UNIT 4

MIX PROPORTIONING OF
CONCRETE
 Concrete Mix Design

 One of the ultimate aims of studying the various properties of the

materials of concrete, plastic concrete and hardened concrete, is to
enable a concrete technologist to design a concrete mix for a
particular strength and durability.

 The conditions that prevail at the site of work, in particular the

exposure condition, and the conditions that are demanded for a
particular work for which the mix is designed.
 Mix design- Definition
The process of determining required and specifiable
characteristics of a concrete mixture is called mix design.
Characteristics can include:
(1) fresh concrete properties;
(2) required mechanical properties of hardened concrete such as
strength and durability requirements;
(3) the inclusion, exclusion, or limits on specific ingredients. Mix
design leads to the development of a concrete specification.
 Concept of Mix Design
 The relationships between aggregate and paste which are the
two essential ingredients of concrete.
 Workability of the mass is provided by the lubricating effect
of the paste and is influenced by the amount and dilution of
paste.
 The strength of concrete is limited by the strength of paste,
since mineral aggregates with rare exceptions, are far stronger
than the paste compound.
 Essentially the permeability of concrete is governed by the
quality and continuity of the paste, since little water flows
through aggregate either under pressure or by capillarity.
 Since the properties of concrete are governed to a considerable
extent by the quality of paste, it is helpful to consider more closely
the structure of the paste.

With the given materials, the four variable factors to be considered

in connection with specifying a concrete mix are
(a ) Water-Cement ratio
(b ) Cement content or cement-aggregate ratio
(c ) Gradation of the aggregates
(d ) Consistency.
Thus the purpose of mix design is of two folds
• First objective - strength and durability
• Second objective - economical production, cost

Cost of concrete - labour and materials

Labour cost
• formwork, batching, mixing, transporting and curing
• nearly same for good concrete and bad concrete

Materials cost
• Attention is mainly directed to the cost of materials – particularly
cost of cement and admixtures.
• Cement used should be as minimum as possible (Minimize
cement)
 Designing Concrete Mixtures
There are three phases in the development of a concrete mixture:
specifying, designing, and proportioning
 Objective of Mix Proportioning

• Produce Concrete – most economical and practical combination

• Satisfy the performance requirements under specified conditions
of use.
• Concrete – Satisfactory both in its fresh and hardened states.
• Trial mixes – integral part of concrete mix proportioning
 Proportioning of Concrete Mixes
• Procedure is available to proportion the most economical
concrete mix for specified durability and grade for required site
conditions.
• The structural engineer stipulates certain minimum strength for
concrete.
• Concrete technologist should design the concrete taking all
properties of materials, exposure condition, field condition, standard
deviation, minimum strength and durability.
• Finally concrete is to be prepared based on the mix design and
this concrete is to be actually tested (laboratory) for the
requirements.
• Engineer-in-charge should approve the mix so proportioned.
• The method gives the guidelines only to arrive at an acceptable
product, which satisfies the requirements of placement required
with development of strength with age, and ensures the
requirements of durability.
• Different countries have their own standardized mix design
methods.
• These methods are mostly based on empirical relations, charts,
graphs, and tables developed as outcomes of extensive
experiments and investigations of locally available materials.
• All the standards and methods follow the same basic trial and
error principles.
 Various Methods of Proportioning
• Arbitrary proportion
• Indian Road Congress, IRC 44 method
• High strength concrete mix design
• Mix design based on flexural strength
• Road note No. 4 (Grading Curve method)
• ACI Committee 211 method
• DOE method
• Mix design for pumpable concrete
• Indian standard Recommended method IS 10262-
2019
 SELECTING MIX CHARACTERISTICS

