Concrete Mix Design

Presented By:
Dr. Ankur Vishwakarma
Syllabus:

• Concrete Mix Design (Introduction)

• Factors Influencing mix proportion

• Mix Design by ACI method

• Mix Design by IS code method

• Design of high strength concrete

Introduction
Department of Environment (British)
FACTORS AFFECTING MIX DESIGN OF CONCRETE

As per IS 456:2000 and IS 1343:1980 codes, the

design of concrete mix depends on the following
factors:-

• Grade of concrete
• Type of cement
• Maximum nominal size of aggregate
• Grading of combined aggregate
• Maximum water cement ratio
• Workability
• Stability
• Quality control
1. Grade of concrete

• The grade of concrete provides characteristic

compressive strength of concrete.

• T h e g r a d e M 2 0 d e f in e s c h a r a c t e r i s t i c
compressive strength fck of 20 N/m2. Based on
the degree of control accessible at construction
site, the concrete mix should be designed for a
target mean compressive strength (fck) with the
use of proper standard deviation.
2. Type of cement

• The rate of development of concrete strength

is dependent on the type of cement.

• If the strength of cement applied in concrete

becomes greater, the cement content will be
lower. If 43 grade and 53 grade of cement are
utilized, the intake of cement will be saved as
much as 15% & 25% relatively with regard to
33 grade of cement. For concrete of grade
M25, application of 43 and 53 grade of cement
are recommended.
3. Maximum nominal size of aggregate

• The maximum size of C.A is decided with sieve analysis. It is

denoted by the sieve size greater than larger size on which 15%
or more of the aggregate is maintained. The maximum nominal
size of C.A. should not be in excess of one-forth of minimum
thickness of the member.

• For heavily reinforced concrete members similar to ribs of main

beams, the nominal maximum size of the aggregate should
normally be restrained to sum under the minimum clear distance
among the main bars of 5 mm less the minimum cover to the
reinforcement, whichever is lower.

• The concrete workability rises with a surge in the maximum size

of aggregate. But the lower size of aggregates offers greater
surface area for bonding with mortar matrix to provide superior
strength.
4. Grading of combined aggregates

• The proportional ratio of the f in e & coarse

aggregate in a concrete mix is one of the
crucial factors to impact the stre ngth of
concrete.

• For thick concrete, it is necessary that the f ine

& coarse aggregate should graded perfectly. If
the aggregate obtained from natural sources
do not comply with the specif ie d grading, the
parting of two or more aggregate is required.
5. Maximum water/cement ratio

• Abram's water cement ratio def in es that for

any specified condition of the test, the strength
of a workability concrete mix is mainly based
on water cement ratio.

• The compressive strength is increased when

the water cement ratio is reduced.
6. Workability

• Workability of fresh concrete describes the

situation with which a concrete mixture is
blended, transported, arranged, condensed
and f inished devoid of damaging segregation
& bleeding.
7. Stability

• Stability needs low water cement ratio. It is

generally obtained by reducing the water
demand at a specif ied cement content rather
than raising the cement content.

• Water demand can be reduced by controlling

the aggregate grading and applying water
reducing admixtures.
American Concrete Institute (ACI) Method
for Mix Proportioning
• In 1991, the American Concrete Institute (ACI)
published its guidelines for normal, heavy-weight
and mass concrete mix design.

• The absolute volume method of mix design as

described by the ACI method is brief ly presented in
t h is s e ct io n a n d t h e d e s ig n s t e p s f o r m ix
proportioning as recommended by ACI Committee
211.
• The ACI mix proportioning method is suitable for
normal and heavy weight concretes having
maximum 28-day cylinder compressive strength
of 45 MPa and work- ability (slump) range of 25
to 100 mm generally used in the applications
listed in Table 10.18.
• Therefore, ACI has provided a table relating,
1. Nominal maximum aggregate size,
2. Air entrainment and
3. desired slump to the required mixing water
quantity.

• The method further assumes that the optimum

ratio of bulk volume of coarse aggregate to the
total volume of concre te de pe nds only on
maximum size of coarse aggregate and on the
grading (fineness modulus) of fine aggregate.
• For a concrete mix of plastic consistency the
bulk volume of coarse aggregate, for the known
f ineness moduli of f ine aggregate to be used, is
selected from Table 10.19.
• Having de te rmine d the maximum size of
available coarse aggregate, the water-content
for specif ied workability and type of concrete is
selected from Table 10.20.
• This recommendation pertains to concrete
with a degree of workability suitable for usual
reinforced construction (ACI, 2000).

• For pavement concrete which is generally

st iffe r a n d le ss w or ka b le , A C I p e r m it s
recommended values of coarse aggregate to
be enhanced about 10 percent.
• The water-cement ratio is determined as in other
methods to satisfy both strength and durability
requirements.

• In general, lower water-cement ratios produce

stronger, more durable concrete.

