Concrete Mix Design

Introduction

1. The selection of the mix ingredients and their proportions is referred to as mix
design. This is considered as a part of the structural design process, concerned with
the required performance of concrete.

Aim

2. The aim of my tropics is give idea about Concrete Mix Design.

Selection Of Concrete Mix Proportions (Mix Design)

3. We Know, Cement concrete = Cement + fine aggregate (sand) + coarse aggregate

(khoa or stone chips) + water.
4. Structural design imposes two criteria for this selection: strength of concrete and
its durability. Another implied requirement is workability, must be appropriate for the
placing conditions, from the time of discharge from the mixer up to the time of
placing of concrete.
5. In addition, the selection of mix proportions has to take into account the method
of transporting the concrete, especially if pumping is envisaged. Other important
criteria are: setting time, extent of bleeding, and ease of finishing. Considerable
difficulties can arise if these criteria are not properly taken into account during the
selection of the mix proportions or when adjusting these proportions.
6. The selection of mix proportions is thus, simply, the process of choosing suitable
ingredients of concrete and determining their relative quantities with the object of
producing as economically as possible concrete of certain minimum properties,
notably strength, durability, and a required consistency.

Cost Considerations

7. The concrete should have certain specified minimum properties, and it should be
produced as economically as possible - a common requirement in engineering.
2 The cost of concreting, as of any other type of construction activity, is made up of
the costs of the materials, plant, and labor. Considering the relative price of cement, in
selecting the mix proportions, it is desirable to avoid high cement content. The use of
comparatively lean mixes confers also considerable technical advantages, not only in
the case of mass concrete where the evolution of excessive heat of hydration may
cause cracking, but also in structural concrete where a rich mix may lead to high
shrinkage and cracking.
8. The cost of labor is influenced by the workability of the mix: workability
inadequate for the available means of compaction results in a high cost of labor (or in
insufficiently compacted concrete). Dealing with blockages in pumping is also labor
intensive. The exact cost of labor depends on the details of organization of the job and
the type of equipment used.

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Specifications

9. In the past, specifications for concrete prescribed the proportions of cement, and
fine and coarse aggregate. Certain traditional mixes were thus produced but, because
of the variability of the mix ingredients, concretes having fixed cement-aggregate
proportions and a given workability vary widely in strength. For this reason, the
minimum compressive strength was later added to other requirements. When the
strength is specified, the prescription of proportions makes the specification unduly
restrictive where good quality materials are available, but elsewhere it may not be
possible to achieve an adequate strength using the prescribed mix proportions. This is
why, sometimes, clauses prescribing the grading of aggregate and the shape of the
particles were added to the other requirements. However, the distribution of
aggregates in many countries is such that these restrictions are often uneconomic. In
this connection it should be noted that, with the exception of specialized construction,
such as nuclear containment vessels, only locally available aggregates are used;
transportation over long distances is prohibitively expensive.
3 More generally, specifying at the same time strength as well as mix ingredients
and their proportions, and also the aggregate shape and grading, leaves no room for
economies in the mix selection, and makes progress in the production of economic
and satisfactory mixes on the basis of the knowledge of the properties of concrete
impossible.
10. It is not surprising, therefore, that the modern tendency is for specifications to be
less restrictive. They lay down limiting values but sometimes give also as a guide the
traditional mix proportions for the benefit of the contractor who does not wish to use a
high degree of quality control. The limiting values may cover a range of properties;
the more usual ones are:
a. ‘Minimum’ compressive strength necessary from structural considerations;
b. Maximum water/cement ratio and/or minimum cement content and, in certain
conditions of exposure, a minimum content of entrained air to give adequate
durability;
c. Maximum cement content to avoid cracking due to the temperature cycle in
mass concrete;
d. Maximum cement content to avoid shrinkage cracking under conditions of
exposure to a low humidity; and
e. Minimum density for gravity dams and similar structures.
In addition, the nature of the cementitious materials, sometimes by a specific
requirement with respect to the type or composition of cement, at other times by
proscription, may be included in the specification.

