mix design of concreteMix design as per M.O.R.T. & H. (sec 1700) / IS 10262-1982 / IS 456-200011.1Grade of concrete mix design desired N/mm235N/mm21.2Charateristic compressive strength Kg/cm2 at 28 days350Kg/cm21.3Nominal max size of aggregate - mm20mm1.4Type of course aggregatecrushed1.5Type or Brand of cementOPC Grade 431.6Type of structurePile Cap1.7Type of sand ( fine aggregate )uncrushed1.8Degree of workability ( slump ) mm40 - 751.9Degree of quality controlGood1.1Type of ExposureModerate1.11Specific gravity of materialsa)cement3.15b)sand2.7c)coarse agg2.71.12Target mean strength of concrete M.O.R.T. & H. sec 1700, table 1700 - 547N/mm21.13Water cement ratio ( fig I - IS 10262 - 1982 )0.3251.14Water req per cubic meter of concrete ( table 1 ) table 4 - (IS 10262-1982)186Kg / Lit1.15Cement test resultsa)Setting time:initial132min:final275minb)Compressive strength:3 days290Kg/cm27 days405Kg/cm22Grading2.1Grading of course aggregates is given in table Itable IIS sieve sizes mmAnalisis of coarse agg fraction ( percent passing )PercentageCombinedIIIIII20 mm10 mm50%50%100%4010010050501002097.810048.95098.9101.679.30.839.6540.44.759.804.94.9Note : Combined gradings conforms IS 383 - 19702.2Fine aggregates ( sand )table IIIS sieve size mmPercent passing by weightRemarks10.00100conforms grading zone II of table - 4 of IS 383-19704.7597.3for grading zone II2.3686.81.1865.70.6053.30.3011.90.153.1F.M.3.183Calculations for Mix Design3.1Target mean strength of concrete N/mm247N/mm23.1.1Selection of water cement ratioFrom fig 1 of IS 10262 - 1982 for the target mean strength of 47.0 N / mm2, water cement ratio required is 0.325 which is lower than max 0.50 water cement ratio for moderate exposure conditions as per IS 456 - 2000so w/c ratio =0.325max=0.53.1.2Selection of water and sand contentFrom table 4 of 10262 - 1982 for 20mm nominal max size aggregate water content per cubic meter of concrete is 186 kg / lit and sand content as percentage of total aggregate by absolute volume is=35%change in values in water cement ratio, compacting factor and sand belonging to grading zone IIChange in conditionsAdjustments required inwater content percentsand in total aggregate percentFor decrese in water cement ratio by ( 0.60 - 0.379) see next page i.e. 0.2210.0-4.4For increase in compacting factor ( 0.93 - 0.80 ) i.e. 0.123.90.0For sand conforming to zone II of IS 383 - 19700.00.0Reduce water while using super plastisizer 1.5 lit / m3-22.5total3.9and-4.4-22.5lit/m3Therefore required sand content as percentage of total aggregate by absolute volume=30.6%Required water content=170.75lit / m33.1.3Determination of cement contentWater cement ratio=0.325Water=170.75lit / m3Cement=525.40kg / m3525.40kg cement is higher than max limit of 450 kg /m3, and as such trail is made with cement kg /m3 and w/c adopted as per equation450Water cement ratio adopted for 450 kg cement=0.379therefore cement required=450.0kg / m33.1.4Determinatin of coarse and fine aggregatesFrom table 3 of IS 10262-1982 for max size aggregate of 20 mm the amount of entrapped air in wet concrete is 2 % (assumed ) Takng this equation into account applying equation as per IS 10262,3.5.1,the calculations are as follows1*2%=0.023.1.4.1.For fine aggregatesV=[W+C+1.fa]*1ScpSfa1000substituting the values0.98m3=[170.75+450.0+1.fa]*13.150.3062.71000980=[170.75+142.86+fa]0.826980=[313.61+fa]0.826666.39=fa0.826550.57=faso fine aggregates=550.57kgFor coarse aggregatesV=[W+C+1.Ca]*1Sc1 - pSca10000.98m3=[170.75+450.0+1.Ca]*13.150.6942.71000980=[170.75+142.8571428571+Ca]1.8738980=[313.61+Ca]1.8738666.39=[Ca]1.87381248.68=Caso coarse aggregates=1248.68kgProportions comes out aswatercementfine aggregatecoarse aggregate170.75450.0550.571248.68ratio0.37911.222.77

design of roadMARSHALL TEST RESULTSNo of blows75each endMaterials% ageSp. GravityBitumen temp170oC10 mmW155G12.620Aggregate temp.160-175oC5.6 mmW215G22.640Mixing temp160oCFine aggW328G32.622Compaction temp150oCHydrated limeW42G42.610Calibration factor of proving ring3.55Grade of bitumenCRMB - 601.02Bulk Sp.Gr of total mix ( Gsb = 100 / (W1/G1+W2/G2+W3/G3+W4/G4)2.623abcdefghijklmnopqrstS.noThickness of specimen (mm) measured (a)Wt of mould (gms) in air (b)Wt of mould (gms) in water ( c)Wt of mould SSD (gms) in air ( d)Vol of mould (cc) (e = d - c)Bulk Density (gm/cc) ( f=b/e)Avg. Density ( g = avg of f)GMM (max sp gr of mix without air voids)(h)%age of bitumen by mix (i)Bitumen by weight of aggregate (%) ( j= (i/(100-i)*100)% age of aggregate by wt of mixAir voids in mix Va (%) (l=(h-g)/h)*100)Total voids in mineral aggregates (Vma) (%) (m=100-((k-g)/Gsb)Voids filled with bitumen(Vfb)(%) (n=((m-l)/m)*100)Reading of proving ring (o)Observed ( p = n x cal. Factor)Correction factor height (q)Corrected load (r = p x q )Flow (mm) (s)Avg flow (mm) (t = avg of s)166.5120468312095262.28929010300.969882.866.512066861211.5525.52.2952.2942.4324.54.71295.55.6816.4965.5829510470.96100532.96612036851208.5523.52.29828510120.969712.923

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