CE2155 Structural Mechanics and Materials

Concrete Mix Design

by
Assoc Professor T. H. Wee
Department of Civil Engineering
Email: [email protected]

MIX
An PROPORTION
over-view of the requirements of good

concrete in construction industry

Strength

Workability
Durability (with good resistance to exposure
W
S
environment eg. chloride attack
carbonation
acid attack
sulfate attack
C
G
alkali-aggregate reaction, etc.)

Mix Proportion, Type of Cementitious Materials

(for 1 m3 of concrete)
(including admixtures) used, etc.

Control of Non-Structural Cracks

(eg. plastic settlement crack
plastic shrinkage crack
thermal crack ,
Delayed Ettringite Formation due to high temperature rise etc.)

Good Concrete Practice (Handling)

Quality Control of Concrete Production
Investigation (Destructive & Non-destructive Tests)
The successful use of concrete depends on:
Proper design (taking the durability & deformation, etc. into consideration)
Choice & Supply of sound constituent materials
Proper handling & production process

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Basic Considerations

Therefore, before starting to specify (or design), it is necessary to consider

what properties/performance we want the concrete to have, and also what
properties we do not want it to have.
Basic Considerations:
Workability - Minimum workability for adequate placement
Compressive Strength Generally 28 days
Other ages depending on the application
Durability Chemical attacks
Control of non-structural cracking, especially on early-

age thermal cracking and DEF

Permeability/water absorption
Repeated freeze/thaw action
Economy

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Tests for Compressive Strength

The specimens are either:
Cubes - 100 mm & 150 mm, or
Cylinders - 150 mm dia. and 300 mm long
- 100 mm dia. and 200 mm long

After fully compacting the concrete into the

moulds, the reference method is to cure the
specimens in water at a controlled
temperature.

The specimens are tested at a fixed age (usually

at 7 and 28 days) in compression to failure, the
load being applied at a controlled rate.
CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Compressive Strength Of Concrete

When designing a structure, the designer will specify that the concrete

should have a given strength ( characteristic strength). When producing

concrete, the mix is designed to have a specific mean strength.

Tests on samples show that the actual strength ( tested strength)

deviates from the mean. The deviation or the spread of the test results
depends on how closely the production process is controlled, and upon
the properties of the individual materials in the mix.

The spread of test results approximates to the normal distribution curve,

Probability density

where x is the mean strength and the spread of the results is measured
by the standard deviation, .
Good
control
Poor
control

For a set of n test

results these are
given by :However, when testing concrete it is
usual to have only a small number of test
results, so must be increased thus :-

Strength
CE 2155 Structural Mechanics and Materials

MIX
PROPORTION
General
view of Quarry and Crushing plant installations
at KARIMUN, INDONESIA

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Concrete Making Materials Aggregates

Blasting of rock in action

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

It can be seen from the normal

distribution curve that the mean
strength of a material is unsuitable for
design purposes since a 50% of all test
results might be expected to fall below
the mean.
Based on BS EN 206, when concrete is
classified with respect to its compressive
strength of concrete, Table 7 (pls refer to
next slide) apply.

Probability density

Compressive Strength Of Concrete

Good
control
Area = 0.05

fcu

1.64

Mean

Strength

From the diagram it is seen that :

Mean
Meanstrength
strength == ffcucu++1.64
1.64

In SS and BS EN 206, the characteristic compressive strength at 28 days, fcu ,

is defined as value of strength below which 5% of the population of all
possible strength determinations of the volume of concrete under
consideration, are expected to fall.

Therefore, to obtain a concrete with characteristic strength 35 N/mm2 from

a concrete batching plant for which a standard deviation of 5 N/mm2 is
expected, the required mean strength will be :35 + (1.64 5) = 43.2 N/mm2
CE 2155 Structural Mechanics and Materials

MIX PROPORTION

BS EN 206 Part 1: 2000

The strength grade of concrete should be selected from the table below:

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Area = 0.05

1.64 Mean

Strength

The concrete grade is expressed as Cn,

where n is the cube strength fcu.
(e.g. C40)

contr

Poor
control

Mean
Mean Mean
(vgood) (good) (poor)

fcu

Tests are carried out on 150 mm cubes at

an age of 28 days to give characteristic
strength ( fcu).

Good
control

ol

fcu

Good
control

Vgoo
d

Probability Density

Probability density

Compressive Strength Of Concrete

1.64 - very good

1.64 - good
1.64 - poor

Strength

Poor quality control produces a

wider spread of results, which
leads to higher value of the
standard deviation, .
Very good quality control
produces a very steep curve, and
it can be seen that the better the
control the lower the mean
strength has to be produced for a
specified value of fcu.

