FORMATE ID: MSS//MD/001

MINING SERVICES & SUPPLIES SAS

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DOCUMENT NAME
CONCRETE MIX DESIGN- C 25
MSS BATCHING PLANT
CLIENT NAME
KAMOA COPPER S.A.

PROJECT NAME
KAMOA PROJECTS

CONCRETE MIX DESIGN DONE BY

MINING SERVICES & SUPPLIES

PREPARED BY REVIEWED BY APPROVED BY

MSS
EFFECTIVE REV.
S.NO MANAGER/ MSS- CIVIL MSS - PROJECT DRA (EPCM) KAMOA
DATE NO.
ENGINEER MANAGER MANAGER (CLIENT)
(QA/QC)
1 20/02/2023 0  
     
     

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Preface

Concrete mix design is a procedure of selecting the suitable ingredients of concrete and their
relative proportions with an objective to prepare concrete of certain minimum strength,
desired workability and durability as economically (value engineered) as possible.

Material Properties
1. Cement
Properties GCK Cement
Normal Consistency % 29%
Initial setting Time (min) 132
Final Setting Time (min) 251
Specific Gravity 3.15
2.Aggregate
(A) Sieve Analysis
% Of Passing
Sieve Size (mm)
20 mm C. Sand
25 100 -
20 79 -
12.5 26.23 -
10 0.33 -
4.75 0.23 100
2.36 - 93.90
1.18 - 66.20
0.600 - 48.70
0.300 - 29.5
0.150 - 9.50
0.075 - 5.40

(B) Specific Gravity, Density, Water Absorption

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Specific Bulk Density Water

Type of Aggregate
Gravity kg/m3 Absorption %
20 mm 2.77 1450 0.64
C. Sand 2.68 1650 1.22

(C) All in Aggregate

Cum % Passing in Material Cum. % IS 383
% % % % Passing All Limits All
IS Sieve in in
62 38
Aggregate Aggregate
20 mm C. Sand 20 mm C. Sand
40 100 100 62 38 100 100
20 79 100 48.98 38 86.98 95 - 100
4.75 0.23 0 100 0.14 38 38.14 30 - 50
0.600 0 48.7 0 18.51 18.51 10 - 35
0.150 9.5 0 3.61 3.61 0-6

As we decide to go for a concrete mix design, collect the following data beforehand as few
designs’ stipulation are feezed on the basis of these data.
Preliminary Data for Design Mix
Purely governed on the local conditions, were the concrete need to be applied Exposure
Condition: Exposure conditions of the structure: The general environment to which the
concrete will be exposed during its service life, is categorized into five class to severity, as per
IS 456, Cls.8.2.2.1 and 35.3.2 Table 3
The exposure condition limits the minimum cement content, maximum water – cement ratio and
minimum grade of concrete.
As per exposure condition, you have the above data for working the first trial and arriving its
mix proportion.
If you are getting desired result at a lower cement content, you need to put extra as
mentioned 
 Minimum thickness of member: Size of aggregate should not be more than one-fourth of
the minimum thickness of member, mostly 20 mm nominal size aggregate is suitable for
most works. It is always suggested to go the maximum nominal size of aggregate to save
on quantity of cement per unit of concrete.
 Cement Grade: Cement type/grade locally available that can be made available
throughout construction period
 Workability: Placing condition of concrete governs its workability, low – slump of 25-75
mm (lightly reinforced sections in slab, beam, column) to high – slump of 100-150 mm
(slip form, pumped concrete)

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Illustrative of C 25 Grade concrete Exposed to Moderate conditions

