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

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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:
1. The minimum compressive strength required from structural consideration
2. The adequate workability necessary for full compaction with the compacting
equipment available. 
3. Maximum water-cement ratio and/or maximum cement content to give adequate
durability for the particular site conditions
4. 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

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 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/mm 2. 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

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 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
Abraham’s 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

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 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 water-cement 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
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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 28-day 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.

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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:

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 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.

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 Understanding Nominal and Design Mixes

Cement concrete in India on large scale is being used since the last about 70 years. In
the early days the following nominal ratio by volume for concrete were specified.

Cement : Sand : Aggregate

1 : 2 : 4 Correspond to M-15 Grade

1 : 1.5 : 3 Correspond to M-20 Grade

1 : 1 : 2 Correspond to M-25 Grade

IS: 456-2000 has recommended that minimum grade of concrete shall be not less than
M-20 in reinforced concrete work. Design mix concrete is preferred to nominal mix. If
design mix concrete cannot be used for any reason on the work for grades of M-20 or
lower, nominal mixes may be used with the permission of engineer-in-charge, which
however is likely to involve higher cement content.

Accordingly all concrete of above M-20 Grade for RCC work must be of design mixes.
The code allows nominal mix for RCC work of M-20 Grade, but what shall be the
nominal mix, the reader will find from the following table that it is better to adopt
design mix, rather than to go for M20 nominal mix which is too cumbersome to
determine a fixed nominal mix value.

Nominal mixes as per IS : 456-2000 if fine aggregate is of Zone II as per IS : 383-1970.

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 As per IS:383-1970 Mix Ratio by Weight
Max Max cement:
Grade of Maximum size of
Fine Coarse W/C Aggregate
Concrete graded coarse Cement
Aggregate Aggregate Ratio ratio by mass
aggregate

M-20 10 1 : 1.8 : 2.7 0.60 1.5

M-20 20 1 : 1.5 : 3.0 0.60 1.5

M-20 40 1 : 1.3 : 3.2 0.60 1.5

Proportions by weight can be converted to proportions by volume, by dividing with the

bulk density of the materials available for use at site. The bulk density of cement may
be taken 1.44 kg/lit.

The above nominal mixes are worked out for Zone II fine aggregate. As per IS: 383-
1970 there are three more zone of sands. Therefore, the total nominal mixes shall be 12
for 10, 20 & 40 mm maximum size of coarse aggregate.

Thus, it could be seen that nominal mixes cannot have a fix conventional proportions
such as 1:2:4 or 1:1.5:3, but may vary according to maximum size of coarse aggregate
and grading of fine aggregate. Hence nominal mixes are also needed to be designed
according to the sizes of aggregates available at site. However, the ultimate aim must be
to get the specified properties of concrete.

As per IS: 456-2000, volume batching may be allowed only where weight batching is
not practical and provided accurate bulk densities of materials to be actually used in
concrete have earlier been established. Allowance for bulking shall be made in
accordance with IS: 2386(Part 3). The mass volume relationship should be checked as
frequently as necessary.

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The exposures of Indian Construction sites at most places are Moderate for which IS:
456-2000 specified that minimum grade of concrete for reinforced concrete should be
M25. Accordingly for durability consideration the structural concrete must not be below
M-25 grade. The high strength benefits obtained should be taken into account in the
design consideration of the concrete structure.

If for practical purpose, we go deeper than we will find that for all reinforced concrete
structures we must have concrete from design mixes.

In the IS: 456-2000 there is nothing mentioned of 1:1:2 ration for M-25 grade of
concrete. Concrete of above M-20 must be design mixes. If one takes 1:1:2 ratio then
the cement content comes to 528 kg/m 3. Where as IS: 456-2000 on page 19 clause
8.2.4.2 mentioned that OPC in excess of 450 kg/m3 should not be used.

The concrete surfaces of the structure exposed to severe rain, alternate wetting and
drying such as RCC OH water tank comes to severe exposure environment for which
the minimum grade of concrete shall be M-30, minimum cement content 320 kg/m 3 and
maximum free W/C ration 0.45. The following table will show the compression of
nominal and design mixes for RCC work.

Materials: OPC 43-grade, River sand of Zone II and 20 mm graded crushed stone
aggregate. Specific gravity of sand and aggregate are 2.65. Workability of design mixes
50±10mm slump.

