DBM (Dense Bituminous Macadam) specificatins,layer thickness, physical requirements, aggregate size, grades and its measurements

August 31, 2019

DENSE BITUMINOUS MACADAM(DBM)

DBM acts as a bituminous base course and thickness of a single compacted layer shall be 50 mm to 100 mm.

In this article we shall discuss about

Technical specifications of DBM (Dense Bituminous Macadam), layer thickness, physical requirements, aggregate size, grades and its measurements

A-Scope: The work shall consist of construction in a single layer of DBM on a previously prepared base or sub-base. The thickness of a single layer shall be
50 mm to 100 mm.
B - Material: The choice of binder material shall be stipulated in the contract or by the engineer, where viscosity grades of bitumen are specified, they are
referred to by a designation in accordance with IS: 73. Where modified bitumen is specified, it shall conform to the requirements of IRC:SP:53 and IS:15462.

Selection criteria for viscosity grade bitumen based on highest and lowest daily mean temperatures at a particular site are ]given in table no -1.
1-Coarse Aggregates: - It shall consist of crushed rock, crushed gravel or other hard material retained on the 2.36mm sieve. They shall be clean, hard, and
durable, of cubical shape, free from dust and soft or friable matter, organic or other deleterious matter.
Where crushed gravel is proposed for use as aggregate not less than 90% by weight of the crushed material retained on the 4.75mm sieve shall have at
least two fracture faces, except that in case of bituminous concrete the requirement in this regard shall be 95%.

2- Fine Aggregates- it shall consist of crushed or naturally occurring material, or a combination of the two, passing 2.36 mm sieve and retained on the
75micron sieve. They shall be clean, hard, durable, dry and free from dust and soft or friable matter, organic or other deleterious matter. Natural sand shall
not be allowed in binder course. However, natural sand up to 50% of the fine aggregates may be allowed in base courses. The fine aggregate shall have a
sand equivalent value of not less than 50 when tested in accordance with the requirement of IS:2720 (Part 37). The plasticity index of the fraction passing
the 0.425mm sieve shall not exceed 4, when tested in accordance with IS:2720 (Part 5).
3-Filler: Filler shall consist of finely divide mineral matter such as rock dust, hydrated lime or cement approved by engineer. The filler shall be grade within
the limits indicated in table no.-2.
The filler shall be free from organic impurities and have a plasticity index not greater than 4, The PI requirements shall not apply if filler is cement or lime.
Where the aggregates fail to meet the requirements of the water sensitivity test in table no.-3, then 2% by weight of aggregates, of hydrated lime shall be
used and percentage of the fine aggregate reduced accordingly.
** if the min. retained tensile test strength falls below 80. Use of antistripping agent is recommended to meet the requirements.

4-Aggregates grading and Binder content (Grades of DBM)

When tested in according with IS:2386 Part 1(wet sieving method. The combined grading of the coarse and fine aggregates and filler for the particular
mixture shall fall within the limits given in table no. -4 for grading 1or 2 as specified in the contract. To avoid gap grading, the combined aggregates
gradation shall not vary from the lower limit on one sieve to higher limit on the adjacent sieve.

Grades of DBM
# GRADING -1
Nominal size of aggregate - 37.5 mm
Layer thickness= 75-100 mm
Bitumen content % by mass of total mix should not be less than 4%.
# GRADING - 2
Nominal size of aggregate - 26.5 mm
Layer thickness= 50-75 mm
Bitumen content % by mass of total mix should not be less than 4.5%.
* The nominal max. particle size is the largest specified sieve size upon which any of the aggregate is retained.

** Corresponds to specific gravity of

aggregate being 2.7. in case aggregate have sp. gravity more than 2.7, the min. bitumen content can be reduced proportionally. Further the region where
highest daily air temperature is 30°C or lower and lowest daily air temperature is -10°C or lower, the bitumen content may be increased by 0.5%.

Bitumen content indicate in table no - 4 is the minimum quantity. The quantity shall be determined in accordance with clause(
C - Mix Design.)

C - Mix Design
The bitumen content required shall be determined following the Marshall mix design procedure contained in Asphalt Institute Manual MS-2.

The Fines to Bitumen (F/B) ratio by weight of total mix shall range from 0.6 to 1.2.

(1) Requirements for the Mix

Apart from conformity with the grading and quality requirements for individual ingredients, the mixture shall meet the requirements set out in table no. -5
(Table 500-11 as per MORTH 5th revision).

Table-5 Requirements for Dense Graded Bituminous Macadam

(2) Binder Content

The binder content shall be optimized to achieve the requirements of the mix set out in Table-5. The binder content shall be selected to obtain 4 percent air
voids in the mix design. The Marshall method for determining the optimum binder content shall be adopted as described in the Asphalt Institute Manual
MS-2.

Where maximum size of the aggregate is more than 26.5 mm, the modified Marshall method using 150 mm diametre specimen described in MS-2 and
ASTM D 5581 shall be used. This method requires modified equipment and procedures. When the modified Marshall test is used, the specified minimum
stability values in table-6 (Table 500-12 as per MORTH 5th revision) shall be multiplied by 2.25, and the minimum flow shall be 3 mm.

Table - 6 Minimum Percent Voids In Mineral Aggregate (VMA)

(3) Job Mix Formula

The Contractor shall submit to the Engineer for approval at least 21 days before the start the work, the job mix formula proposed for use in the works,
together with the following details:
i) Source and location of all materials;
ii) Proportions of all materials expressed as follows:
a) Binder type, and percentage by weight of total mix;
b) Coarse aggregate/Fine aggregate/Mineral filler as percentage by weight of total aggregate including mineral filler;
iii) A single definite percentage passing each sieve for the mixed aggregate;
iv) The individual gradings of the individual aggregate fraction, and the proportion of each in the combined grading;
v) The results of mix design such as maximum specific gravity of loose mix (Gmm), compacted specimen densities, Marshall stability,flow, air voids, VMA,
VFB and related graphs and test results of AASHTO T 283 Moisture susceptibility test; vi) Where the mixer is a batch mixer, the individual weights of each
type of aggregate, and binder per batch;
vii) Test results of physical characteristics of aggregates to be used;
viii) Mixing temperature and compacting temperature. While establishing the job mix formula, the Contractor shall ensure that it is based on a correct and
truly represent6tive sample of the materials that will actually be used in the work and that the mix and its different ingredients satisfy the physical and
strength requirements of these Approal of the job mix formula shall be based on independent testing by the Engineer for whichsamples of all ingredients of
the mix shall be furnished by the Contractor as required by the Engineer.

The approved job mix formula shall remain effective unless and until a revised Job Mix Formula is approved. Should a change in the source of materials be
proposed, a new job mix formua shall be forwarded by the Contractor to the Engineer for approval before the placing of thematerial.

(4) Plant Trials — Permissible Variation in Job Mix Formula

Once the laboratory job mix formula is approved, the Contractor shall carry out plant trials lo establish that the plant can produce a uniform mix conforming
to the approved job nix formula. The permissible variations of the individual percentages of the various ingrecients in the actual mix from the job mix
formula to be used shall be within the limits as specifed in table - 7( Table 500-13 as per MORTH 5th revision) and shall remain within the gradation band.
These variations are intended to apply to individual specimens taken for quality control tests in accordance with Secticn 900.
 Table -7 Permissible Variations in the Actual Mix from the Job Mix Formula
Description Base/binder Course

(5) Laying Trials

Once the plant trials have been successfully completed and approved, the Contractor shall carry out laying trials, to demonstrate that the proposed mix can
be successfully laid and compacted as per relevant standard. The laying trial shall be carried out on a suitable area which is not to form part of the
works. The area of the laying trials shall be a minimum of 100 sq.m of construction similar to that of the project road, and it shall be in all respects,
particularly compaction, the same as the project construction, on which the bituminous material is to be laid.
The Contractor shall previously inform the Engineer of the proposed method for laying and compacting the material. The plant trials shall then establish if
the proposed laying plant, compaction plant, and methodology is capable of producing satisfactory results. The density of the finished paving layer shall be
determined by taking cores, no sooner than 24 hours after laying, or by other approved method. The compacted layers of Dense Graded Bituminous
Macadam (DBM) shall have a minimum field densityww equal to or more than 92% of the density based on theoretical maximum specific gravity (Grnm)
obtained on the day of compaction in accordance with ASTM D 2041.