Before a concrete mixture can be proportioned, mixture characteristics are

selected based on the intended use of the concrete, the exposure
conditions, the size and shape of building elements, and the physical
properties of the concrete (such as frost resistance and strength) required
for the structure. The characteristics should reflect the needs of the
structure; for example, resistance to chloride ions should be verifiable and
the appropriate test methods specified.
Once the characteristics are selected, the mixture can be
proportioned from field or laboratory data. Since most of the
desirable properties of hardened concrete depend primarily upon
the quality of the cementitious paste, the first step in proportioning
a concrete mixture is the selection of the appropriate water-
cementing materials ratio for the durability and strength needed.
Concrete mixtures should be kept as simple as possible, as an
excessive number of ingredients often make a concrete mixture
difficult to control. The concrete technologist should not, however,
overlook the opportunities provided by modern concrete
technology.
Requirements which form the basis for the selection and
proportioning of concrete mix:
• Minimum compressive strength
• Adequate workability
• Maximum W/C ratio and/or Maximum cement content
• Maximum cement content
Water-Cementing Materials Ratio and Strength Relationship
Strength (compressive or flexural) is the most universally used
measure for concrete quality. Although it is an important characteristic,
other properties such as durability, permeability, and wear resistance are
now recognized as being equal and in some cases more important,
especially when considering life-cycle design of structures. Within the
normal range of strengths used in concrete construction, the compressive
strength is inversely related to the water-cement ratio or water-cementing
materials ratio. For fully compacted concrete made with clean, sound
aggregates, the strength and other desirable properties of concrete under
given job conditions are governed by the quantity of mixing water used
per unit of cement or cementing materials
Differences in concrete strength for a given water cementing materials
ratio may result from:
(1) changes in the aggregate size, grading, surface texture, shape,
strength, and stiffness;
(2) differences in types and sources of cementing materials;
(3) entrained-air content;
(4) the presence of admixtures;
(5) the length of curing time.
Water-Cementitious Material Ratio
The water-cementitious material ratio is simply the mass of water
divided by the mass of cementitious material (portland cement,
blended cement, fly ash, slag, silica fume, and natural pozzolans).
The water-cementitious material ratio selected for mix design must
be the lowest value required to meet anticipated exposure
conditions.
When durability does not control, the water-cementitious materials
ratio should be selected on the basis of concrete compressive
strength. In such cases the watercementitious materials ratio and
mixture proportions for the required strength should be based on
adequate field data or trial mixtures made with actual job materials
to determine the relationship between the ratio and strength.
In mix design, the water to cementitious materials ratio, W/CM, is
often used synonymously with water to cement ratio (W/C); however,
some specifications differentiate between the two ratios. Traditionally,
the water to cement ratio referred to the ratio of water to portland
cement or water to blended cement
Aggregates
Two characteristics of aggregates have an important influence on
proportioning concrete mixtures because they affect the workability of the
fresh concrete. They are: 1. Grading (particle size and distribution) 2.
Nature of particles (shape, porosity, surface texture) Grading is important
for attaining an economical mixture because it affects the amount of
concrete that can be made with a given amount of cementitious materials
and water. Coarse aggregates should be graded up to the largest size
practical under job conditions. The maximum size that can be used
depends on factors such as the size and shape of the concrete member to
be cast, the amount and distribution of reinforcing steel in the member, and
the thickness of slabs. Grading also influences the workability and
placeability of the concrete.
Sometimes midsized aggregate, around the 9.5 mm (3⁄8 in.) size, is
lacking in an aggregate supply; this can result in a concrete with
high shrinkage properties, high water demand, and poor workability
and placeability. Durability may also be affected. Various options are
available for obtaining optimal grading of aggregate.
The maximum size of coarse aggregate should not exceed one-fifth
the narrowest dimension between sides of forms nor three-fourths
the clear space between individual reinforcing bars or wire, bundles
of bars, or prestressing tendons or ducts. It is also good practice to
limit aggregate size to not more than three-fourths the clear space
between reinforcement and the forms. For unreinforced slabs on
ground, the maximum size should not exceed one third the slab
thickness. Smaller sizes can be used when availability or economic
consideration require them.
The amount of mixing water required to produce a unit volume of
concrete of a given slump is dependent on the shape and the
maximum size and amount of coarse aggregate. Larger sizes minimize
the water requirement and thus allow the cement content to be
reduced. Also, rounded aggregate requires less mixing water than a
crushed aggregate in concretes of equal slump
The maximum size of coarse aggregate that will produce concrete of
maximum strength for a given cement content depends upon the
aggregate source as well as its shape and grading. For high
compressive-strength concrete (greater than 70 MPa or 10,000 psi),
the maximum size is about 19 mm (3⁄4 in.). Higher strengths can also
sometimes be achieved through the use of crushed stone aggregate
rather than rounded-gravel aggregate.
Air Content
Entrained air must be used in all concrete that will be exposed to
freezing and thawing and de-icing chemicals and can be used to improve
workability even where not required. Air entrainment is accomplished by
using an air entraining Portland cement or by adding an air-entraining
admixture at the mixer. The amount of admixture should be adjusted to
meet variations in concrete ingredients and job conditions. The amount
recommended by the admixture manufacturer will, in most cases,
produce the desired air content.
The amount of air required to provide adequate freeze-thaw resistance is
dependent upon the nominal maximum size of aggregate and the level of
exposure. In properly proportioned mixes, the mortar content decreases
as maximum aggregate size increases, thus decreasing the required
concrete air content.
Exposure levels
The levels of exposure are defined as follows:
Mild Exposure: This exposure includes indoor or outdoor service in a
climate where concrete will not be exposed to freezing or de-icing agents.
When air entrainment is desired for a beneficial effect other than durability,
such as to improve workability or cohesion or in low cement content
concrete to improve strength, air contents lower than those needed for
durability can be used.
Moderate Exposure: Service in a climate where freezing is expected but
where the concrete will not be continually exposed to moisture or free water
for long periods prior to freezing and will not be exposed to de-icing or
other aggressive chemicals. Examples include exterior beams, columns,
walls, girders, or slabs that are not in contact with wet soil and are so
located that they will not receive direct applications of de-icing chemicals.
Severe Exposure: Concrete that is exposed to de-icing or other
aggressive chemicals or where the concrete may become highly
saturated by continual contact with moisture or free water prior to
freezing. Examples include pavements, bridge decks, curbs, gutters,
sidewalks, canal linings, or exterior water tanks or sumps.
Slump
Concrete must always be made with a workability, consistency, and plasticity
suitable for job conditions. Workability is a measure of how easy or difficult it is to
place, consolidate, and finish concrete. Consistency is the ability of freshly mixed
concrete to flow. Plasticity determines concrete’s ease of moulding. If more
aggregate is used in a concrete mixture, or if less water is added, the mixture
becomes stiff (less plastic and less workable) and difficult to mould. Neither very
dry, crumbly mixtures nor very watery, fluid mixtures can be regarded as having
plasticity. The slump test is used to measure concrete consistency. For a given
proportion of cement and aggregate without admixtures, the higher the slump, the
wetter the mixture. Slump is indicative of workability when assessing similar
mixtures. However, slump should not be used to compare mixtures of totally
different proportions. When used with different batches of the same mix design, a
change in slump indicates a change in consistency and in the characteristics of
materials, mixture proportions, water content, mixing, time of test, or the testing
itself.
Water Content
The water content of concrete is influenced by a number of factors:
aggregate size, aggregate shape, aggregate texture, slump, water to
cementing materials ratio, air content, cementing materials type and
content, admixtures, and environmental conditions. An increase in
air content and aggregate size, a reduction in water-cementing
materials ratio and slump, and the use of rounded aggregates, water
reducing admixtures, or fly ash will reduce water demand. On the
other hand, increased temperatures, cement contents, slump, water-
cement ratio, aggregate angularity, and a decrease in the proportion
of coarse aggregate to fine aggregate will increase water demand.
Cementing Materials Content and Type
The cementing materials content is usually determined from the
selected water-cementing materials ratio and water content, although
a minimum cement content frequently is included in specifications in
addition to a maximum water cementing materials ratio. Minimum
cement content requirements serve to ensure satisfactory durability
and finish ability, to improve wear resistance of slabs, and to
guarantee a suitable appearance of vertical surfaces. This is
important even though strength requirements may be met at lower
cementing materials contents. However, excessively large amounts
of cementing materials should be avoided to maintain economy in
the mixture and to not adversely affect workability and other
properties.
For severe freeze-thaw, de-icer, and sulphate exposures, it is desirable to
specify:
(1) a minimum cementing materials content of 335 kg per cubic meter
(564 lb per cubic yard) of concrete
(2) only enough mixing water to achieve the desired consistency without
exceeding the maximum water-cementing materials ratios.
For placing concrete underwater, usually not less than 390 kg of
cementing materials per cubic meter (650 lb of cementing materials per
cubic yard) of concrete should be used with a water to cementing
materials ratio not exceeding 0.45. For workability, finish ability,
abrasion resistance, and durability in flatwork, the quantity of cementing
materials to be used should be not less
To obtain economy, proportioning should minimize the amount of
cement required without sacrificing concrete quality. Since quality
depends primarily on water cementing materials ratio, the water
content should be held to a minimum to reduce the cement
requirement.

