DESIGN MIX

DESIGN MIX
CONTENT:
INTRODUCTION
SPECIFIED PROPERTIES
Plastic Concrete
Hardened Concrete
USEFUL RELATIONSHIPS
Measurement of Workability
Characteristic Strength
Margin of Mix Design
Strength vs w/c ratio
Effect of Aggregate on Water Demand
Workability vs Water Content
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OPTIMISATION OF COST AND PERFORMANCE
Introduction
Normal Performance
Special Performance
DOE MIX DESIGN PROCEDURE
Specification
Stage 1 water/cement ratio
Stage 2 water content
Stage 3 cement content
Stage 4 fresh concrete density
Stage 5 fine aggregate proportion
Worked example
Calculation of Fresh Density
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TRIAL MIXES
Workability Too Low
Cohesion Too Low
Concrete Strength
Concrete Density
AMERICAN METHOD
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OBJECTIVES:
The objective of this lesson is to explore the
various methods of mix design, with particular
reference to DOE method, e.g.
Specification and useful relationship
Optimisation of cost and performance
Available mix design methods
The DOE normal concrete mix design method
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INTRODUCTION

The main aims of concrete mix design:

Firstly
To select suitable constituent materials
(and their proportions) to produce concrete
with all the required properties (both
fresh and hardened states)
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Secondly..
To ensure that the above is achieved for
the minimum cost. (This should include
the cost of materials, as well as the cost of
batching, mixing and placing the concrete
and the cost of site supervision)
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FACTORS TO BE CONSIDERED:
Workability
Cohesiveness, slump
Placement conditions
Strength
Durability
Appearance
Economy
Minimize the amount of cement,
To reduce cement content
Do not sacrifice the quality
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SPECIFIED PROPERTIES:
Plastic Concrete

Concrete should be sufficiently

Workable
Stable
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This means that freshly mixed concrete
Should be sufficiently fluid for it to flow into
and fill all parts of the formwork into which
it is placed
Does not segregate whilst being handled
from the mixer or during placing
Can be fully compacted with the desired
surface finish when placed in position
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USEFUL RELATIONSHIPS
Characteristic Strength and Margin
As a result of variability of concrete in
production, it is necessary to design the
mix to have a mean strength greater than
the specified characteristic strength by an
amount termed margin.
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fm = fc + ks

where
fm = the target mean strength
fc = the specified characteristic strength
ks = the margin which is product of
s = standard deviation
k = constant
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Constant k
The constant k is derived from the
mathematics of the normal distribution and
increases as the proportion of defectives is
decreased, thus
k for 10% defectives = 1.28
k for 5% defectives = 1.64
k for 2.5% defectives = 1.96
k for 1% defectives = 2.33
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Standard deviation s B; minimum s for 20 or more results
9 A; s for less than 20 results
Standard deviation s is 8

Standard deviation, s, (N/mm2)

calculated from n results 7
is only an estimate of the 6
standard deviation of the 5
total population. 4

It is desirable for mix design 3

purposes the standard 2

1
deviation should be
0
calculated from at least 10 20 30 40 50 60 70
20 results. Characteristic strength (N/mm2)
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Workability
Ease of placing concrete such as its
cohesiveness, mobility, compactibility and
finishability.

The DOE method uses the slump and Vebe

time tests as means by which the
workability of the concrete is specified as
one of four ranges given in Table 1
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Table 1

Slump (mm) 0-10 10-30 30-60 60-180

Vebe time >12 6-12 3-6 0-3

(s)
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Strength vs w/c ratio

For a given materials, the strength of

concrete (fcm) is uniquely related to its
water/cement ratio (w/s) as

fcm = A/[B1.5(w/c)]
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Where fcm = compressive strength at
some fixed age
A = empirical constant
B = constant, which depends on
cement properties
w/c = water/cement ratio by
weight
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This means that strength is inversely
proportional to the w/c ratio.