Once the laying trials have been approved, the same plant and methodology shall be applied to the laying of the material on the project, and no variation of
either shall be acceptable, unless approved in writing by the Engineer, who may at his discretion require further laying trials.

5.Measurements of pavements- DBM material shall be measured as finished work either in cubic metres, tonnes or by the square metre at a specified
thickness as indicated in the contract drawing, or documents, or as otherwise directed by the enginee.

Granular Sub base (GSB) specifications, GSB Grading, layer thickness, Water absorption, Physical requirements (like liquid
limit, Plasticity index ,AIV), construction procedure or Rolling , measurement and treatment of GSB as per MORTH 5th
revision and Indian standard in Civil engineering

Granular sub-base (GSB)

SUB BASE (GSB)– The full form of GSB is granular sub base.it is being laid in road work because it
plays two major roles
1- it works as drainage layer
2- it provides a good sub base to laid base layer on it.

How to calculate the quantity, compaction factor value and loose thickness of GSB? To know

more information kindly visit on below link 🔗

www.gyanofcivilengineering.com/granular sub-base(GSB) Quantity.

Material –
The material to be used for the work shall be natural sand, crushed gravel, crushed stone, crushed
slag, or combination thereof depending upon the grading required use of material like brick metal, kankar
and crushed concrete shall be permitted in the lower sub base. The material shall be free from organic or
other deleterious constituents.

Grading III and IV shall be used in lower sub base. Grading V and VI shall be used as sub-base-
cum-drainage layer.
Where the sub-base is laid in two layers as upper sub-base and lower sub-base, the thickness of
each layer shall not be less than 150mm.

If the water absorption of the aggregates determined as per IS: 2386(part-3) is greater than 2 %,
the aggregates shall be tested for wet aggregate impact value (AIV) (IS: 5640). Soft aggregates
like kankar, brick ballast and laterite shall also be tested for wet AIV.
Physical requirements of Granular sub base-
CONSTRUCTION OPERATION -

Spreading and compacting- the sub base material of the specified grading shall be mixed homogenously
with the help of motor grader .the required water content shall be determined in accordance with IS:2720
(part 8).

Moisture content of the mix shall be checked in accordance with IS: 2720 (part 8) and adjusted so
that, at the time of compaction, it is from 1 to 2 % below the OMC.
Immediately spreading the mix, rolling shall be done. If the thickness of the compacted layer does not
exceed 100mm, a smooth wheeled roller of 80 to 100 KN weight may be used. For a compacted single
layer up to 200mm the compaction shall be done with the help of a vibratory roller of min. 80 to
100KN.Rolling shall commence at the lower edge and proceed towards the upper edge longitudinally for
portion having unidirectional cross fall or on super elevation. For carriage way having cross fall on both
sides, Rolling shall commence at the edges and progress towards the crown.

To know more about WMM (wet mix macadam) ,kindly click on below link 🔗

https://www.gyanofcivilengineering.com/2019/02/wet-mix-macadam-wmm-sub-base-base.html

Each pass of the roller shall uniformly overlap not less than one –third of the track made in the preceding
pass. The speed of roller shall not exceed 5 KM per hour.
Rolling shall be continued till the density achieved is at least 98% of the max. Dry density for the material
determined as per IS: 2720 (part8).

All loose, segregated or other defective areas shall be made good to the full thickness and re-
compacted.

Measurement - Granular sub –base shall be measured as finished work in position in cubic metres.
Types of treatment for soil to make suitable for sub-base
(I) Lime treated soil for improved sub-grade/sub-base

(II) Cement treated soil and cement-fly ash treated sub-base/base

Wet Mix Macadam (WMM) technical specifications as per MORTH and Indian standard in Civil
engineering

Wet Mix Macadam (WMM) technical

specifications as per MORTH and Indian
standard in Civil engineering
February 27, 2019
WET MIX MACADAM (WMM) sub – base /base:-

Wet mix macadam (WMM) act as a base course just below the bituminous layer (bitumen base course or

surface course).

The thickness of a single compacted Wet mix macadam(WMM) layer shall not be less than 75mm.when

vibrating or other approved types of compacting equipment are used, the compacted depth of a single

layer of the sub-base course may be up to 200mm.

How to calculate the loose thickness of WMM, compaction factor and quantity of WMM ? Kindly
visit on below link 🔗

https://www.gyanofcivilengineering.com/2020/05/wet-mix-macadam-wmm-quantity-compaction.html

Physical requirements
  Material finer than 425 micron shall have plasticity index (PI) not exceeding 6.

To determine this combined portion, the flaky stone from a representative sample should first be

separated out. Flakiness index is weight of flaky stone metal divided by weight of stone sample. Only the

elongated particles are separated out from the remaining (non-flaky) stone metal. Elongation index is

weight of elongated particles divided by total non flaky particles. The values of flakiness index and

elongation index so found are added up.

If the water absorption value of the coarse aggregate is greater than 2%, the soundness test shall be

carried out on the material delivered to site as per IS: 2386 (part-5)
Grading requirements:-

The aggregates shall conform to the grading given in table below-

The final gradation approved within these limits shall be graded from coarse to fine and shall not vary

from the low limit on one sieve to the high limit on the adjacent sieve or vice versa.

To get the information about surface finish and quality control work of WMM, kindly click on

below link 🔗

https://gyanofengineering.blogspot.com/2020/05/surface-finish-and-quality-control-of.html

CONSTRUCTION OPERATIONS:-
PREPARATION OF BASE:-

The surface of the sub-grade /sub-base/base to receive the WBM/WMM shall be prepared to the

specified grade and camper and cleaned of dust, dirt and other extraneous material.

When WMM/WBM is to be laid on an existing metalled road, damaged area including depressions and

potholes shall be repaired and made good with the suitable material.

If wet mix macadam (WMM)/ Water Bound Macadam (WBM) is to be laid directly over the sub- grade,

without any other intervening pavements course, a 25 mm course of screening (Grading B)or coarse

sand shall be spread on the prepared sub-grade.it is advisable to lay 100 mm insulated layer of

screening or coarse sand on the top of fine grained soil.

PREPARATION OF MIX:-

Wet Mix Macadam(WMM) shall be prepared in an approved mixing plant of suitable capacity having

provision for controlled addition of water and forced/ positive mixing arrangement like pugmill or pan type

mixer of concrete batching plant. The plant shall have following features:

i) For feeding aggregates- three/ four bin feeders with variable speed motor

ii) Vibrating screen for removal of oversize aggregates

iii) Conveyor Belt

iv) Controlled system for addition of water

v) Forced/positive mixing arrangement like pug-mill or pan type mixer

vi) Centralized control panel for sequential operation of various devices and precise process control

vii) Safety devices

Optimum moisture for mixing shall be determined in accordance with IS:2720 (Part-8) after replacing the

aggregate fraction retained on 22.4 mm sieve with material of 4.75 mm to 22.4 mm size. While adding

water, due allowance should be made for evaporation losses. However, at the time of compaction, water

in the wet mix should not vary from the optimum value by more than agreed limits. The mixed material

should be uniformly wet and no segregation should be permitted.

SPREADING OF MIX: Immediately after mixing, the aggregate shall be spread uniformly and evenly

upon the prepared sub-grades/sub-base/base in required quantities. In no case shall be dumped in

heaps directly on the areas where these are to be to laid nor shall their hauling over a partly completed

stretch be permitted. The mix may be spread by a paver finisher.

In exceptional cases where it is not possible for the paver to be utilized, Mechanical means like motor

grader may be used with the approval of Engineer.

The Engineer may permit manual mixing and /or Laying of WMM where small quantity of WMM is to be

executed.

COMPACTION:-After mix has been laid to the required thickness, grade and crossfall/camber the same

shall be compacted to the full depth with roller. If the thickness of single compacted layer does not

exceed 100 mm, a smooth roller of 80-100 KN weight may be used. For a compacted single layer up to

200 mm, the compaction shall be done with the help of vibratory roller of min. static weight of 80 to 100

KN. The speed of the roller shall not be exceed 5 KM/h.

