Concrete Mix Design

UNIT 8 CONCRETE MIX DESIGN

Structure
8.1 Introduction
Objectives
8.2 Objectives of Mix Design
8.3 Grades of Concrete
8.4 Ordinary Concrete Mixes
8.5 Design Mixes
8.6 Steps of Mix Design
8.6.1 Crushing Strength of Concrete
8.6.2 Water-cement Ratio
8.6.3 Fixing Slump for the Mix
8.6.4 Fixing Nominal Size of Coarse Aggregate
8.6.5 Proportioning of Aggregates
8.6.6 Determining the Quantity of Cement Paste
8.7 Methods of Mix Design
8.7.1 Nominal Proportion Method
8.7.2 Maximum Density Method
8.7.3 Fineness Modulus Method
8.7.4 Voids Method
8.7.5 Talbot-Richart Method
8.7.6 Trial and Error Method
8.7.7 The American Concrete Institute (ACI) Mix Design Method
8.7.8 Road Note No. 4 Method
8.8 Yield of Concrete
8.9 Cement Factor
8.10 Summary
8.11 Answers to SAQs

8.1 INTRODUCTION
In previous unit, you have studied the types of concrete and their uses, concreting
under extreme environmental conditions, problems and precautions during
concreting under extreme environmental conditions. In this unit, you will study
the objectives of mix design, their types, yield of concrete and cement factor.
Objectives
After studying this unit, you should be able to
• explain the objectives of mix design,
• discuss the methods of mix design,
• calculate the yield of concrete, and
• calculate the cement factor.
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Concrete Technology
8.2 OBJECTIVES OF MIX DESIGN
Following are the objectives of mix design :
(a) To achieve a minimum compressive strength at 28 days period based
on the value assumed by the designer.
(b) The concrete mix should be cohesive for preventing the possibility of
honeycombing and segregation.
(c) The provision of sufficient workability for obtaining cent-percent
compaction with the available compacting equipment.
(d) Durability, which is associated with compressive strength, the greater
the strength, the more durable the concrete.
(e) The mix should be designed to achieve the desired strength in the
hardened stage.
(f) The mix should be designed in such a way that the minimum quantity
of cement is used as it is the costliest material.
(g) To achieve satisfactory appearance.

8.3 GRADES OF CONCRETE

Normally concrete is graded into seven grades as M10, M15, M20, M25, M30,
M35, and M40. In the designation of concrete, letter M refers to the mix and the
number refers to the specified characteristic compressive strength of 150 mm
cube after 28 days curing expressed in N/mm2.
Table 8.1 : Minimum Characteristic Compressive Strength
(According to IS 456 : 2000)
Sl. No. Concrete Grade Characteristic
Compressive Strength
1. M10 10
2. M15 15
3. M20 20
4. M25 25
5. M30 30
6. M35 35
7. M40 40

Characteristic compressive strength of a material is the value of the material

below which not more than 5% of the test results are expected to fail.

8.4 ORDINARY CONCRETE MIXES

Nominal concrete mixes are made without preliminary tests. In ordinary concrete,
no trial mixes are done in the laboratory. These concretes are used when use of
controlled concrete is not practicable. Ordinary concretes are of grades M10,
M15, M20 and M25. Ordinary concrete mixes offer simplicity and under normal
circumstances, they have a margin of strength above that specified. Nominal
mixes do not account for the varying characteristics of the concrete materials and
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may result in under- or over-rich mixes. The nominal mix is expressed in terms of Concrete Mix Design
aggregate/cement ratios by volume generally. Bulk density has to be consider in
case of weigh batching. In selecting the ratio of fine to coarse aggregates, suitable
modifications or adjustments have to be made.

8.5 DESIGN MIXES

Design mix depends upon the type of cement, quality of the fine and coarse
aggregate, amount of water used. The other factors like the workability;
compacting equipment, curing method adopted, etc. have to be considered before
arriving at the mix proportion. This method also does not guarantee the correct
mix for the designed strength, though the figures are arithmetically correct. Trial
mixes are essential. The design mix will serve as a guide only.

8.6 STEPS OF MIX DESIGN

8.6.1 Crushing Strength of Concrete
To fix the average crushing strength of concrete for laboratory conditions is the
first step in designing a mix. The concrete mix shall be designed for greater
strength than required because the working conditions in the field are not
controlled as in the laboratory. The ISI code specifies that the crushing strength
for which the mix should be designed in the laboratory should be 1.25 times the
strength actually required.

