Com Assignment 1

1.
Using the DOE mix design tables and charts, calculate the weights of all materials that
you would use for the first trial mix on a concrete mix required to achieve a compressive
strength of 40 MPa at 28 days.
Cement type 32.5
Max. Aggregate size 30 mm
Aggregate type Crushed
Rel. density of combined aggregate at SSD 2.70
Fine aggregate grading Zone 2
Required slump 80 mm
Minimum cement content, 380 kg/m3
Max free w/c ratio 0.40
Plant S.D. Unknown
Solution
Step1: Target mean strength
Assuming 40 MPa at 28 days is characteristic compressive strength and risk factor is on the
assumption that 5 percent of results are allowed to fall less than the specified characteristic strength
the target mean strength is;
𝑓𝑚 = 𝑓𝑐 + 𝑘𝑠
For the 5% defective level specified in BS 5328, k = 1.64
Standard deviation is Unknown
Source (BRE, 1997)

Figure 1: Relationship between standard deviation and characteristic strength
From the above figure concrete having a specified characteristic strength of 40 N/mm2 which is less
than 20 results thus standard deviation is 8 N/mm2
Now, Target mean strength
𝑓𝑚= 40 + 1.64 𝑥 8.0
= 53.12 𝑀𝑃𝑎
Step 2: Free water ratios
53.12
49
0.465
Source (BRE, 1997)

Table 1: Approximate compressive strengths Figure 2: Relationship between compressive
(N/mm2) of concrete mixes made with a strength and free-water/cement ratio
free-water/cement ratio of 0.5
Referring to above Table-1, for PPC, crushed aggregate, for w/c ratio of 0.5, 28 days compressive
strength is 49 MPa. In Figure-2 find an intersection point for 49MPa and 0.5 w/c ratios. Draw a
line parallel to the curve. From this curve read off the w/c ratio for a target mean strength of 53.12
MPa. The w/c ratio is = 0.465. Check this w/c ratio from given maximum w/c ratio which
permitted is 0.40. Adopt lower of the two, therefore adopt w/c ratio of 0.40.
Step 3: Water content
Next decide the water content for slump of 80mm and max size 30 mm crushed aggregate from
Table-2 below shows Water demand for crushed coarse 30mm max size aggregate is found to be
= 215 kg/m3 (by interpolation)
Source (BRE, 1997)
Table 2: Approximate free-water contents (kg/ m ) required to give various levels of workability
3
Step 4: Cement content

Cement content = Free-water content
Free-water/ cement ratio
C = w/ (w/c)
= 215/0.40
= 537.5 kg/m3 > the specified minimum (380)…..ok
Mixing water content is 215 kg/m3
Step 5: Weight of total aggregate
This requires an estimate of the wet density of the fully compacted concrete. This can be found
out from by using Rel. density of combined aggregate at SSD 2.70 which is given. And Figure
below for approximate water content and specific gravity of aggregate is 2395kg/m3.
215
Source (BRE, 1997)

Figure 3: Estimated wet density of fully compacted concrete
Weight of Total Aggregate=Wet density −[ Weight of Cement +Weight of Free Water ]
¿ 2395−537.5−215=1642.5 Kg/m3
Step 06: Weight of Fine Aggregate
Zone-1 Zone-2 Zone-3 Zone-4
10mm 100 100 100 100
4.75mm 90-100 90-100 90-100 95-100
2.36mm 60-95 75-100 85-100 95-100
1.18mm 30-70 55-90 75-100 90-100
0.6mm 15-34 35-59 60-79 80-100
0.3mm 5-20 8-30 12-40 15-50
0.15mm 0-10 0-10 0-10 0-15
Fineness modulus(FM) 4.0-2.71 3.37-2.1 2.78-1.71 2.25-1.35
Table 3: Fineness modulus limits for various zones of sand according to IS 383-1970
FM of zone 2 = (3.37+2.1)/2=2.74
36
Figure 4: proportion of fine aggregate determined from fineness modulus

