CONCRET

E MIX
DESIGN

(Fourth Revised Edition)

N.Pokharel

1
 Contents

INTRODUCTION 1
AMERICAN CONCRETE INSTITUTE (ACI) METHOD 4
GENERAL 5
LIMITATION ACI METHOD 5
REQUIRED PARAMETERS OF INGREDIENTS 5
EQUIPMENT AND APPARATUS 6
DESIGN GUIDE LINE 7
SUMMARY OF DESIGN PROCEDURE 12
MIX DESIGN DATA SHEET 13
DESIGN STEPS 14
COMPRESSIVE STRENGTH TEST OF SAMPLE 17
GRAPHICAL DETERMINATION OF REQUIRED
W/C RATIO 18
HIGH STRENGTH MIX METHOD 19
GENERAL 20
FEATURE OF DESIGN 20
LIMITATION OF HIGH STRENGTH DESIGN 21
REQUIRED PARAMETERS OF INGREDIENTS 22
DESIGN PROCEDURE 23
EQUIPMENT AND APPARATUS 24
MIX DESIGN DATA SHEET 27
DESIGN STEPS 28

2
INTRODUCTION

Cement concrete is an artificial rock which can be made of required

size, shape, and strength for the structure in construction work. It is the
most widely used construction material and is very hard to find its
substitution . Technologists may select this construction material as their
requirement such as strength, permanance, durability, impermeability, fire-
resistance, abrasion resintance etc. Regarding these required properties of
concrete, it is very important to determine the proportion as well as quality
of its constituents. Determining process of selecting suitable ingredients,
its proportion, producing minimum strength and durability as economically
as possible is called mix design.

Basic concept of mix design prevails on the relationship between

two essential ingredients i.e. aggregates and paste. Paste is not termed as
solution of cement in water, but the suspension of cement particles. Hence
the degree of dilution of paste may affect workability and strength of the
concrete. The more dilute the paste, the greater the spacing between
cement particles and thus the weaker will be ultimate paste structure. It is
therefore helpful to consider more closely the structure of the paste. It is
important that as little paste as possible should be used and here lies the
importance of grading of aggregates. Excess of paste cause high cost,
greater shrinkage, greater susceptibility to percolation of water and
therefore attack by aggressive waters and weathering action. This is
achieved by minimising the voids by well gradation.

There are several methods of mix design to adopt, but here we

describe only two of them in detail which are more effective and viable in
the contest of Nepal. Most of the renowned projects and agencies of Nepal
have been adopting these two mix-design methods widely as per their
requisites of the concrete materials. These methods are -
1. American Concrete Institute (ACI)
2. High Strength Mix

In Nepal, still we adopt the arbitrary proportional ratio method in

many organizations of HMG departments, municipalities, private buildings
and other small scaled projects. But most of the large scaled foreign aid
projects can not ignore the necessity of mix design of the concrete for
precise supervision. The arbitrary proportinal method may always not
govern the true proportion of ingredients and cause segregation, bleeding,
uneconomic and weaker or over strength. People are not conscious to hire

3
a technician to conduct the supervision and rely on a head mason who will
be contractor of their private construction. In Terai region of Nepal, most of
these masons have tendency of using more sand with large size coarse
aggregate and less sand with small size aggregate which is absolutely
wrong approach . Due this reason, people find their construction defective
after all.

Regarding these common problems all over the country, it is highly

necessary to follow the technical way of construction wheather it's small or
huge construction. Possibly, it is needed to conduct the test of concrete
materials to obtain true design parameters. Otherwise adopt in design
these parameters for concrete materials, if conducting the test is not
possible. These parameters are here tabulated below according to practice
and records.
1. Cement:
a) Portland cement, of possibly 53 grade
b) Specific gravity 3.15
2. Fine Aggregate
a) Required size and well-graded and washed.
b) Saturated surface dry condition (SSD)
c) Very less weathering, alluvial (glacier) blueish grey:
Specific gravity 2.65 to 2.67 Absorption 1.0%
d) Less weathering, alluvial deposit (perennial river), yellowish grey:
Specific gravity 2.62 to 2.64 Absorption 1.5%
e) Less weathering, alluvial deposit (stream), pale yellow:
Specific gravity 2.59 to 2.61 Absorption 2.0%
f) Washed crushed rock:
Specific gravity 2.62 to 2.65 Absorption 1.5%
g) Fineness modulus (FM)
coarser 3.1, moderate 2.9, fine 2.6, very fine 2.3
3. coarse Aggregate
a) Required size and well-graded and washed.
b) Saturated surface dry condition (SSD)
c) Alluvial / glacier (fresh deposit):
Specific gravity 2.67 to 2.72 Absorption 0.3%
d) Alluvial / common perennial river (fresh deposit):
Specific gravity 2.62 to 2.66 Absorption 0.5%
e) Alluvial (loose conglomerate):
Specific gravity 2.62 to 2.65 Absorption 0.7%
f) Washed crushed rock (stream),
Specific gravity 2.62 to 2.65 Absorption 0.7%

4
 3
g) Compacted density (Kg/m ):
Aggregate Screened gravel Crushed rock:
Sp.gr. 2.62 - 2.65 2.66 - 2.69 2.70 - 2.72 2.62 - 2.65 2.66 - 2.69
10 mm 1450 1500 1650 1400 1450
20 mm 1550 1600 1700 1550 1600
38 mm 1650 1750 1800 1600 1650
50 mm 1750 1800 1850 1700 1750

From the above statement, a technical person can easily decide the
nearest true properties of concrete material according to its possession
regarding location, appearance etc. After conforming these data
tentatively, here we can proceed the mix design calculation as per our
requirements. It may give more accurate proportion and workability than
the arbitrary ratio gives. If little bit difference in volume or workability is
found, it may be adjusted very easily.

