Concrete Materials

CENG 2909

Abenezer T.
March 2021

1
 Chapter Four

ACI Mix Design Procedure

 Contents

1 Introduction

2 ACI Mix Design

 Introduction
Mix Design:
Can be defined as the process of selecting suitable
ingredients of concrete & determining their relative
proportions with the object of producing concrete of
certain minimum strength and durability and as
economical as possible.
A properly proportioned concrete mix should possess
these qualities:
1. Acceptable workability of the freshly mixed concrete
2. Durability, strength, and uniform appearance of the
hardened concrete
3. Economy
 ACI MIX
PROPORTIONING

5
 Material Properties Needed For Design:
Water: Coarse Aggregate:
 Bulk specific gravity
 Density
(SSD) ;
Cement:
 Type  Moisture Content

 Specific gravity  dry-rodded unit

weight
Fine Aggregate:
 Absorption capacity
 Bulk specific gravity
(OD/SSD)
 Absorption capacity;
 Fineness modulus
 Moisture content

6
 Bulk Density/Unit Weight

 Sometimes names as “dry-rodded unit weight”: of

an aggregate is the mass of the aggregate divided by
the volume of particles and the voids between
particles.
 Placing three layers of oven-dry aggregate in a
container of known volume, rodding each layer 25
times with a tamping rod, leveling off the surface,
and determining the mass of the container and its
contents.
 The mass of the container is subtracted to give the
mass of the aggregate, and the bulk density is the
aggregate mass divided by the volume of the
container.
 Example 1
  
Calculate the bulk density of an aggregate.
 Mass of aggregate and container = 36.8 kg
 Mass of container = 13.1 kg
 Volume of container = 0.0141 m3
= 1681 kg/m3
 Specific gravity (relative density)

 The specific gravity of an aggregate is the mass of

the aggregate in air divided by the mass of an equal
volume of water.
 Bulk specific gravity(OD) is the oven-dry mass
divided by the mass of a volume of water equal to
the SSD aggregate volume;
 Bulk specific gravity(SSD) is the saturated surface-
dry mass divided by the mass of a volume of water
equal to the SSD aggregate volume.
 Specific gravity (relative density)

   Bulk specific gravity OD =

Bulk specific gravity SSD =
 where A = the mass of oven-dry sample in air;
 B = the mass of saturated surface-dry sample in air;
and
 C = the apparent mass of saturated sample
immersed in water
 Example 2
  
Specific gravity calculation for coarse aggregate:
Oven-dry mass in air = 3168.5 g
Saturated surface-dry mass in air = 3190.0 g
Saturated mass in water = 1972.0 g
Bulk specific gravity(OD) ==2.6
Bulk specific gravity (SSD) = =2.62
 Absorption Capacity and
Total Moisture Content


 Absorption
  Capacity: maximum amount of water
aggregate can absorb
Absorption Capacity (%)=x100
 Moisture Content: of an aggregate in any state
Total Moisture Content(%)=x100
 Surface Moisture: water on surface of aggregate
particles
Surface Moisture (%) = Moisture Content (%)- Absorption
Capacity(%)
 Example 3
  
Calculation of aggregate AC ,TMC and SM.
 Mass of Aggregate Sample: 500g

 Mass of saturated surface-dry aggregate in air = 501.4g

 Mass of oven-dry aggregate in air = 490.7 g

Absorption Capacity (%)=x100=2.2%

Total Moisture Content(%)=x100=1.89%

Surface Moisture(%)=1.89%-2.2%=-0.31%( The aggregate can

absorb additional water) (if +ve: the aggregate gives off it’s
surface moisture)
 ACI Standard Mix Design
Method

 The standard ACI mix design procedure can be

divided up into 8 basic steps:

1. Choice of slump
2. Maximum aggregate size selection
3. Mixing water and air content selection
4. Water-cement ratio
5. Cement content
6. Coarse aggregate content
7. Fine aggregate content
8. Adjustments for aggregate moisture

14
 Step #1: Select Slump

Recommended slumps for various types of construction

Maximum Slump Minimum Slump
Types of construction
(mm) (mm)
Reinforced foundation walls and footings 75 25
Plain footings, caissons, and substructure
75 25
walls
Beams and reinforced walls 100 25
Building columns 100 25
Pavements and slabs 75 25
Mass concrete 75 25

15
 Step #2: Nominal Agg. Size Check

 ACI Limits:
 1/3 of the slab depth

 1/5 the minimum dimension of structural members

 3/4 of the minimum clear space between bars/form

 Aggregate larger than these dimensions may be difficult

to consolidate and compact resulting in a honeycombed
structure or large air pockets.

