Concrete Mix Design Report by Group 1 (SEM III) 2024

A Report on

CONCRETE MIX DESIGN, TESTS AND

CALCULATIONS

By GROUP 1
Sem III, Btech.Civil Engineering
(Batch 2023-2027)
Under the guidance of
Prof. Sumit Geete
Dept. of Civil Engineering, RBU, Nagpur

Course: CONCRETE MIX DESIGN

Course Code: CET 3004

Sign of Subject Teacher:

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Concrete Mix Design Report by Group 1 (SEM III) 2024

Performed and Submitted By:

1. Aastha Khandelwal (A-01)
2. Kritika Salwankar (A-06)
3. Mrunmayee Baitule (A-07)
4. Vedika Agrawal (A-12)
5. Jeet Ratwani (A-30)
6. Jemin Paghadal (A-31)
7. Kishan Agrawal (A-32)
8. Kishor Bawane (A-33)
9. Saim Sheikh (A-37)
10. Shaafi Sheikh (A-38)
11. Neel Shrivastav (A-40)
12. Parth Pande (A-43)

Group: 1
Batch: B.tech Civil engineering (2023-2027) (Sem III)
Date of Project Initiation: 08-07-2024
Date of Project Completion: 21-10-2024
Course: Concrete Mix Design (CET3004)
Course Teacher: Prof. Sumit Geete

Overview of the report:

The report comprises all the tests (involving apparatus, procedure, IS codal provisions,
observations, results and inferences and their respective images of performance) that are
required for designing the concrete mix. It includes the calculations for finding ratios of
the different components of the concrete and necessary adjustments for the given
construction site’s requirement and conditions. This report also includes testing report of
the designed concrete.

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Concrete Mix Design Report by Group 1 (SEM III) 2024

Contents
Sr. Topic/Experiment Page Sign of
No. no. Teacher
1. Material Procurement 4
2. Material Testing 5
2.i. Testing of Fine Aggregate 6
1. Sieve Analysis
2. Water Absorption
3. Free Moisture Content
4. Specific Gravity
2.ii Testing of Coarse Aggregate 16
1. Sieve Analysis
2. Water Absorption
3. Free Moisture Content
4. Specific Gravity
3. Void Ratio Test 25
4. Concrete Mix Design 30
Compressive Test of Concrete 37
a. Proportioning of Concrete for Cube
Casting:
b. Slump Test (in context of CMD)
c. Cube Test (in context of CMD)
5. Annexures 44
1. Slump Test 44
2. Cube Test 45

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Concrete Mix Design Report by Group 1 (SEM III) 2024

1. MATERIAL PROCUREMENT

a. Quantity Of Material Procured -

1. Coarse Aggregate – 50 kg (2 Bags)
2. Fine Aggregate – 50 kg (2 Bags)
3. Cement – 1 Bag (50 kg) (PPC)

b. Source of Procurement –
1. Coarse Aggregate – Pachgao
2. Fine Aggregate – Bhandara
3. Cement – Provided by College

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Concrete Mix Design Report by Group 1 (SEM III) 2024

2. MATERIAL TESTING
i. Fine Aggregate:
a. Sieve Analysis
b. Water Absorption Test
c. Free Moisture Content Test
d. Specific Gravity Test
ii. Coarse Aggregate:
a. Sieve Analysis
b. Water Absorption Test
c. Free Moisture Content Test
d. Specific Gravity Test
iii. Void Ratio Test for FA and CA
iv. Cement:
Type: PPC
No tests were performed as cement was provided by the college.

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Concrete Mix Design Report by Group 1 (SEM III) 2024

2.i. TESTING OF FINE AGGREGATE

1. SIEVE ANALYSIS OF AGGREGATE:

a. Apparatus
Balance or scale is such that it is readable and accurate to 0.1% of the weight of
the test sample. Sieves of the sizes (80 mm, 40 mm, 20 mm, 10 mm, 4.75 mm, 2.36
mm, 1.18 mm, 600 micron, 300 micron, 150 micron) conforming to IS 460-1962 shall
be used and Fine Aggregate 2kg.
b. IS Codal Provisions:
For apparatus and process: I.S. 2386-Part 1-1963
These are used to find upper and lower limit of the grading curves and also table
4 is used to fine the zone of FA by analyzing 600 micron sieve passing.

c. Procedure
1. The sample shall be brought to an air dry condition before weighing and sieving.
This may be achieved either by drying at room temperature or by heating at a
temperature 1000-1100c.
2. The air dry sample shall be weighed and sieved successfully on the appropriate
sieves starting with the largest size sieve.
3. If sieving is carried out with a mechanical sieve shaken not less than 10 minutes
sieving shall be required for each test.