From figure 4 above for fineness modulus of 2.74 and water cement ratio of 0.40 percentage of
fine aggregate for maximum aggregate size of 20mm= 40% while for maximum aggregate size
of 40mm= 36 % by interpolation for maximum aggregate size of 30 mm= 38%.
weight of fine agregate=0.38 x 1642.5=624.15 Kg/m3
weight of coarse agregate=1642.5−624.15=1018.35Kg/m3
Step 7: Summary of quantities for 1 m3 (SSD)
Cement = 537.5 kg/m3
Water = 215 kg/m3
Fine aggregate = 624.15 kg/m3
Coarse aggregate = 1018.35 kg/m3
Wet density = 2395 kg/m3
Step 8: Proportion of gradients per trial mix (SSD) of: 0.02 m3 (For small mixer)
Cement =10.75 kg
Water = 4.3 kg
Fine aggregate = 12.48 kg
Coarse aggregate = 20.37 kg
This trial will make about 47.9 kg of concrete; enough for slump and Vebe tests
2. Using the DOE mix design tables and charts, calculate the wights of materials required to
produce the four trial mixes which the information is given below. Calculate also the
adjusted batch weights that would be suitable for use on site by taking into account the
expected free moisture contents of the aggregates.
Mix no.
1 2 3 4
Characteristic strength, N/mm2 30 35 60 40
Age (days) 28 7 28 7
Cement type PPC OPC OPC PPC
Aggregate type Uncrushed Crushed Uncrushed Crushed
Maximum aggregate size 20 30 30 20
Relative density of combined aggregate 2.65 2.67 2.60 2.56
Fine aggregate grading Zone 3 Zone 2 Zone 2 Zone 1
Required slump (mm) 70 80 50 80
Minimum cement content (kg/m3) 270 320 - 360
Maximum cement content (kg/m3) - 380 500 -
Maximum free w/c 0.65 0.50 0.60 0.60
Allowable failure rate 4.5% 5% 3% 3%
Plant S.D. (N/mm2) 5 Unknown unknown 3
Free moisture content of sand 1.9 2.5 2.0 1.5
Assume the following values of free moisture content for the coarse aggregate: 30 mm 1.5%; 20
mm 2.0% and 10 mm 3.0%.
Solution For trial Mix-1
Characteristic strength, = 30 N/mm2
Risk factor is 4.5 % of results given as (Allowable failure rate)
Standard deviation is 5 N/mm2 (Given)
For the 4.5% defective level specified in BS 5328,
K for 5% defectives = 1.64
K for 2.5% defectives = 1.96
K for 4.5% defective =1.704 (by interpolation)
𝑓𝑚 = 𝑓𝑐 + 𝑘𝑠=30+1.704x5
=38.52 MPa
42
38.52
0.57
Source (BRE, 1997)

Assume PPC cement strength 42.5, & from Table 1, for free w/c = 0.5, uncrushed aggregate the 28
days compressive strength is 42MPa. In Figure-2 find an intersection point for 42MPa and 0.5 w/c
ratios. Draw a line parallel to the curve. From this curve read off the w/c ratio for a target mean
strength of 38.52MPa. The w/c is = 0.57. Check this w/c ratio from given maximum w/c ratio which
Next decide the water content for slump of 70mm and max size 20 mm uncrushed aggregate from
Table-2 below shows Water demand for uncrushed coarse 20mm max size aggregate is found to be
= 195 kg/m3.
Source (BRE, 1997)
3

C = w/ (w/c)
= 195/0.57
= 342.11 kg/m3 > the specified minimum (270)…..ok
2385
195
Source (BRE, 1997)

¿ 238 5−342.11−19 5=1847 . 89 Kg/m3
10mm 100 100 100 100
4.75mm 90-100 90-100 90-100 95-100
2.36mm 60-95 75-100 85-100 95-100
1.18mm 30-70 55-90 75-100 90-100
0.6mm 15-34 35-59 60-79 80-100
0.3mm 5-20 8-30 12-40 15-50
0.15mm 0-10 0-10 0-10 0-15
FM of zone 3 = (2.78+1.71)/2=2.25
34

From figure 4 above, for maximum size of aggregate = 20mm, Slump 70mm, grading zone 3 of fine
aggregate (FM 2.74) & free water cement ratio of 0.57, the proportion of fine aggregates will be
34%.
weight of fine agregate=0.34 x 1847.89=628.28Kg/m3
weight of coarse agregate=1847.89−628.28=1219.61Kg/m3
Assuming that the aggregates are used in SSD condition, the quantities of the constituent materials
per m3 are;
Water = 195 kg/m3
Step 7: Adjustment
Assume the following value of free moisture content for the coarse aggregate 30mm 2%; 20mm
1.5% and 10mm 1.0 % from the given data. The size of the coarse aggregate for the trial mix is
20mm so the value of free moisture content is 1.5 %.
Free moisture content of sand for trial Mix-1 is 1.9%
Free moisture content of CA = 1219.61kg/m3 x 1.5%
Free moisture content of CA = 18.29 kg/m3
Free moisture content of FA = 628.28 kg/m3 x 1.9%
Free moisture content of FA =11.94 kg/m3
Net mixing Water = (195-18.29 -11.94) = 164.77 kg
Step8: Adjusted batch
Weight of water=164.77 kg
Weight of Cement= 342.11 kg
Weight of fine Agg. = 628.28 kg
Weight of coarse Agg. = 1219.61kg

