Final Mix Design

Mix Design Slump

1. Select the slump
2. Determine the required strength
3. Select the NMAS
4. Estimate the water and air contents
5. Adjust the water content for aggregate shape
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
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 table
shows some typical slump ranges for several different applications.
Concrete Mix Procedure
Step 1: Choice of Slump
• If slump is not specified, a value appropriate for the work can be selected
from
• Table 5.8. The slump ranges shown apply when vibration is used to
consolidate the
• concrete. Mixes of the stiffest consistency that can be placed efficiently
should be
• used. Note that the values of the slump listed in Table 5.8 can be increased
when
• chemical admixtures are used.
Determine Required Strength
• As we said in the last lecture, 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.
The Egyptian code

• The characteristic strength of concrete is defined as the strength below which not more
than a prescribed percentages of the test results should fall. The Egyptian code adopts a
percentage of 5%. Hence, by knowing the required concrete characteristic strength fcu, we
can define the target strength (fm) to design the concrete mix, as in the following equation:
fm = fcu + M
fm = fcu + 1.64 S
• Table 5.6 provides a guideline to predict the standard deviation of the concrete after
knowing the QC of the site by visiting the site only; by performing a test and calculating the
standard deviation one can audit and categorize the work and supervising activities of the
QC in this site. This is also is a guide for the QC indicator for the ready-mix batch plant that
supplies the concrete to your site. Table 5.7 is from ACI 214-77 and presents the overall
standard deviation for concrete in laboratory trial mixes and in the field for concrete
strength 35 MPa.
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, considering 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 2: Choice of Maximum Size of
Aggregate
• Large nominal maximum sizes of well-graded aggregates have fewer voids than smaller
sizes. Hence, concretes with the larger-sized aggregates require less mortar per unit
volume of concrete. Generally, the nominal maximum size of aggregate should be the
largest that is economically available and consistent with dimensions of the structure. In
no event should the nominal maximum size exceed one fifth of the narrowest dimension
between sides of forms, one third the depth of slabs, nor three fourths of the minimum
clear spacing between individual reinforcing bars, bundles of bars, or pre-tensioning
strands. These limitations are sometimes waived if workability and methods of
consolidation are such that the concrete can be placed without honeycomb or void. In
areas congested with reinforcing steel, post-tension ducts, or conduits, select a nominal
maximum size of the aggregate so concrete can be placed without excessive segregation,
pockets, or voids. When high strength concrete is desired, best results may be obtained
with reduced nominal maximum sizes of aggregate since these produce higher strengths at
a given water/cement (w/c) ratio.
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
assume 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.
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 3: Estimation of Mixing Water and
Air Content
•The quantity of water per unit volume of concrete required to produce a given slump is dependent on the
nominal maximum size, particle shape, and grading of the aggregates; the concrete temperature; the amount
of entrained air; and use of chemical admixtures. Slump is not greatly affected by the quantity of cement or
cementitious materials within normal use levels (under favorable circumstances the use of some finely divided
mineral admixtures may lower water requirements slightly). Table 5.9 provides estimates of required mixing
water for concrete made with various maximum sizes of aggregate, with and without air entrainment.
Depending on aggregate texture and shape, mixing water requirements may be somewhat above or below the
tabulated values, but they are sufficiently accurate for the first estimate. The differences in water demand are
not necessarily reflected in strength since other compensating factors may be involved. Rounded and angular
coarse aggregates, both of which are similarly graded and of good quality, can be expected to produce concrete
of about the same compressive strength for the same cement factor in spite of differences in w/c ratio resulting
from the different mixing water requirements. Particle shape is not necessarily an indicator that an aggregate
will be either above or below its strength-producing capacity
Step 4: Chemical Admixtures
• Chemical admixtures modify the properties of concrete to make it more workable, durable, and/or
economical; increase or decrease the time of set; accelerate strength gain; and/or control temperature gain.
Chemical admixtures should be used only after an appropriate evaluation has been conducted to show that the
desired effects have been accomplished under the conditions of intended use. Making sure that water
reducing and/or set-controlling admixtures conform to the requirements of ASTM C494, when used
singularly or in combination with other chemical admixtures, will significantly reduce the quantity of water
per unit volume of concrete. The use of some chemical admixtures, even at the same slump, will improve
such qualities as workability, finish ability, pump-ability, durability, and compressive and flexural strength.
