Design & Control of

Concrete Mixtures

Whats fc
???
fc is the specified compressive
strength. Unless otherwise
specified, 28-day strength test
is always utilized.

Abbreviations
SG
wt. or lbs
cy and/or cyd
cf
pcf
DRUW
fl. oz
cwt
w/cm

---Specific Gravity
---Weight
---Cubic Yard(s)
---Cubic Feet
---Pounds per Cubic Feet
---Dry Rodded Unit Weight
---Fluid Ounce
---100 lbs of cement, or hundred
weight of cement
---Water-to-Cementitious Ratio

Constants
1 gallon of water
Specific Gravity of water
Unit Weight of water
1 cubic yard (cy)
1 bag or sack of cement

= 8.33 lbs.
= 1.00
= 62.4 pcf
= 27 cubic feet (cf)
= 94 lbs.

Some Useful Conversions:

1 gallon (gal)
1 fl. oz.
1 cubic feet (cf)
1 gals of water
1 cubic yard (cy)

= 128 fluid ounces (fl. oz.)

= 29.6 milliliters (mL)
= 7.48 gals
= 8.33 lbs.
= 27 cf

Absolute Volume Method of

Concrete Mixture Proportioning

Proportioning Concrete Mixtures

Our objective is to produce a concrete mixture
that will meet the specifications and
performance requirements for its intended
use.

Typical Mix Design Considerations

Strength
Placeability
Durability
Finishability
Available Materials

Appearance
Impermeability
Abrasion Resistance
Economics

Proportioning Procedure
Job specifications may dictate some or all of
the following
Maximum w/cm
Minimum cement content
Air content
Slump
Maximum aggregate size
Strength
Others

Definitions of Basic Terms

Absolute Volume Method - A more accurate

method than weight proportioning methods, it

involves use of specific gravity (SG) values for all the
ingredients to calculate the absolute volume each
will occupy in a unit volume of concrete.

The absolute volume is computed from a

materials weight and its SG as follows:
Abs. Vol. = (Weight of Material)
(SG x Unit Wt. H2O*)
(* The density of water within the normal ambient temperature range is 62.4 pcf)

Definitions Continued
Specific Gravity (SG) - A dimensionless ratio of a
substances density to some standard reference
density. For liquids and solids, the reference density
is pure water.
SG of Water = 1.0
SG of Portland Cement = 3.15 (3.15 times heavier than
water)
A material that weighs twice as much as an equal
volume of water has a SG of 2.0
SG of normal-weight aggregates ranges between 2.4
and 2.9

Definitions Continued
Nominal Aggregate Size The smallest sieve
opening through which the entire amount of
aggregate is permitted to pass.

Saturated Surface Dry (SSD) Aggregates are

generally reported in either SSD or Bulk Dry (Oven
Dry) condition, with SSD most often used
Difference is the absorption
Water

Unit Weight of Stone?

SG of water = 1.0
Unit Weight of water (1 cf) = 62.4 lbs.

How much does 1 cf of stone weigh if Water

the Specific Gravity (SG) is 2.80 and
there are no voids?
Unit Wt.Stone = SGstone X Unit Wt.Water
Unit Wt.Stone = 2.80 X 62.4 pcf
Unit Wt.Stone = 174.7 pcf

Stone

Definitions Continued
Dry Rodded Unit Weight (DRUW) - The

maximum weight of coarse aggregate in a 1 cf bucket

as determined by ASTM C 29.
Fineness Modulus (FM) - is an index of the
fineness of an aggregate - the higher the FM, the
coarser the aggregate.
FM (ASTM C 125) is obtained by adding the
cumulative percentages by weight retained on each
of a specified series of sieves and dividing the sum by
100.
(Specified sieves: #100, #50, #30,
#16, #8, #4, 3/8, , 1.5, 3 and 6)

Overall Concept
Concrete is sold and
proportioned by
volume (ASTM C 94)
Concrete designed
per cubic yard (yd3)
1 yd3 = 27 cf

Concrete Design Methods

Sack (Bag) Mixes (Weight)
Cement content

Performance Mixes (Field Data or Trial Mixes)

Strength and W/CM ratio

Mix Proportioning (Absolute Volume)