16
Step #3: Determine Mixing Water and Air Content

NON-AIR-ENTRAINED CONCRETE
Approximate mixing water (kg/m3) for indicated nominal maximum sizes of aggregate
Slump (mm) 9.5 mm 12.5 mm 19 mm 25 mm 37.5 mm 50 mm 75 mm 150 mm
25 to 50 207 199 190 179 166 154 130 113
75 to 100 228 216 205 193 181 169 145 124
150 to 175 243 228 216 202 190 178 160 -
More than 175 - - - - - - - -
Approximate amount of entrapped air in non-air-entrained concrete (%)
Slump (mm) 9.5 mm 12.5 mm 19 mm 25 mm 37.5 mm 50 mm 75 mm 150 mm
All 3.0 2.5 2.0 1.5 1.0 0.5 0.3 0.2

17
 Contd..
Air-Entrained concrete
Water, kilograms per cubic meter of concrete,
for indicated sizes of aggregate
9.5 12.5 19 25 37.5 50 75 150
Slump, mm mm mm mm mm mm mm mm mm
25 to 50 181 175 168 160 150 142 122 107
75 to 100 202 193 184 175 165 157 133 119
150 to 175 216 205 197 184 174 166 154 -
Recommended average total air content,
percent, for level of exposure
Mild exposure 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0
Moderate exposure 6.0 5.5 5.0 4.5 4.5 4.0 3.5 3.0
Severe exposure 7.5 7.0 6.0 6.0 5.5 5.0 4.5 4.0
TMS(Target Mean Strength)= Specified Strength + Margin(8.5MPa)

18
 Step #4: Select W/C Ratio

Water-cementitious materials ratio by mass

Compressive
strength (Target
Mean Strength) Non-air-entrained Air-entrained
at 28 days, Mpa concrete concrete
45 0.38 0.30
40 0.42 0.34
35 0.47 0.39
30 0.54 0.45
25 0.61 0.52
20 0.69 0.60
15 0.79 0.70

Target Mean Strength=Specified(Design) Strength + Constant*Standard Deviation

19
 Proportioning from Field Data

Modification Factor for Standard Deviation

( 30 Tests)

Modification factor for

Number of tests standard deviation
Less than 15 see next slide
15 1.16
20 1.08
25 1.03
30 or more 1.00
 Proportioning from Field Data
Required Strength When Data Are Available to
Establish a Standard Deviation

Specified compressive Required average

strength, f'c, MPa compressive strength, f'cr, MPa
f'cr = f'c+ 1.34s
 35 f'cr = f'c + 2.33s – 3.45
Use larger value
f'cr = f'c+ 1.34s
Over 35 f'cr = 0.90f'c + 2.33s
Use larger value
 Proportioning from Field Data
Required Strength When Data Are Not
Available to Establish a Standard
Deviation

Specified compressive Required average

strength, compressive strength,
f'c, MPa f'cr, MPa
Less than 21 f'c + 7.0

21 to 35 f'c + 8.5

Over 35 1.10f'c + 5.0

 Requirements for Exposure
Conditions

Maximum w/c- Min. strength,

Exposure condition ratio by mass f'c, MPa (psi)
Select for strength,
No freeze-thaw, deicers, Select for structural
workability, and
aggressive substances requirements
finishing needs
Concrete with low permea-
0.50 28 (4000)
bility; exposed to water
Concrete exposed to freezing
and thawing in a moist 0.45 31 (4500)
condition or deicers