To get the details about Rolling pattern, number of rolling passes to compact the bed of WMM

and more about Rolling please click on below link 🔗

https://www.gyanofcivilengineering.com/2019/02/standard-rolling-process-of-various.html
In portions having unidirectional cross fall/super elevation, rolling shall commence from the lower edges
and progress gradually towards the upper edge. Thereafter, roller should parallel to the centre line of the
road, uniformly overlapping each preceding track by at least one-third width until the entire surface has
been rolled. Alternate trips of the roller shall be terminated in stops at least 1 met away from any
preceding stop.
In portion in camber, rolling should begin at the edge with the roller running forward and backward until
the edges have been firmly compacted. The roller shall then progress gradually towards the center
parallel to the center line of the road uniformly overlapping each of the preceding track by at least one –
third width until entire surface has been rolled.
Rolling should not be done when the sub-grade is soft or yielding or when it causes a wave- like motion
in the sub-base/base course or sub- grade .
If irregularities develop during rolling which exceed 12 mm when tested with 3 m straight edge, the
surface should be loosened and premixed material added or removed as required before rolling again so
as to achieve a uniform surface conforming to the desired grade and crossfall.

Rolling shall be continued till the density achieved is at least 98 % of the max.dry density for the material
as determined by the method outlined in IS: 2720 (part-8)

Setting and drying

After final compaction of WMM course, the road shall be allowed to dry for 24 hours.

Measurements for pavement

WMM shall be measured as finished work in position in cubic metres.

Dense Bituminous Macadam (DBM) or

Bituminous Concrete (BC) layer Quantity /
Compaction Factor value / Loose thickness
calculation
May 19, 2020

Dense Bituminous Macadam (DBM) or Bituminous Concrete (BC) quantity / Compaction Factor

value for DBM or BC / Loose thickness of DBM or BC Layer

In this article we shall discuss three important points about Dense Bituminous Macadam (DBM) or

Bituminous Concrete (BC)

1- How can we calculate the required DBM/BC quantity?

2 - What is value of compaction factor for DBM/BC?

3- How much loose thickness should be taken to get proper compacted layer thickness ?
1- How can we calculate the required DBM/BC quantity?

Let us consider

Length of DBM/BC layer (L) = 1 Km = 1000 Met.

Breadth of DBM/BC Layer (B)= 5 Met.
Thickness of DBM/BC Layer (T) = 50 mm =0.050 Met.

Max. Dry Density (MDD) =2.441 Gram/ Cubic Centimeter = 2441KG/ Cubic metre

Note - The value of MDD is calculated by conducting suitable test .

Then
Volume of DBM/BC Layer = ( Length of DBM/BC layer X Width of DBM/BC layer X Thickness of
DBM/BC Layer)

Volume of DBM/BC Layer = L X B X T Volume of DBM/BC Layer = 1000 X 5 X 0.050

Volume of DBM/BC Layer = 250 Cubic Metre

We Know That
Mass = Volume X Density
in this case -

Mass = Volume X MDD

Putting the value in the above Formula

Mass = 250 X 2441 Kg

Mass = 6,10,250 Kg

To convert above quantity in Tonn

We Know That

1 Tonn = 1000 Kg
Then

Mass =(610250/ 1000) Tonn

Mass = 610.250 Tonn

Hence required DBM/BC quantity is 610.25 Tonn.

2 - What is value of compaction factor for DBM/BC?

Density of Blended aggregate = 1.60 gram/cc to 2.0 gram/cc

= 1600 - 2000 KG/ cubic metre

In this case
Let us consider

Density of Blended aggregate = 1.80 gram/cc = 1800 Kg / cubic metre

Value of Max. Dry Density (MDD) = 2.441 gram/cc = 2441 Kg/cubic metre

Compaction Factor = (Max.Dry Density/Density of Blended Aggregate )

=2.441/ 1.80
=1.3561= 1.36
Hence compaction factor = 1.36

3- How much loose thickness should be taken to get proper compacted layer thickness ?

Compaction factor = 1.36

Thickness of DBM/BC Layer = 50 mm
Hence
Loose thickness of DBM/BC Layer = ( Compacted layer thickness X Compaction Factor )
= 50 X 1.36
=68 mm

Hence Loose Thickness of DBM/BC Layer is 68 mm.

Bituminous Concrete (BC) specifications viz.

Layer thickness, Mix and material
requirements, grading , laying trials, Rolling ,
Construction procedure, transport and joint
specifications, surface finish and quality
control,measurement and rate etc..as per
MORTH and Indian Standard
May 17, 2020

Bituminous concrete(BC)-

Bituminous concrete( BC) is used for wearing course and profile corrective courses.BC is generally laid

in single layer on a previously prepared bituminous bound surface.

The thickness of single layer of BC shall be 30mm,40mm and 50mm.

1 -MATERIAL

A- Bitumen -

The bitumen shall be viscosity graded paving bitumin complying with IS 73 or specified in contract

aggrement.

The type and grade of bitumen to be used would depend upon the climatic condition and the traffic.

Selection criteria of viscosity graded (VG) paving bitumens based on climatic conditions
B- Coarse Aggregate

It consist of crushed rock,crushed gravel or other hard material retained on 2.36 mm sieve. It shall be

clean ,hard,durable and of cubical shape,free from dust,and soft organic and other deleterious

substances.

The aggregates shall satisfy the physical requirements of table no. -2 (Table no. 500-16 ,as per MORTH

5th revision) where crushed gravel is proposed for use as aggregate,not less than 95% by weight of the

crushed material retained on 4.75 mm sieve shall have atleast two fractured faces.

Table no. - 2 Physical requirements for coarse aggregate for

Bituminous concrete
* if the min. retained tensile test strength falls below 80% ,use of stripping agent is recommended to meet

the requirement.

C- Fine aggregates

it shall consist of crushed or naturally occurring material, or a combination of the two, passing 2.36 mm

sieve and retained on the 75micron sieve. They shall be clean, hard, durable, dry and free from dust and

soft or friable matter, organic or other deleterious matter. Natural sand shall not be allowed in binder

course. However, natural sand up to 50% of the fine aggregates may be allowed in base courses. The

fine aggregate shall have a sand equivalent value of not less than 50 when tested in accordance with the

requirement of IS:2720 (Part 37). The plasticity index of the fraction passing the 0.425mm sieve shall not

exceed 4, when tested in accordance with IS:2720 (Part 5).

D- Filler

Filler shall consist of finely divide mineral matter such as rock dust, hydrated lime or cement approved by

engineer. The filler shall be grade within the limits indicated in table no.-3

Table no.- 3

Grading requirement for mineral filler

The filler shall be free from organic impurities and have a plasticity index not greater than 4, The PI

requirements shall not apply if filler is cement or lime. Where the aggregates fail to meet the
 requirements of the water sensitivity test in table no.-2, then 2% by weight of aggregates, of hydrated

lime shall be used and percentage of the fine aggregate reduced accordingly.

E- Aggregates grading and Binder content (Grades of Bituminous concrete (BC))

When tested in accordance with IS 2386 part 1 ( Wet grading method ), the combined grading of coarse

and fine aggregate and filler shall fall within the limits shown in table no.- 4(Table no. 500-17 ,as per

MORTH 5th revision).

The grading shall be as specified in contract aggrement.

Table no.- 4 Composition of Bituminous Concrete pavement layers

Notes:-

** The nominal max. particle size is the largest specified sieve size upon which any of the aggregate is

retained.

** Corresponds to specific gravity of aggregate being 2.7. in case aggregate have sp. gravity more than

2.7, the min. bitumen content can be reduced proportionally. Further the region where highest daily air

temperature is 30°C or lower and lowest daily air temperature is -10°C or lower, the bitumen content may

be increased by 0.5%.

For easy understanding

•Grades of BC

# GRADING -1

Nominal size of aggregate - 19 mm

Layer thickness= 50 mm

Bitumen content % by mass of total mix should not be less than 5.2%.

# GRADING - 2

Nominal size of aggregate - 13.2 mm

Layer thickness= 30-40 mm

Bitumen content % by mass of total mix should not be less than 5.4%.

