Module 6 (Production of Concrete, Design of Concrete Mixes) - 4 PDF

Module No.
6
• To design a concrete mix, the following information
should be known before hand:
By • grade of concrete
• type of cement
Prof. Dr. Fareed Ahmed Memon • size and type of aggregates available
• minimum and maximum cement content
• desired workability
• type and amount of admixture used
• type of curing etc
Prepared By: Prof. Dr. Fareed Ahmed Memon
• A process of selecting suitable ingredients of concrete and

determining their relative quantities.
• Proportioning of various ingredients of a concrete mix is • The mix design methods being followed in different
of utmost importance, as it is the only means of achieving countries are mostly based on empirical relationships,
the fundamental requirements of quality and economy. charts and graphs developed from extensive experimental
investigations.
• The main objects of designing the concrete mix are:
• To attain the minimum compressive strength at specified • Any mix design procedure however will provide a first
age approximation of the proportions and must be checked by
trial batches.
• To achieve the workable concrete mix
• To obtain a cohesive mix which offsets the possibility of

bleeding, segregation and honey combing.
• To achieve durability for particular site conditions and
• To obtain maximum economy

• Concrete mixes can be designed by using any of the
following methods
• British D.O.E. Method of Mix design
STEP NO. 1 Determination of Target Mean Strength
• American Concrete Institute’s mix design procedure
• fm = fc + M
• Where, fm = the target mean strength

• fc = the specified characteristic strength
• M = the margin
• The value of the margin (M) can be derived from the

calculation:

• The British method of concrete mix design, popularly
referred to as DoE method, is used in UK and other parts • British D.O.E. Method of Mix design
of world. STEP NO. 1 Determination of Target Mean Strength
• Originates from the Road Note No 4, published in Great • M= k x s
Britain in 1950. • Where, k = a value appropriate to the % age defectives
permitted below the characteristic strength
• In 1975, the note was replaced by the Design of Normal • s = the standard deviation
Concrete Mixes, published by the British Department of • The value of k is taken as :
Environment. • k for 10% defective = 1.28
• k for 5% defective = 1.64
Prepared By: Prof. Dr. Fareed Ahmed Memon • k for 2.5% defective = 1.96
• k for 1% defective = 2.33
Figure: Normal Distribution of concrete strength

STEP NO. 1 Determination of Target Mean Strength
• Because of the variability of concrete strength during
production, the mix must be designed to have a
considerably higher strength than the specified
characteristic strength.
• This is done by an amount termed as margin, which is

obtained by using the relation:

STEP NO. 2 Determination of water cement ratio
• From Table 1 corresponding to the type of cement, type of • British D.O.E. Method of Mix design
coarse agg. and specified age, the appropriate value of
STEP NO. 3 Determination of water content
strength (at w/c ratio of 0.5) is obtained.
• From Fig. 2, a point corresponding to this strength at a w/c • Table 2 corresponding to the maximum size of coarse
ratio of 0.5 is marked. aggregate and specified slump, the value of water content
• Through this point, a curve ‘parallel’ to the neighboring is obtained.
curves is drawn. Using this new curve, the w/c ratio
corresponding to the specified target mean strength is
obtained.

Table: 1 Approximate compressive strengths (N/mm2) of concrete mixes • British D.O.E. Method of Mix design
made with free w/c ratio of 0.5
Compressive Strengths (N/mm2)
Type of Coarse
Type of Cement Age (days) Table: 2 Approximate free water contents required to give various levels of workability
Aggregate
3 7 28 91
Slump (mm) 0-10 10-30 30-60 60-180
Ordinary Uncrushed 22 30 42 49
Vebe Time (s) > 12 6 -12 3–6 0-3
Portland Cement
• Maximum Size of Type of
or Sulphate
Crushed 27 36 49 56 Aggregate (mm) Aggregate
Resisting
Portland Cement Uncrushed 150 180 205 225
10
Rapid Hardening Uncrushed 29 37 48 54 Crushed 180 205 230 250
Portland Cement Crushed 34 43 55 61 Uncrushed 135 160 180 195
20
Prepared By: Prof. Dr. Fareed Ahmed Memon Crushed 170 190 210 225
Uncrushed 115 140 160 175
40
Crushed 155 175 190 205

Fig: 2 Relationship b/w compressive strength and free w/c ratio.

