Concrete Mix Design

Introduction
The process of selecting suitable ingredients of concrete and determining their relative amounts with the objective of producing a concrete of the required, strength, durability, and workability as economically as possible, is termed the concrete mix design. The proportioning of ingredient of concrete is governed by the required performance of concrete in 2 states, namely the plastic and the hardened states. If the plastic concrete is not workable, it cannot be properly placed and compacted. The property of workability, therefore, becomes of vital importance. The compressive strength of hardened concrete which is generally considered to be an index of its other properties, depends upon many factors, e.g. quality and quantity of cement, water and aggregates; batching and mixing; placing, compaction and curing. The cost of concrete is made up of the cost of materials, plant and labour. The variations in the cost of materials arise from the fact that the cement is several times costly than the aggregate, thus the aim is to produce as lean a mix as possible. From technical point of view the rich mixes may lead to high shrinkage and cracking in the structural concrete, and to evolution of high heat of hydration in mass concrete which may cause cracking. The actual cost of concrete is related to the cost of materials required for producing a minimum mean strength called characteristic strength that is specified by the designer of the structure. This depends on the quality control measures, but there is no doubt that the quality control adds to the cost of concrete. The extent of quality control is often an economic compromise, and depends on the size and type of job. The cost of labour depends on the workability of mix, e.g., a concrete mix of inadequate workability may result in a high cost of labour to obtain a degree of compaction with available equipment. Requirements of concrete mix design The requirements which form the basis of selection and proportioning of mix ingredients are : a ) The minimum compressive strength required from structural consideration b) The adequate workability necessary for full compaction with the compacting equipment available. c) Maximum water-cement ratio and/or maximum cement content to give adequate durability for the particular site conditions d) Maximum cement content to avoid shrinkage cracking due to temperature cycle in mass concrete.

Types of Mixes

1. Nominal Mixes In the past the specifications for concrete prescribed the proportions of cement, fine and coarse aggregates. These mixes of fixed cement-aggregate ratio which ensures adequate strength are termed nominal mixes. These offer simplicity and under normal circumstances, have a margin of strength above that specified. However, due to the variability of mix ingredients the nominal concrete for a given workability varies widely in strength. 2. Standard mixes The nominal mixes of fixed cement-aggregate ratio (by volume) vary widely in strength and may result in under- or over-rich mixes. For this reason, the minimum compressive strength has been included in many specifications. These mixes are termed standard mixes. IS 456-2000 has designated the concrete mixes into a number of grades as M10, M15, M20, M25, M30, M35 and M40. In this designation the letter M refers to the mix and the number to the specified 28 day cube strength of mix in N/mm2. The mixes of grades M10, M15, M20 and M25 correspond approximately to the mix proportions (1:3:6), (1:2:4), (1:1.5:3) and (1:1:2) respectively. 3. Designed Mixes In these mixes the performance of the concrete is specified by the designer but the mix proportions are determined by the producer of concrete, except that the minimum cement content can be laid down. This is most rational approach to the selection of mix proportions with specific materials in mind possessing more or less unique characteristics. The approach results in the production of concrete with the appropriate properties most economically. However, the designed mix does not serve as a guide since this does not guarantee the correct mix proportions for the prescribed performance. For the concrete with undemanding performance nominal or standard mixes (prescribed in the codes by quantities of dry ingredients per cubic meter and by slump) may be used only for very small jobs, when the 28-day strength of concrete does not exceed 30 N/mm2. No control testing is necessary reliance being placed on the masses of the ingredients. Factors affecting the choice of mix proportions The various factors affecting the mix design are: 1. Compressive strength It is one of the most important properties of concrete and influences many other describable properties of the hardened concrete. The mean compressive strength required at a specific age, usually 28 days, determines the nominal water-cement ratio of the mix. The other factor affecting the strength of concrete at a given age and cured at a prescribed temperature is the degree of