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Concrete Mix Design Report by Group 1 (SEM III) 2024

4. Find the weight of aggregates retained on each sieve taken in order.

5. Find Zone of Fine Aggregate conforming to IS 383 table 4.

6. Drawing Grading Curve with upper and lower limits provided in IS 383 to
analyze whether the aggregate is properly graded and necessary precautions if its
not.

d. Observations:

1. Fine Aggregate:

IS Sieve Sieve Weight Cum. Wt. % Cumulative % Cum. Upper Lower

Sizes (mm) size Retained (kg) Retained Wt. Retained Passing Limit Limit
80mm 80 0 0 0 100 100 100
40mm 40 0 0 0 100 100 100
20mm 20 0 0 0 100 100 100
10mm 10 0.04 0.04 2 98 100 100
4.75mm 4.75 0.125 0.165 8.25 91.75 100 90
2.36mm 2.36 0.197 0.362 18.1 81.9 95 60
1.18mm 1.18 0.601 0.963 48.15 51.85 70 30
600µ 0.6 0.709 1.672 83.6 16.4 34 15
300µ 0.3 0.256 1.928 96.4 3.6 20 5
150µ 0.15 0.04 1.968 98.4 1.6 10 0
Total 1.968 354.9

Grading Curve of Fine Aggregate

120
10, 98 20, 100 40, 100 80, 100
100 4.75, 91.75
2.36, 81.9
% Cum. Passing

80

60 1.18, 51.85

40
Upper Limit Curve
0.6, 16.4 Lower Limit Curve
20
0.3, 3.6 Actual Curve
0.15, 1.6
0
0.1 1 Sieve Sizes 10 100

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Concrete Mix Design Report by Group 1 (SEM III) 2024

e. Result: The Zone of FA = 1

f. Inference:
The Zone of FA coefficient of CA and for various adjustments in concrete mix
design.
Below are the images of Sieve Analysis-

Figure 1 of Sieve Analysis of CA and FA Figure 2 of Sieve Analysis of CA and FA

These Images shows the aggregate

retained on different sieves with their
respective weights.

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Concrete Mix Design Report by Group 1 (SEM III) 2024

2. WATER ABSORPTION TEST:

a. Apparatus
Balance, Aggregate sample (500 gm) each, Oven(100-115 degrees)

b. IS Codal Provisions
IS 2386(Part 3):1963 Methods of Test for Aggregates. Reaffirmed- Dec 2016

c. Procedure
1. Take 500gm of CA and FA and immerse them in water for 24hrs.
2. Remove water and keep them in open air for 24hrs.
3. Weigh the aggregate at this SSD condition (W3).
4. Keep the sample in Oven at 110-115 degrees for 24hrs.
5. Weigh the aggregate (W1)

d. Calculation
Water Absorption = W3 – W1
W1

e. Observations
Notation FA Values
W3 SSD Weight (gm) 500
W1 Oven Dry Weight (gm) 491
[(W3-W1) x 100]/W3 Water Absorption (%) 1.83%

f. Result
WA of FA = 1.83%

g. Inference
Water Absorption test is used to find water content of aggregate at SSD content
and aggregate used in CMD calculations is assumed at SSD condition. Necessary
corrections needed to make when aggregate is not at SSD condition.

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Concrete Mix Design Report by Group 1 (SEM III) 2024

• Images of Water Absorption Test:

W3 of FA (at SSD) W3 of FA (Oven Dried )

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Concrete Mix Design Report by Group 1 (SEM III) 2024

3. MOISTURE CONTENT TEST:

a. Apparatus
Balance, Aggregate sample (500 gm) each, Oven(100-115 degrees)

b. IS Code:
IS 2386(Part 3):1963 Methods of Test for Aggregates. Reaffirmed- Dec 2016

c. Procedure
1. Take 500gm of FA (W2).
2. Keep the sample in Oven at 110-115 degrees for 24hrs.
3. Weigh the aggregate (W1)

d. Calculation
Moisture Content = W2 – W1
W1
e. Observations
Notation CA Values
W2 SSD Weight (gm) 500
W1 Oven Dry Weight (gm) 497
[(W2-W1) x 100]/W2 Moisture Content (%) 0.6%

f. Result
FMC of FA = 1.4 %

g. Inference
Here, the aggregate has lower water content than that should be present.
Aggregate generally has different water content at different seasons of the year
and for CMD according to IS Codes, the aggregate must be present in SSD
condition. And if its not present in SSD necessary corrections are needed which
uses the FMC of Aggregate.