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 Mix.
Min. Cement Nominal mixes
Grade of Free Design mixes by Saving in
content by weight
Concrete W/C weight C:S:A cement
kg/m3 C:S:A
ratio

1:1.5:3
1:2.22:3.48
M-20 0.55 300 Cement= 65 kg/m3
Cement= 327kg/m 3

392kg/m3

1:1:2
1:1.93:3.17
M-25 0.50 300 Cement= 168 kg/m3
Cement= 360kg/m 3

528kg/m3

1:1.67:2.84
M-30 0.45 320 — —
Cement= 400kg/m3

Note: For high strength concrete plasticizer/super plasticizer should be used which will
reduce water and with the same W/C ratio reduction in cement content.

From the above table it can be calculated in nominal mixes of M-20 and M-25 how
much extra cement is used in the construction, its total cost and how much CO2 is
emitted in the production of this extra cement.

When a mix is referred for designing, it is design for target strength. For example M-30
(by Vol. ratio) is design for:
30 + 1.65 x 6 = 39.9 N/mm2 at 28 days age

The above is design target strength of the consultant Laboratory. When this mix is used
at construction site, its concrete shall have strength as per table 11 of IS : 456-2000.
30 + 4 = 34 N/mm2 at 28 days age

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For starting the work a construction site cannot weight for 28 days. Therefore according
to various literatures, if at 7 days its strength is about 65% (22 N/mm 2) the work may be
started. However in all the cases 28 days cube compressive strength shall alone be the
criterion for acceptance and rejection of the concrete.

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 Data Required for Concrete Mix Design

i. Concrete Mix Design Stipulation

a) Characteristic compressive strength required in the field at 28 days grade
designation — M 25
b) Nominal maximum size of aggregate — 20 mm
c) Shape of CA — Angular
d) Degree of workability required at site — 50-75 mm (slump)
e) Degree of quality control available at site — As per IS:456
f) Type of exposure the structure will be subjected to (as defined in IS: 456) -Mild
g) (g) Type of cement: PSC conforming IS:455
h) (h) Method of concrete placing: pump able concrete

ii. Test data of material (to be determined in the laboratory)

a) Specific gravity of cement — 3.15
b) Specific gravity of FA — 2.64
c) Specific gravity of CA — 2.84
d) Aggregate are assumed to be in saturated surface dry condition.
e) Fine aggregates confirm to Zone II of IS – 383

Procedure for Concrete Mix Design of M25 Concrete

Step 1 - Determination Of Target Strength

Him worth constant for 5% risk factor is 1.65. In this case standard deviation is taken
from IS:456 against M 20 is 4.0.
ftarget = fck + 1.65 x S
= 25 + 1.65 x 4.0 = 31.6 N/mm2

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Where,
S = standard deviation in N/mm2 = 4 (as per table -1 of IS 10262- 2009)
Step 2 - Selection of water / cement ratio:-
From Table 5 of IS 456, (page no 20)
Maximum water-cement ratio for Mild exposure condition = 0.55
Based on experience, adopt water-cement ratio as 0.5.
0.5<0.55, hence OK.

Step 3 - Selection of Water Content

From Table 2 of IS 10262- 2009,
Maximum water content = 186 Kg (for Nominal maximum size of aggregate — 20 mm)

Table for Correction in water content

Values as per Values as per

Correction in
Parameters Standard reference Present Departure
Water Content
condition Problem

Slump 25-50 mm 50-75 25 (+3/25) x 25 = +3

Shape of
Angular Angular Nil –
Aggregate

Total +3

Estimated water content = 186+ (3/100) x 186 = 191.6 kg /m3

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Step 4 - Selection of Cement Content
Water-cement ratio = 0.5
Corrected water content = 191.6 kg /m3
Cement content =
From Table 5 of IS 456,
Minimum cement Content for mild exposure condition = 300 kg/m3
383.2 kg/m3 > 300 kg/m3, hence, OK.

This value is to be checked for durability requirement from IS: 456.

In the present example against mild exposure and for the case of reinforced concrete the
minimum cement content is 300 kg/m3 which is less than 383.2 kg/m3.
Hence cement content adopted = 383.2 kg/m3.

As per clause 8.2.4.2 of IS: 456

Maximum cement content = 450 kg/m3.

