Professional Documents
Culture Documents
Unit-III
Syllabus
Concrete Mix Design
Mix Design for compressive strength by I.S. Method, Road
Note Method, British method, Mix Design for flexural
Strength
Concrete Mix Design
Concrete mix design may be defines as the art of selecting
suitable ingredients of concrete and determining their relative
proportions with the object of producing concrete of certain
minimum strength & durability as economically as possible.
Objectives of Mix Design
The purpose of concrete mix design is to ensure the most optimum
proportions of the constituent materials to fulfill the requirement of
the structure being built. Mix design should ensure following objectives.
To achieve the designed/ desired workability in the plastic stage
To achieve the desired minimum strength in the hardened stage
To achieve the desired durability in the given environment conditions
To produce concrete as economically as possible.
Basic Considerations
The following point must be considered while designing concrete mixes
Cost
Specification
Workability
Strength and Durability
Basic Considerations
Cost
The cost of concrete is made up of
Material Cost
Equipment Cost
Labour Cost
The variation in the cost of materials arises from the fact that cement is
several times costlier than aggregates. So it is natural in mix design to aim at
as lean a mix as possible. Therefore, all possible steps should be taken to
reduce the cement content of a concrete mixtures without sacrificing the
desirable properties of concrete such as strength and durability.
Basic Considerations
Specifications
The following point may be kept in mind while designing concrete
mixes
Minimum Compressive Strength required
Minimum water/ cement ratio
Maximum cement content to avoid shrinkage cracks
Maximum aggregate / cement ratio
Maximum density of concrete in case of gravity dams
Basic Considerations
Basic Considerations
Workability
The following points related to workability shall be kept in mind while
designing concrete mixes.
The consistency of concrete should no more than that necessary for placing,
compacting and finishing.
For concrete mixes required high consistency at the time of placing, the use
of water-reducing and set-retarding admixtures should be used rather than the
addition of more water
Wherever possible, the cohesiveness and finishibility of concrete should be
improved by increasing sand/ aggregate ratio than by increasing the
proportion of the fine particles in the sand.
Workability
Strength and Durability
Strength and durability
Strength and durability require lower w/c ratio. It is usually achieved
not by increasing the cement content, but by lowering the water at given
cement content. Water demand can by lowered by throughout control
of the aggregate grading and by using water reducing admixtures.
Strength and Durability
Grade of Concrete
The concrete shall be in grades designated
Group Grade designation Characteristics compressive strength
of 150 mm cube at 28 days, N/mm2
Ordinary Concrete M10 10
M15 15
M20 20
Standard Concrete M25 25
M30 30
M35 35
M40 40
M45 45
M50 50
M55 55
High Strength Concrete M60 60
M65 65
M70 70
M75 75
M80 80
What is M 20 ?
M refers to Mix
20 refers to characteristic compressive strength of 150 mm
cube at 28 days in N/mm2
The minimum Grade of Plain Concrete (PCC) shall be 15
N/mm2
The minimum grade of reinforced Concrete ( RCC) shall be
20 N/mm2
Nominal Concrete Mixes
and
Design mix concrete
Nominal Mix Concrete
The wide use of concrete as construction materials has led to
the use of mixes of fixed proportion, which ensures adequate
strength. These mixes are called nominal mixes.
They offer simplicity and Under normal circumstances, has
margin of strength above that specified.
Nominal mix concrete may be used for concrete of grades M5,
M 7.5, M10, M15 and M20.
Nominal Concrete Mixes
and
Design mix concrete
Proportions of Ingredients in Nominal Mixes
The proportions of materials for nominal mix shall be in accordance
Grade Proportions
C: FA: CA
M5 1: 5:10
M 7.5 1:4:8
M 10 1:3:6
M 15 1:2:4
M 20 1:1.5:3
Design Mix Concrete
The concrete mix produced under quality control keeping in view the
strength, durability, and workability is called the design Mix.
Others factors like compaction equipment's available, curing method
adopted, type of cement, quality of fine and coarse aggregate etc. have
to be kept in mind before arriving at the mix proportion.
The design mix or controlled mix is being used more and more in
variety of important structures, because of better strength, reduced
variability, leaner mixed with consequent economy, as well as greater
assurance of the resultant quality.
Design Mix Concrete
Factors Influencing Choice of Mix Design
According to IS 456:2000 and IS 1343:1980 the important influencing the
design of concrete mix are
Grade of Concrete
Type of Cement
Maximum nominal Size of Aggregate
Grading of Combined aggregate
Maximum Water/ Cement Ratio
Workability
Durability
Quality Control.
