Grading Curves for 20mm MSA (Road Note-4, RRL, UK) IS Sieves (mm)

40 20 10 4.75 2.36 1.20 0.600 0.300 0.150 110 100 90 80 75 70 65 % PASSING 60 55 50 40 30 20 10 0 1.5 0 0.150 12 5 3 2 0.300 34 27 21 14 9 0.600 28 21 16 48 100 100

Percentage Passing
Curve (1)
100 45 30 23 16 9 2 0

Curve(2)
100 55 35 28 21 14 3 0

Curve(3)
100 65 42 35 28 21 5 0

Curve(4)
100 100 75 48 42 34 27 12 1.5

*Curve(5)
100 72 40 30 25 15 4 0

42
35 28 23

42
35 30

45

1.20

2.36

4.75

10

20

40

Table-1

Minimum Cement Contents and Maximum W/C ratio for different exposure with normal weight Aggregate of 20mm Nominal maxium size as per IS:456-2000
Plain Concrete (PCC) Reinforced Concrete (RCC) Min Cement Kg/m3 300 300 350 400 400 Max Free W/C 0.55 0.5 0.45 0.45 0.4 Minimum grade of Concrete PCC RCC

Exposure

Min Cement Kg/m3 220 250 260 300 300

Max Free W/C 0.6 0.6 0.5 0.45 0.4

Mild Moderate Severe Very Severe Extreme

---M15 M20 M20 M25

M20 M20 M25 M35 M40

Note: Minimum Cement Content is irrespective of grade of Cement

Table-2

Adjustments to Minimum Cement Contents for aggregates other than 20mm nominal maximum size as per IS:456-2000
Adjustments in Minimum Cements in Table- 1 (Kg/m3) +40 +20 +00 -15 -30

Nominal Max. Agg. Size (mm) 10 15 20 30 40

Table-3 Mild-

Exposure Conditions:
Concrete surface protected against weather or aggressive conditions Concrete surfaces sheltered from severe rain or freezing whilst wet Concrete continuously under water. Concrete exposed to condensation and rain Concrete exposed to non-aggressive sub-soil/ground water or coastal environment Concrete surfaces exposed to severe rain, alternate wetting and drying or occasional freezing whilst wet or severe condensation Concrete in contact or buried under non-aggressive soil/ground water, completely immersed in sea water

Moderate-

Severe-

Very Severe Extreme

Concrete surfaces exposed to sea water spray,corrossive fumes or severe freezing conditions whilst wet Concrete surfaces exposed to abrasive action ,for example machinery, metal tyred vehicles or water carrying solids Concrete surfaces in tidal zone Members in direct contact with liquid /solid aggressive chemicals

Table-6: Gradings limit for Fine Aggregate (IS:383-1970) IS Sieve

10-mm 4.75-mm 2.36-mm 1.18-mm 600-micron 300-micron 150-micron

Percentage passing for Zone-1

100 90-100 60-95 30-70

Zone-2
100 90-100 75-100 55-90

Zone-3
100 90-100 85-100 75-100

Zone-4
100 95-100 95-100 90-100

15-34
5-20 0-10

35-59
38959 0-10

60-79
14946 0-10

80-100
15-50 0-15

Table-8 : Degree of QulityControl expected Very Good Fresh cement from single source and regular tests, weigh batching of all materilas,aggregates supplied in single sizes, control of aggregate grading and moisture content, Control of water added, frequent supervision, regular workability and strength tests, and field laboratory facilities Carefully stored cement and periodic tests, weigh batching of all materials, controlled water, graded aggregate supplied,ocassional grading and moisture tests, periodic check of workability and strength, intermittent supervision and experienced workers Proper storage of Cement, Volume batching of all aggregates allowing to bulking of sand, weigh batching of cement, water content controlled by inspection of mix, and occasional supervision and tests.

