16 ACTA 2012 Fawad Najam

Development and Automation of an
Empirical Mix Proportioning Method for

concretes with indigenous aggregates and
cements of Pakistan
Fawad Ahmed Najam, Syed Ali Rizwan
Presented by: Fawad Ahmed Najam

School of Engineering and Technology (SET),
Asian Institute of Technology (AIT),
Thailand. Date: 7th November 2012
Concrete Mix Design
• Art of balancing various conflicting requirements
• An obvious constraint: Within a fixed volume, one cannot alter

a component independent of others
• Time consuming trial process
• Ready-to-use mix designs
• ACI, BS (DoE) and IS Methods of Mix Design
ACTA 2012, NUST, ISLAMABAD, PAKISTAN Structural Engineering field of Study/SET/ AIT Slide 2
Study Objectives
• Objectives
– To develop (and automate) a method of mix proportioning
based on detailed experimental results for normal strength
concrete
– To develop a consistent relation between w/c and
compressive strength of Concrete for locally available
aggregate and cement types
Study Parameters
• The effect of following variables is studied
– Cement Type
– Concrete age
– Fineness Modulus of Sand
– Maximum aggregate size
– Fine/Total Aggregate Ratio in mix
– Superplasticizer type and dosage
Study Parameters
Cement Type
OPC Grade 43 OPC Grade 53 SR Cement
w/c Ratios
0.3 0.4 0.5 0.6 0.7
Max. Aggregate Size Fineness Modulus

Percentage of
Fine Aggregates 2.058 2.233 2.408 2.582 2.758
3/8” 1/2” 3/4”
30% 35% 40% 45% 50%
SP Type SP Dosage
Rheobuild - 858 Gelenium - 51 1% 1.5 % 2%
Exploring Indigenous Materials
• Specific relationships constituting figures and tables given in
ACI, BS and IS are based on different material properties.
– Different w/c ratio VS compressive strength relations.
– Different Specific gravities, absorption values, bulk densities etc. of

aggregates.
– Different Environmental Conditions (General Temperature and

Humidity ranges)
• Need of exploring and evaluating the performance of local

materials and the extent up to which they affect the desired
characteristics of concrete in both fresh and hardened states.
Need for empirical mix proportioning procedure
• ACI 211 method Considers only sands with Fineness Moduli in the
range of 2.4 to 3.0 for selecting coarse aggregate content. (Fineness
Modulus of Pakistani Sands?)
• BS & IS: Graphs are available to estimate the fine aggregate content for
maximum aggregate sizes of 10 mm and 20 mm. (Maximum aggregates
sizes available in Pakistan?)
• ACI: Distinction between crushed stone aggregates and natural

aggregates is not considered in estimating water requirement in the
mix. No consideration for aggregate surface texture.
• IS: Considers Compacting Factor as measure for workability and to

calculate the water demand. Compacting factor VS Slump.
Control Mixes
Water
Crushed Agg. to
w/c Water Cement Sand Ratios by Ratios by Demand of
Stone Cement
ratio (Kg/m3) (Kg/m3) (Kg/m3) weight Volume the system
(Kg/m3) ratio
(Kg/m3)
Rich 0.30 200.00 666.67 619.23 911.64 1 : 0.93 : 1.37 1 : 0.95 : 1.62 2.30 220.88
0.40 200.00 500.00 676.37 995.77 1 : 1.35 : 1.99 1 : 1.56 : 2.38 3.34 222.80
0.50 200.00 400.00 710.66 1046.25 1 : 1.78 : 2.62 1 : 2.00 : 3.00 4.39 223.96
0.60 200.00 333.33 733.51 1079.90 1 : 2.20 : 3.24 1 : 2.45 : 3.73 5.44 224.73
0.70 200.00 285.71 749.84 1103.93 1 : 2.62 : 3.86 1 : 3.11 : 4.67 6.49 225.28
Lean
1200
Water
Unadjusted Quantities
1000 Cement
Fine Aggregates
800 Coarse Aggregates
(Kg/m3)
600
400
200
0
0.20 0.30 0.40 0.50 0.60 0.70 0.80
w/c Ratio
Test Program
• More than 400, 100 mm x 200 mm cylinders were casted to study all
parameters (Detwiler 2007).
• Casting temperature ranges between 16 to 21 ͦ C, relative humidity
between 61% - 66%.
• Specimens were water cured at 25 ͦ C in curing tank.
• Moisture adjustments for aggregate moisture conditions was carried out
• Every Point on any Strength Graph is an average value of three 100mm x
200 Cylinder Specimens (ACI 318-08)
Servo Hydraulic Compression Testing