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Acceptance of Concrete Strength - SS and BS EN

For the purpose of compliance based on estimated 28-day cube strength,
the conditions are:

C20

C20

Note: The above requirement is more stringent when compared to ACI 301-05
(Specifications for Structural Concrete)

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Example:

For a particular supply of a Grade 40 concrete, six batches were sampled each
day for testing. The 28-day strength results for the first 12 batches are as follows:
Batch No.

Strength

Rolling 4 Average

Criteria A

Criteria B

45.5

--

OK

OK

42.5

44.0

OK

OK

43.0

43.7

OK

OK

44.0

43.6

OK

OK

42.5

43.0

OK

OK

43.0

43.1

OK

OK

42.5

43.0

OK

OK

38.5

41.6

FAIL

OK

36.5

40.1

FAIL

FAIL

10

43.0

40.1

FAIL

OK

11

42.5

40.1

FAIL

OK

12

41.0

40.8

FAIL

OK

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Acceptance of Concrete Strength ACI 301

To provide structural safety, continuous control is necessary to ensure that
the strength of the concrete as furnished is in satisfactory agreement with
the value called for by the designer.
The ACI Code specifies that a pair of cylinders must be tested for each
150yd3 of concrete or for each 5000ft2 of surface area actually placed, but
not less than once a day.
To ensure adequate concrete strength in spite of scatter, the ACI Code
stipulates that concrete quality is satisfactory if
(1) no individual strength test results (the average of a pair of cylinder
tests) falls below the required fc (specified strength) by more than
500 psi (= 3.5 MPa) when fc is 5000psi (=35 MPa) or less or by
more than 0.10 fc when fc is more than 5000 psi (i.e. 35 MPa), and
(2) every arithmetic average of any three consecutive strength tests
equals or exceeds fc
CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Selection of Materials

Primary materials

Cement
Water
Aggregate
Coarse aggregate
Fine aggregate (sand)

(for 1 m3 of concrete)

Optional materials (used upon requirement for specific

application/job)

Mineral Admixture (Supplementary Cementing Materials)

Chemical admixture
Fiber
Air entraining agent

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Some basic rules for workability

Workability (flowability): For a given slump
water requirement when

Max aggregate size

Content of angular or rough-textured aggregate
particles
Content of entrained air
W

C
G
Cohesiveness
Cohesiveness
(for 1 m3 of concrete)
Sand/coarse aggregate ratio
Partial replacement of coarse sand by a fine sand
At given w/c ratio, cement/aggregate ratio

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Fundamentals of Mix Design

Water-cement ratio (w/c)

Abrams Law:
For given materials, the strength
depends only on one factor the
ratio of water to cement

c =

A
B1.5( w / c )

c = compressive strength
A = empirical constant (96.5 MPa)
B = Constant that depends mostly
on cement properties (~4)
w/c = water to cement ratio by
weight
CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Mix Design Process

Determine the job parameters
Compressive strength
Durability requirements? (w/c, cement content and
cement type, etc)
Slump
Aggregate properties, max. aggregate size
Permissible allowable defects and
standard deviation
Design the mix proportions
w/c ratio, cement ,water, aggregates and admixtures, etc.
Calculate batch weights
Adjusting to the batch weights based on trial mix*

*There are various concrete mix design methods (eg. DOE & ACI Methods ). These
methods are based on simplified classifications for type and quality of materials
and it still remains to check whether or not the particular aggregates and cement
selected for use in a given case will behave as anticipated. This is the object of
making the trial mix, and the subsequent feedback of informaton from the trial mix
is an essential part of the mix design process.
CE 2155 Structural Mechanics and Materials

MIX PROPORTION

DOE Method of Mix Design British Method

The British method of concrete mix design, popularly referred

to as the "DOE method", is used in the United Kingdom and
other parts of the world and has a long established record.

The DOE method is based on various assumptions and

requirements:
Mixes are specified by the weights of the different materials
contained in a given volume of fully compacted concrete.
It is assumed that the volume of freshly mixed concrete
equals the sum of the air content and of the absolute volumes
of its constituent materials.
It is assumed that the strength of a concrete mix depends on:
The Free water/Cement Ratio;
The Coarse Aggregate Type;
The Cement Properties.
CE 2155 Structural Mechanics and Materials

MIX PROPORTION

DOE Method of Mix Design British Method

DOE Method of mix deisgn British method

It is assumed that the workability of a concrete mix depends

Primarily on
The free water content;
The fine aggregate type and, to a lesser degree, the coarse
aggregate type;
The maximum size of coarse aggregate.
secondarily on:
The percentage of the fine aggregate as a proportion of the

total aggregate content.

The grading of the fine aggregate.

The free water/Cement Ratio;

The DOE Method also provides guidance on the effects of air

entrainment in a concrete mix.

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

DOE Method of Mix Design Step 1

To Determine Free Water/Cement Ratio Required for Strength

The concept of target mean strength

is introduced, this being equal to the
specified characteristic strength plus a
margin to allow for variability.