Good

Fair

Table-9: Recommended value of Standard Deviation IS:10262-1982

Grade of Concrete Very good M-10 M-15 M-20 M-25 M-30 M-35 M-40 M-45 M-50 M-55 M-60 2.0 2.5 3.6 4.3 5.0 5.3 5.6 6.0 6.4 6.7 6.8 Degree of Quality Control Good 2.3 3.5 4.6 5.0 6.0 6.3 6.6 7.0 7.4 1.7 7.8 Fair 3.3 4.5 5.6 6.3 7.0 7.3 7.6 8.0 8.4 8.7 8.8

Table-4: Workability for different purposes and appropriate test values

Degree of workability Placing conditions Nominal MAS (mm) 10 Compaction factor 0.65 Slump (mm) 0 over 20 20 Small sections subject to intensive vibration and large sections to normal vibrations Simply reinforced sections with good vibration and large sections to normal vibrations 10 20 40 10 20 40 10 20 40 10 High Heavily reinforced sections with light 10 vibrations 20 40 10 20 40 0.68 0.75 0.78 0.78 0.83 0.85 0.85 0.9 0.92 0.92 0.95 40 0.95 0.95 0.97 0.97 0.98 0 0 0-10 0-25 0-5 10-25 25-50 5-25 3-5 25-50 50-100 25-100 50-125 100-175 100-150 0-2 125-200 >200 2-3 5-10 7-20 Vebe time (s)

Section subject to extremely intensive or Extremely Low prolonged vibration; pressure may also be required

Very low

Low

Medium

Simply reinforced sections with normal vibration and heavily reinforced sections with good vibrations

Very high

Cast in situ plies or structures with very heavy reinforcement and light /no vibration

Table-5: Maximum size of the aggregate (MSA) Percentage of Aggregates passing 20mm sieve
0-25 25-75 75-100

Maximum Aggregate Size (MAS)

40 30 20

Table-7: Value of Statistical Constant 't' ( IS:10262-1982) Accepted proportion of low results
1 in 5 1 in 10 1 in 15

't'
0.84 1.28 1.5

1 in 20 1 in 40 1 in 100

1.65 1.96 2.33

WORKSHEET FOR CONCRETE MIXES DESIGN

PROJECT: JOB LOC. Conc. Grade Date:

I.
A. B.

C.

D. E.

F.

II.

III.

IV.

V. VI. A.

B.

VII. A.

B.

C. a.

b. D. a. b.

E. a. b.

F. G. VIII. A. B. C. D. E. IX. A. B. C. D. E. F. G. H. I. J. K.

Design mix Trial Mix

Cement W/C Bulkage S/Moisture FA CA-I CA-II Water Slump

I.

A. B. C. D. E. F.

Result Sheet
Mix NoConc. Grade I II

No. of Cubes Date of Casting Date of testing 7 Day strength a) Cube Weight b)Load c) Comp. Strength 28 Day strength a) Cube Weight b)Load c) Comp. Strength

KSHEET FOR CONCRETE MIXES DESIGN

Const. of Br. No 1/1 for PMGSY Project on road no-1 Abutment no-1 on Silchar side apporoach road. M-25 3/12/2007 REQUIREMENTS/PARAMETERS:
SPECIFIED MINIMUM STRENGTH(Fck ) kg/cm2 DURABILITY REQUREMENTS

300.0
SEVERE 0.45

Exposure Maximum w/c ratio Minimum cement content Minimum Grade of Concrete
CEMENT(TYPE /GRADE)

335.0 M25
OPC/53G kg/cm
2

Type/Grade Characteristic Strength Cement Grade

WORKABILITY OR SLUMP DEGREE OF WORKABILITY DETAILS OF FINE AGREGATE

530.0
E 70 HIGH

(mm)

Type (Natural/Mixed) % passing 600 micron sieve % oversize % passing 600 micron sieve *(pure sand) Select Zone %retained on 4.75mm IS Sieve Specific Gravity Dry Loose Bulk Density (kg/lit) Bulkage Surface Moisture
DETAILS OF COARSE AGGREGATE

Natural 25 19
31%

I
19% 2.96 1.77 15% 2%

Type % Passing 20mm Sieve (CA-II) Maximum size of aggregate(MSA) (mm) %Passing On 4.75mm Sieve (CA-I) Specific Gravity Dry Loose Bulk Density(DLBD)-CAI kg/cm2 Dry Loose Bulk Density(DLBD)-CAII kg/cm2

Crushed
43%

30
9% 2.53 1.44 1.39

TARGET MEAN STRENGTH (Fck)

kg/cm2

Degree of Quality Control Standard Deviation S ( N/mm2 ) Value Selected Target Mean Strength (N/mm2)
WATER TO CEMENT RATIO

