“Rehabilitation and up-gradation of Kundral to Wazar from km 52+730 to k

Name of work
in the state of Maharashtra on
Client Ministry of Road Transport & Highways (PWD-NH DIVISISON, GOV OF
Authority Engineer M/S TPF Engineering Pvt. Ltd.
Contractor Ajaydeep Construction Pvt. Ltd.

CONCRETE MIX DESIGN M-40(RCC) GR

(As per IS: 10262 -2009)

1) DESIGN STIPULATIONS
A) Grade Designation :
B) Type of Cement :
C) Type of Mineral Admixture :
D) Nominal Size of Aggregate :
E) Minimum Cement Content (OPC) :
F) Maximum Water Cement Ratio :
G) Workability(Slump) Required for Concrete :
H) Exposure Condition :
I) Degree of Supervision :
J) Type Of Aggregate :
k) Chemical Admixture Type :
2) TEST DATA FOR MATERIALS
A) Water :
B) Cement
i) Brand Name :
ii) Specific Gravity of Cement :
C) Fly Ash
i) Source Name :
ii) Specific Gravity of Fly Ash :
D) Admixture ( 1.00 %)
i) Brand Name :
ii) Specific Gravity of Admixture :
E) Fiber
i) Brand Name :
ii) Specific Gravity of Fiber :
F) Coarse Aggregate ( 60 %)
i) Source Name :
ii) Specific Gravity of Coarse Aggregate :
a) 20mm ( 60 %) :
c) 10mm ( 40 %) :
iii) Water Absorption of Coarse Aggregate
a) 20mm :
c) 10mm :
iv) Free Moisture of Coarse Aggregate
 a) 20mm :
c) 10mm :
G) Fine Aggregate ( 40.0% )
a) Specific Gravity of Fine Aggregate (Crush Sand) :
iii) Water Absorption of Fine Aggregate (Crush Sand) :
iv) Free Moisture of Fine Aggregate (Crush Sand) :

4) TARGET STRENGTH OF MIX PROPORTIONING

a) Design Compressive Strength for M-40 grade :-
f'ck = f ck + 1.65 x S
Where,
f'ck = Target Average Compressive Strength, N/mm 2 at 28 Days
fck = Characteristic compressive strength, N/mm 2 at 28 Days
S = Standard Deviation, N/mm2

Standard deviation obtained from Table - 1 of IS: 10262 - 2009 is 5

Therefore, Design Compressive Strength = 40 + 1.65 x 5.0 = 48.25 N/mm 2

Target Mean strength as per Table 1700 - 5 of MORT = 52 N/mm2

5) WATER CEMENT RATIO

a) From MORT&H Table 1700-2, maximum water cement ratio = 0.4
We adopt water cement ratio is 0.36 < 0.45, Hence O.K.
0.36≤ 0.4, Hence O.K.

6) SELECTION OF WATER CONTENT

From Table 2, maximum water content = 186 kg. (For 50 mm slump range) For 20 mm Aggregate
therefore, water content for 20mm aggregate for 125 mm Slump (186+186*9/100)= 202.74 kg/m3
As, superplasticizer is proposed to be used, the water content can be reduced maximum upto 30% (vide par
IRC : 44, 2017). For the purpose of present trial exercise, a reduction of water content of 26% has been assumed by
suitably the dosage of the superplasticizer. With30% reduction in water content at W/C ratio of 0.34, the reduced wa
equals to 202.74x 0.7= 141.918 Kg.

7) DETERMINATION OF CEMENT CONTENT

W/C Ratio = 0.36
Water = 152.055
Cement = 422 kg/m3 422 kg/m3
As per MORTH Clause 1700-3, Minimum Cement Content for M-40 = 380 Kg/m 3
422 Kg/m3 > 380 Kg/m3, Hence O.K.

8) PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE AGGREGATE CONTENT

Volume of coarse aggregate corresponding to 20mm size aggregate and fine aggregate Zone-II for Water-C
 From table-3, As per IS 10262 - 2009, Volume of coarse aggregate corresponding to 20mm size aggregate and fine
for Water-Cement ratio of 0.5 = 0.62 , per unit volume of total aggregate.
In the present case water-cement ratio is 0.36. Therefore, volume of coarse aggregate is required to be increased to d
As the water-cement ratio is lower by 0.05, the proportion of volume of coarse aggregate is increased
by 0.01(at the rate of -/+ 0.01for every + 0.05 change in water-cement ratio).
Therefore, corrected proportion of volume of coarse aggregate for the water-cement ratio of 0.36=0.60
Therefore, Volume of fine aggregate content = 1 - 0.6= 0.4

9) MIX CALCULATIONS

a) Volume of concrete = 1 m3
b) Volume of cement = (Mass of Cement/Specific Gravity of cement) x (1/1000)
= 0.134 m3
c) Volume of water = (Mass of water/Specific Gravity of water) x (1/1000)
= 0.152 m3
d) Volume Admixture = (Mass of admixture/Specific Gravity of admixture) x (1/1000
1% by mass of cement = 0.00400 m3
e) Volume all in aggregate = {a - ( b + c + d ) }
= 0.710 m3
f) Mass of coarse aggregate = (f) x 0.60 x Specific gravity of coarse aggregate x 1000
= 1212.36 kg/m3
g) Mass of fine aggregate = (f) x 0.4 x Specific gravity of fine aggregate x 100
= 749.9 kg/m3

10) ACTUAL QUANTITY REQUIRED(SSD) FOR 1 M3

a) Cement 422 Kg
b) Water 152 Kg
c) Fine Aggregate - (Crushed Sand) 750 Kg
d) Coarse Aggregate- (20mm) 727 Kg
e) Coarse Aggregate- (10mm) 485 Kg
f) Admixture 4.2 Kg

The Concrete Mix Proportions then becomes as below :

Water : Cementitious F.A. : C.A .
152.1 Kg 422 Kg. 750 Kg. 1212 Kg.
0.340 : 1 : 1.775 : 2.870

A / C Ratio 1 : 4.646
CA / FA Ratio 1 : 1.617

11) CORRECTIONS REQUIRED FOR FREE MOISTURE IN FINE & COARSE AGGREGATE FOR LAB T

SSD Weight Water Absorption

Free Moisture
Description
(%)
(Kg/m3) (%)
 Cement 422 - -
Water 152 - -
FA-2 (Crushed Sand) 750 2.94 0.00
CA-1 (20mm) 727 0.65 0.00
CA-2 (10mm) 485 0.96 0.00
Admixture 4.22 - -
Total 2540.90

12) WORKABILITY (Slump) MEASURED

a) Initial : mm
b) After 30 minutes : mm
c) After 60 minutes : mm
d) After 90 minutes :
e) After 120 minutes :

13) COMPRESSIVE STRENGTH

a) 7 Days Avg. Compressive Strength :
b) 28 Days Avg. Compressive Strength :

EPC Contractor`s Representative

Wazar from km 52+730 to km 99+250 of NH 161A two lane with paved shoulder

NH DIVISISON, GOV OF MAHAASHTRA)

IGN M-40(RCC) GRADE

10262 -2009)

M-40
OPC - 53 Grade
Fly ash conforming to IS : 3812 (Part - 1)
20 mm (Angular)
380 kg/m3 (As per MORTH Clause 1700-3)
0.45
75-125 mm (MoRT&H Table 1700-4)
Moderate
Good
Crushed Angular Aggregate
Superplasticizer

Bore Well @ Sawarmal Base Camp

Birla Shakti Cement OPC 53 Grade

3.15

Parali Power Plant

2.10
Superplasticizer Confirming to IS: 9103
Apple Chemie (visco flux 2203)
1.055

Nil
0.000

sawarmal base camp crusher #REF!

