Final Report Design Mix

IDAX CONSULTING & RESEARCH GROUP, BBSR
JSPL Project, Angul
DESIGN MIX OF M-25 GRADE OF CONCRETE FOR OATS BATCHING PLANT

Name of the Work: CONSTRUCTI ON OF CIVIL STRUCTURES FO R JSPL PROJECT, ANGUL
Date: 09.05.2012 ODYSSEY ADVANCED TELEMATICS SYSTEMS (OATS) JSPL Project, Angul.
CLIENT: JINDAL STEEL & POWER LTD., ANGUL CONSULTANT: BVIL
TESTING AGENCY: IDAX CONSULTING & RESEARCH GROUP

Tel: +91-674-3199991, 2360019, Fax: +91-674-2360019 E-mail: info@idaxconsulting.com Web: www.idaxconsulting.com
Plot No.- 50/6, Duplex-E, Brundaban Enclave, VSS Nagar, Bhubaneswar-751007, Odisha (INDIA).
Date of Test: 10.04.2012 Date of Submission of Report: 09.05.2012
Design Mix_M25_09.05.2012
Odyssey Advanced Telematics Systems (OATS)
IDAX CONSULTING & RESEARCH GROUP, BBSR
JSPL Project, Angul
Recommendations: From the above 3 Trail Mixes it is concluded that the Trial Mix-I is fit for the concreting purpose. So the Trial Mix-I can be adopted for the Building concreting work. The abstract of the final Trial Mix-I is given separately. The mix designed proportion of cement concrete (Mix-I) is based on the quality of the ingredient materials such as water, cement, fine aggregate and coarse aggregates received in this laboratory. More over as strength of concrete of the said Mix is directly related to the strength of cement mentioned at A-1 (table- II), cement having the same strength must be used while adopting the above Mix design of concrete. Aggregates are used in (S.S.D) saturated surface dry condition in the above Mix-I
NB: The above test reports are based on the sample received by our laboratory. The test results relates only to the items tested. The report shall not be reproduced except in full without the approval of the testing laboratory.
For IDAX CONSULTING & RESEARCH GROUP
(Sr. Scientist)
IDAX CONSULTING & RESEARCH GROUP

(An ISO 9001:2008 Certified Company) Plot No.- 50/6, Duplex-E, Brundaban Enclave, VSS Nagar, Bhubaneswar-751007, Odisha. www.idaxconsulting.com
DESIGN MIX / TRIAL MIX REPORT (IS 456:2000 & IS 10262:1999)

DETAILS OF PROJECT / TRIAL: OATS BATCHING PLANT, JSPL PROJECT, ANGUL TRAIL NO. : 001 LOCATION : IDAX LAB, BHUBANESWAR DATE OF TRIAL BATCHING TIME AIR TEMPERATURE BATCH SIZE SSD (KG) PER 1M3 414 794 530 545 4 169 2456 WATER ABSORPTION % 0.31 0.31 0.72 QTY 2.46 1.64 3.92 DRY PER 1M 414 792 528 541 4 177 2456
3
: : : =
10.04.2012 17:00 0 C 29 0.025 M3 QTY / BATCH WT. 10.35 19.82 13.23 13.54 0.10 4.36 2456 REMARKS
MIX PROPORTION (KG): NAME OF MATERIAL SOURCE / TYPE MOISTURE % 0.15 0.15 0.10 -
DESIGN ADJUSTMENT PER 1M 414