Significant volume of liquid admixtures should be considered as part of the mixing water. The slumps shown
in Table 5.8 from ACI may be increased when chemical admixtures are used, providing the admixture-treated
concrete has the same or a lower water/cement ratio and does not exhibit segregation potential and excessive
bleeding. When only used to increase slump, chemical admixtures may not improve any of the properties of
the concrete. Table 5.9 indicates the approximate amount of entrapped air to be expected in non–air-entrained
concrete and the recommended average air content for air entrained concrete. If air entrainment is desired,
three levels of air content are given for each aggregate size, depending on the purpose of the entrained air and
the severity of exposure if entrained air is needed for durability
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 fly ash) are used, then the ratio
becomes a water-cementitious material ratio. The following table
relates the required 28-day compressive strength (including the
overdesign factor) to the water-cement ratio for both non-air-entrained
and air-entrained concrete mixes.
Step 5: Selection of Water/Cement (w/c)
Ratio
• The required w/c ratio is determined not only by strength requirements but also by
• factors such as durability. Since different aggregates, cements, and cementitious materials
generally produce different strengths in the same amount of water, it is highly desirable to know
the relationship between strength and w/c for the materials actually to be used. In the absence of
such data, approximate and relatively conservative values for concrete containing Type I Portland
cement can be taken from Table 5.10 with typical materials and the tabulated w/c ratio should
produce the strengths shown, based on 28-day tests of specimens cured under standard laboratory
conditions. The average strength selected must, of course, exceed the specific strength by a
sufficient margin to keep the number of low tests within specific limits. For severe conditions of
exposure, the w/c ratio should be kept low even though strength requirements may be met with a
higher value. Table 5.11 gives limiting values. When natural pozzolans, fly ash, GGBF slag, and
silica fume, hereafter referred to as pozzolanic materials, are used in concrete, a water/cement plus
pozzolanic materials ratio (or water/cement plus other cementitious materials ratio) by weight
must be considered in place of the traditional water/cement ratio by weight.
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:
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 up to 10
percent.
• The values in the table are called the b/bo factor. In a nutshell, 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. As we’ve said before, 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.
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 we’ve
estimated the weight of all the other ingredients, whatever is still
missing must be that of the sand
• If our concrete has a “typical” unit weight of 3956 lb per cubic yard of
concrete then, using the estimated weight method, the amount of sand
that is needed to complete the mix design is
• 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 27 ft3 (1 yd3) 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 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.
Mix Proportions

• The selection of the concrete mix depends on the available aggregate near the site. So, the
properties of these aggregate should be defined. The main factor in any engineering
practice is the project economy so the selection of the mix proportion should verify the
following:
• The required concrete characteristic compressive strength
• The durability of concrete, which requires defining the w/c ratio and cement content
• The optimization of availability of materials, performance, and economics
• The following equation defines the concrete mix:
• This equation calculates the quantities of ingredients to produce 1 cubic meter of
concrete. Note that the cement content proposed is based on the environmental
conditions, and the required concrete strength can define the water/cement ratio (w/c).
From experience, the required mixing ratio can define the cement/aggregate ratio [C/(Af
+ Ag)], and the coarse/fine aggregate ratio (Af/Ag). Hence, from these ratios and the
previous equation the mix proportions can be defined.
• 5.6.3.1 British Standard
• The British standard BS8110 provides a guide to suitable concrete mixtures based on the
environmental conditions classified as shown in Table 5.12. After defining the
environmental conditions based on BS8110, described in Table 5.12, refer to Table 5.13,
which provides the minimum concrete grade required with a minimum cement content
based on the maximum aggregate size and the corresponding maximum w/c ratio.
Cubic Test
• The specimens are cast in steel or cast-steel molds, generally 150 mm cubes. The standard
practice prescribed by BS1881:Part 3:1970 is to fill the mold in three layers. Each layer of
concrete is compacted by not less than 35 strokes of a 25 mm (1 in) square steel rod.
Ramming should continue until sufficient compaction has been achieved, for it is
essential that the concrete in the cube be fully compacted if the compressive test is to be
representative of the properties of fully compacted concrete. After the top surface of the
cube has been finished by trowel, the cube is stored undisturbed for 24 hours at 18ºC to
22ºC and relative humidity of not less than 90%. At the end of this period the mold is
stripped, and the cube is further cured in water at 19ºC to 21ºC. The test is generally
performed at 28 days, but additional tests are also performed at 3 and 7 days. In the
compression test, the cube is placed with the cast faces in contact with the platens of the
testing machine, i.e., the position of the cube when tested is at right angles to that as-cast.
It is worth mentioning that according to BS1881:Part 4:1970 the load on the cube should
be applied at a constant rate of stress equal to 15 MPa/min (2200 psi/min).