2.847 2.804
2.859 0.000
2.834 0.118598

0.65 1.39
0.96 1.34
 0.00 (including absorbed)
0.00 (including absorbed)

2.780 (Combined)
2.940 2.33
0.00 (including absorbed) 0.00

48.25

5.432
168.198

144.5

or 20 mm Aggregate
100)= 202.74 kg/m3 202.74 152.055
maximum upto 30% (vide para 7.2 of
t of 26% has been assumed by adjusting 400.7632
/C ratio of 0.34, the reduced water content
159.375

424.6

EGATE CONTENT 84
ggregate Zone-II for Water-Cement ratio of 0.5 = 0.62
20mm size aggregate and fine aggregate Zone-II

is required to be increased to decrease the fine aggregate content.

gate is increased
0.14
atio of 0.36=0.60 2.8

0.09
0.04

ity of cement) x (1/1000)

of water) x (1/1000)
4.22
avity of admixture) x (1/1000) 0.004

oarse aggregate x 1000

ne aggregate x 100

378.3333

0.030375

AGGREGATE FOR LAB TRIALS.

Trial Batch Size
Weight Corrected 0.030 m3
(for 9 cube) =
Trial Weight
Correction Weight
(Kg)
(Kg/m3) (Kg/m3)
 - 422 12.671
31.430 183 5.505
-22.047 728 21.835
-4.728 723 21.681
-4.655 480 14.409
- 4.22 0.127
2540.90 76.227

N/mm2
N/mm2

AE Representative
P

60.86957
 361
0.85503 0.224
152.1

0.776331

13124

381.5789
63.75
362.5

94
 44
0.01
0.01
 “Rehabilitation and up-gradation of Kundral to Wazar from km 52+730 to k
Name of work
in the state of Maharashtra on
Client Ministry of Road Transport & Highways (PWD-NH DIVISISON, GOV OF
Authority Engineer M/S TPF Engineering Pvt. Ltd.
Contractor Ajaydeep Construction Pvt. Ltd.

CONCRETE MIX DESIGN M-30 (PAVER BLOC

(As per IRC: SP: 63-2018)

1) DESIGN STIPULATIONS
A) Grade Designation :
B) Type of Cement :
C) Type of Mineral Admixture :
D) Nominal Size of Aggregate :
E) Minimum Cement Content (OPC) :
F) Maximum Water Cement Ratio :
G) Workability(Slump) Required for Concrete :
H) Exposure Condition :
I) Degree of Supervision :
J) Type Of Aggregate :
k) Chemical Admixture Type :
2) TEST DATA FOR MATERIALS
A) Water :
B) Cement
i) Brand Name :
ii) Specific Gravity of Cement :
C) Fly Ash
i) Source Name :
ii) Specific Gravity of Fly Ash :
D) Admixture ( 0.30 % )
i) Brand Name :
ii) Specific Gravity of Admixture :
E) Fiber
i) Brand Name :
ii) Specific Gravity of Fiber :
F) Coarse Aggregate ( 40 %)
i) Source Name :
ii) Specific Gravity of Coarse Aggregate :
a) 10mm ( 40 %) :
iii) Water Absorption of Coarse Aggregate
a) 10mm :
iv) Free Moisture of Coarse Aggregate
a) 10mm :
G) Fine Aggregate ( 60.0% )
 a) Specific Gravity of Fine Aggregate (Crush Sand) :
iii) Water Absorption of Fine Aggregate (Crush Sand) :
iv) Free Moisture of Fine Aggregate (Crush Sand) :

4) TARGET STRENGTH OF MIX PROPORTIONING

a) Design Compressive Strength for M-30 grade :-
f'ck = f ck + 0.825 x S
Where,
f'ck = Target Average Compressive Strength, N/mm 2 at 28 Days
fck = Characteristic compressive strength, N/mm 2 at 28 Days
S = Standard Deviation, N/mm2

Standard deviation obtained from Table - 3 of IS: 15658 - 2006 is 3.5 for pressure type machine

Therefore, Design Compressive Strength = 30 + 0.825 x 3.5 = 32.88 N/mm 2

5) WATER CEMENT RATIO

a) As per IRC: SP: 63-2018 water cement ratio lie in between 0.34 to 0.38
Let us Take water cement ratio as 0.36
Let water content in the mix be 6% ( IRC: SP: 63-2018 )
0.36≤ 0.38, Hence O.K.