Factors Influencing Choice of Mix Design
Grade of Concrete
The grade of concrete gives characteristic compressive strength
of concrete. It is one of the important factor influencing the
mix design
The grade M 20 denotes characteristic compressive strength fck
of 20 N/mm2. Depending upon the degree of control available
at site, the concrete mix is to be designed for a target mean
compressive strength (fck) applying suitable standard deviation.
Factors Influencing Choice of Mix Design
Factors Influencing Choice of Mix Design
Type of Cement
The rate of development of strength of concrete is influenced
by the type of cement.
The higher the strength of cement used in concrete, lesser will
be the cement content. The use of 43 grade and 53 grade of
cement, gives saving in cement consumption as much as 15 %
and 25 % respectively, as compared to 33 grade of cement. For
concrete of grade M25 it is advisable to use 43 and 53 grade of
cement.
Types of Cement
Factors Influencing Choice of Mix Design
Maximum Nominal Size of Aggregates
The maximum size of C.A is determined by sieve analysis. It is designated by the
sieve size higher than larger size on which 15 % or more of the aggregate is retained.
The maximum nominal size of C.A. should not be more than one-forth of
minimum thickness of the member.
For heavily reinforced concrete members as in the case of ribs of main beams, the
nominal maximum size of the aggregate should usually be restricted to sum less
than the minimum clear distance between the main bars or 5 mm less the
minimum cover to the reinforcement, whoever is smaller.
The workability of concrete increases with an increase in the maximum size of
aggregate. But the smaller size of aggregates provide larger surface area for bonding
with the mortar matrix which gives higher strength.
Factors Influencing Choice of Mix Design
Grading of Combined Aggregates
The relative proportions of the fine and coarse aggregate in a
concrete mix is one of the important factors affecting the
strength of concrete.
For dense concrete, it is essential that the fine and coarse
aggregate be well graded. In the case when the aggregate
available from natural sources do not confirm to the specified
grading, the proportioning of two or more aggregate become
essential
Grading of Combined Aggregates
Factors Influencing Choice of Mix Design
Maximum Water/ Cement Ratio
Abrams water/Cement ratio states that for any given condition of test,
the strength of a workability concrete mix is dependent only on
water/cement ratio. The lower the water/Cement ratio, the greater is
the compressive strength
Workability
Workability of fresh concrete determines the case with which a concrete
mixture can be mixed, transported, placed, compacted and finished
without harmful segregation and bleeding.
Factors Influencing Choice of Mix Design
Durability
Durability require low water/Cement ratio. It is usually
achieved not by increasing the cement content, but by lowering
the water demand at a given cement content.
Water demand can be lowered by through control of the
aggregate grading and by using water reducing admixtures
Method of Concrete Mix Design
Some of the commonly used mix design methods are
I.S. Method
A.C.I method
Road Note 4 method ( U.K. Method)
IRC 44 method
Arbitrary method
Maximum Density method
Fineness modulus method
Surface area Method
Nix design for high strength Concrete
Mix design for pumpable Concrete
DOE (British) Mix design method
IS Method of Mix Design
The Bureau of Indian Standards, recommended a set of procedure for design
of concrete mix. The procedure is based on the research work carried out at
national laboratories.
Data for mix design
The following basic data are required to be specified for design a concrete mix
Characteristic Compressive strength only a few specified proportions of test
results are expected to fall of concrete at 28 days (fck)
Degree of workability desired
Limitation on water/Cement Ratio with the minimum cement to ensure
adequate durability
Type and maximum size of aggregate to be used.
Standard deviations of compressive strength of concrete.
IS Method of Mix Design
Target Strength for Mix Design
The target average compressive strength (fck) of concrete at 28 days is given by
Fck= f ck + t.s
Where,
Fck= target average compressive strength at 28 days
F ck= characteristics compressive strength at 28 days
s= Standard deviation
t= a stastical value, depending upon the accepted proportion of low results
and the number of tests.