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Concrete Mix Design Report by Group 1 (SEM III) 2024

• Images of Moisture Content Test:

W2 of FA (at Natural Condition) W1 of FA (Oven Dried)

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Concrete Mix Design Report by Group 1 (SEM III) 2024

4. SPECIFIC GRAVITY TEST:

a. Apparatus
Balance, Aggregate sample, Drying Oven(100-115 degrees), Pycnometer, Density
Bottle, Distilled Water

b. IS Code:
IS 2386 ( Part III ) – 1963

c. Procedure
1. Take a sample of aggregate and oven dry it.
2. Weigh the empty pycnometer (W1)
3. Fill one-third with oven dry aggregate and weigh it (W2).
4. Fill the remaining pycnometer till its top and weigh it (W3).
5. Fill pycnometer only with water and weigh it (W4).

d. Calculation
Specific Gravity = W2 – W1
[(W2-W1)-(W3-W4)]
e. Observations
I) FA
Empty Wt. of Wt. Density Wt. of Density
density bottle Bottle + FA bottle + FA + Wt. of density bottle
Case (W1) (W2) Water (W3) + Water (W4) Specific Gravity
1 23.32 31.02 69.00 64.8 2.48
2 23.32 31.08 69.08 64.8 2.52
3 23.32 30.97 69.20 64.8 2.68
Avg. = 2.53
f. Result
Specific Gravity of FA = 2.53

g. Inference
Sp. Gravity of aggregate is used to find the mass of aggregate to be used in
construction work when we have volume of aggregate during CMD Calculations.

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Concrete Mix Design Report by Group 1 (SEM III) 2024

Sp. Gravity Test images of Case 1 of FA:

W1 W2

W3 W4

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Concrete Mix Design Report by Group 1 (SEM III) 2024

2.ii. TESTING OF COARSE AGGREGATE

1. SIEVE ANALYSIS OF AGGREGATE:

a. Apparatus
Balance or scale is such that it is readable and accurate to 0.1% of the weight of
the test sample. Sieves of the sizes (80 mm, 40 mm, 20 mm, 10 mm, 4.75 mm, 2.36
mm, 1.18 mm, 600 micron, 300 micron, 150 micron) conforming to IS 460-1962 shall
be used and Coarse Aggregate 5kg.
b. IS Codal Provisions:
For apparatus and process: I.S. 2386-Part 1-1963
For NSA, IS 383

c. Procedure
1. The sample shall be brought to an air dry condition before weighing and sieving.
This may be achieved either by drying at room temperature or by heating at a
temperature 1000-1100c.

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Concrete Mix Design Report by Group 1 (SEM III) 2024

2. The air dry sample shall be weighed and sieved successfully on the appropriate
sieves starting with the largest size sieve.
3. If sieving is carried out with a mechanical sieve shaken not less than 10 minutes
sieving shall be required for each test.
4. Find the weight of aggregates retained on each sieve taken in order.
5. Find the Maximum Nominal Size (NSA) of course aggregate (85% passing).
6. Drawing Grading Curve with upper and lower limits provided in IS 383 to analyze
whether the aggregate is properly graded and necessary precautions if its not.

d. Observations:
1. Coarse Aggregate
IS Sieve Sieve Weight Cum. Wt. % Cumulative % Cum. Upper Lower
Sizes (mm) size Retained (kg) Retained Wt. Retained Passing Limit Limit
80mm 80 0 0 0 100 100 100
40mm 40 0 0 0 100 100 100
20mm 20 0.061 0.061 1.22 98.78 100 100
10mm 10 4.647 4.708 94.16 5.84 20 0
4.75mm 4.75 0.262 4.97 99.4 0.6 5 0
2.36mm 2.36 0 4.97 99.4 0.6 0 0
1.18mm 1.18 0 4.97 99.4 0.6 0 0
600µ 0.6 0 4.97 99.4 0.6 0 0
300µ 0.3 0 4.97 99.4 0.6 0 0
150µ 0.15 0 4.97 99.4 0.6 0 0
Total 691.78

Grading Curve of Coarse Aggregate

120.00
40, 100.00 80, 100.00
20, 98.78
100.00

80.00
% Cum. Passing

60.00

40.00

20.00 10, 5.84 Actual Grading

0.15, 0.60 0.30, 0.60 1.18, 0.60 2.36, 0.60 4.75, 0.60 Curve
0.60, 0.60
0.00
0 1 10 100
-20.00
Sieve Sizes

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Concrete Mix Design Report by Group 1 (SEM III) 2024

e. Result:
1) The NSA of CA = 20mm
f. Inference:
The Zone of FA and NSA of CA is used in finding coefficient of CA and NSA of
CA is used for various adjustments in concrete mix design.

Below are the images of Sieve Analysis-

Figure 1 of Sieve Analysis of CA and FA Figure 2 of Sieve Analysis of CA and FA

These Images shows the aggregate

retained on different sieves with their
respective weights.