2- Mix Design
A- Requirement for the mix

Apart from conformity with the grading and quality requirements for individual ingredients, the rnikre shall

meet the requirements set out in Table - 5 (Table 500-11 as per MORTH 5th revision).

Table -5 Requirements for Bituminous Concrete

# % voids in mineral aggregate are given in below table -6.

B- Binder Content

The binder content shall be optimized to achieve the requirements of the mix set out in Table 5. The

binder content shall be selected to obtain 4 percent air voids in the mix design. The Marshall method for

determining the optimum binder content shall be adopted as described in the Asphalt Institute Manual

MS-2.

Where maximum size of the aggregate is more than 26.5 mm, the modified Marshall method using 150

mm diametre specimen described in MS-2 and ASTM D 5581 shall be used. This method requires

modified equipment and procedures. When the modified Marshall test is used, the specified minimum
stability values in Table-6 shall be multiplied by 2.25, and the minimum flow shall be 3 mm.

Table -6 Minimum percentage voids in the mineral aggregate(VMA)

Note - interpolate minimum voids in the mineral aggregate (VMA) for design percentage air voids value

b/w those listed.

C - Job Mix Formula

The Contractor shall submit to the Engineer for approval at least 21 days before the start the work, the

job mix formula proposed for use in the works, together with the following details:

i) Source and location of all materials;

ii) Proportions of all materials expressed as follows:

a) Binder type, and percentage by weight of total mix;

b) Coarse aggregate/Fine aggregate/Mineral filler as percentage by weight of total aggregate including

mineral filler;

iii) A single definite percentage passing each sieve for the mixed aggregate;
iv) The individual gradings of the individual aggregate fraction, and the proportion of each in the

combined grading;

v) The results of mix design such as maximum specific gravity of loose mix (Gmm), compacted

specimen densities, Marshall stability,flow, air voids, VMA, VFB and related graphs and test results of

AASHTO T 283 Moisture susceptibility test;

vi) Where the mixer is a batch mixer, the individual weights of each type of aggregate, and binder per

batch;

vii) Test results of physical characteristics of aggregates to be used;

viii) Mixing temperature and compacting temperature.

While establishing the job mix formula, the Contractor shall ensure that it is based on a correct and truly

representative sample of the materials that will actually be used in the work and that the mix and its

different ingredients satisfy the physical and strength requirements of these Specifications.

Approval of the job mix formula shall be based on independent testing by the Engineer for whichsamples

of all ingredients of the mix shall be furnished by the Contractor as required by the Engineer.

The approved job mix formula shall remain effective unless and until a revised Job Mix Formula is

approved. Should a change in the source of materials be proposed, a new job mix formua shall be

forwarded by the Contractor to the Engineer for approval before the placing of thematerial.
D - Plant Trials — PermissiblePlant Trials —Variation in Job Mix Formula

Once the laboratory job mix formula is approved, the Contractor shall carry out plant trials lo establish

that the plant can produce a uniform mix conforming to the approved job nix formula. The permissible

variations of the individual percentages of the various ingrecients in the actual mix from the job mix

formula to be used shall be within the limits as specifed in table no. -7 (MORTH 5th revision Table 500-

18) and shall remain within the gradation band. These variations are intended to apply to individual

specimens taken for quality control tests.

Table -7 Permissible Variations in the Actual Mix from the Job Mix Formula
E - Laying Trials

Once the plant trials have been successfully completed and approved, the Contractor shall carry out

laying trials, to demonstrate that the proposed mix can be successfully laid and compacted. The laying
trial shall be carried out on a suitable area which is not to form part of the works. The area of the laying

trials shall be a minimum of 100 sq.m of construction similar to that of the project road, and it shall be in

all respects, particularly compaction, the same as the project construction, on which the bituminous

material is to be laid.

The Contractor shall previously inform the Engineer of the proposed method for laying and compacting

the material. The plant trials shall then establish if the proposed laying plant, compaction plant, and

methodology is capable of producing satisfactory results. The density of the finished paving layer shall be

determined by taking cores, no sooner than 24 hours after laying, or by other approved method.

The compacted layers of bituminous concrete (BC) shall have a minimum field density equal to or more

than 92 percent of the average theoretical maximum specific gravity (Gmm) obtained on the day of

compaction in accordance with ASTM D2041.

Once the laying trials have been approved, the same plant and methodology shall be applied to the

laying of the material on the project, and no variation of either shall be acceptable, unless approved in

writing by the Engineer, who may at his discretion require further laying trials.

3 - Construction Operations

A - Weather and Seasonal Limitations

Laying shall be suspended:

(I) In presence of standing water on the surface

(II) When rain is imminent, and during rain, fog, or dust storm
(III) When the base/binder course is damp

(IV) When the air temperature on the surface

on which it is to be laid is less than 10°C for mixes with conventional bitumen and is less than 15°C for

mixes with modified bitumen

(v) When the wind speed at any temperature exceed the 40 km per hour at 2 m height

B-Preparation of Base

This work shall consist of preparing an black-topped surface for laying bituminous concrete. The work

shall be performed on such widths and lengths as shown on the drawings or as instructed by the
Engineer or engineer in charge. The existing surface shall be firm and clean, and treated with Tack coat.

C - Geosynthetics

Where Geosynthetics are specified in the Contract, this shall be laid in accordance with the required

specifications and Standards.

D - Stress Absorbing Layer

Where a stress absorbing layer is specified in the Contract, this shall be applied in accordance with the

required standard and specifications.

E - Tack Coat
Scope: The work shall be consist of the application of a single coat of low viscosity liquid bituminous

material to existing bituminous, cement concrete or primed granular surface preparatory to the

superimposition of a bituminous mix, when specified in the contract.

Material: The binder used for tack coat shall be either cationic bitumen emulsion (RS 1) complying with

IS:8887 or suitable low viscosity paving bitumen of VG 10 grade conforming to IS:73. The use of cutback

bitumen RC:70 as per IS:217 shall be registered only for sites at sub-zero temperatures or for

emergency applications as directed by the engineer.

Weather and seasonal limitations: Bituminous material shall not be applied during a dust storm or

when the weather is foggy, rainy or windy or when the temperature in the shade is less than 10°C.

Where the tack coat consists of emulsion, the surface shall be slightly damp, but not wet. Where the tack

coat is of cutback bitumen, the surface shall be dry.

Application of Tack coat: The application of tack coat shall be at the rate specified in table below. No

dilution or heating at the site of RS1 bitumen emulsion shall be permitted. Paving bitumen if used for tack

coat shall be heated to appropriate temperature in bitumen boilers to achieve viscosity less than 2

poise. The normal range of spraying temperature for a bituminous emulsion shall be 20°C to70°C and for

cutback 50°C to 80°C .

Curing of Tack coat:Tack coat shall be left to cure until all the volatiles have evaporated before any

subsequent construction is started .

F - Mixing and Transportation of the Mix

(α) Mixing

Pre-mixed bituminous materials shall be prepared in a hot mix plant of adequate capacity and capable of

yielding a mix of proper and uniform quality with thoroughly coated aggregates.

Appropriate mixing temperatures are given intable-8( Table 500-2 of MORTH 5th revision) of these
Specifications. the

difference in temperature between the binder and aggregate shall at no time exceed 14°C. In order to

ensure uniform quality of the mix and better coating of aggregates, the hot mix plant shall be calibrated

from time to time. The essential features of the hot mix plants are given in

Annex A of IRC:27.

Table -8 Mixing, Laying and Rolling Temperatures for Bituminous

Mixes (Degree Celcius)

If a continuous type mixing plant is used, the Contractor must demonstrate by laboratory analysis that the

cold feed combined grading is within the grading limits specified for that bituminous bound material. In

the case of a designed job mix, the bitumen and filler content shall be derived using this combined

grading.
(β) Transporting

Bituninous materials shall be transported in clean insulated and covered vehicles. An asphalt release

agent, such as soap or lime water, may be applied to the interior of the vehicle to prevent sticking and to

facilitate discharge of the material.