IS Method of Mix Design
According to Is 456: 2000 and IS 1343:1980 te characteristic
strength is defined as the value below which not more than 5
percent of results are expected to fall. In such cases the above
equation reduced to
Fck= fck + 1.65 s
The value of standard deviation is obtained from the table
IS Method of Mix Design
IS Method of Mix Design
Step-II
Selection of Water Cement Ratio
Since different cements and aggregates of different maximum sizes,
grading, surface texture shape and other characteristics may produce
concrete of different compressive strength for the same free water
cement ratio, the relationship between strength and free water cement
ratio should preferable be established for the material actually to be
used. In the absence of such data, the preliminary free water-cement
ratio corresponding to the target strength at 28 days may be selected
from the relationship shown below
IS Method of Mix Design
IS Method of Mix Design
Alternatively, the preliminary free water cement ratio by mass
corresponding to the average strength may be selected from the
relationship shown below using the curve corresponding to the
28 days cement strength to be used for the purpose. However,
this will need 28 days for testing of cement.
IS Method of Mix Design
IS Method of Mix Design
The free water-cement ratio thus selected should be checked
against limiting water-cement ratio for the requirements of
durability as per table 5.4 and the lower of the two values
should be adopted.
IS Method of Mix Design
IS Method of Mix Design
Step 3 Estimation of Air Content
Approximate amount of entrapped air to be expected in normal
concrete is given in table 9.6
Nominal Maximum Size of Aggregates Entrapped Air, as percentage of volume
of concrete
10 3%
20 2%
40 1%
IS Method of Mix Design
Selection of Water Content and fine to total aggregate ratio
For the desired workability the quantity of mixing water per unit
volume of concrete and the ratio of fine aggregate (sand) to total
aggregate by absolute volume are to be estimated from table below as
applicable. Depending upon the nominal maximum size and type of
aggregate.
IS Method of Mix Design
Approximate Sand and water Content per Cubic Metre of Concrete for
Grades up to M 35 W/C = 0.6 Workability= 0.8 C.F
Nominal Maximum size Water Content per cubic Sand as percentage total
of Aggregates metre of concrete (kg) aggregate by absolute
volume of (%)
10 200 28
20 180 25
IS Method of Mix Design
Adjustment of values in water content and sand percentage for other
conditions
Change in Condition Adjustment Required
Water Content Percentage sand in total aggregate
For sand confirming to 0 + 1.5 percent for zone I
grading Zones I , III -1.5 percent for zone III
and IV -3.0 for zone IV
Increase or decrease in 3% 0
values of compacting
factor by 0.1
Each 0.05 increase or 0 1%
decrease in free water
cement ratio
-15 kg/m 3 -7 %
For rounded aggregates
Calculation of Cement Content
The cement content per unit volume of concrete may be
calculated from the free water-cement ratio obtained in step-
2, and the quantity of water per unit volume of concrete
obtained in step-4
The cement content so obtained should be checked against
the minimum cement content for the requirement of
durability as per table 5 IS 456:2000 and the greater of the
two value is adopted.
Step -6 Calculation of Aggregate Content
With the quantities of water and cement per unit volume of concrete and the
ratio of fine to total aggregate already determined, the total aggregate content
per unit volume of concrete may be calculated from the following equations
V= [ W + C + 1 x fa ] x 1 for fine aggregate 1
Sc p Sfa 1000
And
V=[W+ C+ 1 x Ca ] x 1 for coarse aggregate ..2
Sc (1-p) Sca 1000
Step -6 Calculation of Aggregate Content
Where,
V= Absolute volume of fresh concrete (m3)
W= Mass of Water (kg) per m3 of concrete
C= Mass of Cement (Kg) per m3 of concrete
Sc= Specific gravity of cement say 3.15
P= ratio of fine aggregate to total aggregate by absolute volume
Fa and Ca = Total masses of fine aggregate and coarse aggregate (kg) / m3 of
concrete mass respectively
Sfa, Sca= Specific gravities of saturated surface dry fine aggregate and coarse
aggregate respectively
Normally Sfa= 2.6 and Sca= 2.7
Trial Mixes
The Calculated mix proportions shall be checked by means of
trial batches. The quantity of material should be sufficient for
at least three 150 mm size cube concrete specimens
Example
Using I.S Method design a concrete mix for reinforced concrete
structure for the following requirement.