Source (BRE, 1997)

𝑓𝑚 = 𝑓𝑐 + 𝑘𝑠=35+1.64x8
=48.12 MPa
48.12
43
0.47
Source (BRE, 1997)

Table 1: Approximate compressive strengths
Figure 2: Relationship between compressive
(N/mm2) of concrete mixes made with a
strength and free-water/cement ratio
Assume OPC cement strength 52.5, & from Table-1, for free w/c = 0.5, uncrushed aggregate the 7
Source (BRE, 1997)

Table 2: Approximate free-water contents (kg/ m3) required to give various levels of workability
Table-2 above shows Water demand for crushed coarse 30mm max size aggregate is found to be =
215 kg/m3 (by interpolation)
C = w/ (w/c)
= 215/0.47
= 457.45 kg/m3
Since this value is greater than the Maximum cement content, the cement content is limited to 380
kg/m3.
2365
215
Source (BRE, 1997)

¿ 236 5−380−2 15=1 7 70 Kg/m3
10mm 100 100 100 100
4.75mm 90-100 90-100 90-100 95-100
2.36mm 60-95 75-100 85-100 95-100
1.18mm 30-70 55-90 75-100 90-100
0.6mm 15-34 35-59 60-79 80-100
0.3mm 5-20 8-30 12-40 15-50
0.15mm 0-10 0-10 0-10 0-15
FM of zone 2 = (3.37+2.1)/2=2.74
38

From Figure-4 above for fineness modulus of 2.74 and water cement ratio of 0.47 percentage of
of 40mm= 38% by interpolation for maximum aggregate size of 30 mm= 39.5%.
weight of fine agregate=0.395 x 1770=699 .15Kg/m3
weight of coarse agregate=1770−699.15=1070.8 5Kg/m3
per m3 are;
Cement = 380 kg/m3
Water = 215 kg/m3
Fine aggregate = 699.15kg/m3
Step 7: Adjustment
30mm so the value of free moisture content is 2%.
Free moisture content of CA = 1070.85kg/m3 x 2%
Free moisture content of FA = 699.15kg/m3 x 2.5%
Weight of Cement= 380 kg
Weight of fine Agg. = 699.15kg
Weight of coarse Agg. = 1070.85 kg
Risk factor is 3 % of results given as (Allowable failure rate)
For the 3% defective level specified in BS 5328,
K for 5% defectives = 1.64
K for 2.5% defectives = 1.96
K for 3% defective =1.9(by interpolation)
Source (BRE, 1997)

𝑓𝑚 = 𝑓𝑐 + 𝑘𝑠=60+1.9x8
=75.2 MPa
48.12
43
0.47
Source (BRE, 1997)

Table 1: Approximate compressive strengths
Figure 2: Relationship between compressive
(N/mm2) of concrete mixes made with a
strength and free-water/cement ratio
Assume OPC cement strength 52.5, & from Table-1, for free w/c = 0.5, uncrushed aggregate the 7
Source (BRE, 1997)
Table 2: Approximate free-water contents (kg/ m3) required to give various levels of workability
Table-2 above shows Water demand for crushed coarse 30mm max size aggregate is found to be =
215 kg/m3 (by interpolation)
C = w/ (w/c)
= 215/0.47
= 457.45 kg/m3
Since this value is greater than the Maximum cement content, the cement content is limited to 380
kg/m3.
2365
215
Source (BRE, 1997)

¿ 236 5−380−2 15=1770 Kg/m3
10mm 100 100 100 100
4.75mm 90-100 90-100 90-100 95-100
2.36mm 60-95 75-100 85-100 95-100
1.18mm 30-70 55-90 75-100 90-100
0.6mm 15-34 35-59 60-79 80-100
0.3mm 5-20 8-30 12-40 15-50
0.15mm 0-10 0-10 0-10 0-15
FM of zone 2 = (3.37+2.1)/2=2.74
38