This relationship is known as Abrams Law

(1919).
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Effect of Aggregate on Water Demand

The properties of aggregate which influence water

requirement and workability of concrete are:
1. Shape and Texture
2. Size Gradation
- particle size distribution
- maximum aggregate size
- fine coarse aggregate ratio
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3. Moisture Content
- absorption and surface moisture
- bulking of sand
4. Relative Density
5. Bulk Unit Weight
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Workability vs Water Content

In general, workability increases with the

water content in the mix.
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OPTIMISATION OF COST / PERFORMANCE
INTRODUCTION
Mix design method should aim to achieve the
required performance of concrete at the
minimum cost.
This can be achieved by minimizing the content of
the most expensive ingredients i.e. cement (in
average 10 times more expensive than
aggregate)
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However, in any such exercise the time
span over which a required performance is
considered must be an important factor.
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In general, the specification for concrete can
be grouped into two categories, normal
performance concrete and special
performance concrete.
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Normal Performance Concrete
Normal range of workability
Normal range of strength
General durability
Special Performance
Very high workability (e.g. flowing concrete)
Low Heat evolution
Early strength development
Very high strength (>C60)
Specific durability (e.g. ASR, Sulphate resistance,
etc)
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Normal Performance
Provision of normal performance can be
achieved with ordinary portland cement by
specifying:
Minimum cement content
Maximum water/cement ratio
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Special performance
For special performance concrete, the use of
other constituent materials may have to be
considered for example:
Rapid hardening
Sulphate resisting
Pulverised Fuel Ash
Low-Heat Portland Blastfurnace
Ground Granulated Blastfurnace Slag
Microsilica
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Chemical Admixtures
Accelerating and retarding
Water-reducing and superplasticizing
Air entraining
Aggregates
Non-shrinkable
Free of deleterious material
lightweight
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DOE MIX DESIGN PROCEDURE 1988
EDITION

Specification
In order to use the method, the following
specification details must be known.
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Cement type
Ordinary portland cement (OPC), Sulphate
resisting Portland Cement (SRPC), or Rapid
Hardening Portland Cement (RHPC)

Aggregate Type
Natural gravels or water-worn materials are
describe as uncrushed; other aggregate are
crushed
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Maximum Aggregate Size
One of the standard sizes 10, 20, or 40mm

Fine Aggregate Grading

The method requires the proportion passing
the 600m sieve
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Aggregate Relative Densities
Assumed values are given if they are not
known

Fresh Concrete
Slump or vebe time required
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Hardened Concrete
The target mean strength and specified age
are required. Specifications are normally
given as grades of characteristics strength.
Hence they must be converted to target mean
values as described earlier.
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STAGE 1 (WATER/CEMENT RATIO)
This is based on target mean strength as stated age,
cement type and aggregate type.
Table 2 gives mean strength at various ages for a 0.5
free w/c ratio for various materials combinations.
The appropriate strength is read off. This strength and
the water/cement ratio 0.5 from starting point for use of
Figure 1.
The curved lines define directions on the graph it is not
necessary to take values from the lines but to read
parallel to them.
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To use Figure 1, find the strength obtained from
Table 2 on the starting line. Then move parallel
to lines until the required target mean strength is
obtained, reading horizontally.
Obtain the corresponding water/cement ratio by
reading downwards.
Check for the correctness of result higher
strength than that from Table 2 require lower
water/cement ratio and vice versa.
Some practice may be necessary to use the
figure correctly and accurately.
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Having obtained the water/cement ratio,
compare with any value specially required
in the specification and take the lowest
value.
The strength/durability of the concrete are
now defined for the given materials and
age.
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Table 2
Figure 1
relationship
between
compressive
strength and
free-
water/cement
ratio
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STAGE 2 ( WATER CONTENT)
This is easily obtained from the workability
requirement together with aggregate
maximum size and type. (Table 3)
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Table 3
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STAGE 3 (CEMENT CONTENT)
This is found from the result of stages 1 and
2 since
cement content = water content
w/c ratio
This value should be compared with any
specified minimum value (for durability) or
maximum value (to restrict shrinkage or
heat of hydration)
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STAGE 4 (FRESH CONCRETE DENSITY; FULLY
COMPACTED)
an estimate of this is required in order to
correlate batch weights with yield of concrete
which as always state in volume terms.
The relatives aggregate should be measures on
a saturated surface dry basis, though the
method can be continued, if less accurately,
using assumed figures.
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Figure 2 is based on a cement density of
3.15, the only other variable being the
water content.
The mass of one cubic meter of concrete
is now known, together with the masses of
cement and water required in that volume.
The aggregate quantity can be therefore
be found by substraction.
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Figure 2 Free-water content (kg/m3)

