ANKARA - TURKIYE

NEW CONCRETE MIX DESIGN APPROACH

Prof – Hakim S. Abdelgadera *, Prof –Jamal M. Khatibb and Dr – Ali [Link]-Badenc
a*
University of Tripoli, Faculty of Engineering, Department of Civil Engineering, Tripoli, Libya, hakimsa@[Link]
b
Faculty of Science and Engineering, University of Wolverhampton, Wulfruna Street,
Wolverhampton, WV1 1LY, [Link]@[Link]
c
University of Tripoli, Faculty of Engineering, Department of Civil Engineering, Tripoli, Libya, elbadenpool@[Link]

Abstract them. Therefore, obtaining a concrete with certain properties

depends fundamentally on the concrete mix design. Generally,
Design of concrete mixes may be defined as a process of selecting
concrete mix design includes two main steps: 1-Selection
suitable ingredients of concrete and determine their relative
of the main components suitable for the concrete (cement,
quantities. The selection of concrete ingredients involves a 367
aggregate, water, and additives); 2-Determination of more
balance between economy and performance. Currently, there
economical mix ratios to fulfill performance and efficiency
are many international methods approved world-wide for mix
requirements. Currently, there are many international methods
designs, such as: the American Concrete Institute (ACI) method
locally approved for mix designs such as American concrete
and the British Standard (BS) method. These methods depend
institute (ACI) and British Standard (BS) methods. They are
on certain equations and graphs based on mathematical
all related to each other, they give relatively comparable
analysis of results obtained from previous field experience (are
quantities of the mix components and they are all capable of
they not empirical?? For some of them). In general, mix design
providing a good concrete mix [1,2]. It is important to consider
methods give some indication to the designer to validate and
that these methods give approximate quantities which should
adjust the mix constituents via experimental mixes in the
be checked by experimental mixes in order to obtain results
local laboratories in order to check the variables related to
suitable for the requirements of both the local environment
the characteristics and properties of the local materials and
and materials. Along with the aforementioned methods, there
the surrounding environment conditions. This paper illustrates
are many other methods used for concrete mix design, such as:
a new approach for concrete mix design named as:“Double
1- The Three Equations Method (Bolomeya Method); 2- Double
Coating Method”, which is currently used in some research
coating method. Three equations method had been presented
centres in the republic of Poland and was recently applied in
and published by the authors [3]. The double coating method
the laboratories of the Civil Engineering Department in the
and assessment of concrete mixes results produced by this
University of Tripoli in Libya. Results obtained by this method
method will be illustrated in this paper.
and the ACI approach, using the local materials subject to local
environmental conditions are presented and discussed. 2. General Philosophy of Double Coating

Keywords: Double coating method, Concrete mix design, The philosophy of concrete mix design using the double coating
Concrete is method based mainly on calculating the weights of the main
ingredients of concrete that occupies a volume of one liter of
1. Introduction
water taking in consideration the following two assumptions:
Fresh or hardened concrete behavior depends basically on the
(a)-The spaces between fine aggregate particles assumed
characteristics of its components and the relationship between
as Rf. This space actually represents the diameter between
 2nd International Sustainable Buildings Symposium

sand particles which will be filled withthe cement paste, as aggregate (Mf and Mg) can be calculated using standard
illustrated in Figure 1. tables as shown in Tables 1 and Table 2.

(b)- The spaces between coarse aggregate particles assumed Table 1. Expansion indicators of fine aggregate
as Rg. This space actually represents the diameter between
Diameter between fine aggregate particles
coarse aggregate particles which will be filled by cement Sieve size
(Rf), (μm)
mortar (mixture of cement and sand), as illustrated in Figure 2.
(mm) 20 30 40 50 60 70

2/1 1.03 1.06 1.08 1.1 1.12 1.15

1/0.5 1.09 1.12 1.17 1.21 1.26 1.31

0.5/0.25 1.16 1.26 1.36 1.45 1.56 1.67

0.25/0.125 1.37 1.56 1.79 2.03 2.3 2.59

Figure 1. Model of fine aggregate particles spacing Table 2. Expansion indicators of coarse aggregate