Steps to minimize water and cement requirements include use of

(1) the stiffest practical mixture
(2) the largest practical maximum size of aggregate
(3) the optimum ratio of fine-to-coarse aggregate.
Minimum Requirements of Cementing Materials for Concrete Used in Flatwork
Cementitious Materials Requirements for Concrete Exposed to De-icing Chemicals
Admixtures
Water-reducing admixtures are added to concrete to reduce the
water-cementing materials ratio, reduce cementing materials
content, reduce water content, reduce paste content, or to improve
the workability of a concrete without changing the water-cementing
materials ratio. Water reducers will usually decrease water contents
by 5% to 10% and some will also increase air contents by 1⁄2 to 1
percentage point. Retarders may also increase the air content. High-
range water reducers (plasticizers) reduce water contents between
12% and 30% and some can simultaneously increase the air content
up to 1 percentage point; others can reduce or not affect the air
content. Calcium chloride-based admixtures reduce water contents
by about 3% and increase the air content by about 1⁄2 percentage
point.
When using a chloride-based admixture, the risks of reinforcing
steel corrosion should be considered. When using more than one
admixture in concrete, the compatibility of intermixing admixtures
should be assured by the admixture manufacturer or the
combination of admixtures should be tested in trial batches. The
water contained in admixtures should be considered part of the
mixing water if the admixture’s water content is sufficient to affect
the water-cementing materials ratio by 0.01 or more. An excessive
use of multiple admixtures should be minimized to allow better
control of the concrete mixture in production and to reduce the risk
of admixture incompatibility.
Maximum Chloride-Ion Content for Corrosion Protection
IS METHOD OF MIX
PROPORTIONING
Salient feature of IS 10262 : 2019

• Applicable to ordinary and standard concrete grades only.

• Durability requirements, Limitations on W/C ratio and
Maximum cement contents are as per IS 456 : 2000.
• Requirements for selection of W/C ratio, water content and
estimations of coarse aggregate content and fine aggregate
content have been reviewed and accordingly modified.
 Data for mix proportioning
• Grade designation
• Type of cement
• Maximum nominal size of aggregate (MSA)
• Minimum cement content
• Maximum water-cement ratio
• Workability
• Exposure conditions as per Table 4 and Table 5 of IS: 456-2000
• Maximum temperature of concrete at the time of placing
• Method of transporting and placing
• Early age strength requirements, if required
• Type of aggregate
• Maximum cement content, and
• Whether an admixture shall or shall not be used and the type of admixture
and the condition of use.
Target Mean Strength
Target strength is computed by
f'ck = fck + 1.65 S
OR
f'ck = fck + X
f'ck = target mean compressive strength at 28 days in N/mm2
fck = characteristic compressive strength at 28 days in N/mm2
S = standard deviation in N/mm2, as per Table 2
X = factor based on the grade of concrete, as per Table 1
Selection of Mix Proportion

