CONCRETE AND MIX DESIGN

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INTRODUCTION

Concrete is obtained by mixing cement, fine aggregate, coarse

aggregate, water and admixtures in required proportions.

The mixture when placed in forms and allowed to cure become

shard like stone.

The hardening is caused by chemical action between water and

the cement due to which concrete grows stronger with age.

It is the most widely-used man-made construction material in

the world.

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 Cement
CONCRETE MAKING
MATERIALS

Aggregate

Water

Admixture

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CEMENT

• Cement and water forms the ‘active’ component of concrete, while the
inactive group comprises the fine and coarse aggregates.
• The cement and water form a paste that hardens and bonds the
aggregates together.

Types of Cement Although around 18 types of cements are

recognized by BIS, more commonly used ones are:
• Ordinary Portland Cement 33, 43, & 53 grade OPC,
• Blended Cements (PPC and PSC).
• Sulphate Resisting Cement (SRC),
• Low Heat Portland Cement (LHPC),
• Hydrophobic Portland Cement,
• Colored Cement (White Cement).
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AGGREGATES
• They are cheaper than cement and impart greater volume
stability and durability to concrete.
• The main purpose is to provide bulk to the concrete.
• Some of the aggregates may be chemically active.

CLASSIFICATION
• Geological origin – natural and artificial
• Size – fine, coarse and all-in
• Shape – rounded, irregular, angular, flaky and elongated
• Unit weight – normal-weight, heavyweight and lightweight
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WATER
• The most important and least expensive ingredient of
concrete. One part of the water is used in the
hydration of cement to form the binding matrix.
• The remaining water affords lubrication and
workability to the concrete.
• Water-cement ratio depends on the grade of
concrete, its workability, durability, nature and type
of aggregates etc.
• Potable water is ideal for concreting.
• Seawater may be used in PCC.
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ADMIXTURES
• Added to the concrete immediately or during mixing to modify its
properties in the fresh or hardened state.
TYPES
• Accelerators - speed up the initial set of concrete.
• Retarders – delay the setting time of concrete mix.
• Plasticizers and Super-plasticizers - water reducers.
• Air entraining admixtures
• Water proofers
• Pigments
• Corrosion-inhibiting chemicals
• Antifungal admixtures

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Why should we go for concrete mix design
• Widely used
• Cost
• Concrete is Heterogeneous
• Conservation of resources
• Properties vary based on constituents

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IS : 456-2000 has recommended that minimum grade of concrete shall be not less than M-
20 in reinforced concrete work.

Design mix concrete is preferred to nominal mix .

If design mix concrete cannot be used for any reason on the work for grades of M-20 or lower, nominal mixes may be
used with the permission of engineer-in-charge, which however is likely to involve a higher cement content.

Accordingly all concrete of above M-20 Grade for RCC work must be of design mixes. The code allows nominal mix for
RCC work of M-20 Grade, but what shall be the nominal mix, the reader will find from the following table that it is better
to adopt design mix, rather than to go for M20 nominal mix which is too cumbersome to determine a fixed nominal mix
value.

Nominal mixes as per IS : 456-2000 if fine aggregate is of Zone II as per IS : 383-1970.

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Materials :
OPC 43-grade, River sand of Zone II and 20 mm graded crushed stone aggregate. Specific gravity of sand
and aggregate 2.65. Workability of design mixes 50±10mm slump.

Mix Ratio by Weight

As per IS:383-1970
Max cement:
Maximum size of Max W/C
Grade of Concrete Aggregate ratio by
graded coarse Ratio
Coarse mass
aggregate Cement Fine Aggregate
Aggregate

M-20 10 1 : 1.8 : 2.7 0.60 1.5

M-20 20 1 : 1.5 : 3.0 0.60 1.5

M-20 40 1 : 1.3 : 3.2 0.60 1.5

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TYPES OF CONCRETE MIXES
• NOMINAL MIX Mixes of fixed proportions, IS:456-2000 permits nominal mixes for concretes of strength M20
or lower
• DESIGN MIX Designed on the basis of requirements of the concrete in fresh and hardened states.

TRIAL MIXES

Prepared to verify whether the Design Mix would perform as per the assumptions. If
appreciable variation exists, the available alternatives are:

directly employ the trial mix proportions at the site

modify the trial mix proportions on the basis of intuition and employ the revised
proportions at the site

prepare further trial mixes incorporating changes in the proportions based on the
feedback generated from the previous mix.