Good 6.00 1.65 40 0.425 0.45 0.43 30.00 70.00 0.43 31%

W/C Ratio (Figure-A) W/C Ratio ( For Durability) W/C Ratio (Selected)
PROPORTION OF FINE AGGREGATE

Maximum Size Of Aggregate(MSA) Slump W/C selected %Passing 600 Mic. IS Sieve Proportion Of Fine Aggregate
PROPORTION OF COARSE AGGREGATE CORRECTIONS IN AGGREGATE PROPOTION

Corrections due to coarse aggregates in fine aggregate : % Passing 4.75mm Sieve % Proportion of Fine Aggregate after correction % Proportion of Coarse aggregate after correction. Corrections due to fine aggregates in coarse aggregates: % passing 4.75mm sieve % proportion of fine aggregate after correction c) % proportion of coarse aggregates after corrections
AGGREGATE TO CEMENT RATIO (A/C): INPUT for A/C determination:

Maximum size of aggregate(MSA) Type Of Aggregates FINE -- CA-I -- CA-II W/C ratio selected workability/slump Grading curve no/zone
A/C RATIO

for fine aggregate for coarse aggregate

AGGREGATE PROPORTION

for fine aggregate

for coarse aggregate

A/C PROPORTIONATELY WORK OUT

for fine aggregate for coarse aggregate

TOTAL=(a. + b.) A/C CORRECTED FOR SP.GRAVITY

for fine aggregate for coarse aggregate

TOTAL=(a. + b.) A/C CORRECTED FOR FLAKINESS A/C FINAL WEIGH BATCHING: CEMENT (50 KG) WATER =(50KG * W/C) FA CA-I CA-II = [ 50KG * A/C (FINAL) * % PROPORTION ] = [ 50KG * A/C (FINAL) * % PROPORTION.] = [ 50KG * A/C(FINAL) * % PROPORTION.] `

VOLUMETRIC BATCHING: CEMENT (50 KG) WATER=(50KG * W/C) WATER AFTER CORRECTION DLBD for FA DLBD - for CA-I DLBD for CA-II FINE AGGREGATE BULKAGE OF FINE AGG. FINE AGG. AFTER BULKAGE COARSE AGGREGATE CA-I COASE AGGREGATE- CA-II

Quality shall be the pride of CIVIL ENGINEER

CONCRETE POST MORTEM

Average wt. of 15cm Concrete Cubes in Kg Concrete Density in Kg/Cu.m W/C selected A/C Final Total Constituents Cement Content (Kg)

8 2400 0.45 5.25 7 358

Result Sheet
Remarks of the Result

RECOMMENDED PROPORTION OF FINE AGGEREGATE FOR % PASSING 600 MICRON IS SIEVE

( As per DOE,UK method) MAS=10mm

Free W/C ratio 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0.45
80

Slump=(0 mm -10mm)
% of FA passing 600 mic. IS Sieve

% Prop. of FA for % passing 600 mic. IS-Sieve 100% 80% 60% 40% 15% 24.00 28.00 33.50 42.00 51.50 25.33 29.50 35.25 44.17 54.25 26.67 31.00 37.00 46.33 57.00 28.00 32.50 38.75 48.50 59.75 29.33 34.00 40.50 50.67 62.50 30.67 35.50 42.25 52.83 65.25 32.00 37.00 44.00 55.00 68.00 26.00 30.25 36.13 45.25 55.63

Proportion of FA for the design mix w.r.to % of FA passing 600 mic. IS Sieve & W/C ratio

See note below

80

70

70

60

60

50

100 % Passing line 80% Passing line 60% passing line

50

40

40% passing line 15% passing line

40

30

30

20

20

10 0.3 0.4 0.5 0.6 0.7 0.8 0.9

10

RECOMMENDED PROPORTION OF FINE AGGEREGATE FOR % PASSING 600 MICRON IS SIEVE

( As per DOE,UK method) MAS=10mm Slump=(10 mm-30mm)