6) SELECTION OF WATER CONTENT

As per IRC: SP: 63-2018 water cement ratio lie in between 0.34 to 0.38 & water content is 5 to 7 % of tota
therefore, Density of Concrete = 2400 kg/m3
so the watercontent = 7%*2400 = 168 Ltr
As, superplasticizer is proposed to be used, the water content can be reduced maximum upto 5% (vide para
IRC :SP:63, 2018). For the purpose of present trial exercise, a reduction of water content of 5% has been assumed b
suitably the dosage of the superplasticizer.
400x 0.05= 20 Kg.
therefore, water content = 148
7) DETERMINATION OF CEMENT CONTENT
W/C Ratio = 0.36
Water = 148
Cement = 411 kg/m3 411 kg/m3
As per IRC: SP:63-2018, Minimum Cement Content for M-30 = 380 Kg/m 3
411 Kg/m3 > 380 Kg/m3, Hence O.K.

8) PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE AGGREGATE CONTENT

Total concrete volume = 1 m3
Assume air content = 2%, air 0.02 m3
Actual concrete volume = 0.98 m3
 as per IRC : SP: 63-2018 the proportion of coarse aggregate in the mix should be X= 40% & that for fine aggregate
Volume of Coarse Aggregate = X%*Vagg= 0.721*40%
Volume of fine Aggregate = X%*Vagg= 0.721*60%

9) MIX CALCULATIONS

a) Volume of concrete = 1 m3
b) Volume of cement = (Mass of Cement/Specific Gravity of cement) x (1/1000)
= 0.131 m3
c) Volume of water = (Mass of water/Specific Gravity of water) x (1/1000)
= 0.148 m3
e) Volume all in aggregate = {a - ( b + c ) }
= 0.721 m3
f) Mass of coarse aggregate = (f) x 0.40 x Specific gravity of coarse aggregate x 1000
= 817.88 kg/m3
g) Mass of fine aggregate = (f) x 0.6 x Specific gravity of fine aggregate x 100
= 1203.4 kg/m3

11) As per IRC: SP: 63-2018 & water content should be in between 5 to 7 % of total mix
therefore, check is required
Volume of Total Mix = Volume of cement + Volume of water + volume of F.A+ volume of C.A
2580.43
% of water content of total mix= 167.96/2580.32
5.74
5% <5.74%> 7%
Total volume of aggregate (Vagg)= volume of F.A+ Volume of C.A = 1203+817.88
2020.88
Aggregate/Cement Ratio = 2020.80/411
4.92
3:1 < 4.92:1 > 6:1
Hence The Design is ok
10) ACTUAL QUANTITY REQUIRED(SSD) FOR 1 M3
a) Cement 411 Kg
b) Water 148 Kg
c) Fine Aggregate - (Crushed Sand) 1203 Kg
d) Coarse Aggregate- (10mm) 818 Kg
e) Admixture 1.2 Kg

The Concrete Mix Proportions then becomes as below :

Water : Cementitious F.A. : C.A .
148.0 Kg 411 Kg. 1203 Kg. 818 Kg.
0.340 : 1 : 2.927 : 1.989

A / C Ratio 1 : 4.917
CA / FA Ratio 1 : 0.680
11) CORRECTIONS REQUIRED FOR FREE MOISTURE IN FINE & COARSE AGGREGATE FOR LAB T

SSD Weight Water Absorption

Free Moisture
Description
(%)
Cement (Kg/m
411 )
3
(%)
- -
Water 148 - -
FA-2 (Crushed Sand) 1203 2.94 0.00
CA-2 (10mm) 818 0.96 0.00
Admixture 1.20 - -
Total 2581.63