3
CEMENT JSPL MINERAL ADM1 MINERAL ADM2 CA : 20MM JSPL CA : 10MM JSPL FA : SAND BRAHMANI FA : CRF ADMIXTURE 1 SIKA ADMIXTURE 2 WATER JSPL THEORETICAL PLASTIC DENSITY FREE W/C = OBSERVATIONS: CONCRETE TEMPERATURE : ACTUAL PLASTIC DENSITY : SETTING TIME OF CONCRETE : 0.42
QTY 1.19 0.79 0.54 -
793 529 542 4 175 2456
JAGANNATH CRUSHER JAGANNATH CRUSHER PRADHAN ENTERPRISES PLASTIMENT-R1
ADMIXTURE DOSAGE =
1.00 %
0 32 C KG/M3 Initial (hr:min) -
COHESIVE / SEGREGATING / BLEEDING AIR CONTENT (%) : 140 min YIELD : 2% Final (hr:min) 135 mm 110 mm 100 mm WEIGHT (KG.) 8.38 8.40 8.42 8.28 8.26 8.31 DENSITY 3 (KG/M ) 2483 2489 2495 2453 2447 2462 STRENGTH 2 (N/MM ) 23.07 23.16 22.80 34.58 34.89 34.44 AVERAGE STRENGTH (N/MM2) 255 min
WORKABILITY
INITIAL SLUMP SLUMP AFTER 30 MINS SLUMP AFTER 60 MINS DATE OF CAST DATE OF AGE (DAYS) SIZE (M3) TEST 7 7 7 28 28 28 0.15x0.15x 0.15= 0.003375 0.15x0.15x 0.15= 0.003375
COMPRESSIV VE STRENGTH DATA
REF NO.
LOAD (KN)
OATS-JSPL PROJ10 04 2012 10.04.2012 TM001M25
16.04.2012
519 521 513 778 785 775
23.01
07.05.2012
34.64
COMMENTS : NB:
1.This test report is based on the samples received by our laboratory. 2. The test result relates only to the items tested. 3. The report shall not be reproduced except in full without the approval.
Sign: QC Engineer
SUB-CONTRACTOR
CONTRACTOR
CLIENT
CONSULTANT
IDAX CONSULTING RESEARCH GROUP
JSPL Project, Angul
Test on materials for cement concrete Mix-Design for
M25 grade.
I:-Water-The sample of water was tested As per IS:456-2000 and IS:3025 Name of Test Determination of pH value A-1:- Cement: Brand: Sl. No. 1 2 3 4 5 JINDAL Physical Properties Observed value PSC 29.50% 140 minutes 255 minutes 3.15 Requirement as per IS:-455 -1989 ------Not less than 30 minutes Not more than 600 minutes ----
Observed value 7.2
Requirement as per I:S:456-2000 Not less than 6
Type and grade Standard consistency Initial setting time Final setting time Specific gravity
6 Compressive strength
Compressive strength of cement at
Load Compressive in Ton strength in kg/cm
Average Compressive strength in kg/cm
Requirement as per IS:-455 -1989
3-days
7-days
28-days
12.0 10.5 11.0 16.5 15.5 15.0 21.0 20.5 21.5
240 210 220 330 310 300 425 410 430
223.333
Min.-160
313.333
Min.-220
421.667
Min.-330
Above test results pertain to the samples received in this laboratory.
JSPL Project, Angul
II:-Fine aggregates (sand):The sample of sand was tested as per IS:383-1970 and IS:2386-1963
1) Grading test:Weight of sample taken= IS sieve Size in mm.
500
gms.
Cumulative Weight of % of % by Weight of material retained material material retained in gms Retained 0.0 0.000 8.400 14.700 28.400 68.400 93.600 100.0 "Zone III"
10 0.00 0.00 4.75 0.00 0.000 2.36 42.00 8.400 1.18 31.50 6.300 0.6 68.50 13.700 0.3 200.00 40.000 0.15 126.00 25.200 PAN 32.00 6.400 Fine Aggregate sample conforms to grading 2)Fineness of Modullus = 2.04 3) Specific gravity = 2.70 4) Bulk density = 1630 kg/cum 5) Water Absorption = 0.72 %
Source: Brahmani % by Percentage Passing Weight of IS-383, 1970 material Passing Zone-I Zone-II 100 100 100 90--100 90--100 100 60--95 75--100 91.6 30--70 55--90 85.3 15--34 35--59 71.6 5--20 8--30 31.6 0--10 0--10 6.4 --0 as per table 4 of IS: 383-1970
as per
Zone-III 100 90--100 85--100 75--100 60--79 12--40 0--10 --
III:-Coarse Aggregates :The sample of coarse aggregate was tested as per IS:383-1970 and IS: 2386-1963 1)Sieve analysis: (60% 20mm & 40% 10mm)
