HLY-GEN-02: Dry-Cast Zero-Slump Concrete Mix Design & Vebe Consistency Norms for Precast Plants

1. Binder Quantity & Water-Cement Ratio Redlines

Cement Grade: Ordinary Portland Cement (OPC Grade 42.5 or 52.5), dosage 320–380 kg/m³.

Water-Cement Ratio (W/C): Strictly maintained at 0.30 to 0.35; unauthorized water trimming is forbidden.

Coarse Aggregate: Clean crushed stone (5–15 mm for small pipes, 5–25 mm for large pipes); flakiness index $\le$ 8%, mud content $\le$ 1.0%.

Fine Aggregate: Medium-coarse sand, fineness modulus 2.4–2.9, silt $\le$ 2.0%.

Sand Ratio: Maintain between 38% and 42% to produce dense, smooth inner slurry skin under roller compaction.

Fill conical slump cone on Vebe vibrating table; swing clear acrylic surcharge disc onto surface; start table vibration.

Time until slurry completely wets the bottom face of the transparent disc: target reading is 25 to 35 seconds.

Cement Grade: Ordinary Portland Cement (OPC Grade 42.5 or 52.5), dosage 320–380 kg/m³.

Water-Cement Ratio (W/C): Strictly maintained at 0.30 to 0.35; unauthorized water trimming is forbidden.

Coarse Aggregate: Clean crushed stone (5–15 mm for small pipes, 5–25 mm for large pipes); flakiness index $\le$ 8%, mud content $\le$ 1.0%.

Fine Aggregate: Medium-coarse sand, fineness modulus 2.4–2.9, silt $\le$ 2.0%.

Sand Ratio: Maintain between 38% and 42% to produce dense, smooth inner slurry skin under roller compaction.

Fill conical slump cone on Vebe vibrating table; swing clear acrylic surcharge disc onto surface; start table vibration.

Time until slurry completely wets the bottom face of the transparent disc: target reading is 25 to 35 seconds.