I

REPORT ON DESIGN MIX M-35

i " -"""-"- "- " """""" """ " -'.........:

: clienr: i
i The XEN/CON/IIIB-S/SCL i
i N. F. Railway, Silchar. i

Name of work:
Construction of superstructure over pile foundation of Major bridge No. 32 (6x30.5 composite
girder) at Ch' 11.770 km., construction of counterfort retaining waliover pile foundation between
Ch. 11560 to 11760 m & Ch. 9550 to 9750 m and other un"lllary works in connection with the
Bairabi-Sairang New Railway BG line Project. CA No. CON/B-S/2 446 dtd,.05-06-201g.

Ref. No. W |362|CON/B-S/SCL IMB-2C1r7 n4 Dated 27 -tt-20t9.

MATERIAL TESTING LABORATORY

ffi
& QUALITY MANAGEMENT CENTRE
NABL Certificate No. TC-6157
Sibbari Road, Athal Basti, P.O. Ghungoor (SMC) Dt. Cachar, Assam
Tel & Fax :03842-224572
e-mail : ms.nikhileshpaul@rediffmail.com
 .6*,d\
iffi$, MATERIAL TESTING LABORATORY Sibbari Road, Athalbasti, P.O. Ghungoor (SMC)
Silchar-78801 4, Dist. Cachar, Assam

M
1s!$qrc!rer!r
& QUALITY IuANAGEI\IENT CENTRE
NABL Certificate No. TC-61-i-
Tel & Fax:03842-224572
email : ms.nikhileshpaul@rediffmail.com

lssue No. MTL-IO/Dg.Cl19-2}t 9,e 2 f Date: B-Lq'19

ULRNo. TC-61s71900000 l0g5 ? FormatNo. MTLiFM|45

Issued to : Agency:
The XEN/CON/II/B-S/S CL, M/s RSV-SSNR (JV)
N. F. Railway, Silchar

Sub :
Design Mix M-35 for the Construction of superstructure over pile foundation of Major bridge No.
32 (6x30.5 composite girder) at Ch. t7.77O km., construction of counterfort retaining wall over pile
foundation between Ch. L1560 to 11760 m & Ch. 9550 to 9750 m and other ancillary works in connection
with the Bairabi-Sairang New Railway BG line Project. CA No. CON/B-S/2446 dtd. 05-06-2018.

Ref. N o. W /3621 CON/B-S/SCL/MB-2017 / 04 Dated 27 -L1-2Ot9.

DETAILS OF SAMPLE SUPPLIED

Sl. No. Name of Samrrles Source Otv. I/Mark.

1. Cement OPC 43 Grade Max 1 sealed bag coN/B-s/2 446tr
2. Fine aggregate (Sand) Dolu river 1 sealed bag coNlB-s/2446t2
3. Stone dust Silchar 1 sealed bag coN/B-s/2446t3
4. 20 mm crushed stone agg Silchar 1 sealed bag coN/B-s/2446t4
5. 10 mm crushed stone agg Silchar 1 sealed bag coN/B-s/2446ts
6. Water Work site 1 sealed bottle coN/B-s/2446t6
7. Admixture Sika 2004 NS 1 sealed bottle coN/B-s/2446t7

Date of sample receive : 02-12-19 Date of Testing: 03-12-19 to 10-12-19

Sample supplied by the agency.

Testing of samples is done in the premises of laboratorl' and using the results. Design mix calculated for
M-35 is achieved. On the basis of trial mix final recommendations are furnished for your necessary action.

1a-Eb-
Authoriy'eil Signatory
Authoized Signatory
Material Testing Laboratory &
Qualitv Management Centre
 MATERIAL TESTING LABORATORY Sibbari Road, Athalbasti, p.O. Ghungoor (SMC)
Silchar-788014, Dist. Cachar, Assam
& QUALITY MANAGEN,IENT CENTRE Tel & Fax:03842-224572
NABL Certificate \o. TC-61_<- email : ms.nikhileshpaul@rediffmail.com

Format No. MTL/FM/45

PROPORTION OF DESIGN MIX M-35

(This result is not valrd without a hologram)

The result conforming to M-35 as obtained from Trial

Mixes are as fbllows :

For 1 CM of mix concrete materials are

Water : l79litre Cement :448kg Sand:3g6 kg

Stone dust = 258 kg 20 mm coarse agg. : 774kg 10 mm coarse agg. : 331 kg

Admixture :4.48 kg

or for per bag of 50 kg cement

Water: 20litre Cement: 50 kg Sand: 43 kg
Stone dust : 29 kg 20 mm coarse agg. : 86.5 kg 10 mm coarse agg. : 37 kg

Admixture :0.500 kg.