Mean strength = fcu + 1.64

Certain strengths are assumed at a w/c ratio of 0.5 for different cements
and type of aggregate (refer to Table 2 given in the next slide). We mark a
point corresponding to this strength at w/c ratio of 0.5 in Figure 4 (given in
the next slide), through this point we now draw a curve parallel to the
neighboring curves. Using this new curve, we read off the w/c ratio
corresponding to the specified target mean strength.

A possible need for a lower w/c ratio for reasons of durability must not be
forgotten.
CE 2155 Structural Mechanics and Materials

MIX PROPORTION

DOE Method of Mix Design Stage I

Table 2 - Approximate compressive strength of

concretes made with a free water/cement ratio of 0.5

Figure 4 Relation between compressive

strength and free water/cement ratio

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

DOE Method of Mix Design Step 2

To Determine Free Water Content Required for Workability

This step is to determine the water content for the required workability,
expressed either as slump or as Vebe time, recognizing the influence of the
maximum size of aggregate and its type, namely crushed or uncrushed
(refer to Table 3 given below)

Table 3 - Approximate water contents required to give various levels of workability

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

DOE Method of Mix Design Step 3

To Determine Required Cement Content

Obtain the minimum cement content, which is required for

strength, by dividing the free water content obtained in
Step 2 by the free water/cement ratio obtained in Step 1.
Check the minimum cement content, which is required for
strength, against the maximum cement content, which is
permitted, and give a warning if the former exceeds the
latter.
Check the minimum cement content, which is required for
strength, against the minimum cement content, which is
allowable for durability, and adopt whichever is greater to
be the cement content in the mix.
Divide the free water content by the cement content used in
the mix to obtain a modified free water/cement ratio.

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

DOE Method of Mix Design Step 4

To Determine Total Aggregate Content

Estimate the fresh/wet concrete density (using Figure 5 given

below) of fully compacted concrete based on the free water
content estimated in Step 2 and specific gravity of aggregate in
the saturated surface-dry condition (SSD).

Total aggregate content (SSD)= Fresh density - (cement content

+ water content)

Figure 5 Estimated fresh/Wet

density of fully compacted concrete
(specific gravity is given for
saturated surface-dry aggregate
CE 2155 Structural Mechanics and Materials

MIX PROPORTION

DOE Method of Mix Design Step 5

Determine Fine and Coarse Aggregate Contents

Figure 6 given next slide)

(Refer to

Either use a specified value of the percentage of fine

aggregate, or obtain the percentage of fine aggregate,
which will provide the desired workability for concrete
made with the given grading of fine aggregate (defined by
its percentage passing a 600 m sieve), maximum size of
coarse aggregate and the free w/c ratio obtained in Step
3.
Calculate the fine and coarse aggregate contents from the
total aggregate content obtained in Step 4 and the
percentage of fine aggregate.

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

DOE Method of Mix Design Step 5

*The numbers refer to percentage of fine aggregate passing 600 m sieve

Figure 6 Recommended proportion of fine aggregate (expressed as percentage
of total aggregate) as function of free water/cement ratio for various workabilities
and maximum sizes

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

DOE Method of Mix Design Step 5

*The numbers refer to percentage of fine aggregate passing 600 m sieve

Figure 6 (Cont) Recommended proportion of fine aggregate
(expressed as percentage of total aggregate) as function of free
water/cement ratio for various workabilities and maximum sizes
CE 2155 Structural Mechanics and Materials

MIX PROPORTION

DOE Method of Mix Design Step 5

*The numbers refer to percentage of fine aggregate passing 600 m sieve

Figure 6 (Cont) Recommended proportion of fine aggregate
(expressed as percentage of total aggregate) as function of free
water/cement ratio for various workabilities and maximum sizes
CE 2155 Structural Mechanics and Materials

MIX
PROPORTION
Recommended

Limiting Values for Composition

& Properties of Concrete SS EN and BS EN 206

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

DOE Method of Mix Design Mix Design Form

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

DOE Method of Mix Design Example

Design concrete with a mean 28-day compressive strength (measured on
cubes) of 44 MPa (which is equivalent to a cylinder compressive strength of 35
MPa); a slump of 50 mm; uncrushed fine and coarse aggregate with a
maximum size of 20 mm; both with specific gravity of 2.64; 60 percent
of fine aggregates passes the 600 m sieve; no air entrainment required
and ordinary Portland cement to be used.

Solution:
Step 1:
From Table 2, for OPC and
uncrushed aggregate, we
find the 28-day strength to
be 42 MPa.

Table 2 -

Approximate compressive strength of concretes

made with a free water/cement ratio of 0.5

CE 2155 Structural Mechanics and Materials

MIX
PROPORTION
DOE
Method of

(Step 1)

Mix Design Example

We enter this value on the

ordinate corresponding to w/c
ratio of 0.5 in Figure; this point
marked A.
Through A, we draw a line
parallel to the nearest curve
until it intersects the ordinate
corresponding to the specified
strength of 44 Mpa; this is point
B.
The ordinate through this point
gives the w/c ratio of 0.48.