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CONCRETE MIX DESIGN DEFINITION
•“ Mix Design is the science of determining the relative proportions of the ingredients of concrete to achieve the desired properties in the most economical way.”

PRINCIPLES OF MIX DESIGN

1. The environment exposure condition for the structure

2. The grade of concrete, their characteristic strength’s and standard deviations

3. The type of cement

4. The types and sizes of aggregates and their sources of supply

5. The nominal maximum sizes of aggregates

6. Maximum and minimum cement content in kg/m3

7. Water cement ratio

8. The degree of workability of concrete based on placing conditions

9. Air content inclusive of entrained air

10. The maximum/minimum density of concrete

11. The maximum/minimum temperature of fresh concrete

12. Type of water available for mixing and curing

13. The source of water and the impurities present in it.

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Factor Defining the Choice of
Mix Proportion
• Compressive Strength
• Workability
• Durability
• Type, size and grading of
aggregates
• Aggregate-cement ratio

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COMPRESSIVE STRENGTH
Abram’s Law log F = log A1 – x log B1 where F is the compressive strength A1, B1 are constants and
x is the w/c ratio by weight.

WORKABILITY
“that property of freshly mixed concrete which determines the ease and homogeneity with which it
can be mixed, placed, consolidated and finished.”

DURABILITY
“the resistance to weathering action due to environmental conditions such as changes in
temperature and humidity, chemical attack, abrasion, frost and fire.”

REQUIREMENTS AND TESTS OF MATERIALS REQUIRED FOR MIX DESIGN

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 METHODS OF CONCRETE MIX DESIGN
• American Concrete Institute Committee 211 method
• Bureau of Indian Standards Recommended method
IS 10262-82
• Road note No. 4 (Grading Curve) method
• Department Of Environment (DOE - British) method
• Trial and Adjustment Method
• Fineness modulus method
• Maximum density method
• Indian Road Congress, IRC 44 method
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 American Concrete Institute Method of Mix Design

Data to be collected

• Fineness modulus of selected F.A.

• Unit weight of dry rotted coarse aggregate.
• Sp. gravity of coarse and fine aggregates in SSD condition
• Absorption characteristics of both coarse and fine aggregates.
• Specific gravity of cement.

From the minimum strength specified, estimate the average design

strength by using standard deviation.

Find the water/cement ratio from the strength and durability points
of view. Adopt the lower value.

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(d) Decide the maximum size of aggregate to be used. Generally for RCC work 20 mm and pre-
stressed concrete 10 mm size are used.
(e) Decide workability in terms of slump for the given job.
(f ) The total water in kg/m3 of concrete is determined, corresponding to the selected slump
and selected maximum size of aggregate.
(g ) Cement content is computed by dividing the total water content by the water/cement
ratio.
(h) Select the bulk volume of dry rodded coarse aggregate per unit volume of concrete, for the
particular maximum size of coarse aggregate
(i) fineness modulus of fine aggregate
( j ) The weight of C.A. per cubic meter of concrete is calculated by multiplying the bulk
volume with bulk density.
(k ) The solid volume of coarse aggregate in one cubic meter of concrete is calculated by
knowing the specific gravity of C.A.
(l ) Similarly the solid volume of cement, water and volume of air is calculated in one cubic
meter of concrete.
(m) The solid volume of FA is computed by subtracting from the total volume of concrete the
solid volume of cement, CA, water and entrapped air.
(n) Weight of fine aggregate is calculated by multiplying the solid volume of fine aggregate by
specific gravity of F.A.
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 ACI METHOD: DESIGN EXAMPLE 1
Design a concrete mix for the construction of an elevated water tank. The specified design strength of concrete (characteristic strength) is 30 MPa at 28 days
measured on standard cylinders. Standard deviation can be taken as 4 MPa. The specific gravity of FA and C.A. are 2.65 and 2.7 respectively. The dry rodded
bulk density of C.A. is 1600 kg/m3, and fineness modulus of FA is 2.80. Ordinary Portland cement (Type I) will be used. A slump of 50 mm is necessary. C.A. is
found to be absorptive to the extent of 1% and free surface moisture in sand is found to be 2 per cent. Assume any other essential data.