From Figure-4 above for fineness modulus of 2.74 and water cement ratio of 0.47 percentage of
of 40mm= 38% by interpolation for maximum aggregate size of 30 mm= 39.5%.
weight of fine agregate=0.395 x 1770=699.15 Kg/m3
weight of coarse agregate=1770−699.15=1070.85Kg/m3
per m3 are;
Cement = 380 kg/m3
Water = 215 kg/m3
Fine aggregate = 699.15kg/m3
Step 7: Adjustment
30mm so the value of free moisture content is 2%.
Free moisture content of CA = 1070.85 kg/m3 x 2%
Free moisture content of FA = 699.15kg/m3 x 2.5%
Weight of Cement= 380 kg
Weight of fine Agg. = 699.15kg
Weight of coarse Agg. = 1070.85 kg
4. Repeat question 1 again using both DOE and ACI methods assuming there are no
restrictions on cement content and w/c
a. Using DOE
Solution
Assuming 40 MPa at 28 days is characteristic compressive strength and risk factor is on the
assumption that 5 percent of results are allowed to fall less than the specified characteristic strength
the target mean strength is;
𝑓𝑚 = 𝑓𝑐 + 𝑘𝑠
Source (BRE, 1997)

From the above figure concrete having a specified characteristic strength of 30 N/mm2 which is
less than 20 results thus standard deviation is 8 N/mm2
Now, 𝑓𝑚= 30 + 1.65 𝑥 8.0

= 53.12 𝑀𝑃𝑎

53.12
49
0.465
Source (BRE, 1997)

Referring to above Table, for PPC, crushed aggregate, for w/c ratio of 0.5, 28 days compressive
strength is 49 MPa. In Fig.2 find an intersection point for 49MPa and 0.5 w/c ratios. Draw a line
parallel to the curve. From this curve read off the w/c ratio for a target mean strength of 53.2
MPa. The w/c ratio is = 0.465.
Table 3 below shows Water demand for crushed coarse 30mm max size aggregate is found to be
= 215 kg/m3 (by interpolation)
Source (BRE, 1997)
3

Cement content = Free-water content
Free-water/ cement ratio
C = w/ (w/c)
= 215/0.465
= 462.37 kg/m3
215
Source (BRE, 1997)

¿ 2395−462.37−215=1717 . 63 Kg/m3
10mm 100 100 100 100
4.75mm 90-100 90-100 90-100 95-100
2.36mm 60-95 75-100 85-100 95-100
1.18mm 30-70 55-90 75-100 90-100
0.6mm 15-34 35-59 60-79 80-100
0.3mm 5-20 8-30 12-40 15-50
0.15mm 0-10 0-10 0-10 0-15
FM of zone 2 = (3.37+2.1)/2=2.74
37

From figure 4 above for fineness modulus of 2.74 and water cement ratio of 0.465 percentage
of fine aggregate for maximum aggregate size of 20mm= 41% while for maximum aggregate
size of 40mm= 37 % by interpolation for maximum aggregate size of 30 mm= 39%.
weight of fine agregate=0.39 x 1717.63=669.88 Kg/m3
weight of coarse agregate=1717.63−669.88=1047.7 5Kg/m3
Step 7: Summary of quantities for 1 m3 (SSD)
Water = 215 kg/m3
Wet density = 2395 kg/m3
Step 8: Proportion of gradients per trial mix (SSD) of: 0.02 m3 (For small mixer)
Cement =9.25 kg
Water = 4.3 kg
Fine aggregate = 13.40 kg
Coarse aggregate = 20.96 kg
This trial will make about 47.91 kg of concrete; enough for slump and Vebe tests

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1.

Source (BRE, 1997)

Source (BRE, 1997)

Step 4: Cement content

Source (BRE, 1997)

Figure 4: proportion of fine aggregate determined from fineness modulus

Source (BRE, 1997)

Table 1: Approximate compressive strengths Figure 2: Relationship between compressive

Step 4: Cement content

Source (BRE, 1997)

Figure 4: proportion of fine aggregate determined from fineness modulus

Solution For trial Mix-2

Source (BRE, 1997)

Source (BRE, 1997)

Source (BRE, 1997)

Source (BRE, 1997)

Figure 4: proportion of fine aggregate determined from fineness modulus

Source (BRE, 1997)

Source (BRE, 1997)

Source (BRE, 1997)

Figure 4: proportion of fine aggregate determined from fineness modulus

Source (BRE, 1997)

Now, 𝑓𝑚= 30 + 1.65 𝑥 8.0

Step 2: Free water ratios

Source (BRE, 1997)

Step 4: Cement content

Source (BRE, 1997)

Figure 4: proportion of fine aggregate determined from fineness modulus

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