Free W/C ratio 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0.45
80

% Prop. of FA for % passing 600 mic. IS-Sieve 100% 80% 60% 40% 15% 26.00 29.50 35.00 27.00 31.00 37.00 28.50 32.50 39.00 29.50 34.00 40.30 30.50 35.00 42.00 32.00 36.50 44.00 33.00 38.00 46.00 26.00 30.25 36.13 45.25 55.63

% of FA passing 600 mic. IS Sieve

Proportion of FA for the design mix w.r.to % of FA passing 600 mic. IS Sieve & W/C ratio

See note below

70

60

50

100 % Passing line 80% Passing line 60% passing line

40

40% passing line 15% passing line

30

20

10 0.3 0.4 0.5 0.6 0.7 0.8 0.9

Aggregate /Cement ratio by weight Degree of workability Grading number W/C ratio by weight 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80

Very low 1 5.6 7.2 2 5 6.4 7.8 3 4.2 4.1 4.9 4 3.2 1 2

Low 3

Low 4 1 2

Medium 3 4 1 2

High 3 4

SA-1 Aggregate Field Test Observatuion Sheet. (Sample-I)

1. JOB 2. TYPE 3. PHYSICAL INSPECTION 4. SAMPLE WT. TAKEN (Natural state ) 5. DRY LOOSE BULK DENSITY 6. SOURCE 7. SPECIFIC GRAVITY : LAB Trials : Crushed CA-II : Sieve Analysis : 4700 : 1.39 : Gumrah quarry : 2.53 gm Kg/lit

Retained on each Sieve IS Sieve WT 40 mm 20mm 10 mm 4.75 mm 2.36 mm 1.18 mm 600 micron 300 micron 150 micron passing 150 micron Wt. of sample (total) 4700 100 0 2670 2030 % 0 57 43

Cumulative Percentage Retained 0 57 100

Passing through Remarks WT 4700 2030 0 % 100 43 0 MAS:30 (25-75)%

8. FINENESS MODULUS 9. SILT CONTENT BY VOLUME BY WEIGHT 10. S.MOISTURE 11. ABSORPTION 12. DATE OF TESTING 13. TESTED BY 14. REMARKS

: : :

-------

NA NA

% at 3 hrs/2hrs/10min % by wt.

: :

7/13/2003 MR. K.B.S Accepted/acceptable subject to washing & / or sieving/rejected

LAB INCHARGE

LAB ENGINEER

SA-2 Aggregate Field Test Observatuion Sheet. (Sample-I)

1. 2. 3. 4. 5. 6. 7. JOB TYPE PHYSICAL INSPECTION SAMPLE WT. TAKEN (Natural state ) DRY LOOSE BULK DENSITY SOURCE SPECIFIC GRAVITY Retained on each Sieve IS Sieve WT 40 mm 20mm 10 mm 4.75 mm 2.36 mm 1.18 mm 600 micron 300 micron 150 micron passing 150 micron Wt. of sample (total) 8. FINENESS MODULUS SILT CONTENT BY 9. VOLUME BY WEIGHT 10. S.MOISTURE 11. ABSORPTION 12. DATE OF TESTING 13. TESTED BY 14. REMARKS 4835 : : : : : : : : 100 ------NA NA % at 3 hrs/2hrs/10min % by wt. 0 0 2665 1735 435 % 0 0 55 36 9 : : : : : : : LAB Trials Crushed CA-I Sieve Analysis 4835 1.44 Gumrah quarry 2.53 Cumulative Percentage Retained 0 0 55 91 100

gm Kg/lit

Passing through Remarks WT 4835 4835 2170 435 0 % 100 100 45 9 0 Fines present

7/13/2003 MR. K.B.S Accepted/acceptable subject to washing & / or sieving/rejected

LAB INCHARGE

LAB ENGINEER

Note:

Mix Design for a particular grade can be designed with two type of coarse aggregate (Single sized CA-I, CA-II) or one type with graded aggregate. The Sieve Analaysis under Sr.No-SA-1 & SA-2 are for coarse aggregate of 30 mm & 15mm nominal single sized respectively.However 20 mm & 10 mm nominal single-sized aggregate or graded aggregate of 20mm nominal size (Sr.No-SA-4) instead can be used. In each case above the % passing for a particular IS SIEVE should conform the prescribed grading limit of IS Code. For fine aggregate with higher finer fines and low FM values, suitable proportion of Crusher (Grit + dust ) can be used with trials to increase FM value. The above effort for making design mix (normal) is a guide only and hence user should take every care to do all related test of aggregate as per IS-codes & go for trials and ascertain the target strength achieved before actual use.