compaction. According to Abrahams law the strength of fully compacted concrete is inversely proportional to the water-cement ratio. 2. Workability The degree of workability required depends on three factors. These are the size of the section to be concreted, the amount of reinforcement, and the method of compaction to be used. For the narrow and complicated section with numerous corners or inaccessible parts, the concrete must have a high workability so that full compaction can be achieved with a reasonable amount of effort. This also applies to the embedded steel sections. The desired workability depends on the compacting equipment available at the site. 3. Durability The durability of concrete is its resistance to the aggressive environmental conditions. High strength concrete is generally more durable than low strength concrete. In the situations when the high strength is not necessary but the conditions of exposure are such that high durability is vital, the durability requirement will determine the water-cement ratio to be used. 4. Maximum nominal size of aggregate In general, larger the maximum size of aggregate, smaller is the cement requirement for a particular water-cement ratio, because the workability of concrete increases with increase in maximum size of the aggregate. However, the compressive strength tends to increase with the decrease in size of aggregate. IS 456:2000 and IS 1343:1980 recommend that the nominal size of the aggregate should be as large as possible. 5. Grading and type of aggregate The grading of aggregate influences the mix proportions for a specified workability and watercement ratio. Coarser the grading leaner will be mix which can be used. Very lean mix is not desirable since it does not contain enough finer material to make the concrete cohesive. The type of aggregate influences strongly the aggregate-cement ratio for the desired workability and stipulated water cement ratio. An important feature of a satisfactory aggregate is the uniformity of the grading which can be achieved by mixing different size fractions. 6. Quality Control The degree of control can be estimated statistically by the variations in test results. The variation in strength results from the variations in the properties of the mix ingredients and lack of control of accuracy in batching, mixing, placing, curing and testing. The lower the difference between the mean and minimum strengths of the mix lower will be the cement-content required. The factor controlling this difference is termed as quality control.

Mix Proportion designations

The common method of expressing the proportions of ingredients of a concrete mix is in the terms of parts or ratios of cement, fine and coarse aggregates. For e.g., a concrete mix of proportions 1:2:4 means that cement, fine and coarse aggregate are in the ratio 1:2:4 or the mix contains one part of cement, two parts of fine aggregate and four parts of coarse aggregate. The proportions are either by volume or by mass. The water-cement ratio is usually expressed in mass Factors to be considered for mix design The grade designation giving the characteristic strength requirement of concrete. The type of cement influences the rate of development of compressive strength of concrete. Maximum nominal size of aggregates to be used in concrete may be as large as possible within the limits prescribed by IS 456:2000. The cement content is to be limited from shrinkage, cracking and creep. The workability of concrete for satisfactory placing and compaction is related to the size and shape of section, quantity and spacing of reinforcement and technique used for transportation, placing and compaction.

Procedure
1. Determine the mean target strength ft from the specified characteristic compressive strength at 28day fck and the level of quality control. ft = fck + 1.65 S where S is the standard deviation obtained from the Table of approximate contents given after the design mix. 2. Obtain the water cement ratio for the desired mean target using the emperical relationship between compressive strength and water cement ratio so chosen is checked against the limiting water cement ratio. The water cement ratio so chosen is checked against the limiting water cement ratio for the requirements of durability given in table and adopts the lower of the two values. 3. Estimate the amount of entrapped air for maximum nominal size of the aggregate from the table. 4. Select the water content, for the required workability and maximum size of aggregates (for aggregates in saturated surface dry condition) from table. 5. Determine the percentage of fine aggregate in total aggregate by absolute volume from table for the concrete using crushed coarse aggregate.

6. Adjust the values of water content and percentage of sand as provided in the table for any difference in workability, water cement ratio, grading of fine aggregate and for rounded aggregate the values are given in table. 7. Calculate the cement content form the water-cement ratio and the final water content as arrived after adjustment. Check the cement against the minimum cement content from the requirements of the durability, and greater of the two values is adopted. 8. From the quantities of water and cement per unit volume of concrete and the percentage of sand already determined in steps 6 and 7 above, calculate the content of coarse and fine aggregates per unit volume of concrete from the following relations:

where V = absolute volume of concrete = gross volume (1m3) minus the volume of entrapped air Sc = specific gravity of cement W = Mass of water per cubic metre of concrete, kg C = mass of cement per cubic metre of concrete, kg p = ratio of fine aggregate to total aggregate by absolute volume fa, Ca = total masses of fine and coarse aggregates, per cubic metre of concrete, respectively, kg, and Sfa, Sca = specific gravities of saturated surface dry fine and coarse aggregates, respectively 9. Determine the concrete mix proportions for the first trial mix. 10. Prepare the concrete using the calculated proportions and cast three cubes of 150 mm size and test them wet after 28-days moist curing and check for the strength. 11. Prepare trial mixes with suitable adjustments till the final mix proportions are arrived at.