Mean Cylinder Compressive Strength Assuming 5 per cent of results are allowed to fall below
specified design strength, The mean strength, fm= fmin + ks = 30 + 1.64 x 4 = 36.5 MPa

Water/cement ratio v Strength criteria v Durability criteria

Mixing Water Content Slump = 50 mm Maximum size of aggregate = 20 mm Concrete is non air-
entrained
The mixing water content is 185 kg/m3 of concrete The approximate entrapped air content is
2%. The required cement content =185/0.47 = 394 kg/m3
Bulk Volume of C.A. Maximum size of C.A = 20mm Fineness Modulus of F.A. = 2.80 Find the dry
rotted bulk volume of C.A .

The dry rodded bulk volume of C.A. = 0.62 per unit volume of concrete The weight of C.A. = 0.62
x 1600 = 992 kg/m3

The first estimate of density of fresh concrete = 2355 kg/m3

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The weight of all the known ingredients of concrete

Weight of water = 185 kg/m3 Estimated quantities of materials per

cubic meter of concrete are:
Weight of cement = 394 kg/m3

Weight of C.A. = 992 kg/m3

Weight of F.A. = 2355 – (185 + 394 + 992) = 784 kg/m3

Water = Cement
Alternatively, the weight of F.A. can be determined by the more accurate
absolute volume method Absolute Volume = weight/(1000ρ) m3 185 kg = 394 kg
Total absolute volume = 697 x 103 cm3

Absolute volume of F.A. = (1000 – 697) x 103 = 303 x 103 C.A = F.A =
Weight of FA = 303 x 2.65 = 803 kg/m3
992 kg 803 kg

Proportions C : F.A : C.A : water 394 : 803 : 992 : 185 1 : 2.04 : 2.52 : 0.47

Weight of materials for one bag mix in kg = 50 : 102 : 126 : 23.5

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The above quantities is on the basis that both F.A and C.A are in saturated and surface dry condition (SSD conditions).

FA has surface moisture of 2% Total free surface moisture in FA = (2/100 x 803) = 16.06 kg/m3

Weight of F.A in field condition = 803 + 16.06 = 819.06 kg/m3

Quantity of water absorbed by C.A. = (1/100 x 992) = 9.92 kg/m3

Weight of C.A in field condition = 992 – 9.92 = 982 kg/m3

C.A absorbs 1% water

Water contributed by F.A = 16.06 kg

Water absorbed by C.A. = 9.92 kg

Extra water contributed by aggs. = 16.06 – 9.92 = 6.14 kg

Total water content = 185.00 – 6.14 = 179 kg/m3 Change in Water Content

Cement = 394 kg/m3 F.A. = 819 kg/m3 C.A. = 982 kg/m3 Water = 179 kg/m3

Field density of fresh concrete = 2374 kg/m3

Quantities of materials to be used in field, corrected for free surface moisture in F.A and absorption characteristic of C.A

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METHOD OF MIX DESIGN Proposed by the Road Research
Laboratory, UK (1950) Procedure:
• The average compressive strength of the mix to be designed is obtained by applying
control factors to the minimum compressive strength
• Water/cement ratio is read from compressive strength v/s w/c ratio graph
• Proportion of combined aggregates to cement is determined from tables, for maximum
size 40 mm and 20 mm
• If the aggregate available differs from the standard gradings, combine FA and CA so as to
produce one of the standard gradings
• The proportion of cement, water, FA and CA is determined from knowing the
water/cement ratio and the aggregate/cement ratio.
• 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.

DRAWBACKS
• Cannot be used directly for the design of air - entrained concrete
• No recommendations for durability or strength, regarding the water/cement ratio
• The design tables refer to mixes in which the FA and CA are of the same shape
• In selecting aggregate/cement ratio, only 3 shapes of aggregates and 4 gradings are recommended.