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STAGE 5 (FINE AGGREGATE PROPORTION)
12 sets of graphs (Figure 3) are shown requiring
the maximum aggregate size, workability and %
of fine aggregate passing the 600micrometer
sieve.
Select the appropriate graph, reading the
proportion of the aggregate against the free
water/cement ratio and % passing the 600
micrometer sieve.
Fine and coarse aggregate quantities can then
be calculated.
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Finally, batch quantities per cubic meter of
concrete may be listed. For trial mix, a
small amount of the concrete, say 50 litres
may be produced.
The figures being weighed appropriately
(note 1m3 = 1000 litres)
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Figure 3
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Worked example:
Produce batch quantities for 1m3 of concrete to
have a slump of 30 to 60 mm and
characteristic 28-day compressive strength of
25N/mm2 (5% failures permitted). No previous
results are available. The materials used are
Cement: OPC; Fine aggregate: crushed,
medium zone, 65% passing 600m sieve,
relative density 2.7; coarse aggregate:
crushed, maximum size 20mm, relative
density 2.7.
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stage Item Reference or Values
calculation (C)
1 1.1 Specified _____25_______ N/mm2 at _28___ days
Characteristic Proportion defectives __5____ %
strength

1.2 Standard C _____ N/mm2 or no data ____ N/mm2

deviation

C
1.3 Margin (k = _1.64) _1.64 x __8__ = _13_ N/mm2

1.4 Target ___25__ + __13___ = _38___ N/mm2

mean strength

1.5 Cement Specified

OPC / SRPC / RHPC
Type
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stage Item Reference or Values
calculation
(C)
1 1.6
Aggregate Specified Crushed / uncrushed
type: coarse
Aggregate Specified Crushed / uncrushed
type: fine

1.7 Free
water/cement Table 2 ___0.58____
ratio Figure 1 use the lower value

1.8 Max free Specified ______-____ 0.58

water/cement
ratio
Table 2
Table 2

Fig 1
fm = 38 MPa
Relationship
between
compressive
strength and
free-
water/cement
ratio

0.58
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stage Item Reference or Values
calculation
(C)
2 2.1 Slump or Specified Slump 30-60_ mm or vebe time _____s
vebe time

2.2 Max Specified ____20_ mm

aggregate
size

2.3 Free
Table 3 ________________ 210 kg/m3
water content
Table 3
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stage Item Reference or Values
calculation
(C)

3 3.1 Cement C __210___ / ___0.58_ = _362__ kg/m3

content

3.2 Max Specified ____-___ kg/m3

cement
content

3.3 Min
cement Specified __-_____ kg/m3
content Use 3.1 if 3.2
Use 3.3 if > 3.1 362 kg/m3

3.4 modified -
free w/c ratio
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stage Item Reference or Values
calculation
(C)

4 4.1 relative ______2.7__________known/ assumed

density of
aggregate
(SSD)

4.2 Concrete
density Figure 2 ___2400__ kg/m3

4.3 Total
aggregate 2400__ - _362__ - _210_ = _1828 kg/m3
content
2400 kg/m3

Figure 2 Free-water content (kg/m3)

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stage Item Reference or Values
calculation
(C)

