ACI Mix Design ACI Mix Design

] The most common method used in North America is ] Water/cement ratio (w/c ratio) theory states that
that established by ACI Recommended Practice 211.1 for a given combination of materials and as long as
] Any mix design procedure will provide a first workable consistency is obtained, the strength of
approximation of the proportions and must be checked concrete at a given age depends on the w/c ratio
by trial batches ] The lower the w/c ratio, the higher the concrete
] Local characteristics in materials should be considered strength.
] Whereas strength depends on the w/c ratio, economy
] The following sequence of steps should be followed: depends on the percentage of aggregate present that
(1) determine the job parameters - aggregate properties, would still give a workable mix.
maximum aggregate size, slump, w/c ratio, admixtures,
] The aim of the designer should always be to get
(2) calculation of batch weight, and concrete mixtures of optimum strength at minimum
(3) adjustments to batch weights based on trial mix. cement content and acceptable workability.

ACI Mix Design ACI Mix Design

] Once the w/c ratio is established and the workability ] The flowchart is a representation
or consistency needed for the specific design is of the principal properties of
“good” concrete
chosen, the rest should be simple manipulation with
] cement
diagrams and tables based on large numbers of trial
mixes. ] w/c ratio
] aggregate
] Such diagrams and tables allow an estimate of the
] cement paste and aggregate
required mix proportions for various conditions and
] mixing
permit predetermination on small unrepresentative
batches. ] placement and handling of
fresh concrete
] curing

ACI Mix Design ACI Mix Design

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

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 ACI Mix Design ACI Mix Design
Basic Considerations
] Strength and Durability -- In general, the minimum ] A measure of the degree of consistency and extent of
compressive strength and a range of w/c ratios are workability is the slump.
specified for a given concrete mix.
] In the slump test the plastic concrete specimen is
] Possible requirements for resistance to freeze-thaw formed into a conical metal mold as described in
and chemical attack must be considered. ASTM Standard C-143.

] Therefore, a balance or compromise must be made ] The mold is lifted, leaving the concrete to "slump,"
between strength and workability. that is, to spread or drop in height.

ACI Mix Design ACI Mix Design

] This drop in height is the slump measure of the

degree of workability of the mix. ] Here are some examples of different measures of
slump:

ACI Mix Design ACI Mix Design

Mix Design Procedures
] The flowchart is a
representation of the
principal properties of “good” 1. Required material information -- sieve analyses of
concrete both fine and coarse aggregates, unit weight, specific
] cement gravities, and absorption capacities of aggregates.
] w/c ratio
] aggregate 2. Choice of slump -- Generally specified for a particular
] cement paste and aggregate job. However, if not given, an appropriate value may be
] mixing chosen from Table 1. As a general rule, the lowest
] placement and handling of slump that will permit adequate placement should be
fresh concrete selected.
] curing

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 ACI Mix Design ACI Mix Design
Mix Design Procedures
Table 1. Recommended Slumps for Various Types of Construction

3. Maximum aggregate size -- The largest maximum

aggregate size that will conform to the following
limitations:
] Maximum size should not be larger than 1/5 the minimum
dimension of structural members, 1/3 the thickness of a slab,
or 3/4 the clearance between reinforcing rods and forms.
These restrictions limit maximum aggregate size to 1.5 inches,
except in mass applications.
] Current thought suggests that a reduced maximum aggregate
size for a given w/c ratio can achieve higher strengths. Also,
in many areas, the largest available sizes are 3/4 in. to 1 in.

ACI Mix Design ACI Mix Design

Mix Design Procedures Mix Design Procedures

4. Estimation of mixing water and air content -- An Approximate mixing water (lb/yd3) and air content for different
estimation of the amount of water required for air- slumps and nominal maximum sizes of aggregates
entrained and non-air-entrained concretes can be
Maximum aggregate size (in)
obtained from Table 2.
Slump(in) 0.375 0.5 0.75 1 1.5 2 3 6
1 to 2 350 335 315 300 275 260 220 190
385 365 340 325 300 285 245 210
It is suggested that trial batches incorporating the 3 to 4
6 to 7 410 385 360 340 315 300 270 -
maximum air content and the maximum allowable slump
be used to develop the strength relationship for the Air Content 3.0% 2.5% 2.0% 1.5% 1.0% 0.5% 0.3% 0.2%
best combination of air content and water content.
Nonair-Entrained Concrete