8.6.2 Water-Cement Ratio

The ratio of minimum quantity of water to the weight or volume of cement
required for obtaining a consistent and workable concrete mix is called
water-cement ratio. Water-cement ratio is expressed as number of litres of water
required per bag of cement. Table 8.2 indicates water-cement ratio for various
crushing strength of concrete.
Table 8.2 : Crushing Strength of Concrete and Water-Cement Ratio

Crushing Water-cement Ratio

Sl. Quantity of
Strength in
No Water Remarks
kg/cm2 after By Weight By Volume
. (Litres/Bag)
28 Days
1. 530 0.35 0.50 17.5 Mix-dry

2. 470 0.40 0.57 20.0 Mix-dry

3. 420 0.45 0.64 22.5 Mix-dry

4. 370 0.50 0.71 25.0 Mix-dry

5. 320 0.55 0.79 27.5 Mix workable

6. 280 0.60 0.86 30.0 Mix workable

7. 250 0.65 0.93 32.5 Mix workable

8. 220 0.70 1.00 35.0 Mix workable

9. 200 0.75 1.07 37.5 Wet mix

10. 180 0.80 1.14 40.0 Wet mix

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Concrete Technology 8.6.3 Fixing Slump for the Mix
After fixing the water-cement ratio, the next step is to fix the workability of
concrete and it is done by slump test or compaction factor test. Table 8.3 indicates
the permissible slump values as recommended for different concrete works.
Table 8.3 : Permissible Slump Values in Mm for Various Concrete Works

Sl. Slump Compacting Degree of Use for which Concrete is

No. (mm) Factor Workability Suitable
1. 0-25 0.78-0.85 Very low to Vibrated concrete in roads where
low powerful vibrating equipment can
be used, vibrated piles, pre-cast
beams and railway sleepers and
similar works where high strength
is desired.
2. 25-50 0.85-0.92 Low to Roads with ordinary forms of
medium vibrating and finishing machines
and manually operated compactors,
mass concrete foundations without
vibrations, simple reinforced
sections with vibrations.
3. 50-100 0.92-0.95 Medium to High tamped roads with slump
high 50-75 mm, for normal reinforced
work without vibration and heavily
reinforced sections with vibration.
4. 100-180 >0.95 High For sections with congested
reinforcement other works where
placing is difficult not normally
suitable for vibration.

8.6.4 Fixing Nominal Size of Coarse Aggregate

After fixing slump for the mix, the next step is to fix nominal size of coarse
aggregate for making the concrete. Table 8.4 gives the nominal size of coarse
aggregate for various concrete works.
Table 8.4 : Nominal Size of Coarse Aggregate for Various Concrete Works
Sl. No. Nominal Size of Suitable Concrete Works
Coarse Aggregate
(mm)
1. 15 Reinforced cement concrete lintels and slabs
(50-120 mm), posts and battens (area 40 cm2).
2. 20 Un-reinforced cement concrete work between
50-150 mm, conglomerate floors, reinforced cement
concrete work exceeding 120 mm but not 450 mm.
3. 40 Un-reinforced mass cement concrete work on small
jobs over 150 mm, for reinforced work over 450 mm.
4. 65 Un-reinforced mass concrete work on ordinary works.

8.6.5 Proportioning of Aggregates

After fixing the water-cement ratio, slump and nominal size of aggregate, the next
step is to determine the economical proportion for coarse and fine aggregates.
The methods adopted for proportioning of aggregates are arbitrary method,
fineness modulus method, voids method, etc.
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 Concrete Mix Design
8.6.6 Determining the Quantity of Cement Paste
This step consists of preparing a number of batches of combined aggregate in
fixed proportions. In each batch, varying quantities of water-cement paste having
fixed water-cement ratio are added to get the required slump.

SAQ 1

(a) What is the purpose of designing a concrete mix?

(b) How will you fix slump for the mix?
(c) State the steps of mix design.
(d) Fill in the blanks.
(i) Design mix must achieve the desired workability in the _______.
(ii) The concrete mix should be _________________.
(iii) Water-cement ratio determines the _____________ of concrete.
(iv) Slump is measured by ________________.

