MINING CHEMICAL SUPPLIERS

DOCUMENT NAME
CONCRETE MIX DESIGN

CLIENT NAME
KICO SA

PROJECT NAME
KIPUSHI ZN PROJECT-0045

CONCRETE MIX DESIGN DONE BY

MINING CHEMICAL SUPPLIERS
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Preface
Concrete mix design is a procedure of selecting the suitable ingredients of concrete and their
relative proportions with an objective to prepare concrete of certain minimum strength,
desired workability and durability as economically (value engineered) as possible.

As we decide to go for a concrete mix design, collect the following data beforehand as few
designs’ stipulation are feezed on the basis of these data.
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Preliminary Data for Design Mix
Purely governed on the local conditions, were the concrete need to be applied
Exposure Condition: Exposure Conditions of the structure: The general environment to which the concrete
will be exposed during its service life, is categorized into five class to severity, as per IS 456, Cls.8.2.2.1 and
35.3.2 Table 3.

The exposure condition limits the minimum cement content, maximum water – cement ratio and minimum
grade of concrete.
As per exposure condition, you have the above data for working the first trial and arriving its mix proportion.
If you are getting desired result at a lower cement content, you need to put extra as mentioned by IS 456.
• Minimum thickness of member: Size of aggregate should not be more than one-fourth of the
minimum thickness of member, mostly 19 mm nominal size aggregate is suitable for most works. It is
always suggested to go the maximum nominal size of aggregate to save on quantity of cement per unit
of concrete.
• Cement Grade: Cement type/grade locally available that can be made available throughout
construction period
Workability: Placing condition of concrete governs its workability, low – slump of 25-75 mm (lightly reinforced
sections in slab, beam, column) to high – slump of 100-150 mm (slip form, pumped concrete)
Illustrative of C20 Grade concrete Exposed to Moderate conditions
(i) Stipulation for Proportioning Concrete Ingredients

(a)Characteristic compressive strength required in the field at 28 days grade designation — C20
(b) Type of Cement: OPC 42.5N Grade confirming to IS 12269
(b) Maximum Nominal size of aggregate — 19MM DOWN
(c) Shape of CA — Angular
(d) Workability required at site — 100 mm (slump)
(e) Type of exposure the structure will be subjected to (as defined in IS: 456) — Moderate
(h) Method of concrete placing: pump able concrete.
(ii) Test Data of Material
The following materials are to be tested in the laboratory and results are to be ascertained for the design mix
(a) Cement Used: OPC 42.5N Grade Confirming to IS 12269
(b) Specific Gravity of Cement: 3.15
(c) Chemical admixture: Super plasticizer confirming to IS 9103
(d) Specific gravity
Specific gravity of Fine Aggregate (sand): 2.70
Specific gravity of Coarse Aggregate: 2.80

(e) Water Absorption

Coarse Aggregate: 2.41%
Fine Aggregate: 4.6%
(f) Free (surface) moisture
Coarse Aggregate: Nil
Fine Aggregate: Nil
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Aggregate is assumed to be in saturated surface dry condition (SSD) usually while preparing design mix.

(g) Sieve Analysis

Fine aggregates: Confirming to Zone I of Table 4 IS – 383

Procedure for Concrete Mix design of C20 Grade.

Step-1: Determining the Target Strength for Mix Proportioning.

F’ck = fck + 1.65 x S

Where,
F’ck = Target average compressive strength at 28 days
Fck = Characteristic compressive strength at 28 days
S = Assumed standard deviation in N/mm2 = 5 (as per table -1 of IS 10262- 1909, Clauses 3.2.1.2, A-3 and B-3)
= 26 + 1.65 x 4.0 = N/mm2
Note: Under control conditions if Target average compressive strength is achieved then at field the probability
of getting compressive strength of 20 MPa is very high.

Step-2: Selection of Water Cement ratio

From Table 5 of IS 456, Cla.6.1.2 Maximum water-cement ratio = 0.60
Note: Do not start with w/c ratio above 0.60, even though the other desired results like Strength, workability
could be achieved.
As per the experience water – cement ratio = 0.60

Step-3: Selection of Water Content

Maximum water content for 19 mm aggregate = 186 Kg (for 25 to 50 slump) as per table no 2 of IS 456 cl.4.2
We are targeting a slump of 100 mm; we need to increase water content by 3% for every 25mm above 50 mm
i.e. increase 6% for 100mm slump

i.e. Estimated water content for 100 Slump = 186+(6/100) X 186 = 197 liter

Water content = 197 liters.

Step-4: calculation of Cement Content

Water-Cement Ratio = 0.55
Water content from Step – 3 i.e., 197 liters
Cement Content = Water content / “w-c ratio” = (197/0.60) = 328.33 kgs
From Table 5 of IS 456,
Minimum cement Content for moderate exposure condition = 300 kg/m3
328.33kg/m3 > 300 kg/m3, hence, OK.
As per clause 8.2.4.2 of IS: 456
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Step-5: Proportion of Volume of Coarse Aggregate and Fine aggregate Content.
From Table 3 of IS 10262- 1909, Clauses 4.4 Volume of coarse aggregate corresponding to 19 mm size and fine
aggregate (Zone I) = 0.60
Note 1: In the present case water-cement ratio is 0.60 So there will be no change in coarse aggregate volume
i.e. 0.60.

