Design of Concrete Mix

1
The basic procedure for mix design is applicable
to concrete for most purposes
including pavements.
• Concrete mixes should meet;

Workability Compressive Durability

(slump/Vebe) strength (w/c ratio)

2
 The workability of concrete
Measurement of workability

• A workable concrete is defined as a concrete

suitable for placing and compacting under
the site conditions.

• Slump and Vebe time tests will be used

(see Table 3).

3
 Water content

• The water content expressed as mass per

unit volume of concrete.
• It is the major factor influencing the
workability of concrete.
• Uncrushed aggregates require a lower
water content than crushed aggregates to
make concrete of equal workability.
• The smaller the maximum size of the aggregate
the higher the water content needed.
4
 Water content

• Table 3 gives typical values of the free-water

content for use in the mix design at four
different levels of slump or Vebe time, with
different types and maximum sizes of aggregate.

• Figure 6 shows how the fines content of the

mix should be reduced as the sand becomes
finer, ie as the percentage passing the 600 µm
test sieve increases.

5
 Type and strength class of cement

• Different types and strength classes of

cement have different water requirements to
produce pastes of standard consistence.

6
 The compressive strength of concrete
Age at test and curing conditions

• The strength is specified at an age of 28 days.

• The strength development depends on the temperature
and humidity conditions during curing.
• Higher temperatures increase the speed of the chemical
reaction and thus the rate of strength development.
• In order to achieve higher strengths at later ages loss of
water from the concrete must be prevented (CURING).
• Concrete test specimens are stored in water at a
constant temperature as specified in standards.

7
 Type and strength class of cement

• Class 52.5 Portland cements initially proceeds at a

faster rate than in class 42.5 Portland cements; the
effect of this on typical concretes having a free-
water/cement ratio of 0.5 is shown in Table 2.
• Information available related to local materials
can be used instead of the values given in Table 2.

8
 Cement strength variation

• This is due to the variability of cement supplied

from different works and to normal variations
in production from any one works over a period
of time.
• Standard deviation (s) of the strength of concrete
cubes at 28 days made with Portland cement class
42.5 from different works is about 5 N/mm2.
• The standard deviation due to the variability of
the cement from a single work is about 3 N/mm2.
9
 Aggregate type and grading

• The type and source of the aggregate has a considerable influence on

the compressive strength of concrete.
• Uncrushed coarse aggregate makes a concrete with a lower strength
than one with crushed coarse aggregate.
• Factors such as
– the type of fine aggregate,
– the maximum size of aggregate,
– the overall grading, and
– particle shape and surface texture,
have little direct effect on the compressive strength.

• Typical strength values when uncrushed or crushed coarse aggregates

are used are given in Table 2.

10
 Relationship between compressive strength and free-
water/cement ratio

• Figure 4 shows the the relationship between the compressive strength

and the free-water/ cement ratio.
• Table 2 gives typical data for a concrete having a free water/ cement
ratio of 0.5 to give a datum point on Figure 4 appropriate to the age of
test and materials to be used.
• The strength development shown in Table 2 applies to a concrete with
a cement content of about 300 kg/m3 cured in water at 20°C. Such a mix
made with Portland cement class 42.5 has a 7-day strength about 70%
of that attained at 28 days.
• Richer mixes initially gain strength more rapidly so that 7-day strength
may well exceed 75% of the 28-day strength.

11
 Type of mixing

• Certain types of mixes require a higher

degree of workability for efficient operation.

• Hand-mixing is likely to produce a

lower strength concrete than machine-
mixed concrete of similar proportions.

12
 Variability of concrete strength during production
Factors contributing to the overall variation

• The overall variation in the measured

strength of concrete that is obtained during a
job can be considered to be made up of three
component sources which are:
– - Variation in the quality of the materials used
– - Variation in the mix proportions due to
the batching process
– - Variation due to sampling and testing

13
 The distribution of results

• Variation in concrete strengths follows the normal distribution such as that shown in Figure l.
• The proportion of results less than some specified value is represented by the area beneath
the curve to the left-hand side of a vertical line drawn through the specified value.
• This normal distribution curve is symmetrical about its mean, has a precise
mathematical equation and is completely specified by two parameters, its mean “m”
and its standard deviation “s”.
• The standard deviation is a measure of the variability calculated from the equation:

• where
• x = an individual result
• n = the number of results
• m= the mean of the n results

14
 Example
• Fc1=45 MPa
• Fc2=48 MPa
• Fc3=44 MPa
• What is standard (s) deviation and average
of these samples?
• s=

• Fcav= Average of results

15
 The distribution of results

• Standard deviation increases as the

specified characteristic strength increases
up to a particular level.
• This type of relationship is shown in Figure 3,
the standard deviation being independent of
the specified characteristic strength above 20
2
N/mm .