• Selection of Water cement ratio

• For the same water cement ratio ,the compressive strength may
differ according to different cement, supplementary cementitious
materials, aggregate size, grading, shape and surface texture.
• Preliminary w/c may be selected from established relationship
between w/c ratio and compressive strength.
• Alternatively w/c ratio may be selected from table 5 of IS: 456
for respective exposure condition.
Selection of Water-Cement Ratio
Different cements, supplementary cementitious materials and aggregates
of different maximum size, grading, surface texture, shape and other
characteristics may produce concrete of different compressive strength for
the same free water-cement ratio. Therefore, the relationship between
strength and free water-cement ratio should preferably be established for
the materials actually to be used. In the absence of such data, the
preliminary free water-cement ratio (by mass) (w/c) corresponding to the
compressive strength at 28 days may be selected from the relationship
shown in Fig.1, for the expected 28 days strength of cement. The final w/c
is arrived at, based on the results of all the trials and any change in strength
of cement shall get adjusted in the trials. In case, the actual strength of
cement is known, the curve corresponding to the actual strength of cement
may be used.
Where supplementary cementitious materials are used, that is, mineral
admixtures, the water cementitious materials ratio (w/cm) shall be calculated,
in accordance with Table 5 of IS 456 and this w/cm shall be in accordance with
Table 3 and Table 5 of IS 456 or as specified.
Estimation of Air Content
Approximate amount of entrapped air to be expected in normal
(non-air-entrained) concrete is given in Table 3. The actual values
of air content can also be adopted during mix proportioning, if the
site data (at least 5 results) for similar mix is available.
Selection of Water content
Water content is influenced by
• Aggregate size
• Shape
• Texture
• Workability
• w/c ratio
• Other supplementary cementitious material
• Admixture
• Environment conditions
Water content for admixtures
• 5 to 10% for water reducing admixtures
• 20% for superplasticisers.
1.Water reducers
• At constant workability – The reduction in mixing water is expected
to be of the order of 5% to 15%. Naturally increases the strength.
• At constant w/c ratio – Increased workability. Slump of 30mm to 150
mm.
• Thin walls of water retaining structures with high percentage of steel
reinforcement
• Deep beams, column and beam junctions
• Tremie concreting
• Pumping of concrete
• Hot weather concreting
• Concrete to be conveyed for considerable distance and in ready mixed
concrete industries
Calculation of Cement/Cementitious Materials Content
The cement and supplementary cementitious materials content per unit
volume of concrete may be calculated from the free water-cement ratio
and the quantity of water per unit volume of concrete. In certain situations,
while using part replacement of cement by fly ash, ground granulated blast
furnace slag (GGBS), silica fume, and other mineral admixtures, increase
in cementitious materials content may be warranted, particularly if fly ash
is 20 percent or more. The decision on increase in cementitious materials
content and its percentage may be based on experience and trials; or the
cementitious materials content so calculated may be increased by 10
percent for preliminary trial. The water-cementitious materials ratio shall
be recalculated, based on the increased cementitious materials content, as
per Table 5 of IS 456.
TABLE 5 OF IS 456
Estimation of Coarse Aggregate Proportion
Aggregates of essentially the same nominal maximum size, type and
grading will produce concrete of satisfactory workability when a given
volume of coarse aggregate per unit volume of total aggregate is used.
Approximate values for this aggregate volume are given in Table 5 for
a water-cement/water cementitious materials ratio of 0.5, which may be
suitably adjusted for other ratios, the proportion of volume of coarse
aggregates to that of total aggregates is increased at the rate of 0.01 for
every decrease in water-cement/cementitious materials ratio by 0.05
and decreased at the rate of 0.01 for every increase in water cement
ratio by 0.05.
For more workable concrete mixes which is sometimes required when
placement is by pump or when the concrete is required to be worked
around congested reinforcing steel, it may be desirable to reduce the
estimated coarse aggregate content determined using Table 5 up to 10
percent. However, caution shall be exercised to assure that the resulting
slump, water-cement/cementitious materials ratio and strength properties
of concrete are consistent with the recommendations of IS 456 and meet
project specification requirements as applicable.
Combination of Different Coarse Aggregate Fractions
The coarse aggregate used shall conform to IS 383. Coarse aggregates
of different sizes may be combined in suitable proportions so as to
result in an overall grading conforming to Table 7 of IS 383 for
particular nominal maximum size of aggregate.

TABLE 3 OF IS 383
Estimation of Fine and Coarse Aggregate Contents
With the completion of procedure all the ingredients have been
estimated except the coarse and fine aggregate content. These quantities
are determined by finding out the absolute volume of cementitious
materials, water and the chemical admixture; by dividing their mass by
their respective specific gravity, multiplying by 1/1000 and subtracting
the result of their summation from unit volume (excluding the volume
of entrapped air). The values so obtained are divided into coarse and
fine aggregate fractions by volume in accordance with coarse aggregate
proportion already determined. The coarse and fine aggregate contents
are then determined by multiplying their volume with their respective
specific gravities and multiplying by 1000.
1.Estimation of coarse aggregate proportion
• Table -3 is for water cement ratio of 0.5, proportion may be suitably adjusted for
other water cement ratio.(@-or+.01 for every change in water cement ratio of .05)
• For given workability ,the volume of coarse aggregate depends upon its nominal
max size and grading zone of fine aggregate.
• Reduce the estimated CA content by 10% if pumping is to be done. It should be
consistent with IS 456
2.Estimation of Fine aggregate Proportion
• Find out the absolute volume of cementitious material, water and chemical
admixture by dividing their masses by their respective specific gravity and multiplying
by 1/1000.
• Subtract the result of summation above from unit volume. Find volume of total
aggregates
• Divide coarse and fine aggregate fractions by volume as per clause 4.4.
• Find CA and FA by multiplying their volumes with respective specific gravities and
multiplying by 1000.
Calculation of aggregate content (FA and CA)

where V = absolute volume of concrete

= gross volume (1m 3 ) minus the volume of entrapped air
S c = specific gravity of cement
W = Mass of water per cubic metre of concrete, kg
C = mass of cement per cubic metre of concrete, kg
p = ratio of fine aggregate to total aggregate by absolute volume
f a , C a = total masses of fine and coarse aggregates, per cubic metre of concrete,
respectively, kg, and
S fa , S ca = specific gravities of saturated surface dry fine and coarse aggregates,
respectively
ILLUSTRATIVE EXAMPLE ON CONCRETE MIX
PROPORTIONING USING IS 10262:2019
 STIPULATIONS FOR PROPORTIONING
a) Grade designation : M40
b) Type of cement : PPC conforming to IS 1489 (Part 1)
c) Maximum nominal size of aggregate : 20 mm
d) Minimum cement content and maximum water-cement ratio to be adopted
and/or : Severe (for reinforced concrete) Exposure conditions as per Table 3
and Table 5 of IS 456
e) Workability : 75 mm (slump)
f) Method of concrete placing : Chute (Non pumpable)
g) Degree of site control : Good
h) Type of aggregate : Crushed angular aggregate
j) Maximum cement content not including fly ash : 450 kg/m3
k) Chemical admixture type : Superplasticizer - normal
 TEST DATA FOR MATERIALS
a) Cement used : PPC conforming to IS 1489 (Part 1)
b) Specific gravity of cement : 2.88
c) Chemical admixture : Superplasticizer conforming to IS 9103
d) Specific gravity of
1) Coarse aggregate [at saturated surface dry : 2.74 (SSD)
Condition]
2) Fine aggregate [at saturated surface dry : 2.65 (SSD)
Condition]
3) Chemical admixture : 1.145
e) Water absorption
1) Coarse aggregate : 0.5 percent
2) Fine aggregate : 1.0 percent
f) Moisture content of aggregate [As per IS 2386 (Part 3)]
1) Coarse aggregate : Nil
2) Fine aggregate : Nil
g) Sieve analysis:
1) Coarse aggregate

