2.DLC Mix Design With Cement Flyash

NATIONAL HIGHWAY AUTHORITY OF INDIA
(MINISTRY OF ROAD TRANSPORT & HIGHWAYS)
Four Laning of Tuljapur-Ausa (including Tuljapur Bypass) section of NH-361 from km 0.000 to km 55.835 (Existing
Project
Chainage : km 416.000 to km 470.000) under NHDP Phase-IV in the state of Maharashtra on Hybrid Annuity Mode.
Employer National Highway Authority of India

Independent Engineer Lion Engineering Consultant
Concessionaire DBL Tuljapur Ausa Highways Limited
EPC Contractor Dilip Buildcon Limited
DRY LEAN CEMENT CONCRETE (DLC) MIX DESIGN - 01 (AS

PER GUIDE LINES IN MORT&H Cl: 601, IRC:44, I.S.-10262 & SP23)
Design Stipulations
1 Min. compressive strength required in the field at 7 days 10 MPa
2 Maximum size of aggregate 26.5 mm
3 Minimum Cement Content 150 Kg/cu.m
4 Minimum Cement Content blending with flyash 120 Kg/cu.m
5 Maximum Aggregate Cement Ratio 15 : 1
6 Type of exposure Normal
Source of Material
1 Cement (Ultratech Cement OPC 53 grade)
2 CA1 ( 26.5mm ) Aggregate DBL Crusher Camp-1
3 CA2 ( 10 mm ) Aggregate DBL Crusher Camp-1
4 FA - Sand DBL Crusher Camp-1
5 FA - Crushed stone sand DBL Crusher Camp-1
6 Water ( Bore Hole @ Base Camp-1 ) 13+700 RHS
Material Report
1 Type of Cement ( Ultratech Cement OPC 53 grade @ 130 kg/m3 ) OK
2 Sp. Gravity of Cement 3.15
3 Flyash (@30kg/M3) OK
4 Sp. Gravity of Flyash 2.12
5 Sp. Gravity of CA1 ( 26.5 mm ) Aggregate 2.866
6 Sp. Gravity of CA2 ( 10 mm ) Aggregate 2.831
7 Sp. Gravity of FA Crushed stone Sand 2.764
8 Water Absorption of CA1 ( 26.5 mm ) Aggregate 0.50%
9 Water Absorption of CA-2 ( 10 mm ) Aggregate 0.77%
10 Water Absorption of FA - Crushed stone Sand 1.77%
11 Flakiness & Elongation Indix CA1 ( 26.5 mm ) Aggregate 25.29%
12 Flakiness & Elongation Indix CA1 ( 10 mm ) Aggregate 29.30%
13 AIV of Coarse Aggregate 12.44%
14 LAAV of CA-1 ( 26.5 mm ) Aggregate 17.01%
15 LAAV of CA-2 ( 10 mm ) Aggregate 19.75%
16 Sieve Analysis of Aggregate Gradation for DLC OK
1 Maximum Dry Density ( MDD ) 2.432g/cc

2 Optimum Moisture Content ( OMC ) 5.93%
3 Average Compressive Stergnt of DLC Mix Cubes at OMC 5.93 % at 7 days 15.56 N/mm2
The Material Proportions of DLC Mix

Coarse Aggregate
Cement Flyash
CA1
Material Water CA2 FA (Stone Total Qty
(10mm) Dust)
(26.5mm)
For 1 cu.m ( in Kg ) 142.32 130 30 716.8 627.2 896 2542.32
Proportions 5.60 5.11 1.18 28.19 24.67 35.24 100.00
Contractor Independent Engineer

1 M3 2.4 MT 1 MT %
Cement 130 0.130 0.054 5.42 MT M3

Flyash 30 0.030 0.013 1.25 cement 21.654 9.1
26.5 mm 716.8 0.717 0.299 29.87 26.5 119.899 50.176
10mm 627.2 0.627 0.261 26.13 10 104.661 43.904
Stone Dust 896 0.896 0.373 37.33 sand 149.573 62.72
Total 2400 2.400 1.000 100.00 Flyash 5.213 2.1
142.32
3125
62.5
Total 23400 5400 129024 112896 161280
30.754 23.4 5.4 129.024 112.896 161.28
170.075
148.565
212.293
7.313
569
Four Laning of Tuljapur-Ausa (including Tuljapur Bypass) section of NH-361 from km 0.000 to km
Project 55.835 (Existing Chainage : km 416.000 to km 470.000) under NHDP Phase-IV in the state of
Maharashtra on Hybrid Annuity Mode.
DRY LEAN CEMENT CONCRETE (DLC) MIX DESIGN

(AS PER GUIDE LINES IN MORT&H Cl: 601, IRC:44, I.S.-10262 & SP23)
A.DESIGN STIPULATIONS:
a) Minimum compressive strength required in the field at 7 days 10 MPa
( as per MORT&H Cl: 601.3.4 )
b) Maximum size of aggregate ( as per MORT&H Cl: 601.2.3.2 ) 26.5 mm
c) Minimum Cement Content ( as per MORT&H Cl: 601.3.3 ) 150 Kg/cu.m
d) Minimum Cement Content blending with flyash ( as per MORT&H Cl: 601.3.3 ) 120 Kg/cu.m
e) Maximum Aggregate Cement Ratio ( as per MORT&H Cl: 601.3.1 ) 15 : 1
f) Type of exposure Normal
B.TEST DATA FOR MATERIAL:
a) Cement
i) Source DBL Crusher Camp-1
ii) Grade &Brand name OPC 53 Grade , Ultratech
ii) Specific gravity 3.15
b) Aggregate:
i) Coarse aggregate
Water
Material Specific Gravity AIV LAAV Flakiness
Absorption
CA1( 26.5mm ) 2.866 0.450 17.01 25.29
12.44
CA2 ( 10 mm ) 2.831 0.770 19.75 29.30
FA1 ( Stone Dust) ) 2.764 1.77
C) Free Moisture
Coarse aggregate - CA1 ( 26.5mm ) - NIL
CA2 ( 10mm ) - NIL
Fine aggregate - FA1 ( Crushed stone sand ) - NIL
D. Combination of Aggregate Gradation for DLC ( as per MORT&H Table : 600.1 ) :
Per cent Passing ( Combined Grading )