Machine
(Load Controlled)
Ideally, a displacement controlled machine is

best for Compression Testing of Cement
Based Materials
Proposed Method of Mix Design
Step 1: Determination of Mean Target Strength
′ ′
f1 + f2
𝑓𝑐𝑟 = 𝛼𝑓𝑐 + 𝑆𝐷 α=2−( )
2
Maximum Aggregate Sizes 3/8” 1/2” 3/4”
Fineness Modulus
2 1.026 1.036 1.051
2.2 0.881 0.891 0.906
2.4 0.828 0.838 0.852
2.6 0.866 0.876 0.890
2.8 0.996 1.005 1.020
Where,
fc’ = Compressive strength of concrete specified at 28 days.
fcr’ = Mean target strength.
SD = Standard deviation recommended by ACI 318-11.
f1 = A factor for maximum aggregate size (f1 = 1, at maximum aggregate size of ¾”,)
f2 = A factor for fineness modulus of sand (f2 = 1, at fineness modulus of 2.057)
Note: The factors f1 and f2 are calculated from proposed regression equations
developed as a result of statistical analysis of experimental data.
Step 2: Determination of (w/c)st:
• Two values of w/c ratio are introduced here namely (w/c)st and (w/c)wo.
• Their average is proposed to be final w/c ratio.
• (w/c)st can be obtained from experimental w/c – strength curves for
given cement type using fcr′.
• (w/c)wo can be determined from experimental w/c – slump curves for
given cement type.
– If Super plasticizer is to be used, an adjusted slump value is calculated by
subtracting “average slump increase” provided by SP from original slump
requirement. This “average slump increase” provided by SP is determined
from regression relations based on experimental data between SP dosage
and average slump increase at a given w/c ratio. In this case, (w/c)wo is
proposed to be calculated using adjusted slump requirement instead of
original slump requirement.
Step 3: Determination of Cement content:
𝑓𝑐𝑟′
𝐶=
𝐶1
C1 = 0.0014 (fcr′) + 4.1025
Step 4: Determination of Water content:
𝑊= 𝑤 𝑐 × 𝐶
Step 5: Determination of Total absolute volume of aggregates:
C W
Absolute Aggregate Volume = 1 − − − 0.015
3.15 x 1000 1000
Step 6: Determination of fine and coarse aggregate contents:
Fine Aggregate Content = Fine Aggregate Volume x Sp. Gr of Fine Aggregates x 1000
Fine Aggregate Volume = 0.35 x Total Aggregate Volume
Coarse Aggregate Volume = 0.65 x Total Aggregate Volume
Coarse Aggregate Content = Coarse Aggregate Volume x Sp. Gr of Coarse Aggregates x 1000
Step 7: Moisture Adjustment
Experimental Results
Water-Cement Ratio VS 28 Day Compressive Strength
8000
7000
BS Mix Design Method
Compressive Strength (Psi)
6000
IS 10262 (43 Grade Cement)
IS 10262 (53 Grade Cement)
5000 ACI 211.1
Experimental Results (OPC Grade 43)
4000 Experimental Results (OPC Grade 53)
3000
2000
1000
0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8 0.85
w/c ratio
Bestway Cement (Grade 43) Fauji Cement (Grade 53)
8000 8000
1 Day 1 Day
7000 7000

7 Day 7 Day
6000 6000
28 Day 28 Day
5000 5000
56 Day 56 Day
4000 4000
3000 3000
2000 2000
1000 1000
0 0
0.30 0.40 0.50 0.60 0.70 0.3 0.4 0.5 0.6 0.7
w/c w/c
Sulfate Resistant Cement
8000
7000 1 Day
6000 7 Day
5000 28 Day
56 Day
4000
3000
2000
1000
0
0.30 0.40 0.50 0.60 0.70
w/c
8000 Comparison of Experimental Results with Abram’s Rule
Compressive Strength (Psi) 7000
6000
Experimental Values (Grade 43)
5000 Values Predicted by Abram's Law
4000 Experimental Values (Grade 53)
3000
2000
1000
0
0.4 0.5 0.6 0.7 0.8 0.9 1 1.1
w/c ratio (by Volume)
Proposed Equations
Abram’s Rule OPC Grade 43 OPC Grade 53
(R2 = 0.925) (R2 = 0.977)

Experimental Relative Strength Gain vs Predicted values
120
Percentage of 28 days Compressive
100
80
Strength (Psi)
1 Day
60
7 Day
40 28 Day
20
0
Experimental Results ACI 209 Prediction CEB-FIP MC 90
Formula
6000
28 Day Compressive Strength

5000
4000
(Psi) 3000 Effect of Maximum Aggregate Size on 28 Day

Compressive Strength
2000
1000
Maximum Size of Aggregates
0
3/8" 1/2" 3/4"
6000
5000
4000
(Psi)
3000
Effect of Fineness Modulus of sand on 28
1000 Finnes modulus of Fine Aggregates
0
2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8
Effect of Fine/Total Aggregate Ratio on 28 Day Compressive Strength
6000
28 Day Compressive Strength (Psi)
5000
4000
3000
2000
1000
0
30 35 45 50
Volumetric Percentage of Fine Aggregates (of Total Aggregate Content)
Relation between SP dosage and Slump
w/c = 0.3 w/c = 0.4