2) Fine aggregate : Conforming to grading Zone II of Table 9

of IS 383
STEP 1: TARGET STRENGTH FOR MIX PROPORTIONING
f’ck=fck+1.65 S or f’ck = fck + X
whichever is higher.
where f’ck = target average compressive strength at 28 days,
fck = characteristic compressive strength at 28 days,
S = standard deviation, and
X = factor based on grade of concrete.
From Table 2, standard deviation, S = 5 N/mm2.
From Table 1, X = 6.5.
Therefore, target strength using both equations, that is,
a) f’ck = fck+1.65 S = 40+1.65 × 5 = 48.25 N/mm2
b) f’ck = fck + 6.5 = 40 + 6.5 = 46.5 N/mm2
The higher value is to be adopted.
Therefore, target strength will be 48.25 N/mm2 as 48.25 N/mm2 > 46.5 N/mm2.
STEP 2: APPROXIMATE AIR CONTENT
From Table 3, the approximate amount of entrapped air to be expected in
normal (non-air-entrained) concrete is 1.0 percent for 20 mm nominal maximum
size of aggregate.

STEP 3: SELECTION OF WATER-CEMENT RATIO

From Fig. 1, the free water-cement ratio required for the target strength of 48.25
N/mm2 is 0.36 for OPC 43 grade curve. (For PPC, the strength corresponding to
OPC 43 grade curve is assumed for the trial). This is lower than the maximum
value of 0.45 prescribed for ‘severe’ exposure for reinforced concrete as per
Table 5 of IS 456.
0.36< 0.45, hence O.K.
STEP 4: SELECTION OF WATER CONTENT
From Table 4, water content = 186 kg (for 50 mm slump) for 20 mm
aggregate. Estimated water content for 75 mm slump
= 186 + (3 *186/100)
= 191.58 kg
As superplasticizer is used, the water content may be reduced. Based on trial
data, the water content reduction of 23 percent is considered while using
superplasticizer at the rate 1.0 percent by weight of cement.
Hence the water content
= 191.58 × 0.77
= 148 kg
STEP 5: CALCULATION OF CEMENT CONTENT
Water-cement ratio = 0.36
Cement content
= 148 / 0.36
= 411.11 kg/m3
= 412 kg/m3
From Table 5 of IS 456, minimum cement content for ‘severe’
exposure condition = 320 kg/m3, 412 kg/m3> 320 kg/m3
hence, O.K
STEP 6: PROPORTION OF VOLUME OF COARSE AGGREGATE
AND FINE AGGREGETE CONTENT
From Table 5, the proportionate volume of coarse aggregate corresponding
to 20 mm size aggregate and fine aggregate (Zone II) for water-cement
ratio of 0.50 = 0.62. In the present case water-cement ratio is 0.36.
Therefore, volume of coarse aggregate is required to be increased to
decrease the fine aggregate content. As the water-cement ratio is lower by
0.14, the proportion of volume of coarse, aggregate is increased by 0.028
(at the rate of 0.01 for every ± 0.05 change in water cement ratio).
Therefore, corrected proportion of volume of coarse aggregate for the
water-cement ratio of 0.36 = 0.62 + 0.028 = 0.648.
Volume of fine aggregate content = 1 – 0.648 = 0.352
STEP 7: MIX CALCULATIONS
The mix calculations per unit volume of concrete shall be as follows:
a) Total volume = 1 m3
b) Volume of entrapped air in wet concrete = 0.01 m3
c) Volume of cement
= (Mass of cement * 1) / (Specific gravity of cement * 1000)
= (412 * 1) / (2.88 *1000)
= 0.143 m3
d) Volume of water
= (Mass of water * 1) / (Specific gravity of water * 1000)
= (148 * 1) / (1 * 1000)
= 0.148 m3
e) Volume of chemical admixture (superplasticizer) (@ 1.0 percent by mass of cementitious
material)
= (Mass of chemical admixture * 1) / (Specific gravity of admixture * 1000)
=(4.12 * 1) / (1.145 * 1000)
= 0.0036 m3
f) Volume of all in aggregate
= [(a-b)-(c+d+e)]
= (1-0.01)-(0.143 + 0.148 + 0.0036)
= 0.695 m3
g) Mass of coarse aggregate
= f × volume of coarse aggregate × Specific gravity of coarse aggregate × 1 000
= 0.695 × 0.648 × 2.74 × 1000
= 1233.98 kg
= 1234 kg
h) Mass of fine aggregate
= f × Volume of fine aggregate × Specific gravity of fine aggregate × 1 000
= 0.695 × 0.352 × 2.65 × 1 000
= 648.29kg =648 kg
MIX PROPORTIONS FOR TRIAL NUMBER 1

Cement = 412 kg/m3

Water = 148 kg/m3
Fine aggregate (SSD) = 648 kg/m3
Coarse aggregate (SSD) = 1234 kg/m3
Chemical admixture = 4.12 kg/m3
Free water-cementitious materials ratio = 0.36
ACI Mix Design
 ACI Mix Design
 The most common method used in North America is that established by ACI
Recommended Practice 211.1
 Any mix design procedure will provide a first approximation of the proportions
and must be checked by trial batches.
 Local characteristics in materials should be considered.
Water/cement ratio (w/c ratio) theory states that for a given combination of
materials and as long as workable consistency is obtained, the strength of concrete
at a given age depends on the w/c ratio.
 The lower the w/c ratio, the higher the concrete strength.
 Whereas strength depends on the w/c ratio, economy depends on the percentage
of aggregate present that would still give a workable mix.
 The aim of the designer should always be to get concrete mixtures of optimum
strength at minimum cement content and acceptable workability.
 Basic Considerations

 Economy -- The material costs are most important in determining

the relative costs of different mixes.
• The labour and equipment costs, except for special concretes, are
generally independent for the mix design.
• Since cement is more expensive than aggregate, it is clear that
cement content should be minimized.
• This can be accomplished by
1.using the lowest slump that will permit handling,
2. using a good ratio of coarse to fine aggregate, and
3. possible use of admixtures.
 Workability -- A good mix design must be capable of being placed and
compacted, with minimal bleeding and segregation, and be finish able.
• Water requirements depend on the aggregate rather than the cement
characteristics.
• Workability should be improved by redesigning the mortar faction
rather than simply adding more water.