FA1 Achieved
CA1 Specification Limits
IS Sieve Size CA2 Results
(mm) (10mm) ( crushed stone
(26.5mm)
sand )
32% 28% 40% 100% Lower Limit Mid Limit Upper Limit
26.5 100.00 100 100 100.00 100 100 100
19.00 63.04 100 100 88.17 75 85 95
9.50 1.11 87.83 100 64.95 50 60 70
4.75 0.26 8.24 99.15 42.05 30 42.5 55
2.36 0.00 2.02 87.74 35.66 17 29.5 42
0.6 0.00 1.11 42.19 17.19 8 15 22
0.3 0.00 0.23 21.28 8.58 7 12 17
0.150 0.00 0.00 11.58 4.63 2 7 12
0.075 0.00 0.00 6.65 2.66 0 5 10
100
80
60
40
20
0
0.01 0.1 1 10 100
E. Proportioning of Materials for the Mix

As per Combination of Aggregate Gradation for DLC ( as per MORT&H Table : 600.1 )
a. Aggregate Cementinous Material Ratio 14 :1
b. Aggregate Content ( 160 X 14 ) 2240 Kg/cu.m
c. Cement Content 130 Kg/cu.m
d.Flyash 30 Kg/cu.m
d. Coarse Aggregate 26.5 mm (32%) 716.8 Kg/cu.m
e. Coarse Aggregate 10 mm (28%) 627.2 Kg/cu.m
f. Fine Aggregate Crusher Stone Dust (40%) 896 Kg/cu.m
g. Total Quantity of Material 2400 Kg/cu.m
F. From Proctor Graph :
Maximum Dry Density ( MDD ) 2.432 gm/cc
Optimum Moisture Content ( OMC ) 5.93 %
Total Quantity of Water Required for the DLC Mix ( 2400 X 5.50% ) 142.32 Kg/cu.m
G. The Material Proportions are therefore ( per 1cu.m of DLC Mix ) :
Coarse Aggregate
Material Water Cement Flyash CA1 CA2 FA Total Qty

(26.5- (Stone
mm) (10mm) Dust)
Weight in Kg 142.32 130 30 716.8 627.2 896 2542.32
Proportions 5.60 5.11 1.18 28.19 24.67 35.24 100.00
Cubes Casted Date 10/17/2017

I. Compressive Strength @ 7 Days
Corrected Compressive Avg. Compressive
S.no Wt of Cube Density
Load Strength Strength
1 8801 2.608 340 15.11
2 8783 2.602 350 15.56
3 8752 2.593 370 16.44
Spec.
4 8745 2.591 330 14.67 Strength @
7days 10Mpa
5 8823 2.614 350 15.56 15.56
6 8783 2.602 350 15.56
7 8752 2.593 360 16.00
8 8735 2.588 370 16.44
9 8786 2.603 330 14.67
Remarks :

Four Laning of Tuljapur-Ausa (including Tuljapur Bypass) section of NH-361 from km 0.000 to km 55.835
Project (Existing Chainage : km 416.000 to km 470.000) under NHDP Phase-IV in the state of Maharashtra on Hybrid
Annuity Mode.

MODIFIED PROCTOR'S COMPACTION TEST

As per IS 2720 (part - 8)
Source DBL Crusher Camp-1 Date of Sampling 10/1/2017

Location 13+700 RHS Date of Testing 10/15/2017
Testing Laboratory 13+700 RHS Sampled By Jointly
Weight of Sample 7000 gms Tested By Jointly
Mould No.:3 Mould Vol (V): 2250 Weight of the mould (gms) 5610
Description Test 1 Test 2 Test 3 Test 4 Test 5 Test 6
% of Water added 2% 3.0% 4.0% 5.0% 6.0% 7.0%
Weight of water added in gms 140 210 280 350 420 490
Weight of mould + Compacted soil in gms (m2) 10978 11164 11297 11406 11409 11304
Weight of compacted soil in gms m3 = (m2-m1) 5368 5554 5687 5796 5799 5694
Wet Density in gm/cc gb = m3/v 2.386 2.468 2.528 2.576 2.577 2.531
Container No. 100 101 102 103 104 105
Weight of container (W1) 96.53 89.96 95.04 99.52 92.96 91.30
Weight of container + wet soil (W2) 285.69 290.14 284.12 301.46 305.40 287.96
Weight of container + dry soil (W3) 280.57 282.58 275.37 290.28 291.65 273.90
Weight of water ( W2- W3) 5.12 7.56 8.75 11.18 13.75 14.06
Weight of dry soil ( W3 - W1) 184.04 192.62 180.33 190.76 198.69 182.60
W2 - W3
Moisture Content, W= x 100 2.78 3.92 4.85 5.86 6.92 7.70
W3 - W1
Dry density in gms/cc gd=gb/(1+w/100) 2.321 2.375 2.411 2.433 2.411 2.350
MDD = 2.433 (g/cc) OMC = 5.90 (%)
2.450
2.430
2.410
2.390
2.370
2.350
2.330
2.310
2.290
2.270
2.250
2.00 3.00 4.00 5.00 6.00 7.00 8.00
11406.64
189.16 200.18 189.08 201.94 212.44 196.66

280.5736 282.5889 275.3738 290.2814 291.6506 273.8998
5.45
1.02782 2.242
Annuity Mode.