11. All these various requirements must be satisfied in the selection and proportioning
of mix ingredients.
4 A designed mix is specified by the designer principally in terms of strength, cement
content, and water/cement ratio; compliance relies on strength testing.
A prescribed mix is specified by the designer in terms of the nature and proportions of
mix ingredients; the concrete producer simply makes the concrete 'to order'. The

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assessment of mix proportions is used for compliance purposes, strength testing not
being routinely used. The use of prescribed mixes is advantageous when particular
properties of concrete, for instance with respect to its finish or abrasion resistance, are
required. However, a prescribed mix should be specified only when there are sound
reasons for assuming that it will have the required workability, strength, and
durability.
A standard mix is based on ingredients and proportions fully listed in BS 5328: part
2: 1991 for several values of compressive strength up to 25 MPa, measured on cubes.
The fourth and last type of mix is the designated mix, for which the concrete producer
selects the water/cement ratio and the minimum cement content, using a table of
structural applications coupled with standard mixes. This approach can be used only if
the concrete producer holds a special certificate of product conformity based on
product testing and surveillance, coupled with certification of quality assurance.

Factors Affecting Properties Of Concrete

12. Properties (e.g., strength and durability) of concrete depend upon the following
parameters:
a. Water-cement (w/c) ratio
b. Grading of aggregate (shape, size, surface texture, strength and stiffness of
aggregate)
c. Moisture content (m/c) of aggregate
d. Quality of cement, sand, water
e. Method of mixing, transportation, placing and compaction
f. Curing

5 Factors Governing The Selection Of Mix Proportions

13. The basic objective is to determine the proportions of the most economical
concrete mix that will be satisfactory both in the fresh and in the hardened state.

a. Durability

It has been stated, on more than one occasion, that the selection of mix proportions
must satisfy not only the strength requirements but must also ensure adequate
durability.
However, there does not yet exist a generally agreed and reliable approach to the
selection of mix of proportions required for durability under any given conditions
Penetrability of concrete, which plays a crucial role in its durability, cannot be
directly controlled in the production of concrete. Hence, reliance is necessary on the
water/cement ratio, cement content, compressive strength - indeed, any one of these,
or two, or all three at the same time, can be used. It is worth re-iterating that, whatever
mix proportions are chosen, the concrete must be capable of full compaction using the
means available, and that such compaction must be achieved in practice.
It is very much doubted that strength alone can be used as an indicator of durability. If
durability requires a certain maximum water/cement ratio, but structural

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requirements are for a value of strength which can be readily achieved at a higher
water/cement ratio, a set of incompatible values of strength and water/cement ratio
should not be specified. Rather, a higher specified strength should be used so as to
correspond to the water/cement ratio required for reasons of durability. In this manner,
there will be no temptation on the part of the concrete producer to disregard the
water/cement ratio and to rely solely on an adequate level of strength. This higher
strength should be established prior to the commencement of the structural design so
that advantage can be taken of the use of a higher strength of concrete in the structural
design.
The water/cement ratio alone does not determine the resistance of concrete to
chloride penetration: the type of cementitious material used greatly affects the
penetrability of the resulting concrete. In particular, concretes containing both ground
granulated blast-furnace slag and silica fume offer particularly good resistance. This
situation exemplifies the difficulty of basing the specification for durability on
strength alone. The same argument applies to the use of cement content alone.
The nature of the cementitious materials to be used is of vital importance also
under other conditions of exposure. When concrete is to be subjected to chemical
attack, a suitable type of cement must be used but, if resistance to freezing and
thawing is the only durability requirement, the choice of the type of cement is
governed by other considerations, for instance, the development of early strength or of
a high heat of hydration for concreting in cold weather. Indeed, the beneficial
properties of the various cementitious materials should be exploited in the selection of
the cement. However, the limits on the maximum content of fly ash and ground
granulated blast-furnace slag, imposed by ACI 318-95 for concrete exposed to de-
icing agents, should be remembered.
Because the type of cement affects the early development of strength, it may be
necessary, with some cement, to use a low water/cement ratio to ensure a satisfactory
strength at early ages. Thus, strength, type of cement, and durability determine
between them the water/cement ratio required - one of the essential quantities in the
calculation of mix proportions.

