CEMENT CONCRETE MIX

DESIGN

By

Binod Kumar
Scientist, Rigid Pavements Division
CRRI, New Delhi
 What is Concrete?

A mixture of cement, water, coarse and

fine aggregate which consolidate into a
hard mass due to chemical reaction
between cement and water.
 What IS Mix Design?

An art of obtaining a concrete of

required properties, at lowest cost,
by a suitable choice and proportion
of available materials.
Mix Design Should Ensure that
the Concrete has:

•Required strength
•Required durability
•Required workability
•Economy
Characteristic Compressive
Strength of Concrete, fck
It is the strength below which not more than 5%
of the test results as obtained from
cubes(150mm) should fail. E.g. M20 . It depends
on:
• Quality of cement (chemical comp. & fineness)
• Water-Cement ratio (Key Parameter)
• Grading of aggregates
• Degree of compaction
• Efficiency of curing
• Age of concrete etc.
 Durability of Concrete
The resistance to weathering action due
to atmospheric changes in temperature
and humidity, chemical attack, abrasion,
frost and fire.
•Volume changes-cement & water reaction,
alkali-agg. reaction, moisture content,
temperature, and sulphate attack
•Porosity- Water cement ratio, minimum
cement content
 Workability of Concrete
A workable concrete is one which is
cohesive and flows well and which can,
without segregation, be fully compacted
with predetermined means of compaction.
It depends upon:
•Type of aggr.-size, rounded, angular etc.
•Grading of coarse & fine aggregate
•Quantity of cement paste in the mix
•Consistency of the paste
 Proportioning The Ingredients

Basic Data for Mix-Design:

•Min. compressive/flexural strength in the field

at 28 days
• Max. size of the aggregate and its type
• Degree of workability
•Degree of quality control-V. good, good, fair
and permissible coefficient of variation
• accepted tolerance level
 Degree of Quality Control
•Very good:Fresh cement with regular tests, weigh-
batching, control of agg. Grading and moisture
content, control of water added, Frequent
supervision, regular workability and strength tests,
field laboratory facilities.
•Good:Carefully stored cement & periodic tests,
weigh batching, controlled water, graded aggregates,
periodic checks of workability and strength,
intermittent supervision, experienced workers.
•Fair:Proper storage of cement, volume batching of
aggregates & weigh batching of cement, water
controlled by inspection of mix, occasional
supervision and tests.
 Tests For Materials
(A) Cement:
• Compressive strength of cement at 7days
• Specific gravity of cement(3.15), IS:269
(B) Aggregate:
• Specific Gravity
• Percent water absorption
• Sieve analysis, IS:2386
 Selection of Aggregate Grading

N.M. Size of % passing IS sieve sizes,mm

Aggregate 40 20 10 4.75
40 mm 100 40-45 18-20 0

20 100 100 31-40 0

Two or more aggregate fractions are

combined to obtain the required grading
 Design Strength of Concrete
Concrete mix has to be designed for somewhat
higher comp. Strength depending upon degree
of quality control. Design strength(S) at 28
days is:
S = Ŝ / (1 - t.v/100), where
Ŝ = Strength in the field
t = Factor based on tolerance level
v = Coefficient of variation, %
 Value of Tolerance Factor, t
No. of Samples Tolerance Level
1 in 10 1in 15 1 in 20 1 in 40 1 in 100

10 1.37 1.65 1.81 2.23 2.76

20 1.32 1.58 1.72 2.09 2.53

30 1.31 1.54 1.70 2.04 2.46

infinite 1.28 1.50 1.64 1.96 2.33

Selection of Water-Cement Ratio
W-C ratio is selected from the graphs
given in the code. Graphs are drawn
between w-c ratio, designed compressive
strength,S, and 7-days compressive
strength of cement.

Correlation between flexural and

compressive strength of concrete is
given in the code.
 Selection of Water and Sand Content
Water & sand contents are taken from the table for w-c
ratio of 0.50, slump of 25 mm, and F.M. of 2.6 for sand

Max size of Water content(kg) Sand,%of total agg

aggr. On SSD basis by abs. Volume

40 mm 175.0 33.5
25 mm 177.5 38.0
20 mm 178.0 40.0
 Adjustment of Water and sand
Content for Other Conditions
Change in Condition Adj. In water Adj. In sand

Each ±0.05 in w-c ratio 0 ±1%

Each ±0.01 in sand FM 0 ±0.5%
Each ±25 mm in slump ±4% 0
Rounded aggregate -15 litter -6 to 8%

Note: Knowing the w-c ratio and water content, the

cement content can be calculated.
Determination of Sand Content per
unit volume of concrete
V = ( W + C/Sc + S/P.Ss )/1000
Where, V = Gross volume(1 cu.m.) of wet mix minus
the volume of entrapped air(1%)
W= Weight of water in kg. Per cu.m.
C = Weight of cement in kg. Per cu.m.
S = Weight of sand in kg. Per cu.m.
P = Proportion of sand in decimal fraction
Sc and Ss are sp. Gravity of cement and sand
Determination of Coarse Aggregate
Content per unit volume of concrete