Description Test 1 Test 2 Test 3 Test 4 Test 5 Test 6
% of Water added 2% 3.0% 4.0% 5.0% 6.0% 7.0%
Weight of water added in gms 140 210 280 350 420 490
Weight of mould + Compacted soil in gms (m2) 10915 11042 11185 11293 11302 11186
Weight of compacted soil in gms m3 = (m2-m1) 5415 5542 5685 5793 5802 5686
Wet Density in gm/cc gb = m3/v 2.407 2.463 2.527 2.575 2.579 2.527
Container No. 106 107 108 109 110 111
Weight of container (W1) 97.35 91.88 91.64 119.95 121.34 118.52
Weight of container + wet soil (W2) 265.41 274.89 280.14 290.33 256.48 264.89
Weight of container + dry soil (W3) 260.72 268.29 271.51 280.79 247.79 254.27
Weight of water ( W2- W3) 4.69 6.60 8.63 9.54 8.69 10.62
Weight of dry soil ( W3 - W1) 163.37 176.41 179.87 160.84 126.45 135.75
W2 - W3
Moisture Content, W= x 100 2.87 3.74 4.80 5.93 6.87 7.82
W3 - W1
Dry density in gms/cc gd=gb/(1+w/100) 2.340 2.374 2.411 2.431 2.413 2.344
MDD = 2.431 (g/cc) OMC = 5.90 (%)
2.450
2.430
2.410
2.390
2.370
2.350
2.330
2.310
2.290
2.270
2.00 3.00 4.00 5.00 6.00 7.00 8.00
11293.21
168.06 183.01 188.50 170.38 135.14 146.37

260.7212 268.2922 271.5064 280.7921 247.7927 254.274
5.45
1.028708 2.242
Annuity Mode.



Description Test 1 Test 2 Test 3 Test 4 Test 5
% of Water added 3% 4.0% 5.0% 6.0% 7.0%
Weight of water added in gms 210 280 350 420 490
Weight of mould + Compacted soil in gms (m2) 11010 11221 11372 11470 11463
Weight of compacted soil in gms m3 = (m2-m1) 5344 5555 5706 5804 5797
Wet Density in gm/cc gb = m3/v 2.375 2.469 2.536 2.580 2.576
Container No. 112 113 114 115 116
Weight of container (W1) 116.43 120.48 117.04 125.48 127.40
Weight of container + wet soil (W2) 305.69 301.24 289.57 294.15 288.66
Weight of container + dry soil (W3) 300.23 294.07 281.29 284.44 277.94
Weight of water ( W2- W3) 5.46 7.17 8.28 9.71 10.72
Weight of dry soil ( W3 - W1) 183.80 173.59 164.25 158.96 150.54
W2 - W3
Moisture Content, W= x 100 2.97 4.13 5.04 6.11 7.12
W3 - W1
Dry density in gms/cc gd=gb/(1+w/100) 2.307 2.371 2.414 2.431 2.405
MDD = 2.431 (g/cc) OMC = 6.00 (%)
2.450
2.400
2.350
2.300
2.250
2.200
2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00
HORITY OF INDIA
OF ROAD TRANSPORT & HIGHWAYS)
usa (including Tuljapur Bypass) section of NH-361 from km 0.000 to km 55.835
16.000 to km 470.000) under NHDP Phase-IV in the state of Maharashtra on Hybrid
y of India
ant
ays Limited
10/1/2017
10/15/2017
Jointly
Jointly
Test 6
8.0%
560
11339
5673
2.521
117
128.20
298.13
285.51
12.62
157.31
8.02
2.334
5.00 6.00 7.00 8.00 9.00

Independent Engineer
260
165000
11465.18 87000
252000
189.26 180.76 172.53 168.67 161.26 169.93
300.2311 294.0707 281.2917 284.4377 277.9414 285.5135
5.45
2.242
2.431667
5.933333
Four Laning of Tuljapur-Ausa (including Tuljapur Bypass) section of NH-361 from km
Project 0.000 to km 55.835 (Existing Chainage : km 416.000 to km 470.000) under NHDP
Phase-IV in the state of Maharashtra on Hybrid Annuity Mode.
ACCEPTANCE CRITERIA FOR DRY LEAN CONCRETE ( DLC )

COMPRESSIVE STRENGTH at 7
days( as per MOSRT&H Cl:601.3.4 )
The Material Proportions are therefore ( per 1cu.m of DLC Mix ) :
Cement Aggregate
Flyash
Material Water CA1 CA2 FA (Stone
(26.5-mm) (10mm) Dust)
Weight
142.32 130 30 716.8 627.2 896
in Kg
Proportions 5.60 5.11 1.18 28.19 24.67 35.24
Average Compressive
Compressive Avg. Compressive Strength Shall not less
Sample No Strength
Strength (MPa) than 10 Mpa
(Mpa)
15.11 OK
1 15.56 15.70 OK
16.44 OK
14.67 OK
15.56 > 10
2 15.56 15.26 OK OK
MPa
15.56 OK
16.00 OK
3 16.44 15.70 OK
14.67 OK
AUTHORITY OF INDIA
NISTRY OF ROAD TRANSPORT & HIGHWAYS)
f Tuljapur-Ausa (including Tuljapur Bypass) section of NH-361 from km
5.835 (Existing Chainage : km 416.000 to km 470.000) under NHDP
e state of Maharashtra on Hybrid Annuity Mode.
way Authority of India
ing Consultant
Ausa Highways Limited
Limited
RY LEAN CONCRETE ( DLC )

COMPRESSIVE STRENGTH at 7
per MOSRT&H Cl:601.3.4 )
Total Qty
2542.32
100.00
Remarks

SIEVE ANALYSIS REPORT OF DLC
( As per MORTH Sec-600 )
26.5mm Aggregate
Date of Sampling 10/1/2017
Date of Testing 10/4/2017
Sample-1 T.Wt 13568 Sample-2 T.Wt 14520
Cum. Cum. Cum.Passi Cum. Cum.