M-25 Mix Designs as per IS-10262-2009. M-25 CONCRETE MIX DESIGN As per IS 10262-2009 & MORT&H A-1 Stipulations for Proportioning 1 Grade Designation M25 OPC 53 grade confirming to IS2 Type of Cement 12269-1987 3 Maximum Nominal Aggregate Size 20 mm Minimum Cement Content (MORT&H 4 1700-3 A) 310 kg/m3 Maximum Water Cement Ratio (MORT&H 5 1700-3 A) 0.45 6 Workability (MORT&H 1700-4) 50-75 mm (Slump) 7 Exposure Condition Normal 8 Degree of Supervision Good 9 Type of Aggregate Crushed Angular Aggregate Maximum Cement Content (MORT&H Cl. 10 1703.2) 540 kg/m3 Superplasticiser Confirming to IS11 Chemical Admixture Type 9103 A-2 Test Data for Materials 1 Cement Used Coromandal King OPC 53 grade 2 Sp. Gravity of Cement 3.15 3 Sp. Gravity of Water 1.00 4 Chemical Admixture BASF Chemicals Company 5 Sp. Gravity of 20 mm Aggregate 2.884 6 Sp. Gravity of 10 mm Aggregate 2.878 7 Sp. Gravity of Sand 2.605 8 Water Absorption of 20 mm Aggregate 0.97% 9 Water Absorption of 10 mm Aggregate 0.83% 10 Water Absorption of Sand 1.23% Free (Surface) Moisture of 20 mm 11 Aggregate nil Free (Surface) Moisture of 10 mm 12 Aggregate nil 13 Free (Surface) Moisture of Sand nil Sieve Analysis of Individual Coarse 14 Aggregates Separate Analysis Done Sieve Analysis of Combined Coarse 15 Aggregates Separate Analysis Done 15 Sp. Gravity of Combined Coarse Aggregates 2.882 16 Sieve Analysis of Fine Aggregates Separate Analysis Done

A-3 Target Strength for Mix Proportioning 1 Target Mean Strength (MORT&H 1700-5) 2 Characteristic Strength @ 28 days A-4 Selection of Water Cement Ratio Maximum Water Cement Ratio (MORT&H 1 1700-3 A) 2 Adopted Water Cement Ratio A-5 Selection of Water Content 1 Maximum Water content (10262-table-2) Estimated Water content for 50-75 mm 2 Slump 3 Superplasticiser used A-6 Calculation of Cement Content 1 Water Cement Ratio 2 Cement Content (138/0.43)

36N/mm2 25N/mm2

0.45 0.43 186 Lit. 138 Lit. 0.5 % by wt. of cement

0.43 320 kg/m3 Which is greater then 310 kg/m3 A-7 Proportion of Volume of Coarse Aggregate & Fine Aggregate Content 1 Vol. of C.A. as per table 3 of IS 10262 62.00% 2 Adopted Vol. of Coarse Aggregate 62.00% Adopted Vol. of Fine Aggregate ( 1-0.62) 38.00% A-8 Mix Calculations 1 Volume of Concrete in m3 1.00 3 2 Volume of Cement in m 0.10 (Mass of Cement) / (Sp. Gravity of Cement)x1000 3 Volume of Water in m3 0.138 (Mass of Water) / (Sp. Gravity of Water)x1000 4 Volume of Admixture @ 0.5% in m3 0.00134 (Mass of Admixture)/(Sp. Gravity of Admixture)x1000 5 Volume of All in Aggregate in m3 0.759 Sr. no. 1 (Sr. no. 2+3+4) 6 Volume of Coarse Aggregate in m3 0.471 Sr. no. 5 x 0.62 7 Volume of Fine Aggregate in m3 0.288 Sr. no. 5 x 0.38 A-9 Mix Proportions for One Cum of Concrete (SSD Condition) 1 Mass of Cement in kg/m3 320 3 2 Mass of Water in kg/m 138 3 3 Mass of Fine Aggregate in kg/m 751 3 4 Mass of Coarse Aggregate in kg/m 1356

Mass of 20 mm in kg/m3 Mass of 10 mm in kg/m3 5 Mass of Admixture in kg/m3 6 Water Cement Ratio

977 380 1.60 0.43

We are thankful to Er. Raj M. Khan for sharing this information with us on engineeringcivil.com. We hope this would be of great significance to civil engineers.