Design data
Characteristic compressive strength= 20 N/mm 2
Maximum size of aggregates= 20 mm (angular)
Degree of workability= 0.9 CF
Degree of quality Control= Good
Type of exposure= Mild
Example
Test data for Material
Cement used= Ordinary Portland cement of grade 43 with 28 days strength
51 N/mm2
SG= 3.15
Bulk Density = 1450 kg/m3
Aggregate Fine Aggregate Coarse Aggregate
SG 2.66 2.75
Bulk Density 1700 1800
Water absorption 1 0.5
Free Moisture 2 Nil
Example
Step-I Target Mean Strength
Fck= fck + ts
fck= 20 N/mm2
T= 1.65
S= 4 from table 9.5 for M 20
Therefore
Fck= 20 + 1.65 x 4
= 26.6 N/mm2 (Mpa)
Example
Step-II
Selection of Water Cement Ratio
From the fig the free water cement ratio required for the target mean
strength of 26.6 N/ mm2 is 0.5
From fig, for 28 days strength of cement 51 N/mm2, for curve D the
free water cement ratio is 0.52
From table the maximum free water cement ratio for mild exposure is
0.55
Hence the free water cement ratio is taken as the minimum of above
three values i.e. w/c = 0.5
Example
Step III
Estimation of Air Content
For maximum Size of aggregate of 20 mm, the air content is taken as 2
%
Example
Step-4 Selection of water and Sand Content
From table 9.7 for 20 mm nominal maximum size aggregate and sand
confirming to grading zone II water content per cubic metre of
concrete = 186 kg and sand content as percentage of total aggregate by
absolute volume= 35 %
Water= 186 kg/m3 of concrete
Sand= 35 % of total aggregate by absolute volume
Example
For change in values in water cement ratio, compaction factor and sand
belonging to zone III the following adjustments required.
Change in Condition Water Content Percentage Sand in
total aggregate
For Decrease in water cement ratio 0 -2.0
(0.6-0.5) that is 0.1
0.1 x 1 = 2.0
0.05
For increase in compacting factor (0.9 -0.8) + 3 0
= 0.1
0.1 x 3 = 3
0.1
For Sand conforming to Zone III 0 -1.5
+3 -3.5
Example
Required Water Content = 186 + ( 186 x 3 / 100)
= 186 + 5.58
= 191.6 lit /m3
= required sand content as percentage of total aggregate by absolute
volume= 35 3.5
= 31.5 %
Example
Determination of Cement Content
Water Cement ratio= 0.5
Water = 191.6 lit= 191.6 kg
Therefore W/c = 0.5
191.6 = 0.5
C
C=383.4 kg/m3
= 383kg/m3 > 300 kg / m3 therefore O.K.
Example
Determination of fine and coarse Aggregates
Consider volume of Concrete= 1 m3
But entrapped air in wet concrete = 2 %
Therefore volume of fresh concrete= 1 2
100
1- 0.02
V= 0.98 m3
Example
With the quantities of water and cement per unit volume of concrete and the
ratio of fine to total aggregate already determined, the total aggregate content
per unit volume of concrete may be calculated from the following equations
V= [ W + C + 1 x fa ] x 1 for fine aggregate 1
Sc p Sfa 1000
0.98 = [ 191.6 + 383 + 1 + fa ] x 1
3.15 0.315 2.66 1000
980 = 313.187 + 1.19 fa
fa= 558.75 kg mass of F.A
Example
And
V=[W+C+ 1 x Ca ] x 1 for coarse aggregate ..2
Sc (1-p) Sca 1000
0.98 = [ 191.6 + 383 x 1 x Ca ] x 1
3.15 (1-0.315) 2.75 1000
980 = 313.187 + 0.5308 Ca
Ca= 1256.24 kg mass of C.A
Example
Water Cement F.A C.A
191.6 li 383 kg 558.75 kg 1256.24 kg
0.5 1 1.46 3.28
W= 0.44
C
Example
Step III Estimation of air Content
For maximum Size of Aggregate of 20 mm, the air content is taken as
2.0 %
Example
Step-4
Selection of Water and Sand Content
From table 9.7 for 20 mm nominal maximum size aggregates and sand
confirming to grading Zone-II, water content per cubic metre of
concrete = 186 kg and sand content as percentage of total aggregate by
absolute volume = 35 % i.e.
Water = 186 kg/m3
Sand = 35 % of total aggregate by absolute Volume.
Example
For Change in values in water-Cement ratio, compaction factor and
sand belonging to zone I the following adjustments are required.