ACI Mix Design ACI Mix Design

Mix Design Procedures Mix Design Procedures

Approximate mixing water (lb/yd3) and air content for different 5. Water/cement ratio - This component is governed by
slumps and nominal maximum sizes of aggregates
strength and durability requirements
Maximum aggregate size (in)
(a) Strength -- Without strength vs. w/c ratio data for a
Slump(in) 0.375 0.5 0.75 1 1.5 2 3 6
certain material, a conservative estimate can be made for the
1 to 2 305 295 280 270 250 240 225 180 accepted 28-day compressive strength from Table 3.
3 to 4 340 325 305 295 275 265 250 200
6 to 7 365 345 325 310 290 280 270 -
(b) Durability -- If there are severe exposure conditions,
Air Content
such as freezing and thawing, exposure to seawater, or
Mild 4.5% 4.0% 3.5% 3.0% 2.5% 2.0% 1.5% 1.0%
sulfates, the w/c ratio requirements may have to be adjusted.
Moderate 6.0% 5.5% 5.0% 4.5% 4.5% 4.0% 3.5% 3.0%
Extreme 7.5% 7.0% 6.0% 6.0% 5.5% 5.0% 4.5% 4.0%

Air-Entrained Concrete

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 ACI Mix Design ACI Mix Design
Mix Design Procedures Mix Design Procedures

Relationship between water/cement ratio and compressive strength 6. Calculation of cement content -- Once the water
of concrete content and the w/c ratio is determined, the amount
of cement per unit volume of the concrete is found by
28-day Compressive Non-AE AE dividing the estimated water content by the w/c ratio.
Strength (psi) However, a minimum cement content is required to
2,000 0.82 0.74 ensure good finishability, workability, and strength.
3,000 0.68 0.59
0.57 0.48 weight of water
4,000
weight of cement =
5,000 0.48 0.40 w /c
6,000 0.41

ACI Mix Design ACI Mix Design

Mix Design Procedures Mix Design Procedures

7. Estimation of coarse aggregate content - The percent Volume of dry-rodded coarse aggregate per unit volume of concrete
for different coarse aggregates and fineness moduli of fine
of coarse aggregate to concrete for a given maximum aggregates
size and fineness modulus is given by Table 4.
Fineness Modulus
Max Aggregate (in) 2.4 2.5 2.6 2.7 2.8 2.9 3
The value from the table multiplied by the dry-rodded 0.375 0.50 0.49 0.48 0.47 0.46 0.45 0.44

unit weight (the oven-dry (OD) weight of coarse 0.500 0.59 0.58 0.57 0.56 0.55 0.54 0.53

aggregate required per cubic foot of concrete). 0.750 0.66 0.65 0.64 0.63 0.62 0.61 0.60
1.000 0.71 0.70 0.69 0.68 0.67 0.66 0.65
1.500 0.75 0.74 0.73 0.72 0.71 0.70 0.69
To convert from OD to saturated surface dry (SSD) 2.000 0.78 0.77 0.76 0.75 0.74 0.73 0.72

weights, multiply by [1 + absorption capacity (AC)]. 3.000 0.82 0.81 0.80 0.79 0.78 0.77 0.76
6.000 0.87 0.86 0.85 0.84 0.83 0.82 0.81

ACI Mix Design ACI Mix Design

Mix Design Procedures Mix Design Procedures
8. Estimation of fine aggregate content -- There are two 9. Adjustment for moisture in the aggregate -- The
standard methods to establish the fine aggregate water content of the concrete will be affected by the
content, the mass method and the volume method. We moisture content of the aggregate.
will use the "volume" method.

] "Volume" Method -- This method is the preferred method, as it

is a somewhat more exact procedure
] The volume of fine aggregates is found by subtracting the
volume of cement, water, air, and coarse aggregate from the
total concrete volume.

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 ACI Mix Design ACI Mix Design Example
Mix Design Procedures
] Concrete is required for an exterior column located
10. Trial batch -- Using the proportions developed in the above ground where substantial freezing and thawing
preceding steps, mix a trial batch of concrete using only may occur. The 28-day compressive strength should be
5,000 lb/in2. The slump should be between 1 and 2 in.
as much water as is needed to reach the desired slump
and the maximum aggregate size should not exceed 3/4
(but not exceeding the permissible w/c ratio). in.
] The properties of the materials are as follows:
The fresh concrete should be tested for slump, unit ] Cement : Type I, specific gravity = 3.15
weight, yield, air content, and its tendencies to
] Coarse Aggregate: Bulk specific gravity (SSD) = 2.70;
segregate, bleed, and finishing characteristics. Also, absorption capacity = 1%; dry-rodded unit weight = 100 lb/ft3;
hardened samples should be tested for compressive and surface moisture = 0%
flexural strength. ] Fine Aggregate: Bulk specific gravity (SSD) = 2.65; absorption
capacity = 1.3%; fineness modulus = 2.70; surface moisture = 3%