G - Spreading

prior to spreading the mix, the base shall be well prepared. Except the area where paver cannot get

access, bituminous materials shall be spread, levelled and tamped by an approved self-propelled paving

machine equipped with an electronic sensing device.

When laying binder course or wearing course approaching an expansion joint of a structure, machine

laying shall stop 300 mm short of the joint. The remainder of the pavement up to the joint, and
corresponding area beyond, it shall be laid by hand, and the joint or joint cavity shall be kept clear of

surfacing material.

H - Rolling

(α)Compaction

Bituminous material shall be laid and compacted in layers, Which enable the specified thickness, surface

level, regularity requirements and compaction to be achieved. Compaction of bituminous materials shall

commence as soon as possible after laying and completed before the temperature falls below min.

Rolling temperature. Rolling shall commence at the edges and progress towards center longitudinally

except that on super elevation and unidirectionally cambered portions, it shall progress from lower to the

upper edge parallel to the C.L. of the pavement. Rolling shall be continued until all roller marks have

been removed from the surface. The initiator breakdown rolling shall be done with 8-10 tonne static
weight smooth- wheel rollers. The intermediate rolling shall be done with 8-10 tonne static weight or

vibratory roller or with a pneumatic tyre roller (PTR) of 12 to 15 tonne weight, with a tyre pressure of at

least 0.56 MPa. The finish rolling shall be done with 6 to 8 tonne smooth wheel tandem rollers.

The roller shall first compact material adjacent to joints and then work from the lower to the upper side

of the layer, overlapping on successive passes by at least one-third of the width of the rear roll or, in the

case of pneumatic tyres roller at least the nominal width of 300 mm.

In portions with super- elevated and unidirectional camber, after the edge has been rolled, the roller shall

progress from the lower to the upper edge.

Roller should move at least at a speed of not more than 5 Km per hour.
The roller shall not be permitted to stand on pavement which has not been fully compacted, and

necessary precautions shall be taken to prevent dropping of oil, grease, petrol/ diesel or other foreign

matter on the pavement either when the rollers are operating or standing. The wheels of roller machine

shall be in good working order, to prevent the mix from adhering to the wheels. Only sufficient moisture to

prevent adhesion between the wheels of rollers and the mix should be used. Surplus water shall not be

allowed to stand on the partially compacted pavement.

(β)Joints

Where joints are made, the material shall be fully compacted and the joint made flush in one of the

following ways:

a) All joints shall be cut vertical to the full thickness of the previously laid mix. All loosened material shall

be discarded and the vertical face coated with a suitable viscosity grade hot bitumen, or cold applied
emulsified bitumen. While spreading the material along the joint the material spread shall overlap 25 mm

to 50 mm on the previously laid mix beyond the vertical face of the joint. The thickness of the loose

overlap material should be approximately a quarter more than the final compacted thickness. The

overlapped mix shall be dragged back to the hot lane so that the roller can press the small excess into

the hot side of the joint to obtain a high joint density.

b) By using two or more pavers operating in echelon, where this is practicable and in sufficient proximity

for adjacent widths. to be fully compacted by continuous rolling.

(1) All longitudinal joints shall be offset at least 300 mm from parallel joints in the layer beneath or as

directed, and in a layout approved by the Engineer. Joints in the wearing course shall coincide with either

the lane edge or the lane marking, whichever is appropriate. Longitudinal joints shall not be situated in

wheel track zones.

(2) For transverse joints method

a) above shall apply. Transverse joints in the successive and adjoining layers shall have a minimum

offset of 2 m.

I - Opening to Traffic

As directed by the engineer

J - Surface Finish and Quality Control

A- Horizontally alignments

Horizontally alignments shall be reckoned w.r.t. the center line of the carriageway as shown on the
drawings. The edge of the carriage way as constructed shall be correct within a tolerance of ±10 mm

there from.

B- Surface Level

The levels of the Bituminous Concrete layer shall not vary from those calculated with reference to the

longitudinal and cross-profile of the road shown on the drawing or as directed by the engineer beyond the

tolerance mentioned in table below(table 900-1).

Provided, however, that the negative tolerance for wearing course shall not be permitted in conjunction

with the positive tolerance for base course, if the thickness of the former is thereby reduced by more than

the following limits-

4mm for bituminous wearing course of thickness 40 mm or more

3mm for bituminous wearing course of thickness less than 40 mm

Measurements of the surface levels shall be taken on a grid of points placed at 6.25 m longitudinally and
3.5 m transversely. For any 10 consecutive measurements taken longitudinally or transversely, not more

than one measurement shall be permitted to exceed the tolerance as above, this one measurements

being not excess of 5mm above the permitted tolerance.

For checking the compliance with the above requirements for bituminous wearing course, Measurements

of the surface levels shall be taken on a grid of points spaced at 6.25 m along the length and at 0.5 m

from the edge and at the centre of the pavement. In any length of the pavement, compliance shall be

deemed to be met for the final road surface, only if the tolerance given above is satisfied for any point on

the surface.

C - Surface Regularity of pavement courses

The longitudinal profile shall be checked with a 3 metre long straight edge/moving straight- edge as
directed by the engineer at the middle of each traffic lane along a line parallel to the centre line of the

road.
The max. allowable difference b/w the road surface and underside of a 3 met.
Straight-edge when placed parallel with or right angles to the centre line of the road at points decided by

the engineer shall be:-

For bituminous pavements surface 3mm

D - Rectification

Where the surface regularity of subgrade and the various pavements course fall outside the specified

tolerance. The contractor shall be liable to rectify these in manner described below -

For wearing course, where the surface is high or low, the full depth of layer shall be removed and

replaced with fresh material and compacted. In all cases where the removal and replacement of a

bituminous layer is involved, the area treated shall not be less than 5m in length and not less than 3.5 m
in width.

E -Riding Quality:

The riding quality of bituminous concrete wearing surface, as measured by a standard towed fifth wheel

bump integrator(TFWBI- It is also known as Roughometer or Automatic Road Unevenness Recorder

gives quantitative integrated evaluation of surface irregularities on an digital counter I LCD screen. It

comprises of a single wheeled trailer, with a pneumatic tyre mounted on a chassis, on which an

integrating device is fitted ), shall not more than 2000mm per Km.

K - Arrangements for Traffic

Dung the period of construction, arrangements for traffic shall be made in accordance with the required

specifications and standards.

L - Measurement for Payment

Bituminous concrete material shall be measured as finished work either in cubic metres, tonnes or by

the square metre at a specified thickness as indicated in the contract drawing, or documents, or as

otherwise directed by the engineer.

M - Rate
The contract unit rate for premixed bituminous material shall be payment in full for carrying
out the required operations including full compensation for, but not necessarily limited to:
i) Making arrangements for traffic as by the engineer
ii) Cleaning of the surface;
iii) Providing all materials to be incorporated in the work including arrangement for stock yards, all
royalties, fees, rents where necessary and all leads and lifts;
iv) Mixing, transporting, laying and compacting the mix, as specified including all wastage in cutting
joints;
v) All labour, tools, equipment, plant including installation of hot mix plant, power supply units and all
machinery, incidental to complete the work
to these Specifications;
vi) Carrying out the work in part widths of the road where directed;
vii) Carrying out all tests for control of quality;
viii) The rate shall cover the provision of bitumen at the application rate
specified in the contract, with the provision that the variation in actual percentage of bitumen used shall
be assessed and the payment adjusted accordingly as per Contract;
ix) The rates include for all testing, mix design, transporting and testing of
samples, and cores and tests as directed by the Engineer; and
x) The cost of all plant and laying trials as specified to prove the mixing and laying methods shall be
deemed to be included in the Contractor's
rates.

All above apply except that the rate shall include the provision of bitumen at 5.2 percent & 5.4 percent for
grading 1 and grading 2 by weght of total mix respectively. The variation in actual percentage of bitumen
used will be assessed and the payment adjusted plus and minus accordingly.