• Note: When coarse and fine aggregate of different types • British D.O.E. Method of Mix design
are used, the free-water content is estimated by the STEP NO. 5 Determination of Total aggregate content
expression:
• Knowing the water content and cement content, the total
• 2/3 Wf + 1/3 Wc aggregate content is determined by using the relation:
• Where: • Total aggregate content = D – Wc - WFW
• Wf = water content appropriate to type of fine agg.
• Where:
• Wc = water content appropriate to type of coarse agg.
• D = the wet density of concrete (kg/m3)
• Wc = the cement content (kg/m3)
• WFW = the free-water content (kg/m3)

STEP NO. 4 Determination of cement content
• Cement is determined by dividing the water content • British D.O.E. Method of Mix design
obtained in Step (3) with the w/c ratio obtained in Step (2). STEP NO. 6 Determination of Fine & Coarse aggregate content
• The value obtained should be checked against any • This step involves deciding how much of the total
maximum or minimum cement contents that may have aggregate should consist of material smaller than 5 mm, i.e
been specified. fine aggregate content.
• If the cement content as calculated above is below a • The F.A content of concrete is estimated by reference to
specified minimum, this minimum must be used. Fig. 4, which relates the amount of F.A as a %ge of the
total aggregate content to the w/c ratio for different values
of workability, max. size of aggregate and grading of F.A.

STEP NO. 4 Determination of cement content
• On the other hand, if the calculated cement content is

higher than a specified maximum, then the specified
strength and workability cannot simultaneously be met
with the selected materials.
• Consideration should then be given to changing the type of

cement, the type and maximum size of the aggregate.

STEP NO. 6 Determination of Fine & Coarse aggregate content
• The coarse aggregate content is then simply obtained by
subtracting the fine aggregate content from the total
aggregate content.
Fig: 4 (c) Recommended proportion of fine aggregate according to percentage passing

600µm sieve
DOE MIX DESIGN PROCEDURE

Example:
• Using the D.O.E method of mix design, compute the batch
quantities required for a cubic meter of concrete to suit the
following data:
• Characteristic cube strength is 30 MPa at 28 days with 5%
defective rate.
• Type of cement: Ordinary Portland Cement
• Coarse aggregate: Crushed of max. size 20 mm
• Fine aggregate: Natural river sand (uncrushed) confirming to
Fig: 4 (a) Recommended proportion of fine aggregate according to percentage passing grading zone II
600µm sieve
• Desirable slump: 50-75 mm
• Standard deviation = 6 N/mm2

Fig: 4 (b) Recommended proportion of fine aggregate according to percentage passing

600µm sieve
STEP NO. 1 Determination of Target Mean Strength DOE MIX DESIGN PROCEDURE
Target mean strength (fm) = fc + ks k for 10% defectives = 1.28
= 30 + 1.64 x 6 k for 5.0% defectives= 1.64 STEP NO. 2 Determination of water cement ratio
= 30 + 9.84 k for 2.5% defectives= 1.96
= 39.84 ≈ 40 N/mm2 k for 1.0% defective = 2.33
30 28 30 28
5 5
6
1.64 1.64 6 9.84 6
30 9.84 39.84 1.64 1.64 6 9.84
30 9.84 39.84
crushed
uncrushed
0.57 Use this value
-
STEP NO. 2 Determination of water cement ratio DOE MIX DESIGN PROCEDURE
STEP NO. 3 Determination of Free water content

