July 16, 2024

Mix Design of M40 Grade of Concrete with OPC Cement

1. Mix stipulation for ingredients of concrete

      • Grade of Concrete : M40

      • Type of Cement : OPC 53 grade confirming to IS 269

    •  

      • Maximum Nominal Size Aggregate : 20 mm

      • Minimum Cement content : 380Kg/cum

      • Maximum Water- Cement Ratio : 0.4

      • Workability : 150 ± 25 mm (slump)

      • Exposure Condition : Moderate

      • Method of Concrete Placing : Pumping/Bucket 

      • Degree of Supervision : Good

      • Type of Aggregate : Crushed angular Aggregate, Crushed Stone Sand

      • Chemical admixture type : Super plasticizers Confirming IS 9103:1999

    2. Material Properties

        • Cement : Ultratech OPC 53 grade confirming to IS 269

        • Specific Gravity of cement : 3.15

      •  
      •  

        • Chemical Admixture : BASF Master Glenium Sky 8511

        • Specific Gravity of Admixture : 1.07

        • Specific Gravity
              • Coarse aggregate

                    • 20mm : 2.65

                    • 12.5mm : 2.63

                • Fine aggregate :      Crushed stone aggregate  : 2.59                                                        

                • Water : 1 

            • Water Absorption 

                  • Coarse aggregate :                                                                              

                        • 20 mm  :  0.37%                                                         

                        • 12.5 mm   : 0.54%                                                                  

                    • Fine aggregate                                                                                                                                      

                          • Crushed Stone Aggregate :  2.35%                                                                   

                  • Free Surface Moisture                                                                        

                      Coarse aggregate :  Nil                                                                                                          Fine aggregate  : Nil     

                    • Sieve Analysis :

                          • Coarse aggregate :

                            IS Seive Sizes % Passing IS Requirement as per IS 383 Table 2 Ratio   Confirming to IS 383 table 2
                            Single Sized Graded 40% 60%  
                              20 mm 12.5 mm 20 mm 12.5 mm   20 mm 12.5 mm Combined 100%
                            20 95.01 100 85-100 100 100 38.00 60 98.00
                            12.5 0 99.15 85-100 90-100 0.00 59.49 59.49
                            10 2.54 51.07 0-20 0 – 45 40 – 85 1.02 30.64 31.66
                            4.75 0.88 0.42 0-5 0-10 0 – 10 0.35 0.25 0.60
                            PAN 0 0 0 0 0
                          • Fine Aggregate  : Confirming to grading Zone II of table 4 of IS 383      Note: – as per field trials for pumpable concrete fine aggregate should pass zone II; According to IS 383 clause No. 31.2.2 allows to use crushed stone sand as fine aggregate for concrete. According to IS 383-2016 for crushed stone sand, the permissible limit on 150 micron IS sieve is increased to 20%.

                            IS Seive Sizes  

                            % Passing Ratio River Sand:Msand A Combined Passing
                            A B IS 383 Zone II
                              R Sand M Sand R Sand M Sand    
                            4.75 0 100 0 100 90-100 100
                            2.36 0 85.88 0 85.88 75-100 85.88
                            1.18 0 58.95 0 58.95 55-90 58.95
                            600 0 38.87 0 38.87 35-59 38.87
                            300 0 21.47 0 21.47 8-30 21.47
                            150 0 9.74 0 9.74 0-10 9.74
                          • All in Aggregate :  

                            IS Seive Sizes 22.8% 34.2% 43% Specification Combined Passing
                            20mm 12.5mm c sand min-max
                            40 100 100 100 100-100 100.00%
                            20 95.01 100 100 95-100 98.86%
                            4.75 0.88 0.42 100 30-50 43.34%
                            0.6 0 0 38.87 10-35 16.71%
                            0.15 0 0 9.74 0-6 4.19%

                            3. Stipulation of Target Mean Strength and Mix Proportioning as per MORTH

                            Target Mean Strength for M-40 Grade =52Mpa                                                                                                                                                                                                

                            4. Calculation for water/Cement Ratio (W/C) 

                          • As per technical specification max Water/Cement + Binder=  0.4   

                            5.Calculation for Water content

                          • Ref Tab 2 , IS 10262 , Maximum water content per cum for  20mm Aggregate             =             186         litre for 50 mm slump                          186 + (0.09 * 186) (add 3% for every 25 mm increase) =203 lit        

                          •   Based on trials with super plasticizers, water content reduced by 29%, hence the arrived water content   = 139.89                                                      Let us add water 140lit                                                                         

                            6. Calculation for Cementious content            

                             Water-Cementitious Ratio = 0.36                                                       Cementious content (Cement OPC 53 + GGBFS) = 389                         Say         Cementitious     = 390  ,

                            Cement =390         kg/m3                                                  

                            Based on experience and lab trials,     super plasticizer= 0.48 %                                                                                                  

                            7.Calculation for arriving Aggregate content                                                          

                          • Ref Tab 3 of IS 10262, for Sand Zone II ,  volume of coarse aggregate per unit vol of total aggregate for 0.5 water-cement ratio =   0.62     

                          •     Adjust for W/c ratio: Add @ 0.01 for every decrease in 0.05 = 0.028 

                          • Therefore, corrected proportion=  0.648 

                          •    Adjust for pumpability, i.e. decrease by 10%    =   0.58 %                   

                          •  Based on experience  Considering Volume of coarse aggregate=0.57                           

                          • Therefore, Volume of Fine aggregate =0.43                                                       

                            8.Mix volume Calculation per cubic meter                                      

                          • a)Volume of concrete   =   1  m3 

                          • b) Volume of cement   =   Mass of cement  specific gravity of cement × 1000 = 0.1238   m3         

                          • c)Volume of water = Mass of water  x  specific gravity of water× 1000    =    0.140     m3  

                          • d)Volume of admixture =  Mass of admixture  x specific gravity of admixture× 1000    =   0.00175  m3

                          • e) Volume of all in aggregate =  [a-(b+c+d)]   =  0.73        m3    

                            • f) Mass of coarse aggregate                                                                                                                               

                                                                        1) 20 mm    =   e × volume of CA × sp. gravity × % of 20mm × 1000   
                                                                                                                            =             0.73*0.57*2.65*0.5*1000                                                                            
                                                                                                                            =             443.75   kg/m3                                                  
                                                                                                                    Say                   444  kg/m3                                                  

                                                                      2) 12 mm  =   e× volume of CA × sp. gravity × % of 12mm × 1000                                                                               
                                                                                                                            =             0.73*0.57*2.63*0.5*1000                                                                            
                                                                                                                            =             660.60   kg/m3                                                  
                                                                                                                    Say              661   kg/m3                                                  

                            • g) Mass of Fine aggregate =  e × volume of FA × sp. gravity × 1000                                                                               

                                                                                                =      0.73*0.43*2.59*1000                                                                     
                                                                                                =      817.95   kg/m3                                                  
                                                                                       Say          818  kg/m3  

                                                                            

                            9.Mix Details   

                                                                                                                                                                          
                                             cement     =   390  kg                                                                                                                 
                                            20mm        =    444  kg                                                         
                                            12mm        =    661   kg                                                          
                                            Crushed stone sand   =    818   kg                                                          
                                            Chemical admixture   =    1.87  kg                                                          
                                            Free Water       =    140 kg                                                          
                                            Water-Cement Ratio   =     0.36                                                                       
                                            Concrete density     =    2454  kg/m3                                                  

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