• High Performance Concrete Mix
• Based on ACI 211.4 (93), high-strength concrete has a specified
compressive strength fc´ of 42 N/mm2 (6000 psi) or greater. This
guide is intended to cover field strengths up to 84 N/mm2 (12,000 psi)
as a practical working range, although greater strengths may be
obtained. Recommendations are based on current practice and
information from contractors, concrete suppliers, and engineers
involved in projects dealing with high-strength concrete.
5.11.1 Required Strength
• ACI 318 allows concrete mixtures to be proportioned based on field experience or laboratory trial
batches. To meet the specified strength requirements, the concrete must be proportioned in such a
manner that the average compressive strength results of field tests exceed the specified design
compressive strength fc´ by an amount sufficiently high to make the probability of low tests small.
When the concrete producer chooses to select high-strength concrete mixture proportions based
upon field experience, it is recommended that the required average strength fc´ used as the basis
for selection of concrete proportions be taken as the larger value calculated from the following:
The average of all sets of three consecutive strength test results equals or exceeds the required fc´.
No individual strength test (average of two cylinders) falls below 0.90 fc´. Note that this different
from the ACI 318 requirement. The latter criterion differs from the 3.4 MPa (500 psi) under
strength criterion in ACI 318, because a deficiency of 3.4 MPa (500 psi) may not be significant
when high-strength concrete is used.
• High-strength concretes may continue to gain significant strength after the acceptance test
especially if fly ash or ground granulated blast furnace slag is used. Experience has shown that
strength testing under ideal field conditions attains only 90% of the strength measured by tests
performed under laboratory conditions. To assume that the average strength of field production
concrete will equal the strength of a laboratory trial batch is not realistic, since many factors can
influence the variability of strengths and strength measurements in the field. Initial use of a high
strength concrete mixture in the field may require some adjustments in proportions and proper
selection of its components. Once sufficient data have been generated from the job, mixture
proportions should be reevaluated using ACI 214 and adjusted accordingly. For high-strength
concrete or high-performance concrete there are no standard or typical mix proportions, so it is
more beneficial to present results on several successful mixes as presented by Neville (1983) in
Table 5.22. This table contains different high performance concrete mixing ratios for different
countries. There are nine mixes: (A) and (D) are from the United States; (B), (C), (E), (F), and (I)
are from Canada; (G) is from Morocco, and (H) is from France.
Admixture
• Standard Specification for Chemical Admixtures for Concrete
• Abstract
This specification covers the materials and the test methods for use in chemical admixtures to be added to
hydraulic-cement concrete mixtures in the field. The seven types of admixtures are indicated as follows: Type A
—water reducing; Type B—retarding; Type C—accelerating; Type D—water reducing and retarding; Type E—
water reducing and accelerating; Type F—water reducing, high range; and Type G—water reducing, high range,
and retarding. The materials used in the concrete mixtures shall include Type I or Type II cement, pozzolan, fine
and coarse aggregates, and air-entraining admixture. Samples of freshly mixed concrete from at least three
separate batches for each condition of concrete shall be tested in accordance with the slump, air content, time of
setting, and water content tests. Physical properties retesting shall consist of uniformity and equivalence tests
using infrared analysis which is intended to compare qualitatively the composition of different samples, residue
by oven drying which shall be either a forced circulation type or one with provision for free access of air, and
specific gravity determination using hydrometers. Test specimens of the hardened concrete shall be prepared in
accordance to compressive strength, flexural strength, resistance to freezing and thawing, and length change.
Scope1.1 This specification covers materials for use as chemical admixtures to be added to
hydraulic-cement concrete mixtures in the field for the purpose or purposes indicated for the eight
types as follows:
• 1.1.1 Type A—Water-reducing admixtures,
• 1.1.2 Type B—Retarding admixtures,
• 1.1.3 Type C—Accelerating admixtures,
• 1.1.4 Type D—Water-reducing and retarding admixtures,
• 1.1.5 Type E—Water-reducing and accelerating admixtures,
• 1.1.6 Type F—Water-reducing, high range admixtures,
• 1.1.7 Type G—Water-reducing, high range, and retarding admixtures, and
• 1.1.8 Type S—Specific performance admixtures.
• 1.2 This specification stipulates tests of an admixture with suitable concreting materials as described in 11.1
– 11.3 or with cement, pozzolan, aggregates, and an air-entraining admixture proposed for specific work
(11.4). Unless specified otherwise by the purchaser, the tests shall be made using concreting materials as
described in 11.1 – 11.3.