12) WORKABILITY (Slump) MEASURED

a) Initial : 25 mm
b) After 30 minutes : 10 mm

13) COMPRESSIVE STRENGTH

a) 7 Days Avg. Compressive Strength :
b) 28 Days Avg. Compressive Strength :

EPC Contractor`s Representative

Wazar from km 52+730 to km 99+250 of NH 161A two lane with paved shoulder

NH DIVISISON, GOV OF MAHAASHTRA)

-30 (PAVER BLOCK) GRADE

: SP: 63-2018)

M-30
OPC - 53 Grade
Fly ash conforming to IS : 3812 (Part - 1)
12 mm (Angular)
380 kg/m3 (As per IRC: SP: 63-2018)
0.38 (As per IRC: SP: 63-2018)
0-25 mm (As per IS.15658 CL.5)
Moderate
Good
Crushed Angular Aggregate
Superplasticizer

Bore Well @ Sawarmal Base Camp

Birla Shakti Cement OPC 53 Grade

3.15

Parali Power Plant

2.10
Superplasticizer Confirming to IS: 9103
Apple Chemie (visco flux 2203)
1.055

Nil
0.000

sawarmal base camp crusher #REF!

2.834 2.804
2.834 #REF!

0.96 1.34

0.00 (including absorbed)

 2.780 (Combined)
2.940 2.33
0.00 (including absorbed) 0.00

5 for pressure type machine 32.8875

168.198

144.5

er content is 5 to 7 % of total mix

202.74 152.055

maximum upto 5% (vide para 6.2 of 168

tent of 5% has been assumed by adjusting 400.7632 20
20
159.375

424.6

EGATE CONTENT 84
 40% & that for fine aggregate should be Y=60%

0.09
0.04

ity of cement) x (1/1000)

of water) x (1/1000)
4.22

oarse aggregate x 1000

ne aggregate x 100

A+ volume of C.A

#REF!

167.92

378.3333
7.933536
#REF!

0.030375
AGGREGATE FOR LAB TRIALS.
Trial Batch Size
Weight Corrected 0.030 m3
(for 9 cube) =
Trial Weight
Correction Weight
- 3) 411 3) (Kg)
12.333
(Kg/m (Kg/m
43.233 191 5.737
-35.381 1168 35.042
-7.852 810 24.301
- 1.20 0.036
2581.63 77.449

N/mm2
N/mm2

AE Representative
P

60.86957
 361
0.85503 0.224

152.1

0.776331

13124

381.5789
63.75
362.5

94
0.01
0.01
Project :-“Rehabilitation and up-gradation of Kundral to Wazar from km 52+730 to km 99+
shoulder in the state of Maharashtra on (EPC) mode..

Ministry of Road Transport & Highways

CLIENT
(PWD-NH Division Gov. Of Maharashtra)

AUTHORITY ENGINEER M/S TPF Engineer Pvt. Ltd.

EPC CONTRACTOR Ajay Deep Construction Pvt. Ltd.

TEST SUMMARY OF M-40 RCC MIX DES

SOURCE OF MATERIAL:-

Coarse Aggregate 20 mm

Coarse Aggregate 10mm

Fine Aggregate (Crush Sand)

Water

Admixture

Cement

Flyash

PROPORTION OF MATERAL

20 mm Aggregate
Coarse Aggregate
10 mm Aggregate

Fine Aggregate Crush Sand

W/C Ratio
AC-MENT-BV-430-PQC-Apple chemie

Cement (kgs)

Flyash(kgs)

TEST SUMMARY:
SLUMP:
Duration Initial ½ hour
Slump (mm) 150 120
Compressive Strength:
Age in days 7 days
Compressive Strength (N/mm2) 40.62

EPC Contractor's Representative

rom km 52+730 to km 99+250 of NH 161A two lane with paved

nsport & Highways

ov. Of Maharashtra)

t. Ltd.

on Pvt. Ltd.