For under water pile construction and as there is no chance for crack. l}oh extra cement
should be used for imparting in-situ strength.

Pre-conclition .'Both Fine aggregate (sand) & coarse aggregateshould

be saturated before mixing or
yatgr absorption @.1.14 o/o of_fine aggregate & 0.9270 oi.ourre aggregate thus total approx.2.06
%' thus total 3.60 litre water for sand& aggregate should be usedlxtra per cum.
"ou...

@
RuthoTElTienatorv
Authorized Signatorl
tlaterial Iesflng Laboratory &
Qualitv Management Centre
 CA No. CON/B-S/2446
N.F. Raillway, Silchar
Format

TEST RESULT CN CtrMENT

Sample: Cement Source: Max

Type : OPC 43 Grade Date of sample receive : 02-12-19
Qnty. Supplied: 1 seated bag Date oftesting :03-12-19 to 10-12-19
Identit-rcation mark: CON/B-S/2 446 11

sl. Name of Test Method of Test Results

No. Requirement Result obtained
1 Consistency IS 4031 (Part - 1) 28.5 %
2 Initial setting time IS 4031 (Part-V) 30 min" t hr. 30 min
Vicat apparatus
J Final setting time IS 4031 (Part-V) 10 hrs. max 3 hrs. 25 min
Vicat apparatus
4 Soundness IS 4031 (Part-III) Le 1Omm (max.) 1.5 mm
Chatelier apparatus i;i'
5 Fineness By Dry Sieving method 0% (Max.)
6 Compressive strength
i) 72 + t hr. strength Cube is made mixing
cement and standard sand
23 N/mm2 24:iNlmm2
in the ratio of I : 3 and by
gauging water (Pl4+3) %
ii) 168 + 2 hrs. strength
of combined mass of 33 N/mfiiz, 35.6 N/mmz
cement and standard sand.
(IS 4031 Part-VD
7 Specific gravity Specific gravity bottle 3.1s 3.15

Results conforms to Requirements

TeEng-Cfiffir"
lfrn- & oMC
 CA No" CONIB-Si2446
N.F. Railway, Silchar
Format No)

TEST RESULT ON FINE AGGREGATtr

Sample : Fine aggregate Source : Dolu river
Size : 10 mm down Date of sample receive : 02-12-19
Qnty.Supplied: 1 bag Date of testing : 03-12-19 to 05-12-19
Identification mark: CONIB-S/2 446 t2

SIEVE ANALYSIS

Sieving is done taking L000 gms sample in each cycle.

The result is based on the average of 3 cycles.
EssentialTest Results
IS Sieve size oZ passing Grading Zone IY Name of test Method of test Results
10 mm 100 100 Sieve analysis r.s 2386 FM: L.7l
4.75 mm 99.r 95-100 (Part -I)
2.36 mm 98.3 9s- 1 00 Bulking at I.S 2386 Pr-ilI
l%o t6.3 %
1.18 mm 96.t 90-100 moisture
600 u 88.8 80- 1 00 Moisture I.S 2386 Pt-[I 0.30 %
300 u 32.2 15-50 content
150 u 8.6 0-1 5 Water I.S 2386 Pt-m Nil
absorption
Organic I.S 23,86 Pt-Ir NiI
impurities
Silt content r.s 2386 Pt-r t.13 %
Specific I"S 2386 Pt-m ) <.,
gravitv

TEST RESULT ON STONE DUST

Sample : Stone Dust Source : Silchar
Size:5mmdown Date of sample receive :02-12-19
Qnty. Supplied: 1 bag Date of testing 03-12-19 to 05-12-lg
Identification mark: CON/B-S/2 446 t3

SIEVE ANALYSIS

Sieving is done taking 1000 gms sample in each cycle.

The result is based on the average of3 cycles.

IS Sieve size o/o passing

5mm 100
4.75 mm 96.8
2.36 mm 78.6
1.18 mm 60.2
600 p 41.4
300 p 22.7
150 p 6_4

iJffL & OMC

 CA No. CON/B-S/2446
N.F" Railway, Silchar
Format

% passing As per IS 383 grading

IS Sieve size of Screening
60 % ofsand
40o/a Combined (Zone III)
materials
mm
1U 60 40 100 100
4.75 mm 59.46 38.72 98.1 8 90-i00
2.36 mm s8.98 3t.44 90.42 85-100
1.18 mm 57.66 24.08 81.74 75-100
600 p 53.28 16.56 69.84 60-79
300 p 19.32 9.08 28.4CI 12-4A
150 rr 5.16 2.56 7.V2 0-10