Sieve Size Wt.Retained Retained Retained ng Sieve Size Wt.Retained Retained Retained
mm ( gm ) ( gm ) % % mm ( gm ) ( gm ) %
26.5 0 0 0 100 26.5 0 0 0
19.00 5228 5228 38.53 61.47 19.00 5187 5187 35.72
9.50 8210 13438 99.04 0.96 9.50 9139 14326 98.66
4.75 83 13521 99.65 0.35 4.75 131 14457 99.57
2.36 2.36
0.600 0.600
0.300 0.300
0.150 0.150
0.075 0.075
mm ( gm ) ( gm ) % % mm ( gm ) ( gm ) %
26.5 0 0 0 100 26.5 0 0 0
19.00 5297 5297 35.26 64.74 19.00 4557 4557 37.83
9.50 9550 14847 98.83 1.17 9.50 7319 11876 98.58
4.75 138 14985 99.75 0.25 4.75 154 12030 99.86
2.36 2.36
0.600 0.600
0.300 0.300
0.150 0.150
0.075 0.075
Sieve Size Wt.Retained Sieve Size Wt.Retained
Retained Retained ng Retained Retained
mm ( gm ) ( gm ) % % mm ( gm ) ( gm ) %
26.5 0 0 0 100 26.5 0 0 0
19.00 4377 4377 36.94 63.06 19.00 5204 5204 37.45
9.50 7371 11748 99.14 0.86 9.50 8561 13765 99.06
4.75 78 11826 99.80 0.20 4.75 107 13872 99.83
2.36 2.36
0.600 0.600
0.300 0.300
0.150 0.150
0.075 0.075
26.5mm Aggregate
Sieve Size mm S-1 S-2 S-3 S-4 S-5 S-6 Avg MORTH Spe.Limit
26.5 100 100 100 100 100 100 100 100
19.00 61.47 64.28 64.74 62.17 63.06 62.55 63.04 75-95
9.50 0.96 1.34 1.17 1.42 0.86 0.94 1.11 50-70
4.75 0.35 0.43 0.25 0.14 0.20 0.17 0.26 30-55
2.36 17-42
0.600 8-22
0.300 7-17
0.150 2-12
0.075 0-10
& HIGHWAYS)
NH-361 from km 0.000 to km

Phase-IV in the state of
10/1/2017
10/4/2017
Cum.Passi
ng
% 26.5 12047 100

100 19.00 4557 4557 37.83 62.17
64.28 9.50 7319 11875.93 98.58 1.42
1.34 4.75 154 12030 99.86 0.14
0.43 2.36 17 12047 100
0.600 0 12047 100
0.300 0 12047 100
0.150 0 12047 100
0.075 0 12047 100
Cum.Passi
ng
%
100
62.17
1.42
0.14
Cum.Passi
ng
26.5 13895 100
% 19.00 5204 5204 37.45 62.55
100 9.50 8561 13764.39 99.06 0.94
62.55 4.75 107 13871 99.83 0.17
0.94 2.36 24 13895 100
0.17 0.600 0 13895 100
0.300 0 13895 100
0.150 0 13895 100
0.075 0 13895 100
& HIGHWAYS)
NH-361 from km 0.000 to km
Phase-IV in the state of
MORTH Spe.Limit
100 100
75-95 63.04
50-70 1.12
30-55 0.25
17-42
8-22
7-17
2-12
0-10

10mm Aggregate
Cum. Cum. Cum.Passi Cum. Cum. Cum.Passi

Sieve Size Wt.Retained Retained Retained ng Sieve Size Wt.Retained Retained Retained ng
mm ( gm ) ( gm ) % % mm ( gm ) ( gm ) % %
26.5 0 0 0 100 26.5 0 0 0 100
19.00 0 0 0.00 100.00 19.00 0 0 0.00 100.00
9.50 1191 1191 11.77 88.23 9.50 1241 1241 12.59 87.41
4.75 8100 9291 91.78 8.22 4.75 7693 8934 90.65 9.35
2.36 619 9910 97.90 2.10 2.36 681 9615 97.55 2.45
0.600 93 10003 98.81 1.19 0.600 111 9726 98.68 1.32
0.300 103 10106 99.83 0.17 0.300 86 9812 99.55 0.45
0.150 0 0.150 0
0.075 0 0.075 0
Sieve Size Wt.Retained Retained Retained ng Sieve Size Wt.Retained Retained Retained ng
mm ( gm ) ( gm ) % % mm ( gm ) ( gm ) % %
26.5 0 0 0 100 26.5 0 0 0 100
19.00 0 0 0.00 100.00 19.00 0 0 0.00 100.00
9.50 1655 1655 13.43 86.57 9.50 1419 1419 12.04 87.96
4.75 9675 11330 91.96 8.04 4.75 9483 10902 92.48 7.52
2.36 758 12088 98.12 1.88 2.36 632 11534 97.84 2.16
0.600 106 12194 98.98 1.02 0.600 117 11651 98.83 1.17
0.300 106 12300 99.84 0.16 0.300 104 11755 99.71 0.29
0.150 0 0.150 0
0.075 0 0.075 0
Retained Retained ng Retained Retained ng
mm ( gm ) ( gm ) % % mm ( gm ) ( gm ) % %
26.5 0 0 0 100 26.5 0 0 0 100
19.00 0 0 0.00 100.00 19.00 0 0 0.00 100.00
9.50 1565 1565 11.63 88.37 9.50 1446 1446 11.55 88.45
4.75 10675 12240 90.96 9.04 4.75 10169 11615 92.75 7.25
2.36 967 13207 98.15 1.85 2.36 698 12313 98.32 1.68
0.600 135 13342 99.15 0.85 0.600 73 12386 98.91 1.09
0.300 96 13438 99.87 0.13 0.300 111 12497 99.79 0.21
0.150 0.150
0.075 0.075
10mm Aggregate
Sieve Size
mm
S-1 S-2 S-3 S-4 S-5 S-6 Avg MORTH Spe.Limit
26.5 100 100 100 100 100 100 100 100
19.00 100 100 100 100 100 100 100 75-95
9.50 88.23 87.41 86.57 87.96 88.37 88.45 87.83 50-70
4.75 8.22 9.35 8.04 7.52 9.04 7.25 8.24 30-55
2.36 2.10 2.45 1.88 2.16 1.85 1.68 2.02 17-42
0.600 1.19 1.32 1.02 1.17 0.85 1.09 1.11 8-22
0.300 0.17 0.45 0.16 0.29 0.13 0.21 0.23 7-17
0.150 2-12
0.075 0-10
26.5 9856 100
19.00 0 0 0 100
9.50 1241 1240.87 12.59 87.41
4.75 7693 8933 90.64 9.36
2.36 681 9615 97.55 2.45
0.600 111 9726 98.68 1.32
0.300 86 9812 99.55 0.45
0.150 44 9856 100 0
0.075 0 9856 100 0.00
26.5 11789
100
19.00 0 0 0 100
9.50 1419 1419.396 12.04 87.96
4.75 9483 10902 92.48 7.52
2.36 632 11534 97.84 2.16
0.600 117 11651 98.83 1.17
0.300 104 11755 99.71 0.29
0.150 34 11789 100 0
0.075 0 11789 100 0.00
26.5 12523 100