b. Workability

So far, we have considered the requirements for the concrete to be satisfactory in

the hardened state but, as said before, properties when being transported, possibly
pumped, and placed are equally important. One essential at this stage is a satisfactory
workability. Selection of mix proportions which do not permit the achievement of
appropriate workability totally defeats the purpose of rational mix proportioning.
The workability that is considered desirable depends on two factors. The first of
these is minimum size of the section to be concreted and the amount and spacing of
reinforcement; the second is the method of compaction to be used.
It is clear than when the section is narrow and complicated, or when there are
numerous corners or inaccessible parts, the concrete must have a high workability so
that full compaction can be achieved with a reasonable amount of efforts. The same
applies when embedded steel sections or fixtures are present, or when the amount and
spacing of reinforcement make placing and compaction difficult. Because these

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features of the structure are determined during its design, the necessary workability
must be ensured in the selection of mix proportions. On the other hand, when no such
limitations are present, workability may be chosen within fairly wide limits, but the
means of transportation and compaction must be decided upon accordingly; it is
important that the prescribed method of compaction is used during the entire progress
of construction.
A property closely related to workability is cohesiveness. This depends largely on
the proportion of fine particles in the mix and, especially in lean mixes, attention must
be paid to the grading of the aggregate at the fine end of the scale. It is sometimes
necessary to make several trial mixes with different proportions of fine to coarse
aggregate in order to find the mix with an adequate cohesiveness.
While every mix should be cohesive so that uniform and well-compacted concrete
can be obtained, the exact importance of cohesiveness varies. For instance, where
concrete has to be hauled without agitation over a long distance or is handled down a
chute, or has to pass through reinforcement, possibly to some inaccessible corner, it is
essential that the mix be truly cohesive. In cases when the conditions leading to
segregation are less likely to be encountered, cohesion is of smaller importance, but a
mix which segregates easily must never be used.

c. 8 Maximum Size Of Aggregate

In reinforced concrete, the maximum size of aggregate which can be used is

governed by the width of the section and the spacing of the reinforcement. With this
proviso, it used to be considered desirable to use as large a maximum size of
aggregate as possible. However, it now seems that the improvement in the properties
of concrete with an increase in the size of aggregate does not extend beyond about 40
mm (1.5 inch) so that the use of larger sizes may not be advantageous. In particular, in
high performance concrete, the use of aggregate larger than 10 to 15 mm (3/8 to 5/8
in.) is counter-productive.
Furthermore, the use of a larger maximum size means that a greater number of
stockpiles has to be maintained and the batching operations become correspondingly
more complicated. This may be uneconomical on small sites but, where large
quantities of concrete are to be placed, the extra handling cost may be offset by a
reduction in the cement content of the mix.
The choice of the maximum size may also be governed by the availability of materials
and by their cost. For instance, when various sizes are screened from a pit, it is
generally preferable not to reject the largest size, provided this is acceptable on
technical grounds.

d. Grading And Type Of Aggregate

Most of the remarks in the preceding section apply equally to the considerations of
aggregate grading because it is often more economical, to use the material available
locally, even though it requires a richer mix (but provided it will produce concrete free

5
from segregation) rather than to bring in a better graded aggregate from farther field.
It has been stressed repeatedly that, although there are certain desiderata for a
good grading curve, no ideal grading exists, and excellent concrete can be made with a
wide range of aggregate grading.
9 The grading influences the mix proportions for a desired workability and the
water/cement ratio: the coarser the grading the leaner the mix which can be used, but
this is true within certain limits only because a very lean mix will not be cohesive
without a sufficient amount of fine material.
It is possible, however, to reverse the direction of choice: if the cement content is
fixed (e.g. a lean mix may be essential for massive concrete construction) then a
grading must be chosen such that concrete of given water/cement/aggregate
proportions and having a satisfactory workability can be made. Clearly, there are
limits on grading outside which it is not possible to make good concrete.
The influence of the type of aggregate should also be considered because its surface
texture, shape and allied properties influence the aggregate/cement ratio for a desired
workability and a given water/cement ratio. In selecting a mix, it is essential;
therefore, to know at the outset what type of aggregate is available.
An important feature of satisfactory aggregate is the uniformity of its grading. In
the case of coarse aggregate, this is achieved comparatively easily by the use of
separate stockpiles for each size fraction. However, considerable care is required in
maintaining the uniformity of grading of fine aggregate, and this is especially
important when the water content of the mix is controlled by the mixer operator on the
basis of a constant workability: a sudden change toward finer grading requires
additional water for the workability to be preserved, and this means a lower strength
of the batch concerned. Also, an excess of fine aggregate may make full compaction
impossible and thus lead to a drop in strength.
Thus, while narrow specification limits for aggregate grading may be unduly
restrictive, it is essential that the grading of aggregate varies from batch to batch
within prescribed limits only.