Step 5- Estimation of Coarse Aggregate proportion

From Table 3 of IS 10262- 2009,
For Nominal maximum size of aggregate = 20 mm,
Zone of fine aggregate = Zone II
And For w/c = 0.5
Volume of coarse aggregate per unit volume of total aggregate = 0.62

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Table for correction in estimation of coarse aggregate proportion

Values as per Values as Correction in

Standard per Coarse
Parameter Departure Remarks
reference present Aggregate
condition problem proportion

W/c 0.5 0.5 Nil – See Note 1

pump able
Workability – – -10% See Note 2
concrete

Total -10%

Note 1: For every ±0.05 change in w/c, the coarse aggregate proportion is to be
changed by 0.01. If the w/c is less than 0.5 (standard value), volume of coarse aggregate
is required to be increased to reduce the fine aggregate content. If the w/c is more than
0.5, volume of coarse aggregate is to be reduced to increase the fine aggregate content.
If coarse aggregate is not angular, volume of coarse aggregate may be required to be
increased suitably, based on experience.

Note 2: For pump able concrete or congested reinforcement the coarse aggregate
proportion may be reduced up to 10%.
Hence,
Volume of coarse aggregate per unit volume of total aggregate = 0.62 x 90% = 0.558
Volume of fine aggregate = 1 – 0.558 = 0.442

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Step 6: Estimation of the mix ingredients
a) Volume of concrete = 1 m3
b) Volume of cement = (Mass of cement / Specific gravity of cement) x (1/100)
= (383.2/3.15) x (1/1000) = 0.122 m3
c) Volume of water = (Mass of water / Specific gravity of water) x (1/1000)
= (191.6/1) x (1/1000) = 0.1916 m3
d) Volume of total aggregates = a – (b + c ) = 1 – (0.122 + 0.1916) = 0.6864 m3
e) Mass of coarse aggregates = 0.6864 x 0.558 x 2.84 x 1000 = 1087.75 kg/m3
f) Mass of fine aggregates = 0.6864 x 0.442 x 2.64 x 1000 = 800.94 kg/m3

Concrete Mix proportions for Trial Mix 1

Cement = 383.2 kg/m3
Water = 191.6 kg/m3
Fine aggregates = 800.94 kg/m3
Coarse aggregate = 1087.75 kg/m3
W/c = 0.5

For trial -1 casting of concrete in lab, to check its properties.

It will satisfy durability & economy.

For casting trial -1, mass of ingredients required will be calculated for 4 no’s cube
assuming 25% wastage.

Volume of concrete required for 4 cubes = 4 x (0.153 x1.25) = 0.016878 m3

Cement = (383.2 x 0.016878) kg/m3 = 6.47 kg
Water = (191.6 x 0.016878) kg/m3 =3.23 kg
Coarse aggregate = (1087.75 x 0.016878) kg/m3 =18.36 kg
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Fine aggregates = (800.94 x 0.016878) kg/m3 = 13.52 kg

Step 7: Correction due to absorbing / moist aggregate:-

Since the aggregate is saturated surface dry condition hence no correction is required.

Step 8: Concrete Trial Mixes:-

Concrete Trial Mix 1:

The mix proportion as calculated in Step 6 forms trial mix1. With this proportion,
concrete is manufactured and tested for fresh concrete properties requirement i.e.
workability, bleeding and finishing qualities.
In this case,
Slump value = 25 mm
Compaction Factor = 0.844

So, from slump test we can say,

Mix is cohesive, workable and had a true slump of about 25 mm and it is free from
segregation and bleeding.
Desired slump = 50-75 mm
So modifications are needed in trial mix 1 to arrive at the desired workability.

Concrete Trial Mix 2:

To increase the workability from 25 mm to 50-75 mm an increase in water content by
+3% is to be made.
The corrected water content = 191.6 x 1.03 = 197.4 kg.
As mentioned earlier to adjust fresh concrete properties the water cement ratio will not
be changed. Hence
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Cement Content = (197.4/0.5) = 394.8 kg/m3

Which also satisfies durability requirement.