V = { W + C/Sc + A/(1-P).Sa}/1000

Where, Sa is the sp. Gravity of coarse aggregate

and A is the weight of coarse aggregate in per
cu.m. of concrete

Thus the quantities of sand, CA,cement

and water in a concrete mix are known.
 Trial Mix
•Prepare the mix with the quantities so
obtained.
•Measure the workability and adjust the water
content, if required.
•Recalculate the mix proportions for three w-c
ratios one higher and one lower by 0.05
•Determine the comp. & flexural strengths.
•Plot the values against w-c ratio and choose
appropriate w-c ratio for the required strength.
•Recalculate the final mix proportions
 Worked-Out Example For CC
Mix design
(A) Basic data for mix design:
1. Minimum 28 days comp. Strength in field: 280kg/cm2
2. Maximum size of aggregate: 40 mm, angular
3. Degree of workability: 25 mm slump
4. Degree of quality control: good, coeff. of variation 10%
5. Accepted tolerance level: 1 in 15
6. Type of job: Major work, testing of large number of
samples, i.e. t = 1.50
 (B) Test Data For Materials

1. 7 days compressive strength of cement: 210 kg/cm2

2. Specific gravity of cement: 3.15
3. Specific gravity of both fine & coarse agg.: 2.65
4. Water absorption of coarse aggregate: 0.4%
5. Water absorption of fine aggregate: 0.6%
6. Free surface moisture for coarse aggregate: nil
7. Free surface moisture for fine aggregate: 2%
8. Fineness modulus of sand as obtained by sieve
analysis: 2.48
 Combination of Coarse aggregate
Fractions
IS % pas. % pas. C.G. Fra. I Fra. II Com.
Sieve Fra. I Fra. II Rqd. 68 % 32 % Grad.
40 mm 100 100 100 68.0 32.0 100
20 mm 14 100 40 9.5 32.0 41.5

10 mm 8 34 18 5.4 10.9 16.3

4.75 mm 2 6 0 1.4 1.9 3.3
 Design Strength of Concrete
S = Ŝ / (1 - t.v/100)
= 280 / (1- 1.5 x 10/100)
= 330 kg/cm2

Choosing curve E corresponding to 7 day cement

strength of 210 kg/cm2, for design strength of 330
kg/cm2, w-c ratio required is 0.43
 Selection of water and Sand
Contents
For maximum size of 40 mm, water content per
cu. m. of concrete is 175 kg and sand content is
33.5 % of total aggregate . Adjustments required
for the change in w-c ratio, F.M. of sand, and
slump are:
Water content adjustment = 0
Sand content adjustment = (-1.4)+(-0.6)
= (-2.00) %
Therefore, water content = 175 kg
Sand Content = 33.5-2.0 = 31.5%
 Determination of Cement
Content

W-C ratio = 0.43, but w = 175 kg

hence, cement = 175/0.43
= 407 kg
Determination of Sand Per cu.m.of
Concrete
V = ( W + C/Sc + S/P.Ss )/1000
For 40mm size of aggregate, the entrapped air is
1%, so, V = 1-0.01 = 0.99, W = 175 kg, C = 407kg

P = 31.5% = 0.315

Hence, S = 572.5 kg. Per cu.m. of concrete

Determination of Coarse aggregate
Per cu.m. of Concrete
V = { W + C/Sc + A/(1-P).Sa}/1000

Thus, A = 1244.9 kg
 The Mix Proportions are:

Water Cement Sand CA TA

175kg 407kg 572.5kg 1244.9kg 1817.4kg
0.43 1 1.41 3.06 4.47
Aggregate-Cement ratio = 4.47
Quantities required per bag of cement (50 kg)

21.5kg 50kg 70.5kg 153kg

 Actual quantity of Water After
Moisture & Water Absorption
Adjustment
Extra water required for absorption by CA @ 0.4%
= 153 x 0.004 = 0.61 kg

Water to be deducted for free moisture in fine

aggregate @ 2% = 70.5 x 0.02 = 1.41 kg

Hence, actual quantity of water = 21.5+0.61-1.41

= 20.70kg
 Actual Quantity of Coarse & Fine
Aggregate After Moisture And
Water Absorption Adjustment
Actual Quantity of Coarse aggregate = 153 - 0.61
= 152.39 kg
Fraction I = 68% = 152.39 x 0.68 = 103.58 kg
Fraction II = 32% = 152.39 x 0.32 = 48.81 kg
 Actual Quantities of Different
Constituents for the Mix Per Bag
of Cement

Water Cement Sand CA

20.70 kg 50 kg 71.91 kg 103.58 kg - I
48.81 kg -II
 Mix Design for Concrete Blocks as per
IRC:SP:63-2004
• Same materials as for conventional concrete

• Max. size of CA: 12 mm

• Zero slump or dry concrete

• Water content from 5 to 7 % of total mix

• More fines than conventional concrete

 Mix Design for Concrete Blocks contd.

• 60 – 65% fine aggregate

•Aggregate-cement ratio 3:1 to 6:1

• Minimum binder content 380 kg/m3

• Max. cement content 425 kg/m3

• Colour pigment dose 5 to 9 % of binder content

• Fly ash up to 35 % replacement of OPC may be used

Approximate Cement Content
Compressive Cement
Strength of Block, Content, kg/m3
MPa
30 350 – 375

40 375 – 400

50 400 - 425
 Mix Design Steps

• Select cement content for required strength

• Select aggregate – cement ratio
• Calculate quantity of aggregates
• Select fine aggregate percent
• Calculate quantity of fine aggregate
• Calculate quantity of coarse aggregate
• Prepare mixes with different water content
• Prepare blocks, cure & test at 7 & 28 days
• Adjust the mix proportions if required
Example for Mix Proportions (M40)

• Cement content : 385 kg

• Aggregate – cement ratio : 5 :1
• Aggregates quantity : 1925 kg
• Fine aggregate (65%) : 1251 kg
• Coarse aggregate (35%) : 674 kg
• Water Content(5,6,7%) : 115.5, 138.6,

161.7 kg