5 5.1 Grading of % passing 600m sieve ____65___ %

fine aggregate

5.2 Proportion
of fine
aggregate Figure 3 _________________33______ %

5.3 Fine C _33%___ x _1828_= 603 kg/m3

aggregate
content

5.4 Coarse C _1828_ - _603____ = 1225 kg/m3

aggregate
content
 Figure 3

33%

65%
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Quantities Cement Water (kg Fine Coarse aggregate (kg)
(kg) or litre) aggregate
(kg)

Per m3 (to 10mm 20mm 40mm

nearest 5 __360___ _210____ _605____ ______ _1225_ ______
kg)

Per trial _______ _______ ________ ______ ______ ______

mix of
_____ m3
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TUTORIAL
QUESTION 1
Using British design method, produce batch
quantities for 50 litres of concrete to the
following specification:
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Cement OPC
Aggregate sand uncrused
- relative density 2.6
- 59% passing 600 m
sieve
CA - uncrushed
- r.d 2.6
Workability 30 60 slump
Compressive strength 35 N/mm2
5% defective
Assume s = 4
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Q2
Using British method, determine batch
quantities for 10 litres of concrete for the
following specification:
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Cement RHPC
Aggregate sand -uncrushed
- r.d 2.7
- 75% passes 600 m
sieve
CA - uncrushed
- r.d 2.7
- max size 20mm
Minimum cement content 350 kg/m3
Compressive strength 35 N/mm2 at 28 days
Standard deviation 5 N/mm2; 5% defectives
Workability 10 30 mm slump
 Table 15.1: Requirements of BS 8110: Part1: 1985 to ensure durability under
specified conditions of exposure of plain concrete

Environment Exposure Max free Minimum content of cementitious Minimum

condition w/cementitious material* kg/m3 (lb/yd3) for nominal grade
material* ratio maximum size of aggregate MPa (psi)

40 mm 20 mm 14 mm 10 mm
(1 in.) (3/4 in.) (5/8 (3/8
in.) in.)

Mild Concrete surfaces protected 0.80 150 180 200 220 20

against weather or (250) (300) (340) (370) (2900)
aggressive conditions

Moderate Concrete surfaces sheltered 0.65 245 275 295 315 30

from severe rain or freezing (410) (460) (500) (530) (4400)
whilst wet.
Concrete subject to
condensation.
Concrete surfaces
continuously under water
Concrete in contact with
non-aggressive soil
Severe Concrete surfaces exposed 0.60 270 300 320 340 35
to severe rain, alternating (450) (510) (540) (570) (5100)
wetting and drying or
occasional freezing or
severe condensation

Very severe Concrete surfaces exposed 0.55 295 325 345 365 35
to seawater spray, de-icing (500) (550) (580) (610) (5100)
salts (directly or
indirectly), corrosive fumes
or severe freezing condition
whilst wet

Extreme Concrete surfaces exposed 0.50 320 350 370 390 45

to abrasive action, e.g (540) (590) (620) (660) (6500)
seawater carrying solids or
flowing water with pH
4.5 or machinery or
vehicles

* inclusive of slag or PFA

Table 14.5: Requirements of BS8110: Part 1: 1985 to ensure durability under specified exposure condi
reinforced and prestressed concrete made with normal weight aggregate

Condition of exposure (see Nominal cover of concrete in mm (in.)