30 28 Table 3. Approximate Free-Water Contents (kg/m3) required to
5 give Various Levels of Workability
6 Slump (mm) 0-10 10-30 30-60 60-180 Free-water content
1.64 1.64 6 9.84 Vebe Time (s) > 12 6 -12 3–6 0-3 = 2/3(195) + 1/3(225)
30 9.84 39.84
Maximum Size of Type of
= 130 + 75
Aggregate (mm) Aggregate
Uncrushed 150 180 205 225 = 205 kg/m3
crushed 10
Crushed 180 205 230 250
uncrushed 20
Uncrushed 135 160 180 195
Crushed 170 190 210 225
Uncrushed 115 140 160 175
40
Crushed 155 175 190 205
Note: When coarse and fine aggregate of different types are used, then free-water content is
estimated by the expression
2/3 Wf + 1/3 Wc
Where: Wf = free-water content appropriate to type of fine aggregate
Wc = free-water content appropriate to type of coarse aggregate
Table 2. Approximate Compressive Strength (N/mm2) Figure 4. Relationship between Compressive

of Concrete Mixes made with a Free-Water/Cement strength and Free-Water/ Cement
0.5
Compressive Strengths
Type of
Type of (N/mm2)
Coarse
Cement Age (days)
Aggregate
3 7 28 91
Ordinary
Uncrushed 22 30 42 49
Portland
Cement
(OPC) of
Sulphate
Resisting Crushed 27 36 49 56
Portland
Cement
(SRPC)
Rapid Uncrushed 29 37 48 54
Hardening
Portland
Cement Crushed 34 43 55 61
(RHPC)
STEP NO. 4 Determination of Cement content DOE MIX DESIGN PROCEDURE
Free water content

Cement content = STEP NO. 6 Determination of fine and coarse
Water / cement ratio
aggregate content
= 205 / 0.57
= 359.65 ≈ 360 Kg/m3
2
37% - 44% use 40.5%
205 0.57 360
0.405 1835 743
- 1835 743 1092
-
STEP NO. 5 Determination of total aggregate content DOE MIX DESIGN PROCEDURE
As,
Total aggregate content = D – Wc - WFW
Assuming a trial mix of 0.05 m3 to be used using aggregate with
saturated surface dry condition for this example
Where:
D = the wet density of concrete (kg/m3) The required amount for each material for this volume is listed in
Wc = the cement content (kg/m3)
the final line of this mix design form.
WFW = the free-water content (kg/m3)
Therefore,
Total aggregate content
= 2400 – 205 – 360
= 1835 Kg/m3
360 205 743 1092
Figure 5. Estimated Wet Density of Fully Compacted Concrete
0.05 18 10.25 37.15 54.6
STEP NO. 6 Determination of fine and coarse

aggregate content
Fine aggregate content = Total

aggregate content x proportions of
fines
And,
Coarse aggregate content = Total
aggregate content – fine aggregate
content
Figure 6. Recommended Proportions of Fine Aggregate

According to Percentage Passing 600 m sieve
ACI Method of Mix Design
 This method of mix design, widely used in the USA,

was first published in 1944 by ACI committee 613
 Step 1: Choice of Slump
 In 1954 the method was revised to include, among other
modifications, the use of entrained air  Select the slump of concrete depending on the type of
construction and the degree of workability
 In 1970, the method became the responsibility of ACI
committee 211  If slump is not specified, a value appropriate for the
work can be selected from Table 1
 As a general rule, the lowest slump that will permit
adequate placement, should be selected
 Data to be required for the design of the mix

 Before starting the mix design process, the following
material properties should be determined:  Step 1: Choice of Slump
 Specific gravity of cement Table 1. Recommended Slumps for Various Types of Construction
 Fineness modulus of selected Fine Aggregate

 Unit weight of dry rodded coarse aggregate
 Sp. gravity of coarse and fine aggregates in SSD condition
 Absorption characteristics of both coarse & fine aggregates
 The ACI mix design procedure can be divided into the

following steps:
 Choice of slump
 Maximum aggregate size selection
 Mixing water and air content estimation
 Determination of Water-cement ratio
 Determination of Cement content
 Determination of Coarse aggregate content
 Determination of Fine aggregate content
 Adjustment for aggregate moisture
 Step 2: Selection of Maximum Aggregate size