16
 Characteristic strength

• Concrete cube strengths follow the normal distribution.

• There is therefore always the probability that a result will
be obtained less than the specified strength.
• Specify the quality of concrete not as a minimum strength
but as a ‘characteristic strength’ below which a specified
proportion of the test results, often called ‘defectives’,
may be expected to fall.

17
 Margin and target mean
strength

fm= fc+ k s
where
fm = the target mean strength
fc = the specified characteristic strength
ks = the margin, which is the product of:
s = the standard
deviation, k = a constant
The constant k is derived from the mathematics of the normal distribution and increases as
the proportion of defectives is decreased, thus:
k for 10% defectives = 1.28
k for 5% defectives = 1.64 k
for 2.5% defectives = 1.96
k for 1% defectives = 2.33

18
 The Mix Design Process
Flow chart of procedures

• A suitable mix design form for recording the values derived

is shown in Table 1.
• Initial information is divided into two categories:
►- specified variables, the values of which are usually
nominated in specifications,
►- additional information, which is normally available
to the producer of the concrete.
• This initial information is also subdivided into two categories:
- the mix parameters
- the final unit proportions

19
 The Mix Design Process
Flow chart of procedures

Stage 1 deals with strength leading to the “free-water/cement ratio”

Stage 2 deals with workability leading to the “free-water Content”
Stage 3 combines the results of Stages 1 and 2 to give the “cement content”
Stage 4 deals with the determination of “the total aggregate content” Stage 5
deals with the selection of the “fine and coarse aggregate contents”

The mix design form shown in Table 1 is sub-divided into the same
five stages and the separate item numbers.

20
 Selection of target water/cement ratio (Stage 1)

• If previous information concerning the variability of strength tests

comprises fewer than 20 results, the standard deviation to be adopted
should be that obtained from line A in Figure 3. If previous information is
available consisting of 20 or more results, the standard deviation of such
results may be used provided that this value is not less than the
appropriate value obtained from line B. The margin can then be derived
from calculation C1:
M=kxs .........…C1
Where:
M = the margin
k = a value appropriate to the ‘percentage defectives’ permitted below
the characteristic strength
s = the standard deviation.
(The margin itself may be specified directly).

21
 Selection of target water/cement ratio
(Stage 1)

• Calculation C2 determines the target

mean strength:

fm = fc+ M ….........C2
Where:
fm = the target mean strength
fc = the specified characteristic
strength M = the margin

22
 Selection of target water/cement ratio (Stage 1)

• A value is obtained from Table 2 for the strength of a mix

made with a free-water/cement ratio of 0.5 according to
the specified age, the strength class of the cement and the
aggregate to be used.

• This strength value is then plotted on Figure 4 and the free-

water/cement ratio can then be read from the abscissa.

• Compare this value with maximum free-water/cement ratio

that may be specified and the lower of these two values used.

23
 Selection of free-water content (Stage 2)

• Consists of determining the free-water content from Table 3 depending upon

the type and maximum size of the aggregate to give a concrete of the specified
slump or Vebe time.

8.7.4 Determination of cement content (Stage 3)

Cement content = free-water content / free-water/cement ratio …C3
The result should be checked against any maximum or minimum value that may be specified.

24
 Determination of total aggregate content (Stage 4)

• Estimate of the density of the fully compacted concrete which is

obtained from Figure 5.
• If no information is available assume a value of 2.6 for uncrushed
aggregate and 2.7 for crushed aggregate.
• Total aggregate content is determined from calculation C4:

Total aggregate content = D — C — W …C4 where

D = the wet density of concrete (kg/m3)

C = the cement content (kg/m3)
W = the free-water content (kg/m3)

25
 Selection of fine and coarse aggregate contents (Stage 5)

• Involves deciding how much of the total aggregate should consist

of materials smaller than 5 mm.
• Figure 6 shows recommended values for the proportion of fine
aggregate depending on the maximum size of aggregate, the workability
level, the grading of the fine aggregate (defined by its percentage
passing a 600 µm sieve) and the free-water/cement ratio.
• The final calculation, C5, to determine the fine and coarse
aggregate contents:

Fine aggregate content = (total aggregate content) x (proportion of fines) …C5

Coarse aggregate content = (total aggregate content)  (fine aggregate

content)..C5

26
 Selection of fine and coarse aggregate contents (Stage 5)

The coarse aggregate content itself can be

subdivided if single sized 10, 20 and 40
mm materials are to be combined.