Essential Test Results of combined sand & Stone Dust

Name of test Method of test Results

Specific gravity I.S 2386 (Part -III) 2.58
Water absorption I.S 2386 (Par1-III) t.t4 %

TEST RESULT OF CRUSHED STONE

Sample : Stone aggregate Source : Silchar
Type : Crushed stone Date of sample receive : O2-lZ-19
Size : 20 mm Date of testing : 03- 12-19 to 05- I 2- I 9
Qnty. Supplied : 1 seated ba Identification mark: CON/B-S/2 446 t4

SIEVE ANALYSIS
EssentialTest Results
Sieving is done taking 2000 gms sample in each cycle.
The result is based on the average of 3 cycles. Name of test Nlethod ofteit Results
oZ
Specific gravity IS 2386 Pt-3 2.60
IS Sieve size passing Range Bulk density IS 2386 Pt-3 7.62 gmlcc
40 mm 100 100 Moisture content IS 2386 Pt-3 Nil
Water absorption IS 2386 Pt-3 0.92 %
20 mm 94.30 85-100 Impact value IS 2386 Pt-4 2t%
Abrasion value IS 2386 Pt-4 27%
10 mm 14.85 0-20 Flakiness & IS 2386 Pt-l 12.3 %
Elongation Index
4.75 mm 1.22 0-5 .IS 2386 Pt-2
Deleterious Nil
materials
Organic impurities IS 2386 Pt-2 Nil
Soundness IS 2386 Pt-5 4.45 %
Potential reactivity IS 2386 Pt-7 Since the agg. is
free from
deleterious
materials, there is
no indication of
Potential
reactiviW
 CA No" CON/B-S/2446
N.F" Railway, Silchar
Format No.

TEST RESULT OF CRUSHED STONtr

Sample : Stone aggregate Source : Silchar

Type : Crushed stone Date of sample receive :02-12-19
Size : 10 mm Date of testing : 03-12-19 to 05-12-19
Qnty. Supplied: 1 seated bag Identification mark: CON/B-S/2 446 15

SIEVE ANALYSIS

Sieving is done taking 2000 gms sample in each cycle.

The result is based on the average of 3 cycles.
Essential Test Results
IS Sieve size %o passing Range
Name of test Method of test Results
12.5 mm 100 100
Specific gravity I.S 2386 2.60
10 mm 93.20
(Part -IID
85-100
Water absorption I.S 2386 0.92 %
4.75 mm (Part -III)
t2.30 0-20

2.36 mm 1.60 0-5

COMBINED 20 MM & 10 MM AGGREGATE

Combining 70Yo of 20 tnm and 30%o of 10 rnrn aggregate we get graded aggregate as follows.

Sieve size % passing Combined As per IS'383 Grading

20 mm 10 mm Range for graded Remarks
70% 30% aggregate
40 rnm 70 30 100 40 mm - 100

20 mrn 66.01 30 96.01 20 mm - 95-100

Results conform to
10 mm 10.39 27.96 38.35 10 mm - 25-55 graded aggregate as

4.75 mm
perIS 383:2016
0.8s 3.69 4.54 4.75mm - 0-10

2.36 ntm 0 0.48 0.48 2.36 rnm - 0

qffi:
ftrilxlmi
t#tl & oMc
 CA No. CON/B-S12446
N.F. Railway, Silchar
Format N

TEST RESULT OF
( Coarse Aggregate : Fine Aggregate : 64 :36 as per IS 10262 -2009)
o/o
Passins
As per I.S. 383 grading
Sieve Size Coarse Aggregate Fine Aggregate Combined
64% 36 Yo Range Remarks

36 100
40 mm 64 100
Eb
oq
9a
36 97 "44 13cB\o
20 mm 61.44 9s - 100
tro*
!'rA
x
,rY t$ N
4.75 mm 35_34 38.24 30-50 c
2.90 a9.o
e(cao
€
:6)
bocn
600 p 25.14 25.14 10-35 ) ila
0
E
oru
S-
150 p 2.78 2.78 0-6
0 l-

TEST RESULT ON WATER

Sample: Water Source : Work site
Qnty. Supplied : 1 sealed container Date of sample receive : 02-12-19
Identification mark: CON/B-S/2 446 l6 Date of testing : 03-12-19 to 04-12-19

s/. Nome of Test lS ReSuirerii.,.g.nt Result

No.
L Quantity of 0.02 normal NaOH required to neutralize 100 5 ml (max.) 1.14 ml
ml sample of water using phenolphthalein as indicator
2 Quantity of 0.02 normal Hz SO+ to neutralize 100 ml 25 ml (max). 6.4
sample of water using mixed indicator
3 Sulphate as SO3 400 mg/ltr. 47