(i) Stipulation for Proportioning Concrete Ingredients
(a)Characteristic compressive strength required in the field at 28 days grade designation —
C25
(b) Type of Cement: OPC 42.5N Grade confirming to EN207
(b) Maximum Nominal size of aggregate — 20MM
(c) Shape of CA — Angular
(d) Workability required at site — 120 mm (slump)
(e) Type of exposure the structure will be subjected to (as defined in IS: 456) — Moderate
(h) Method of concrete placing: Manual concrete.
(ii) Test Data of Material
The following materials are to be tested in the laboratory and results are to be ascertained for
the design mix
(a) Cement Used: OPC 42.5N Grade Confirming.
(b) Specific Gravity of Cement: 3.15
(d) Specific gravity
Specific gravity of Fine Aggregate (sand): 2.68
Specific gravity of Coarse Aggregate: 2.77
(e) Water Absorption
Coarse Aggregate: 0.62 %
Fine Aggregate: 1.22 %
(f) Free (surface) moisture
Coarse Aggregate: Nil
Fine Aggregate: Nil
Aggregate is assumed to be in saturated surface dry condition (SSD) usually while preparing
design mix.
(g) Sieve Analysis
Fine aggregates: Confirming to Zone II of Table 4 IS – 383 
Procedure for Concrete Mix design of C25 Grade.
Step-1: Determining the Target Strength for Mix Proportioning.
F’ck = fck + 1.65 x S
Where,
F’ck = Target average compressive strength at 28 days
Fck = Characteristic compressive strength at 28 days
S = Assumed standard deviation in N/mm2 = 4 (as per table -1 of IS 10262- 2019, Clauses
3.2.1.2, A-3 and B-3)
= 25 + 1.65 x 4 = 31.6 N/mm2

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Note: Under control conditions if Target average compressive strength is achieved then at field
the probability of getting compressive strength of 30 MPa is very high.

Step-2: Selection of Water Cement ratio

From IS 10262, FIG. 1 free water cement ratio in curve 2, Maximum water-cement ratio = 0.50
Note: Do not start with w/c ratio above 0.50, even though the other desired results like
Strength, workability could be achieved.
Step-3: Selection of Water Content
Maximum water content for 20 mm aggregate = 186 Kg (for 25 to 50 slump) as per table no 2
of IS 10262 table no 4, cl.5.3
We are targeting a slump of 120 mm; we need to increase water content by 3% for every
25mm above 50 mm i.e increase 12% for 120mm slump.
i.e Estimated water content for 100 Slump = 186+(12/100) X 186 = 208.32 liter
For desired workability (other than 50mm slump), required water content may be increased or
decreased by above 3% for each 25mm slump variation
In D.R Congo fines content in sand are excessive. When the fines content is excessive, there is
need to add more water to the concrete mix in other to improve the workability. So, we are
assuming 5.225% variation in water in each 25mm slump variation. So, our targeted 140mm
slump, water content will come around 20.9% extra.
Estimated water content for 120 mm slump =186 kg + 20.9% of 186kg =225 kg
Step-4: calculation of Cement Content
Water-Cement Ratio = 0.50
Water content from Step – 3 i.e., 225 kg
Cement Content = Water content / “w-c ratio” = (225/0.50) = 450 kgs
From Table 5 of IS 456,
Minimum cement Content for moderate exposure condition = 320 kg/m3
450kg/m3 > 320 kg/m3, hence, OK.
As per clause 8.2.4.2 of IS: 456
Step-5: Proportion of Volume of Coarse Aggregate and Fine aggregate Content .
From Table 3 of IS 10262- 2019, Clauses 4.4 Volume of coarse aggregate corresponding to 20
mm size and fine aggregate (Zone II) = 0.62
Note 1: In the present case water-cement ratio is 0.50 So there will be no change in coarse
aggregate volume i.e 0.62

Note 2: Incase the coarse aggregate is not angular one, then also volume of coarse aggregate
may be required to be increased suitably based on experience.

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Step-6: Estimation of Concrete Mix calculations