Verify concrete ingredients - visual
Verify slump at plant (job site)
Communicate slump adjustment
Delivery Ticket Accuracy

The Sack or Bag Method

Proportioning by Weight
1 bag of cement = 94 lbs.
Specified number of bags and water per bag
Example:
6-1/2 bags with 5.2 gals of water/bag, or
611 lbs of cement , 282 lbs of water
W/CM ratio of 0.46

Performance Mixes
Proportioning by Field Data
Strength Data & Standard Deviations (S) Test
record must equal or exceed the required avg.
compressive strength, fcr;

fcr=fc + 1.34S
fcr = fc +2.33S-500 (psi)
Minimum of 30 consecutive tests; If only 15 to
29 are available, use modification factor for
correction.

Performance Mixes
Proportioning by Lab Trial Mixes
When field test records are not available, 3
mix designs @ 3 different w/cm ratios or
cementitious contents.
This is referred to as a 3-point curve.

Absolute Volume Method

Sample Mix

Absolute Volume Method

Water
Cement

Air

Coarse Aggregates
(Limerocks)

Fine Aggregates
(Sand)

Design Method
Design for SSD weights; SSD condition is
neither absorbing water nor contributing
water to the concrete mixture.
Example:
Abs. Vol. =
Abs. Vol. =
Abs. Vol. =

Weight of Material
Water
(SG X Unit Wt. of Water)
1700 lbs of #57
(2.5 SG #57 Limestone X 62.4 pcf)
10.9 cf of #57 Limestone

Required Information
The SG of the coarse and fine aggregates.
The SG of mineral admixture to be used.
(E.g. fly ash, slag, etc.)
The SG of cement = 3.15
Is there a specification ?
Minimum cement content?
Maximum w/cm ratio?

Example Mix Information

Specification requirements:
Minimum cement content of 658 lbs.
Water-Cementitious Ratio of 0.41
Allowable Replacement of fly ash 18-22 % pound
per pound of cement.
Air Content 2.0 - 4.0 %

Calculating for Water & Portland

Wt. of Water/yd3 = (Wt. of cement X w/cm ratio)
Wt. of Water/yd3 = 658 lbs. X 0.41 = 270 lbs./yd3
Convert Wt. to Gal. (1 gal. = 8.33 lbs.)
Gal./yd3 = 270 lbs. / 8.33 lbs./gal. = 32.4 gal./yd3
Wt. of Cement & Fly Ash/ yd3 :
Wt. of Fly Ash/ yd3 = 658 lbs. X 20% Replacement
Wt. of Fly Ash/ yd3 = 132 lbs.
Wt. of Cement = 658 lbs. 132 lbs. = 526 lbs.

Calculating for Air Content

Cement
Fly ash
Water

526 lbs.
132 lbs.
270 lbs. (32.4 gals)

Specification allows 2.0 - 4.0%; Target = 3.0%!

1.0% of entrained/entrapped air represents
0.27 cubic feet of volume

Calculating for Air Content

Example : 3.0 % x 27 cubic feet = 0.81 cf
Many times mix designs over 4,000 psi will not
have any entrained air, however you should
still design for entrapped air.
Typical Entrapped Air Content
Large Rock Mix (#57 & # 67 Stone) = 1.5 %
Small Rock Mix (# 89 Stone) = 2.5 %

Calculate Volumes of Known Materials

What is the SG of the fly ash and aggregates in
this mix.
These SGs will vary from source to source.
The SG of mineral admixtures (fly ash, slag,
etc.) can be found on the mill certification.
The aggregate SG is the SSD Bulk Specific
Gravity and can be obtained from the mine.

Specific Gravity
We will use the following specific gravities for
the fly ash, coarse and fine aggregates
Fly ash
2.40
Coarse aggregate 2.50
Fine aggregate
2.63

Calculate Volumes of Known Materials

Abs. Vol. =
Material
Cement
Fly Ash
Water
Air

Weight of Material
(SG X Unit Wt. of Water)

Equation
526/(3.15 X 62.4)
132/ (2.40 X 62.4)

270/(1.0 X 62.4)
27 X 0.03

Total

Abs. Vol. (cf)

2.68
0.88
4.33
0.81
8.70

The Paste
The paste is composed of Portland cement,
fly-ash, water, and entrapped air or entrained
air.
The paste volume = 8.70 cubic feet. This
means the rest of the volume (68%) will be
made up of our coarse and fine aggregates.