8.7 METHODS OF MIX DESIGN

For the given concrete materials, the various factors to be considered in
specifying a concrete mix are :
(a) water-cement ratio,
(b) cement content or cement-aggregate ratio,
(c) gradation of the aggregates, and
(d) consistency of the fresh concrete.
In general, all these factors cannot be chosen arbitrarily. Usually two or three of
the factors are specified and others are adjusted to give minimum workability and
economy. The requirements are usually dictated by general experience with
regard to structural design conditions, durability and conditions of placing.
Water-cement ratio expresses the dilution of the paste. Cement content depends
upon the amount of paste. By varying the amount of given fine and coarse
aggregate, gradation of aggregate is controlled. Consistency depends upon the
practical requirement of placing of concrete.
Following are the methods, which are used for proportioning.
(a) Nominal proportion method
(b) Maximum density method
(c) Fineness modulus method
(d) Voids method
(e) Talbot-Richart Method
(f) Trial and error method
(g) ACI mix design method
(h) Road Note No. 4 method 161
Concrete Technology 8.7.1 Nominal Proportion Method
The method of nominal grading of aggregate is frequently used for minor
concrete works, where design mix is not practiced or practicable. The nominal
grading of concrete is usually one part of cement to ‘b’ part of fine aggregate and
‘2b’ part of coarse aggregate, i.e. 1 : 1 : 2; 1 : 1½ : 3, 1 : 2 : 4, 1 : 3 : 6; 1 : 4 : 8
and 1 : 8 : 16, etc.
In general the coarse aggregate preparation is twice that of fine aggregate.
8.7.2 Maximum Density Method
This method is economical to design for a minimum amount of cement-water
paste in a concrete mix. Fuller assumes that the greater the amount of solid
particles that can be packed in a given volume of concrete, the higher will be its
strength. In this method, the aggregates should be graded in such a way that the
mixture attains the maximum density. Fuller suggested curves for this purpose
which are based on,
0.5
⎛d⎞
P = 100 ⎜ ⎟
⎝D⎠
where, D = Maximum size of coarse aggregate,
P = Percentage of total material smaller than size d, and
D = Maximum size of fine aggregate.
The drawback of this method is that the effect of particle interference is ignored.
The aggregates graded to give maximum density results in harsh and practically
unworkable mix. The workability can be improved only when there is excess of
paste above that required to fill the voids in the coarse aggregate.
Suppose it is desired to grade a mix with 20 mm maximum size coarse aggregate
and 4.75 mm fine aggregate, then the value of P, i.e. percentage of material finer
than 4.75 mm, will be given by 0.5
⎛ 4.75 ⎞
P = 100 ⎜ ⎟
⎝ 20 ⎠
= 8.73
= say 50%.
8.7.3 Fineness Modulus Method
The index number, which describes the relative sizes of coarse and fine
aggregates, is called as fineness modulus.
Fineness modulus is determined separately by sieving coarse and fine aggregates
through the following set of sieve.
IS sieves for coarse aggregates are 80 mm, 40 mm, 20 mm, 10 mm and 4.75 mm.
IS sieves for fine aggregates are 1 mm, 600 μ, 300 μ, 212 μ, 150 μ, and 75 μ.
X −Z
P= × 100
Z −Y
where, X = Fineness modulus of coarse aggregate,
Y = Fineness modulus of fine aggregates, and
Z = Economical value of fineness modulus for combined aggregate.
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The above formula will fix the proportion of fine aggregate to coarse aggregate. Concrete Mix Design
The percentage of the coarse aggregate is equal to 100 minus the percentage of
fine aggregate.
Table 8.5 gives the economical value of F.M. for combined aggregate.
Table 8.5 : Economical Value of F.M. for Combined Aggregate
Sl. No. Particle Size Fineness Modulus Average F.M.
(mm)
Minimum Maximum
1. 20 4.7 5.1 4.90
2. 25.4 5.0 5.5 5.25
3. 31.5 5.2 5.7 5.45
4. 38.1 5.4 5.9 5.65
5. 40 5.7 6.3 6.00
6. 80 6.5 7.0 6.75

