NCC LIMITED

PART DESIGN AND CONSTRUCTION OF ELEVATED VIADUCT AND 5 ELEVATED STATIONS VIZ. DIAMOND GARDEN, SHIVAJI
CHOWK ,BSNL METRO, MANKHURD & MANDALE (EXCLUDING ARCHITECTURAL FINISHING & PRE ENGINEERED STEEL ROOF
STRUCTURE OF STATIONS) FROM CHAINAGE 52665.359 M TO 57630.000 M OF LINE 2B CORRIDOR (D.N NAGAR TO
MANDALE) OF MUMBAI METRO RAIL PROJECT OF MMRDA.
Mix DESIGN DATE –01.09.2021
Trial Mix No :- 03 NCC
CONCRETE MIX DESIGN DETAILS FOR THE GRADE OF M35

A-1: STIPULATIONS FOR PROPORTIONING

a) Grade Designation : M35
b) Type of Cement : Confirming to IS: 455 JSW PSC
c) Maximum nominal size of aggregate : 20 MM
d) Minimum cement content : 400 Kg/Cum
e) Maximum water to cement ratio : 0.45
f) Workability ( Slump) : 150 - 180mm Retention @ 03 Hrs
g) Expousre condition (for RCC) : Severe
h) Method of concrete placing : Pumping/Tremie
i) Degree of supervision : Good
j) Type of aggregate : Crushed angular aggregate
l) Maximum cement content : 500 Kg/Cum
m) Chemical admixture type
: Super Plasticizer Confirming to IS 9103
(TP AQUALOC5G3)
A-2: TEST DATA FOR MATERIALS (Sheet Attached)
a) Cement used : PSC Confirming to IS: 455 JSW PSC
b) Specific gravity of cement 3.0
c) Chemical admixture : Super Plasticizer Confirming to IS 9103
Specific gravity of Admixture : 1.10

e) 1) Coarse aggregate 20 MM 2.89

Source- Uran 10 MM 2.88
2) Fine aggregate CRUSHED SAND 2.65
Source- Uran
f) Water absorption (%):
1) Coarse aggregate 20 MM 1.24
(Source-Uran ) 10 MM 1.37
2) Fine aggregate CRUSHED SAND 4.12
(Source-Uran )
g) Free surface moisture (%):
1) Coarse aggregate Nil
2) Fine aggregate Nil
h) Sieve analysis:
1) Coarse aggregate : Sheet attached
2) Fine aggregate : Sheet attached Zone-2

A-3: TARGET STRENGTH FOR MIX PROPORTIONING

f'ck = fck + T*SD
Where
f'ck = target average compressive strength at 28 days,
fck = characteristics compressive strength at 28 days and
As IS-456
f'ck = fck + T*SD
=35+1.65*5
Therefore, target strength =43.25
74.9 MPa
A-4: SELECTION OF WATER-CEMENT RATIO
From table 5 of IS 456-2000, max water-cementitous ratio for expouser condition (Severe) = 0.4
Based on experimental lab trials & use of superplasticizer, adopt water-cementitious ratio = 0.344
0.344 is not grater than 0.4, hence, O.K.
A-5: SELECTION OF WATER CONTENT
From table 2 of IS 10262-2009, maximum water content for 20mm aggregate = 186 Litre
(for 25mm to 50mm controlled slump range)
Estimated water content for the 150mm, (Slump) = 186 + (0.14 X 186) = 213 Litre
(Increase by about 3% of every additional 25mm slump)
As superplasticizer is used, the water content can be reduced up to 35 percent
Based on trials with superplasticizer (PcE-Based), water content reduction of 27.23 % has been achieved.
Hence, the arrived water content = 213X 0.727= 155 Litre

A-6: CALCULATION OF CEMENT/ CEMENTITIOUS CONTENT

Water - cementitious ratio (as arrived above) = 0.344
Cementitious (Cement (PSC)) content: 155/0.344= 450 Kg/Cum
So,PSC Cement IS - 450 kg/M3
From table 5 of IS 456, minimum cement content for ' Severe' exposure condition = 400 Kg/Cum
450 Kg/Cum is not less than 400 Kg/Cum , hence, O.K.

A-7: PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE AGGREGATE CONTENT

From table 3 of IS 10262-2009, volume of coarse aggrege corrosponding to 20 mm size aggregate and fine aggregate (Zone-2)
for water cement ratio of 0.50 = 0.62
Corrected proportion of volume of coarse aggregate for water-cement ratio of 0.344 = 0.65
(at the rate of -/+ 0.01 for every +/- 0.05 change in water cement ratio)
Therefore, corrected volume of coarse aggregate = 0.56
Volume of fine aggregate content = 1 - 0.56 = 0.44

A-8: MIX CALCULATION

The mix calculations per unit volume of concrete(Considering 1 % air) shall be as follows:
a) Volume of Concrete is 0.990 Cum
b) Volume of Cement [450/(3.0x1000)] 0.150 Cum
e) Volume of water [155/(1.00X1000)] 0.155 Cum
f) Volume of chemical admixture [6.75/(1.10x1000)] 0.006 Cum
(@ 1.5% by mass of cementitoues)
g) Volume of all in aggregate [a-(b+c+d+e+f)] 0.679 Cum
h) Mass of CA (20 MM) [0.679X 0.56X0.57X 2.89 X 1000] 626 Kgs.
i) Mass of CA (10 MM) [0.679X0.56X0.43X 2.88 X 1000] 470 Kgs.
Mass of FA
j) (CRUSHED SAND) [0.679X 0.44X 2.65 x 1000] 791 Kgs.

A-9: FINAL MIX PROPORTION

Cementitious Content (Cement PSC:450 Kg ) 450 Kg/Cum
b) Water Content ( Free Water) 155 Kg/Cum
c) Fine Aggregate Content ( CRUSHED SAND) 791 Kg/Cum
d) Coarse Aggregate Content (20MM + 10MM) 1096 Kg/Cum
e) Chemical Admixture [@ 1.5 % by mass of cementitoues] 6.75 Kg/Cum
f) Plastic density of concrete 2499 Kg/Cum

A-10: THE MIX PROPORTION SUMMARY FOR ONE CUBIC METER OF CONCRETE
FINE AGG COARSE AGGREGATE ADMIXTURE
(OPC ) CEMENT WATER
CRUSHED SAND 20 MM 10 MM TP AQUALOC 5G3
Kg/Cum Kg/Cum Kg/Cum Kg/Cum Kg/Cum Kg/Cum
450 155 791 626 470 6.75

Dosage of admixture will vary depend on weather and ambient temperature condition. However, it will be less than max
recommended dosage by Manufacturer
Absorption/Moisture correction will be applied if aggregate find in dry/wet condition.
As the grading of aggregate, the Proportions of coarse and fine aggregate may be vary with in +/- 5%
for combined grading

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