Calculate Volume of Aggregates

First, determine the available volume for
aggregates:
You know there is 27.0 cf in a cubic yard
You know there is 8.70 cf of paste

27 cf - 8.70 cf = 18.30 cf for Aggregates

Calculating for the Aggregates

Now we must determine our Rock-to-Sand
Ratio or our Coarse-to-Fine Ratio.
This will be determine by many factors
Gradation
Fineness Modulus (FM)
Method of Placement
Workability Needs
Strength Requirements

Typical Rock-to-Sand Ratios

Type of Mix
Pre-stress
Flatwork
6 Boom Pump
2 Pump Mix
High-Strength

Rock-to-Sand Ratio
65:35
60:40
60:40
45:55
65:35

These ratios can vary. The biggest influencer is the FM

of the fine aggregate
The higher the FM or coarser the fine aggregate, the
higher the percent of fine aggregate.

Calculating for the Aggregates

We will use a rock-to-sand ratio of 60:40
Remember you have 18.30 cubic feet of
aggregates
Coarse Aggregate:
18.30 cf X 60% = 10.98 cf
Fine Aggregate:
18.3 cf X 40% = 7.32 cf

Specific Gravity
We will use the following specific gravities for
the fly ash, coarse and fine aggregates
Fly ash
2.40
Remember!
Coarse aggregate 2.50
Fine aggregate
2.63

Calculating for the Aggregates

Determine the weight of coarse and fine
aggregates:
Abs. Vol. =
Weight of Material
(SG X Unit Wt. of Water)
Wt. of Matl = Abs. Vol. X (SG X Unit Wt. of
Water)
Wt. of Coarse = 10.98 X (2.50 X 62.4) = 1713 lbs.
Wt. of Fine = 7.32 X (2.63 X 62.4) = 1201 lbs.

The Mix Design

Cement
Fly Ash
Water
Entrained Air
Coarse Agg.
Fine Agg.

526 lbs
2.68 cf
132 lbs
0.88 cf
270 lbs
4.33 cf
3.0 %
0.81 cf
1713 lbs
10.98 cf
1201 lbs
7.32 cf
3842 lbs
27.00 cf
Theoretical Unit Weight = Total Wt/cf
Theoretical Unit Weight = 3842/27 = 142.3 pcf

Verification
Remember a cubic yard of concrete has 27 cf
Your mix design should add up to 27.
Also, remember the SG of your fly ash, coarse
aggregate, and fine aggregate can change
from source to source. Make sure you verify
prior to doing your calculation.

Adjustment for Aggregate Moisture

Remember the aggregates are designed at the
SSD condition. We must take a moisture
content and determine the free moisture.
This can be oven dry, or towel dry method. If
you utilize the oven dry method you must
account for the absorption of the aggregate.

Moisture Conditions

Total Moisture = Free (surface) Moisture + Absorbed Moisture

Determining Moisture Content

Oven or Hot Plate (Most accurate method)
Results in total moisture, need to adjust for absorption
performed on fine or coarse aggregate

Chapman Flask
Determines free moisture volumetrically
Calculate or use chart, need to know specific gravity
(dependent on sand cleanliness)

Speedy Moisture Meter

Determines fine aggregate free moisture, based on gas produced from
reaction
Use manufacturers adjustment value (less accurate)

Towel Dry
Performed on coarse aggregate to determine free moisture by weight.
(dependent on aggregate cleanliness and less accurate)

Moisture Corrections
Coarse Aggregates (CA)
Free Moisture of CA = 1.5%

Fine Aggregates
Free Moisture of FA = 4.2%

1701 lbs X 0.015 = 26 lbs H2O

1201 lbs X 0.042 = 50 lbs H2O

Batch water must be adjusted for the free water in the aggregates

Adjusted Batch Water = Batch water CA Free water FA Free water

Adjusted Batch Water = 270 lbs 26 lbs 50 lbs = 194 lbs

Any Questions