M-40 RCC MIX DESIGN

: Sawarmal Base Camp Stone Crusher & Quarry

: Sawarmal Base Camp Stone Crusher & Quarry

: Sawarmal Base Camp Stone Crusher & Quarry

: Bore hole @ Batching plant location

:Apple chemie

:Birla Shakti OPC – 53 Grade

: Parli power plant

60%

40%

40%

0.36
1.00%

422

1 hour 1½ hours
105 90

28 days Remarks
54.80

Authority Engineer's Representative

Project :-“Rehabilitation and up-gradation of Kundral to Wazar from km 52+730 to km 99+250 of N
paved shoulder in the state of Maharashtra on (EPC) mode..

CLIENT Ministry of Road Transport & Highways (PWD-NH Division

AUTHORITY ENGINEER M/S TPF Engineer Pvt. Ltd.

EPC CONTRACTOR Ajay Deep Construction Pvt. Ltd.

COMPRESSIVE STRENGTH OF M-40 RCC GRA

(As per IS:516)

Location QC Lab @ Base Camp Cement

Date of Casting 8/10/2019 Water/Cement Retio

Date of Testing 8/17/2019 Cube Size in mm

Tested By Jointly Age of Cubes

Density of Cube
Sl. No. Weight of Cube (gm) Load KN
(gm/cc)

1 8687 2.574 915

2 8697 2.577 926

3 8668 2.568 921

4 8745 2.591 910

5 8795 2.606 905

6 8801 2.608 902

7 8862 2.626 909

8 8879 2.631 921

9 8842 2.620 916

 Avarege

EPC's Representative
+730 to km 99+250 of NH 161A two lane with

ways (PWD-NH Division Gov. Of Maharashtra)

M-40 RCC GRADE

Birla Shakti OPC 53 Grade

0.36

150X150X150

7 Days

Strength N/mm2 Average (N/mm2)

40.67

41.16 40.92

40.93

40.44

40.22 40.25

40.09

40.40

40.93 40.68

40.71
Avarege 40.62

Authority Engineer
Project :-“Rehabilitation and up-gradation of Kundral to Wazar from km 52+730 to km 99+250 of N
paved shoulder in the state of Maharashtra on (EPC) mode..

CLIENT Ministry of Road Transport & Highways (PWD-NH Division

AUTHORITY ENGINEER M/S TPF Engineer Pvt. Ltd.

EPC CONTRACTOR Ajay Deep Construction Pvt. Ltd.

COMPRESSIVE STRENGTH OF M-40 RCC GRA

(As per IS:516)

Location QC Lab @ Base Camp Cement

Date of Casting 8/10/2019 Water/Cement Retio

Date of Testing 9/7/2019 Cube Size in mm

Tested By Jointly Age of Cubes

Density of Cube
Sl. No. Weight of Cube (gm) Load KN
(gm/cc)

1 8837 2.618 1236

2 8812 2.611 1247
3 8821 2.614 1249
4 8923 2.644 1209
5 8911 2.640 1215
6 8869 2.628 1234
7 8962 2.655 1239
8 8978 2.660 1241
9 8889 2.634 1238
10 8929 2.646 1242
11 8897 2.636 1224
12 8897 2.636 1235
13 8969 2.657 1226
 14 8957 2.654 1234
15 8927 2.645 1229
16 8991 2.664 1228
17 8967 2.657 1221
18 8886 2.633 1248

Avarege

EPC's Representative
+730 to km 99+250 of NH 161A two lane with

ways (PWD-NH Division Gov. Of Maharashtra)

M-40 RCC GRADE

Birla Shakti OPC 53 Grade

0.36

150X150X150

28 Days

Strength N/mm2 Average (N/mm2)

54.93
55.42 55.29
55.51
53.73
54.00 54.19
54.84
55.07
55.16 55.08
55.02
55.20
54.40 54.83
54.89
54.49
54.65
 54.84 54.65
54.62
54.58
54.27 54.77
55.47

Avarege 54.80

Authority Engineer