Weight of sample taken= IS sieve Size in mm. 40 20 12.5 10 4.75 PAN 5000 gms. Source: Cumulative % of material Retained 0.0 1.7 ---11.9 95.9 98.8 % by Weight of material Passing 100 98.30 ---88.10 4.10 1.20 Jagannath Crusher
Weight of % by Weight of material retained material retained in gms 0.0 85.0 ---510.0 4200.0 145.0 0.00 1.70 ---10.20 84.00 2.90
Required percent passing of Aggregate as per IS:383-1970 40mm 95-100 30-70 ---10-35 0-5 ---20mm 100 95-100 ---25-55 0-10 ---10mm ------100 85-100 0-20 0-5
The coarse aggregate sample conforms to 20mm graded aggregate as per Table-2 of IS:383-1970 2) Bulk density = 1680 kg/cum 3) Water absorption = 6) Specific gravity = 4) Crushing value = 5) Impact value = 0.31 2.80 17.5 17 22.6 % % %
Max : 30% by wt. for wearing surfaces such as runway, railways & pavements and 45% by wt. for other concrete as per IS:383-1970. Max : 30% by wt. for wearing surfaces such as runway, railways & pavements and 50% by wt. for other concrete as per IS:383-1970.
7) Abrasion Value =
Above test results pertain to the samples received in this laboratory
TRIAL MIX - I
JSPL Project, Angul
Trial Mix-I
A-2-Design Stipulations of M25 grade cement concrete as per IS: 10262-1982 & IS: 456-2000 25 N/mm 20 mm (angular) 100-135 mm Good "Moderate" 421.667 kg/cm a) Characteristic compressive strength after 28 days b) Maximum size of aggregate c) Degree of workability (slump) d) Degree of quality control e) Type of exposure f) Compressive strength of cement at 28days A-3-Target Mean strength of concrete:For a tolerance factor of 1.65 and using table-8 of IS:456-2000, the target mean strength for M-25 grade concrete is = 25 + 1.65 x 4.0 = A-4-Selection of water cement Ratio: - (W/C) From Fig.2 of IS:10262-1982, the free water cement ratio required for the target mean strength of 31.6 N/mm is 0.42 which is less than the maximum value of as prescribed "Moderate" for exposure at table-5 of IS:456-2000. A-5-Selection of water & Sand content:From Table-4 of IS:10262-1982, for 20mm maximum size aggregate and sand conforming to grading Water content per cubic metre of concrete = Admixture Dose = 174 4 kg/m kg/m "Zone III" (Source: Jindal Tanker) (Make: SIKA-Plastiment R1) 35 %
31.6 N/mm
0.6
And sand content as percentage of total aggregate by absolute volume= For change in W/C & value for fine aggregate (sand) conforming to following adjustments are required. I) For decrease in W/C ratio= 0.6 "Zone III" the
Adjustment required in percentage (%) sand in total aggregate 0.42 = 0.18 0.18 x
20
3.6
1.50 ii) For sand conforming to zone III of table-4 of IS:383-1970 Total 5.10 Therefore required sand content as percentage (%) of total aggregate by absolute volume= 35 5.10 = 29.90 % Coarse aggregate = 100 29.90 = 70.10 % Required water content = 174 kg/m
JSPL Project, Angul
A-6-Determination of cement content:Water cement ratio (W/C) = Water requirement = Cement requirement =
Or, say= 0.42 174 414.29 414.00
kg/cum kg/cum kg/cum
A-7-Determination of Fine and Coarse aggregate content:From Table 3 for the specified maximum size of aggregate of 20mm, the amount of entrapped air in the wet concrete is= (%) percent. 2 Taking this into account and applying equation from 3.5.1 of IS:10262-1982 .
Determination of fine aggregate (fa): 0.98 ={174+(414/3.15)+(1/0.299)x(fa/2.70)}x1/1000 fa= 544.582 Kg