Rg Sieve size , (mm)

(mm) 63/32 32/16 16/8 8/4
0.25 1.02 1.03 1.06 1.13
0.5 1.03 1.06 1.13 1.27
0.75 1.04 1.09 1.19 1.37
1 1.05 1.13 1.27 1.6
1.5 1.09 1.2 1.42 1.95
Figure 2. Model of coarse aggregate particles spacing
2 1.12 1.27 1.59 2.37
368 The diameters (Rf & Rg) which represent the spaces between
2.5 1.17 1.35 1.76 2.85
aggregate particles, will be assumed either using previous
3 1.27 1.44 1.95 3.36
experience in the the subject or using tables given by standards
as explained later in this paper. The spaces between aggregate c. Absorbed water by fine aggregate (Wf), coarse aggregate
particles play an important role to know and control the (Wg) and cement (Wc) will be calculated knowing: a)- the
weights of cement and sand that fill those spaces. Quality aggregated particles-gradation ;b)- the degree of concrete
control investigations for concrete ingredients should be workability and c)- the expansion indicators of aggregate
carried out to find accurately some of their mechanical and (Mf and Mg). Table 3 shows values of water absorbed per
physical characteristics according to the specifications. For kilogram of cement and aggregate.
example, properties such as: unit-weight, specific gravity and
d. Weights of concrete ingredients calculated using equations
gradations are very important in this method. Assumption
as explained in the following sections.
or selection of diameters between fine aggregate particles
depends mainly on the cement type, strength and fineness. 3.1. Weight of Coarse Aggregate
The common range of Rf is considered to be between: 30 to
The weight of coarse aggregate G in Kg was calculated as
70 micrometer (µm). Assumption or selection of diameters
follows:
between coarse aggregate particles depends mainly on the
sand type, cross section, reinforcement quantity and the G= [ϒg/ (Mg)] (1)
reinforcement distribution in the section. The common range Where: ϒg is the unit weight of coarse aggregate in terms of
of Rg is considered to be between: 0.25 to 3 millimeter (mm). either weight per liter (Kg/l) or weight per cubic decimetre (Kg/
(reference!!) dm3) and Mg is the expansion indicator of the coarse aggregate.
3. Design Steps Summary 3.2. Weight of Fine Aggregate
a. Both Rf and Rg should be assumed within the acceptable The weight of fine aggregate f was calculated as follows:
range as previously indicated.
f= [ϒf/ Mf] * Z (2)
b. Knowing the aggregate particles gradation (Sieve analysis),
Z= [1 - G/ (ρg)] (3)
the swelling or expansion indicators for both fine and coarse
 28 - 30th May 2015 | Ankara - TURKIYE

Where: Z is the volume of mortar in (dm3), ρg is the specific Table 4. Values of coefficients A1 and A2
gravity of coarse aggregate, ϒf is the unit weight of fine
Variables Compressive strength of
aggregate in terms of either weight per liter (Kg/l) or weight Aggregate
of A cement (MPa)
per cubic decimetre (Kg/dm3)and f is the fine aggregate weight. Shape   32.5 42.5 52.5
3.3. Weight of Cement A1 18 20 21
Round
A2 12 13 14.5
The weight of cement C was calculated as follows:
A1 20 22 24
Angular
Z0= 1- [ (G/ ρg) - (f/ ρf) ] (4) A2 13.5 14.5 16

C = [ (Z0) – (G*Wg) – (f * Wf) ] / [Wc + (1/ ρc)] (5) 3.7. Calculation of required strength (fc`req)

Where: Z0 is the volume of cement paste in (kep in cm may fc` (lab.) = 1.3 * [fc` (req.)] (9)
bedm3), C is the weight of cement in (Kg), ρc is the specific gravity
Where: fc` in units of MPa.
of cement, and Wc, Wg, and Wf are the weights of absorbed
water by cement, coarse and fine aggregate respectively. 4. The Experimental Program