With high water-cement ratio, lower value of fineness modulus should be adopted
and with low water-cement ratio, higher value of fineness modulus should be
adopted.
The next step is to find out the quantity of water-cement paste to be added to fine
and coarse aggregates in order to obtain the required workability. Slump test is
used to confirm the quantity of water-cement paste. The method consists of
preparing a number of batches of combined aggregate in the fixed proportions. In
each batch, varying quantities of water-cement paste having fixed water-cement
ratio are added to get the required slump. In order to start with, the minimum
quantity of water is added in the first batch. It is determined from the following
formula :
W
0.3 P + 0.1 Y + 0.01 Z = ×P
C
where, P = Quantity of cement by weight,
Y = Quantity of fine aggregate by weight,
Z = Quantity of coarse aggregate by weight, and
W
= Water cement ratio.
C
8.7.4 Voids Method
The principle involved in this method is that the voids in the coarse aggregate are
to be filled in by the fine aggregates and the voids in the fine aggregate are to be
filled in by cement paste. As such, it is necessary to determine voids in fine and
coarse aggregates.
Volume of fine aggregate required for 1cu-m of coarse aggregate = Total voids in
coarse aggregate + 10% aggregate extra to allow for additional voids created by
wedging action.
Volume of cement paste required for 1cu-m of coarse aggregate = Total volume
of voids in fine aggregate + 15% used with 1cu-m of coarse aggregate extra to
allow for additional voids created by wedging action.
The volume of dry cement is usually calculated as equal to 1.2 × Volume of
cement paste. 163
Concrete Technology For determining the percentage of voids, aggregate are filled up to the top in a
vessel of known volume. In this vessel, measured volume of water is poured in
order to fill it.
Measured volume of water added into the vessel
Percentage of voids = × 100
Total volume of aggregate filled in the vessel

SAQ 2

(a) Design a concrete mix from the following data :

Fineness modulus of fine aggregate = 3
Fineness modulus of coarse aggregate = 7
Fineness modulus of combined aggregate = 6
Using 40 mm particles water-cement ratio = 0.58
Weight of coarse aggregate = 50 kg
(b) Design a concrete mix from the following data :
Percentage of voids in fine aggregate = 40%
Percentage of voids in coarse aggregate = 50%

8.7.5 Talbot-Richart Method

This method is based on the experimental investigations, in which the
compressive strength of concrete depends upon Cement Space Ratio (CSR) given
by :
C
CSR =
C +v