e. .1e Cement Content

All the factors considered up to now, including water/cement ratio, will determine
between them the aggregate/cement ratio or the cement content of the mix.
The choice of the cement content is made either on the basis of experience or
alternatively from charts and tables prepared from comprehensive laboratory tests.
Such tables are no more than a guide to the mix proportions required because they
apply fully only to the actual aggregates used in their derivation. Moreover,
recommended proportions are usually based on aggregate grading’s which have been
found to be satisfactory. When a significant departure from such grading’s is
necessary, it may be useful to bear in mind some of the guidance 'rules' established as
far back as 1950. One of these 'rules' is: when there is an excess of particles smaller
than 600 μm (No. 30 ASTM) sieve, the quantity of material passing the 4.76 mm sieve
should be reduced by an amount up to 10 per cent of the total aggregate. On the other
hand, when there is an excess of particles in the 1.20 to 4.76 mm (No. 16 ASTM to

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3/16 in.) size range, the quantity of fine aggregate should be increased. However, fine
aggregate with a large excess of particles between 1.20 mm (No. 16 ASTM) and 4.76
mm ( 3/16 in.) sieves produces a harsh mix and may require higher cement content
for a satisfactory workability.
In comparing various mixes, it is sometimes convenient to convert rapidly the
aggregate/cement ratio into the cement content or vice versa.

f. Mix Proportions And Quantities Per Batch

With the water/cement ratio and the cement content known, there is no difficulty
in determining the proportions of cement, water, and aggregate. In practice, the
aggregate is supplied from at least two stockpiles, and the quantities of aggregate of
each size have to be given separately. This presents no problem because, in finding a
suitable grading, we already had to calculate the proportions of the different size
fractions of aggregate.
For practical purposes, the mix quantities are given in kilograms or pounds per
batch. When cement is supplied in bulk, we choose the batch quantities so that their
sum is equal to the capacity of the mixer; when cement is supplied in bags, and there
is no provision for weighing it, it is preferable to choose the batch quantities so that
the mass of cement per batch is one bag or its multiple. The mass of cement is then
known accurately. In exceptional cases, a half-bag cement be used, but other fractions
cannot be reliably determined and should never be used.
If a concrete mix of certain proportions is to be modified by the use of an admixture,
some changes in the quantity of some of the ingredients are necessary. An important
principle is to maintain the volume of the coarse aggregate in a unit volume of
concrete, and to adjust only the volume of fine aggregate. This is done by changing
the quantity of fine aggregate on an absolute volume basis by an amount equal and
opposite to the changes in the volume of water, entrained air and cement. The liquid
part of any admixture is considered to be a part of the mix water.

Statistical Quality Control of Concrete (I29)

14. Concrete produced at site is likely to have variability of strength from batch to
batch and also within the batch. The magnitude of this variation depends on several
factors, such as, the quality of materials, method of mixing, proportioning, placing and
the overall workmanship and supervision at site. The purpose of controlling the
quality of concrete using the statistical means is to produce concrete of uniform
quality. The compressive strength test results of cubes from random sampling of a
mix, exhibit variations, which are inherent in the various operations involved in
making and testing of concrete. If a large number of cube strength test results are
plotted on a histogram, the results are found to follow a bell shaped curve, termed as
‘Normal Distribution Curve’. The average strength should be appreciably higher than
the design strength of concrete.
a. Standard Deviation. The root mean square deviation of the whole consignment is
termed as the ‘Standard Deviation’ and is defined numerically as:
As, σ = SQRT ((Σ (X-X1)2/(N-1))

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Where, σ = the standard deviation of the samples.
X = any value in the set of numbers.
X1 = the arithmetic mean of the set of numbers.
N = the number values in the set.

Table : 4.1 Values of standard deviation for different types of control (according to
Himsworth)

Type of Control Standard Deviation

Kg/cm2
Excellent 28
Very Good 35
Good 42
Fair 56
Poor 70
Uncontrolled 84

b. Coefficient of Variation. An alternative method of expressing the variation of

results about the mean is by coefficient of variation, which is a non-dimensional
measures of variation obtained by dividing the standard deviation by the average and
is expressed as : V = (σ/X1) * 100
The values of coefficient of variation suggested by Stanton Walker for different
degrees of control are shown in Table 4.2. The standard deviation and the coefficient
of variation are useful in the design and control of strength of concrete mixes.