The mix calculations per unit volume of concrete shall be as follows:
1. Volume of concrete = 1 m3
2. Volume of cement = (Mass of cement / Specific gravity of cement) x (1/100) =
(450/3.15) x (1/1000) = 0.143 m3
3. Volume of water = (Mass of water / Specific gravity of water) x (1/1000) =
(225/1) x (1/1000) = 0.225 m3
4. Total Volume of Aggregates = 1- (b+c) =1- (0.143+0.225) = 0.632m3
5. Mass of coarse aggregates = d X Volume of Coarse Aggregate X Specific Gravity
of Coarse Aggregate X 1000 = 0.632 X 0.62 X 2.77 X 1000 = 1085.40 kgs/m3
6. Mass of fine aggregates = d X Volume of Fine Aggregate X Specific Gravity of
Fine Aggregate X 1000 = 0.632 X 0.38 X 2.68 X 1000 = 643.63 kgs/m3
Step-7: Concrete Mix Proportions for Trial Mix
Mix Proportions for trial Mix-1:
7. Cement = 450 kg/m3
8. Water = 225 kg/m3
9. Fine aggregates = 643.63 kg/m3
10. Coarse aggregate = 1085.40 kg/m3
11. Water-cement ratio = 0.50
12. Note-1: Aggregates should be used in saturated surface dry condition. If otherwise,
when computing the requirement of water, allowance shall be made for the free
(surface) moisture contributed by coarse aggregate and fine aggregate. On the other
hand, if the aggregates are already dry, the amount of water mixed should be increased
by an amount equal to the moisture likely to be absorbed by the aggregates. Necessary
adjustments are also required to be made in the mass of the aggregates. The surface
water and percentage water absorption shall be determined according to IS 2386.
13. Correction in water content due to absorption or moist aggregates
14. The slump shall be measured and the water content and shall be adjusted for achieving
the required slump based on trial, if required. The mix proportions shall be reworked
for the actual water content and checked for durability requirement

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MIX DESIGN PROPORTION FOR CONCRETE- C 25 IN KG/M3

FINE COARSE AGGREGATE
CEMENT WATER ADMIXTURE
AGGREGATE 20MM 10-12MM
450 KG 644 KG 1085 KG - 225 KG -
Mix Proportion Table: -

MIX DESIGN PROPORTION FOR CONCRETE- C 25 IN RATIO BASES PER BAG

C 25 (1:1.26:2.41)
FINE COARSE AGGREGATE
CEMENT WATER ADMIXTURE
AGGREGATE 20MM 10-12MM
1 1.26 2.41 - 25 LTR. -

N.B: -The standard size of a measuring box is 300mmx300mmx383mm whose volume is equal
to volume of 1 bag of cement i.e, 0.0345 m3

Determination of Consistency of fresh concrete

Quantity Representing sample
Date: - 20-JAN-2023 Mixing time: - 02:45 pm to 02:50 pm
Slump test
Initial stage - 145 mm
30 minutes - 120 mm
60 minutes - 90 mm

RAMBABU.ADUSUMALLI
Sr. Manager QA/QC (HOD)

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CONCRETE CUBE COMPRESSIVE STRENGTH TEST RESULTS

Specimen Dimensions: 150mm x 150mm x 150mm

Sr. Crush Age Wt. Of Density Crushing Strength Avg. Strength
Cube Id Date
No. Days Cube (KG) (KG/ M³) Load (KN) (MPA) (MPA)
1 MSS/MD/C25/01 27-01-2023 8.21 2432.59 651.1 28.94
2 MSS/MD/C25/02 27-01-2023 7 28.85
8.18 2423.70 623.7 27.72
3 MSS/MD/C25/03 27-01-2023 8.28 2453.33 672.4 29.88
4 MSS/MD/C25/04 03-02-2023 8.32 2465.19 771.3 34.28
5 MSS/MD/C25/05 03-02-2023 14 32.27
8.23 2438.52 696.2 30.94
6 MSS/MD/C25/06 03-02-2023 8.16 2417.78 710.5 31.58
7 MSS/MD/C25/07 17-02-2023 8.27 2450.37 816.1 36.27
8 MSS/MD/C25/08 17-02-2023 28 36.66
8.24 2441.48 843.6 37.49
9 MSS/MD/C25/09 17-02-2023 8.34 2471.11 814.9 36.22

Criteria of Criteria of Coefficient Results Avg. Cube Density

Class of Operations Standard Results Variance kg/ m³
Deviation
Excellent Below = 2.8 0.72 7 1.96
Very Good = 2.80 to 3.40 - 7.0 to 9.0 -
Good = 3.40 to 4.10 - 9.0 to 11.0 - 2443.79
Fair = 4.10 to 4.80 - 11.0 to 14.0 -
Poor = 4.8 (Above) - 14 (Above) -

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CONCLUSION: The 28 days compression strength of C25 cube test results have been achieved as per standard.
TEST METHOD: SANS 5861-3/2006, 5863/2006

RAMBABU.ADUSUMALLI
Sr. Manager QA/QC (HOD)

1 DAY 3 DAY 7 DAYS 14 DAYS 28 DAYS

16% 40% 65% 90% 100%

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