Table 15.1)
Mild 25 (1) 20 ( ) 20 ( ) 20 ( ) 20 ( )
Moderate - 35 ( 1 ) 30 (1 ) 25 (1) 20 ( )
Severe - - 40 (1 ) 30 (1 ) 25 (1)
Very severe - - 50 (2) 40 (1 ) 30 (1 )
Extreme - - - 60 (2 ) 50 92)
Maximum free/water 0.65 0.60 0.55 0.50 0.45
cementitious material
ratio
Minimum content of 275 300 325 350 400
cementitious material in (460) (510) (550) (590) (670)
kg/m3 (lb/yd3)
Minimum grade * MPa 30 35 40 45 50
(psi) (4400) (5100) (5800) (6500) (7300)
Grade is characteristic cube strength
Note: This table applies when the maximum size of aggregate is 20 mm ( in). when
It is 10 mm ( 3/8 in.) and 14 mm ( 5/8 in.), respectively, the content of cementitious material
should be increased by 40 kg/m3 and 20 kg/m3 (70 lb/yd3) and 35 lb/yd3); conversely, for maximum
size of aggregate of 40 mm (1 in.) the content of cementitious material can be reduced by
30 kg/m3 (50 lb/yd3) but BS8110: Part 1: 1985 imposes some overall limitations.
Specifically, prestressed concrete must contain at least 300 kg/m 3 (500 lb/yd3) of cementitious material.
For exposure to freezing and thawing, air entrainment should be used.
Inclusive of any ground granulated blast-furnace slag or PFA
 Table 5.1 Workability, slump, and compacting factor of
concretes with 19 or 38 mm ( or 1 in.) maximum size of aggregate

Degree of Slump Compacting Use for which concrete is suitable

workability factor

mm In.
Very low 0-25 0-1 0.78 Roads vibrated by power-operated machines. At
the more workable end of this group, concrete may
be compacted in certain cases with hand-operated
machines.

Low 25-50 1-2 0.85 Roads vibrated by hand-operated machines. At the

more workable end of this group, concrete may be
manually compacted in roads using aggregate of
rounded or irregular shape. Mass concrete
foundations without vibration or lightly reinforced
sections with vibration.

Medium 25-100 2-4 0.92 At the less workable end of this group, manually
compacted flat slabs using crushed aggregates.
Normal reinforced concrete manually compacted
and heavily reinforced sections with vibration.

High 100-175 4-7 0.95 For sections with congested reinforcement. Not
normally suitable for vibration
 EXAMPLE 3
A mix is required for a reinforced concrete wall which will be
exposed to the moderate conditions. A mean compressive
strength of 30 MPa (4350 psi) is required at the age of 28 days,
and the size of the section and reinforcement dictate a nominal
cover of 25 mm (1 in.), using a maximum size of aggregate of 20
mm (3/4 in.), the appropriate workability requires a slump of
75mm (3 in.).

The available coarse aggregate is uncrushed, and both the fine

and coarse aggregate conform to the gradings of BS882: 1983,
the fine aggregate corresponding to the M grade, of which 50
per cent passes a 600 micrometer sieve. The aggregates have
an absorption of 1 per cent, a total moisture content of 3 per
cent, and bulk specific gravity of 2.65.
 MIX DESIGN
TRIAL MIXES

Most important part in mix design

procedure.
Initial trial mixes may be made in small
quantities, for example using a 20 kg
sample of concrete.
 MIX DESIGN
WORKABILITY TOO LOW
The slump, say, 10 mm instead of 30 6-
mm.
There will be little point in proceeding with
strength test if it is found that extra water
is required for workability, since this will
decrease the strength of the concrete.
 MIX DESIGN
Note the increase of water required and
obtain the corresponding figure per cubic
meter (say 15 litre).
Now, increase the cement content to keep
the water cement ratio the same as
previously, for example if water/cement
ratio = 0.58
new cement content = 210 + 15 = 380 kg
0.58
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Find the new density of the material (with
the higher water content) and hence adjust
the mass of coarse aggregate.
The proportion of fine aggregate should
not need to be altered.
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CONCRETE STRENGTH
In order to save time 28 day concrete strength
can be predicted by accelerated curing or by
testing early referring to strength/ age/
correlations.
If the strength is incorrect, reference should be
made to the original water/cement ratio value
obtained from figure 4.
Locate the position corresponding to the old
value of water/cement and actual strength
obtained and then follow parallel lines to obtain
the desired strength.
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If the strength was too low, a decrease of
water/cement ratio will be required and
vice versa.
Follow the mix design procedure from
stage 1 using the new water/cement ratio.
The main effect will be an increase of
cement content usually in the region of 6
kg per cubic meter for every 1 MPA
increase of compressive strength.