5
American Concrete
Institute (ACI)
METHOD

6
GENERAL
The American Concrete Institute (ACI) has recommended an efficient
procedure of concrete mix design considering more economical use of
locally avilable materials to produce desirable workability, durability and
strength. The ACI method is able to produce concretes from very stiff to
fluid state workability as it is required in different conditions.The design
tables incorporating the basic relationships between the parameters, are
useful in selecting optimum combinations of the ingredients of non air-
entrained or air-entrained concrete mixes. The following design criteria are
assumed in formulating the design tables:
F Type-I, non air-entraining (OPC) as per ASTM/C-150, Specific Gravity
of 3.15
F Coarse aggregate:- Gradation as per ASTM/C-33, Specific Gravity of
2.68, Absorption of 0.5%.
F Fine Aggregate :- Gradation as per ASTM/C-33, Specific Gravity of
2.64, Absorption of 0.7%, FM of 2.8

LIMITATION ACI METHOD

F It is better to design a concrete mix only up to 35 MPa of plastic state.
F Though the specific gravity of coarse aggregate is taken 2.68 in this
ACI manual but if it is different see footnote of table-4.
F It is important to note that the mix design tables serve as a guide in
selecting proportions and suitable minor adjustments should be
effected in the field for any departures in quality of aggregates and
type of cement used.

REQUIRED PARAMETERS OF INGREDIENTS

Before starting to design a concrete mix, it is very much important to have
all informations about concrete ingredients i.e physical test reports. These
physical parameters may be obtained by own laboratory test or by the
manufacturer. Basicaly for the design mix, the following parameters should
be available in the time.
A. CEMENT
1. Grade and type as ACI - classification
2. Specific Gravity

B. FINE AGGREGATE
1. Gradation (Sieve Analysis)
2. Fineness Modulus (FM i.e. 2.4 to 3.1preferable)
3. Specific Gravity (SSD Bulk)
4. Absorption

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 C. COARSE AGGREGATE
1. Gradation (Sieve Analysis)
2. Dry Rodded Unit Weight
3. Specific Gravity (SSD Bulk)
4. Absorption

D. WATER
1. Chemical content(free of salt and alkalies)
2. Turbidity (potable or clear)

EQUIPMENT AND APPARATUS

To perform a mix design, the following equipment or apparatuses must be
available in advance:
A. SLUMP TEST 2. Mixer or mixing pan
1. Slump cone 3. Triple beam balance (1 g.)
2. Base plate 4. Scoop
3. Tamping rod 5. Straight edge
4. Graduated scale 6. Tamping rod or
5. Straight edge 7. Vibrator plate
6. Mixer (1 cft.) or 8. Rubber mallet
7. Mixing pan with shovel 9. Weighing containers
8. Scoop 10. Thermometer
9. Triple beam balance (1 g.) C. STRENGTH TEST
10. Weighing containers 1. Compressive St. machine
B. SAMPLE PREPARATION 2. Triple beam balance (1 g.)
1. 6 nos. cylinder or cube mould 3. Rubber sheet
RELATIONSHIP OF W/C RATIO TO STRENGTH
50
45 Non Air Entarined Mix
CYLINDER STRENGTH IN 28 DAYS (MPa)

40
35
30
Air Entarined Mix
25
20
15
10
0.36 0.40 0.44 0.48 0.52 0.56CEMENT
WATER 0.60 RATIO
0.64 0.68 0.72 0.76 0.80
fig.- 1

8
DESIGN GUIDE LINE
F Firstly, to know the water cement ratio of concrete mix, find out it by
coinciding the required designed strength (i.e. minimum required
strength plus strength for safety factor as specified or assumed) to the
appropriate graph line mentioned in figure -1 above.

F To know the quantity of water for 1 m3 of fresh concrete made in

screened river gravel, find out that required quantity with regarding the
desirable workability (slump) mentioned in table -1 below. This table
does not entertain crushed aggregate.

Table : 1 Approximate Mixing of Water (Kg/m 3 of Concrete)

Requirements for Different Slumps and Maximum Size of Aggregates
Slump Maximum Size of Coarse Aggregates (mm)
(mm) 10 12.5 20 25 40 50 70 150
Non Air Entrained Concrete
20 - 50 205 200 185 180 160 155 145 125
80 - 100 225 215 200 195 175 170 160 140
150 - 180 240 230 210 205 185 180 170 -
Approximate 3 2.5 2 1.5 1 0.5 0.3 0.2
percentage amount of entrapped air in non air entrained concrete.
Air Entrained Concrete
20 - 50 180 175 165 160 145 140 135 120
80 - 100 200 190 180 175 160 155 150 135
150 - 180 215 205 190 185 170 165 160 -
Percentage of 8.0 7.0 6.0 5.0 4.5 4.0 3.5 3.0
recommended average total air content.

