Mix design M40 Grade designed as per IS 10262:2009 & IS 456:2000

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(FOR BANGAlORE REGION)
DESIGNED By: G.PRABHAKARAN M.TECh, QA/QC ENGINEER

Mix proportioning for a concrete of M40 grade is given in A·I to A-ll.
A·I STIPULATIONS FOR PROPORTIONING

a) Grade designation : M40
b) Type of cement : OPC 53 Grade conforming IS 12269
c) Maximum nominal size of aggregate : 20mm
d) Minimum cement content : 360 kg/m³ (IS 456:2000)
e) Maximum water-cement ratio : 0.40 (Table 5 of IS 456:2000)
f) Workability : 100-120mm 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
m) Maximum cement content : 420 kg/m³
n) Chemical admixture type : Super Plasticizer ECMAS HP 890

A-2 TEST DATA FOR MATERIALS
a) Cement used : OPC 53 Grade conforming IS 12269

b) Specific gravity of cement : 3.15

c) Chemical admixture : Super Plasticizer conforming to IS 9103 (ECMAS HP 890)

d) Specific gravity of

1) Coarse aggregate 20mm : 2.67
2) Fine aggregate : 2.65
3) GGBS : 2.84 (JSW)

e) Water absorption:

1) Coarse aggregate : 0.5 %
2) Fine aggregate (M.sand) : 2.5 %

f) Free (surface) moisture:

1) Coarse aggregate : Nil (Absorbed Moisture also Nil)
2) Fine aggregate : Nil

g) Sieve analysis:

1) Coarse aggregate: Conforming to all in aggregates of Table 2 of IS 383
2) Fine aggregate : Conforming to Grading Zone II of Table 4 of IS 383

A-3 TARGET STRENGTH FOR MIX PROPORTIONING
f’ck =fck + 1.65 s
where
f’ck = target average compressive strength at 28 days,
fck = characteristics compressive strength at 28 days, and
s = standard deviation.

From Table I of IS 10262:2009, Standard Deviation, s = 5 N/mm². Therefore, target strength = 40 + 1.65 x 5 = 48.25 N/mm².

A-4 SELECTION OF WATER•CEMENT RATIO
Adopted maximum water-cement ratio = 0.36

From the Table 5 of IS 456 for Very severe Exposure maximum Water Cement Ratio is 0.40
0.36 < 0.40 Hence ok. A-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) Estimated water content for 100 mm slump = 186+ (6/186) = 197 litre.

(Note: If Super plasticizer is used, the water content can be reduced upto 20% and above.)

Based on trials with Super plasticizer water content reduction of 23% has been achieved, Hence the arrived water content = 197-[197 x (23/100)] = 151 litre.

A-6 CALCULATION OF CEMENT CONTENT
Adopted w/c Ratio = 0.36
Cement Content = 151/0.36 = 420 kg/m³
From Table 5 of IS 456, Minimum cement content for ‘Very severe’ exposure conditions 360kg/m³

420 kg/m³ > 360 kg/m³ hence ok.

A-7 PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE AGGREGATE CONTENT
From Table 3 of (IS 10262:2009) Volume of coarse aggregate corresponding to 20 mm size aggregate and fine aggregate (Zone II) for water-cement ratio of 0.50 =0.62 .

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 0.02 (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 0.44 = 0.65

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 =0.65 x 0.9 =0.585

Volume of fine aggregate content = 1 – 0.585= 0.415

A-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}
= 151/{1 x 1000}
= 0.151m³

d) Volume of chemical admixture = 1.89 litres/ m³ (By Trial and Error Method used 0.4% by the weight cement)

e) Volume of all in aggregate = [a-(b+c+d)]
= [1-(0.133+ 0.151+ 0.0045)]
= 0.7115 m³

f) Mass of coarse aggregate= e x Volume of Coarse Aggregate x Specific Gravity of Fine Aggregate x 1000
= 0.7115x 0.585 x 2.67 x 1000
= 1111 kg/m³

g) Mass of fine aggregate= e x Volume of Fine Aggregate x Specific Gravity of Fine Aggregate x 1000
= 0.7115 x 0.415 x 2.60 x 1000
= 768 kg/m³

A-9 MIX PROPORTIONS
Cement = 336 kg/m³
GGBS = 84 kg/m³ (20% By Total weight of Cement)
Water = 151 l/m³
Fine aggregate = 768 kg/m³
Coarse aggregate 20mm = 889 kg/m³
12mm = 222 kg/m³ (20% By Total weight of Coarse Aggregate)
Chemical admixture = 1.89 kg/m³ (0.4% by the weight of cement)
Density of concrete = 2451 kg/m³
Water-cement ratio = 0.41
Mix Proportion By weight = 1:1.83:2.65

NOTE – Aggregates should be used in saturated surface dry condition. If otherwise, when computing the requirement of mixing water, allowance shall be made for the free (surface) moisture contributed by the fine and coarse aggregates. On the other hand, if the aggregates are dry the amount of mixing water should be increased by an amount equal to the moisture likely to be absorbed by the aggregates. Necessary adjustments are also required to be made In mass of aggregates. The surface water and percent water absorption of aggregates shall be determined according to IS 2386

A-10 The slump shall he measured and the water content and dosage of admixture shall be adjusted for achieving the required slump based on trial , if required. The mix proportions shall he reworked for the actual water content and checked for durability requirements.

A-11 Two more trials having variation of ± 10 percent of water-cement ratio in A-10 shall be carried out and a graph between three water-cement ratios and their corresponding strengths shall he plotted to work out the mix proportions for the given target strength for field trials. However, durability requirement shall be met.

We are thankful to G. Prabhakaran for sharing this information with us on engineeringcivil.com. We hope this would be of great significance to civil engineers seeking information on M40 design mix in Bangalore region.

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