1 : 2 for combination of 10 and 20 mm

1 : 1.5 : 3 for combination of 10, 20 and 40 mm

27
 Trial mixes

 use the trial mix proportions in the

 production mixes 


 modify the trial mix proportions slightly in the
 production mixes 


 prepare further trial mixes incorporating
major changes to the mix proportions 
28
 Production of trial mixes

Typically, a 50 litre (0.05 m3) mix is sufficient to make six cubes of 150
mm side and to carry out, separately, measurements of slump, Vebe time
and density.

The individual batch quantities (in kg) would then be equal to the
appropriate contents, multiplied by 0.05.

The British Standard allows the use of aggregates in any one of four
moisture conditions, ie
(a) oven-dry,
(b) air-dried,
(c) saturated surface-dry, or
(d) saturated by soaking in water for at least 24 hours.

29
 Tests on trial mixes

• Slump
• Vebe time
• Density
• Make test cubes
• Apply Normal curing on test cubes
• Compression testing of cubes

30
 Adjustments to mix proportions
(workability)

• Workability

During the mixing of the trial mix an experienced technician is able to adjust the
water content by inspection if the workability of the mix is much outside the
specified range.

It is thus useful, initially, to withhold a small proportion, say 10%, of the mix
water until the technician has assessed visually that its addition is needed to
achieve the required workability.

Furthermore, if at the designed water content the workability of the trial mix
appears below that required, additional water should be added to obtain the
required workability.

31
After completion of the mixing cycle and workability
measurements a change of water content may still be
needed, either for use in the production mix or for a further
trial mix, and this can be estimated by reference to Table 3.

During the measurement of workability the concrete

should also be assessed subjectively for its other
rheological properties; this may indicate a need to change
the relative aggregate proportions

32
 Adjustments to mix proportions
(density)
• Density
After the density of the fresh concrete is measured, the
resultant value is compared with the density value used
during the design.

If there is an appreciable difference, the constituent contents will

differ from those intended in the initial design.

In this case, the initial design values should be corrected by

the ratio of measured density to assumed density in order
to determine the actual masses.

33
 Adjustments to mix proportions
(strength)

• When results of the strength tests become available they are compared with the target mean strength. If
necessary an adjustment is made to the water/cement ratio by using the curves of Figure 4. Two
examples of this adjustment are shown in Figure 7, where:

A represents the reference data given in Table 2

B represents the free-water/cement ratio estimated for the trial mix

B' represents the actual free-water/cement ratio used in the trial mix when different from B.

C represents the strength result of the test specimens made from the trial mix.

D represents the new estimate of the free-water/cement ratio required to give the target mean strength.

Minor adjustments may be made to the mix proportions for use in production mixes without the need to carry
out further trials. Exceptionally, when large adjustments seem to be necessary to the water/cement ratio
it is advisable to make a second trial mix using the revised proportions and recalculated batch quantities
based on the updated value for density of the mix.

34
 Examples of mix design
Example 1: unrestricted design

• Characteristic compressive strength (fc) = 30 N/mm2 at 28

days, with a 2.5% defective rate (k = 1.96)
• Portland cement class 42.5
• Slump required = 10–30 mm
• Maximum aggregate size = 20 mm (uncrushed)
• Fine aggregate: 70% passing 600 µm sieve (uncrushed)
• Maximum free-w/c ratio = 0.55
• Minimum cement content = 290 kg/m3
• Maximum cement content = not specified.