Volume of all in aggregate = 1 – [{394.8/(3.15×1000)} + {197.4/(1 x 1000)}] = 0.6773
m3
Mass of coarse aggregate = 0.6773 x 0.558 x 2.84 x 1000 = 1073.33 kg/m3
Mass of fine aggregate = 0.6773 x 0.442 x 2.64 x 1000 = 790.3 kg/m3

Concrete Mix Proportions for Trial Mix 2

Cement = 384.8 kg/m3
Water = 197.4 kg/m3
Fine aggregate =790.3 kg/m3
Coarse aggregate = 1073.33 kg/m3
For casting trial -2, mass of ingredients required will be calculated for 4 no’s cube is
assuming 25% wastage.
Volume of concrete required for 4 cubes = 4 x (0.153 x1.25) = 0.016878 m3
Cement = (384.8 x 0.016878) kg/m3 = 6.66 kg
Water = (197.4 x 0.016878) kg/m3 =3.33 kg
Coarse aggregate = (1073.33 x 0.016878) kg/m3 =18.11 kg
Fine aggregates = (790.3 x 0.016878) kg/m3 = 13.34 kg
In this case,
Slump value = 60 mm
Compaction Factor = 0.852
So, from slump test we can say,
Mix is very cohesive, workable and had a true slump of about 60 mm.
It virtually flowed during vibration but did not exhibit any segregation and bleeding.
Desired slump = 50-75 mm

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So, it has achieved desired workability by satisfying the requirement of 50-75 mm
slump value.
Now, we need to go for trial mix-3.

Concrete Trial Mix 3:

In case of trial mix 3 water cement ratio is varied by +10% keeping water content
constant. In the present example water cement ratio is raised to 0.55 from 0.5.
An increase of 0.05 in the w/c will entail a reduction in the coarse aggregate fraction by
0.01.
Hence the coarse aggregate as percentage of total aggregate = 0.558 – 0.01 = 0.548
W/c = 0.55
Water content will be kept constant.

Cement content = (197.4/0.55) = 358.9 kg/m3

Hence, volume of all in aggregate
= 1 – [{(358.9/(3.15 x 1000)} + (197.4/1000)] =0.688 m3
Mass of coarse aggregate = 0.688 x 0.548 x 2.84 x 1000 = 1070.75 kg/m3
Mass of fine aggregate = 0.688 x 0.452 x 2.64 x 1000 = 821 kg/m3

Concrete Mix Proportions of Trial Mix 3

Cement = 358.9 kg/m3

Water = 197.4 kg/m3
FA = 821 kg/m3
CA = 1070.75 kg/m3
For casting trial -3, mass of ingredients required will be calculated for 4 no’s cube is
assuming 25% wastage.
Volume of concrete required for 4 cubes = 4 x (0.153 x1.25) = 0.016878 m3
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Cement = (358.9 x 0.016878) kg/m3 = 6.06 kg
Water = (197.4 x 0.016878) kg/m3 =3.33 kg
Coarse aggregate = (1070.75 x 0.016878) kg/m3 =18.07 kg
Fine aggregates = (821 x 0.016878) kg/m3 = 13.85 kg
In this case,
Slump value = 75 mm
Compaction Factor = 0.89
So, from slump test we can say,
Mix is stable, cohesive, and workable and had a true slump of about 75 mm.
Desired slump = 50-75 mm
So, it has achieved desired workability by satisfying the requirement of 50-75 mm
slump value.
Now, we need to go for trial mix-4.

Concrete Trial Mix 4:

In this case water / cement ratio is decreased by 10% keeping water content constant.
W/c = 0.45
A reduction of 0.05 in w/c will entail and increase of coarse aggregate fraction by 0.01.
Coarse aggregate fraction = 0.558 +.01 =.568
W/c = 0.45 and water content = 197.4 kg/m3
Cement content = (197.4/0.45) = 438.7 kg/m3
Volume of all in aggregate
= 1 – [{438.7/(3.15 x 1000)} + (197.4/1000)] = 0.664 m3
Mass of coarse aggregate = 0.664 x 0.568 x 2.84 x 1000 = 1071.11 kg/m3
Mass of fine aggregate = 0.664 x 0.432 x 2.64 x 1000 = 757.28 kg/m3