ACI Mix Design Example ACI Mix Design Example

] Step 4. Estimation of mixing water and air content.
Since freezing and thawing is important, the concrete
] Step 1. Required material information (already given).
must be air-entrained. From Table 2, the recommended
] Step 2. Choice of slump. The slump is given, consistent air content is 6%; the water requirement is 280 lb/yd3.
with Table 1.
Maximum aggregate size (in)
Slump(in) 0.375 0.5 0.75 1 1.5 2 3 6
1 to 2 305 295 280
280 270 250 240 225 180
3 to 4 340 325 305 295 275 265 250 200
6 to 7 365 345 325 310 290 280 270 -
Air Content
Mild 4.5% 4.0% 3.5% 3.0% 2.5% 2.0% 1.5% 1.0%
Moderate 6.0% 5.5% 5.0% 4.5% 4.5% 4.0% 3.5% 3.0%
Extreme 7.5% 7.0% 6.0%
6.0% 6.0% 5.5% 5.0% 4.5% 4.0%
Step 3. Maximum aggregate size. Given: 3/4 inches

ACI Mix Design Example ACI Mix Design Example

] Step 5. Water/cement ratio. From Table3, the ] Step 6. Calculation of cement content. Based on steps 4
estimate for required w/c ratio to give a 28-day and 5, the required cement content is:
strength of 5,000 lb/in2 is 0.4.

28-day Compressive Non-AE AE 280lb / yd 3

weight of cement = = 700lb / yd 3
Strength (psi)
0.4
2,000 0.82 0.74
3,000 0.68 0.59
4,000 0.57 0.48
5,000 0.48 0.40
0.40
6,000 0.41

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 ACI Mix Design Example ACI Mix Design Example
] Step 7. Estimation of coarse aggregate content. ] The coarse aggregate will occupy:
Interpolating Table 4 for the fineness modulus of the
17.01 ft
3
0.63 × 27ft
3
fine aggregate of 2.70 =
yd 3 yd 3
Value from
Fineness Modulus Table 4
Max Aggregate (in) 2.4 2.5 2.6 2.7 2.8 2.9 3
0.375 0.50 0.49 0.48 0.47 0.46 0.45 0.44 ] The OD weight of the coarse aggregate
0.500 0.59 0.58 0.57 0.56 0.55 0.54 0.53

17.01ft × 100 lb 1,701 lb

0.750 0.66 0.65 0.64 0.63
0.63 0.62 0.61 0.60 3
=
1.000
1.500
0.71
0.75
0.70
0.74
0.69
0.73
0.68
0.72
0.67
0.71
0.66
0.70
0.65
0.69 yd 3 ft 3 yd 3
2.000 0.78 0.77 0.76 0.75 0.74 0.73 0.72
3.000 0.82 0.81 0.80 0.79 0.78 0.77 0.76 Dry-Rodded
6.000 0.87 0.86 0.85 0.84 0.83 0.82 0.81 Unit Weight

ACI Mix Design Example ACI Mix Design Example

] The SSD weight of coarse aggregate is: ] Step 8. Estimation of fine aggregate content by the
absolute volume method.
] Water: 280 lb/62.4 lb/ft3 = 4.49 ft3
1,701 lb 3 × (1 + 0.01 ) = 1,718
lb
yd yd 3 ] Cement: 700 lb/(3.15 x 62.4 lb/ft3) = 3.56 ft3

Absorption ] Coarse Aggregate: 1,718 lb/(2.70 x 62.4 lb/ft3) = 10.20 ft3

Capacity
AC = 1.0%
] Air: 6% x 27ft3/yd3 = 1.62 ft3

Total 19.87 ft3

ACI Mix Design Example ACI Mix Design Example

] Therefore, the fine aggregate must occupy a volume of: ] Step 9. Adjustment for moisture in the aggregate.

27 ft 3 − 19.87 ft 3 = 7.13 ft 3 ] 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.
] The SSD weight of the fine aggregate is:
] Decrease the amount of water required by surface
7.13 ft 3 × 2.65 × 62.4lb = 1,179 lb moisture content of the weight of the fine aggregate
ft 3
] Increase the amount of aggregate by the amount equal to
Specific Gravity
of Fine Aggregate Unit Weight the surface moisture
of Water

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 ACI Mix Design Example ACI Mix Design Example

] Step 9. Adjustment for moisture in the aggregate. ] Thus the estimated batch weights per yd3 are:

] The fine aggregate required is:

Water = 245 lb
1,179 lb (1 + 0.03) = 1,214.4 lb/yd3 or 1,214 lb/yd3 Cement = 700 lb
Coarse aggregate = 1,718 lb
Surface Moisture 3% Fine aggregate (wet) = 1,214 lb
Surface Moisture 3%