F The way of inspection and testing of consistency or workability of

concrete may differ as the specification quotes in different projects, so
compare the following consistency as it requires.
Table : 2 Comparison of Consistency Measurements by Various Methods
Consistency Slump Vebe Compacting Drop Table
Description (mm) (Sec.) Factor Revolutions
Extremely dry - 32 to 18 - 112 to 56
Very stiff - 18 to 10 0.70 56 to 28
Stiff 0 - 25 10 to 5 0.75 28 to 14
Stiff plastic 25 - 50 5 to 3 0.85 14 to 7
Plastic 75 - 100 3 to 0 0.90 7
Flowing 150 - 175 - 0.95 -

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F The exposure condition of structure may be affected by the climatic
condition, chemicals in contact (such as sulphate, salt, water etc) or
air. It means that durability of concrete should be considered as its
exposure condition that governs the strength of concrete (required w/c
ratio will be selected from the table-3 below).
Table : 3 Maximum Permissible Water Cement Ratios for Different Types
of Structures and Degrees of Exposure
Exposure Condition *
Severe wide range in
temperature, or frequent
Mild temperature rarely below
alternations of freezing and
freezing, or rainy, or aid.
thawing (air entrained concrete
only)
Type of structures
At the water line or with in At the water line or with in
the range of fluctuating the range of fluctuating
In water level or spray In water level or spray
air In sea water or air In sea water or
In fresh In fresh
in contact with in contact with
water water
sulphates1 sulphates1
Thin sections, such as railings, curbs,
sills, ledges, ornamental or architectural
concrete, reinforced piles, pipes and all
sections with less than 25 mm. Concrete
cover reinforcing. 0.48 0.44 0.39 0.53 0.48 0.39
Moderate sections, such as retaining
walls, abutments, piers, girders, beams. 0.53 0.48 0.44** # 0.53 0.44**
Exterior portions of heavy (mass)
sections. 0.57 0.48 0.44 # 0.53 0.44**
Concrete deposited by tremie under
water - 0.44 0.44 - 0.44 0.44
Concrete slabs laid on the ground. 0.53 - - # - -
Concrete protected from weather,
interiors of buildings, concrete below
ground. # - # - - -
Concrete which will later be protected by
enclosure or backfill what which may be
exposed to freezing and thawing for
several years before such protection is
offered. 0.53 - - # - -
*Air entrained concrete concrete should be used under all conditions involving severe exposure and may be
used under mild exposure conditions to improve workability of the mixture.
1
Soil or ground water containing sulphate concentrations of more than 3.2%.
**When sulphate resisting cement (as per ACI type-V) is used, maximum water/cement ratio may be increased
by 0.13 litres per bag.
# Water/cement ratio should be selected on basis of strength workability requirements.

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F Find out the volume of aggregate for per unit volume of concrete with
respect to the fineness modulus of sand and nominal maximum size of
aggregate. The value not given in following table will be determined by
interpolation of given value which are only for the particular aggregate
with specific gravity of 2.68. If our specific gravity is different then, see
the note of table 4.

Table : 4 Volume of Dry Rodded Coarse Aggregates per Unit

Volume of Concrete (V D ) only for Plastic Consistency
Maximum Size of Fineness Modulus (FM) of Sand
Coarse Aggregate 2.40 2.60 2.80 3.00 3.20
10 0.50 0.48 0.46 0.44 0.42
12.5 0.59 0.57 0.55 0.53 0.51
20 0.66 0.64 0.62 0.60 0.58
25 0.71 0.69 0.67 0.65 0.63
40 0.76 0.74 0.72 0.70 0.68
50 0.78 0.76 0.74 0.72 0.70
70 0.81 0.79 0.77 0.75 0.73
150 0.87 0.85 0.83 0.81 0.79
Note: The volume of dry rodded coarse aggregate recommended in above table, applies to the aggregate of the
given specific gravity g which in this case is 2.68. If the aggregate used has a specific gravity g 1 , the volume of
coarse aggregates specified in the table should be multiplied by the ratio (g 1 /g ) to account for gross apparent
volume (VA) of solid particles. i.e. V A = g 1 /2.68xV D
Where,
VA = apparent vol. of solid particles per unit volume of concrete
g1 = used specific gravity
VD = Vol. of dry rodded agg. per unit volume of concrete

F To determine the exact volume of coarse aggregate in per unit volume

of concrete in non-plastic consistency (i.e. in stiff condition), select the
appropriate multiplying factor (f) listed below to the volume mentioned
in table-4. For example, see note# of table-5 in next page.
for example:
If it is to prepare a concrete mix with a slump (0 - 25 mm) and 20 mm aggregate in a
sand with FM 2.8 then the corrected volume of coarse aggregate per unit volume of
VC = f x VA = 1.15 x 0.62 = 0.71
Where,
VC = corrected vol. of aggregate in per unit vol. of stiff concrete
f = multiplying factor from table-5 (next page)
VA = apparent vol. of solid particles per unit volume of concrete from table-4

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 Table:5 Factor ( f ) to Applied to the Volume of Coarse Aggregate
Calculated on the Basis of Table:4, for Mixes of Consistence Other than
Plastic
Factors for Maximum Size of Coarse Aggregate (mm)
Consistence
10 12.5 20 25 40
Extremely dry 1.9 1.7 1.45 1.4 1.3
Very stiff 1.6 1.45 1.3 1.25 1.25
Stiff 1.35 1.3 1.15 1.15 1.2
Stiff plastic 1.08 1.06 1.04 1.06 1.09
Plastic (Reference) 1 1 1 1 1
Fluid 0.97 0.98 1 1 1

F To know the quantity of water for 1 m3 of fresh concrete made in

crushed aggregate, find out that required quantity with regarding the
desirable workability (slump) mentioned in table -6 below. This table
does not entertain the aggregate produced by screened river gravel.