where, C = Solid volume of cement, and

V = Volume of water plus voids per unit volume of freshly made concrete.
This method is not popular, as it requires more laboratory work. It also does not
take into account the water-cement ratio law as the basis of strength. This method
involves complicated calculation work and trial mixes to achieve a workable mix.
8.7.6 Trial and Error Method
In this method, the proportion of fine aggregate to coarse aggregate is find out by
trial, which gives the maximum weight of the combined aggregate. The density of
particle of fine aggregate and coarse aggregate is nearly the same, the mixture
which will give the maximum weight will have the maximum solid matter
therefore the least voids and surface area. In another method of trial mix fine
aggregate and coarse aggregate are combined in several proportions. The quantity
of cement per unit volume of concrete is found to give a certain water-cement
ratio for each mixture. The percentage of sand is known as optimum percentage.
Cement required will be more for the same consistency if sand used is more than
optimum. The mix will become harsh for low quantity of sand. Optimum
percentage of sand is lower for lower water-cement ratio.
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The following steps are suggested to determine the mix proportions of a cement Concrete Mix Design
concrete mix.
(a) Select the water-cement ratio corresponding to the designed target of
average compressive strength of concrete and for the required
climatic condition.
(b) Find out the workability in terms of slump for selected water-cement
ratio for a particular job.
(c) Find out the maximum size of coarse aggregate, which is desired to use,
or which is available.
(d) Mix fine aggregate and coarse aggregate in such a manner that either the
mixed aggregate has a grading corresponding to Fuller’s formula or mix
aggregate has a fineness modulus as economical value of fineness
modulus for combined aggregate or mix the aggregate so that the weight
per litre of the mixed aggregates is the maximum or the sand corresponds
to the optimum percentage.
(e) Determine the quantity of cement required per unit volume of coarse
aggregates to get desired slump by actual trials.
(f) Find out the actual proportions of cement, fine aggregate, coarse
aggregate and water to meet the requirements of strength, workability,
durability and economy.
8.7.7 The American Concrete Institute (ACI) Mix Design Method
This method is based on the estimated weight of the concrete per unit volume.
This method takes into consideration the requirements for consistency,
workability, strength and durability.
Following are the steps of ACI mix design method :
(a) Depending on the degree of workability and placing condition
determine the slump value.
(b) Depending on the economical availability and dimensions of the
structure determine the maximum size of aggregate.
(c) For the given slump and maximum size of coarse aggregate determine
the amount of mixing water.
(d) Determine the minimum water-cement ratio either from strength
considerations or from durability considerations.
(e) Determine the amount of cement per unit volume of concrete from
steps (c) and (d). This cement content should not be less than the
cement content required based on durability criteria.
(f) Determine the amount of coarse aggregate required for a unit volume
of concrete. This value is multiplied by the dry rodded unit weight of
the aggregate to get the required dry weight.
(g) Determine the amount of fine aggregate. If the weight of concrete per
unit volume is assumed, the required weight of fine aggregate is
obtained by the difference between the weight of fresh concrete and
the total weight of all other ingredients. The weight of fresh concrete
may be estimated by using following equation.
⎛ ρ ⎞
Wm = 10 ρ A (100 − A) + γ c ⎜1 − A ⎟ − γ w (ρ A − 1)
⎝ ρc ⎠
165
Concrete Technology where, Wm = Weight of fresh concrete in kg/m3,
ρA = Weighted average specific gravity of combined fine
and coarse aggregate,
ρc = Specific gravity of cement = 3.15,
γc = Cement requirement in kg/m3,
γw = Mixing water requirement in kg/m3, and
A = Air content in percent.
(h) Adjust the mixing water quantity on the moisture content in the
aggregate.
(i) Check the calculated mix proportions by trial batches prepared and
tested in accordance with the IS specifications and make another trial
if required.
8.7.8 Road Note No. 4 Method
The experimental investigation is the main base of this method. The designed
concrete must be satisfactory both in plastic as well as in the hardened state. The
choice of mix proportions is governed by both the above conditions. Strengths
produced by different cements are not same at same water-cement ratio. The
required water-cement ratio to produce the designed strength depends upon the
properties of concrete. As strength is proportional to water-cement ratio for a
given type of cement, the Road Note No. 4 method presents a set of curves
relating water-cement ratio and compressive strength at different ages and for
different types of cement.
Design Procedure
The following steps are adopted for mix design :
(a) The average compressive strength of the mix to be designed is
obtained by applying the control factors to the minimum
compressive strength. Table 8.6 shows the relation between
compressive strength and water-cement ratio and it depends
upon the degree of quality control.
Table 8.6 : Relation between Minimum and Mean Compressive Strengths
Sl. No. Conditions Minimum Strength
as a Percentage of
Average Strength
1. Poor control, no supervision, 40
inaccurate volume-batching of all
aggregates.
2. Fair control with weigh batching, 60
occasional supervision, use of two
sizes of aggregate only.
3. Constant supervision, very good 75
control with weigh batching, use
of graded aggregates.`

(b) The water-cement ratio required to give the desired necessary

average compressive strength can be obtained directly from the
curve of Figure 8.1.
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 Concrete Mix Design

Figure 8.1 : Average Compressive Strength and Water-cement Ratio Curves

(c) The proportion of combined aggregate to cement is determined

for aggregates of max. size 40 mm and 20 mm, respectively.
(d) The fine aggregates and coarse aggregates must be combined so
as to produce one of the standard grading if the aggregates
available at the works site differs from the standard grading.
(e) The proportion of cement, fine aggregate, coarse aggregate and
water is determined by using knowledge of aggregate-cement
ratio and water-cement ratio of the mix.
(f) To produce 1 m3 of concrete the quantities of ingredients
required is calculated with the absolute volume method by using
the specific quantities of cement and aggregate.
Method of Combining Aggregates
It is desirable to proportion the available materials in such a way that the
grading of the combined aggregate corresponds to one of the four standard
grading curves. It can be achieved as suggested in Road Note No. 4 method.
Analytical Method
The grading of fine aggregate and coarse aggregate available at works site
are shown in Table 8.7. The fine aggregate and coarse aggregate of 20 mm
maximum size have to be combined in order to approximate to the coarsest
grading of the standard grading. This method is explained by a numerical
example. In standard grading, 25% total aggregate passes through 4.7 mm
IS sieve.
Table 8.7 : Grading of Fine and Coarse Aggregate Available at Site
% Passing FA × 1.0 CA × 3.0 (iii) + (iv) Grading of
I.S. Combined
Sieve FA CA
Aggregate
Size
(i) (ii) (iii) (iv) (v) (v)/4
20 mm 100 100 100 300 400 100
10 mm 100 30 100 90 190 48
4.75 mm 80 6 80 18 and so 98 25
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Concrete Technology Let x and y be the proportions of fine aggregate and coarse aggregate in
combined state. Therefore, to satisfy the percentage passing 4.75 mm IS
sieve, we have
80 x 6y 25 ( x + y )
+ =
100 100 100
0.8 x + 0.06 y = 0.25 ( x + y )