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DOE METHOD OF MIX DESIGN Can be used for
concrete containing fly ash. PROCEDURE
• Target mean strength is calculated
• Select water/cement ratio, from the type of cement and CA.
Compare this with the ratio from durability conditions.
• Decide the water content for required workability
• Compare the cement content with the minimum cement
content value and adopt the higher value
• Find out the total aggregate content
• Determine the proportion of FA using the appropriate FA%
v/s CA size graph, and find the weight of CA and FA
• Work out a trial mix.
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BIS RECOMMENDED MIX DESIGN METHOD The BIS recommended mix design
procedure is covered in IS 10262-82.
• In line with IS 456-2000, the first revision IS 10262-2009 was published, to accommodate some of the
following changes:
• Increase in strength of cement
• Express workability in terms of slump, rather than the compacting factor
• Extend the W/C ratio v/s compressive strength graph CONCRETE MIX DESIGN Modifications in IS
10262-2009

MIX DESIGN BASED ON IS RECOMMENDATIONS Based on IS 10262:1982 Procedure:

• Target mean strength for mix design: fck* = fck + tS
• where fck = characteristic compressive strength at 28 days
• S = standard deviation
• t = a statistical value depending on the risk factor.
• Selection of Water/Cement ratio
• Estimation of Entrapped Air CONCRETE MIX DESI
• Selection of Water Content and Fine to Total Aggregate ratio

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 Choice of cement
Portland Puzzolona Economical Late removal of formwork.
Cement Resistant to sulphate attack.
Lesser heat of hydration.
Longer Initial & Final setting times; hence good for mass
pours.
Rapid Hardening Early striking of formwork. High heat of hydration.
Portland Cement Early strength gain; hence can be loaded early.
Good for pre-casting.
Low Heat Portland Cement Useful in mass pours to reduce thermal cracks. Less workable; hence requires wetting agents.
Blast Furnace Low heat of hydration. Final setting being less, rapid hardening
Slag Cement More resistant to chemical attacks; useful in sea water. admixtures required
Economical..
High Alumina High early strength. Cannot be used at ambient temp > 180C,
Cement High refractionary properties causes reduction in strength & durability.
Good cold weather cement due to high heat of hydration.
Super Sulphate Suitable for highly aggressive chemical environment. Not advisable when ambeint temperature
Cement Low heat of hydration. >400C.
High resistance to sulphates in sub-soil, water & admixtures. Not advisable when ambeint temperature
<150C.
Sulphate Resistant Sulphate resistant.
Portland Cement Low heat of hydration.
Used in Marine structures, pipe lining, canals, etc.

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Choice of aggregates
Strength efficiency point of view
• larger sized aggregates may be used for low strength
concretes whereas a size of 10 & 20mm could be
more beneficial in case of high strength concretes.

Durability point of view

• Max. Size of aggregate is such that it is : < ¼ th of min.
thickness of the member & clear space between
Rebars/cables minus 5mm or clear cover minus 5mm

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 Tests on course aggregates and their limiting values
Crushing value 45 % for aggregates used in general concrete
30 % for concrete on wearing surfaces such as roads, runways etc.
Abrasion Los Angeles abrasion value limits are 30 % for wearing surfaces
50 % for non - wearing surfaces.

Flakiness Index <25 % for coarse aggregates as per SP 23.

restricted to not more than 15% from durability & economy point of view.

Sodium Chloride 0.1 % & 0.03 % in fine & coarse aggregates respectively by the dry
weight of aggregates.
Absorption This has to be taken into account during Mix design.

Silt Content in This should not exceed 8%. If more, the % by Weight is to be calculated.
sand If this also exceeds 3% than washing is necessary.

Silt ( %) by Volume = Thickness of silt layer X 100

Height of clear sand

Source IS : 383

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 Information required
• Desired strength
• Maximum size of aggregates
• Nature and properties of aggregates
• Degree of severity of exposure
• Required degree of quality control

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 Target mean strength
ft = f ck + k x s

Ft = target mean strength

f ck= characteristic compressive strength
k = constant based on quality control
s = standard deviation

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 Quality control and ‘k’
Expected proportion of results falling below specified k
strength
1 in 5 Very Poor QC requirements 0.84

1 in 10 Bad QC requirements 1.28

1 in 15 Fair QC requirements 1.50

1 in 20 Good QC requirements 1.65

1 in 40 Very Good QC requirements 1.96

1 in 100 Excellent QC requirements 2.33

Source:IS10262

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Quality control and Standard deviation
Grade of Concrete Standard Deviation for different degrees of control ( N / mm2 )
Very Good Good Fair
M10 2.0 2.3 3.3
M15 2.5 3.5 4.5
M20 3.6 4.6 5.6
M25 4.3 5.3 6.3
M30 5.0 6.0 7.0
M35 5.3 6.3 7.3
M40 5.6 6.6 7.6
M45 6.0 7.0 8.0
M50 6.4 7.4 8.4
M55 6.7 7.7 8.7
M60 6.8 7.8 8.8