19.00 0 0 0 100
9.50 1446 1446.406 11.55 88.45
4.75 10169 11615 92.75 7.25
2.36 698 12313 98.32 1.68
0.600 73 12385 98.9 1.10
0.300 111 12497 99.79 0.21
0.150 26 12523 100 0
0.075 0 12523 100 0.00
100
100
87.83
8.24
2.02
1.1
0.24
0
0
Fine Aggregate (Crushed stone sand)

mm ( gm ) ( gm ) % % mm ( gm ) ( gm ) %
26.5 0 0 0 100 26.5 0 0 0
19.00 0 0 0.00 100 19.00 0 0 0.00
9.50 0 0 0.00 100 9.50 0 0 0.00
4.75 9.3 9.3 0.77 99.23 4.75 13.3 13.3 1.26
2.36 145.4 154.7 12.86 87.14 2.36 111.2 124.5 11.79
0.600 548.1 702.8 58.42 41.58 0.600 480.7 605.2 57.31
0.300 235.3 938.1 77.98 22.02 0.300 221.2 826.4 78.26
0.150 124.3 1062.4 88.31 11.69 0.150 102.6 929 87.97
0.075 65.7 1128.1
1128.1 93.77
110.60 6.23 0.075 54.7
70.6 983.7 93.15
mm ( gm ) ( gm ) % % mm ( gm ) ( gm ) %
26.5 0 0 0 100 26.5 0 0 0
19.00 0 0 0 100 19.00 0 0 0
9.50 0 0 0 100 9.50 0 0 0
4.75 18.1 18.1 1.59 98.41 4.75 4.2 4.2 0.32
2.36 116 134.1 11.76 88.24 2.36 171.1 175.3 13.28
0.600 518 652.1 57.20 42.80 0.600 594.4 769.7 58.31
0.300 246.8 898.9 78.85 21.15 0.300 265.8 1035.5 78.45
0.150 113.8 1012.7 88.83 11.17 0.150 140.7 1176.2 89.11
0.075 46.2 1058.9 92.89 7.11 0.075 62.2 1238.4 93.82
Retained Retained ng Retained Retained
mm ( gm ) ( gm ) % % mm ( gm ) ( gm ) %
26.5 0 0 0 100 26.5 0 0 0
19.00 0 0 0 100.00 19.00 0 0 0
9.50 0 0 0 100.00 9.50 0 0 0
4.75 3.5 3.5 0.31 99.69 4.75 10.8 10.8 0.84
2.36 129.4 132.9 11.83 88.17 2.36 144.5 155.3 12.05
0.600 511 643.9 57.34 42.66 0.600 595.9 751.2 58.28
0.300 247.3 891.2 79.36 20.64 0.300 272.8 1024 79.44
0.150 102 993.2 88.44 11.56 0.150 108.7 1132.7 87.87
0.075 56.7 1049.9 93.49 6.51 0.075 66 1198.7 92.99
Fine Aggregate(Crusher Stone Dust)
Sieve Size mm S-1 S-2 S-3 S-4 S-5 S-6 Avg MORTH Spe.Limit
26.5 100 100 100 100 100 100 100 100
19.00 100 100 100 100 100 100 100 75-95
9.50 100 100 100 100 100 100 100 50-70
4.75 99.23 98.74 98.41 99.68 99.69 99.16 99.15 30-55
2.36 87.14 88.21 88.24 86.72 88.17 87.95 87.74 17-42
0.600 41.58 42.69 42.80 41.69 42.66 41.72 42.19 8-22
0.300 22.02 21.74 21.15 21.55 20.64 20.56 21.28 7-17
0.150 11.69 12.03 11.17 10.89 11.56 12.13 11.58 2-12
0.075 6.23 6.85 7.11 6.18 6.51 7.01 6.65 0-10
IA
RT & HIGHWAYS)
n of NH-361 from km 0.000 to km
HDP Phase-IV in the state of
10/1/2017
10/4/2017
Cum.Pass
ing 26.5 1056 100
% 19.00 0 0 0 100
100 9.50 0 0 0.00 100
100.00 4.75 13.3 13 1.26 98.74
100.00 2.36 111.2 125 11.79 88.21
98.74 0.600 480.7 605 57.31 42.69
88.21 0.300 221.2 826 78.26 21.74
42.69 0.150 102.6 929 87.98 12.02
21.74 0.075 54.7 984 93.16 6.84
12.03
6.85
26.5 1320 100
Cum.Pass
ing 19.00 100
0 0 0
% 9.50 0 0 0.00 100
100 4.75 4.2 4 0.32 99.68
100 2.36 171.1 175 13.28 86.72
100 0.600 594.4 770 58.31 41.69
99.68 0.300 265.8 1036 78.45 21.55
86.72 0.150 140.7 1176 89.11 10.89
41.69 0.075 62.2 1238 93.82 6.18
21.55
10.89
6.18
100.00
Cum.Pass
ing
26.5 1289 100
% 19.00 0 0 0 100
100 9.50 0 0 0.00 100
100 4.75 10.8 11 0.84 99.16
100 2.36 144.5 155 12.05 87.95
99.16 0.600 595.9 751 58.28 41.72
87.95 0.300 272.8 1024 79.44 20.56
41.72 0.150 108.7 1133 87.87 12.13
20.56 0.075 66.1 1199 93 7.00
12.13
7.01
IA
RT & HIGHWAYS)
n of NH-361 from km 0.000 to km
HDP Phase-IV in the state of
MORTH Spe.Limit
100 100
75-95 100
50-70 100
30-55 99.15
17-42 87.74
8-22 42.19
7-17 21.28
2-12 11.57
0-10 6.64
SPECIFIC GRAVITY AND WATER ABSORPTION OF COARSE AGGREGATE
IS: 2386 (Part – 3)
Type of Material C.Agg (26.5mm) Date of Sampling 10/1/2017