Table : 6 Approximate Mixing of Water (Kg/m 3 of Concrete) Required for

Different Consistencies and Maximum Size of Aggregates *
Relative Water, Kg. Per m3 for
Drop
Slump Vebe, Compacting Water indicated maximum size
Workability Table
(mm) (sec.) Factor content of C. A. (mm)
Revolutions
(%) 10 12 20 25 40
Non - Air-Entrained Concrete
Extremely dry - 32 to 18 112 - 56 - 78 177 168 158 148 137
Very Stiff - 18 to 10 56 - 28 0.70 83 188 182 168 158 148
Stiff 0 - 25 10 to 5 28 - 14 0.75 88 196 192 177 168 158
Stiff plastic 25 - 50 5 to 3 14 - 7 0.85 92 206 196 182 177 162
Plastic 75 - 100 3 to 0 7 0.91 100 226 217 203 192 177
Flowing 150 - 175 - - 0.95 106 240 226 212 203 188
Percentage of approximate amount of entrapped air in non-air - entrained concrete, 3.0 2.5 2.0 1.5 1.0
Air-Entrained Concrete
Extremely dry - 32 to 18 112 - 56 - 78 158 148 137 133 123
Very Stiff - 18 to 10 56 - 28 0.70 83 168 158 148 137 133
Stiff 0 - 25 10 to 5 28 - 14 0.75 88 177 168 158 148 137
Stiff plastic 25 - 50 5 to 3 14 - 7 0.85 92 182 177 162 152 143
Plastic 75 - 100 3 to 0 7 0.91 100 203 192 177 168 158
Flowing 150 - 175 - - 0.95 106 212 203 188 177 168
Recommended average total air content, percent (%) 8.0 7.0 6.0 5.0 4.5
* These quantities of mixing water are use in computing factors for trial batches. They are for reasonably well-
shaped angular coarse aggregates graded within limits of accepted specifications. If more water is required
than shown, the cement factor, estimated from these quantities, should be increased to maintain desired water-
cement ratio, except as otherwise indicated by laboratory tests for strength.

12
F The aggregates to be used in concrete mix should fall with in the zone
of limit envelope for each NMSA mentioned below.

Table : 7 Zone of Limit of Concrete Aggregate as adpoted by ACI

(ASTM:C-33)
Sieve
0~5 2.36~9.5 4.75~12.5 4.75~19 9.5~19 4.75~25 9.5~25
Size (mm)
100
90
75
63
50
37.5 100 100
25 100 100 95 ~ 100 90 ~ 100
19 100 90 ~ 100 90 ~ 100 40 ~ 85
12.5 100 90 ~ 100 20 ~ 55 25 ~ 60 10 ~ 40
9.5 100 85 ~ 100 40 ~ 70 20 ~ 55 0 ~ 15 0 ~ 15
4.75 95 ~ 100 10 ~ 30 0 ~ 15 0 ~ 10 0~5 0 ~ 10 0~5
2.36 80 ~ 100 0 ~ 10 0~5 0~5 0~5
1.18 50 ~ 85 0~5
0.6 25 ~ 60
0.3 10 ~ 30
0.15 2 ~ 10
Sieve
12.5~25 4.75~37.5 19~37.5 4.75~50 25~50 37.5~63 37.5~90
Size (mm)
100 100
90 90 ~ 100
75 100
63 100 100 90 ~ 100 25 ~ 60
50 100 100 95 ~ 100 90 ~ 100 35 ~ 70
37.5 100 95 ~ 100 90 ~ 100 35 ~ 70 0 ~ 15 0 ~ 15
25 90 ~ 100 20 ~ 55 35 ~ 70 0 ~ 15
19 20 ~ 55 35 ~ 70 0 ~ 15 0~5 0~5
12.5 0 ~ 10 10 ~ 30 0~5
9.5 0~5 10 ~ 30 0~5
4.75 0~5 0~5
2.36
1.18
0.6
0.3
0.15

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F Find the fineness modulus (FM) of sand from the sieve analysis report
prepared in laboratory same as demonstrated in table-7 below.

Table : 8 Example , Determination of Fineness Modulus of Fine Aggregate

(Sand) from Sieve Analysis Report
Sieve Size Mass of ACI Specification
% cum. % of
Retained % of Retained Limit (ASTM:C-
Retained Passing
BS mm (gms) 33)
No # 4 4.75 0.0 0.0 0.0 100.0 95 to 100
No # 8 2.36 60.0 8.5 8.5 91.5 80 to 100
No # 16 1.18 200.0 28.4 36.9 63.1 50 to 85
No # 30 0.60 300.0 42.6 79.4 20.6 25 to 60
No # 50 0.30 100.0 14.2 93.6 6.4 10 to 30
No # 100 0.15 25.0 3.5 97.2 2.8 2 to 10
Pan 20.0 2.8 100.0 - -
TOTAL 705 284.4
FM = 284.40 /100 = 2.84

SUMMARY OF DESIGN PROCEDURE

F Collect the all the properties of concrete materials by conducting
necessary tests.
F Determine the min. design strength including safety factor for site.
F Determine the quantity of water required and percentage of air
entraining using table-1 or table-6 as the coarse aggregate is used.
F Find out the W/C ratio as per strength consideration using fig.-1 or as
per durability in exposer consideration table-3, whichever is lower.
F Find out the volume of coarse aggregate using table-4 and table-5,
with respect to FM value as well as specific gravity of sand.
F Thus find out the quantity of cement having value of W/C ratio and
water required for 1 m 3 of concrete.
F Similarly, multiplying the dry rodded density to volume required as per
table-4, find out the quantity of coarse aggregate required.
F Now calucate the absolute volume of concrete by using the respective
specific gravity of materials excluding sand.
F Then subtracting that absolute volume in 1 m3 volume, the remaining
value will be determined as the volume of sand which is converted in
weight by using the specific gravity of sand.
F Now prepare three sample after varying W/C ratio with 5% more & 5%
less but keeping the quantity of water same in two of them.
F Test these three sample in specified time and plot graph strength vs
W/C ratio. Here it is determined the actual W/C ratio required for min.
design strength graphically.