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

DOE Method of Mix Design Example

Step 2:
From Table 3 given below, for 20 mm uncrushed aggregate and a slump of 50
mm, we find that the water requirement to be 180 kg/m3.
Table 3 - Approximate water contents required to give various levels of workability

Step 3:
The cement content is 180/0.48 = 375 kg/m3.
CE 2155 Structural Mechanics and Materials

MIX PROPORTION

DOE Method of Mix Design Example

Step 4:
From the Figure 5 below, for a water content of 180 kg/m3 and 20 mm aggregate
with a specific gravity of 2.64, we read off the fresh density of concrete of 2400
kg/m3.
The total aggregate content
is thus:
=(2400 375 -180) kg/m3
=1845 kg/m3

Figure 5 Estimated fresh density of fully compacted concrete (specific gravity is given for saturated
surface-dry aggregate)

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

DOE Method of Mix Design Example

Step 5:
In Figure 6, we find the particular diagram
for the 20 maximum size of aggregate and a
slump encompassing the value of 50 mm.
On the line representing fine aggregate
60 percent passing the 600 m sieve,
w/c ratio of 0.48, the proportion of
aggregate is 32 percent (by mass of
aggregate).

with
at a
fine
total

Hence, the fine aggregate content is 0.32 x

1845 = 590 kg/m3 and the coarse aggregate
content is 1845 590 = 1255 kg/m3.

Figure 6 Recommended proportion of fine aggregate (expressed as percentage of total

aggregate) as function of free water/cement ratio for various workabilities and maximum sizes

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Moisture Content (MC) of Aggregate - Example

Fine Aggregate :
Absorption Capacity = 1.5%
Total Moisture Content = 4%
Free Moisture Content = (4 1.5) %=2.5 %

Fine Aggregate Content

= 590 kg/m3 of concrete (on SSD basis - from previous slide)
= 590 + 590 (2.5 %) = 605 kg/m3 (if the above wet sand is used)
The extra water due to the use of wet sand has to be deducted
accordingly.

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Approach to Variability

Estimation of Required Average Compressive Strength from the
Specified Compressive Strength
Because of the Statistical distribution of concrete strength
Concrete cannot be designed on the basis of specified
strength

In order to compute the required average compressive

strength of concrete mix, three information are needed:
Specified compressive strength fc
Variability or standard deviations of concrete
Allowable risk of having concrete with an unacceptable
strength

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Estimation of Required Average Strength (ACI 301)

The required average compressive strength fcr is determined as

the larger value of the following two criteria:
(1) The probable frequency of the average of any 3 consecutive
tests below specified strength fc should not exceed 1 in 100
fcr = fc + 2.33 s/ 3 = fc + 1.34 s
where
fcr = required average compressive strength
fc = specified compressive strength
s = standard deviation

(2) (a) For fc 35 MPa, the probable frequency of tests more

than 3.5 MPa below fc should not exceed 1 in 100
fcr = fc + 2.33 s - 3.5 (MPa)
(b) For fc > 35 MPa, the probable frequency of tests below
0.90fc should not exceed 1 in 100

fcr = 0.90 fc + 2.33 s

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Estimation of Required Average Strength (ACI 301)

(When Data Are Available to Establish a Standard Deviation)

Specified compressive
strength, f'c, MPa
35

Required average compressive

strength, f'cr, MPa

f'cr = f'c+ 1.34s

f'cr = f'c + 2.33s 3.5
Use larger value

> 35

f'cr = f'c+ 1.34s

f'cr = 0.90f'c + 2.33s
Use larger value

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Estimation of Required Average Strength (ACI 301)

Modification Factor for Standard Deviation ( 30 Tests)

Number of tests

Modification factor for

standard deviation

Less than 15

Use Table given in the next

slide

15

1.16

20

1.08

25

1.03

30 or more

1.00

s is multiplied by the above factor

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Estimation of Required Average Strength (ACI 301)

(When There Are Insufficient Data to Establish S)

Specified compressive
strength,
f'c, MPa

Required average compressive

strength,
f'cr, (MPa)

Less than 20

f'c + 7.0

20 to 35

f'c + 8.5

Over 35

1.1f'c + 5.0

These estimates are very conservative, and should not be

used for large projects (over-design, non-economical)
CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Cylinder vs Cube Specimens

Compressive Strength Test:

Cubes - 100 mm & 150 mm, or
Cylinders - 150 mm dia. and 300 mm long
- 100 mm dia. and 200 mm long
Cube specimen will
have higher strength
due
to
more
confinement !!!