• NOTE 1: It is recommended that, whenever practicable, tests be made using the cement, pozzolan,
aggregates, air-entraining admixture, and the mixture proportions, batching sequence, and other physical
conditions proposed for the specific work (11.4) because the specific effects produced by chemical
admixtures may vary with the properties and proportions of the other ingredients of the concrete. For
instance, Types F and G admixtures may exhibit much higher water reduction in concrete mixtures having
higher cement factors than that listed in 12.1.1.

Mixtures having a high range water reduction generally display a higher rate of slump loss. When high-range
admixtures are used to impart increased workability (6 to 8-in. slump [150 to 200–mm]), the effect may be of
limited duration, reverting to the original slump in 30 to 60 min depending on factors normally affecting rate
of slump loss. The use of chemical admixtures to produce high-slump (flowing) concrete is covered by
Specification C1017/C1017M.
• NOTE 2: The purchaser should ensure that the admixture supplied for use in the work is equivalent in composition to the admixture
subjected to test under this specification (see Section 6, Uniformity and Equivalence).
• NOTE 3: Admixtures that contain relatively large amounts of chloride may accelerate corrosion of prestressing steel. Compliance
with the requirements of this specification does not constitute assurance of acceptability of the admixture for use in prestressed
concrete.
• 1.3 This specification provides for three levels of testing.
• 1.3.1 Level 1—During the initial approval stage, proof of compliance with the performance requirements defined in Table
1 demonstrates that the admixture meets the requirements of this specification. Admixtures (except for Types B, C, E, and S) shall
qualify for provisional compliance when the physical requirements and any of the alternative compressive strength requirements
in Table 1 are met. If subsequent test results at six months or one year fail to meet the standard requirement of 100 % of reference
strength, the compliance of the admixture to this standard is withdrawn and all users of the admixture shall be notified immediately.
Uniformity and equivalence tests of Section 6 shall be carried out to provide results against which later comparisons can be made
(see Note 4).
• (A) The values in the table include allowance for normal variation in test results. The object of the 90 %
compressive strength requirement for a Type B amd Type S admixture is to require a level of performance
comparable to that of the reference concrete.
• (B) The compressive and flexural strength of the concrete containing the admixture under test at any test age
shall be not less than 90 % of that attained at any previous test age. The objective of this limit is to require
that the compressive or flexural strength of the concrete containing the admixture under test shall not
decrease with age.
• (C) Alternative requirement. If the physical requirements are met and any of the measured relative strengths
are greater than the requirement in parentheses, the admixture shall be considered provisionally qualified
until the one-year strength test results are obtained.
• (D) Alternative requirements, see 17.1.4, % of control limit applies when length change of control is 0.030 %
or greater; increase over control limit applies when length change of control is less than 0.030 %.
• (E) This requirement is applicable only when the admixture is to be used in air-entrained concrete which may
be exposed to freezing and thawing while wet.
• NOTE 4: Allowing for provisional compliance while retaining longer term compressive strength requirements
promotes more rapid qualification of new materials, but also provides assurance that new admixture
technologies will not exhibit unexpected longer-term performance. The alternative compressive strength
requirements in Table 1 are based on statistical analysis of 103 Specification C494/C494M evaluation tests.
The alternative requirements correspond to a 99 % probability of passing subsequent test age requirements.2
• 1.3.2 Level 2—Limited retesting is described in 5.2 – 5.2.2. Proof of compliance with the requirements
of Table 1 demonstrates continued conformity of the admixture with the requirements of the specification.
• 1.3.3 Level 3—For acceptance of a lot or for measuring uniformity within or between lots, when specified by
the purchaser, the uniformity and equivalence tests of Section 6 shall be used.
• 1.4 The values stated in either SI units or inch-pound units are to be regarded separately as standard. The
values stated in each system may not be exact equivalents; therefore, each system shall be used independently
of the other. Combining values from the two systems may result in non-conformance with the standard.
• 1.5 The text of this standard references notes and footnotes which provide explanatory
material. These notes and footnotes (excluding those in tables and figures) shall not be
considered as requirements of the standard.
• 1.6 The following precautionary caveat pertains only to the test method sections,
Sections 11 – 18 of this Specification: This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the responsibility of the user of this
standard to establish appropriate safety and health practices and determine the
applicability of regulatory limitations prior to use.
• 1.7 This international standard was developed in accordance with internationally
recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the
World Trade Organization Technical Barriers to Trade (TBT) Committee.
End