Table 4.2 Values of coefficient of variation for different degrees of control (according
to Stanton Walker)

Type of Control Coefficient of Variation (in

percent)
Attainable only in well controlled laboratory tests 5
Excellent, approaching laboratory precision 10
Excellent 12
Good 15
Fair 18
Fair minus 20
Bad 25

Example: Calculate the standard deviation and co efficient of variation for a given test
date as follows:
Cube Number Compressive (X-X1) (X-X1)2
2
strength (Kg/cm )
X

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 1 165 - 35 1225
2 155 + 45 2025
3 225 + 25 625
4 185 - 15 225
5 210 + 10 100
6 265 + 65 4225
7 195 - 5 25
8 250 + 50 2500
9 180 - 20 400
10 230 + 30 900
11 260 + 60 3600
12 195 - 5 25
13 160 - 40 1600
14 175 - 25 625
15 150 - 50 2500
ΣX= 3000 Σ(X-X1)2= 20600

Mean strength = X1 = ΣX/N = 3000/15 = 200 kg/cm2

Standard deviation, σ = SQRT ((Σ (X-X1)2/(N-1)) = SQRT (20600/14) = 38.5 kg/cm2
Co efficient of variation, : V = (σ/X1) * 100 = (38.5/200) X 100 = 19.25 %.

Design Of Concrete Mix:

15. It is a process of selecting suitable ingredients of concrete and determining their

relative quantities with the objective of producing as economically as possible
concrete of certain minimum properties, notably consistency, strength and durability.

There are mainly four method of designing of concrete mix:

a. Fineness modulus method
b. Minimum voids method
c. Trial mixes method
d. Arbitrary method

Design Examples:

Fineness Modulus Method: (B167) In fig 10.25 (B168) and 10.26 are shown two
types of graphs to explain the relationship between four factors (water / cement ratio,
slump, size of the coarse aggregates and fineness modulus) with strength. To design a

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concrete mix by this method, the relationships shown in figs 10.25 and 10.26 are very
essential.

Problem:
Design a concrete mix for design compressive strength of 3500 psi after 28 days from
the following data:
Maximum size of coarse aggregate = 3/4 inch
Size of the fine aggregate =1/16 to 3/16 inch
Fineness modulus of fine aggregate =2.85
Fineness modulus of coarse aggregate =6.27
Moisture content of fine aggregate (sand) =5%
Moisture content of coarse aggregate (brick khoa) = 6%
Shrinkage factor =0.75
Hand worked concrete with desired slump of 2 inch
Ordinary Portland cement is to be used.

Solution:
From Table: 10.26
Combined fineness modulus, Fcom= 5.13 and volume of compacted aggregate is 3.75
cft for one cft of cement. (For 3500 Psi strength and ¾ inch C.A.)
Ratio of fine aggregate to be mixed with 1 unit of coarse aggregate,
R = (6.27- 5.13)/ (5.13- 2.85) = 0.5.
So, if the coarse aggregate is 100 cft then the fine aggregate is 50 cft.
Therefore, in every 100 cft of combined aggregate, F.A = 33.34 cft & C.A = 66.66 cft.
Since the shrinkage factor is 0.75 and volume of compacted aggregates is 3.75, then
Loose volume of combined aggregates = (3.75/0.75) = 5.0 cft.
Quantity of fine aggregate = 5.0 X (33.34/100) = 1.67 cft.
Quantity of Coarse aggregate = 5.0 X (66.66 / 100) = 3.33 cft.
Hence, the trail mix ratio is:
Cement: F.A: C.A = 1: 1.67: 3.33
The bulking of F.A is 5%
The bulking of C.A is 6%
So, amount of F.A = 1.67x 1.05= 1.75cft
Amount of C.A.= 3.33x1.06= 3.53 cft

Field mix ratio is:

Cement: fine aggregate: coarse aggregate = 1: 1.75: 3.53
= 1: 1.75: 3.5

Minimum Voids Method: The method of concrete mix design is based on the
assumption that the fine aggregate fills in the voids of the coarse aggregate and that
the cement fills the voids of the fine aggregate.
Problem: (B169).
Design a concrete mix by minimum voids method for the following data:
Voids in the coarse aggregate = 40%
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Voids in the fine aggregate = 30%
Size of coarse aggregate = 3/4 to 1 inch
Size of fine aggregate = 3/16 to ¼ inch
Allow an excess of 10% for cement and 7% for fine aggregate. Ordinary Portland
cement is to be used.