Source of Material DBL Crusher Camp-1 Date of Testing 10/2/2017
Used for Concrete Tested By Jointly
Test Method By Basket
Sr. No Description 1 2 3 Average

A Wt. of S.S.D. Sample in air (gm) 1823.0 1956.0 2015.0
B Wt. of Sample in Water (gm) 1188.0 1272.0 1312.0
C Weight of Oven dry sample in air (gm) 1814.0 1946.0 2005.0
D Spe. Gravity on oven dried = C/(A-B) 2.857 2.845 2.852 2.851
E Spe. Gravity on S.S.D. = A/(A-B) 2.871 2.860 2.866 2.866
F Apparent Specific Gravity = C/(C-B) 2.898 2.887 2.893 2.893
G Water absorption = 100(A-C)/C 0.50 0.51 0.50 0.50
Remark:

IS: 2386 (Part – 3)
Type of Material C.Agg (10 mm) Date of Sampling 10/1/2017

Test Method By Pycnometer

B Wt. of Pycnometer+S.S.D Sample+Water (gm) 1882.0 1878.5 1875.0
C Wt. of Pycnometer + filled with water (gm.) 1552.0 1552.0 1552.0
D Wt. of Oven dried sample (gm.) 505.5 501.5 496.0
E Spe. Gravity on oven dried = D/A-(B-C) 2.816 2.810 2.802 2.809
F Spe. Gravity on S.S.D. = A/A-(B-C) 2.838 2.829 2.825 2.831
G Apparent Specific Gravity = D/D(B-C) 2.880 2.866 2.867 2.871
H Water absorption = 100(A-D)/D 0.79 0.70 0.81 0.77
Remark:


IS: 2386 (Part – 3)
Type of Material F.Agg (Crusher Stone Sand) Date of Sampling 10/1/2017
Test Method By Pycnometer
B Wt. of Pycnometer+S.S.D Sample+Water (gm) 1870.5 1871.5 1878.0
C Wt. of Pycnometer + filled with water (gm.) 1552.0 1552.0 1552.0
D Wt. of Oven dried sample (gm.) 491.2 492.0 501.0
E Spe. Gravity on oven dried = D/A-(B-C) 2.706 2.718 2.723 2.716
F Spe. Gravity on S.S.D. = A/A-(B-C) 2.755 2.765 2.772 2.764
G Apparent Specific Gravity = D/D(B-C) 2.844 2.852 2.863 2.853
H Water absorption = 100(A-D)/D 1.79 1.73 1.80 1.77
Remark:

AGGREGATE IMPACT VALUE TEST

( As per IS 2386, ( Part-lV ) )
Lab job No. Date of Sampling 10/1/2017

Type of Material C.Agg (12.5-10mm) Sampled by Jointly
Location 13+700 RHS Tested by Jointly
Proposed Use Concrete
Description Unit Test 1 Test 2

Sl.No.
Weight of surface dry sample passing 12.5 mm. and retained on
1 (gm) 356 353 352
10 mm. IS sieves,W1
Weight of fraction passing on 2.36 mm.sieve after the test,W2

2 (gm) 45 44 43
Weight of fraction retained on 2.36 mm.sieve after the test,W3

3 (gm) 311 309 309
4 Loss in wt. of aggregate W4 = W1 - (W2 + W3 ) (gm) 0 0 0
5 Aggregate Impact Value ( A .I .V.) = ( W2 / W1 ) x 100 % 12.64 12.46 12.22
6 Average value of ( A. I .V.) % 12.44
Note :- If W4 > 1 gm., Repeate the test
Remarks :
44.9628 43.5249 42.592
311.0372 309.4751 309.408

Four Laning of Tuljapur-Ausa (including Tuljapur Bypass) section of NH-361 from km 0.000
Project to km 55.835 (Existing Chainage : km 416.000 to km 470.000) under NHDP Phase-IV in the
state of Maharashtra on Hybrid Annuity Mode.

FLAKINESS & ELONGATION INDICES
( As per IS 2386, (Part - l ) & MOST Specification )

Type of Material 26.5 mm aggregate Sampled by Jointly
Proposed Use
Wt. of Aggregate Wt. of non -flaky Wt. of flaky Wt. of Elongated particle retained on
Taken particle Retained particle Passed elongation gauge of non-flaky
I.S.Sieve Size mm. On Thickness Through particle ( D )
(A) Gauge (B ) Thickness Gauge
Passing Retained gm gm gm( C ) gm
63 50
50 40
40 31.5
31.5 25
25 20 2356 2188 168 226
20 16 2877 2637 240 317
16 12.5 3562 3211 351 504
12.5 10 2045 1750 295 339
10 6.3 850 677 173 162
Total wt. of sample 11690 10463 1227 1548
Flakiness Index ( FI ) = ( C / A ) x 100 : 10.50 %

Elongation Index ( EI ) = ( D / B ) x 100 : 14.79 %
Combined Flakiness and Elongation indeces = ( FI + EI ) : 25.29 %
Specification Maximum : 35.00 %


FLAKINESS & ELONGATION INDICES
( As per IS 2386, (Part - l ) & MOST Specification )