14
Mix Design Data Sheet
TRIAL MIX TM-….… A
Project A1
Location A2
Structure A3
Member A4
Concrete Class A5
Type and Brand of Cement A6
Source of Fine Aggregate A7
Type of Coarse Aggregate A8
Source of Coarse Aggregate A9
Specific Gravity of Cement A10
Specific Gravity of Fine Aggregate A11
Fineness Modulus (FM) of F.A. (as determined in table-7) A12
Nominal Max. Size of Coarse Aggregate (mm) A13
Specific Gravity of Coarse Aggregate A14
Rodded Unit Weight of Coarse Aggregate (Kg/m3) A15
# A16
Minimum Cylinder Strength Required (MPa)
( # If cube strength is required, select 80% of cylinder strength above i.e Cube Strenght = 1.2 x Cyl. Strength )

Percentage of Safety Factor Specified (%) A17

Net Design Cylinder Strength (MPa) A16 + (A17/100)xA16 A18
Water Cement Ratio (wc1) - [whichever is lower below] A20
Strength Consideration (fig.-1) or Durability Consideration (table-2 )

Desirable Workability (Slump) (mm) A21

*Required Weight of Water (table-1or 6) (Kg/m3) A22
*Entrained Air in Concrete (table-1 or 6) (%) A23
(* If the coarse aggregate is crushed rock i.e angular shape, use table-6)
Volume of Coarse Aggregate Required (table-4) A24

TRIAL MIX TM-….… B

Water Cement Ratio (wc2) - [10% more than specified] A20 + 0.10 x A20 A25

TRIAL MIX TM-….… C

Water Cement Ratio (wc3) - [10% lesser than specified] A20 - 0.10 x A20 A26

15
Design Steps
TRIAL MIX TM-….… A

Weight of water Required (Kg/m3) A22 B1

Weight of Coarse Aggregate Required (Kg/m3) A24 x A15 B2

Weight of Cement Required (Kg/m3) B1 / A20 B3

Solid Volume of Cement in Concrete (cc) B3 x 1000 / A10 B4

Solid Volume of Water in Concrete (cc) B1 x 1000 B5

Solid Volume of Coarse Aggregate in Concrete (cc) B2 x 1000 / A14 B6

Volume of Entrained Air in Concrete (cc) A23 /100 x 1000000 B7

Total Volume of Ingredients (except F. Agg.) (cc) B4+ B5+ B6+ B7 B8

Required Volume of Fine Aggregate in Concrete (cc) 1000000 - B8 B9

Weight of Fine Aggregate Required (Kg/m3) B9 x A11 /1000 B10

ESTIMATED BATCH QUANTITY

For 1 m3 7 Litres for Slump 40 Litres for Lab.
Ingredients
Volume Test Sample
Cement (Kg) B3 0.007 x B3 0.04 x B3
Water (Kg) B1 0.007 x B1 0.04 x B1
Fine Aggregate (Kg) B10 0.007 x B10 0.04 x B10
Coarse Aggregate (Kg) B2 0.007 x B2 0.04 x B2

Density of Fresh Concrete (Kg/m3) B3+B1+B10+B2

NOTE: Here, check the slump of this TRIAL-A. If the desirable slump range is not obtained,
recalculate by increasing or decreasing the weight of water by 5% again and again until the slump is
maintained but keeping the W/C ratio same. After maintaining the desirable slump, prepare six nos. of
sample (cylinder or else) for strength test and then proceed to TRIAL -B.

16
Design Steps
TRIAL MIX TM-….… B

Weight of water Required (Kg/m3) A22 C1

Weight of Coarse Aggregate Required (Kg/m3) A24 x A15 C2

Weight of Cement Required (Kg/m3) C1 / A25 C3

Solid Volume of Cement in Concrete (cc) C3 x 1000 / A10 C4

Solid Volume of Water in Concrete (cc) C1 x 1000 C5

Solid Volume of Coarse Aggregate in Concrete (cc) C2 x 1000 / A14 C6

Volume of Entrained Air in Concrete (cc) A23 /100 x 1000000 C7

Total Volume of Ingredients (except F. Agg.) (cc) C 4 + C5 + C 6 + C7 C8

Required Volume of Fine Aggregate in Concrete (cc) 1000000 - C8 C9

Weight of Fine Aggregate Required (Kg/m3) C9 x A11 /1000 C10

ESTIMATED BATCH QUANTITY

For 1 m3 7 Litres for Slump 40 Litres for Lab.
Ingredients
Volume Test Sample
Cement (Kg) C3 0.007 x C3 0.04 x C3
Water (Kg) C1 0.007 x C1 0.04 x C1
Fine Aggregate (Kg) C10 0.007 x C10 0.04 x C10
Coarse Aggregate (Kg) C2 0.007 x C2 0.04 x C2

Density of Fresh Concrete (Kg/m3) C3+C1+C10+C2

Note: Prepare minimum 6 nos. of samples (cube or cylinder). 3 nos for 7 days and 3 nos. for 28 days.