For corrosion protection for

reinforced concrete exposed to 0.40 35 (5000)
chlorides
 Requirement for Concrete Exposed
to Sulfates
Sulfate Sulfate Minimum
(SO4) in (SO4) in Maximum strength,
Sulfate soil, % by water, w/c-ratio, f'c, MPa
exposure mass ppm Cement type by mass (psi)
No special
Less Less than
Negligible type — —
than 0.10 150
required
II, MS,
IP(MS),
0.10 to 150 to IS(MS),
Moderate 0.50 28 (4000)
0.20 1500 P(MS),
I(PM)(MS),
I(SM)(MS)
0.20 to 1500 to
Severe V, HS 0.45 31 (4500)
2.00 10,000
Very Over Over
V, HS 0.40 35 (5000)
severe 2.00 10,000
 Step #5: Cement Content

 The
   calculated cement amount is based on
the selected mixing water content and water-
cement ratio.

25
 Step #6: Coarse Agg. Content
Volume of dry-rodded coarse aggregate per unit volume
of concrete for different coarse aggregates and fineness
modulus of fine aggregates.
Volume of oven-dry-rodded coarse aggregate per unit volume of concrete for
different fineness moduli of fine aggregate
Nominal
maximum size of 2.40 2.60 2.80 3.00
aggregate (mm)
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
75 0.82 0.80 0.78 0.76
150 0.87 0.85 0.83 0.81
26
 Absolute Volume Calculation
Absolute Volume: of a material occupies in concrete is
calculated as the mass of material is divided by the
absolute density which is the specific gravity multiplied
by the density of water.

Va(material)=Massmaterial /(ρ(water)*SG(material))

 Va(CA)=Mass(CA) /(ρ(water)*SG(CA))

 Mass(CA)=Vdr(CA)*ρb(CA)

27
 Step #7: Fine Agg. Content

 Va(Fine Aggregate)=1m3-(Va(Cement)+Va(water)+Va(air)+Va(CA))

 Massmaterial =Va(material) *ρ(water)*SG(material)

28
 Step #8: Batch Weight & Water Adjustment

 Aggregate weights. 
 Aggregate volumes are calculated based on Oven dry

condition, but aggregate is batched in the field are very

seldom Oven dry. 
 Any moisture in the stockpiled aggregate will increase or

decrease its weight.

 Without correcting for this, the batched aggregate volumes

will be incorrect.
 Amount of mixing water. 
 If the batched aggregate is not in saturated surface dry state

it will absorb water (if 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.
29
 Contd…..
  Since we did our calculations based on bulk OD specific
gravity but the aggregates most likely have some water in
their permeable pores, we have to adjust the OD weights in
to actual weights.

= (1+

 Free Moisture From Aggregates= *Surface Moisture(%)

 Total Free Moisture From Aggregates= FMFA+FMCA
 Adjusted Amount of water= Calculated Amount- Total Free
Moisture From Aggregates

30
 Example One
 Concrete is required for an reinforced footing pad and
column .The 28-day compressive strength should be
25Mpa. The properties of the materials are as follows:

31
 Material Properties:
Property of Cement:
• Type :OPC
• Specific gravity:3.15
Properties of coarse aggregate from the test results :
• Nominal maximum size =19mm
• Unit weight =1662.9 kg/m3
• Bulk Specific gravity(OD) =2.83
• Absorption =0.8%
• Moisture content =0.64%
Properties of fine aggregate from the test results :
• Unit weight =1813.26 kg/m3
• Fineness modulus =2.8
• Bulk Specific gravity (OD) =2.69
• Absorption =1.18%
• Moisture content =2.29%
32
 Solution
Step #1: Select Slump: 25-75mm(Footing)

Step #2: Check nominal maximum aggregate size

ACI Limits: minimum of
 One-fifth the narrowest dimension of a concrete
member= 200/5= 40 mm
 Three-quarters the clear spacing between
reinforcing bars and between the reinforcing bars
and forms= 50mm*(3/4)= 37.5 mm
 One-third the depth (thickness) of slabs= 250mm/3=
83.33mm