Type of Material 10 mm aggregate Sampled by Jointly
Proposed Use
Wt. of Aggregate Wt. of non -flaky Wt. of flaky Wt. of Elongated particle retained on
Taken particle Retained particle Passed elongation gauge of non-flaky
I.S.Sieve Size mm. On Thickness Through particle ( D )
(A) Gauge (B ) Thickness Gauge
Passing Retained gm gm gm( C ) gm
63 50
50 40
40 31.5
31.5 25
25 20
20 16
16 12.5
12.5 10 2045 1808 237 227
10 6.3 1000 832 169 195
Total wt. of sample 3045 2640 405 422
Flakiness Index ( FI ) = ( C / A ) x 100 : 13.31 %
Elongation Index ( EI ) = ( D / B ) x 100 : 15.99 %

Combined Flakiness and Elongation
indeces = ( FI + EI ) : 29.30 %
Specification Maximum : 35.00 %

Four Laning of Tuljapur-Ausa (including Tuljapur Bypass) section of NH-361 from km 0.000 to
Project km 55.835 (Existing Chainage : km 416.000 to km 470.000) under NHDP Phase-IV in the state
of Maharashtra on Hybrid Annuity Mode.
LOS ANGELS ABRASION VALUE TEST
IS: 2386, PART- 4
Lab. Job No Date of Sampled 10/1/2017

Type of Material DLC (Grade-B) Sampled by Jointly
Source DBL Crusher Camp-1 Date of Tested 10/5/2017
Proposed Used DLC Total Weight 5000 gm
Grading and Weight in gm of Test Sample

Retained on IS
A B C D
Sieve (mm)
Sieve (mm)
Passing IS
Weight of
Weight of
Weight of
Specified
Specified
Specified
Specified
Sample
Sample
Sample
Value
Value
Value
Value
(gm)
(gm)
(gm)
40 25 1250 - - -
25 20 1250 - p -
20 12.5 1250 2500 - -
12.5 10 1250 2500 - -
10 6.3 - - 2500 -
6.3 4.75 - - 2500 -
4.75 2.36 - - - 5000
Total 5000 5000 5000 5000
Note: The test samples shall conform to one of the grading in the above table.
Speed Grading No. of Spheres Weight of charge, gm
Rotate at 30 to 33 rpm for 500 A 12 5000±25
revaluation B 11 4584±25
C 8 3330±20
D 6 2500±15
Note: The abrasive charge shall consist of cast iron or steel spheres approximately 47.6 mm in diameter and each
weight shall be between 390 and 445 grams. The charge depending upon grading of test sample shall be as
tabulated above.
1 Trial No 1 2
2 Weight of oven dried specimen = W1g 5000 5000
Weight of over dried specimen after abrasion test, coarser than 1.70
3 4159 4140
mm IS Sieve = W2g
Percentage abrasion loss wear = W1 – W2
4 x 100 16.82 17.2
W1
5 Average 17.01
Remarks
17.01
LOS ANGELS ABRASION VALUE TEST
IS: 2386, PART- 4
Lab. Job No Date of Sampled 10/1/2017

Type of Material DLC (Grade-C) Sampled by Jointly
Source DBL Crusher Camp-1 Date of Tested 10/5/2017
Proposed Used DLC Total Weight 5000 gm
Grading and Weight in gm of Test Sample

Retained on IS
A B C D
Sieve (mm)
Sieve (mm)
Passing IS
Weight of
Weight of
Weight of
Specified
Specified
Specified
Specified
Sample
Sample
Sample
Value
Value
Value
Value
(gm)
(gm)
(gm)
40 25 1250 - - -
25 20 1250 - p -
20 12.5 1250 2500 - -
12.5 10 1250 2500 - -
10 6.3 - - 2500 -
6.3 4.75 - - 2500 -
4.75 2.36 - - - 5000
Total 5000 5000 5000 5000
Note: The test samples shall conform to one of the grading in the above table.
Speed Grading No. of Spheres Weight of charge, gm
Rotate at 30 to 33 rpm for 500 A 12 5000±25
revaluation B 11 4584±25
C 8 3330±20
D 6 2500±15
Note: The abrasive charge shall consist of cast iron or steel spheres approximately 47.6 mm in diameter and each
weight shall be between 390 and 445 grams. The charge depending upon grading of test sample shall be as
tabulated above.
1 Trial No 1 2
2 Weight of oven dried specimen = W1g 5000 5000
Weight of over dried specimen after abrasion test, coarser than 1.70
3 4003 4022
mm IS Sieve = W2g
Percentage abrasion loss wear = W1 – W2
4 x 100 19.94 19.56
W1
5 Average 19.75
Remarks
19.75
Project (Existing Chainage : km 416.000 to km 470.000) under NHDP Phase-IV in the state of Maharashtra on
Hybrid Annuity Mode.

Lab Job No Date of Sampling 10/3/2017

Source Ultratech Cement Factory Sampled by Jointly
Grade of Cement OPC 53 grade Date of Testing 10/10/2017
Brand Ultratech Tested by Jointly
Batch 39-2017
CEMENT PHYSICAL TEST
FINENESS OF CEMENT
IS 4031 (Part 1)
Description Trial 1 Trial 2 Trial 3 Remarks
Weight of Cement taken A (gm) 100 100 100
Weight of Cement ratained on 90 mic. Sieve B (gm) 1.63 1.47 1.85
Fineness of Cement (%) 1.63 1.47 1.85
Average Fineness(B/A)x100 (%) 1.65
STANDARD CONSISTENCY
IS 4031 (Part 4)
Weight of cement
Sl. No. Water added (ml) % of water Penetration (mm) Remarks
taken (gms)
1 400 116 29 10
2 400 118 29.5 7
3 400 120 30 4
Consistency =29.5
SETTING TIMES
IS 4031 (Part 5)
Initial Setting time (min.) 138 Min. 30 min. Remarks
Final Setting time (min.) 295 Max. 10 hrs.
SOUNDNESS OF CEMENT
IS 4031 (Part 5)
Descriptions Trial 1 Trial 2 Trial 3 Remarks
Initial length of Specimen A (mm) 10.5 12.1 11.4
Final length of Specimen B (mm) 11.4 13.2 12.6
Expansion B-A(mm) 0.9 1.1 1.2
Average Expansion (mm) 1.10
COMPRESSIVE STRENGTH
IS 4031 (Part 3)
Dimension 70.6 * 70.6 * 70.6 mm Date of Casting :- 10/10/2017
Volume of cube 0.00035 m3
Area of the cube 4984.36 mm2
Cube No. 1 2 3 4 5 6 7 8 9
Age of cube 3 days 7days 28 days
Date of testing 10/13/2017 10/17/2017 11/7/2017
Weight of cube (Kg) 811 810 810 820 818 815 825 823 827
Density (Kg/m3) 2.30 2.30 2.30 2.33 2.32 2.32 2.34 2.34 2.35
Failure load (Kn) 196 212 210 256 258 260 290 294 292
Compressive strength(N/mm2)
39.33 42.54 42.13 51.36 51.77 52.17 58.19 58.99 58.59
Avg.Comp. strength(N/mm2)
41.33 51.77 58.59
Comp.Strength(N/mm2) Minimum.33 Minimun.43 Minimun.53
Remarks :
0.9 1.1 1.2
4984.36
Project (Existing Chainage : km 416.000 to km 470.000) under NHDP Phase-IV in the state of Maharashtra on
Hybrid Annuity Mode.
Independent Engine Lion Engineering Consultant
SPECIFIC GRAVITY OF FLYASH