0.866d*
0.866d

* Effective distance
of end restraining
effect

Confinement at both ends

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Cylinder vs Cube Specimens

Effect of specimen parameters on strength

Height/diameter ratio of cylinder , the strength
In general, larger specimen have lower strength

Correlation between cube and cylinder strength

Commonly assumed to be

fcu = 1.25 fcyl

Fcu/fcyl ranges from 1.3 for low-strength
concrete to 1.04 for higher strength concrete

Cylinders are cast and tested in the same position, whereas for cubes, the
loading direction is perpendicular to the casting direction

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design - Ten Steps

1. Required information
2. Choice of slump
3. Choice of maximum aggregate size
4. Estimation of mixing water and the air content
5. Selection of w/c or w/cm
6. Calculation of cement or cm content
7. Estimation of coarse aggregate content
8. Estimation of fine-aggregate content
9. Adjustments for moisture in the aggregates
10. Trial batch

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

Step 1 Required information
Sieve analysis of fine and coarse aggregate, fineness modulus
Dry-rodded unit weight of coarse aggregate
Bulk specific gravity of materials
Absorption capacity, or free moisture in the aggregate
Information on structure including the type and dimensions of
structural members, minimum space between reinforcing bars
Required strength
Exposure conditions
Relationship between strength and w/c for available
combinations of cement and aggregate
Job specifications [e.g., max w/c, min. slump, strength at early
age (normally 28d)]

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Recommended Slump Ranges (ACI 211)

Step 2 Choice of slump
Recommended Slump Ranges
Slump, mm

Concrete construction

Maximum

Minimum

Reinforced foundation walls and

footings

75

25

Plain footings, caissons, and

substructure walls

75

25

Beams and reinforced walls

100

25

Building columns

100

25

Pavements and slabs

75

25

Mass concrete

50

25

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

Step 3 Choice of maximum size of aggregate

Using a large max size of a well-graded aggregate will

produce less void space than using a smaller size
Large aggregates minimize the amount of water required,
therefore reduce the amount of cement required.
The maximum allowable aggregate size is limited by
the dimensions of the structural elements and space
between reinforcement
capabilities of construction equipment

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

Step 4 Estimation of mixing water and the air content
The quantity of water required to produce a given slump is
dependent on the max size, shape and grading of

aggregate, amount of entrained air

not greatly affected by cement content

Estimation of water from Table given in the next slide if no

data are available for a given aggregate
The recommendations in the Table are reduced for other
aggregate shapes by the amount stated below.

kg/m3

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

Approximate Water and Air Requirements for Different Slumps
and Maximum Sizes of Aggregate
Non-air-entrained concrete
Water, kg/m3 of concrete,
for indicated sizes of aggregate
Slump, mm

9.5
mm

12.5 19
mm mm

25
mm

37.5
mm

50
mm

75
mm

150
mm

25 to 50

210

200

185

180

160

155

130

113

75 to 100

225

215

200

195

175

170

145

124

150 to 175

240

230

210

205

185

180

160

Approximate amount of
entrapped air in non-airentrained concrete,
percent

2.5

1.5

0.5

0.3

0.2

Based on well-shaped, angular coarse aggregate

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

Air entrainment requirements
Air entrainment is required whenever concrete is exposed to
freeze-thaw conditions
Air entrainment is also used for workability
The amount of the air required varies with
exposure conditions
mild: indoor or outdoor service where concrete is not
exposed to freezing and de-icing salts. AEA may be used
to improve workability
moderate: some freezing exposure occurs but concrete
not exposed to moisture
severe
size of the aggregates

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

Approximate Water and Air Requirements for Different
Slumps and Maximum Sizes of Aggregate
Air-entrained concrete
Water, kg/m3 of concrete,
for indicated sizes of aggregate
Slump, mm

9.5
mm

12.5
mm

19
mm

25
37.5
mm mm

50
mm

75
mm

150
mm

25 to 50

180

175

165

160 145

140

120

107

75 to 100

200

190

180

175 160

155

135

119

150 to 175

215

205

190

185 170

165

155

Recommended average total air content,

percent, for level of exposure
Mild exposure

4.5

4.0

3.5

3.0

2.5

2.0

1.5

1.0

Moderate exposure

6.0

5.5

5.0

4.5

4.5

4.0

3.5

3.0

Severe exposure

7.5

7.0

6.0

6.0

5.5

5.0

4.5

4.0

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

Step 5 Selection of w/c or w/cm for strength
If no historical data are available
make trial batches with different w/c, establish a relationship
between strength and w/c
estimation of w/c for the trial mixes from the table given below

Water/Cement Ratio by mass

Compressive
strength at 28
days, MPa

Non-air-entrained
concrete

Air-entrained
concrete

45

0.37

40

0.42

35

0.47

0.39

30

0.54

0.45

25

0.61

0.52

20

0.69

0.60

15

0.79

0.70

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

5. Selection of w/c or w/cm for durability
Durability
Checking w/c against the max. allowable w/c for exposure
conditions
Generally, more severe exposure conditions require
lower w/c
The minimum of the w/c for strength and durability is
selected for proportioning of the concrete