10
9
8
7
Slump (in)
6
Rheobuild - 858, Beta-Naphthalenesulphonate based
5 Gelenium - 51, Polycarboxylic ether based
4
3
2
1
0
0 1 1.5 2 0 1 1.5 2
SP Dosage as Percentage of Cement by weight
A Graphical User Interface (GUI)
for proposed procedure
MATRIX LABORATORY – A high-performance computer language and a
software environment for technical computing.
START
FLOWCHART
Given Data: Specified Strength and Workability in terms of
Slump, Material Properties.
Calculation of fcr’: Mean Target Strength is calculated using

the proposed relation. Factors f1 and f2 accounts for
fineness modulus and maximum aggregate sizes
Calculate average strength increase per 1 Kg/m3 increase in

cement content (C1). Cement Content is estimated by dividing
fcr’ by C1
From w/c – Strength relations, get (w/c)St
From w/c – Slump relations, get (w/c)wo
Find average w/c ratio and water content by multiplying average w/c with
cement content.
Calculate the Total Absolute volume of Aggregates using the relation,
Abs. Vol. of Fine Aggregates = 0.35 x Total Absolute Volume

Fine Aggregate Content = Abs. Vol x Sp. Gravity x 1000
From w/c-SP Dosage

graphs, Calculate adjusted Want to adjust
YES
(reduced) value of slump slump value for
provided by water only Super Plasticizer
or Not?
NO
Perform moisture
Adjustments if aggregates
are not in Saturated
Surface Dry Condition
Print Final Quantities
END
Getting Started
View Graphs Used in main Module Enter in to the Main Module
Limitations and Assumptions
• Not valid for 28 day compressive strength greater than 7000 Psi
• Not valid for sands with fineness modulus greater than 2.8
• Two basic assumptions are,
– The compressive strength of concrete is governed by its water-

cement ratio
– For a given aggregate characteristics, the workability of concrete
is governed by its water content
Conclusions
• 28 day strength VS w/c ratio relations proposed by BS (DoE)
and IS are more close to experimental results than proposed
by ACI 211.
• For w/c ratio range between 0.4 to 0.6, Experimental strength

results fully comply with values predicted by Abram’s Law.
• Sands with Fineness Modulus (FM) in the range of 2.35 – 2.5

give optimum strength while keeping all other parameters
constant when used with ¾” down grading of margalla crush.
Conclusions
• Fine to total aggregates volumetric ratio of 0.35 gives the
optimum strength at 28 days while keeping all other
parameters constant.
• Polycarboxylic ether polymer (PCE) based superplasticizer

(Gelenium - 51) is more efficient in reducing water content for
constant workability than Beta-Naphthalenesulphonate
Polycondensate based superplastcizer (Rheobuild - 858).
THANK YOU

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Development and Automation of an

Empirical Mix Proportioning Method for

Presented by: Fawad Ahmed Najam

• An obvious constraint: Within a fixed volume, one cannot alter

• Time consuming trial process

• Ready-to-use mix designs

• ACI, BS (DoE) and IS Methods of Mix Design

OPC Grade 43 OPC Grade 53 SR Cement

0.3 0.4 0.5 0.6 0.7

Max. Aggregate Size Fineness Modulus

30% 35% 40% 45% 50%

Rheobuild - 858 Gelenium - 51 1% 1.5 % 2%

– Different w/c ratio VS compressive strength relations.

– Different Specific gravities, absorption values, bulk densities etc. of

– Different Environmental Conditions (General Temperature and

• Need of exploring and evaluating the performance of local

• ACI: Distinction between crushed stone aggregates and natural

• IS: Considers Compacting Factor as measure for workability and to

Servo Hydraulic Compression Testing

Ideally, a displacement controlled machine is

Step 7: Moisture Adjustment

Compressive Strength (Psi)

w/c ratio (by Volume)

(R2 = 0.925) (R2 = 0.977)

28 Day Compressive Strength

(Psi) 3000 Effect of Maximum Aggregate Size on 28 Day

w/c = 0.3 w/c = 0.4

SP Dosage as Percentage of Cement by weight

Calculation of fcr’: Mean Target Strength is calculated using

Calculate average strength increase per 1 Kg/m3 increase in

From w/c – Strength relations, get (w/c)St

From w/c – Slump relations, get (w/c)wo

Calculate the Total Absolute volume of Aggregates using the relation,

Abs. Vol. of Fine Aggregates = 0.35 x Total Absolute Volume

From w/c-SP Dosage

Print Final Quantities

View Graphs Used in main Module Enter in to the Main Module

• Two basic assumptions are,

– The compressive strength of concrete is governed by its water-

• For w/c ratio range between 0.4 to 0.6, Experimental strength

• Sands with Fineness Modulus (FM) in the range of 2.35 – 2.5

• Polycarboxylic ether polymer (PCE) based superplasticizer

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