17
Design Steps
TRIAL MIX TM-….… C

Weight of water Required (Kg/m3) A22 D1

Weight of Coarse Aggregate Required (Kg/m3) A24 x A15 D2

Weight of Cement Required (Kg/m3) D1 / A26 D3

Solid Volume of Cement in Concrete (cc) D3 x 1000 / A10 D4

Solid Volume of Water in Concrete (cc) D1 x 1000 D5

Solid Volume of Coarse Aggregate in Concrete (cc) D2 x 1000 / A14 D6

Volume of Entrained Air in Concrete (cc) A23 /100 x 1000000 D7

Total Volume of Ingredients (except F. Agg.) (cc) D 4 + D5 + D 6 + D7 D8

Required Volume of Fine Aggregate in Concrete (cc) 1000000 - D8 D9

Weight of Fine Aggregate Required (Kg/m3) D9 x A11 /1000 D10

ESTIMATED BATCH QUANTITY

For 1 m3 7 Litres for Slump 40 Litres for Lab.
Ingredients
Volume Test Sample
Cement (Kg) D3 0.007 x D3 0.04 x D3
Water (Kg) D1 0.007 x D1 0.04 x D1
Fine Aggregate (Kg) D10 0.007 x D10 0.04 x D10
Coarse Aggregate (Kg) D2 0.007 x D2 0.04 x D2

Density of Fresh Concrete (Kg/m3) D3+D1+D10+D2

Note: Prepare minimum 6 nos. of samples (cube or cylinder). 3 nos for 7 days and 3 nos. for 28 days.

18
Compressive Strength Test of Sample
TRIAL MIX TM-….… A
Age of Sectional

W/C Ratio
Sample Compressive Compressive Average
Sample Area Remarks
No. Load (N) 2 Strength (Mpa) Strength (Mpa)
(day) (mm )
1 7 p1 a s1 = p1 / a
2 7 " p2 " s2 = p2 / a X7=(S1+S2+S3)/3

3 7 " p3 " s3 = p3 / a
4 28 " p4 " s4 = p4 / a
5 28 " p5 " s5 = p5 / a X28=(S1+S2+S3)/3

6 28 " p6 " s6 = p6 / a

TRIAL MIX TM-….… B

Age of Sectional
W/C Ratio

Sample Compressive Compressive Average

Sample Area Remarks
No. Load (N) 2 Strength (Mpa) Strength (Mpa)
(day) (mm )
1 7 p1 a s1 = p1 / a
2 7 " p2 " s2 = p2 / a X7=(S1+S2+S3)/3

3 7 " p3 " s3 = p3 / a
4 28 " p4 " s4 = p4 / a
5 28 " p5 " s5 = p5 / a X28=(S1+S2+S3)/3

6 28 " p6 " s6 = p6 / a

TRIAL MIX TM-….… C

Age of Sectional
W/C Ratio

Sample Compressive Compressive Average

Sample Area Remarks
No. Load (N) 2 Strength (Mpa) Strength (Mpa)
(day) (mm )
1 7 p1 a s1 = p1 / a
2 7 " p2 " s2 = p2 / a X7=(S1+S2+S3)/3

3 7 " p3 " s3 = p3 / a
4 28 " p4 " s4 = p4 / a
5 28 " p5 " s5 = p5 / a X28=(S1+S2+S3)/3

6 28 " p6 " s6 = p6 / a

19
Graphical Determination of Required W/C Ratio
Summary of Designed Mix
7 Days Strength 28 Days Strength
Mix Design W/C Ratio Remarks
(Mpa) (Mpa)
TRIAL MIX TM-….… B W/C2 w/c=5% more
TRIAL MIX TM-….… A W/C1 as per design
TRIAL MIX TM-….… C W/C3 w/c=5% less

Example: A tipical required value of W/C ratio (as shown in fig.-2) for
minimum design strength is determined by the observed data as
demontrated below.
7 Days Strength 28 Days Strength
Mix Design W/C Ratio Remarks
(Mpa) (Mpa)
TRIAL MIX TM-11, B 0.56 18 25 w/c=5% more
TRIAL MIX TM-11, A 0.52 21 30 as per design
TRIAL MIX TM-11, C 0.48 27 39 w/c=5% less

Determination of Actual W/C Ratio

50
Example:
Compressive Strength (MPa)

45 For Design Str. = 32 Mpa

Requires W/C Ratio = 0.51
40
35
Design Strength
Required W/C Ratio

30
25
20
15
10
0.48 0.52 0.56
W/C Ratio
Fig.- 2

20
High Strength Mix
METHOD

21
GENERAL
This high strength concrete mix design has been developed by B. W.
Shacklock and H. C. Erntroy in 1954. For designing concrete mix of low
and medium grade compressive strength i.e. up to 35 MPa, it is assumed
the strength of fully compacted concrete at a required age to be dependent
only on the w/c ratio of the mix. However, compressive strength of high-
strength mix above 35 MPa is mainly influenced by the properties of
aggregates in addition to that of w/c ratio. The methods of mix design used
for medium grade concrete cannot therefore, govern to lead to an accurate
estimate of the required mix proportions for high strength concrete under
all circumstances.

FEATURE DESIGN
The methods of high strength design-mix has been developed on the basis
of these following features:
F In general, only a natural sand is needed for use of fine aggregate
because high strength are rarely obtained with crushed rock fine
aggregate.

IRREGULAR GRAVEL COARSE AGGREGATE WITH NATURAL

SAND AND ORDINARY PORTLAND CEMENT

90
COMPRESSIVE STRENGTH (MPa)

80
70
60
50
40
30
20
10
0
0 10 20 30 40 50 60 70

REFERENCE NUMBER

Fig.1

F Crushed aggregate (possibly granite) is more preferred than that use

of irregular gravel coarse aggregate for strength assurance.
F Low workability is introduced instead of high degree of workability.