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

5. Selection of w/c or w/cm for concrete in severe exposure

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

Requirement for Concrete Exposed to Sulfates

Sulfate
exposure
Negligible

Sulfate
(SO4) in
soil, %
by mass
< 0.10

Sulfate
(SO4) in
water,
ppm

Cement type

Maximum
w/c-ratio,
by mass

Minimum
strength,
f'c, MPa

< 150

No special
type required

0.50

28

Moderate

0.10 to
0.20

150 to
1500

II, MS,
IP(MS),
IS(MS),
P(MS),
I(PM)(MS),
I(SM)(MS)

Severe

0.20 to
2.00

1500 to
10,000

0.45

31

Very
severe

> 2.00

> 10,000

V +pozzolans
or slag

0.45

31

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

Step 6 Calculation of cement or cementitious material content

= mixing water (step 4) divided by the w/c (step 5)

if the concrete is used in flatwork, check minimum
cement content requirement
Nominal maximum size of
aggregate, mm

Cementing materials,
kg/m3

37.5

280

25

310

19

320

12.5

350

9.5

360

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

Step 7 Estimation of coarse aggregate content
V, workability (pavement)
V, workability (pumping, shotcrete)
Volume of Coarse Aggregate per Unit volume of Concrete
Fineness modulus of sand

Maximum size
of aggregate,
mm

2.40

2.60

2.80

3.00

9.5

0.50

0.48

0.46

0.44

12.5

0.59

0.57

0.55

0.53

19

0.66

0.64

0.62

0.60

25

0.71

0.69

0.67

0.65

37.5

0.76

0.74

0.72

0.70

50

0.78

0.76

0.74

0.72

75

0.82

0.80

0.78

0.76

150

0.87

0.85

0.83

0.81

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

Step 7 Estimation of coarse aggregate content per m3 of concrete

For example, assume:

Max. size of coarse aggregate 19 mm and
Fineness modulus of sand = 2.8
From the previous table,
Volume of coarse aggregate required for 1 m3 of concrete
with the above aggregates is = 0.62
Assume: Dry rodded unit weight of coarse aggregate
= 1567 kg/m3 (oven dry condition)
Estimated coarse aggregate content (Oven dry condition)
= 0.62 x 1567 kg/m3 = 971.5 kg/m3
Estimated coarse aggregate content (SSD condition)
= 971.5 x (1+Absorption capacity)
CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

Step 8 Estimation of fine aggregate content
Mass (Weight) method
Wfa = Wc - Weight of other ingredients

Wfa = weight of fine aggregate

Wc = unit weight of concrete

Estimate according to Table below

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

Step 8 Estimation of fine aggregate content
Volume method
The components weight and specific gravity are used to
determine the volumes of the water, coarse aggregate, and
cement. These volume + volume of air are subtracted from
a unit volume of concrete to determine the V of fine
aggregate

convert the V to weight (generally using bulk SSD specific

gravity)

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

Step 9 Adjustments for aggregate moisture
The mix proportions determined by steps 1 to 7 are assumed
to be on a saturated surface dry (SSD) basis.
If aggregate contains free moisture, the mixing water
should be and aggregates correspondingly according to
the amount of free moisture in the aggregates.
If aggregate is air dry, the mixing water should be and
aggregates correspondingly
Total water in aggregate absorption = free moisture

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

Step 9 Adjustments for coarse and fine aggregate moistures

For example, assume
Coarse aggregate with absorption capacity =1%, effective
absorption = 0.5%, and
Fine aggregate with absorption capacity = 1.3%, total moisture
content 4.5%
Assume a concrete mix proportion based on SSD:
Cement = 400 kg/m3, Water = 200 kg/m3, Coarse aggregate
= 1050 kg/m3, Fine aggregate = 710 kg/m3, and Estimated
unit weight = 2360 kg/m3
Actual mix proportion with the given aggregates
CA: 1050 1050x0.5% = 1045 kg/m3
FA: free moisture = 4.5% 1.3% = 3.2%

710 + 710x3.2% = 733 kg/m3

Water: 200 + 1050x0.5% - 710x3.2% = 182 kg/m3
Estimated unit weight = 2360 kg/m3
CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

Step 10 Trial batch
Purpose: Verifies that a concrete mixture meets design
requirements prior to use in construction.
To determine
Fresh concrete: slump, cohesiveness, segregation
tendency, unit weight, air content, finishing
Hardened concrete: strength 28 days or other ages
To adjust concrete mixture accordingly
Strength does not meet requirement (workability ok)
Reduce w/c
o Keep water content unaltered
o cement, aggregate

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design

Step 10 Trial batch
Adjust concrete mixture accordingly (contd)
Workability does not meet requirement (strength ok)
Keep w/c unaltered
o Slump too low
water and cement content