 Decide the maximum size of coarse aggregate that is
Table 2. Approximate Mixing Water and Air Content Requirements for different Slumps
economically available and conform to the following and Maximum Aggregate sizes
limitations:
 ACI 211.1 suggests that maximum size should not be
larger than:
 1/5 the minimum dimension of structural member,
 1/3 the thickness of a slab,
 or 3/4 the clearance between reinforcing rods and forms
 Step 2: Selection of Maximum Aggregate size

 These restrictions limit maximum aggregate size to 40
mm (1.5 inches), except in mass applications  Step 4: Determination of water cement ratio
 Generally for RCC work 20 mm and prestressed  Find the minimum water-cement ratio based on the
concrete 10 mm size are used dual criterion of durability and strength using Tables 3
and 4.
 Note: Aggregate larger than these dimensions may be
difficult to consolidate & compact resulting in a honey-
combed structure or large air pockets.
 Step 3: Estimation of Mixing water and Air content
 Determine the amount of mixing water required for air

entrained or non-air entrained concrete for the selected
slump and maximum size of coarse aggregate from
Table 2.
 This Table 2 also indicates approximate amount of

entrapped air.

Table 3. Maximum Permissible W/C Ratios for Different Types of Structures and Degrees of Exposure
 Step 6: Determination of Coarse aggregate content
 Determine the amount of coarse aggregate required for

a unit volume of concrete from Table 5.
 The value thus obtained is multiplied by the dry

rodded unit weight of coarse aggregate to get the
required weight of coarse aggregate per unit volume
Prepared By: Prof. Dr. Fareed Ahmed Memon of concrete.


Table 5. Dry bulk volume of Coarse Aggregate per unit volume of concrete
 Step 5: Determination of cement content
 Once the water content and w/c ratio is determined

from steps 3 and 4, the amount of cement per unit
volume of the concrete is found by dividing the
estimated water content by the w/c ratio.
i.e. Cement content = Water content / Water cement ratio
 This cement content should not be less than the cement
content required based on durability or some other
criterion.
 Step 7: Determination of Fine aggregate content

 Determine the amount of fine aggregate.
 Step 8: Adjustment for aggregate moisture
 If the weight of concrete per unit volume is assumed,
the required weight of fine aggregate is simply the  Adjust the mixing water quantity and proportions of
difference b/w the weight of fresh concrete and the fine and coarse aggregate based on the surface
total weight of all other ingredients. moisture and absorption capacity in the aggregate.
 An estimate of weight of fresh concrete can be made  Check the calculated mix proportions by means of trial
either by using the following Equation (1) or Table 6 batches and make some adjustments in the mix
proportions, if necessary.
ρ = 10 γa (100 - A) + C (1 – γa / γ ) – W (γa - 1) … 1(a) (kg/m3)

ρ = 16.85 γa (100 - A) + C (1 – γa / γ ) – W (γa - 1) … 1(b) (lb/ft3)
where,  Example: Using the ACI method, design a concrete mix
ρ = density (unit weight) of fresh concrete, kg/m3(lb/ft3) for construction of internal columns of a building. The
γa = weighted av. specific gravity of combined fine & coarse agg. specified strength of concrete is 30 MPa at 28 days
A = air content, percent measured on standard cylinders. The size of the column
C = cement content, kg/m3(lb/ft3) sections and the spacing of the reinforcement require a
γ = specific gravity of cement ( generally 3.15)
slump of 50 mm (2 in.) and a maximum size of aggregate
W = mixing water requirement, kg/m3 (lb/ft3)
of 20 mm (3/4 in.). The specific gravity of Fine &
Coarse aggregates are 2.65 and 2.70 respectively. The

Table 6. First Estimate of density (unit weight) of fresh concrete
dry rodded bulk density of Coarse aggregate is 1600 ACI Method of Mix Design
kg/m3(100 lb/ft3) and fineness modulus of Fine aggregate
is 2.80. Ordinary Portland cement (Type 1) will be used.  Step 2: Selection of Maximum Aggregate size
Coarse aggregate is found to be absorptive to the extent  Decide the maximum size of coarse aggregate to be used.
of 1% with a moisture surface of 2.2% while the fine
 The maximum size of 20 mm (3/4 in.) of coarse
aggregate has a absorption of 0.7% and free surface
aggregate is given.
moisture is found to be 3.5%.