• If natural pozzolans such as fly ash are used in the

mix then the ratio becomes a water-cementing
material ratio (cementing material = Portland
cement + pozzolonic material).
• Table 10.21 provides a general estimate of 28
-day compressive strength vs. water-cement
ratio (or water-cementing ratio).
• Values in this table tend to be conservative
(ACI, 2000).

• The air-content in concrete is taken into

account for calculating the volume of f in e
aggregate.

• Maximum water-cement ratio for a variety of

construction conditions are listed in the Table
10.21.

• Construction conditions include concrete

protection from exposure to freezing and
thawing; water tightness of concrete, and
exposure of concrete to deicing salts, brackish
water, sea-water, etc.
 Mix Design Procedure

• The standard ACI mix design procedure can

be divided into 8 basic steps.

• The steps are the following:

1. Selection of Slump
• Generally, the mixes of stiffest consistency
that can still be placed adequately should be
used.
• Normally, the consistency expressed in terms
of slump is specif ie d depending upon the
placing conditions.
• The generally used slump ranges for specif ic
applications are given in Table 10.18.

2. Selection of Maximum Aggregate Size

• In general, the maximum size of the coarse

a ggre ga t e is lim it e d t o on e - t h ird of t h e
minimum thickness of the member and three-
fourth of the minimum clear space between
reinforcing bars.

• The maximum size of the coarse aggregate is

determined by sieve analysis.
3. Determination of Mixing Water and Air Content

• Approximate mixing wa-ter quantity and air

content are selected from Table 10.20 for the
desired slump and nominal maximum size of
aggregate.

4. Computation of Target Mean Compressive

Strength

• The average compressive strength of concrete

from trial batch tests must equal or exceed the
target mean compressive strength f’cr in order
for the concrete proportions to be acceptable.
• The target mean compressive strength f’cr
prime for selecting the mix proportions is larger
of the values given by Eqs (10.10) and (10.11):

f'cr = f’c + 1.34S 10.10

f'cr = f’c + 2.33 S - 3.45 10.11

where f‘c = Specif ie d compressive strength of

concrete, Mpa
S = Standard deviation, Mpa
When f ie ld data to establish a standard deviation
are not available f’cr can be obtained from Table
10.22.
5. Selection of Water-Cement Ratio

• In ge ne ra l, a low e r w a te r-ce m e nt ra tio

produces stronger and more durable concrete.

• If natural pozzolans (such as f ly ash) more

durable cones a water-cementing material
ratio (cement ing materiale Portland cement +
pozzolonic material).
• The water-cement ratio is selected from Table
10.23 for the desired 28-day compressive
strength.
6. Determination of Cement Content

• Cement content computed from the selected

mixing water content and water-cement ratio, is
compared with specif ie d minimum cement
con t e n t f r om d u r a b ilit y con sid e r a t ion s
(generally, 300-360 kg/m³), if applicable.

7. Determination of Coarse Aggregate Content

• The coarse aggregate content is estimated

from Table 10.19 for the indicated nominal
maximum aggregate size and f in e aggregate
fineness modulus.
8. Determination of Fine Aggregate Content

• At this stage of mix design, the volumes of

w a t e r, Port la n d ce m e n t , a ir a n d coa rse
aggregate have been specified.

• Thus, the f in e aggregate volume is just the

re maining v olume and is de te rmine d by
subtracting the sum of absolute volumes of
w a t e r, Port la n d ce m e n t , a ir a n d coa rse
aggregate from the unit volume (1 m³) of
concrete.

• The wet density of fully com- pacted fresh

concrete is given in the Table 10.24.
9. Adjustments for Aggregate Moisture Aggregate

• Volumes are calculated on the basis of oven-

dry unit weights, but are typically batched on
actual weight basis.

• Therefore, aggregate moisture content must be

taken into account to ensure correct amount of
free-water in the mix.

• It is rare to have aggregate at the batch plant

that is in the saturated surface dry condition.

• Trial batches are tested and f inal proportions

are obtained by adjustments.
Example 1. It is required to proportion a concrete mix for
use in a 250 mm thick pavement with mean 28-day
f lexural strength of at least 4.25 MPa and a slump of
the order of 25-50 mm. The coarse aggregate available
is well-shaped having nominal maximum size of 37.5
mm, specif ic gravity of 2.66, dry-rodded mass of
1600kg/m 3 , moisture content = 1.0 per cent, and
absorption = 0.5 per cent. Whereas the f ine ag-gregate
to be used has fineness modulus = 2.60, specific gravity
= 2.64, moisture content = 5 per cent, absorption = 0.7
per cent, the available Portland cement has specif ic
gravity of 3.15.
The other stipulations are,
Air content = 4.0-6.0 percent
Maximum allowable water-cement ratio = 0.44
Minimum cement content = 335kg/m3
Density of water = 1000kg/m3.
Solution
1. Slump:
Specif ie d slump range of 25-50 mm is typical for
concrete pavements.