( 6 kg/m3 water will slump by ~25 mm)

Use WRA or superplasticizer
o Slump too high
water and cement content
the dosage of WRA or SP
Segregation
fine aggregate and coarse aggregate accordingly
Replace coarse sand with a finer sand
Air content: 1% entrained air, water by 3 kg/m3
CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design Example

Design a concrete required for an exterior column located above
ground level in an area where it will be wet and subjected to
substantial freezing and thawing. The concrete is required to
have an average 28-day compressive strength of 30 MPa. For the
condition of placement, the slump should be between 75 and 100
mm. The column is 635 mm square with a minimum clear space
for aggregate of 50 mm. The properties of the materials are as
follows:
Cement Type I, specific gravity = 3.15
Fine aggregate Bulk specific gravity (SSD) = 2.63; absorption
capacity = 1.3%; surface moisture = 4.2%
based
on
SSD
state; fineness modulus = 2.70.
Coarse aggregate Maximum size = 19 mm; Bulk specific
gravity
(SSD) = 2.68; absorption capacity = 1.0%; surface moisture = 0.5%
based on SSD state; dry rodded unit weight =
1600 kg/m3
The sieve analyses of the coarse and fine aggregates fall within
the limits specified in ASTM C33.

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design Steps 1 & 2

Solution:
Step 1: Required information This is already given in the
previous slide.
Step 2: Choice of slump The slump also given, consistent with
Table given below
Recommended Slump Ranges
Slump, mm

Concrete construction

Maximum

Minimum

75

25

75

25

Beams and reinforced walls

100

25

Building columns

100

25

75

25

50

25

Reinforced foundation walls and footings

Plain footings, caissons, and substructure
walls

Pavements and slabs

Mass concrete

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design Steps 3 & 4

Step 3: Maximum aggregate size The maximum aggregate size,

19 mm meets the limitations of

1) 1/5th of the minimum dimension between forms and
2) 3/4th clear space.
Step 4: Estimation of mixing water and air content Since the concrete
will be exposed to freezing and thawing, it must be air entrained.
From the below table, the air content recommended for severe
exposure is 6% and the water requirement is 180 kg/m3
Water, kg/m3 of concrete,
for indicated sizes of aggregate

Table - Approximate
Water
and
Air
Requirements
for
Different
Slumps
and Maximum Sizes
of Aggregate (for
air-entrained
concrete)

Slump, mm

9.5
mm

12.5
mm

19
mm

25
mm

37.5
mm

50
mm

75
mm

150
mm

25 to 50

180

175

165

160

145

140

120

107

75 to 100

200

190

180

175

160

155

135

119

150 to 175

215

205

190

185

170

165

155

Recommended average total air content,

percent, for level of exposure
Mild exposure

4.5

4.0

3.5

3.0

2.5

2.0

1.5

1.0

Moderate exposure

6.0

5.5

5.0

4.5

4.5

4.0

3.5

3.0

Severe exposure

7.5

7.0

6.0

6.0

5.5

5.0

4.5

4.0

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design Step 5

Step 5: Water/cement ratio From table give below, the estimate of

required w/c ratio to a given 28-day compressive strength of 30

MPa is 0.45. This does not exceed the limits based on durability
(Tables are given in the next slides)
Table- Relationship between w/c ratio and compressive
strength
Water/Cement Ratio by mass

Compressive
strength at 28
days, MPa

Non-air-entrained
concrete

Air-entrained
concrete

45

0.37

40

0.42

35

0.47

0.39

30

0.54

0.45

25

0.61

0.52

20

0.69

0.60

15

0.79

0.70

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design Step 5

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design Step 5

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design Steps 6 & 7

Step 6: Calculation of cement content The required cement content,

based on the results of Steps 4 and 5, is 180/0.45 = 400 kg/m3

Step 7: Estimation of coarse aggregate content Interpolating in Table

given below, for the fineness modulus of the fine aggregate of

2.70, the volume of dry-rodded coarse aggregate per unit volume
of concrete is 0.63. Therefore, the coarse aggregate will occupy
0.63m3/m3.
The OD weight of CA is 0.63 x 1600 = 1008 kg.
The SSD weight is 1008 x 1.01 = 1018 kg.