Solution:
Let, C.A. = 100 cft (assumed). Since the void of the coarse aggregate is 40%, so the
void of the coarse aggregate is 40 cft. So the volume of Fine aggregate with excess of
7% is
F.A= 1.07 X 40 =42.8 cft.
Since the void of the fine aggregate is 30%, so the void of the fine aggregate is (42.8
X0 .30) cft. So the volume of Cement with excess of 10% is

Cement= 1.10 X (42.8 X 0.30) =14.12 cft.

So, cement: F.A: C.A. =14.12: 42.8: 100
= 1: 3: 7 (dividing by 14.12) Hence, Cement: F.A.: C.A. = 1:3:7.

Trial Mixes Method: (B170) In this method, fine and coarse aggregates are mixed in
different proportions and the mixture is filled in a container of known volume. After it
is thoroughly compacted, its weight is noted per cft of each proportion. The proportion
which gives heaviest unit weight is taken for a dense concrete. Test cylindrical
specimens are then made with the concrete of this proportion to determine the
compressive strength after 7 and 28 days.

Arbitrary Method: (B170) In this method of concrete mix design the proportion of
cement is taken as 1 part to be mixed with ‘x’ parts of the fine aggregate and ‘2x’
parts of the coarse aggregates. For example, the common proportions are (say,
‘x’=1.5) 1:1.5:3, or (say, ‘x’=2) 1:2:4, or (say, ‘x’=3) 1:3:6 etc. The quantity of water
is not specified but it is often taken to be 30% of the cement plus about 5% of the
aggregates, when all the quantities are measured by weight. Generally, 100 cft of wet
concrete requires 150 cft dry mix (shrinkage factor is 1.5).

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Example: Determine the volume (in cft) of the different ingredients of a cement
concrete of the proportion 1:3:6 per cft.

Solution:
Let, wet volume= 100 cft
Dry volume= (100 X 1.5) cft = 150 cft (Shrinkage factor 1.5).
So, cement= (150x 1)/10 = 15 cft = 15/1.25 = 12 Bag (1 Bag = 1.25 cft).
Fine aggregate = (150X3)/10 = 45 cft
Coarse aggregate = (150X6)/10 = 90 cft.
Water = (15 X 0.30) + (90+45) X0.05 = 11.25 cft
Water / Cement Ratio = 11.25/15 = 0.75
From Table 10.4 (B120), Amount of water = 8.40 gallon.

Absolute Volume Method (British Method) (B171) This method assumes that the
volume of the compacted concrete is equal to the sum of the absolute volumes of all
ingredients.
It is usual to calculate the quantities of ingredients (in lb) of produces 1 cubic yard of
concrete. Say,
C= Weight of Cement in lb required
W = Weight of water in lb required
Af = Weight of fine aggregate in lb required

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Ac = Weight of coarse aggregate in lb required
Sc= Specific gravity of Cement
Sca= Specific gravity of Coarse Aggregate
Sfa= Specific gravity of Fine Aggregate
Pw= Density of Water in FPS system.
We Know,

Density = Weight/Volume

 Volume = Weight / Density

Again, in FPS system, Density of water = 62.5 lb/cft (In CGS system, it is 1 gm/cc).

And Density of any material = Density of water X Specific gravity of that material.

So, here volume of each ingredient is equal to the 1 cubic yard or 27 cft.

 W/62.5 + C/(62.5XSc) + Af/(62.5X Sfa) + Ac / (62.5 X Sca) = 27 ------- (10.9)

When entrained air is present and its presence is say, p percentage of the
volume of the concrete, then the equation will be

W/62.5 + C/(62.5XSc) + Af/(62.5X Sfa) + Ac / (62.5 X Sca) = 27 (1- p/100)

If the aggregate contains free moisture whose weight is say, m percent of the
weight of the dry aggregate, then the weight of the added water W and of
(wet) aggregate must be adjusted. The weight of free water in A pound of
aggregate is ‘x’ pound. So that

m/100 = x/(A-x) ---------------------------------- (10.10)

 X = Am/(100+m) ----------------------------------- (10.11)

This weight is added to aggregate A and give the weight to the wet aggregate
per batch (A+ Am/(100+m)). And subtracted from water W and give the
weight to the added water (W- Am/(100+m)).

