CHAPTER 2 - CONCRETE MIX DESIGN

At the end of this session, the students should be able to design the concrete mix with specific
requirement.

1. MATERIAL TEST
Material used in reinforced concrete structures are subjected to preliminary material tests
according to specifications or standards for concrete steel. Material tests for concrete include
slump test and compression tests, whilst tests for steel reinforcement include tensile, bend and
steel fabric tests.and

1.1 Concrete
The keys to good quality concrete are the raw materials used to make concrete and the mix
design as specified in the project specifications.

1.1.1 Mix Design Process

The concrete mix design process consists of five stages and is explained according to the British
Standard (BS1881). Stage 1 consists of selection of target water/cement ratio. Figure 1 shows a
relationship between standard deviation and characteristic strength. If previous information
concerning the variability of the strength tests comprises less than 20 results, the standard
deviation to be adopted should be that obtained from line A. 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. In Table 1 the margin
can then be derived from calculation Bl.
M = kxs

(B1)

Where M = margin (Item 1.3)

k = a value appropriate to the 'percentage defectives' permitted below the characteristic
strength
s = standard deviation
The constant k is derived from the mathematics of the normal distribution and increase
as the proportion of the defective is decreased, thus:
k for 10 % defectives = 1.28
k for 5 % defectives = 1.64
k for 2.5 % defectives = 1.96
Mix Design Appendix

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k for

1 % defectives = 2.33

Instead of working from the standard deviation and obtaining the margin through calculation
Bl, the margin itself may be specified direct. Hence item of Table 2 may be a derived value or
an optional specified value. Calculation B2 determines the target mean strength (expressed to
two significant figures):
f m =f c +M

(B2)

where fm = target mean strength

fc = specified characteristic strength
M = margin

Figure 1: Relationship between standard deviation and characteristic strength

Mix Design Appendix

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Next, 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 type of cement and the aggregate to be used.
This strength value is then plotted on Figure 2 and a curve is drawn from this point and parallel
to the printed curves until it intercepts a horizontal line passing through the
ordinate representing the target mean strength. The

corresponding value for the free-

water/cement ratio can then be read from the abscissa. This should be compared with any
maximum free-water/cement ratio that may be specified and the lower of these two values
used.

Note: When coarse and fine aggregates of different types are used, the free content is
estimated by the expression,
2 Wf + 1 Wc
(B3)
3
3
Where Wf = free water content appropriate to type of fine aggregate and Wc = free water
content appropriate to type of coarse aggregate

Mix Design Appendix

-3-

Stage 3 is the determination of cement content where the resulting value should be checked
against any maximum or minimum value that may be specified. If the calculated cement
content from in Table 3 is below a specified minimum, this minimum value must be adopted
and a modified free water/cement ratio calculated which would be less than that determined in
Stage 1. This will result in a concrete that has a mean strength somewhat higher than the target
mean strength. Alternatively, the free water/ cement ratio from Stage 1 is used resulting in
higher free water content and increased workability. On the other hand, if the design method
indicates a cement content that is higher than a specified maximum, then it is probable that
the specification cannot be met simultaneously on strength and workability requirements with
the selected materials. Consideration should then be given to changing the type of cement, the
type and maximum size of aggregate or the level of workability of the concrete, or to use waterreducing admixture.

Mix Design Appendix

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Figure 2: Relationship between compressive strength and free-water/cement ratio

Mix Design Appendix

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Figure 3: Estimated wet density of fully compacted concrete

Figure 4: Recommended proportions of fine aggregate according to percentage passing a

600m sieve
Mix Design Appendix

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Figure 4: Recommended proportions of fine aggregate according to percentage passing a 600

m sieve

Mix Design Appendix

-7-

Stage 4 consists of determination of total aggregate which requires an estimate of the density
of the fully compacted concrete which is in Figure 3 depending upon the free water content and
the relative density of the combined aggregate in the saturated surface dry condition (SSD).
If no information is available regarding the relative density of the aggregate, an approximation
value of wet density may be deduced by assuming a value of 2.6 for uncrushed aggregate and
2.7) for crushed aggregate. From this estimafe3rdfengityvof the concrete, the total aggregate
content is determined from calculation B4,
Total aggregate content = D - C W

(B4)