 Select the slump of concrete depending on the type of
construction and degree of workability. If not given, an  Step 3: Estimation of Mixing water and Air content
appropriate value may be chosen from Table 1
 Determine the amount of mixing water required for air
 The slump of 50 mm (2 inch) is given, which is entrained or non-air entrained concrete for the selected
consistent with Table 1. slump and maximum size of coarse aggregate from Table
2.
 Since there are no special exposure conditions,
Ordinary Portland cement will be used without air
entrainment.

Table 1. Recommended Slumps for Various Types of Construction

 Step 3: Estimation of Mixing water and Air content

 From Table 2, the mixing water content for non air-
entrained concrete with a slump of 50 mm (2 in.), and  Step 4: Determination of water cement ratio
a maximum size of aggregate of 20 mm (3/4 in.) is  From Table 4, for non air-entrained concrete, the
190 kg/m3 (315 lb/yd3) estimated w/c ratio is 0.55 for an average strength of
30 N/mm2
 Also, we note that the entrapped air content is 2%
 Therefore, adopt w/c ratio of 0.5

Table 2. Approximate Mixing Water and Air Content Requirements for different Slumps
and Maximum Aggregate sizes
 Step 4: Determination of water cement ratio

 Find the water-cement ratio based on the dual criterion of
durability and strength using Tables 3 and 4.
 Adopt the lower value out of strength and durability
consideration.
 From Table 3, based on the exposure/durability

conditions, the estimated w/c ratio is 0.5

Table 4. Relationship Between W/C Ratio and Compressive Strength of Concrete
Table 5. Dry bulk volume of Coarse Aggregate per unit volume of concrete
 Step 5: Determination of cement content

 Find the amount of cement per unit volume of the
concrete by dividing the estimated water content by the  Step 6: Determination of Coarse aggregate content
w/c ratio.
 Thus,
Thus, Cement content = 190 / 0.5
= 380 kg/m3 the weight of coarse aggregate = 0.62 x 1600 = 992 kg/m3
 Step 6: Determination of Coarse aggregate content

 Determine the amount of coarse aggregate required for a
unit volume of concrete from Table 5.
 The value thus obtained is multiplied by dry rodded unit
weight of coarse aggregate to get the required weight of
coarse aggregate per cubic unit of concrete.
 From Table 5, for 20 mm coarse aggregate and for

Fineness modulus of 2.80, the dry rodded bulk volume
of Coarse agg. is 0.62 per unit volume of concrete.

 Determine the amount of fine aggregate.
 If the weight of concrete per unit volume is known, the  Step 7: Determination of Fine aggregate content
required weight of fine aggregate is simply the difference
 Thus,
b/w the weight of fresh concrete and the total weight of all
other ingredients. the weight of fine aggregate = 2355 – 190 – 380 – 992
 An estimate of weight of fresh concrete can be made = 793 kg/m3
either by using Table 6 or using the Equation (1).  Alternatively, the weight of fine aggregate can also be
found out by absolute volume method which is more
accurate and is given by,

Table 6. First Estimate of density (unit weight) of fresh concrete
 Thus,
the absolute volume of fine aggregate = 1000 – 698.04
= 301.96
 Therefore,
the weight of fine aggregate = 301.96 x 2.65
= 800.19 say 800 kg/m3
 From Table 6, the first estimate of density of fresh

concrete for 20 mm maximum size of coarse aggregate
and for non air-entrained concrete is 2355 kg/m3
 The weight of all the known ingredients of concrete:

 Weight of water = 190 kg/m3
 Weight of cement = 380 kg/m3
 Weight of coarse aggregate = 992 kg/m3