Therefore : 37.5 > 19mm OK

33
 Solution
Step #3: Determine Mixing Water and Air Content

NON-AIR-ENTRAINED CONCRETE
Approximate mixing water (kg/m3) for indicated nominal maximum sizes of aggregate
Slump (mm) 9.5 mm 12.5 mm 19 mm 25 mm 37.5 mm 50 mm 75 mm 150 mm
25 to 50 207 199 190 179 166 154 130 113
75 to 100 228 216 205 193 181 169 145 124
150 to 175 243 228 216 202 190 178 160 -
More than 175 - - - - - - - -
Approximate amount of entrapped air in non-air-entrained concrete (%)
Slump (mm) 9.5 mm 12.5 mm 19 mm 25 mm 37.5 mm 50 mm 75 mm 150 mm
All 3.0 2.5 2.0 1.5 1.0 0.5 0.3 0.2

 Mass of Mixing Water:190kg

 Air Content(%)=2%

34
 Solution
Step #4: Select Water Cement Ratio

Water-cementitious materials Target mean strength calculation

ratio by mass
for non air entrained concrete
Compressive
strength
TMS=25+8.5=33.5MPa
(Target Mean Non-air-
Strength) at 28 entrained Air-entrained
days, Mpa concrete concrete For 30 MPa W/C ratio is 0.54
45 0.38 0.30 and for 35 MPa W/C ratio is
40 0.42 0.34
35 0.47 0.39 0.47. The W/C ratio for 33.5
30 0.54 0.45 MPa can be found by
25 0.61 0.52
20 0.69 0.60
interpolation as follows:

 𝑊 15( . 47 −0.79
. 54 ) 0.70
= ( 3 3.5 − 30 ) +0. 54=𝟎 . 𝟒𝟗𝟏
𝐶 ( 35− 30 )
35
 Solution
 Step #5: Calculate amount of Cement

Mass of cement===386.96kg/m3

36
 Procedure:
Step #6: Calculate amount of CA

Nominal
maximum size of 2.40 2.60 2.80 3.00
aggregate (mm)
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
75 0.82 0.80 0.78 0.76
150 0.87 0.85 0.83 0.81

 Mass(CA)=Vdr(CA)*ρb(CA)

 Mass(CA)=0.62m3* 1662.9 kg/m3=1031kg

37
 Solution
 Step #7: Calculate amount of FA

Va(Fine Aggregate)=1m3-(Va(Cement)+Va(water)+Va(air)+Va(CA))

Va(Fine Aggregate)= 1m3-(+ + + )=0.314m3

Massmaterial =Va(material) *ρ(water)*SG(material)

MassFA= 0.314m3*1000*2.69=844.66kg

38
 Solution
 Step#8: Batch weight and water
adjustment
I. Batch weight adjustment

= (1+
=844.66kg(1+=864kg
=1031kg(1+=1037.6kg

39
 Solution
 
II. Water adjustment
 Free Moisture From Aggregates= *Surface Moisture(%)
 Total Free Moisture From Aggregates= FMFA+FMCA
 Adjusted Amount of water= Calculated Amount- Total Free
Moisture From Aggregates

FMFA=8641kg*=9.5kg
FMCA=1037.6kg*=-1.66kg
Total Free Moisture From Aggregates=9.5kg-1.66kg
=7.84kg
Adjusted Amount of water=190kg-7.84kg=182.16kg

40
 Solution
 
Final Batch :
I. By Weight
• Cement:386.96kg
• Water:182.16kg
• Fine Aggregate: 864kg
• Course Aggregate:
Ratio: C:FA:CA
: :   =0.47
1 : 2.23 : 2.68

41
 Solution
 
II. By Volume
• Cement:=7.74 Bags
• Water: =0.182m3 =182.16lit
• Fine Aggregate:
• Course Aggregate:
Ratio: C:FA:CA
: :
1 : 2.6 : 2.98

42
 Example Two
 Concrete is required for an exterior slab (thickness=20cm)
located at top terrace where moderate freezing and
thawing may occur. The 28-day compressive strength
should be 21.5 Mpa. The slump should be between 75mm
and 100 mm. Find the final batch weights (per one cubic
meter of concrete)?
 The properties of the materials are as follows:

Property of Cement:
• Type :OPC
• Specific gravity:3.15

43
 Material Properties:
Properties of coarse aggregate from the test results :
• Nominal maximum size =25mm
• Unit weight =1600 kg/m3
• Bulk Specific gravity(OD) =2.70
• Absorption =0.3%
• Moisture content =1%
Properties of fine aggregate from the test results :
• Unit weight =1813.26 kg/m3
• Fineness modulus =2.8
• Bulk Specific gravity (OD) =2.55
• Absorption =0.8%
• Moisture content =1.1%