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Concrete Mix Design Report by Group 1 (SEM III) 2024

2. WATER ABSORPTION TEST:

a. Apparatus
Balance, Aggregate sample (500 gm), Oven(100-115 degrees)

b. IS Code:
IS 2386(Part 3):1963 Methods of Test for Aggregates. Reaffirmed- Dec 2016

c. Procedure
6. Take 500gm of CA and immerse them in water for 24hrs.
7. Remove water and keep them in open air for 24hrs.
8. Weigh the aggregate at this SSD condition (W3).
9. Keep the sample in Oven at 110-115 degrees for 24hrs.
10. Weigh the aggregate (W1)

d. Calculation
Water Absorption = W3 – W1
W1

e. Observations
Notation CA Values
W3 SSD Weight (gm) 500
W1 Oven Dry Weight (gm) 491
[(W3-W1) x 100]/W3 Water Absorption (%) 1.83%

f. Result
WA of CA = 1.83%

g. Inference
Water Absorption test is used to find water content of aggregate at SSD content
and aggregate used in CMD calculations is assumed at SSD condition. Necessary
corrections needed to make when aggregate is not at SSD condition.

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Concrete Mix Design Report by Group 1 (SEM III) 2024

• Images of Water Absorption Test:

W3 of CA (at SSD) W1 of CA (Oven Dried)

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Concrete Mix Design Report by Group 1 (SEM III) 2024

3. MOISTURE CONTENT TEST:

a. Apparatus
Balance, Aggregate sample (500 gm) each, Oven(100-115 degrees)

b. IS Code:
IS 2386(Part 3):1963 Methods of Test for Aggregates. Reaffirmed- Dec 2016

c. Procedure
1.Take 500gm of CA and FA (W2).
2. Keep the sample in Oven at 110-115 degrees for 24hrs.
3. Weigh the aggregate (W1)

d. Calculation
Moisture Content = W2 – W1
W1
e. Observations
Notation CA Values
W2 SSD Weight (gm) 500
W1 Oven Dry Weight (gm) 497
[(W2-W1) x 100]/W2 Moisture Content (%) 0.6%

h. Result
FMC of CA = 0.6%

i. Inference
Here, the aggregate has lower water content than that should be present.
Aggregate generally has different water content at different seasons of the year
and for CMD according to IS Codes, the aggregate must be present in SSD
condition. And if its not present in SSD necessary corrections are needed which
uses the FMC of Aggregate.

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Concrete Mix Design Report by Group 1 (SEM III) 2024

• Images of Moisture Content Test:

W2 of CA (at Natural Condition) W1 of CA (Oven Dried)

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Concrete Mix Design Report by Group 1 (SEM III) 2024

4. SPECIFIC GRAVITY TEST:

a. Apparatus
Balance, Aggregate sample, Drying Oven(100-115 degrees), Pycnometer, Density
Bottle, Distilled Water

b. IS Code:
IS 2386 ( Part III ) – 1963

c. Procedure
6. Take a sample of aggregate and oven dry it.
7. Weigh the empty pycnometer (W1)
8. Fill one-third with oven dry aggregate and weigh it (W2).
9. Fill the remaining pycnometer till its top and weigh it (W3).
10. Fill pycnometer only with water and weigh it (W4).

d. Calculation
Specific Gravity = W2 – W1
[(W2-W1)-(W3-W4)]
e. Observations
CA
Empty Wt. of
Pycnometer Wt. of Pyc. + Wt. of Pyc. + CA + Wt. of Pyc. + Water
Case (W1) CA (W2) Water (W3) (W4) Specific Gravity
1 647 900 1792 1448 2.78
2 647 902 1789 1448 2.96
3 647 900 1791 1448 2.81

h. Result
Specific Gravity of CA = 2.85

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Concrete Mix Design Report by Group 1 (SEM III) 2024

i. Inference
Sp. Gravity of aggregate is used to find the mass of aggregate to be used in
construction work when we have volume of aggregate during CMD Calculations.

Sp. Gravity Test images of Case 1 of CA:

W1 W2 W3 W4

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Concrete Mix Design Report by Group 1 (SEM III) 2024

2.iii. MINIMUM VOID RATIO TEST FOR AGGREGATE

a. Apparatus
Balance, Aggregate CA and FA, 3 litre container, 4.75mm sieve, water, measuring
cylinder

b. IS Code:
IS: 2386(Part III)- 1963

c. Procedure
1. Take 5kg of aggregate in CA:FA ratio of 50:50 by weight and mix them
thoroughly.
2. Fill the container with the aggregate mix and keep aside the remaining
aggregate. The Agg. be filled in 3 parts with 25 no. of tamping each time.
3. Weigh the aggregate(W1) with container. Add water in the container by
volumetric cylinder upto the top of the container in short time such that the
aggregate doesn’t absorb the water. Note the volume of water added and
measure its weight (W2).
4. Take remaining aggregate and sieve it through 4.75mm sieve and separate
out CA and FA and weigh them accordingly.
5. Repeat the steps for CA:FA ratios of 30:70, 40:60, 60:40,70:30 and 80:20.
And Take the ratio for which void content is minimum.