22
F Combined grading of total aggregates may be assumed to be constant
with 30% passing in No. #4 sieve (4.75 mm size sieve).

CRUSHED GRANITE COARSE AGGREGATE WITH NATURAL

SAND AND ORDINARY PORTLAND CEMENT

90

80
COMPRESSIVE STRENGTH (MPa)

70

60

50

40

30

20

10

0
0 10 20 30 40 50 60 70
REFERENCE NUMBER

Fig. 2

F An arbitrary reference number is determined from a graph connecting

average design strength and reference number which is needed to
know the required water cement ratio (w/c) for the particular strength.

LIMITATION OF HIGH STRENGTH DESIGN

F No concrete of plastic consistency is suggested to design but only stiff
mix is preferred to get high strength.
F Nominal maximum size of aggregate(NMSA) is taken only up to 20
mm. Maximum.
F Graphical tables are used instead of analytical formulas or so on.
F These graphs used (to find out the Reference Number) in this method
are obtained from the aggregates containing 30% of material passing
through the 4.75 mm sieve. If other grading are used, suitable
adjustment have to be made as shown in fig. - 7.

23
REQUIRED PARAMETERS OF INGREDIENTS
As usual for designing a concrete mix, it is very much important to be
known all information about concrete ingredients i.e. physical test reports.
These physical parameters may be obtained by own laboratory - test or by

IRREGULAR GRAVEL COARSE AGGREGATE WITH NATURAL

SAND AND RAPID HARDENING PORTLAND CEMENT

90
COMPRESSIVE STRENGTH (MPa)

80
70
60
50
40
30
20
10
0
0 10 20 30 40 50 60 70

REFERENCE NUMBER

Fig. 3

the manufacturer. Basically for the high strength design mix, the following
parameters should be available in the time.
A. CEMENT
1. Grade and type
2. Specific Gravity

B. FINE AGGREGATE
1. Gradation (Sieve Analysis)
2. Specific Gravity (SSD Bulk)
3. Absorption

C. COARSE AGGREGATE
1. Gradation (Sieve Analysis)
2. Specific Gravity (SSD Bulk)
3. Absorption

24
D. WATER
1. Chemical content(free of salt and alkalis)
2. Turbidity (potable or clear)
CRUSHED GRANITE COARSE AGGREGATE WITH NATURAL SAND
AND RAPID HARDENING PORTLAND CEMENT
90

80
COMPRESSIVE STRENGTH (MPa)

70

60

50

40

30

20

10

0
0 10 20 30
REFERENCE 40
NUMBER 50 60 70

Fig. 4

DESIGN PROCEDURE
F Estimate the average design strength using standard deviation or as it
is specified for the special job.
F Find out the arbitrary reference number according to necessity and
availability of concrete materials using fig. 1, 2, 3, 4.
F Determine the water/cement ratio (w/c) in terms of reference number
using fig. 5, 6.
F Knowing the type of aggregate, size of aggregate, degree of workability
and water cement ratio (w/c), find the aggregate/cement ratio using
table- 1 or table- 2.
F Plot the gradation (percentage passing) of available materials i.e. fine
aggregate and coarse aggregate as shown in fig. 7 and then determine
the required fine aggregate/total aggregate ratio connecting with 30%
passing line.

25
EQUIPMENT AND APPARATUS
To perform a mix design, no special equipment or apparatus is required
more than it requires for normal mix design except a special vibrating
machine is needed to compact the stiff concrete-sample. For the stiff
concrete no hand-mixing is suggested to come true reporting results and
hence is always preferred laboratory mixer to mix vigorously.

20 mm. AGGREGATE
Degree of Workability

0.50
0.48
0.46
WATER/CEMENT RATIO

0.44
0.42
0.40
0.38
0.36
0.34
0.32
0.30
0 10 20 30 40 50 60 70
REFERENCE NUMBER

Fig. 5

For preparing the sample following euipments are needed:

1. 6 nos. Cylinder or Cube Mould 4. Scoop 7. Rubber Mallet
2. Mixer or Mixing Pan 5. Straight Edge 8. Tamping Rod or Vibrator
3. Triple Beam Balance (1 g.) 6.Thermometer 9. Weighing Containers

To find out the strength of specimens following equipment are needed :

1. Compressive Strength Machine
2. Triple Beam Balance (1 g.)
3. Rubber Sheet (Filler)

26
Table- 1: Aggregate / cement ratio (by weight) required to give four
degrees of workability with different water cement ratios using Ordinary
Portland cement
Type & Size Irregular Gravel Crushed Granite
of C. A. * 20 mm Size 10 mm Size 20 mm Size 10 mm Size
Degree of
EL VL L M EL VL L M EL VL L M EL VL L M
Workability +
0.30 3.0 2.4 3.3 2.9
Water Cement Ratio (by weight)