44
 Solution
Step #1: Select Slump: 75-100mm (Given)

Step #2: Check nominal aggregate size

ACI Limits: minimum of
 One-third the depth (thickness) of slabs= 200mm/3=
66.66mm

Therefore : 66.66mm > 25mm OK

45
 Solution
Step #3: Determine Mixing Water and Air Content
Water, kilograms per cubic meter of
Air-Entrained concrete concrete, for indicated sizes of aggregate
9.5 12.5 19 25 37.5 50 75 150
Slump, mm mm mm mm mm mm mm mm mm
25 to 50 181 175 168 160 150 142 122 107
75 to 100 202 193 184 175 165 157 133 119
150 to 175 216 205 197 184 174 166 154 -
Recommended average total air content,
percent, for level of exposure
Mild exposure 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0
Moderate exposure 6.0 5.5 5.0 4.5 4.5 4.0 3.5 3.0
Severe exposure 7.5 7.0 6.0 6.0 5.5 5.0 4.5 4.0

 Mass of Mixing Water:175kg

 Air Content(%)=4.5%
46
 Solution
Step #4: Select Water Cement Ratio

Target mean strength calculation

Water-cementitious materials
ratio by mass for air entrained concrete
Compressive
strength (Target Non-air- TMS=21.5+8.5=30 MPa
Mean Strength) entrained Air-entrained
at 28 days, Mpa concrete concrete
For 30 MPa W/C ratio is 0.45 :
45 0.38 0.30
40 0.42 0.34
35 0.47 0.39
30 0.54 0.45
25 0.61 0.52
20 0.69 0.60
15 0.79 0.70

47
 Solution
 Step #5: Calculate amount of Cement

Mass of cement===388.89kg/m3

48
 Procedure:
Step #6: Calculate amount of CA

Nominal
maximum size of 2.40 2.60 2.80 3.00
aggregate (mm)
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
75 0.82 0.80 0.78 0.76
150 0.87 0.85 0.83 0.81

 Mass(CA)=Vdr(CA)*ρb(CA)

 Mass(CA)=0.67m3* 1600 kg/m3=1072kg

49
 Solution
 Step #7: Calculate amount of FA

Va(Fine Aggregate)=1m3-(Va(Cement)+Va(water)+Va(air)+Va(CA))

Va(Fine Aggregate)= 1m3-(+ + +)

Va(Fine Aggregate)= 1m3- (0.397+0.045+0.145+0.123)=0.29m3

Massmaterial =Va(material) *ρ(water)*SG(material)

MassFA= 0.29m3*1000*2.65=768.5kg

50
 Solution
 Step #8: Batch weight and water adjustment
I. Batch weight adjustment

= (1+
=768.5 kg(1+= 776.95 kg
=1072 kg(1+=1082.72 kg

51
 Solution
 
II. Water adjustment
 Free Moisture From Aggregates= *Surface Moisture(%)
 Total Free Moisture From Aggregates= FMFA+FMCA
 Adjusted Amount of water= Calculated Amount- Total Free Moisture
From Aggregates

FMFA=776.95 kg*=2.33 kg
FMCA=1082.72 kg*= 7.58kg
Total Free Moisture From Aggregates=2.33kg+7.58kg
=9.91kg
Adjusted Amount of water=175kg-9.91kg=165.1 kg

52
 Solution
 
Final Batch :
I. By Weight
• Cement:388.89 kg
• Water:165.1 kg
• Fine Aggregate: 776.95 kg
• Coarse Aggregate:
Ratio: C:FA:CA
: :   =0.424
1 : 2 : 2.78

53
 Solution
 
II. By Volume
• Cement: 388.89kg/50kg = 7.78 Bags
• Water: =0.165m3 =165.10lit
• Fine Aggregate:
• Course Aggregate:
Ratio: C:FA:CA
: :
1 : 2.33 : 3.1

Note:
  Bulk Density of Cement is: 1440

54