Generally, each size fraction of aggregate has different moisture content and
correction should be applied to Af, Ac etc with an appropriate value of
moisture content, m.

Combining Aggregates to Obtain Particular Type Grading: Where there is no

ideal grading, it is desirable to proportion the available materials in such a way
that the grading of the combined aggregate is properly achieved. Suppose the
grading of the fine aggregate and two coarse aggregate (size fractions are

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listed in table 10.9 (B173)) are desired to combined the materials so as to
appropriate to coarsest grading. According to the British standard, 24% of the
total aggregate should pass through 3/16 inch sieve and 50% through ¾ inch
sieve.

Table 10.9: Example of Combined Aggregate to obtained a Type Grading

B.S Cumulative percentage (1)X1 (2)X0.94 (3)X2.59 (4) + Grading

Sieve passing for (5) + of
Size (6) combined
Fine 3/16 – ¾ - 1.5
aggregate
aggregate ¾

(1) (2) (3) (4) (5) (6) (7) (8)

1.5” 100 100 100 100 94 259 453 100

¾ in 100 99 13 100 93 34 227 50

3/8 in 100 33 8 100 31 21 152 34

3/16 in 99 5 2 99 5 5 109 24

No. 7 76 0 0 76 0 0 76 17

No. 14 58 58 58 13

No. 25 40 40 40 9

No. 52 12 12 12 3

No. 2 2 2 0.5
100

Let, x, y and z be the proportions of fine, 3/16 to ¾ inch and ¾ to 1.5 inch
aggregates respectively. Then to satisfy the condition that 50% of the
combined aggregate should pass through ¾ inch British standard (B.S) sieve.
We have,

1.0 x + 0.99y + 0.13z = 0.5(x+y+z) ------------------------------------ (10.12)

Again, the condition that 24% of the combined aggregate should pass through
3/16 inch B.S. sieve, can be written as

0.99x + 0.05y + 0.02z = 0.24 (x+y+z) ---------------------------------(10.13)

From these two equations (Eqs 10.12 & 10.13), it is found,

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 X:y:z = 1: 0.94 : 2.59

I,e the aggregates are combined in the proportions

1:0.94:2.59. ---------------------------------------------------------- (10.14)

Example: A concrete mix with a mean compressive strength of 5000 psi at 28

days is required for use in a road slab. Ordinary Portland Cement (OPC) will be
used. Compaction will be effected by vibration. The aggregate / cement ratio
is 7.2.

24% and 50% of the total aggregates should pass through 3/16 and ¾ sieve
respectively. Assume the specific gravity of cement to be 3.15 that of coarse
aggregate 2.50 and of fine aggregate 2.60.

Solution:

From Fig 10.10 (B119), Water / Cement ratio = 0.48 (for 5000 psi at 28 days
strength concrete).

From eqs 10.14, Total parts of aggregates = 1+0.94 + 2.59 = 4.53

Say, Cement = 1 part.

Given,

Aggregate / Cement = 7.2

 Aggregate = 7.2 X 1 = 7.2 part

Fine aggregate = (7.2X1)/4.53 = 1.59 parts.

Coarse aggregate (3/16 to ¾ inch) = (7.2X0.94)/4.53 = 1.5 parts.

Coarse aggregate (3/4 to 1.5 inch) = (7.2X2.59)/4.53 = 4.11 parts.

Now, consider 1 cubic yard of concrete.

Cement = C pound.

Since, Water / Cement ratio = 0.48

 Water, W = 0.48C pound.

Fine aggregate, Af = 1.59 C pound

Coarse aggregate, Ac(3/16 to ¾ inch and 3/4 to 1.5 inch) = (1.5 + 4.11)C pound

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 =5.61 C pound.

From Eqs (10.9),

W/62.5 + C/(62.5XSc) + Af/(62.5X Sfa) + Ac / (62.5 X Sca) = 27

 0.48C/62.5 + C/(62.5X3.15) + 1.59 C/(62.5X2.60) + 5.61 C/(62.5X 2.50) =27

 C = 462 pounds in one cubic yard of concrete.