Or, say= 545 Kg
Determination of Coarse aggregate (Ca) 0.98 ={174+(414/3.15)+(1/0.701)x(Ca/2.80)}x1/1000 Ca= 1324.049 Kg

Or, say= 1324 Kg
Water 174 0.420 21.01 21.01 Kg Kg Kg
Cement 414 1 50 50 Kg(1Bag) Kg(1Bag) Kg/cum
Fine aggregate 545 1.316 65.82 1.43 Kg Cft Kg/cum
Coarse aggregate 1324 3.198 159.90 3.36 Kg Cft Kg/cum
Remarks
% wt. w.r.t Cement By weight By Volume
Admixture Dose =
Kg/cum
JSPL Project, Angul
A-9-Observation of Trial Mix:a)Slump= 110mm b) Compressive strength of

(Satisfactory as per design)
M25 grade preliminary cement concrete (15cm) cubes.

Compressive Strength in kg/cm 230.667 231.556 228.000 3457.778 3488.889 3444.444 3463.704 230.074 Average compressive strength in kg/cm
Sl.No.
1 2 3 4 5 6
Reference Mix1 Mix1 Mix1 Mix1 Mix1 Mix1
Age in days
Load in M T 51.9
7-days
52.1 51.3 778.0
28-days
785.0 775.0
Remarks:- The mix designed proportion of cement concrete (Mix-I) is based on the quality of the
ingredient materials such as water, cement, fine aggregate and coarse aggregates received in this laboratory. More over as strength of concrete of the said Mix is directly related to the strength of cement mentioned at A-1 (table- II), cement having the same strength must be used while adopting the above Mix design of concrete. 2:-Aggregates are used in (S.S.D) saturated surface dry condition in the above Mix-I
TRIAL MIX - II
JSPL Project, Angul
Trial Mix-II
A-2-Design Stipulations of M25 grade cement concrete as per IS: 10262-1982 & IS: 456-2000 25 N/mm 20 mm (angular) 150-180 mm Good "Moderate" 421.667 kg/cm a) Characteristic compressive strength after 28 days b) Maximum size of aggregate c) Degree of workability (slump) d) Degree of quality control e) Type of exposure f) Compressive strength of cement at 28days A-3-Target Mean strength of concrete:For a tolerance factor of 1.65 and using table-8 of IS:456-2000, the target mean strength for M-25 grade concrete is = 25 + 1.65 x 4.0 = A-4-Selection of water cement Ratio: - (W/C) ( Varying the pre-selected free W/C by(+) 10%as per IS : 10262 - 1982 ) From Fig.2 of IS:10262-1982, the free water cement ratio required for the target mean strength of 31.6 N/mm is 0.50 which is less than the maximum value of as prescribed "Moderate" for exposure at table-5 of IS:456-2000. A-5-Selection of water & Sand content:From Table-4 of IS:10262-1982, for 20mm maximum size aggregate and sand conforming to grading Water content per cubic metre of concrete = Admixture Dose = 200 4 kg/m kg/m "Zone III" (Source: Jindal Tanker) (Make: SIKA-Plastiment R1) 35 %
31.6 N/mm
0.6
20
JSPL Project, Angul
Or, say= 0.5 200 400.00 400.00

Or, say= 555 Kg

Or, say= 1252 Kg
Water 200 0.500 25.00 25.00 Kg Kg Kg
Remarks
Admixture Dose =
Kg/cum
JSPL Project, Angul

(Not fit for Pile Concrete)

Sl.No.
1 2 3 4 5 6
Age in days
Load in M T 44.0
7-days
42.5 45.0 65.5
28-days
62.0 68.5
Remarks:- The mix designed proportion of cement concrete (Mix-II) is based on the quality of the
ingredient materials such as water, cement, fine aggregate and coarse aggregates received in this laboratory. More over as strength of concrete of the said Mix is directly related to the strength of cement mentioned at A-1 (table- II), cement having the same strength must be used while adopting the above Mix design of concrete. 2:-Aggregates are used in (S.S.D) saturated surface dry condition in the above Mix-II
TRIAL MIX - III
JSPL Project, Angul
Trial Mix-III
A-2-Design Stipulations of M25 grade cement concrete as per IS: 10262-1982 & IS: 456-2000 25 N/mm 20 mm (angular) 80-110 mm Good "Moderate" 421.667 kg/cm a) Characteristic compressive strength after 28 days b) Maximum size of aggregate c) Degree of workability (slump) d) Degree of quality control e) Type of exposure f) Compressive strength of cement at 28days A-3-Target Mean strength of concrete:For a tolerance factor of 1.65 and using table-8 of IS:456-2000, the target mean strength for M-25 grade concrete is = 25 + 1.65 x 4.0 = A-4-Selection of water cement Ratio: - (W/C) ( Varying the pre-selected free W/C by(-) 10%as per IS : 10262 - 1982 ) From Fig.2 of IS:10262-1982, the free water cement ratio required for the target mean strength of 31.6 N/mm is 0.40 which is less than the maximum value of as prescribed "Moderate" for exposure at table-5 of IS:456-2000. A-5-Selection of water & Sand content:From Table-4 of IS:10262-1982, for 20mm maximum size aggregate and sand conforming to grading Water content per cubic metre of concrete = Admixture Dose = 165 4 kg/m kg/m "Zone III" (Source: Jindal Tanker) (Make: SIKA-Plastiment R1) 35 %
31.6 N/mm
0.6
20
JSPL Project, Angul
Or, say= 0.40 165 412.50 413.00

Or, say= 545 Kg

Or, say= 1350 Kg
Water 165 0.400 19.98 19.98 Kg Kg Kg
Remarks
Admixture Dose =
Kg/cum
JSPL Project, Angul

(Not fit for Pile Concrete)