CONCRETE MIX DESIGN OF M25 GRADE – AS PER IS 10262:2019

1.STIPULATIONS FOR PROPORTIONING

a) Grade designation : M 25 RCC

b) Type of cement : 43 grade Ordinary Portland Cement conforming IS 8112

c) Maximum nominal size of coarse aggregate : 20 mm

d) Minimum amount of cement : 300 kg/m³ as per IS 456

e) Maximum water-cement ratio : 50 as per Table 5 of IS 456:2000

f) Workability : 75-125 mm slump

g) Exposure condition : Moderate (For Reinforced Concrete)

h) Method of concrete placing : Pumping

j) Degree of supervision : Good

k) Type of aggregate : Crushed Angular Aggregates

l) Chemical admixture type : Super Plasticizer Normet

2.TEST DATA FOR MATERIALS

a) Cement used : Sagar 43 grade Ordinary Portland cement conforming IS 8112

b) Specific gravity of cement : 3.14

c) Chemical admixture : Super Plasticizer conforming to IS 9103

d) Specific gravity of

1) Coarse aggregate 20 mm : 2.799

2) Coarse aggregate 10 mm: 2.789

3)Combined Specific Gravity of aggregate ( 20 mm- 60% & 10 mm 40 % )=2.795

4) Fine aggregate : 2.517

e) Water absorption:
1) Coarse aggregate 20 mm : 0.41 %

2) Coarse aggregate 10 mm : 0.59 %

3) Fine aggregate : 1.87 %

f) Aggregate Impact Value : 20.52%

g) Combined Flakiness & Elongation Index : 27.57 %

h) Sieve analysis:

1) Coarse aggregate: Conforming to all in aggregates of Table 2 of IS 383

2) Fine aggregate : Conforming to Grading Zone III of Table 4 of IS 383

3 TARGET STRENGTH FOR MIX PROPORTIONING

f’ck =fck + 1.65 s Or f’ck = fck + X where

f’ck = average target compressive strength of concrete at 28 days,

fck = characteristics compressive strength of concrete at 28 days,

X = Factor based on grade of concrete

S = standard deviation. From table 2 of IS 10262-2019 S = 4 N/mm² & from table 1 , X=5.5

Therefore target strength of concrete using both equation

.

a) f’ck= fck+ 1.65 S = 25 + 1.65 x 4 = 31.60 N/mm²

b) f’ck = fck+ X = 25 + 5.5 = 30.5 N/mm².

The higher value to be adopted , therefore target strength will be 31.60 N/mm². Can adopt this value while doing the concrete mix
design those who are working other than highway project.
But as per MORT&H Table 1700.5 required target mean compressive strength = 25 + 11 = 36.00 N/mm² where 11 is the current
margin. Adopt this value those who are working in highway project.

4. APPROXIMATE AIR CONTENT

From Table 3, the approximate amount of entrapped air to be expected in normal (non-air-entrained)
concrete is 1.0 percent for 20 mm nominal maximum size of aggregate.

5 SELECTION OF WATER-CEMENT RATIO

From Fig. 1 of IS 10262 -2019, the free water-cement ratio required for the target strength of 31.60 N /mm² is 0.48 may be used
for OPC 43 grade curve. (For other than MORT&H)

Maximum water cement ratio required for the target strength of 36.00 N /mm²(As per MORT&H requirement) is 0.44 from figure 1 of
IS 10262-2019.

My suggestion & experience , never adopt higher water cement ratio because it is the main reason for cube failure at site. In IS code ,
suggestion has been given for adopting the water cement ratio but concrete designer has to take the decision what to keep water cement
ratio.

Based on trial & experience adopted 0.44 water cement ratio.

This is lower than the maximum value of 0.50 prescribed for from the Table 3 of IS 456 maximum Water Cement Ratio for moderate
condition

As per MORT&H, maximum water cement ratio is 0.45 for moderate condition so 0.44 is satisfying all codal provision whether it
is IS 456 or MORT&H

0.44 < 0.50 < 0.45 hence ok.

6. SELECTION OF WATER CONTENT

From Table 4 of IS 10262:2019, maximum water content for 20 mm aggregate = 186 liter (for 25 to 50 mm slump range)

but for an increase by about 3 percent for every additional 25 mm slump so here estimated water content for 125 mm slump

= 186+(9/100) x 186

= 202 liter.

Based on trials with Super plasticizer water content reduction of 23.76 % has been achieved . How it comes ,

We will see the back calculation

(Water requirement , if we intended to keep cement 350 kg & w/c ratio 0.44 for our concrete mix design calculated water will
be 154 liter , so required reduction in water when using superplaticizer = 100 – (154/202 x 100) = 23.76 %.)

Net required water = 202 – (202 x 23.76) % = 202 – 48 = 154.0 litre

Note :For 75 mm slump increase 3% , for 100 mm increase 6% , increase 9 % for 125 mm slump, increase 12 % for 150 mm slump &
increase 15 % for 175 mm slump

7 CALCULATION OF CEMENT CONTENT

As discuss earlier adopted based on trial w/c Ratio = 0.44

Cement Content = 154/0.44 = 350 kg/m³

,from Table 5 of IS 456, minimum cement content for ‘moderate’ exposure conditions is 300 kg/m³ but taken 350 kg/m³ > 300 kg/m³
hence ok.

As per MORT&H 5th revision for moderate exposure with reference to Table number 1700-2 maximum water cement ratio 0.45 &
minimum cement 340 kg/m³ is specified but we had taken 350 kg/m³ , hence ok

but we had taken 350 kg/m³ > 340 kg/m³ hence ok.

8 PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE AGGREGATE CONTENT

As per table number 5 of IS 10262:2019 volume of coarse aggregate for 20 mm nominal size aggregate and fine aggregate (Zone III) for
having water-cement ratio of 0.50 =0.64 (a)

20 mm aggregate and fine aggregate (Zone III) for having water-cement ratio of 0.50 =0.64 (a)

In the present case water-cement ratio is 0.44. Therefore. volume of coarse aggregate is required to be increased to decrease the fine
aggregate content. As the water-cement ratio is lower by 0.06. the proportion of volume of coarse aggregate is increased by 0.012 (at the
rate of -/+ 0.01 for every ± 0.05 change in water-cement ratio).
= (0.06/0.05) = 1.2 times of 0.01 so 0.01 x 1.2 = 0.012 (b)

= a+b = 0.64 + 0.012 =0.65 (at the rate of -/+ 0.01 for every ± 0.05 change in w/c ratio).

Therefore, corrected proportion of volume of coarse aggregate for the water-cement ratio of 0.44 = 0.65

For pumpable concrete these values should be reduced up to 10%. Therefore, volume of coarse aggregate =0.65 x 0.9 =0.585 or say 0.59

Volume of fine aggregate content = 1 – 0.59 = 0.41

9 MIX CALCULATIONS

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

a)Volume of concrete = 1 m³

b)Volume of the entrapped air in wet concrete =0.01m³

c) Volume of cement = [Mass of cement] / {[Specific Gravity of Cement] x 1000}

= 350/{3.15 x 1000} = 0.111 m³

d) Volume of water = [Mass of water] / {[Specific Gravity of water] x 1000}

= 154/{1 x 1000} = 0.154 m³

e) Base on trial we had kept admixture 50 percentage by weight of cement(You can increase % admixture dosage as per requirement)

Volume of admixture = [Mass of admixture ] / {[Specific Gravity of admixture ] x 1000}

= 1.75 /{1.090 x 1000}

= 0.0016 m³

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

= [(1-0.01)-(0.111+0.154+0.0016)]= 0.99-0.250

= 0.723 m³

g) Mass of coarse aggregate= e x Volume of Coarse Aggregate x Specific Gravity of coarse Aggregate x 1000

= 0.723 x 0.59 x 2.795 x 1000

= 1192.26 kg/m³

h) Mass of fine aggregate= e x Volume of Fine Aggregate x Specific Gravity of Fine Aggregate x 1000

= 0.723 x 0.41 x 2.517 x 1000

= 746.11 kg/m³
10 MIX proportion

Cement = 350 kg/m³

Water = 154 l/m³

Fine aggregate = 746.11 kg/m³

Coarse aggregate 20 mm = 1192.26 x 60 %= 715.36 kg/m³

Coarse aggregate 10 mm = 1192.26 x 40 %= 476.90 kg/m³

Chemical admixture = 1.75 kg/m³

Water-cement ratio = 0.44

11 CALCULATION
1.Aggregate 20 mm = 715.26/ (1+(0.41/100)} = 712.0 kg

2. Aggregate 10 mm = 476.90/ (1+(0.59/100)} = 474.0 kg

3.Sand = 746.11/ (1+(1.87/100)} = 732.0 kg

4.Water = 2444 – 350 – 1.75 -732 -712 – 474 = 174.25 kg

Can say 174 kg alternatively can calculate in the following manner.