So, in one yard of concrete, the weights of the ingredients are as follows:

Cement = 462 lb.

Water, W = 0.48X462 =222 lb.

Fine Aggregate = 1.59X462 =735 lb.

Coarse aggregate (3/16 to ¾ inch) = 1.5X462 = 693 lb.

Coarse aggregate (3/4 to 1.5 inch) = 4.11 x 462 = 1900 lb.

Total = 4012 lb

The density of the concrete = 4012 lb/yd3 = 4012/27 = 149 lb /ft3

Now, a trial mix should be made and the proportion adjusted as necessary. It is
important to remember that if the workability is to be changed, but the strength is to
be remains unaffected, the water/cement ratio must remain unaltered. Changes can
be made in the aggregate/cement ratio or if suitable aggregates are available in the
grading of aggregates.

American Method of Concrete Mix Design: (B174) The ACI method utilizes the fact
that, for a given maximum size of aggregate, the water content in pound per cubic
yard of concrete, determines the workability of the mix. It is thus possible to design a
concrete mix by selecting the water content from the Table 10.10 (by ACI). A further
assumption is made that the optimum ratio of the bulk volume of coarse aggregate
to the total volume of the concrete depends only one the maximum size of aggregate
and on the grading of the fine aggregate.

Table: 10.10 Mixing Water Requirement (Approximate) for Different Slumps and
Maximum Size of Aggregates.

Slump inch Water requirement (lb/yd3) of concrete with size of the aggregate (inch)

3/8 ½ ¾ 1 1.5 2

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1 to 2 350 333 308 300 276 253

3 to 4 384 367 342 325 300 384

5 to 6 408 384 358 242 317 300

Table 10.11 gives values of optimum volume of coarse aggregate when used with
fine aggregates of different fineness modulus.

Table 10.11 Bulk Volume of coarse Aggregate per unit Volume of Concrete

Max size Bulk volume of rodded coarse aggregate per unit volume of concrete for
Aggregate (inch) fineness modulus of sand of

2.40 2.60 2.80 3.00

3/8 0.46 0.44 0.42 0.40

½ 0.55 0.53 0.51 0.49

¾ 0.65 0.63 0.61 0.59

1 0.70 0.68 0.66 0.64

1.5 0.76 0.74 0.72 0.70

2 0.72 0.77 0.75 0.73

Example: Design a concrete mix from the following data:

Design mean compressive strength = 5600 psi.

Cement to be used: Ordinary Portland Cement (OPC).

Slump desired = 2 inch.

Maximum size of aggregate = 1.5 inch, its bulk density = 100 lb/ft 3 and specific gravity
= 2.64.

Fineness modulus of fine aggregate = 2.60 and its specific gravity = 2.58.

Specific gravity of Cement = 3.15.

Solution:

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From table 10.10 (Slump 2” and maximum size of aggregate 1.5”), Water
requirement = 276 lb/yd3.

From Fig 10.10 (B119), Water / Cement ratio = 0.48 (for 5600 psi).

Quantity of cement = 276/0.48 = 575 lb/yd3

From Table 10.11, the bulk volume of coarse aggregate per unit volume of concrete
(using the given fineness modulus of fine aggregate (sand) is 2.60 & Maximum size of
aggregate = 1.5 inch) is 0.74.

Given, bulk density of coarse aggregate = 100 lb/ft3 = (100 X 27) lb/yd3 = 2700 lb/yd3

Hence, the weight of coarse aggregate per cubic yard of concrete = o.74 X 2700
= 1998 lbs.

The absolute volumes of the mix ingredients per cubic yard of concrete are:

Cement = 575/(3.15X62.4) = 2.925 cft

Water = 276/62.4 = 4.423 cft

Coarse aggregate = 1998/(2.64X62.4) = 12.128 cft

Total = 19.476 cft

Hence, the volume of the fine aggregate = 27 – 19.476 = 7.524 cft.

The weight of fine aggregate = 7.524 X 2.58 X 62.4 = 1211 lbs.

The weights of the materials per cubic yard of concrete are:

Cement = 575 lbs

Water = 276 lbs

Fine aggregates = 1211 lbs

Coarse aggregates = 1998 lbs

Total = 4060 lbs

Hence, the density of the concrete = 4060/27 = 150.37 lb/ft 3

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