( As per IS 4031 , Part - ll )
Lab.Job no. Date of Sample 10/5/2017

Type of Material Fly ash Sampled by Jointly
Source DBL Crusher Camp-1 Date Tested 10/10/2017
Proposed Use DLC Method of Test Pycnometer
Sl.no. Description Unit Sample 1 Sample 2

1 Weight Pycnometer bottle W1 gm 32.31 32.31
2 Weight of Sample W2 gm 19.65 19.7
3 Weight Pycnometer bottle + sample W3 gm 51.96 52.01
4 Weight Pycnometer bottle + sample + Kerosen W4 gm 85.53 85.56
5 Wt. of Pycnometer Bottle + full of Kerosen W5 gm 73.32 73.32
6 Wt. of Pycnometer Bottle + full of Water W6 gm 83.39 83.39
7 Specific Gravity of Flyash = W2/((W2)-(W4-W5)) A 2.641 2.641
8 Density of Kerosen =W5-W1/W6-W1 B 0.803 0.803
9 Specific Gravity of Flyash = A*B 2.120 2.120
12 Average Specific Gravity 2.120
30.99
19.65 19.7 8.404669
0.36549 0.35854 98.37 89.97
19.28451 19.34146
9.9456 9.77856
2.641 1541.963 1541.983 2099.3
2.120 1865.3
#VALUE!
8.574251
91.13

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NATIONAL HIGHWAY AUTHORITY OF INDIA

(MINISTRY OF ROAD TRANSPORT & HIGHWAYS)

Employer National Highway Authority of India

DRY LEAN CEMENT CONCRETE (DLC) MIX DESIGN - 01 (AS

1 Maximum Dry Density ( MDD ) 2.432g/cc

The Material Proportions of DLC Mix

Contractor Independent Engineer

Cement 130 0.130 0.054 5.42 MT M3

DRY LEAN CEMENT CONCRETE (DLC) MIX DESIGN

Per cent Passing ( Combined Grading )

26.5 100.00 100 100 100.00 100 100 100

19.00 63.04 100 100 88.17 75 85 95

9.50 1.11 87.83 100 64.95 50 60 70

4.75 0.26 8.24 99.15 42.05 30 42.5 55

2.36 0.00 2.02 87.74 35.66 17 29.5 42

0.6 0.00 1.11 42.19 17.19 8 15 22

0.3 0.00 0.23 21.28 8.58 7 12 17

0.150 0.00 0.00 11.58 4.63 2 7 12

0.075 0.00 0.00 6.65 2.66 0 5 10

E. Proportioning of Materials for the Mix

Maximum Dry Density ( MDD ) 2.432 gm/cc

Optimum Moisture Content ( OMC ) 5.93 %

G. The Material Proportions are therefore ( per 1cu.m of DLC Mix ) :

Material Water Cement Flyash CA1 CA2 FA Total Qty

Weight in Kg 142.32 130 30 716.8 627.2 896 2542.32

Proportions 5.60 5.11 1.18 28.19 24.67 35.24 100.00

Cubes Casted Date 10/17/2017

Contractor Independent Engineer

Employer National Highway Authority of India

MODIFIED PROCTOR'S COMPACTION TEST

Source DBL Crusher Camp-1 Date of Sampling 10/1/2017

MDD = 2.433 (g/cc) OMC = 5.90 (%)

189.16 200.18 189.08 201.94 212.44 196.66

Employer National Highway Authority of India

MODIFIED PROCTOR'S COMPACTION TEST

Source DBL Crusher Camp-1 Date of Sampling 10/1/2017

MDD = 2.431 (g/cc) OMC = 5.90 (%)

168.06 183.01 188.50 170.38 135.14 146.37

Employer National Highway Authority of India

MODIFIED PROCTOR'S COMPACTION TEST

Source DBL Crusher Camp-1 Date of Sampling 10/1/2017

MDD = 2.431 (g/cc) OMC = 6.00 (%)

As per IS 2720 (part - 8)

5.00 6.00 7.00 8.00 9.00

ACCEPTANCE CRITERIA FOR DRY LEAN CONCRETE ( DLC )

The Material Proportions are therefore ( per 1cu.m of DLC Mix ) :

Proportions 5.60 5.11 1.18 28.19 24.67 35.24

RY LEAN CONCRETE ( DLC )

Employer National Highway Authority of India

Cum. Cum. Cum.Passi Cum. Cum.

NH-361 from km 0.000 to km

% 26.5 12047 100

Employer National Highway Authority of India

Cum. Cum. Cum.Passi Cum. Cum. Cum.Passi

26.5 12523 100

Cum. Cum. Cum.Passi Cum. Cum.

Type of Material C.Agg (26.5mm) Date of Sampling 10/1/2017

Sr. No Description 1 2 3 Average