0.8 x − 0.25 x = 0.25 y − 0.06 y

0.55 x = 0.19 y

x : y =1: 3 (Approx.)
It means that fine aggregate and coarse aggregate should be combined in
ratio 1 : 3. The grading of combined aggregate is determined by
multiplying,
(a) by 1.0, and
(b) by 3.0 and then dividing the sum of these products by 4.0.
The resulting combined grading can be obtained as shown in last column.
Graphical Method
Draw a final curve. Vertical line is drawn through the point where sloping
line shows 4.75 mm IS sieve and it intersects the horizontal line
representing the percentage of material say 30%. The ordinate of the
intersections represents the grading of the combined aggregate.
Determination of Weights of Ingredients by Absolute Volume Method
The weight of cement required to produce one cu-m of concrete is found
out by this method. The principle of this method is that the volume of
compacted concrete is equal to the sum of the absolute volume of all
ingredients.
If W = Weight of cement required per cu-m of concrete,
ρc = Specific gravity of cement,
ρCA = Specific gravity of coarse aggregate,
ρFA = Specific gravity of fine aggregate,
ρw = Specific gravity of water, and
V = % age of entrained air in concrete.
Proportions by weight of material
= Cement : FA : CA : Water
= 1 : NFA : NCA : W
The weight of cement can be found out as below :
W1 N HA N W W .W
+ + CA 1 + + 0.01 V = 1 cu.m
pg Pw pFA . pw1 pCA Pw1 pw

In case any admixtures are used as additional ingredients in mix, then

168 similar terms with respect to WB1 may be added.
Limitations Concrete Mix Design

This method covers only three shapes of aggregates and four types grading
which differs greatly from practical aspects. This method should only be
considered as a guide to select the mix proportions since it is strictly
applicable only to the actually aggregates used in their derivation.

SAQ 3

(a) Design a concrete mix required for casting the junctions of columns
and beams with reinforcement to suit the following data using the
method of Road Note No. 4.
Cement − Ordinary Portland
Specified works cube strength – 200 kg/cm2 at 28 days.
Fine aggregate – Natural sand
Coarse aggregate – Crushed granite
Degree of workability – High
Degree of control – Very good
Angular aggregate – 20 mm maximum size.
The aggregates available at works site have the following grading :
IS Sieve No. S 20 10 4.75 2.36 1 0.6 0.3 0.15
mm mm mm mm mm mm mm mm
% Passing C.A. 100 30 8 − − − − −
F.A. − − 100 90 75 45 25 4

The specific gravity and bulk density of various ingredients are as

follows :
Ingredient Dry Bulk Density (kg/m3) Specific Gravity
Cement 1470 3.15
Coarse 1525 2.6
aggregate
Fine aggregate 1685 2.6

After carrying out the design, calculate the quantities of materials

required for 1 cu-m of concrete by weight and volume.
(b) State True or False.
(i) In maximum density method the effect of particle interference is
ignored.
(ii) Talbot-Richart method is not popular and does not take into
account water-cement ratio.
(iii) Water-cement ratio determines the strength of concrete.
(iv) Mix should be designed, in such a way that the desired strength
in the hardened concrete is achieved.
(v) The method of grading the aggregates arbitral is called specific
mix method. 169
Concrete Technology (c) (i) Enlist methods of mix design.
(ii) In fineness modulus method how will you find out the
percentage of fine aggregate to combined aggregate?
(iii) Explain in brief maximum density method for designing mix.
What are its drawbacks?
(iv) State the drawback of Talbot-Richart method of designing
concrete mix.
(v) Explain briefly trial and error method of designing a concrete
mix. Discuss the procedure step-wise.
(vi) Discuss the design procedure of designing a concrete mix
according to Road Note No. 4 method.
(vii) State the limitations of Road Note No. 4 method.