d. Calculation
For Actual CA:FA ratio R,
Volume of Container = 3
Void Content (%) = W2 – W1
3
e. Observations

Theoretical
Empty Wt. of Wt. of Wt. of Initial Weight Initial Weight Ratio
Case Cylinder Cyl.+CA+Fa Cyl.+CA+Fa+Water of CA of FA (CA:FA)
1 2.82 8.339 9.122 1.8 4.2 30:70
2 2.82 8.346 9.097 2.4 3.6 40:60
3 2.82 8.577 9.272 3 3 50:50
4 2.82 8.647 9.389 3.6 2.4 60:40
5 2.82 8.561 9.401 4.2 1.8 70:30
6 2.82 8.499 9.376 4.8 1.2 80:20

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Concrete Mix Design Report by Group 1 (SEM III) 2024

Wt. Actual Ratio

Balance Wt. Balance Actual Wt. of Actual Wt. Actual Ratio (CA:FA) Void
CA FA CA of FA (CA:FA) (Fraction) Content
0.149 0.323 1.651 3.877 29.87 : 70.13 0.426 0.260
0.189 0.26 2.211 3.34 39.83 : 60.17 0.662 0.250
0.12 0.098 2.88 2.902 49.81 : 50.19 0.992 0.232
0.096 0.03 3.504 2.37 59.65 : 40.35 1.478 0.247
0.196 0.069 4.004 1.731 69.82 : 30.18 2.313 0.280
0.24 0.046 4.56 1.154 79.8 : 20.2 3.951 0.292

Void Content Curve

35%

3.951, 29.23%
30% 2.313, 28.00%
0.426, 26.03% 1.478, 24.73%
25%
0.662, 25.03%
Void Content %

0.992, 23.17%
20%

15%

10%

5%

0%
0.000 0.500 1.000 1.500 2.000 2.500 3.000 3.500 4.000 4.500

CA : FA Ratio

f. Result
Minimum Void Content is at CA:FA of 50:50

g. Inference
Selection of CA coefficient for CMD can be based on this experiment or based
on IS 10262.
h. Images of Void Ratio Test:

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Concrete Mix Design Report by Group 1 (SEM III) 2024

1) For 30:70 Ratio:

Dry Weight Wet Weight

2) For 40:60 Ratio:

Dry Weight Wet Weight

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Concrete Mix Design Report by Group 1 (SEM III) 2024

3) For 50:50 Ratio:

Dry Weight Wet Weight

4) For 60:40 Ratio:

Dry Weight Wet Weight

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Concrete Mix Design Report by Group 1 (SEM III) 2024

5) For 70:30 Ratio:

Dry Weight Wet Weight

6) For 80:20 Ratio:

Dry Weight Wet Weight

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Concrete Mix Design Report by Group 1 (SEM III) 2024

Inference of Void Ratio Experiment:

The Void Content was obtained minimum at 50:50 (by weight) or 0.53:0.47 (by volume)
but for concrete mix design we used the CA coefficient from IS 10262 and not from the
experiment of min. void ratio. The CA:FA obtained from IS 10262 was 0.61:0.39

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Concrete Mix Design Report by Group 1 (SEM III) 2024

3. CONCRETE MIX DESIGN (CMD)

Data:
1. Grade of Concrete – M30
2. Type of cement – RCC
3. Maximum NSA of Aggregate – 20mm
4. Environmental Condition – Moderate
5. Workability/Slump – 100mm
6. Method of Placing of concrete – No Pumping
7. Type of Aggregate – Crushed Angular
8. Degree of Site Control – Good
9. Specific Gravity of Cement – 2.88
10. Chemical Admixture – None
11. Specific Gravity of CA – 2.85
12. Specific Gravity of FA – 2.53
13. Zone of FA – 1
(This data is from obtained from the site as well as are the results of above
experiments.)

Step 1: Calculation of Target Mean Strength (fck’):

For M30 grade, 𝑓𝑐𝑘 = 30 𝑁/𝑚𝑚^2
′
Case 1: 𝑓𝑐𝑘 = 30 + 1.65(𝑆)
From Table 2 of IS 10262, for good quality control, S = 5
′
𝑓𝑐𝑘 = 30 + 1.65(5) = 𝟑𝟖. 𝟐𝟓 𝑵/𝒎𝒎^𝟐
′
Case 2 : 𝑓𝑐𝑘 = 30 + 𝑋
From Table 1 of IS 10262, X = 6.5
′
𝑓𝑐𝑘 = 30 + 6.5 = 𝟑𝟔. 𝟓 𝑵/𝒎𝒎^𝟐
Now, considering higher value of 𝒇′𝒄𝒌 i.e. 38.25 N/mm^2

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IS Code 10262: 2019 Table 1 and Table 2

Step 2: Assessment of % Air Content:

From IS 10262 Table 3,
% of Air voids on the basis of NSA = 20mm is 1%.
Volume of air entrapped in 1m^3 of concrete = 0.01 m^3.