Sl.No.
1 2 3 4 5 6
Age in days
Load in M T 59.5
7-days
61.0 60.0 85.0
28-days
84.5 85.5
Remarks:- The mix designed proportion of cement concrete (Mix-III) is based on the quality of the
ingredient materials such as water, cement, fine aggregate and coarse aggregates received in this laboratory. More over as strength of concrete of the said Mix is directly related to the strength of cement mentioned at A-1 (table- II), cement having the same strength must be used while adopting the above Mix design of concrete. 2:-Aggregates are used in (S.S.D) saturated surface dry condition in the above Mix-III

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IDAX CONSULTING & RESEARCH GROUP, BBSR

JSPL Project, Angul

DESIGN MIX OF M-25 GRADE OF CONCRETE FOR OATS BATCHING PLANT

CLIENT: JINDAL STEEL & POWER LTD., ANGUL CONSULTANT: BVIL

TESTING AGENCY: IDAX CONSULTING & RESEARCH GROUP

Date of Test: 10.04.2012 Date of Submission of Report: 09.05.2012

Odyssey Advanced Telematics Systems (OATS)

IDAX CONSULTING & RESEARCH GROUP, BBSR

JSPL Project, Angul

For IDAX CONSULTING & RESEARCH GROUP

Odyssey Advanced Telematics Systems (OATS)

IDAX CONSULTING & RESEARCH GROUP

DESIGN MIX / TRIAL MIX REPORT (IS 456:2000 & IS 10262:1999)

DESIGN ADJUSTMENT PER 1M 414

QTY 1.19 0.79 0.54 -

793 529 542 4 175 2456

JAGANNATH CRUSHER JAGANNATH CRUSHER PRADHAN ENTERPRISES PLASTIMENT-R1

0 32 C KG/M3 Initial (hr:min) -

COMPRESSIV VE STRENGTH DATA

OATS-JSPL PROJ10 04 2012 10.04.2012 TM001M25

519 521 513 778 785 775

IDAX CONSULTING RESEARCH GROUP

JSPL Project, Angul

Test on materials for cement concrete Mix-Design for

Observed value 7.2

Requirement as per I:S:456-2000 Not less than 6

Compressive strength of cement at

Load Compressive in Ton strength in kg/cm

Average Compressive strength in kg/cm

Requirement as per IS:-455 -1989

12.0 10.5 11.0 16.5 15.5 15.0 21.0 20.5 21.5

240 210 220 330 310 300 425 410 430

Above test results pertain to the samples received in this laboratory.

Odyssey Advanced Telematics Systems (OATS)

IDAX CONSULTING RESEARCH GROUP

JSPL Project, Angul

1) Grading test:Weight of sample taken= IS sieve Size in mm.

Above test results pertain to the samples received in this laboratory

Odyssey Advanced Telematics Systems (OATS)

IDAX CONSULTING RESEARCH GROUP

JSPL Project, Angul

Odyssey Advanced Telematics Systems (OATS)

IDAX CONSULTING RESEARCH GROUP

JSPL Project, Angul

kg/cum kg/cum kg/cum

Determination of fine aggregate (fa): 0.98 ={174+(414/3.15)+(1/0.299)x(fa/2.70)}x1/1000 fa= 544.582 Kg

Determination of Coarse aggregate (Ca) 0.98 ={174+(414/3.15)+(1/0.701)x(Ca/2.80)}x1/1000 Ca= 1324.049 Kg

Water 174 0.420 21.01 21.01 Kg Kg Kg

Cement 414 1 50 50 Kg(1Bag) Kg(1Bag) Kg/cum

Fine aggregate 545 1.316 65.82 1.43 Kg Cft Kg/cum

Coarse aggregate 1324 3.198 159.90 3.36 Kg Cft Kg/cum

% wt. w.r.t Cement By weight By Volume

Odyssey Advanced Telematics Systems (OATS)

IDAX CONSULTING RESEARCH GROUP

JSPL Project, Angul

A-9-Observation of Trial Mix:a)Slump= 110mm b) Compressive strength of

M25 grade preliminary cement concrete (15cm) cubes.

Reference Mix1 Mix1 Mix1 Mix1 Mix1 Mix1

52.1 51.3 778.0

Above test results pertain to the samples received in this laboratory.

For IDAX CONSULTING & RESEARCH GROUP

Odyssey Advanced Telematics Systems (OATS)

IDAX CONSULTING RESEARCH GROUP

JSPL Project, Angul