154+(746.11-732.0) +(715.26-712) +(476.90-474) = 154 + 14.11 + 3.26 + 2.90 = 174.27 or say 174 kg

Note 1.Do the trial in dry position as in practical in batching plant you can cot use aggregate in SSD condition.

2.Do the number of trials with variation of ± 10 percent of water-cement ratio & different cement content,

3.Do the surface moisture correction whenever required.

Posted onOctober 23, 2019CategoriesConcrete Mixes8 Commentson CONCRETE MIX DESIGN OF M25 GRADE – AS PER IS 10262:2019
Concrete Mix Design Of M35 Grade(Pile) as per IS 10262:2009
1.STIPULATIONS FOR PROPORTIONING

a) Grade designation : M35 RCC (Pile)

b) Type of cement :53 grade Ordinary Portland Cement conforming IS 12269

c) Maximum nominal size of coarse aggregate : 20 mm

d) Minimum amount of cement : 400 kg/m³ as IS 2911-Part 1/Sec 2 & IRC 78-2014.

e) Maximum water-cement ratio : 0.40 as per IRC 78 -2014 ,Cl 709.1.9

f) Workability : 150-200 mm slump as per IRC 78-2014 , Cl 709.1.9

g) Exposure condition : Moderate (For Reinforced Concrete)

h) Method of concrete placing : Trieme

j) Degree of supervision : Good

k) Type of aggregate : Crushed Angular Aggregates

l) Chemical admixture type : Super Plasticizer Normet

2.TEST DATA FOR MATERIALS

a) Cement used : Sagar 53 grade Ordinary Portland cement conforming IS 12269

b) Specific gravity of cement : 3.14

c) Chemical admixture : Super Plasticizer conforming to IS 9103

d) Specific gravity of

1) Coarse aggregate 20 mm : 2.799

2) Coarse aggregate 10 mm: 2.789

Combined Specific Gravity of aggregate ( 20 mm-45% & 10 mm 55% )=2.792

2) Fine aggregate : 2.517

e) Water absorption:

1) Coarse aggregate 20 mm : 0.41 %

2) Coarse aggregate 10 mm : 0.59

3) Fine aggregate : 1.87 %

f) Aggregate Impact Value : 20.52

g) Combined Flakiness & Elongation Index : 27.57 %

h) Sieve analysis:

1) Coarse aggregate: Conforming to all in aggregates of Table 2 of IS 383

2) Fine aggregate : Conforming to Grading Zone III of Table 4 of IS 383

3 TARGET STRENGTH FOR MIX PROPORTIONING

f’ck =fck + 1.65 s where

f’ck = average target compressive strength of concrete at 28 days,

fck = characteristics compressive strength of concrete at 28 days,

S = standard deviation.From table 1 of IS 456 & IS 10262 assumed Standard Deviation, s = 5 N/mm² ; therefore target strength of concrete = 35
+ 1.65 x 5 = 43.25 N/mm². Can adopt this value while doing the concrete mix design those who are working other than highway project.
But as per MORT&H Table 1700.5 required target mean compressive strength = 35 + 12 = 47.00 N/mm² where 12 is the current
margin. Adopt this value those who are working in highway project.
4 SELECTION OF WATER•CEMENT RATIO

Based on the trial , adopted water cement ration 0.40

From the Table 5 of IS 456 maximum Water Cement Ratio for moderate condition is 0.50

As per Section 709.1.9 of IRC 78, maximum water cement ratio is 0.40

so 0.40 is satisfying all codal provision whether it is IS 456 or MORT&H

0.40 < 0.50 = 0.40 hence ok.

5 SELECTION OF WATER CONTENT

From Table 2 of IS 10262:2009, maximum water content for 20 mm aggregate = 186 litre (for 25 to 50 mm slump range)

but for an increase by about 3 percent for every additional 25 mm slump so here estimated water content for 175 mm slump

= 186+(15/100) x 186

= 213.9 or 214 liter.

Based on trials with Super plasticizer water content reduction of 21.50% has been achieved.How it comes , see below calculation:

Water requirement , if we intended to keep cement 420 kg for & w/c ratio 0.40 for our concrete mix design calculated water will be 168.0
liter , so required reduction in water when using superplaticizer = 100 – (168/214 x 100) = 21.50 %.
Net required water = 214 – (214 x 21.50) % = 214 –46.1 = 167.99 liter say 168 liter.

Note :For 75 mm slump increase 3% , for 100 mm increase 6% , increase 9 % for 125 mm slump, increase 12 % for 150 mm slump &
increase 15 % for 175 mm slump

6 CALCULATION OF CEMENT CONTENT

As discuss earlier adopted based on trial w/c Ratio = 0.40

Cement Content = 168.0/0.40 = 420 kg/m³

As per IS 2911-Part 1/Sec 2 minimum cement content for tremie concrete is 400 kg/m³.

(As per Section 709.1.9 of IRC 78 – 2014 minimum cement content 400 kg & maximum water cement ratio is 0.40 specified)

but we had taken 420 kg/m³ > 400 kg/m³ hence ok.

7 PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE AGGREGATE CONTENT

As per table number 3 of IS 10262:2009 volume of coarse aggregate for 20 mm nominal size aggregate and fine aggregate (Zone III) for having
water-cement ratio of 0.50 =0.64 (a)

In the 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 ratio is lower by 0.10. the proportion of volume of coarse aggregate is increased by 0.02 (at the rate of -/+ 0.01 for
every ± 0.05 change in water-cement ratio). As the water-cement ratio is lower by 0.10. The proportion of volume of coarse
aggregate is increased by

= (0.10/0.05) = 2.0 times of 0.01 so 0.01 x 2.0= 0.020 (b)

= a+b = 0.64 + 0.020 =0.66

(at the rate of -/+ 0.01 for every ± 0.05 change in water-cement ratio).

Therefore, corrected proportion of volume of coarse aggregate for the water-cement ratio of 0.40 = 0.66

NOTE – In case the coarse aggregate is not angular one, then also volume of coarse

aggregate may be required to be increased suitably based on experience & Site conditions.

For pumpable concrete these values should be reduced up to 10%. Therefore, volume of coarse aggregate =0.66 x 0.9 =0.59.

Volume of fine aggregate content = 1 – 0.59 = 0.41.

8 MIX CALCULATIONS

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 1000}

= 420/{3.15 x 1000} = 0.133 m³

c) Volume of water = [Mass of water] / {[Specific Gravity of water] x 1000}

= 168.0/{1 x 1000} = 0.168 m³

d) Base on trial we had kept admixture 1.0 percentage by weight of cement

Volume of admixture = [Mass of admixture ] / {[Specific Gravity of admixture ] x 1000}

= 4.2 /{1.090 x 1000}

= 0.0039 m³

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

= [1-(0.133+0.168+0.0039)]

= 0.695 m³

f) Mass of coarse aggregate= e x Volume of Coarse Aggregate x Specific Gravity of coarse Aggregate x 1000

= 0.695 x 0.59 x 2.792 x 1000

= 1144.86 kg/m³
g) Mass of fine aggregate= e x Volume of Fine Aggregate x Specific Gravity of Fine Aggregate x 1000

= 0.695 x 0.41 x 2.517 x 1000

= 724.22 kg/m³

9 MIX PROPORTIONS

Cement = 420 kg/m³

Water = 168.0 l/m³

Fine aggregate = 724.22 kg/m³

Coarse aggregate 20 mm = 1144.86 x 45 %= 515.19 kg/m³

Coarse aggregate 10 mm = 1144.86 x 55%= 629.67 kg/m³

Chemical admixture = 4.2 kg/m³

Water-cement ratio = 0.40

Calculation :
1. Aggregate 20 mm= 515.99/ (1+(0.41/100)} = 514.0 kg

2. Aggregate 10 mm = 629.67/ (1+(0.59/100)} = 725 kg

3. Sand = 724.44/ (1+(1.87/100)} = 626.0 kg

3. Water = 2460-420-711-514-626 = 189

NOTE

1.Do the trial in dry position as in practical in batching plant you can cot use aggregate in SSD condition.