Step 3: Selection of W/Cm ratio:

Case 1: From IS 10262 Figure 1:

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Concrete Mix Design Report by Group 1 (SEM III) 2024

Type of Cement is RCC and no compressive strength is known then

Considering curve 2 : W/Cm = 0.43
Case 2: From IS 456 Table 5:
For Moderate condition and RCC, max. W/Cm = 0.5 and minimum grade
for moderate condition is M25 and we have M30. Hence it is OK.
Minimum cement content is 300kg/m^3 and this table pertains to 20mm
NSA, and we have 20mm NSA so no correction needed for the size.
Selecting the minimum value of W/Cm of the 2 cases i.e. W/Cm = 0.43
IS Code 10262 Figure 1:

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IS Code 456 Table 5:

IS 456 Table 6 for minimum Cement Content for different NSA:

Step 4: Selection of Water Content:

From IS 10262 Table 4 and NSA 20mm, W = 186 kg/m^3
And this table is valid for angular and we have angular, hence no correction is
needed (for other shapes such as sub-angular, gravel and rounded, the water content is
reduced by 10kg, 15kg and 20kg respectively per cubic metre).
The table is valid for Slump value of 50mm, but the desired slump is 100mm, and for
each 25mm increase in slump value the water content is increased by 3%.

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Concrete Mix Design Report by Group 1 (SEM III) 2024

Here, for increase in slump = 50mm, increase in water content is 6%.

Therefore, corrected water content, W = 186 + 6% of 186 = 197 kg/m^3.
No plasticizers used so no correction for them.

IS Code 10262 Table 4:

Step 5: Calculation of cement content from W/Cm:

W/Cm = 0.43 implies, Cm = 458kg/m^3
And contains 20% mineral admixture,
Wt. of mineral admixture = 20% of 458 = 92 kg/m^3
Wt. of Cement = C = 366 kg/m^3 and it is greater than 300kg/m^3 viz. min. cement
content.

Step 6: Determination of Coefficients of CA and FA:

From IS 10262 Table 5, for Zone 1 FA and NSA =20mm,
Coefficient of CA = 0.6
This table is valid for W/Cm = 0.5, here W/Cm = 0.43
For every 0.05 decrease in W/Cm, the Coefficient of CA should be increased by 0.01,
Decrement in W/Cm = 0.07

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Concrete Mix Design Report by Group 1 (SEM III) 2024

Increase in Coeff. Of CA = 0.014

Corrected Coeff. Of CA = 0.61
Corrected Coeff. Of FA = 0.39

IS Code 10262, Table 5:

Step 7: For Pumpable Concrete, here no pumping used so no correction.

Step 8: Calculation of the mix:

a. Volume of Concrete = 1 m^3
b. Volume of Entrapped Air = 0.01 m^3
c. Volume of cementatious material (PPC) = 458/(2.88 x 1000) = 0.16 m^3
d. Volume of Water = 197/1000 = 0.197
e. Volume of Total Aggregate = a – (b+c+d) = 1-0.01-0.16-0.197 = 0.633 m^3

Volume of CA = 0.633 x 0.61 = 0.39 m^3

Volume of FA = 0.633 x 0.39 = 0.24 m^3
Wt. of CA = 0.39 x 2.85 x 1000 = 1112 kg
Wt. of FA = 0.24 x 2.53 x 1000 = 607.2 kg

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Concrete Mix Design Report by Group 1 (SEM III) 2024

At SSD Condition,
Cm : FA : CA : W = (458 : 607 : 1112 : 197) kg/m^3
= ( 1 : 1.32 : 2.42 : 0.43) for 1kg of cement
= ( 1 : 66 : 121 : 21.5) for 1 bag (50kg) of PPC cement

Step 9: Adjustment for Moisture Content:

FA CA
Water Absorption 1.83 1.83
Moisture Content 1.41 0.6
Difference +0.42 +1.23

Addition of Water to CA = (1.23 x 1112) / 100 = 13.67 kg/m^3

Addition of Water to FA = (0.42 x 607) / 100 = 2.54 kg/m^3
Total Water Content = 197+13.67+2.54 = 213.21kg/m^3
Corrected CA = 1112 – 13.67 = 1098.33 kg/m^3
Corrected FA = 607 – 2.54 = 604.46 kg/m^3

Corrected Ratio = Cm : CA : FA : W
(458 : 1098.33 : 604.46 : 213.21) kg/m^3
(1 : 2.39 : 1.32 : 0.465 ) for 1kg of PPC cement
(1 : 119.5 : 66 : 23.25 ) for 1 Bag of PPC Cement
This is as per site condition.