3.4. Weight of Water 4.1. Materials Used

The weight of water W was calculated as follows: The cement used was ordinary Portland cement having a 28-
days compressive strength of 46.8 MPa and Blaine fineness of
W = C* Wc + G * Wg + f * Wf (6)
approximately 3178 cm2/g. Cement properties confirmed with
of water in (Kg), and Wc, Wg, and Wf are the weights of absorbed British standards [5].
water by cement, coarse and fine aggregate respectively.
The coarse aggregate used was angular aggregate with
3.5. Total Volume maximum size of 19 mm, it was imported from a local quarry
(nearly 45 km south of Tripoli city). Tests are carried out
V= (C/ ρc) + (G/ ρg) + (f/ ρf ) + W =1 (7)
to check the aggregate specifications according to the BS
Where: C is the total volume of concrete components. 882-1992 standards [6]. Table 5 demonstrates some of its
3.6. Calculation of Required Strength (fc`req) mechanical and physical characteristics.
369
After the weights of mix ingredients have been calculated per Table 5. Physical properties of Coarse Aggregate
liter then will be magnified for one cubic meter. The design British Standards limits
compressive strength (fc`req.) will calculated using the first Property name The result
(BS 882-1992)
equation of the three equation method [3,4] using one of the
following equations: Specific gravity 2.64 2.4-2.8

C/W=[(fc`/A1)+0.5] if (C/W) < 2.5 (8 –a) Absorption 1.21 3%

Unit weight 1559 1400-1800 Kg/m3
C/W=[(fc`/A1)-0.5] if (C/W) ≥ 2.5 (8 –b)
Impact value 17.21% ≤ 45
Values for A1 and A2 are given in Table 4.
Crushing value 4.82% ≤ 45
Table 3. Water absorbed by aggregate and cement
Sieve Size Degree of workability Natural, fine aggregate that was used in the mixture was natural
Very Very
(mm) low Med. high beach sand from the zliten quarry (nearly 200 km east of Tripoli
Low High
city). The sand used has grain size not exceeding 2 mm, specific
63/32 0.008 0.011 0.013 0.015 0.016
gravity of 2.68 and a unit weight of 1412 Kg/m3. Tests were
32/16 0.011 0.014 0.016 0.018 0.022
carried out according to the BS 882-1992 standards [6].
16/8 0.013 0.017 0.02 0.023 0.027
8/4 0.017 0.022 0.026 0.029 0.034 Fresh, dirt-free water is used, with a percentage of total
4/2 0.022 0.028 0.032 0.037 0.044 dissolved salts not exceeding 2,000 particles per million as per
2/1 0.029 0.037 0.043 0.048 0.058 Libyan Standards [7].
1/0.5 0.039 0.05 0.058 0.065 0.077
0.5/0.25 0.056 0.072 0.084 0.095 0.112 4.2. Mix Proportions
0.25/0.125 0.082 0.104 0.122 0.137 0.151 The calculations of mix proportions of the materials used in this
0.125/0 0.16 0.205 0.239 0.255 0.296 research were performed in accordance to the steps explained
0.5/0 0.098 0.127 0.148 0.168 0.198
earlier in this paper (See section). Table 6 represents sample
0.25/0 0.124 0.16 0.186 0.211 0.248
of calculation of water absorbed by fine aggregate (Wf) for
W(cement) 0.23 0.25 0.27 0.29 0.31
 2nd International Sustainable Buildings Symposium

medium workability using the diameter between fine aggregate period 28 days specimen removed from curing tank and screed
grains (Rf) as 30 μm. Knowing that the specific gravity and the off the all face of specimen and taken for testing.
unit weight were 2.68 and 1560 Kg/m3 respectively. Table 7
4.5. Laboratory Investigations
represents sample of calculation of water absorbed by coarse
aggregate (Wg) for medium workability using the diameter Slump test is used to determine the degree of workability
between fine aggregate grains (Rg) as 0.5 mm. Knowing that of the concrete mix in order to watch the consistency of the
the specific gravity and the unit weight were 2.64 and 1410 Kg/ concrete and check the design workability according to the
m3 respectively. Table 8 shows sample of weights of the mixes British Standards BS 1881-Part 102 [8]. Table 9 shows sample
components targeted in this research. of results obtained through this research.