SA-4 Aggregate Field Test Observatuion Sheet. (Sample-II)

1. JOB 2. TYPE 3. PHYSICAL INSPECTION 4. SAMPLE WT. TAKEN (Natural state ) 5. DRY LOOSE BULK DENSITY 6. SOURCE 7. SPECIFIC GRAVITY : LAB Trials : Natural River Gravel, (Rounded + Irregular) : Sieve Analysis : 2985 : 1.67 : Gumrah quarry : 2.53 gm Kg/lit

Retained on each Sieve IS Sieve WT 40 mm 20mm 10 mm 4.75 mm 2.36 mm 1.18 mm 600 micron 300 micron 150 micron passing 150 micron Wt. of sample (total) 2165 72.52931 0 180 1985 790 % 0 6 66 26

Cumulative Percentage Retained 0 6 73 99

Passing through Remarks WT 2985 2805 820 30 % 100 94 27 1 MAS:20 (75-100)%

8. FINENESS MODULUS 9. SILT CONTENT BY VOLUME BY WEIGHT 10. S.MOISTURE 11. ABSORPTION 12. DATE OF TESTING 13. TESTED BY 14. REMARKS

: : :

-------

NA NA

% at 3 hrs/2hrs/10min % by wt.

: :

7/13/2003 MR. K.B.S Accepted/acceptable subject to washing & / or sieving/rejected

LAB INCHARGE

LAB ENGINEER

SA-3 Aggregate Field Test Observatuion Sheet. (Sample-I)

1. 2. 3. 4. 5. 6. 7. JOB TYPE PHYSICAL INSPECTION SAMPLE WT. TAKEN (Natural state ) DRY LOOSE BULK DENSITY SOURCE SPECIFIC GRAVITY Retained on each Sieve IS Sieve WT 40 mm 20mm 10 mm 4.75 mm 2.36 mm 1.18 mm 0 0 55 137 112 218 % 0 0 6 14 11 22 : : : : : : : LAB Trials River Sand (FA) Sieve Analysis gm 1000 Kg/lit 1.77 Vaitarna (Mumbai) 2.96 Cumulative Percentage Retained 0 0 6 19 30 52 Passing through Remarks WT 1000 1000 945 808 696 478 % 100 100 95 81 70 48 19% over size

600 micron
300 micron 150 micron passing 150 micron Wt. of sample (total) 8. FINENESS MODULUS SILT CONTENT BY 9. VOLUME BY WEIGHT 10. S.MOISTURE 11. ABSORPTION 12. DATE OF TESTING 13. TESTED BY 14. REMARKS

230
170 68 10 1000 : : :

23
17 7 1 100 3.74

75
92 99

248
78 10

25
8 1

31%* Zone-I

374

5 % at 3 hrs/2hrs/10min ---% by wt.

: : :

7/13/2003 MR. K.B.S Accepted/acceptable subject to washing & / or sieving/rejected

LAB INCHARGE

LAB ENGINEER

FIG-A: Relation between Free Water-Cement Ratio & Concrete Strength at 28 days for different cement strenghts (IS:10262-1982)
70

28-DAY CONCRETE STRENGTH, N/mm2

60

F E

NOTE: 28 days Strength of Cement tested according to IS: 4031-1968 Curve (A,B,C,D,E,F) A 31.9-36.8 N/mm2 (325-375 kg/cm2) B 36.8-41.7 N/mm2 (375-425 kg/cm2) C 41.7-46.6 N/mm2 (425-475 kg/cm2) D 46.6-51.5 N/mm2 (475-525 kg/cm2)

50

C
40

B A

30

20

E 51.5-56.4 N/mm2 (525-625 kg/cm2) F 56.4-61.3 N/mm2 (575-625 kg/cm2)

10

0.30

0.35

0.40

0.45

0.50

0.55

0.60

0.65

WATER-CEMENT RATIO

0.335 0.635

34.35 12.5

39.25 14.5

44.15 16.5

49.05 18

53.95 19.5

58.85 22