0.32 3.8 2.5 3.2 4.0 2.6 3.6 2.3

0.34 4.5 3.0 2.5 3.9 2.6 4.6 3.2 2.6 4.2 2.8 2.3
0.36 5.2 3.5 3.0 2.5 4.6 3.1 2.6 5.2 3.6 3.1 2.6 4.7 3.2 2.7 2.3
0.38 4.0 3.4 2.9 5.2 3.5 3.0 2.5 4.1 3.5 2.9 5.2 3.6 3.0 2.6
0.40 4.4 3.8 3.2 3.9 3.3 2.7 4.5 3.8 3.2 4.0 3.3 2.9
0.42 4.9 4.1 3.5 4.3 3.6 3.0 4.9 4.2 3.5 4.4 3.6 3.1
0.44 5.3 4.5 3.8 4.7 3.9 3.3 5.3 4.5 3.7 4.8 3.9 3.3
0.46 4.8 4.1 5.1 4.2 3.6 4.8 4.0 5.1 4.2 3.6
0.48 5.2 4.4 5.4 4.5 3.8 5.1 4.2 5.5 4.5 3.8
0.50 5.5 4.7 4.8 4.0 5.4 4.5 4.7 4.0
* Natural sand used in combination with both types of coarse aggregates.
+ EL = Extremely Low VL = Very Low L = Low M = Medium

10 mm. AGGREGATE
Degree of Workability

0.50
0.48
0.46
WATER/CEMENT RATIO

0.44
0.42
0.40
0.38
0.36
0.34
0.32
0.30
10 20 30 40 50 60 70

REFERENCE NUMBER

Fig. 6

27
Table- 2: Aggregate / cement ratio (by weight) required to give four
degrees of workability with different water cement ratios using Rapid
Hardening Portland cement
Type & Size Irregular Gravel Crushed Granite
of C. A. * 20 mm Size 10 mm Size 20 mm Size 10 mm Size
Degree of
EL VL L M EL VL L M EL VL L M EL VL L M
Workability +
0.32 2.6 2.9 2.5
Water Cement Ratio (by weight)

0.34 3.4 2.2 2.8 3.6 2.4 3.2

0.36 4.1 2.7 2.3 3.5 2.4 4.3 2.9 2.4 3.9 2.5
0.38 4.8 3.2 2.8 2.3 4.2 2.9 2.4 4.9 3.4 2.9 2.4 4.5 3.0 2.5
0.40 5.5 3.7 3.2 2.7 4.9 3.3 2.8 2.3 5.5 3.9 3.3 2.7 5.0 3.4 2.9 2.4
0.42 4.2 3.6 3.0 3.7 3.0 2.6 4.2 3.6 3.0 5.5 3.8 3.2 2.7
0.44 4.6 4.0 3.4 4.1 3.5 2.9 4.7 4.0 3.3 4.2 3.5 3.0
0.46 5.0 4.3 3.7 4.5 3.8 3.2 5.1 4.3 3.6 4.6 3.8 3.2
0.48 5.5 4.7 4.0 4.9 4.1 3.5 5.5 4.6 3.9 5.0 4.1 3.4
0.50 5.0 4.3 5.2 4.4 3.7 4.9 4.1 5.3 4.4 3.7
* Natural sand used in combination with both types of coarse aggregates.
+ EL = Extremely Low VL = Very Low L = Low M = Medium
20 mm
100 10 mm
4.75 mm
10 mm
90
Required Ratio = 24%

Percentage Passing of F. A.
2.36 mm
80
Percentage Passing of C. A.

70
1.18 mm
60

50 0.60 mm

40
Line of 30% Passing
30

20

10 0.30 mm
4.75 mm

2.36 mm
0 0.15 mm
0 10 20 30 40 50 60 70 80 90 100

28
Mix Design Data Sheet
TRIAL MIX: TM - …. A

Project A0
Location A1
Structure A2
Member A3
Concrete Class A4

Type and Brand of Cement A5

Source of Fine Aggregate A6
Type of Coarse Aggregate A7
Source of Coarse Aggregate A8

Specific Gravity of Cement A9

Specific Gravity of Fine Aggregate A10
Specific Gravity of Coarse Aggregate A11
Nominal Max. Size of Coarse Aggregate (mm) A12

Minimum Cylinder Strength Required # (MPa) A13

(# If cube strength is required, select 80% of cylinder strength above)
Additional Strength for Safety Factor (MPa) A14
Average Design Cylinder Strength (MPa) A13+A14 A15

Arbitrary Reference Number (from fig. 1, 2, 3 or 4) A16

Degree of Workability (as required) A17

Water Cement Ratio (from fig. 5 or 6) A18

Total Aggregate to Cement Ratio (from table 1 or 2) A19

% of Fine Aggregate to Total Aggregate (from fig. 7) A20

29
Design Steps
TRIAL MIX: TM - A

A : Mix Proportion by Weight (with reference to cement)

1 Cement 1 B1
2 Water A18 B2
3 Fine Aggregate A20/(100x A19) B3
4 Coarse Aggregate {1-(A20/100)}x A19 B4

3
B : Absolute Volume (for 1 m )
1 Cement B1/A9 B5
2 Water A18 B6
3 Fine Aggregate B3/A10 B7
4 Coarse Aggregate B4/A11 B8
B5+B6+B7+B8 B9

\ Required Weight of -
Cement 1000/B9 B10
Water B2xB10 B11
Fine Aggregate B3xB10 B12
Coarse Aggregate B4xB10 B13

Density of Fresh Concrete (Kg/m3) B10+B11+B12+B13

C : Batching for
* Lab.Sample
Materials Unit 1 m3 Volume
for 40 Lit. Vol.
CEMENT Kg B10 0.04xB10
WATER Kg B11 0.04xB11
FINE AGGREGATE Kg B12 0.04xB12
COARSE AGGREGATE Kg B13 0.04xB13
* Note : Estimated quantity 40 liters is for 6 nos. of cylindrical moulds
(size dia. 15 cm & ht. 30 cm.). If it is to prepare 6 nos. of 15x15x15 cm.
cubical moulds, take 25 liters volume for laboratory sample.

30