Source:IS10262

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 How to access the quality ?
Degree of quality Condition of Production
control
Very Good Fresh cement from single source and regular tests, Weigh batching of all
materials. Aggregates supplied in single sizes, control of aggregates’
gradation & moisture content, frequent supervision, regular workability
and strength tests, field lab. tests.

Good Carefully stored cement and periodic tests, Weigh batching of all materials,
controlled water, graded aggregates, occasional grading & moisture
tests, periodic check of workability & strength, intermittent supervision,
experienced workers.

Fair Proper storage of cement, volume batching of all aggregates, allowing for
bulking of sand, weigh-batching of cement, water content controlled by
inspection of mix, occasional supervision & tests.

Source :SP 23

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Characteristic Compressive Strength
Compliance Requirement

Source IS :456 2000

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 Water cement ratio-strength point of view
60
28 DAY COMPRESSIVE STRENGTH OF CONCRETE

50
40
(N/mm2)
30
20
10
0

0.3 0.35 0.40 0.45 0.50 0.55 0.60 0.65

Water cement ratio Source:IS10262

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Water cement ratio-durability point of view
Exposure Plain Concrete ( PCC ) Rein. Concrete (RCC) Min. Grade of Concrete

Minimum Maximum Minimum Maximum PCC RCC

Cement Free Cement Free
Kg/m3 W/C Kg/m3 W/C

Mild 220 0.6 300 0.55 - M20

Moderate 250 0.6 300 0.5 M15 M20

Severe 260 0.5 350 0.45 M20 M25

Very Severe 300 0.45 400 0.45 M20 M35

Extreme 300 0.4 400 0.4 M25 M40

Source IS :456 2000

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 Exposure conditions
Environment Exposure Conditions
Mild Concrete surfaces protected against weather or aggressive conditions
Moderate Concrete surfaces sheltered from severe rain or freezing whilst wet
Concrete exposed to condensation & rain
Concrete continuously under water
Concrete exposed to non aggressive sub soil / ground water or coastal environment
Severe Concrete surfaces exposed to severe, alternate wetting & drying or occasional freezing
whilst wet or severe condensation
Concrete in contact or buried under non aggressive soils / ground water, completely
immersed in sea water
Very Severe Concrete surfaces exposed to sea water spray, corrosive fumes or severe freezing
conditions whilst wet
Extreme Concrete surfaces exposed to abrasive actions, e.g. machinery, metal Tyrell vehicles or
water carrying solids
Concrete surfaces in tidal zones
Members in direct contact with liquid/ solid aggressive chemicals

Source IS :456 2000

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 Concrete subjected to Sulphate attack
Class Concentrate of Sulphates as SO3 Type of Cement Dense fully compacted
Concrete made with 20mm
MAS complying with IS 383
In soil total SO3 % Cement content Free W/C
not <Kg/m3 Ratio
1 < 0.2 OPC or Portland Slag cement or 280 0.55
PPC
2 0.2 to 0.5 OPC or Portland Slag 330 0.50
cement or PPC
3 0.2 to 0.5 SRPC or Super 310 0.50
Sulphated Cement
4 0.5 to 1.0 SRPC or Super 330 0.50
Sulphated Cement
5 0.5 to 1.0 Portland Slag cement or PPC 350 0.45
6 1.0 to 2.0 SSRPC 370 0.45
7 > 2.0 SRPC or Super Sulphated 400 0.40
Cement

Source IS :456 2000

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 Quantities of Water and Cement
Max. Water – kg/cum of concrete Sand as % of total agg. By volume
Aggregate
Size
Medium Strength Concrete ( up to M35 )
10 208 40
20 186 35
40 165 30
High Strength Concrete ( above M35 )
10 200 28
20 180 25
Source :SP 23

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 Adjustments
Change in conditions from above assumptions Adjustments required in
water Sand

sand - Zone I 0 + 1.5 %

sand - Zone III 0 - 1.5 %

sand - Zone IV 0 - 3.0 %

Increase/decrease in compacting factor by 0.1 +/- 3% 0

increase/decrease in W/C ratio by 0.05 0 +/- 1%

For rounded aggregates - 15 kg / m3 -7 %

For: Source :SP 23

W/C of 0.6 & 0.35 for medium & high strength concrete respectively;
Workability -Compacting factor- 0.8.