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4. COMPRESSIVE STRENGTH TEST OF CONCRETE

a. Proportioning Of Concrete for Cube Casting:

Concrete calculation for casting 6 cubes of dimensions 15cm x 15cm x 15cm

for compressive test at 7 days and 28 days. Each cube weighs 9.5 kg.

Let X be weight of cement in kg for cube making.

Therefore, X(1+2.39+1.32+0.465) = 6 x 9.5

Or, 5.175X = 57 ➔ X = 11.01

Weight of different materials used:

PPC cement = 11.01 kg

Coarse Aggregate = 11.01 x 2.39 = 26.31 kg
Fine Aggregate = 11.01 x 1.32 = 14.54 kg
Water = 11.01 x 0.465 = 5.14 kg

b. Slump Test:

1. IS Code
Conforming to IS 7320:1974 (Fourth revision) (Reaffirmed- 2018) Specifications
for Concrete Slump Test Apparatus
IS 1199 (Part 2): (First revision) 2018 Fresh Concrete— Methods of Sampling,
Testing and Analysis - Part 2 Determination of Consistency of Fresh Concrete

2. Observation and Recording

The vertical difference between top of the mould and the displaced original
center of the top surface of the specimen is 115 mm (Subsidence). Slump
obtained is True Slump.

5. Result and Inference

The Desired Slump Value of 100mm has been achieved

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Image showing slump value of 115mm.

c. Cube Testing:

I. IS Code
For Apparatus: IS 10086: 1982 for cube moulds
: IS 14858: 2000 for C.T.M.
For Process: IS 516: 1959

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II. Observations

Testing Results:
Sr. Cube Date Date of Age of Failure L B H Comp.
No. Name of Testing Concrete Load (mm) (mm) (mm) Strength
Castin (kN) (MPa)
g
1. 1 26-09 03-10 7 days 518.6 148 150 148 23.36
2. 2 26-09 03-10 7 days 459.7 150 151 150 20.29
3. 3 26-09 03-10 7 days 503.8 147.5 150 148 22.74
4. 1 26-09 24-10 28 days 697.8 146 149 147 32.07
5. 2 26-09 24-10 28 days 683.2 148 151 148 30.57
6. 3 26-09 24-10 28 days 721.2 148 150 150 32.49

Wt. of Density Avg. Avg. Criteria Of Remark

Cube (kg/m^3) Comp. Density Acceptance
(kg) Strength
8.688 2644.26 18.81 < 23.36 < 25.44 OK
8.619 2536.86 22.13 2592.10 18.81 < 20.29 < 25.44 OK
8.498 2595.20 18.81 < 22.74 < 25.44 OK
8.738 2714.33 26.95 < 32.07 < 36.46 OK
8.751 2645.80 31.71 2640.08 26.95 < 30.57 < 36.46 OK
8.413 2560.12 26.95 < 32.49 < 36.46 OK

III. Calculations and Result:

According to above stated IS Codes, the individual cube’s strength values
should lie between their 15% variation of their mean value

For 7 Days Testing:

Mean Value = 22.13 N/mm^2
+15% value = 25.44 N/mm^2
-15% value = 18.81 N/mm^2
As each cube value lies in the above range, all the results of 7 days are OK.

For 28 Days Testing:

Mean Value = 31.71 N/mm^2
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+15% value = 36.46 N/mm^2

-15% value = 26.95 N/mm^2
As each cube value lies in the above range, all the results of 28 days are OK.

IV. Inference
The Desired Grade of Concrete 30MPa has been achieved and the all the
results are satisfied.

VII. Images
a. Cube Casting Images:

6 Cubes

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b. 7 Days Testing Cube Samples and their testing results

Cube 1 Cube 1 Test Result

Cube 2 Cube 2 Test Result

Cube 3 Cube 3 Test Result

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c. 7 Days Cubes Failure Pattern Images:

Cube 1 Cube 2 Cube 3

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d. 28 days Cubes Samples and their Test Results

Cube 1 Cube 1 Test Result

Cube 2 Cube 2 Test Result

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Cube 3 Cube 3 Test Result

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Concrete Mix Design Report by Group 1 (SEM III) 2024

ANNEXURES

1. SLUMP TEST

1. Apparatus Required
Fig. 1: Schematic Slump Cone Apparatus
The Slump Cone apparatus for conducting the slump test
essentially consists of a metallic mould in the form of a
frustum of a cone having the internal dimensions as:
Bottom diameter: 200 mm, Top diameter : 100 mm,
Height : 300 mm and the thickness of the metallic sheet
for the mould should not be thinner than 1.6 mm.