Concrete Mix Proportions of Trial Mix 4

Cement = 438.7 kg/m3
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Water = 197.4 kg/m3
FA = 757.28 kg/m3
CA = 1071.11 kg/m3
For casting trial -4, mass of ingredients required will be calculated for 4 no’s cube
assuming 25% wastage.
Volume of concrete required for 4 cubes = 4 x (0.153 x1.25) = 0.016878 m3
Cement = (438.7 x 0.016878) kg/m3 = 7.4 kg
Water = (197.4 x 0.016878) kg/m3 =3.33 kg
Coarse aggregate = (1071.11 x 0.016878) kg/m3 =18.07 kg
Fine aggregates = (757.28 x 0.016878) kg/m3 = 12.78 kg
A local correction due to moisture condition of aggregate is again applied on this
proportions. With corrected proportions three concrete cubes are cast and tested for 28
days compressive strength.
A summary of all the trial mixes is given in the following Table.

Recommended mix proportion of ingredients for grade of concrete M25:

From Compressive Strength vs. c/w graph for target strength 31.6 MPa we get,
W/c = 0.44
water content = 197.4 kg/m3
Cement content = (197.4/0.44) = 448.6 kg/m3
Volume of all in aggregate
= 1 – [{448.6/(3.15 x 1000)} + (197.4/1000)] = 0.660 m3
A reduction of 0.05 in w/c will entail and increase of coarse aggregate fraction by 0.01.
Coarse aggregate fraction = 0.558 +.01 =.568
Volume of fine aggregate = 1 – 0.568 = 0.432
Mass of coarse aggregate = 0.660 x 0.568 x 2.84 x 1000 = 1064.65 kg/m3
Mass of fine aggregate = 0.660 x 0.432 x 2.64 x 1000 = 752.71 kg/m3

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 Cement and their Uses in Concrete Construction

There are various types of cement used in concrete construction. Each type of cement
has its own properties, uses and advantages based on composition materials used during
its manufacture.
13 Types of Cement and their Uses
1. Ordinary Portland Cement (OPC)
2. Portland Pozzolana Cement (PPC)
3. Rapid Hardening Cement
4. Quick setting cement
5. Low Heat Cement
6. Sulphates resisting cement
7. Blast Furnace Slag Cement
8. High Alumina Cement
9. White Cement
10.Coloured cement
11.Air Entraining Cement
12.Expansive cement
13.Hydrographic cement

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1. Ordinary Portland Cement (OPC)
Ordinary Portland cement is the most widely used type of cement which is suitable
for all general concrete construction. It is most widely produced and used type of
cement around the world with annual global production of around 3.8 million cubic
meters per year.  This cement is suitable for all type of concrete construction.

2. Portland Pozzolana Cement (PPC)

Portland pozzolana cement is prepared by grinding pozzolanic clinker with Portland
cement. It is also produced by adding pozzolana with the addition of gypsum or
calcium sulfate or by intimately and uniformly blending Portland cement and fine
pozzolana.
This cement has high resistance to various chemical attacks on concrete compared
with ordinary portland cement and thus it is widely used. It is used in marine
structures, sewage works, sewage works and for laying concrete under water such as
bridges, piers, dams and mass concrete works etc.

3. Rapid Hardening Cement

Rapid hardening cement attains high strength in early days it is used in concrete
where formworks are removed at an early stage and is similar to ordinary portland
cement (OPC). This cement has increased lime content and contains higher c3s
content and finer grinding which gives greater strength development than OPC at an
early stage.
The strength of rapid hardening cement at the 3 days is similar to 7 days strength of
OPC with the same water-cement ratio. Thus, advantage of this cement is that
formwork can be removed earlier which increases the rate of construction and
decreases cost of construction by saving formwork cost.
Rapid hardening cement is used in prefabricated concrete construction, road works,
etc.
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4. Quick setting cement
The difference between the quick setting cement and rapid hardening cement is that
quick setting cement sets earlier while rate of gain of strength is similar to Ordinary
Portland Cement, while rapid hardening cement gains strength quickly. Formworks
in both cases can be removed earlier.
Quick setting cement is used where works is to be completed in very short period
and for concreting in static or running water.

5. Low Heat Cement

Low heat cement is prepared by maintaining the percentage of tricalcium aluminate
below 6% by increasing the proportion of C2S. This makes the concrete to produce
low heat of hydration and thus is used in mass concrete construction like gravity
dams, as the low heat of hydration prevents the cracking of concrete due to heat.
This cement has increased power against sulphates and is less reactive and initial
setting time is greater than OPC.