 Strength and Durability -- In general, the minimum compressive

strength and a range of w/c ratios are specified for a given concrete
mix.
• Possible requirements for resistance to freeze-thaw and chemical
attack must be considered.
• Therefore, a balance or compromise must be made between strength
and workability.
 Mix Design Steps
1.Select the slump
2.Select the NMAS
3.Estimate the water and air contents
4.Adjust the water content for aggregate shape
5.Determine the required strength
6.Select the w/cm ratio
7.Calculate the cement weight
8.Estimate the coarse aggregate content
9.Calculate the fine aggregate content
10.Adjust for aggregate moisture and absorption
Step 1: Select the slump
The choice of slump determines the workability of the mix. Workability
encompasses a combination of PCC properties that are related to the
rheology of the concrete mix:
• Ease of mixing
• Ease of placing
• Ease of compacting
• Ease of finishing.
You should aim for the stiffest mix that will provide adequate placement.
The following tables how some typical slump ranges for several different
applications.
Step 2: Select the NMAS
The maximum aggregate size will affect parameters such as cement
paste content, workability and strength. In general, the maximum
aggregate size is limited by the dimensions of the finished product
and the room available inside the formwork, taking into account
things such as rebar. If the coarse aggregate is too large the concrete
may be difficult to consolidate and compact in the forms, resulting in
a honeycombed structure or large air pockets.
Step 3: Estimate the water and air
The amount of mixing water basically determines the amount of
cement paste in the mix. It depends on the desired slump, the size and
shape of the aggregate and the amount of air present in the mix. Some
air (called entrapped air) is normal and is a consequence of the
mixing process. Admixtures can also be used to introduce entrained
air in order to enhance the freeze/thaw durability of the concrete.
The table on the next slide recommends the amount of water per
cubic yard of concrete as a function of the desired slump and the
NMAS. The top half of the table is for non-air-entrained mixes and
includes an estimate of the amount of entrapped air in the concrete.
The bottom half is for air-entrained mixes. It includes target air
contents based on the expected severity of the freeze/thaw exposure.
Step 4: Adjust for Aggregate Shape
An often overlooked part of the table used to estimate the water content is
the passage at the bottom, which states that the estimates are based on an
assumption of reasonably well-shaped angular coarse aggregate. If you are
using a rounded aggregate such as gravel rather than an angular aggregate
such as crushed stone you need less water than is shown in the table. The
table in the next slide estimates the adjustments needed.
Step 5: Determine Required Strength
The required strength of the concrete mix is not the same as the design
strength. The design strength is the minimum strength that is required from
a structural standpoint. Since concrete strength can vary greatly from one
batch to the next, you need to build in a factor of safety to ensure that most,
if not all, of the concrete exceeds the design strength. If you don’t yet know
the variability, the table on the next slide estimates the overdesign you need
to build into the mix.
Step 6: Select the w/cm ratio
The water-cement ratio is correlated with strength and durability. In general,
lower water-cement ratios produce stronger, more durable concrete. If
natural pozzolans (such as flyash) are used then the ratio becomes a water-
cementitious material ratio.
The following table relates the required 28-day compressive strength
(including the over design factor) to the water-cement ratio for both non-air-
entrained and air-entrained concrete mixes.
Step 7: Calculate the cement content
Now that we know the amount of water in the mix and the
required w/cm ratio, we can calculate the amount of cement
we need in the mix:
Step 8: Estimate coarse aggregate
Selection of coarse aggregate content is empirically based on mixture
workability. The following table estimates the volume percentage of
coarse aggregate (based on bulk volume) needed to produce concrete
with a proper degree of workability for reinforced concrete construction.
For things like pavement slabs that don’t require as much workability,
ACI allows the values to be increased by upto 10 percent.
The values in the table are called the b/bo factor. In a nut shell, it tells
you how big a box you would need to build to exactly contain all of the
coarse aggregate in your mix (including all of the void spaces between
the aggregate particles). As shown in the next slide, if you are trying to
make a volume of concrete with dimensions 1×1×bo you’d need to build
a box with dimensions 1×1×b to hold all the coarse aggregate.
The b/bo factors are a function of the NMAS of the coarse aggregate
and the fineness modulus of the fine aggregate. The larger the
aggregate, the less cement paste is needed to coat the surface area, so
the more room there is for coarse aggregate. Also, as the fineness
modulus of the sand increases it becomes coarser and the blend of
coarse and fine aggregate becomes less gap-graded. As a result you
need slightly more sand and less gravel in the mix.
Once you know how large your virtual box needs to be, you can
calculate the weight of coarse aggregate needed to fill that box by
multiplying the volume of the box by the dry-rodded unit weight of
the coarse aggregate.
Step 9: Estimate fine aggregate
ACI provides two different methods to estimate the amount of fine
aggregate needed. The first method, the estimated weight method, uses
typical values for the unit weight of concrete mixes to determine how
much the concrete should weigh once it’s mixed. Once estimated the
weight of all the other ingredients, what ever is still missing must be
that of the sand.
The estimated weight method is very approximate because it’s based
on “typical” unit weights. A more precise method is the absolute
volume method, which determines the volume occupied by each
ingredient based on its bulk specific gravity (this is what is meant by
the absolute volume) then subtracts those from 27ft3 (1yd3) to get
the required volume of the sand. Since the entrapped or entrained air
occupies some of that volume, it needs to be included, too.
In this approach, we use the bulk specific gravities of the aggregate to
determine their absolute volumes because all of the water in the mix is
supposed to be in the cement paste and not in the pervious pores of
the aggregate. We will later add some water to the mix to ensure the
aggregate is SSD and doesn’t try to absorb water from the cement
paste.
Step 10: Adjust for Moisture Content
The final step in the mix design (whether we used the absolute volume
or estimated weight method) is to
(1) add additional water to the mix to make sure the aggregate is
saturated and doesn’t absorb water from the cement paste,
(2) adjust the weights of the aggregate and the mixing water to account
for the fact that the aggregate stock piles at the batch plant will not be
oven-dry.
1.Increase W by an amount equal to the weight of water needed to
water