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 Adjustments
Nominal maximum Adjustments to minimum
aggregate size cement content
10 40

20 0

40 -30

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 Entrapped air
Nominal Max. Aggregate Size Entrapped air, as % of volume of
concrete
10 3%
20 2%
40 1%

Source :SP 23

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 Aggregate content
V = W + C + 1 x fa x 1
Sc p S fa 1000

V = W + C + 1 x Ca x 1
Sc p Sca 1000
V - Absolute volume of fresh concrete = Gross volume ( 1m3 )
minus volume of entrapped air.
Sc - Specific Gravity of Cement.
W - Mass of water ( kg ) per m3 of concrete.
C - Mass of Cement ( kg ) per m3 of concrete.
p - Ratio of fine aggregate to total aggregate by absolute volume.
fa , Ca - Total masses of FA & CA, ( kg ) per m3 of concrete respectively.
Sfa , Sca - Specific Gravities of saturated surface dry FA & CA respectively.

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 Workability
Placing condition Degree of Values of workability
workability
Concreting of shallow sections with vibration Very low 20-10 seconds, Vee-Bee time or 0.75-
0.80, Compacting Factor

Concreting of lightly reinforced sections with Low 10-5 seconds, Vee-Bee time or 0.80-0.85,
vibration Compacting Factor

Concreting of lightly reinforced sections Medium 5-2 seconds, Vee-Bee time or 0.85-0.92,
without vibration, or heavily reinforced Compacting Factor or 25-75mm,
sections with vibration slump for 20mm* aggregate

Concreting of heavily reinforced sections high Above 0.92, Compacting Factor or 75-
without vibration 125mm, slump for 20mm* aggregate

Source :SP 23

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Calculation of Cement Content:

cement by mass = Water content/Water cement ratio To be checked against the minimum cement
content for the requirement of durability and the greater of the two values to be adopted.

Calculation of aggregate content:

Actual quantities required for mix Adjust the mix for deviations from assumed conditions

Check the calculated mix proportions

DESIGN EXAMPLE: BIS RECOMMENDED METHOD Grade M20

(a ) Design stipulations

(i ) Characteristic compressive strength required in the field at 28 days - 20 MPa

(ii ) Maximum size of aggregate - 20 mm (angular)

(iii ) Degree of workability - 0.90 compacting factor

(iv ) Degree of quality control - Good

(v ) Type of Exposure - Mild

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 • Specific gravity of cement - 3.15
• Compressive strength of cement at 7 days - Satisfies
the requirement of IS: 269–1989
Test data • Specific gravity of coarse aggregates - 2.60
for • Specific gravity of fine aggregates - 2.60
• Water absorption of Coarse aggregate - 0.50%
Materials • Water absorption of Fine aggregate - 1.0%
• Free (surface) moisture of Coarse aggregate - Nil
• Free (surface) moisture of Fine aggregate - 2.0%

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Design Procedure
Target mean strength of concrete fck* = fck + tS
fck = 20, t = 1.64 , S = 4
fck* = 26.6 MPa
Selection of Water/Cement Ratio
Durability Criteria: Mild Exposure Conditions
W/C ratio from strength considerations = 0.50
W/C ratio from durability considerations = 0.55
Adopt the lower value
Selection of water and sand content
Adjustments in Water and Sand Contents
Determination of cement content
Water-cement ratio = 0.50
water = 191.6 kg/m3
Cement = 191.6/0.50 = 383 kg/m3 Is this satisfactory for ‘mild’ exposure condition?
Determination of coarse and fine aggregate contents
Specified max. size of aggregate = 20 mm Corresponding entrapped air = 2%
fa = 546 kg/m3 , Ca = 1188 kg/m3
Final Mix Proportions Water Cement FA CA 191.6 383 546 1188 0.50 1 1.425 3.10

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 PREPARED BY BIKASH GHOSH
REVIEWED BY ABHIJIT DAS

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