2. Maximum aggregate size:

Specif ie d maximum aggregate size of 37.5 mm is

well with in the general recommendations for a
pavement application.
3. Estimation of mixing water and air content:

• In order to achieve air content above 2-3 per

cent, concrete must be air-entrained.

• Therefore, from Table 10.20, an air-entrained

concrete with a target slump of 25-50 mm and
a nominal maximum aggregate size of 37.5
mm will require about 150 kg/m3 mixing water.

NOTE: Ade quate quantity of air-e ntraining

admixtures will have to be Note added to achieve
5.0 per cent air content (mean of the specif ie d
range 4.0-6.0 per cent).
• I t sh ou ld be n ot e d t h a t w a t e r- re du cin g
admixtures can reduce water requirements by
about 5 to 10 percent and some admixtures
may also increase the entrained air content by
about 0.5-1.0 percent.
4. Water-cement ratio:

• Since the specif ie d strength is in terms of

f le xural strength, the relationship between
f le xural and compressive strengths, expressed
by Eq. (10. 12) m a y be use d to obta in a n
approximate equivalent compressive strength
in order to use Table 10.23.

fb = 0.623 sqrt (fc) (after ACI Code) (10.12)

w h e re f b a n d f c re pre se n t t h e f le x u ra l a n d
compressive strengths in MPa, respectively.
Therefore, for fb = 4.25MPa, fc = 46.5 MPa. This
v a lu e d oe s n ot a p p e a r in Ta b le 1 0 . 2 3 for
• He nce e ithe r Fig. 10.3 can be re fe rre d or
experience with local conditions or a more
involved determination of the water-cement
ratio can be used.
• Additionally, for concrete exposed to severe
environmental conditions, e.g. freezing and
tha w ing in m oist conditions, e tc. , A C I
recommends a maximum water-cement ratio of
0.45 as listed in Table 10.21.
• In this particular illustrative example, consider
that local experience dictates a water-cement
ratio of around 0.40.
6. Coarse aggregate content:

From Table 10.19 for the nominal maximum

aggregate size of 37.5 mm having reference
specif ic gravity Sca = 2.68 and the f ine aggregate
f in eness modulus of 2.60, the recommended
volume fraction of rodded coarse aggregate is
0.73.

This is to be modif ie d for actual specif ic gravity

S’ca = 2.66.

Thus the volume fraction of rodde d coarse

aggregate to be used is 0.73(2.68/2.66) = 0.735.
This means that the coarse aggregate should
occupy 73.5 per cent of the total volume.

However, this volume of aggregate includes the

volume of air entrapped between the aggregate
particles.

Therefore, the mass of coarse aggregate per

cubic metre of concrete is,

Ca = 0.735 * 1600 = 1176kg

7. Fine aggregate content:

• The f ine aggregate content can be determined

by subtracting the sum of absolute volumes of
mix ingredients from the unit volume of concrete.
Therefore,

• Volume of entrapped air = 5/100 = 0.050 m³,

• Volume of water = W/Sw = 150/1000 = 0.150 m3
• Volume of cement = C / Sc = 375 / (3.15 * 1000)
= 0.119 m³
• Volume of C.A. = Ca /Sca = 1176/(2.66*1000)
= 0.442m3
• Sum of absolute volumes = 0.761 m³
• Thus, volume of f in e aggre gate pe r unit
volume =
1 - 0.761 = 0.239 m3

• Mass of f ine aggregate = 0.239(2.64 * 1000)=

631 kg
8. Adjustments for aggregate moisture:

Since there is moisture in both the coarse and fine

aggregate, their trial batch weights must be
adjusted as,

Weight of fine aggregate = 631 * 1.05 = 663 kg

Weight of coarse aggregate = 1176 * 1.01=1188
kg

T he a m ount of m ixing w a te r a lso ne e ds

adjustment because both the coarse and f in e
aggregate are wet and will contribute to cement
paste.
Free-water present in the aggregate:

Fine aggregate = 631x (0.05-0.007) = + 27.1kg

Coarse aggregate = 1176(0.01 - 0.005) = + 5.9kg

Aggregate free-water = +33.0 kg

Therefore, the amount of mixing water to be

added at the batching plant is =

= stipulated in the mix design report - aggregate

free-water

= 150 - 33 = 117kg.
9. Summary:

The f inal trial batch quantities per cubic metre

of concrete are:

Water- Water Cement Fine Coarse

cement aggregate aggregat
ratio e
0.40 117 375 663 1188
- - 1.0 1.77 3.17

Cement, Sand & Aggregate proportion will be:-

1 : 1.77 : 3.17 by weight
10. Trial batches:

Usually, to make trial batches, something less

than the unit volume is made a typical trial
batch size is 0.03 m³.

Once the trial batch is made, it can be tested for

- slump,
- air content,
- flexural strength,
- compressive strength and
- any other required property.
Thank you