35
 Example 2: mix restricted by maximum
water/cement ratio

CALCULATE MIX PROPORTIONS FOR FOLLOWING CONDITIONS:

• Characteristic compressive strength (fc), 25 N/mm2 at 28 days
• Portland cement class 42.5
• Slump required, 30–60 mm
• Maximum aggregate size, 40 mm (fine and coarse uncrushed)
• Maximum free-water/cement ratio, 0.50
• Minimum cement content, 290 kg/m3
• There are no previous control data but a margin of 10 N/mm2 is specified and
is used in Item 1.3.
• The following information is known concerning the aggregates to be used and the
data are entered under the relevant items on the mix design form, as shown in
Table 5:
• Aggregate relative density = 2.5 Item 4.1
• Fine aggregate, 90% passing a 600µm sieve

36
 Example 4: Restricted by maximum cement content

CALCULATE MIX PROPORTIONS FOR CONDITIONS GIVEN BELOW:

• Characteristic compressive strength (fc), 50 N/mm2 at 7
days, defective rate 1% (k = 2.33)
• Portland cement class 52.5 Item 1.5
• Slump required, 30–60 mm Item 2.1
• Maximum aggregate size, 10 mm Item 2.2
• Maximum cement content, 550 kg/m3 Item 3.2
• Previous control data indicated an expected standard
deviation of 5 N/mm2 and this is used in Item 1.2.

37
k for 10% defectives = 1.28
k for 5% defectives = 1.64 k
for 2.5% defectives = 1.96
k for 1% defectives = 2.33

38
39
Figure 3. Relationship between standard deviation and characteristic strength

40
Figure 4. Relation between compressive strength and free-water/cement ratio

41
Table 2

42
Table 3

43
Figure 5. Estimated wet density of fully compacted concrete.

44
Figure 6. Recommended proportions of fine aggregate
according to percentage passing 600 m sieve (Dmax 10 mm).

45
Figure 6. Recommended proportions of fine aggregate
according to percentage passing 600 m sieve (Dmax 20 mm).

46
Figure 6. Recommended proportions of fine aggregate
according to percentage passing 600 m sieve (Dmax 40 mm).

47
Table 4

48
Table 5

49
Table 6

50
Table 7

51
 • Mix Design Problems

1. Calculate the quantities of cement, water, fine aggregate and coarse

aggregate per trial mix of 0.05 m3 for the following specifications.
Characteristic compressive strength = 30 MPa at 28
days; Defective rate = 5%;
Cement = Cement strength class
42.5; Slump required = 10-30 mm;
Max. Aggregate size = 20 mm;
Coarse aggregate UNCRUSHED (10, 20 mm),
fine aggregate UNCRUSHED (70% pass 600 microns));
Maximum allowable free – water/cement ratio = 0.55;
Minimum allowable cement content = 290 kg/m3

52
 Mix Design Problems

2. Calculate the quantities of cement, water, fine aggregate and coarse

aggregate per trial mix of 0.08 m3 for the following specifications.
Characteristic compressive strength = 15 MPa at 28
days; Defective rate = 5%;
Cement = Cement strength class
42.5; Slump required = 30-60 mm;
Max. Aggregate size = 40 mm;
Coarse aggregate UNCRUSHED (10, 20 40 mm),
fine aggregate UNCRUSHED (90% pass 600
microns); Relative density of aggregates = 2.50;
Maximum allowable free – water/cement ratio = 0.50;
Minimum allowable cement content = 290 kg/m3

53
 Mix Design Problems

3. Calculate the quantities of cement, water, fine aggregate

and coarse aggregate per trial mix of 0.08 m3 for the
following specifications.
Characteristic compressive strength = 50 MPa at 28
days; Defective rate = 1%;
Cement strength class 42.5;
Slump required = 30-60 mm;
Max. Aggregate size = 10 mm;
Coarse aggregate CRUSHED (10 mm),
fine aggregate CRUSHED (85% pass 600 microns)
Maximum allowable free – water/cement ratio = 0.50;
Maximum allowable cement content = 550 kg/m3

54
 Problem with different
moisture conditions:
4. Calculate the quantities of cement, water, fine aggregate, and coarse
aggregate per trial mix of 0.05 m3 for the following specifications.
Characteristic compressive strength = 30 MPa at 28
days; Defective rate = 5%;
Cement strength class 42.5;
Slump required = 100 mm;
Max. Aggregate size = 40 mm;
Coarse aggregate UNCRUSHED (10, 20, 40mm),
fine aggregate UNCRUSHED (80% pass 600 microns);
Maximum allowable free – water/cement ratio = 0.50;
Minimum allowable cement content = 290 kg/m3