2.Batch for trial is given in dry position.

3.Do the number of rials with variation of ± 10 percent of water-cement ratio & different cement content

4.Do the surface moisture correction whenever required.

Posted onSeptember 9, 2019CategoriesConcrete MixesLeave a commenton Concrete Mix Design Of M35 Grade(Pile) as per IS 10262:2009
Concrete Mix Design for M25 grade as per IS 10262:2009

1.STIPULATIONS FOR PROPORTIONING

a) Grade designation : M25 RCC

b) Type of cement :53 grade Ordinary Portland Cement conforming IS 12269

c) Maximum nominal size of coarse aggregate : 20 mm

d) Minimum amount of cement : 300 kg/m³ as per IS 456:2000

e) Maximum water-cement ratio : 0.50 as per Table 5 of IS 456:2000

f) Workability : 100 – 125 mm slump

g) Exposure condition : Moderate (For Reinforced Concrete)

h) Method of concrete placing : Pumping

j) Degree of supervision : Good

k) Type of aggregate : Crushed Angular Aggregates

l) Chemical admixture type : Super Plasticizer Normet

2.TEST DATA FOR MATERIALS

a) Cement used : Sagar 53 grade Ordinary Portland cement conforming IS 12269.

b) Specific gravity of cement :3. 15

c) Chemical admixture : Super Plasticizer conforming to IS 9103.

d) Specific gravity of

1) Coarse aggregate 20 mm : 2.799

2) Coarse aggregate 10 mm: 2.789

3) Combined Specific Gravity of aggregate

( 20 mm-45% & 10 mm -55% )=2.792.

4) Fine aggregate : 2.517

e) Water absorption:

1) Coarse aggregate 20 mm : 0.41 %

2) Coarse aggregate 10 mm : 0.59 %

3) Fine aggregate : 1.87 %

f) Aggregate Impact Value : 20.52 %

g) Combined Flakiness & Elongation Index : 27.57 %

h) Sieve analysis:

1) Coarse aggregate: Conforming to all in aggregates of Table 2 of IS 383

2) Fine aggregate : Conforming to Grading Zone III of Table 4 of IS 383

3 TARGET STRENGTH FOR MIX PROPORTIONING

f’ck =fck + 1.65 s

where

f’ck = average target compressive strength of concrete at 28 days,

fck = characteristics compressive strength of concrete at 28 days, and

s = standard deviation.
From table 1 of IS 10262 assumed Standard Deviation, s = 4 N/N/mm². Therefore, target strength of concrete = 25 + 1.65 x 4 = 31.6 N/mm².
But as per MORT&H 5th revision Table 1700.5 required target mean compressive strength = 25 + 11 = 36.00 N/mm² where 11 is the
current margin.

4 SELECTION OF WATER•CEMENT RATIO

Based on the trial , adopted water cement ratio 0.38

From the Table 5 of IS 456 maximum Water Cement Ratio is 0.50

0.38 < 0.50 Hence ok.

As per MORT&H 5th revision Maximum Water Cement Ratio water cement ratio for moderate exposure is 0.45 , hence it is ok

5. SELECTION OF WATER CONTENT

From Table 2 of IS 10262:2009, maximum water content for 20 mm aggregate = 186 liter for 25 to 50 mm slump range but for an increase by
about 3 percent for every additional 25 mm slump so here estimated water content for 125 mm slump = 186+(9/100) x 186 = 202 liter.

Water requirement if we are considering cement 360 kg & w/c ratio o.38 for concrete mix design ; calculated water will be 136.8 so net
reduction in water while using super plasticizer = 100 – (136.8/202 x 100) = 32.28 %.

Now we had got reduction percentage of water , calculate of the required water = 202 – (202 x 32.28) % = 202 – 65.20 = 136.80 (For 75 mm
slump increase 3% , for 100 mm increase 6% & increase 9 % for 125 mm slump)
 

6. CALCULATION OF CEMENT CONTENT

Adopted w/c Ratio = 0.38 then Cement Content = 136.80/0.38 = 360 kg/m³ ,from Table 5 of IS 456, minimum cement content for ‘moderate’
exposure conditions is 300 kg/m³ but taken 360 kg/m³ > 300 kg/m³ hence ok.

As per MORT&H 5th revision for moderate exposure with reference to Table number 1700-2 maximum water cement ratio 0.45 &
minimum cement 340 kg/m³ is specified but we had taken 360 kg/m³ , hence ok


7. CALCULATION OF COARSE AGGREGATE AND FINE AGGREGATE PROPORTION

From Table 3 of (IS 10262:2009) Volume of coarse aggregate corresponding to 20 mm size aggregate and fine aggregate (Zone III) for water-
cement ratio of 0.50 =0.64 (a)

In the present case water-cement ratio is 0.38 therefore, volume of coarse aggregate is required to be increased to decrease the fine aggregate
content.

As the water cement ratio is lower by 0.12 , the proportion of volume of coarse aggregate is increased by= (0.12/0.05) = 2.4 times of 0.01 ,so
0.01 x 2.4= 0.024 (b)

Net required water cement ratio= a+b = 0.64 + 0.024 =0.66(at the rate of -/+ 0.01 for every ± 0.05 change in water-cement ratio) therefore,
corrected proportion of volume of coarse aggregate for the water-cement ratio of 0.38 = 0.66

NOTE – In case the coarse aggregate is not angular one, then also volume of coarse aggregate may be required to be increased suitably based on
experience & Site conditions.

If we are doing concrete with pump , reduce upto 10% these value ,therefore volume of coarse aggregate =0.66 x 0.9 =0.59.

Actual reduced volume of fine aggregate content = 1 – 0.59 = 0.41.

 

8. MIX CALCULATIONS

Determination of mix calculation will be as under:

a)Volume of concrete = 1 m³

b)Volume of cement = [Mass of cement] / {[Specific Gravity of Cement] x 1000} = 360/{3.15 x 1000} = 0.115 m³

c)Volume of water = [Mass of water] / {[Specific Gravity of water] x 1000}

= 136.80/{1 x 1000} = 0.136 m³

d) Base on trial we had kept admixture 0.45 percentage by weight of cement

Volume of admixture = [Mass of admixture ] / {[Specific Gravity of admixture ] x 1000}

= 1.62 /{1.090 x 1000} = 0.00149 m³

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

= [1-(0.115+0.134+0.00149)] = 0.750 m³

f)Mass of coarse aggregate= e x Volume of Coarse Aggregate x Specific Gravity of coarse Aggregate x 1000

= 0.750 x 0.59 x 2.792 x 1000 = 1235.46 kg/m³

g)Mass of fine aggregate= e x Volume of Fine Aggregate x Specific Gravity of Fine Aggregate x 1000

= 0.750 x 0.41 x 2.517 x 1000 = 773.98 kg/m³

9. MIX PROPORTIONS

Cement = 360 kg/m³

Water = 136.80 l/m³

Fine aggregate = 834 kg/m³

Coarse aggregate 20 mm = 1235.46 x 45 %= 555.96 kg/m³

Coarse aggregate 12 mm = 1235.46 x 55%= 679.50 kg/m³

Chemical admixture = 1.62 kg/m³

Water-cement ratio = 0.38

1.Aggregate 20 mm = 555.96/ (1+(0.41/100)} = 554.0 kg

2. Aggregate 10 mm = 679.50/ (1+(0.59/100)} = 676.0 kg

3.Sand = 834.0/ (1+(1.87/100)} = 819.0 kg

4.Water = 2568 -360 – 819 -554 – 676 = 160.0 kg

NOTE

1.Do the trial in dry position as in practical in batching plant you can cot use aggregate in SSD condition.

2.Batch for trial is given in dry position.

3.Do the number of rials with variation of ± 10 percent of water-cement ratio & different cement content

4.Do the surface moisture correction whenever required.