 Adjust the proportions of fine & coarse aggregate and the
mixing water quantity based on the surface moisture and Final Mix Proportions
absorption capacity in the aggregate.
Fine Coarse
Ingredients Cement Water
 Since, both fine and coarse aggregates contain surface Aggregate Aggregate
moisture, therefore their weights must be adjusted. Quantity
380 828 1014 156
Thus, the weight of fine aggregate = 800 + 3.5% (800) kg/m3
= 828 kg/m3 Ratio 1 2.18 2.67 0.41
 and, the weight of coarse aggregate = 992 + 2.2% (992)

= 1013.82
≈ 1014 kg/m3
 Similarly, the required adjusted amount of water will be
calculated as follows:
 Water from fine aggregate = 800 x (3.5 – 0.7)%
= 22.40 kg/m3
 Water from coarse aggregate = 992 x (2.2 – 1.0)%

= 11.90 kg/m3
 therefore, the required adjusted amount of water
= 190 – 22.4 – 11.90
= 155.70 ≈ 156 kg/m3

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Module No.

Prepared By: Prof. Dr. Fareed Ahmed Memon

• A process of selecting suitable ingredients of concrete and

Prepared By: Prof. Dr. Fareed Ahmed Memon

• To achieve the workable concrete mix

• To obtain a cohesive mix which offsets the possibility of

• To achieve durability for particular site conditions and

• To obtain maximum economy

Prepared By: Prof. Dr. Fareed Ahmed Memon

• Where, fm = the target mean strength

• The value of the margin (M) can be derived from the

Prepared By: Prof. Dr. Fareed Ahmed Memon

• British D.O.E. Method of Mix design

• British D.O.E. Method of Mix design

• This is done by an amount termed as margin, which is

Prepared By: Prof. Dr. Fareed Ahmed Memon

Prepared By: Prof. Dr. Fareed Ahmed Memon

• British D.O.E. Method of Mix design

• British D.O.E. Method of Mix design

Fig: 2 Relationship b/w compressive strength and free w/c ratio.

Prepared By: Prof. Dr. Fareed Ahmed Memon

• British D.O.E. Method of Mix design

Prepared By: Prof. Dr. Fareed Ahmed Memon

• British D.O.E. Method of Mix design

• On the other hand, if the calculated cement content is

• Consideration should then be given to changing the type of

Prepared By: Prof. Dr. Fareed Ahmed Memon

Prepared By: Prof. Dr. Fareed Ahmed Memon

Fig: 4 (c) Recommended proportion of fine aggregate according to percentage passing

DOE MIX DESIGN PROCEDURE

• British D.O.E. Method of Mix design

Fig: 4 (b) Recommended proportion of fine aggregate according to percentage passing

DOE MIX DESIGN PROCEDURE

STEP NO. 3 Determination of Free water content

DOE MIX DESIGN PROCEDURE

Table 2. Approximate Compressive Strength (N/mm2) Figure 4. Relationship between Compressive

STEP NO. 4 Determination of Cement content DOE MIX DESIGN PROCEDURE

Free water content

DOE MIX DESIGN PROCEDURE

DOE MIX DESIGN PROCEDURE

STEP NO. 6 Determination of fine and coarse

Fine aggregate content = Total

Figure 6. Recommended Proportions of Fine Aggregate

 This method of mix design, widely used in the USA,

Prepared By: Prof. Dr. Fareed Ahmed Memon

ACI Method of Mix Design

 Data to be required for the design of the mix

 Fineness modulus of selected Fine Aggregate

Prepared By: Prof. Dr. Fareed Ahmed Memon

Prepared By: Prof. Dr. Fareed Ahmed Memon

ACI Method of Mix Design

 The ACI mix design procedure can be divided into the

 Step 2: Selection of Maximum Aggregate size

ACI Method of Mix Design

 Step 2: Selection of Maximum Aggregate size

Prepared By: Prof. Dr. Fareed Ahmed Memon

ACI Method of Mix Design

 Step 3: Estimation of Mixing water and Air content

 Determine the amount of mixing water required for air

 This Table 2 also indicates approximate amount of

Prepared By: Prof. Dr. Fareed Ahmed Memon

ACI Method of Mix Design

 Step 6: Determination of Coarse aggregate content