2018-TE-01

EXPERIMENT N0. 09
Preparing a concrete mix and casting various samples required for
different tests.
ASTM Standard: ACI 211.1-19
Scope and Significance:
This method takes into consideration the requirements for consistency, workability, strength and
durability. This article presents ACI method of concrete mix design. In this experiment certain
number of samples will be prepared which will then be tested for the verification of concrete mix
design process.

Apparatus:
• Concrete Mixer
Materials
• Cement
• Sand/Fine Aggregate
• Crush/Coarse Aggregate
• Water
Molds for samples to be prepared
• Cylinders 300mm x 150mm Ø(10+2), compressive strength & split cylinder test
• Cylinders 300mm x 150mm Ø (2), double punch test
• Cubes 150mm (10), compressive strength
• Beams 76mm x 153mm x 1370mm (4),

Required Data:
• Before starting concrete mix design, basic information on raw materials shall be prepared which
include:
• Sieve analyses of fine and coarse aggregates.
• Unit weight (dry rodded density) of coarse aggregate.
• Bulk specific gravities and absorptions or moisture content of aggregates.
• Mixing-water requirements of concrete developed from experience with available aggregates.
• Specific gravities of Portland cement and other cementitious materials, if used.
• Relationships between strength and water-cement ratio or ratio of water-to-cement plus other
cementitious materials, for available combinations of cements, other cementitious materials if
considered, and aggregates.
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Procedure:
The standard ACI mix design procedure can be divided up into 8 basic steps:

• Choice of slump
• Maximum aggregate size selection
• Mixing water and air content selection
• Water-cement ratio
• Cement content
• Coarse aggregate content
• Fine aggregate content
• Adjustments for aggregate moisture

Slump:
• The choice of slump is actually a choice of mix workability:
• Slump Ranges for Specific Applications (after ACI, 2000)
Construction type Slump value, mm
Minimum Maximum*
Reinforced foundation walls and footings 25 75
Plain footings, caissons, and substructure walls 25 75
Beams and reinforced walls 25 100
Building columns 25 100
Pavements and slabs 25 75
Mass concrete 25 50
*May increased 25mm for methods of consolidation other than vibration

Maximum Aggregate Size:

Maximum aggregate size will affect such PCC parameters as amount of cement paste,
workability and strength. In general, ACI recommends that maximum aggregate size be limited
to 1/3 of the slab depth. If the coarse aggregate is too large the concrete may be difficult to
consolidate and compact in the forms, resulting in a honeycombed structure or large air pocket.
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Mixing Water and Air Content Estimation:

The quantity of water per unit volume of concrete required to produce a given slump is
dependent on:
• Nominal maximum size
• Particle shape
• Grading of the aggregates
• Concrete temperature
• Amount of entrained air
• Use of chemical admixtures.
Table 2 and Table 3 provide estimates of required mixing water for concrete made with various
maximum sizes of aggregate, for non-air and air-entrainment concrete, respectively.
Table 2 Approximate mixing water (Kg/m3) and air content for different slumps and
nominal maximum sizes of aggregates for non-air content concrete
Slump, mm Water, Kg/m3 of concrete for indicated nominal maximum sizes of
aggregate
9.5 12.5 mm 19 mm 25 37.5 50 75 150 mm
mm mm mm mm mm
25-50 207 199 190 179 166 154 130 113
75-100 228 216 205 193 181 169 145 124
150-175 243 228 216 202 190 178 160 ----
Approximate Air 3 2.5 2 1.5 1 0.5 0.3 0.2
Content quantity,
%

Table 3 Approximate mixing water (Kg/m3) and air content for different slumps and
nominal maximum sizes of aggregates for air content concrete
Slump, mm Water, Kg/m3 of concrete for indicated nominal maximum sizes of aggregate
9.5 mm 12.5 mm 19 25 mm 37.5 50 75 150 mm
mm mm mm mm
25-50 181 175 168 160 150 142 122 107
75-100 202 193 184 175 165 157 133 119
150-175 216 205 197 184 174 166 154 ----
Recommended average total air content (%) for different level of exposure
Mild exposure 4.5 4 3.5 3 2.5 2 1.5 1
Moderate exposure 6 5.5 5 4.5 4.5 4 3.5 3
Severe exposure 7.5 7 6 6 5.5 5 4.5 4
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Water Cement Ratio:

The water-cement ratio is a convenient measurement whose value is well correlated with PCC
strength and durability. In general, lower water-cement ratios produce stronger, more durable
PCC.
Table 4 Relationship between water-cement or water-cementitious materials ratio and
compressive strength of concrete
28-days compressive strength in MPa (psi) Water cement ratio by weight
Non-air entrained Air entrained
41.4 (6000) 0.41 ---
34.5 (5000) 0.48 0.40
27.6 (4000) 0.57 0.48
20.7 (3000) 0.68 0.59
13.8 (2000) 0.82 0.74

Table 5 maximum permissible water/cement ratios for concrete in severe exposure

Types of structure Structure wet continuously of Structure exposed
frequently exposed to freezing to seawater
and thawing
Thin sections (railings, curbs, sills, ledges, 0.45 0.40
ornamental work) and sections with less
than 25mm cover over steel
All other structures 0.50 0.45

Cement Content:
The calculated amount based on the selected mixing water content and water-cement ratio.
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Coarse Aggregate Content:

• Selection of coarse aggregate content is empirically based on mixture workability. ACI
recommends the percentage (by unit volume) of coarse aggregate based on nominal
maximum aggregate size and fine aggregate fineness modulus.
Volume of coarse aggregate per unit of volume of concrete
Maximum aggregate size, mm fineness moduli of fine aggregate
2.40 2.60 2.80 3
9.5 0.50 0.48 0.46 0.44
12.5 0.59 0.57 0.55 0.53
19 0.66 0.64 0.62 0.60
25 0.71 0.69 0.67 0.65
37.5 0.75 0.73 0.71 0.69
50 0.78 0.76 0.74 0.72

Fine Aggregate Content:

At the completion of Step 6, all ingredients of the concrete have been estimated except the fine
aggregate. There are two standard methods to establish the fine aggregate content, the mass
method and the volume method. the "volume" method will be used because it is a somewhat
more exact procedure. The volume of fine aggregates is found by subtracting the volume of
cement, water, air, and coarse aggregate from the total concrete volume. Then once the volumes
known the weights of each ingredient can be calculated from the specific gravities. The volume
occupied in concrete by any ingredient is equal to its weight divided by the density of that
material (the latter being the product of the unit weight of water and the specific gravity of the
material).
Adjustments for Aggregate Moisture:
Unlike HMA, PCC batching does not require dried aggregate. Therefore, aggregate moisture
content must be accounted for. Aggregate moisture affects the following parameters:
• Aggregate weights. Aggregate volumes are calculated based on oven dry unit
weights, but aggregate is typically batched based on actual weight.
• Amount of mixing water. If the batched aggregate is anything but saturated
surface dry it will absorb water (if oven dry or air dry) or give up water (if wet) to
the cement paste. This causes a net change in the amount of water available in the
mix and must be compensated for by adjusting the amount of mixing water added.