8.8 YIELD OF CONCRETE

The volume of fully compacted concrete per bag of cement is known as yield of
concrete.
Yield of concrete = 2 (volume of one bag of cement)/3 + volume of per bag of
cement aggregates in loose state used for one bag of cement.
The above formula gives approximate value of yield of concrete.
Following methods may be used to obtain exact value of yield of concrete.
(a) Absolute volume method.
(b) Bulk density method.
8.8.1 Absolute Volume Method
The exact yield of concrete per batch of fully compacted concrete may be
calculated by the fact that the volume of concrete is equal to the sum of the
absolute volumes of cement, fine aggregate, coarse aggregates and water. The
absolute volume of loose material is the total volume of solid matter in all the
particles. This is calculated from the weight and the specific gravity of surface of
dry material.
Weight of material
Absolute Volume =
Specific gravity × Weight of water per cum
The specific gravity of cement may be assumed as 3.1. The specific gravity for
aggregates normally adopted as follows :
Fine aggregate 2.5 to 2.6
Quartzite 2.6 to 2.7
Granite 2.7 to 2.8
Basalt 2.8 to 3.0
Lime stone 2.7 to 3.9

The specific gravity of aggregates may be assumed as 2.65 if not given.

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 Concrete Mix Design
8.8.2 Bulk Density Method
Bulk density method is the simplest and accurate method of calculating the yield
of a batch of fully compacted concrete. The bulk density of fresh concrete is
found by fully compacting the concrete into a vessel of known volume and
weighing the sample thus the weight of a 1 m3 concrete can be calculated in six
equal layers and the surface trowelled level before weighing.

8.9 CEMENT FACTOR

The weight of cement required for producing one cubic meter of compacted
concrete is known as cement factor. It is expressed in number of cement bags.
Cement factor is the reciprocal of yield of concrete per bag of cement.
1
Cement Factor =
Yield of Concrete

SAQ 4

(a) Write short note on yield of concrete.

(b) Let us take a mix of 1 bag of cement, 71 litres of sand, 113.3 litres of
coarse aggregate and 30 litres of water. The fine and coarse
aggregates are weighing 1735 kg and 1577 kg per m3, respectively in
loose state. What is the yield of concrete from one bag of cement?
(c) Consider a mix containing 1 bag of cement, 57 litres of dry sand,
113.3 litres of dry coarse aggregate and 30 litres of water is made
with fine aggregate weighing 1577 kg per m3 and coarse aggregate
weighing 1498 kg/m3. Determine yield of concrete.
(d) Define cement factor. State the relation between yield of concrete and
cement factor.

8.10 SUMMARY
In this unit, you have studied objectives of mix design, types of mix design, yield
of concrete and cement factor.

8.11 ANSWERS TO SAQs

SAQ 1
(d) Fill in the blanks.
(i) plastic stage
(ii) cohesive
(iii) strength
(iv) slump test
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Concrete Technology SAQ 2
(a) Here, X = 7
Y=3
Z=6
W
= 0.58
C
Using formula,
(X − Z)
P= × 100
(Z − Y )
(7 − 6)
P= × 100
(6 − 3)
P = 33.3 %.
It means that fine aggregate should be 33.3% of mix aggregates by
weight. Therefore, coarse aggregates will be 66.7%
The weight of coarse aggregate is given 50 kg, the weight of fine
⎛ 33.3 ⎞
aggregate will be, 50 × ⎜ ⎟ = 25 kg (approximately).
⎝ 66.7 ⎠
Make about 5 samples of the combined aggregates in the above
proportions by weighing. The quantity of water required for harsh mix
is calculated by using following equation.
W
0.3 P + 0.1 Y + 0.01 Z = ×P
C
We have Y = 25 kg
Z = 50 kg
W
= 0.58
C
0.3P + 0.1 × 25 + 0.01 × 50 = 0.58 × P
P = 10.71 say 10.5 kg.
Water required = 10.5 × 0.58
= 6.09 say 6 kg.
Therefore mix 10.5 kg of cement and 6 kg of water in the first batch
to perform the slump test. It may be zero. Then add 11.5 kg cement
and 7.75 kg of water (1 kg of cement = 1.75 kg of water)
(as 10.5/6 = 1.75).
Again perform the slump test. The slump may increase. Go on
increasing the quantity of cement and water till the required slump is
obtained. Let us assume that the required slump is obtained by adding
12.5 kg cement and 9.5 kg water.
Therefore, ratio of cement, fine aggregate and coarse aggregate works
out to be 12.5 : 25 : 50 which means 1 : 2 : 4 by weight. It can be
conveniently converted into proportions by volume if volume
batching is required to be performed.
Therefore, designed mix is 1 : 2 : 4.
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 (b) Sand required for 1 cu-m of coarse aggregates Concrete Mix Design