Fig. 2: Slump Cone Apparatus

The Slump Cone apparatus along with Tamper (16 mm
in diameter and 600 mm length and with rounded ends),
Ruler, Scoop etc.
2. Reference Conforming to IS 7320:1974 (Fourth revision)
(Reaffirmed- 2018) Specifications for Concrete Slump Test Apparatus
IS 1199 (Part 2): (First revision) 2018 Fresh Concrete— Methods of Sampling,
Testing and Analysis - Part 2 Determination of Consistency of Fresh Concrete

4. Procedure
a. If this test is being carried out in the field, the sample mixed
concrete shall be obtained.
b. The internal surface of the mould shall be thoroughly cleaned and
freed from superfluous moisture and any set concrete before commencing
the test. The mould shall be placed on a smooth, horizontal, rigid and non-
absorbent surface, such as a carefully levelled metal plate, the mould being
firmly held in place while it is being filled.
c. Immediately after obtaining the sample, fill the mould in three
layers, each approximately one third of the height of the mould when
compacted. During filling, clamp or hold the mould firmly in place by
standing on the two feet pieces.

d. Tamp each layer with 25 strokes of the tamping rod.

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e. Tamp the second layer and top layer each throughout its depth, so
that the strokes just penetrate into the underlying layer.
f. In filling and tamping the top layer, heap the concrete above the
mould before the tamping is started.
g. The bottom layer shall be tamped throughout its depth. After the
top layer has been tamped, the concrete shall be struck off level with a
trowel or the tamping rod, so that the mould is exactly filled.l

h. After the top layer has been rodded tamped, strike off the surface of
the concrete by means of screeding and rolling motion of the tamping rod.
After the top layer has been tamped, scrap off the surface of the concrete
level with the top of the mould by means of a sawing and rolling motion of
the tamping rod. Remove spilled concrete from the base plate/surface.

i. Any mortar which may have leaked out between the mould and the
base plate shall be cleaned away. The mould shall be removed from the
concrete immediately by raising it slowly and carefully in a vertical direction.

j. Immediately after removal of the mould, determine the slump, h, by

measuring the difference between the height of the mould and the highest
point of the slumped concrete.

k. The above operations shall be carried out at a place free from

vibration or shock. The entire operation from the start of the filling to the
removal of the mould shall be carried out without interruption and shall be
completed within 180 s.
Measure slump to the nearest 5mm.

2. CUBE TEST
Cube Testing:

1. Apparatus
1) Compression testing machine capable of applying a load of 100 tons
2) Vibrating table
3) Weighing balance
4) Cube moulds 15 cm size
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5) Tamping rod 16 mm diameter and 0.6 m long bullet end

6) G.I. tray and trowel for mixing
7) Glass plate thicker than 6.5 mm or machined metal plate 13 mm thickness and
of dimensions greater than 17.5 mm

2. IS Code
For Apparatus: IS 10086: 1982 for cube moulds
: IS 14858: 2000 for C.T.M.
For Process: IS 516: 1959

3. Procedure
1. Calculate proportion for concrete for desired compressive strength

2. Mix all ingredients in dry state and then mix water.

3. Perform slump test.

4. Oil the internal surface of cube moulds.

5. Fill concrete into the mould in three layers and each layer is compacted by tamping
rod not less than 35 blows. Mechanical vibrator may be used.
6. Level the surface of concrete at top of the mould using trowel.

7. Cover the top with a glass or metal plate to prevent evaporation.

8. Store the specimen in a place at temperature 27 0 + 2 0 C for 24 hours

9. Remove the specimen from the mould, engrave an identification mark on it and
keep it submerged in clean, fresh water just prior to the test. Water in which
specimen is submerged shall be changed every seven days.
10. Carry out testing after 7 days and 28 days, the time is measured from the time the
water is added to the dry ingredients.
Testing the samples
1. Wipe off extra water from surfaces of test specimens (If the specimens are
received dry, keep them in water 24 hours before testing).
2. Note down dimensions and weight of specimen.

3. Place the specimen in such a manner that the load shall be applied to opposite
faces of the cubes as cast. As shown in fig.
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Axis of loading

Loading plates

Axis of casting

4. Align carefully the center of thrust of the spherically seated plate. (Even small
eccentricity can cause serious deviations)
5. Apply load slowly and at the rate 140 kg / sq. cm / min., till the cube breaks.

6. Note down the maximum load and appearance of the concrete failure i.e.,
whether aggregate has broken or cement paste has separated from aggregate etc.
7. Calculate compressive strength of cement and tabulate the results in observation
table. Repeat the above procedure for other two sets of cube.

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6. Group Photo:

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