Change in Condition Adjustment Required
Water Content Percentage Sand in total
Aggregate
(i) For Decrease in Water-Cement ratio (0.6 0 -3.2
0.44) that is 0.16
Therefore 0.16 x 1 = 3.2
0.05
(ii) For Increase in Compacting factor (0.9 - +3 0
0.8)= 0.1
Therefore 0.1 x 3 = 3.0
0.1
(iii) For Sand Conforming to Zone-I of table 4 0 +1.5
of IS 383-1970
Example
Required water Content = 186 + ( 186 x 3 )
100
= 191.6 lit / m3
Required Sand Content as Percentage of Total aggregate by absoluter
Volume
p= 35 1.7
= 33.3 %
Example
Step- V Determination of Cement Content
Water Cement Ratio = 0.44
Water = 191.6 lit = 191.6 kg
Therefore,
W= 0.44
C
191.6 = 0.44
C
C= 435.45 kg/m3 > 300 kg /m3
This cement content is adequate for Moderate Exposure condition, according
to table 5 IS 456-2000)
Example
Determination of fine and Coarse content:
Consider volume of concrete = 1 m3
But, entrapped air in wet concrete= 2 %
Therefore, absolute volume of fresh concrete= 1 2
100
= 1 0.02
V= 0.98 m3
Therefore,
Example
V= [ W + C + 1 x fa ] x 1 for fine aggregate1
Sc p Sfa 1000
And
0.98= [ 191.6 + 436 + 1 + fa ] x 1
3.15 0.33 2.6 1000
980 = 191.6 + 138.41 + 1.15 fa
fa= 562.76 kg
= 563 kg mass of F.A.
Example
Similarly,
V=[W+C+ 1 x Ca ] x 1 for coarse aggregate..2
Sc (1-p) Sca 1000
0.98 = [ 191.6 + 436 x 1 x Ca ] x 1
3.15 (1-0.333) 2.65 1000
980 = 191.6 + 138.41 + 0.5657 Ca
Ca= 1149 kg/m3 mass of C.A.
Example
Mix Proportions (By Mass)
45 0.38 -
40 0.43 -
35 0.48 0.4
30 0.55 0.46
25 0.62 0.53
20 0.7 0.61
15 0.8 0.71
The ACI Method of Mix Design
The water Cement ratio obtained from Strength point of view
is to be checked against maximum W/C Ratio given for special
exposure condition given in table 9.11 and minimum of the
two is to be adopted.
The ACI Method of Mix Design
Requirement of ACI for W/C Ratio and Strength for Special Exposure
Condition
Exposure Condition Maximum W/C ratio, normal Minimum Design Strength, low
density aggregate concrete Density aggregate Concrete, MPA
Concrete Intended to be Watertight
(a) Exposed to fresh Water 0.5 25
(b) Exposed to brackish or sea Water 0.45 30
Concrete Exposed to freezing and Thawing in a moist Condition:
45 0.38 -
40 0.43 -
35 0.48 0.4
30 0.55 0.46
25 0.62 0.53
20 0.7 0.61
15 0.8 0.71
Exposure Condition Maximum W/C ratio, normal Minimum Design Strength, low
density aggregate concrete Density aggregate Concrete, MPA
Concrete Intended to be Watertight
(a) Exposed to fresh Water 0.5 25
(b) Exposed to brackish or sea Water 0.45 30
Concrete Exposed to freezing and Thawing in a moist Condition:
Check this w/c ratio for durability considerations and adopt the lower
value
Minimum 30 35 40 45 50
grade
Maximum 0.65 0.6 0.55 0.5 0.45
w/c ratio
Maximum 275 300 325 350 400
cement
content
Introduction
In this method, the aggregate to cement ratios are worked out on the basis of type of
aggregate, max size of aggregate and different levels of workability.
The relative proportion of aggregates is worked on basis of combined grading curves. This
method facilitates use of different types of fine and coarse aggregates in the same mix.
The relative proportion of these can be easily calculated from combined grading curves.
The values of aggregate to cement ratio are available for angular rounded or irregular coarse
aggregate.
2. w/c ratio is read from compressive strength v/s w/c ratio graph.
3. Proportion of combined aggregates to cement is determined from tables, for maximum size 40 mm and 20
mm.
4. If the aggregate available differs from the standard grading, combine FA and CA so as to produce one of the
standard grading.
5. The proportion of cement, water, FA and CA is determined from knowing the water/cement ratio and the
aggregate/cement ratio.
6. Calculate the quantities of ingredients required to produce 1 m3 of concrete, by the absolute volume method,
using the specific gravities of cement and aggregates.
(1x Sc + 1.45x Sfa +0.75x Sca10 +1.6 x Sca20 + w/c)x 1000 x (1 Ea)
Plastic Density =
5.26
This method leads to very high cement contents and thus is becoming
obsolete.
Internet websites
http://www.foundationsakc.org/
Thanks