4 Chloride as CL 2000 mglltr. Nil

5 Organic Solids 200 mgltr. t26
6 Inorganic Solids 3000 mg/ltr. 848

7 Suspended matter 2000 mg/ltr. r07t

8 P" Value 6 6.8

Discussion : 1) Testing for rvater work is done part-XXX.

as per IS 3025 Paft-I to
2) Results conforms to the requirement of IS 456-2000 and suitable for C.C. & RCC works only.
 CA No. CON/B-S/2446
N.F. Railway, Silchar
Format N

A .1 - STIPULATIONS FOR PROPORTIONING:-

a) Grade designation M - 35 Azo.

b) Type of cement OPC 43 grade.
c) Maximum nominal size of aggregate 20 mm.
d) Minimum cement content(MORTH) 340 Kglm3 (fbr RCC)
e) Maximum water - cement ratio 0"45.
0 Workability 50 -75 mm Slump.
s) Exposure condition Very Severe
h) Method of concrete placing Tremie & pump method
i) Degree of supervision Good.
i) Type ofaggregate Crushed angular agg.
k) Maximum cement content 450 Kg/m3.

1) Chemical admixture type Sika 2004 NS

Conforming to IS 9103
A.2 _ TEST DATA FOR MATERIALS:-
a) Cement used Max OPC 43

b) Specific gravity of cement 3.15

c) Specific gravity of water ,1..0

d) Specific gravity of admixture ,1.15

i
e) Specific gravity of:
i) Coarse aggregate 20 mm & 1Omm: 260 I
ii) Fine aggregate 2,,s8
:::: :l

f) Water absorption: '

t:l

i) Coarse aggregate 20 & 1Omm 0.92%

ii) Fine aggregate t.t4%
g) Free (surface) moisture:

i) Coarse aggregate Nil

ii) Fine aggregate Nil
IS Analysis of % of different fraction Remarks
h) Sieve analysis:
Sieve coarse agg
i) Coarse aggregate (mm) I II I II Combined
70% 30% 100%
9ro
20 94.30 100 66.01 30 96.01 3
.iPob
L r- ..
o'l
l0 14.85 93.20 10.39 27.96 38.35 LOJ

4,75 1.22 12.30 0.85 3.69 4.54

€*H
o' th
(J
2.36 0 1.60 0 0.48 0.48

ii) Fine aggregate Conforming to grading ZoneIII of Table 9 of IS 383 :201'6.

 CA No. CON/B-S/2446
N.F. Railway, Silchar
Format

A .3 - TARGET STRENGTH F,OR MrX pROpORTIONING:

Characteristic compressive strength : 35 N
f,c*:f"*+ 1.65 s
Where,
f'"k : target average compressive strength at 2g days.
Fa, : Characteristic compressive strength at 2g days.
And, S : Standarddeviation
: 5 N/mm2
Therefore target strength: 35 + 1.65 x 5 : 43.25 N/mm2

4.4 - SELECTION OF WATER CEMENT RATIO:-

From table 5 of IS 456 maximum water cement ratio: 0.45
Based on experience and 20 Nos. of trial mixes we are adopting a water cement ratio
of 0.40
0.40 < 0.45, hence ok
A'5- ,-

From table 2 of IS 10262 :2009 maximum water content : 1 86 litre (for 25 mmto 50 mm slump
range) for 20 mm coarse aggregate.
So" estimated water content f,or 150 mm slump: 186 + (l2l1OO) x 186 :208.321itre. Say 20g
litre.
1.0 % by weight of cementations material, admixture should be used to strengthen the concrete
and
to increase its plasticity and to reduce the water content.
Based on experience a reduction of water 14%o ispossible i.e.29litre water reduced.
So estimated water content will be 179 litre.

A.6 - SELECTION OF CEMENT CONTENT:-

Water cement ratio :0.40
Cement content : (17910.40): 447.5 Kg/m3 Say 44g Kg/m3

4,7 _ PROPORTION OF VOLUME OF COARSB

AGGREGATE AND FINE AGGREGATE:-

Volume of coarse aggregate corresponding 20mm size aggregate and fine aggregate of Zone III for
water cement ratio of 0.50 : 0.64.
in present case water cement ratio is 0.40. Therefore volume of coarse aggregate is required to be
increased to decrease the fine aggregate content. As the water cement ruiiolr lower iy
0.10 the
proportion of volume of coarse aggregate is increased by O.O2 (at the rate of + 0.01 for
evlry + 0.05
change in water cement ratio. Therefore corrected proportion of volume of coarse aggregate
for the
rvater cement ratio of 0.40 : 0.66.
For pumpable concrete these value should be reduced upto 10%. i.e. reduced 5%
Therefore volume of coarse aggregate:0.66 x 0.95 :0.627 say 0.63.
\/olume of fine aggregate content : 1-0.63 : 0.37 .