6. Sulphates Resisting Cement

Sulfate resisting cement is used to reduce the risk of sulphate attack on concrete and
thus is used in construction of foundations where soil has high sulphate content. This
cement has reduced contents of C3A and C4AF.
Sulfate resisting cement is used in construction exposed to severe sulphate action by
water and soil in places like canals linings, culverts, retaining walls, siphons etc.

7. Blast Furnace Slag Cement

Blast furnace slag cement is obtained by grinding the clinkers with about 60% slag
and resembles more or less in properties of Portland cement. It can be used for
works economic considerations is predominant.

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 8. High Alumina Cement
High alumina cement is obtained by melting mixture of bauxite and lime and
grinding with the clinker. It is a rapid hardening cement with initial and final setting
time of about 3.5 and 5 hours respectively.
The compressive strength of this cement is very high and more workable than
ordinary portland cement and is used in works where concrete is subjected to high
temperatures, frost, and acidic action.

9. White Cement
It is prepared from raw materials free from Iron oxide and is a type of ordinary
portland cement which is white in color. It is costlier and is used for architectural
purposes such as precast curtain wall and facing panels, terrazzo surface etc. and for
interior and exterior decorative work like external renderings of buildings, facing
slabs, floorings, ornamental concrete products, paths of gardens, swimming pools
etc.

10.Colored cement
It is produced by mixing 5- 10% mineral pigments with ordinary cement. They are
widely used for decorative works in floors.
 
11.Air Entraining Cement
Air entraining cement is produced by adding indigenous air entraining agents such
as resins, glues, sodium salts of sulphates etc. during the grinding of clinker.
This type of cement is especially suited to improve the workability with smaller
water cement ratio and to improve frost resistance of concrete.

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12.Expansive Cement
Expansive cement expands slightly with time and does not shrink during and after
the time of hardening. This cement is mainly used for grouting anchor bolts and pre-
stressed concrete ducts.

13.Hydrographic cement
Hydrographic cement is prepared by mixing water repelling chemicals and has high
workability and strength. It has the property of repelling water and is unaffected
during monsoon or rains. Hydrophobic cement is mainly used for the construction of
water structures such dams, water tanks, spillways, water retaining structures etc.

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 Applications of Different Types of Cement for Concrete
Construction
Selection of cement based on suitability for different concrete construction is important
for durability considerations of structures. Thus, making wise choice of cement type for
particular construction site, prevents structure from deteriorating and saves much repair
and rehabilitation cost later.

Following are the suitability of various cements for different environmental conditions:

Applications of 33 Grade Ordinary Portland Cement (OPC)

It is used for normal grade of concrete upto M-20, plastering, flooring, grouting of cable
ducts in PSC works etc. The fineness should be between 225 and 280.

Application of 43 Grade Ordinary Portland Cement (OPC)

o It is the most widely used general purpose cement. For concrete grades up to M-
30, precast elements.
o For marine structures but C3A should be between 5 – 8%.

Application of 53 Grade OPC Cement

o For concrete grade higher than M-30, prestressed concrete works, bridge, roads,
multi-storied buildings etc.
o For use in cold weather concreting.
o For marine structures but C3A should be between 5 – 8%.

Applications of Portland Slag Cement (PSC)

It is OPC + granulated slag cement. It gives low heat of hydration. The slag should be
more than 50%and upto 70%. It is used for;

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 o Marine and off shore structures- very high chloride and sulphate resistant.
o Sewage disposal treatments works
o Water treatment plants
o Constructions which are expected to be attacked by dissolved chlorides and
sulphate ions.
o Should be mainly used for all future structures.

Applications of Portland Pozzolana Cement

IS:1489(part-I ) -1991 (using fly ash). It gives low heat of hydration and reduces the
leaching of calcium hydroxide. This cement should be used only after proper
evaluation. This should be tested as per IS:1489 (Pt I) – 1991. It is used for:
o hydraulic structures-dams, retaining walls
o Marine structures
o Mass concrete works- like bridge footings
o under aggressive conditions
o Masonry mortar and plastering.

Applications of Sulphate Resisting Cement

(C3A < 3%) Sulphate Resisting Portland Cement is a type of Portland Cement in which
the amount of tricalcium aluminate (C3A) is restricted to lower than 5% and 2C 3A
+C4AF lower than 25%. The SRC can be used for structural concrete wherever OPC or
PPC or Slag Cement is usable under normal conditions.