Concrete mix designs is best defined as a process in selecting suitable ingredients, which is cement, aggregate, sand and water, and determining their relative proportions to give the required strength, workability and durability. The mix designs, which is a performance specification stating required strength and minimum cement content but leaving the grading and details of the concrete mix design to be work out.

Objective of Concrete Mix Design

Concrete Mixer Drum type 140L Two main objectives for concrete mix design:

To determine the proportions of concrete mix constituents of; Cement, Fine aggregate (or normally Sand), Coarse aggregate, and Water. To produce concrete of the specified properties. To produce a satisfactory of end product, such as beam, column or slab as economically as possible.

Theory of Mix Designs

The Process of Concrete Mix Design The method of concrete mix design applied here is in accordance to the method published by the Department of Environment, United Kingdom (in year 1988). There are two categories of initial information required: 1. Specified variables; the values that are usually found in specifications. 2. Additional information, the values normally available from the material supplier. Reference data consists of published figures and tables is required to determine the design values including;

Mix parameters such as target mean strength, water-cement ratio and concrete density. Unit proportions such as the weight of materials.

The design process can be divided into 5 primary stages. Each stage deals with a particular aspect of the concrete mix design: Stage 1: Determining the Free Water/ Cement Ratio i) Specify the required characteristic strength at a specified age, fc ii) Calculate the margin, M. M=kxs .. [ F1 ]

where; k = A value appropriate to the defect percentage permitted below the characteristic strength. [ k = 1.64 for 5 % defect ] s = The standard deviation (obtained from CCS 1).

CCS 1: Approximate compressive strength (N/mm2) of concrete mixes made with a freewater/cement ratio of 0.5 iii) Calculate the target mean strength, fm fm = fc + M .. [ F2 ]

where; fm = Target mean strength fc = The specified characteristic strength iv) Given the type of cement and aggregate, use the table of CCS 1 to obtain the compressive strength, at the specified age that corresponds to a free water/cement ratio of 0.5.

CCS 4: Relationship between compressive strength and free-water/ cement ratio. v) In figure CCS 4, follow the starting line to locate the curve which passes through the point (the compressive strength for water/cement ratio of 0.5). To obtain the required curve representing the strength, it is necessary to interpolate between the two curves in the figure. At the target mean strength draw horizontal line crossing the curve. From this point the required free water/cement ratio can be determined. Stage 2: Determining the Free-Water Content

CCS 2: Approximate free-water contents (kg/m3) required to give various levels of workability. Given the Concrete Slump or Vebe time, determine the free water content from table CCS 2. Stage 3: Determining the Cement Content Cement Content = Free Water Content / Free-water or Cement Ratio .. [ F3 ]

The resulting value should be checked against any maximum or minimum value that may be specified. If the calculated cement content from F3 is below a specified minimum, this minimum value must be adopted resulting in a reduced water/cement ratio and hence a higher strength than the target mean strength. If the calculated cement content is higher than a specified maximum, then the specified strength and workability simultaneously be met with the selected materials; try to change the type of cement, the type and maximum size of the aggregate. Stage 4: Determining the Total Aggregate Content This stage required the estimate of the density of fully compacted concrete which is obtained from figure CCS 5. This value depends upon the free-water content and the relative density of the combined aggregate in the saturated surface-dry condition. If no information is available regarding the relative density of the aggregate, an approximation can be made by assuming a value of 2.6 for un-crushed aggregate and 2.7 for crushed aggregate.