Note 2: Incase the coarse aggregate is not angular one, then also volume of coarse aggregate may be required
to be increased suitably based on experience.

Step-6: Estimation of Concrete Mix calculations

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

1. Volume of concrete = 1 m3
2. Volume of cement = (Mass of cement / Specific gravity of cement) x (1/100) = (328.33/3.15) x
(1/1000) = 0.104 m3
3. Volume of water = (Mass of water / Specific gravity of water) x (1/1000) = (197/1) x (1/1000) =
0.197 m3
4. Total Volume of Aggregates = 1- (b+c) =1- (0.104+0.197) = 0.699m3
5. Mass of coarse aggregates = d X Volume of Coarse Aggregate X Specific Gravity of Coarse
Aggregate X 1000 = 0.669 X 0.60 X 2.80 X 1000 = 1123.92 kgs/m3
6. Mass of fine aggregates = d X Volume of Fine Aggregate X Specific Gravity of Coarse Aggregate X
1000 = 0.669 X 0.40 X 2.70 X 1000 = 722.52 kgs/m3

7. Step-7: Concrete Mix Proportions for Trial Mix

8. Mix Proportions for trial Mix-1:
9. Cement = 328.33 kg/m3
10. Water = 197 kg/m3
11. Fine aggregates = 722.52 kg/m3
12. Coarse aggregate = 1123.92 kg/m3
13. Water-cement ratio = 0.60
14. Note-1: Aggregates should be used in saturated surface dry condition. If otherwise, when computing
the requirement of water, allowance shall be made for the free (surface) moisture contributed by
coarse aggregate and fine aggregate. On the other hand, if the aggregates are already dry, the amount
of water mixed should be increased by an amount equal to the moisture likely to be absorbed by the
aggregates. Necessary adjustments are also required to be made in the mass of the aggregates. The
surface water and percentage water absorption shall be determined according to IS 2386.

15. Correction in water content due to absorption or moist aggregates

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16. The slump shall be measured and the water content and shall be adjusted for achieving the required
slump based on trial, if required. The mix proportions shall be reworked for the actual water content
and checked for durability requirements.
17. Two more trials having variation of +/- 10% of water cement ratio shall be carried out and a graph
between three water-cement ratios and their corresponding strength shall be plotted to work out the
mix proportions for the given target strength for field trials. However, durability requirement shall be
met.

Mix Proportions for trial Mix-2

We have achieved workability is more than targeted say 100 mm. Reduce water content by 3% (for every 25
mm increase)
Water Content for Trial 2
Water content = 197 – (197X6/100) = 185.18 liters
Calculation of Cement Content for Trial 2
Water-Cement Ratio = 0.45
Water content for Trial 2 = 185.18 liters
Cement Content = Water content / “w-c ratio” = (185.18/0.60) = 308.63kgs
From Table 5 of IS 456,
Minimum cement Content for moderate exposure condition = 300 kg/m3
308.63 kg/m3 > 300 kg/m3, hence, OK.
As per clause 8.2.4.2 of IS: 456

Proportion of Volume of Coarse Aggregate and Fine aggregate Content

If the mix is cohesive and slump was true, we can infer that there would be no change in Volume of coarse
aggregate = 0.60
Estimation of Concrete Mix Calculations
The mix calculations per unit volume of concrete shall be as follows:

1. Volume of concrete = 1 m3
2. Volume of cement = (Mass of cement / Specific gravity of cement) x (1/1000) = (308/3.15) x
(1/1000) = 0.098 m3
3. Volume of water = (Mass of water / Specific gravity of water) x (1/1000) = (185.18/1) x (1/1000)
= 0.185 m3
4. Total Volume of Aggregates = 1- (b+c) =1- (0.098+0.185) = 0.717m3
5. Mass of coarse aggregates = d X Volume of Coarse Aggregate X Specific Gravity of Coarse
Aggregate X 1000 = 0.717X 0.60 X 2.80 X 1000 = 1204.56 kg/m3
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6. Mass of fine aggregates = d X Volume of Fine Aggregate X Specific Gravity of Coarse Aggregate X
1000 = 0.717 X 0.40 X 2.70 X 1000 = 774.36 kg/m3

Final Concrete Mix proportions for Trial Number 2

Cement = 308 kg/m3
Water = 185.18 kg/m3
Fine aggregates = 774.36 kg/m3
Coarse aggregate = 1204.56 kg/m3
Water-cement ratio = 0.60

On trial no. 02
Determination of Consistency of fresh concrete (As per IS 1199-2018 Part -2
Quantity Representing sample
Date: - 07/09/2022 Starting time: - 11:00 am
Slump test
Initial stage - 150
30 minutes - 110
60 minutes - 80

Determination of Compressive Strength as per IS 516

Cast date – 07/09/2022

Sr.No. Crush Cube Id Age Weight Density Applied Compressive Average

Date days (Kg) (Kg/m3) load Strength (N/mm2)
( KN) (N/mm2)
1 14/09/2022 Kico C20-1 07 8.16 2417.78 383.60 17.04
2 14/09/2022 Kico C20-2 07 8.09 2397.04 382.90 17.01 17.03
3 14/09/2022 Kico C20-3 07 8.10 2400.00 383.50 17.04

CONCLUSION: The 07 days compression strength of C20 cube test results are achieved as per requirement.

RAMBABU.ADUSUMALLI
Sr. Manager QA/QC (HOD)