55
 Problem with different
moisture conditions:
5. Calculate the quantities of cement, water, fine aggregate, and coarse aggregate
per trial mix of 1 m3 for the following specifications.
Target mean compressive strength = 30 MPa at 7
days; Cement strength class 42.5;
Slump required = 100 mm;
Max. Aggregate size = 20 mm;
Specific gravity of aggregates = 2.65; Coarse
aggregate UNCRUSHED (10, 20mm),
fine aggregate CRUSHED (50% pass 600 micros);
Maximum allowable free – water/cement ratio =
0.40; Minimum allowable cement content = 275
kg/m3; Absorption of fine aggregate = 1.0%;
Absorption of coarse aggregate = 1.0%;
Total Moisture content of coarse aggregate = 3.0%;
Total Moisture content of fine aggregate = 3.0%

56
 Problem with different
moisture conditions:
6. The following requirements are specified for the mix design as follows; Make a trial mix of
0.5 m3 concrete. Show your results on Table 1.
Characteristic compressive strength = 20 MPa at 28
days; Defective rate = 10%;
Cement strength class 42.5;
Slump required = 65 mm;
Max. Aggregate size = 40 mm;
Coarse aggregate CRUSHED (all in aggregate),
fine aggregate UNCRUSHED (70% pass 600
microns) Relative density of aggregates = 2.65;
Maximum allowable free – water/cement ratio = 0.55;
Minimum allowable cement content = 250 kg/m3 ;
Maximum allowable cement content = 350 kg/m3 ;
Absorption of fine aggregate = 2%; Absorption of coarse aggregate = 1.1%
Total Moisture content of coarse aggregate = 2.2%; Total Moisture content of fine
aggregate = 1.5%

57
 Problem with different
moisture conditions:
7. The following requirements are specified for the mix design as follows;
Characteristic compressive strength = 35 MPa at 28 days;
Defective rate = 2.5%; Cement
strength class 52.5; Slump
required = 100 mm; Max.
Aggregate size = 20 mm;
Coarse aggregate CRUSHED (10, 20mm),
fine aggregate UNCRUSHED (55% pass 600
microns) Relative density of aggregates = 2.75;
Maximum allowable free – water/cement ratio = 0.50;
Minimum allowable cement content = 285 kg/m3 ;
Maximum allowable cement content = 400 kg/m3;
Absorption of fine aggregate = 1.8%; Absorption of coarse aggregate = 1.2%
Total Moisture content of coarse aggregate = 2.3%; Total Moisture content of fine aggregate
= 3.4%
Make a trial mix of 0.08 m3 concrete. Show your results on Table 1.

58
 Problem with different
moisture conditions:
8. The following requirements are specified for the mix design as
follows; Characteristic compressive strength = 25 MPa at 28 days;
Defective rate = 5%;
Cement strength class 42.5;
Slump required = 35 mm;
Max. Aggregate size = 20 mm;
Coarse aggregate CRUSHED (all in aggregate),
fine aggregate CRUSHED (90% pass 600
microns) Relative density of aggregates = 2.75;
Maximum allowable free – water/cement ratio =
0.55; Minimum allowable cement content = 250
kg/m3; Absorption of fine aggregate = 1.5%;
Absorption of coarse aggregate = 1.0%;
Total Moisture content of coarse aggregate = 3.0%
Total Moisture content of fine aggregate = 2.0%
Make a trial mix of 0.05 m3 concrete. Show your results on Table 1.

59
 Problem with different
moisture conditions:
9. The following requirements are specified for the mix design as
follows; Target, mean compressive strength = 40 MPa at 28 days;
Cement strength class 52.5;
VeBe required = 12 sec;
Max. Aggregate size = 25 mm;
Coarse aggregate CRUSHED (all in aggregate),
fine aggregate CRUSHED (55% pass 600
microns); Relative density of aggregates = 2.65;
Maximum allowable free – water/cement ratio =
0.55; Minimum allowable cement content = 350
kg/m3; Maximum allowable cement content = 500
kg/m3; Absorption of coarse aggregate = 2.0%;
Total Moisture content of coarse aggregate = 1.5%
Surface Moisture content of fine aggregate = 2.5%
Make a trial mix of 0.05 m3 concrete. Show your results on Table 1.

60