Table - Volume of
Coarse Aggregate
per Unit volume
of Concrete

Fineness modulus of sand

Maximum size of
aggregate, mm

2.40

2.60

2.80

3.00

9.5

0.50

0.48

0.46

0.44

12.5

0.59

0.57

0.55

0.53

19

0.66

0.64

0.62

0.60

25

0.71

0.69

0.67

0.65

37.5

0.76

0.74

0.72

0.70

50

0.78

0.76

0.74

0.72

75

0.82

0.80

0.78

0.76

150

0.87

0.85

0.83

0.81

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design Step 8

Step 8: Estimation of fine aggregate content The fine aggregate

content can be established either by the a) mass (weight) method

or b) absolute volume method.
a) Mass (weight) method: From table given below, the estimated
concrete weight is 2280 kg/m3. The more exact calculation on
the following equation is
Um = 10 (2.66) (100 - 6) + 400 (1-2.66/3.15) 180 (2.66 - 1)
= 2264 kg/m3 .
Therefore, the weight of fine aggregate(SSD)
= 2264-180-400-1018 = 666 kg

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design Step 8

Step 8: Volume method Knowing the weights and specific gravities

of water, cement, and coarse aggregate and knowing air
volume, we can calculate the volume per m3 occupied by the
different ingredients.
Water
Cement
Coarse aggregate
Air content

180/1000

0.180 m3

400/(3.15x1000)

0.127 m3

1018/(2.68x1000)

0.380 m3

6/100

0.06 m3
0.747 m3

Total volume

Therefore, the fine aggregate must occupy a volume of 1

0.747 = 0.253 m3 .
The required SSD weight of fine aggregate
= 0.253 x 2.63 x 1000 = 665 kg.
This is essentially same as the weight calculated according to the
weight method
CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design Step 9

Step 9: Adjustment of moisture in the aggregate Since the

aggregates will be neither SSD nor OD in the field, it is
necessary to adjust the aggregate weights for the amount of
water contained in the aggregate
(note that very dry
aggregates will absorb water from the mix, and this too must
be allowed for.). Only surface water need be considered;
absorbed water does not become part of mixing water. For the
given moisture contents the adjusted aggregate weights
become:
Coarse aggregate
Fine aggregate

1018 x 1.005

1023 kg/m3

665 x 1.042

693 kg/m3

Surface moisture contributed by the coarse aggregate is 0.5%;

by the fine aggregate 4.2%. Therefore, the mixing water
= 180 - 1018 x 0.005 - 665 x 0.042 = 147 kg/m3

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design Step 10

Step 10: Trial batch A trial batch is now made using the proportions
calculated. The properties of the concrete in the trial batch (including
unit weight) must be compared with the desired properties, and the
mix design must be corrected as described. To illustrate this process,
consider the following trial batch results:
Small trial batched are prepared based on the example for 0.015 m3. The
desired slump is 100 mm and the desired air content is 6%. During the course
of trial match, we find that extra water is needed to achieve the desired
slump. The final properties of the concrete are slump = 75 mm, air content =
5% and unit weight = 2286 kg/m3. The weights used in the trial batches are
expressed in terms of SSD aggregate:
Cement
Coarse aggregate (SSD)
Fine aggregate (SSD)
Water
Total batch weight

6.00 kg
15.27 kg
9.98 kg
2.84 kg
34.09 kg

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design Step 10

Based on the manufacturers recommendations, air entraining agent

was added at a rate of 0.23 L/m3.
The batch weights and unit weight can now be used to determine the
actual quantities used on a m3 basis.
Batch factor = 2286/34.09 = 67.06 batched/m3
Cement
Coarse aggregate (SSD)

6.00 x 67.06 = 402 kg

15.27 x 67.06 = 1024 kg

Fine aggregate (SSD)

9.98 x 67.06 = 669 kg

Water

2.84 x 67.06 = 190 kg

Note that, due to extra water required and lower air content, the
actual weights of the ingredients differ from the original values.
The mix design must now be modified to obtain the desired slump,
air content and w/c ratio.

CE 2155 Structural Mechanics and Materials

MIX PROPORTION

ACI Method of Mix Design Step 10

The water content for a 100 mm slump will be 190 kg/m3 + 6 kg/m3
[to increase the slump from 88 mm] 3 kg/m3 [to take into account
the extra slump that will be obtained as the 5% actual air content is
increased to the desired 6%] = 193 kg/m3.
We now proceed to Step 5 to recalculate the batch weights.
Step 5: w/c = 0.45 is unchanged
Step 6: Cement content = 193/0.45 = 429 kg
Step 7: Coarse aggregate (SSD content ) = 1018 kg is unchanged
Step 8: Fine aggregate (SSD) content : for this problem we will use
the volume method.
193/1000

0.193 m3

429/(3.15x1000)

0.136 m3

1018/(2.68x1000)

0.380 m3

6/100

0.06 m3

Water
Cement
Coarse aggregate
Air content
Total volume

0.769m3

Absolute volume of fine aggregate = 1-0.769 = 0.231 m3.

SSD weight of fine aggregate = 0.231x2.63x1000 = 608 kg.
CE 2155 Structural Mechanics and Materials

MIX PROPORTION

Use of Admixtures
Admixtures
Chemical admixtures
Depend on applications

Mineral admixtures
Depend on applications
When used to replacement on mass basis, need to adjust
aggregate as specific gravity of cement & mineral
admixtures are different

CE 2155 Structural Mechanics and Materials