CCS 5: Estimated wet density of fully compacted concrete. With the estimate of the density of the concrete the total aggregate content is calculated using equation F4: Total Aggregate Content = D C W .. [ F4 ]

where; D = The wet density of concrete ( in kg/m3) C = The cement content (in kg/m3) W = The free-water content (in kg/m3) Stage 5: Determining of The Fine and Coarse Aggregate Contents This stage involves deciding how much of the total aggregate should consist of materials smaller than 5 mm, i.e. the sand or fine aggregate content. The figure CCS 6 shows recommended values for the proportion of fine aggregate depending on the maximum size of aggregate, the workability level, the grading of the fine aggregate (defined by the percentage passing a 600 m sieve) and the free-water/ cement ratio. The best proportion of fines to use in a given concrete mix design will depend on the shape of the particular aggregate, the grading and the usage of the concrete.

CCS 6: Recommended proportions of fine aggregate according to percentage passing a 600 m sieve. The final calculation, equation F5, to determine the fine and coarse aggregate is made using the proportion of fine aggregate obtained from figure CCS 6 and the total aggregate content derived from Stage 4. Fine Aggregate Content = Total Aggregate Content x Proportion of Fines .. [ F5 ] Coarse Aggregate Content = Total Aggregate Content Fine Aggregate

Procedures of Design Mixing

Production of Trial Mix Design 1. The volume of mix, which needs to make three cubes of size 100 mm is calculated. The volume of mix is sufficient to produce 3 numbers of cube and to carry out the concrete slump test. 2. The volume of mix is multiplied with the constituent contents obtained from the concrete mix design process to get the batch weights for the trial mix. 3. The mixing of concrete is according to the procedures given in laboratory guidelines. 4. Firstly, cement, fine and course aggregate are mixed in a mixer for 1 minute. 5. Then, water added and the cement, fine and course aggregate and water mixed approximately for another 1 minute. 6. When the mix is ready, the tests on mix are proceeding.

Slump Test apparatus for Concrete Workability Tests on Trial Mix Design

1. The slump tests are conducted to determine the workability of fresh concrete. 2. Concrete is placed and compacted in three layers by a tamping rod with 25 times, in a firmly held slump cone. On the removal of the cone, the difference in height between the uppermost part of the slumped concrete and the upturned cone is recorded in mm as the slump. 3. Three cubes are prepared in 100 mm x 100 mm each. The cubes are cured before testing. The procedures for making and curing are as given in laboratory guidelines. Thinly coat the interior surfaces of the assembled mould with mould oil to prevent adhesion of concrete. Each mould filled with two layers of concrete, each layer tamped 25 times with a 25 mm square steel rod. The top surface finished with a trowel and the date of manufacturing is recorded in the surface of the concrete. The cubes are stored undisturbed for 24 hours at a temperature of 18 to 220C and a relative humidity of not less than 90 %. The concrete all are covered with wet gunny sacks. After 24 hours, the mould is striped and the cubes are cured further by immersing them in water at temperature 19 to 21oC until the testing date. 4. Compressive strength tests are conducted on the cubes at the age of 7 days. Then, the mean compressive strengths are calculated.

The Calculations
Here is one example of calculation from one of the concrete mix design obtained from the laboratory. We have to fill in all particulars in the concrete mix design form with some calculations

CCS 3: Relationship between standard deviation and characteristic strength. Firstly, we specified 30 N/mm2 at 7 days for the characteristic strength. Then, we obtained the standard deviation, s from the figure CCS 3. So, s = 8 N/mm2. From the formula F1, k = 1.64 for 5 % defect. The margin, M is calculated as below: M = k x s = 1.64 x 8 = 13.12 N/mm2 With the formula F2, target mean strength, fm is calculated as below: Target mean strength, fm = fc + M = 30 + 13.12 = 43.12 N/mm2 The type of cement is Ordinary Portland Cement (OPC). For the fine and course aggregate, the laboratorys fine aggregate is un-crushed and for coarse aggregate is crushed before producing concrete. Then, we obtain the free-water/ cement ratio from table CCS 1. For OPC ( 7 days ) using crushed aggregate, water/cement ratio = 36 N/mm2. After that, from the figure CCS 4, the curve for 42 N/mm2 at 0.5 free-water ratio is plotted and obtained the free-water ratio is 0.45 at the target mean strength 43.12 N/mm2. Next, we specified the slump test for slump about 20 mm and the maximum aggregate size we used in laboratory is 10 mm. For the specified above, we can obtained the free-water content from table CCS 2 at slump 10 30 mm and maximum size aggregate 10 mm, the approximate free-water content for the un-crushed aggregates is 180 kg/m3 and for the crushed aggregates is 205 kg/m3. Because of the coarse and fine aggregates of different types are used, the free-water content is estimated by the expression: Free-water Content, W = 2/3 Wf + 1/3 Wc = (2/3 x 180) + (1/3 x 205) = 188.33 kg/m3 where, Wf = Free-water content appropriate to type of fine aggregate Wc = Free-water content appropriate to type of coarse aggregate Cement content also can obtained from the calculation with the expression at F3: Cement Content, C = Free Water Content / Free-water or Cement Ratio = 188.33 / 0.45 = 418.52 kg/m3 We assumed that the relative density of aggregate (SDD) is 2.7. Then, from the figure CCS 5 with the free-water content 188.33 kg/m3, obtained that concrete density is 2450 kg/m3. The total aggregate content can be calculated by:

Total Aggregate Content = D C W = 2450 418.52 188.33 = 1843.15 kg/m3 The percentage passing 600 m sieve for the grading of fine aggregate is about 60 %. The proportion of the fine aggregate can be obtained from the figure CCS 6, which is 38 %. Then, the fine and course aggregate content can be obtained by calculation: Fine Aggregate Content = Total Aggregate Content x Proportion of Fines = 1868.74 x 0.38 = 700.40 kg/m3 Coarse Aggregate Content = Total Aggregate Content Fine Aggregate = 1843.15 700.40 = 1142.75 kg/m3 The quantity per m3 can be obtained, which is; Cement = 418.52 kg Water = 188.33 kg Fine aggregate = 700.40 kg Coarse aggregate (10 mm) = 1142.75 kg The volume of trial mix for 3 cubes = [(0.1 x 0.1 x 0.1) x 3] + [25% contingencies of trial mix volume] = 0.006 + 0.00075 = 0.00375 m3 The quantities of trial mix = 0.00375 m3, in which is; Cement = 1.57 kg Water = 0.71 kg Fine aggregate = 2.61 kg Coarse aggregate (10 mm) = 4.29 kg The Results of Mix Design Slump Test = True Slump of 55 mm All the 3 concrete cubes produced were then cured for 7 days. After that, the compressive cube test is carried out. The results are as follows: Sample Compressive Strength Average 1 2 3 32.37 33.54 35.70 (32.37 + 33.54 + 35.70) / 3 = 33.87

For cubes after 7 days of curing, compressive strength should not be less than 2/3 target mean strength. = 2/3 43.12 = 28.75 N/mm2 < 33.9 N/mm2

After 7 days of curing, the compressive strength of concrete cubes produced by the mix design method pass the specific strength requirements.

Discussions Upon Concrete Mix Designs

Although our compressive strength passes the specific requirements, we still identified several factors which contribute to the lacking of compressive strength of concrete mixes produced in the experiment. However, the main factor is the condition of aggregates whether it is exposed to sunlight or rainfall. When the free water/cement ration is high, workability of concrete is improved. However, excessive water causes honey-comb effect in the concrete produced. The concrete cubes become porous, and hence its compressive strength is well below the design value. Other possible reasons include over compaction, improper mixing methods and some calculation errors. Few suggestion upon several steps to avoid the problems previously faced:

All the raw materials, which is cement, aggregates, and sand should be protected from precipitation or other elements which may affect its physical properties. The quantity of ingredients may be adjusted if necessary, theoretical values are not always suitable. For example, if the aggregates are wet or saturated, less amount of water should be added, vice versa. Compaction should be done carefully, as either under or over-compaction will bring significant negative effect on the concrete produced.

The Conclusion
1. By using the concrete mix design method, we have calculated the quantities of all ingredients, that is water, cement, fine and coarse aggregate according to specified proportion. 2. The concrete produced did not fulfill the compressive strength requirements due to several reasons. Furthermore, some steps mentioned above should be taken into consideration to overcome this problem. Standard reference for the concrete mix design is as accordance to British Standard; BS 5328: 1981 : Methods of Specifying Concrete including Ready-Mixed Concrete