MTL & shlf

 CA No. CONIB-S/2446
N.F" Raiiway, Silchar
Format No

A.8-MIXCALCULATION:-

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

a) Volume of concrete : 1 m3
b) Volume of cement: (mass of cement/specific gravity of cement) x (1/1000)
: (44813.15) x (i/1000) : 0.1422 m3
c) Volume of water: (mass of water/specific gravity of water) x (1/1000)
: (l79ll) x (111000) : 0.179 m3
d) Volume of chemical admixture @ 1.0 % by mass of cementatious materials:
(mass of chemical admixture/specific gravity of admixture) x (1/1000)
:
(4.481L 15) x (1/1000) 0.00389 m3
e) Volumeof all inaggregate: Ia-(b+c +d)]
: t 1 - (0.t422+ O.I7g+0.00389)l : 0.6149 m3
f) Mass of coarse aggregate
: (e) x (volume of coarse aggregate) x (specific gravity of C.A) x (1000)
: 0.6749 x 0.63 x2.60 x 1000
: 1 105 Kg/m3

g) Mass of fine aggregate

: (e) x (volume of fine aggregate) x (specific gravity of F.A) x 1000

0.6749 x0.37 x2,58 x 1000

644 Kglm3

A. 9 - MIX PROPORTION FOR TRIAL:-

Cement 448 Kglm3

Water l79Kglm3
FineAggregate = 644Kglm3
60 % of Sand : 386 Kg/m3

40 oh of Stone dust : 258 Kglm3

Coarse Aggregate = 1105 kg/m3

70% of 20 mm : 774Kglm3
30o/o of 10 mm 331Kg/m3
Admixture @1.0% : 4.48kgm3
Water cement ratio = 0.40
+drffi
Tdninrg-Orffltri--
MTL & OMC
 CANo" CON/B-S/2446
N"F. Railway, Silchar
Format No.

MIX PROPORATION FOR TRIAL DATA SHEET FOR CONCRE,TE M

Grade of eoncrete M - 35
Using the data obtained from laboratory tests of Material samples supplied and calculation done using
lS 10262:2009 atest program for trial mixes of 7 days are calculated and results are shown below:-
Date of Casting :05-T2-19 Date of 7 days testing : 12-12-19
Target Strength :43.25 N/mm2

TRIAL MIXES USING MAX OPC 43 GRADE

Trial Quantities in Kg/cum Avg. Compressive
o
Nos. kro
56\ Strength in N/mm2)
Water L Fine Aggregate Coarse aggregate xo 7 days
() ()
cement E E (S)
() 60 Yo 40% Stone 70 Yo 30 Yo
ratio O
sand dust 20 mm l0 mm
1 0.40 t79 448 386 258 774 331 4"48 31.60

2 0.41 fi9 437 391 260 776 JJJ 4.37 26.76

a
J 0.42 t79 426 393 262 78t 335 4.26 23.t2

Therelore. considering slump, economy. Trial test results and strength point of view the proportion of
materials as follows : Trial I is selected which requires :

Water : Cement : Sand : Stone dust : 20 mm CA : 10 mm CA i.e. per M3 of mass concrete will require
Water:179ltr.: Cement:448 kg:Sand:386kg: Stonedust:258 kg:20mmCA:774kg: 10 mm

CA:331 kg.. Admixture:4.48 kg. = 0.'40 : I :0.86 :0.58 z 1.73 z 0.71.

So that in case of I bag of cement quantity necessary will be as follow : Water: 20 ltr. Cement: 50 kg
Sand: 43 kg, Stone dust: 29 kg, 20 mm CA : 86.5 kg, 10 mm CA: 37 kg.
with admixture : 0.500 kg.

For under water pile construction and as there is no chance for crack. 10"/o extra cement should be
used for imparting in-situ strength.

Pre-condition : Both Fine aggregate (sand) & coarse aggregate should be saturated before mixing or water
absorption @ 1.14 Yo of fine aggregate &. 092 oZ of coarse aggregate thus total approx. 2.06 %. thus total
3.60 litre water for sand & coarse aggregate should be used extra per cum.

Authorized Silnatory
Authcrized Slgnatory
Material Iestlng Laboratary i
-
Ou alitv Man agement Centre

"The results relate only to the items tested".

"Test report should not be reproduced without written approval of the Laboratory management.
+*+ End the test report***