The use of SRC is particularly beneficial in such conditions where the concrete is
exposed to the risk of deterioration due to sulphate attack, for example, in contact with
soils and ground waters containing excessive amounts of sulphates as well as for
concrete in sea water or exposed directly to sea coast.

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The use of Sulphate Resisting Cement is recommended for following applications:
o Foundations, piles
o Basement and underground structures
o Sewage and water treatment plants
o Chemical factories
o Suitable for underground works where Sulphate is present in the Soil and water.

Sulphate Resisting Cement is Not Suitable for:

o Sulphate resisting cement is not suitable where there is danger of chloride attack.
This will cause corrosion of rebar.
o If both Chlorides and Sulphates are present, Ordinary Portland Cement with C3A
between 5 & 8 should be used.

Applications of Low heat portland cement

Low Heat Portland Cement is particularly suited for making concrete for dams and
many other types of water retaining structures, bridge abutments, massive retaining
walls, piers and slabs etc. In mass concreting, there is often considerable rise in
temperature because of the heat produced as the cement sets and hardens.

The shrinkage which occurs on subsequent cooling sets up tensile stresses in the
concrete, may result in cracking. The use of low heat cement is advantageous since it
evolves less heat than OPC. This cement is not available in the market on regular basis
and has to be obtained on specific orders.

Applications of Rapid hardening cement

The Rapid Hardening Cement is used for repair and rehabilitation works and where
speed of construction and early completion is required due to limitations of time, space
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or other reasons. The cement is to be used in cold weather concreting i.e. temperature <
5oC.
Rapid hardening cement is basically OPC but its fineness is 3250 cm 2/g against 2250
cm2/g in case of OPC. The compressive strength after 1 day is 16 N/mm 2 and that of 3
days 27 N/mm2.
These days higher grade OPC are available in the country to meet these requirements
and therefore, this cement is not being manufactured and marketed on regular basis. The
characteristics of this cement can be effectively met by only good quality 53 grade
OPC.

Applications of Hydrophobic portland cement

Hydrophobic Portland cement is manufactured on special requirement for high rainfall
areas to improve the shelf life of the cement. The cement particles are given a chemical
coating during manufacturing which provides water repelling property and the cement
is not affected due to high humidity and can be stored for a longer period . This has to
be obtained on special order from the cement manufactures.

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 Tests on Cement at Construction Site To Check Quality of
Cement

Quality tests on cements at construction site (also called field tests on cement) are
carried to know the quality of cement supplied at site. It gives some idea about cement
quality based on colour, touch and feel and other tests.

Tests on Cement at Construction site

The following are the quality tests on cement at construction site:
o Color test
o Presence of lumps
o Adulteration test
o Temperature test
o Float tests
o Strength test
o Setting test
o Date of packing

Color Test of Cement

The color of the cement should be uniform. It should be grey colour with a light
greenish shade.
Presence of Lumps
The cement should be free from any hard lumps. Such lumps are formed by the
absorption of moisture from the atmosphere. Any bag of cement containing such lumps
should be rejected.

Cement Adulteration Test

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The cement should feel smooth when touched or rubbed in between fingers. If it is felt
rough, it indicates adulteration with sand.

Temperature Test of Cement
If hand is inserted in a bag of cement or heap of cement, it should feel cool and not
warm.

Float Test
If a small quantity of cement is thrown in a bucket of water, the particles should float
for some time before it sinks.

Setting Test
A thick paste of cement with water is made on a piece of glass plate and it is kept under
water for 24 hours. It should set and not crack.

Strength of Cement Test

A block of cement 25 mm ×25 mm and 200 mm long is prepared and it is immersed for
7 days in water. It is then placed on supports 15cm apart and it is loaded with a weight
of about 34 kg. The block should not show signs of failure.

The briquettes of a lean mortar (1:6) are made. The size of briquette may be about 75
mm ×25 mm ×12 mm. They are immersed in water for a period of 3 days after drying.
If cement is of sound quality such briquettes will not be broken easily.

Date of Packing:
Strength of cement reduces with time, so it is important to check the manufacturing date
of the cement. Generally, the cement should be used before 90 days from the date of
manufacturing.
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