] The water required is: ] Total = 3,877 lb/yd3

280 lb - 1179 lb (0.03) = 244.6 lb/yd3 or 245 lb/yd3

Class ACI Mix Design Example Class ACI Mix Design Example

] Consider the following example: The 28-day ] Step 1. Required material information (already given).
compressive strength should be 4,000 lb/in2. The slump
should be between 3 and 4 in. and the maximum ] Step 2. The slump is given, consistent with Table 1.
aggregate size should not exceed 1 inch. The fine
aggregate in the storage bins is very wet.
] 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 = 1.1%; dry-rodded unit weight = 105 lb/ft3
surface moisture = 1%
] Fine Aggregate: Bulk specific gravity (SSD) = 2.67; absorption
capacity = 1.3%; fineness modulus = 2.70;
surface moisture = 1.5% Step 3. Maximum aggregate size. Given: 1 inch

Class ACI Mix Design Example Class ACI Mix Design Example

Step 4. Estimation of mixing water and air content. From Step 5. Water/cement ratio. From Table3, the estimate
Table 2, the recommended air content is 1.5%; the water for required w/c ratio to give a 28-day strength of 4,000
requirement is 325 lb/yd3. lb/in2 is 0.57.

Maximum aggregate size (in)

28-day Compressive Non-AE AE
Slump(in) 0.375 0.5 0.75 1 1.5 2 3 6
350 335 315 300 275 260 220 190
Strength (psi)
1 to 2
3 to 4 385 365 340 325
325 300 285 245 210 2,000 0.82 0.74
6 to 7 410 385 360 340 315 300 270 -
3,000 0.68 0.59

Air Content 3.0% 2.5% 2.0% 1.5% 1.0% 0.5% 0.3% 0.2% 4,000 0.57 0.48
1.5%
5,000 0.48 0.40
6,000 0.41

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 Class ACI Mix Design Example Class ACI Mix Design Example
] 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

325 lb / yd 3
= 570 lb / yd 3
Fineness Modulus
weight of cement = Max Aggregate (in) 2.4 2.5 2.6 2.7 2.8 2.9 3
0.57 0.375 0.50 0.49 0.48 0.47 0.46 0.45 0.44
0.500 0.59 0.58 0.57 0.56 0.55 0.54 0.53
0.750 0.66 0.65 0.64 0.63 0.62 0.61 0.60
1.000 0.71 0.70 0.69 0.68
0.68 0.67 0.66 0.65
1.500 0.75 0.74 0.73 0.72 0.71 0.70 0.69
2.000 0.78 0.77 0.76 0.75 0.74 0.73 0.72
3.000 0.82 0.81 0.80 0.79 0.78 0.77 0.76
6.000 0.87 0.86 0.85 0.84 0.83 0.82 0.81

Class ACI Mix Design Example Class ACI Mix Design Example
] The coarse aggregate will occupy:
] The SSD weight of coarse aggregate is:
18.36 ft
3
0.68 × 27ft
3
=
yd 3 yd 3

1,928 lb × (1 + 0.011) = 1,949 lb

yd 3 yd 3
Value from
Table 4

] The OD weight of the coarse aggregate Absorption

Capacity

18.36ft × 105 lb 1,928 lb

3 AC = 1.1%
=
yd 3 ft 3 yd 3
Dry-Rodded
Unit Weight

Class ACI Mix Design Example Class ACI Mix Design Example

] Step 8. Estimation of fine aggregate content by the ] Therefore, the fine aggregate must occupy a volume of:
absolute volume method.
] Water: 325 lb/62.4 lb/ft3 = 5.21 ft3 27 ft 3 − 20.09 ft 3 = 6.91 ft 3
] Cement: 570 lb/(3.15 x 62.4 lb/ft3) = 2.90 ft3

] The SSD weight of the fine aggregate is:

] Coarse Aggregate: 1,949 lb/(2.70 x 62.4 lb/ft3) = 11.57 ft3

6.91 ft 3 × 2.67 × 62.4lb = 1,151 lb

] Air: 1.5% x 27ft3/yd3 = 0.41 ft3
ft 3
Total 20.09 ft3 Specific Gravity
of Fine Aggregate Unit Weight
of Water

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 ACI Mix Design Example ACI Mix Design Example

] Step 9. Adjustment for moisture in the aggregate. ] Step 9. Adjustment for moisture in the aggregate.

] The fine aggregate required is: ] The water required is:

1,151 lb (1 + 0.015) = 1,168 lb/yd3 325 lb – 1,168 lb (0.015) – 1,968 lb (0.01) = 288 lb

Fine Aggregate
Surface Moisture 1.5% Surface Moisture 1% Coarse Aggregate
Surface Moisture 1.5%
Surface Moisture 1%

] The coarse aggregate required is:

1,949 lb (1 + 0.01) = 1,968 lb/yd3 ] The adjusted required water is 288 lb/yd3

Class ACI Mix Design Example End of ACI Mix Design

Questions?
] Thus the estimated batch weights per yd3 are:

Water = 288 lb
Cement = 570 lb
Coarse aggregate (wet) = 1,968 lb
Fine aggregate (wet) = 1,168 lb

] Total = 3,994 lb/yd3