saturate the fine and coarse aggregate.

2.Increase W and Wgravel to account for the current moisture contents
sand

of the aggregate in the batch plant stockpiles.

3.Decrease Wwater by the same amount you increased Wsand and Wgravel.
ILLUSTRATIVE EXAMPLE ON CONCRETE MIX
PROPORTIONING USING ACI METHOD
Concrete is required for an exterior column located above ground
where substantial freezing and thawing may occur. The 28-day
compressive strength should be 5,000 lb./in2. The slump should be
between 1 and 2 in. and the maximum aggregate size should not
exceed ¾ in. The properties of the materials are as follows:
 Cement : Type I, specific gravity = 3.15
 Coarse Aggregate: Bulk specific gravity (SSD) = 2.70;
absorption capacity = 1%; dry-rodded unit weight = 100 lb./ft.3;
surface moisture = 0%
 Fine Aggregate: Bulk specific gravity (SSD) = 2.65; absorption
capacity = 1.3%; fineness modulus = 2.70; surface moisture = 3%
Step 1. Required material information (already given).
Step 2. Choice of slump. The slump is given, consistent with
Table 1.

Step 3. Maximum aggregate size. Given: ¾ inches

Step 4. Estimation of mixing water and air content. Since freezing and
thawing is important, the concrete must be air entrained.

From Table 2, the recommended air content is 6%; the water

requirement is 280 lb./yd3.
Step 5. Water/cement ratio.
From Table3, the estimate for required w/c ratio to give a 28-day
strength of 5,000 psi.
Step 6. Calculation of cement content.
Based on steps 4 and 5, the required cement content is:
Step 7. Estimation of coarse aggregate content.
Interpolating Table 4 for the fineness modulus of the fine aggregate
of 2.70
The coarse aggregate will occupy:

The OD weight of the coarse aggregate

Step 8. Estimation of fine aggregate content by the absolute
volume method.
 Water: (280 lb)/(62.4 lb./ft3) = 4.49 ft3
 Cement: (700 lb)/(3.15 x 62.4 lb./ft3) = 3.56 ft.3
 Coarse Aggregate: (1,701 lb)/(2.70 x 62.4 lb./ft3) = 10.10 ft.3
 Air: 6% x 27ft3/yd3 = 1.62 ft.3
Total = 19.77 ft.3
Therefore, the fine aggregate must occupy a volume of:

The SSD weight of the fine aggregate is

Therefore, the fine aggregate must occupy a volume of:

The OD weight of the fine aggregate is:

Step 9. Adjustment for moisture in the aggregate.
 Since the moisture level of the fine aggregate in our storage bins
can vary, we will apply a simple rule to adjust the water required.
 Decrease the amount of water required by surface moisture
content of the weight of the fine aggregate
 Increase the amount of aggregate by the amount equal to the
surface moisture.

The weight of aggregate from the stock pile is:

The change in the weight water due to the moisture of the aggregate
from the stock pile is:

Fine aggregate required from the stockpile is:

Coarse aggregate required from the stockpile is:

The required mixing water required is:
Thus the estimated batch weights per yd.3 are:
Water = 244 lb.
Cement = 700 lb.
Coarse aggregate = 1,718 lb.
Fine aggregate (wet) = 1,247 lb.
Total = 3,909 lb./yd.3
= 144.8 lb./ft.3
COMPARISION BETWEEN IS METHOD
AND ACI METHOD WITH EXAMPLE
Mix Proportions

A total of five mix proportions were prepared and tested. The

first one (M1) was according to ACI code, second (M2) was ACI
with super-plasticizer addition, third one (M3) was according to
IS code, fourth (M4) was according to IS code with super-
plasticizer addition and keeping the W/C ratio same as in the
original IS code mix proportions(M3)and the fifth (M5) was IS
code with super-plasticizer addition. The weight of constituents
per cubic meter used are given in Table
 Weight of constituents per cubic meter of concrete

Mix Descriptio Mix Proportions

Names n
Water Cement FA CA SP

M1 ACI 185.000 393.882 870.479 966.240  -

M2 ACI + SP 166.500 393.882 870.479 966.240 3.939

M3 IS 188.790 377.009 688.885 1146.027  -

M4 IS + SP 184.911 369.263 566.322 1286.858 3.693

(W/C
same)

M5 IS + SP 169.911 377.009 688.885 1146.027 3.770

 Methodology

• All the selected materials were collected and checked for any discrepancies.
Cement is checked for lumps, aggregates for moisture content.

• After the quality of materials is approved, each material is weighed for

material required for 12 cubes according to the design mix.

• Aggregates and cement are weighed on a scale having precision up to 100

grams and water and plasticizer are weighed on a scale having precision up
to 0.1 grams.
• If superplasticizer is to be added to the mix, then it was taken in the required
quantity and added in water and mixed thoroughly.
 The aggregates are taken and put into batch mix plant and are mixed with the
mouth of mixer covered to prevent loss of material.