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

C = cement content (kg/m3)
W = free water content (kg/m3)
Stage 5 consists of selection of fine and coarse aggregate which involves deciding how
much of the total aggregate should include materials smaller than 5 mm, i.e. the sand or fine
aggregate content. Figure 4 shows recommended values for the proportion of fine aggregate
depending on the maximum size of the aggregate, the workability level, the grading of the fine
aggregate (define by its percentage passing a 600m sieve.) and the free water/cement ratio.
The best proportion of fines to be used in a given mix will depend on the actual grading of
shape of the particular aggregate and the use to which the concrete is to be put. However,
adoption of a proportion obtained from Figure 4 will generally give a satisfactory concrete in
the first trial mix that can then be adjusted as required for the exact conditions prevailing.
The final calculation B5 to determine the fine and coarse aggregate contents is made
using the proportion of fine aggregate obtained from Figure 4 and the total aggregate content
derived in Stage 4 Fine aggregate content = Total aggregate content x proportion of fines
Coarse aggregate content = Total aggregate content x fine aggregate content The coarse
aggregate content itself can be subdivided if single sized 10, 20 and 40 mm materials are to be
combined. Again, the best proportions will depend on aggregate shape and concrete usage but
the following ratios are suggested as a general guide:
1: 2 for combination of 10 and 20 mm material
1:1.5:3 for combination of 10, 20 and 40 material
Mix Design Appendix

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EXAMPLE 1: CONCRETE MIXES DESIGN

The British method has applied to design the concrete. General process for designing concrete
mix is summarizes as follows:

STAGE

DESCRIPTION

Deals with strength leading to the free-water/cement ratio

Deals with workability leading to the free-water content

Combines the results of Stages 1 and 2 to give the cement content.

Deals with the determination of the total aggregate content.

Deals with the selection of the fine and coarse aggregate contents.

The unrestricted design has been selected. The information of the requirement item on mix design
is shown in Table 3.1 and all available data for designing concrete mix are attached as Appendix.
You shall produce concrete mixes for Grade 30 concrete cubes. You need to prepare 3 concrete
test cubes (150x150x150 mm) for compression test at 7, and 28 days lifetime.
Table 3.1: The requirements and relevant item on the mix design form
No.

Descriptions

Specified

Characteristic compressive strength at 28 days

Proportion defective

Cement type

Maximum aggregate size

Aggregate type:
i.

Coarse aggregate

ii.

Fine aggregate

30N/mm2
5% (k=1.64)
OPC
20mm

Crushed
Uncrushed

Slump required

30 60 mm

Grading of fine aggregate - % passing 600m

54%

Relative density

2.70

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Calculation for Quantity of Concrete

Calculation of quantity required to cast concrete structure must be based on the volume of the
structure. In addition, extra quantity is required for cubes to enable compression strength tests to be
carried out. However, during mixing, an additional of 10% volume is recommended to
accommodate for waste. Table 3.3 shows the calculation in obtaining the concrete volume.
Table 3.3: Calculation of concrete Volume

Type of structure
Cube

Calculation
Size of mould 150mm x 150mm x

6 cubes

150mm Volume for one cube

= 6x0.003375

= 0.15x0.15x0.15

= 0.02025 m3

= 0.003375 m3

i)

Total volume

The trial mix cubes mixing volume

= Total Volume + 10% additional

= (0.02025 + 0.002025) m3
= 0.022275 m3

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Table 3.2: Concrete Mix Design Form

Stage
1

Reference or
calculation

Item
1.1 Characteristic strength

Values

Specified
Specified

1.2 Standard deviation

C1

1.4 Target mean strength

C2

1.5 Cement type

(k = 1.64
N/mm2

1.64

N/mm2

43

N/mm2

= 13

+ 13

Crushed
Uncrushed
Table A1.3
Figure A1.2

0.54

1.8 Maximum free water/ cement ratio

Specified

2.1 Slump or Vebe time

Specified

2.2 Maximum aggregate size

Specified

20

mm

Table A1.4

190

kg/m3

2.3 Free-water content/cement ratio

3.1 Cement content

Use the lower value

Slump

C3

3.2 Maximum cement content

3.3 Minimum cement content

30 60

190

0.54

Specified

352
2.7

352

5.1 Grading of fine aggregate

5.2 Proportion of fine aggregate

kg/m3

kg/m3
known/assumed

Figure A1.3

4.3 Total aggregate content

- kg/m3
Use 3.1, if < 3.2
Use 3.3, if > 3.1

4.1 Relative density of aggregate

(SSD)
4.2 Concrete density

mm or Vebe time

- kg/m3

Specified

3.4 Modified free water/cement ratio

Percent

OPC

Specified

1.7 Free-water/cement ratio

30

Aggregate type: fine

days

_____8_______ N/mm2 or no data

1.6 Aggregate type: coarse

28

Proportion defective

Figure A1.1

1.3 Margin

N/mm2 at

30

C4

2445 - 190

- 352 =

% pass 600m
sieve

54

Figure A1.4

38

5.3 Fine aggregate content

C5

1903

x 0.38 =

5.4 Coarse aggregate content

C5

1903

- 723

723

= 1180

1903

kg/m3

kg/m3

Coarse aggregate (kg)

20 mm
40 mm

Cement
(kg)

Water
(kg)

Fine aggregate
(kg)

10 mm

Per m3 (to nearest 5 kg)

355

190

725

395

785

Per trial mix of 0.022275 m3

7.91

4.23

16.15

8.80

17.49

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kg/m3

kg/m3

Quantities

Note: Design as according to BS 1881

2445