 5.00 95.00 95.00 95.00 7.50 14.00 21.00
 ZONE III ZONE I ZONE II ZONE III
UM. % RETAIN % RETAIN
1.66 1.59 1.63 1.66
39.90 36.51 37.38 38.24
64.85 24.05 24.50 24.95
69.01 9.56 5.88 4.16
70.69 10.04 5.25 1.68
76.72 9.31 8.93 6.03
91.29 4.38 9.80 14.57
98.33 2.74 4.90 7.04