The fresh concrete density (ρlab) calculated after the concrete

4.3. Mixing Procedures
mixing process completed and before casting the moulds
All Concrete batches were prepared in a rotating drum mixer as described by the British Standards BS 1881-Part 107 [9].
having a capacity of 0.05 m3. First, the aggregates and cement Theoretically the concrete density calculated by summing the
are introduced and mixed on dry condition for not less than 2 ingredients of each mix per cubic meter. By knowing the density
minutes to ensure the homogeneity of the blend. Mixing water the voids percentage could be found as previous described by
in a clean container introduced to the mixer slowly. Mixing the specifications [9]. Sample of results obtained through this
continues for three minutes and then stopped for one minute research is presented in Table 9.
for absorption then the mixing resumed and continues for other
Compressive strength test conducted to determine the
2 minutes. maximum compressive strength of the hardened concrete
4.4. Test specimens and curing subject to compressive stresses. It is carried out by putting the
samples under a compression on the centerline of the concrete
Standard cubes of size 150*150*150 mm are used to investigate
samples used. The load is increased gradually up to failure.
the compressive strength, density and voids percentage. A total
The compressive strength is calculated as the mean of three
of 72 samples were casted out of all mixes. After conducting samples per each mix as shown in Table 9. The test is conducted
the slump test as a workability characteristics experiment, the according to the requirements of the British Standards BS
concrete mix was poured in the moulds required for assessment. 1881-Part 116 [10]. A graphical presentation of compressive
370 After 24 hours of casting the specimens were demoulded and strength results after 28 days of curing are demonstrated in
were transferred to the curing water tanks. After the curing Figures 3 and 4.

Table 6. Sample of calculation of water absorbed by fine aggregate

Sieve Aggregate Aggregate Absorption water Expansion

size passing retained indicator quantity Indicator Quantity
(mm) % % (L/Kg) l (L/Kg) l
2.36 100 0        
1.18 100 0.64 0.043 0.02752 1.06 0.6784
0.6 99.36 67.56 0.058 3.91848 1.12 75.6672
0.3 31.8 26.76 0.084 2.24784 1.26 33.7176
0.15 5.04 5.04 0.122 0.61488 1.56 7.8624
    100   6.80872   117.9256
Mf= 0.0680872 Wf= 1.179256
Table 7. Sample of calculation of water absorbed by coarse aggregate

Sieve Aggregate Aggregate Absorption water Expansion

size passing retained indicator quantity Indicator Quantity
(mm) % % (L/Kg) l (L/Kg) l
37.5 100 0        
19 100 47.86 0.016 0.76576 1.06 50.7316
14 52.14 47.24 0.02 0.9448 1.13 53.3812
10 4.9 4.9 0.026 0.1274 1.27 6.223
    100   1.83796   110.3358
Mg= 0.0183796 Wg= 1.103358
 28 - 30th May 2015 | Ankara - TURKIYE

80
Rg= 0.5
Rf= 30 Rg= 1
Rg= 1.5
Rg= 3
60
fc` (MPa)

40

20
0.4 0.45 0.5 0.55 0.6 0.65 0.7
W/C

Figure 3. Compressive strength results at (Rf=30μm) Figure 4. Compressive strength results at (Rf=50μm)
Table 8. Sample of mix proportions
Required Design Degree
Components weight ( Kg/m3)
strength strength of
Rg Rf W/C coarse
R(req) workability cement water fine Agg.
Agg.
(MPa) (MPa)   C W G f
28 37 0.5 0.47 335 158 1462 482
30 39 1 0.46 371 170 1362 523
30
31 40 1.5 0.45 401 179 1275 558
32 42 3 0.43 483 206 1041 654
Medium
33 43 0.5 0.42 394 167 1462 408
34 44 1 0.41 433 179 1362 443
50
35 45 1.5 0.4 468 190 1275 473
36 47 3 0.39 560 218 1041 555 371
19 25 0.5 0.63 278 176 1462 482
20 26 1 0.61 311 189 1362 523
30
21 27 1.5 0.59 339 200 1275 558
23 29 3 0.56 413 229 1041 654
Very high
23 30 0.5 0.55 336 185 1462 408
24 32 1 0.53 373 199 1362 443
50
25 33 1.5 0.52 405 210 1275 473
27 35 3 0.49 490 241 1041 555
Table 9. Sample of experimental results