 After that, cement was also added to the mixer and water is gradually added
and simultaneously the mass is thoroughly mixed for 2 minutes.

 Then the concrete mass is poured into the concrete tray. Slump/workability of
concrete is checked using slump cone test.

 The cube moulds are oiled to prevent sticking of concrete and ensuring a
smooth surface. Concrete is then poured into the moulds.

 After one day, the moulds are opened and the cubes are placed in water pond
for curing till they are tested.
Results and Discussion
Compressive Strength

The compressive strength achieved after 7 days, 28 days were recorded

and are shown in Table. The same results have been graphically
represented with bar charts in figure
 Table : compressive strength in MPa with various codes

Test Results

(All the test values are in MPa.)

Mix /result M1 M2 M3 M4 M5

  ACI ACI+SP IS IS+SP (W/C same) IS+SP

7days  

1 18.57 34.77 19.23 27.02 34.16

2 18.37 36.31 21.4 21.49 35.6

3 22.45 35.56 18.59 18.04 37.41

Average 19.80 35.55 19.74 22.18 35.72

28Days  

1 31.92 38.18 28.57 26.2 40.49

2 33.56 37.68 30.88 31.49 37.09

3 34.97 36.35 29.43 29.26 38.57

Average 33.48 37.40 29.63 28.98 38.72

 Graphical Representation of Compressive Strength with age
Concrete has achieved its actual strength at the age of 28 days of casting. For M30, the target to be
achieved within 7 days was taken to be 20 MPa and within 28 days is taken to be 30 MPa.

With the use of super-plasticizers, the strength is achieved earlier as compared to mix design not
using Super-Plasticizers. Thus, the target was taken to be 25 MPa for 7 days and 35 MPa for 28
days.
Figure shows the comparison of the compressive strength results
achieved with their respective targets. While M1 and M3
achieved the target strengths, M4 struggled to keep up with the
target which gives a clear indication that presence of too much
water content with plasticizer has an adverse effect on the results.
Meanwhile, M2 and M5 showed satisfactory compressive
strengths that too in early stages of tests advocating the use of
super-plasticizers and clearly showing the benefits.
Cost Analysis

A cost analysis was done for all the five mix proportions and an excel
program was made to compare the costs. The basic costs were taken from
the DAR Civil (Delhi) 2016 for cement, coarse aggregates and sand. For
super plasticizer, the cost incurred for buying the specific brand was
taken. Table 1 shows the costs of constituents of concrete. Table 2 shows
the cost of the mix designs per cubic meter of concrete. Figure gives the
graphical representation of costs of mix design of table 2.
 Figure : Graphical Representation of cost Analysis

 
 Table 1: Cost of Materials

Material Cost Quantity Unit Cost of 1kg(INR)

Cement 5700 100 kg 5.70

FA 1200 1 m3 3.36

CA 1300 1 m3 3.53

Super Plasticizer 1200 20 kg 60.00

 Table 2: Cost of Mix Designs

Design mix Cements FA CA SP Cost for 1m3(INR)

M1(ACI) 393.882 870.479 966.240   8496.09

M2(ACI+SP) 393.882 870.479 966.240 3.939 8732.42

M3(IS) 377.009 688.885 1146.027   8442.87

M4(IS+SP W/C same) 369.263 870.479 1286.858 3.693 9709.78

M5(IS+SP) 377.009 688.885 1146.027 3.770 8669.08

It is clear from the analysis that M4 design costs the most followed
by M2, M5, M1 and M3. Two more mix proportions of IS mix
design for M35 (water: 188.790, Cement: 416. 803, FA: 658.789,
CA: 1141.730) and ACI mix design for M35 (water: 185.000,
Cement: 462.040, FA: 810.448, CA: 966.240) were taken to
compare with M5 and M2 and checking their adequacy. The cost
of the ACI mix proportion for M35 per cubic meter is INR
8688.87 and cost for IS mix proportion for M35 is INR8556.40.
According to test results, M4 is highly undesirable for high costs
and less strength.
When the mix proportions without super-plasticizers are compared
ACI (M1) gives better results than IS (M3) mix proportion with a
very small compromise on cost. Thus, ACI should be preferred for
mix design without plasticizer.

While ACI (M2) mix design with super-plasticizer has more cost
than the IS(M5) mix design with super-plasticizer, the IS mix
design showed better results both at the age of 7 days and 28 days
which gives IS mix design a clear edge over the ACI mix design for
both economy and test results.
Now, ACI and IS mix designs for M35 which will give
approximately same strength are compared to M30 mix designs
with super-plasticizer. Though the ACI M35 and IS M35 are more
cost-effective than M2 and M5 respectively, it is anticipated that
they will gain strength later than M2 and M5, thus increasing the
time of construction, but if the time of construction is not
necessary than ACI M35 and IS M35 should be preferred.
Between ACI M35 and IS M35, ACI M35 should be chosen as
ACI mix designs give better results without super-plasticizer.

If the speed of construction is important then IS mix design with

super-plasticizer should be chosen for better economy and results.
 Conclusion

1. ACI mix design gives better results without super-plasticizers with a small compromise on cost.

2. IS mix design gives better results with PCE based super-plasticizers and gives better results and is also better
economically.

3. Maintaining the same water to cement ratio while using super-plasticizers can lead to poor results as the
super-plasticizers are meant to reduce water content and increase workability. Thus, the mix design with same
water to cement ratio as the initial design using IS mix design failed to show satisfactory results.

4. Water content has a direct relationship with time of setting and strength gained at age of 7 days (initial
strength). Less is the water content, more is the initial strength and satisfactory workability can be attained
with the help of super-plasticizer.

5. PCE based super-plasticizers are a practical choice for gaining more initial strength and speeding up the
construction but are costlier than the counterparts of more design strengths that provide comparable strength
at later stages such as at the age of 28 days.
THANK YOU