Required Design Degree Experimental results

fresh Compressive
strength strength of Dry density Voids Slump
Rg Rf density strength
R(req) workability ρ(lab) ρ. fc`
W/C
MPa) MPa Kg/m3 Kg/m3 MPa % mm
28 37 0.5 0.47 2434.8 2434.1 60.61 0.09 0
30 39 1 0.46 2420.6 2418.1 58.07 0.22 10
30
31 40 1.5 0.45 2417.4 2414.9 57.92 0.18 15
32 42 3 0.43 2414.8 2412.3 55.13 1.29 40
medium
33 43 0.5 0.42 2444.0 2411.5 64.29 0.53 0
34 44 1 0.41 2434.5 2430.4 63.10 0.70 10
50
35 45 1.5 0.4 2430.1 2426.2 61.56 1.00 15
36 47 3 0.39 2370.4 2349.6 57.77 0.15 50
19 25 0.5 0.63 2430.6 2428.1 45.30 1.36 0
20 26 1 0.61 2412.3 2406.4 43.20 1.14 20
30
21 27 1.5 0.59 2405.9 2404.4 42.40 1.43 60
23 29 3 0.56 2350.1 2396.6 41.80 0.50 230
very high
23 30 0.5 0.55 2433.6 2429.6 49.90 1.78 0
24 32 1 0.53 2410.0 2408.4 48.40 1.39 20
50
25 33 1.5 0.52 2403.5 2400.0 44.00 1.69 65
27 35 3 0.49 2363.0 2356.0 43.70 1.54 210
 2nd International Sustainable Buildings Symposium

5. Discussion

The results obtained from the concrete mix components and

quality control tests show that:

1. The results of the slump test are relatively reduced in

each degree of workability specifically when the diameter
between coarse aggregate particles (Rg) reduced to a
value less than 1.5 mm.

2. This method efficiently meets the compressive strength

requirements.

6. Conclusions and Recommendations

• This method is considered as an added value to the

concrete mix design methods due to the following
advantages:

• Introducing of the effect of spaces between aggregate

particles in the design process;

• Introducing of the effect of water demand by cement.

• Introducing of the effect of water demand by fine and

coarse aggregate as well as the grading in the design.

• In order to make this method more efficient, it is

recommended to carry out more researches to know the
quantities of water demand by the cement and aggregate
for the local raw materials similar to those used in this
372 method.

• It is recommended to carry out more researches to

investigate other concrete properties such as: shrinkage,
creep ……etc.

7. References
[1]. [1]. Neville, A.M., “Properties of concrete”, 3rd Edn Pitman Books
Limited, London, (1981).
[2]. [2]. Neville, A.M. and Brooks, J.J., “Concrete Technology”, 1st Edn
Longman Scientific and Technical, London, (1987).
[3]. [3]. Abdelgader, H.S., Saud A.F. and El-Baden A.S. “ Three equation
method for normal concrete mix design” Study of Civil Engineering and
Architecture (SCEA). 2 (4) 109-113, (2013).
[4]. [4]. Jamrozy, Z. ` Beton I Jego Technologie`, PWN,. (In Polish),
Warszawa (2008)
[5]. [5]. British Standard Institution, BS 12, “Ordinary and rapid-
hardening Portland cements”, BSI, London, (1991).
[6]. [6]. British Standard Institution: BS 882, “Testing aggregates:
specification for aggregate from natural sources for concrete”, BSI,
London, (1992).
[7]. [7]. British Standard Institution: BS 882, “ Water for making
concrete”, BSI, London, (1985).
[8]. [8]. British Standard Institution: BS 1881-part 102, “Method of
determination of slump”, BSI, London, (1992).
[9]. [9]. British Standard Institution: BS 1881-part 107, “Method of
determination of density of compacted fresh concrete”, BSI, London,
(1992).
[10]. [10].British Standard Institution: BS 1881-part 116, “Method of
determination compressive strength of concrete cubes”, BSI, London,
(1992).