1 × 50 1 × 50 10
= + × = 0.5 + 0.05 = 0.55 cu m
100 100 100
Cement Paste Required
0.55 × 40 0.55 × 40 15
= + × = 0.22 + 0.033 = 0.253 cu m
100 100 100
Dry cement required = 0.253 × 1.2
= 0.3036 cu-m.
Therefore, ratio of cement, sand and coarse aggregate is
0.3036 : 0.55 : 1
1 : 1.81 : 3.29.
SAQ 3
(a) Minimum strength is 75% of the average strength.
Therefore, mean design strength = 200/0.75
= 266.67 kg/m2 say 270 kg/m2.
Water cement ratio = 0.62
Required aggregate-cement ratio for high workability depending upon
water-cement ratio = 4.85
Proportion of fine to total aggregate = 40%
Therefore, proportions by weight of ingredients are as follows :
Cement 1 1
Fine Aggregate 4.85 × 40/100 1.94
Coarse Aggregate 4.85 × 60/100 2.91
Proportions by volume 1 1
Cement
Fine Aggregate 1.94 × 1470/1685 1.692
Coarse Aggregate 2.91 × 1470/1525 2.8
i.e. Ratio of Cement : FA : CA is 1 : 1.692 : 2.8

Quantity of materials required per cu-m of concrete

Let W1 = weight of cement required per cu m of concrete.
Therefore, by absolute volume method :
W1 1.94 W1 2.91 W1 0.62 W1
3
+ 3
+ 3
+ =1
3.15 × 10 2.6 × 10 2.6 × 10 103
W1
(0.3174 + 0.746 + 1.1119 + 0.62) = 1
103
W1 = 1000/2.7953 = 357.74 kg
Cement = 357.74 kg
Water = 357.74 × 0.62 = 221.79 kg
Fine aggregate = 357.74 × 1.94 = 694 kg
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Concrete Technology Coarse aggregate = 357.74 × 2.91 = 1041 kg
Density of fresh concrete = 2314.53 kg/m3.
Quantities of materials required by volume;
Cement = 357.74/1470 = 0.243 cu-m
Water = 221.79/1000 = 0.221 cu-m
Fine aggregate = 694/1685 = 0.411 cu-m
Coarse aggregate = 1041/1525 = 0.682 cu-m
(b) (i) True
(ii) True
(iii) True
(iv) True
SAQ 4
50
(b) Absolute volume of cement = = 0.01613 m3 .
3.1 × 1000

0.071 × 1735
Absolute volume of fine aggregate = = 0.04648 m3 .
2.65 × 1000
Absolute volume of coarse aggregate
0.1133 × 1577
= = 0.06742 m3 .
2.65 × 1000

30
Absolute volume of water = = 0.03 m3 .
1000
Total volume = 0.160 m3.
Therefore, yield of concrete per bag = 160 m3.
= 160 litres.
Therefore, the quantities of ingredients per m3 of concrete would be
as follows
1
Cement = × 50 = 312.5 kg
0.16
1
Fine aggregate (dry) = × 71 = 443.75 litres
0.16
1
Coarse aggregate (dry) = × 113.3 = 708.123 litres
0.16
1
Water = × 30 = 187.5 litres
0.16
(c) Yield of concrete may be determined as follows:
Weight of cement = 50 kg
Weight of fine aggregate (sand) = 0.057 × 1577 = 89.9 kg

174 Weight of coarse aggregate = 0.1133 × 1498 = 170 kg (say)

Weight of water = 30 kg Concrete Mix Design

Total weight = 339.9 kg

Bulk density of concrete = 2400 kg/m3.
Total weight
Therefore, yield of concrete =
Bulk density of concrete

339.9
= = 0.1416 m3
2400
= 141.6 litres
Therefore, the quantities of ingredients per m3 of concrete would be
calculated as follows :
1
Cement = × 50 = 353.107 kg
0.1416
1
Fine aggregate (dry) = × 57 = 402.542 litres
0.1416
1
Coarse aggregate (dry) = × 113.3 = 800.141 litres
0.1416
1
Water = × 30 = 211.864 litres
0.1416

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Concrete Technology
FURTHER READING
Neville, A. M., Brooks J. J., Concrete Technology, ELBS with Longman
Singapore Publishers Ltd., Singapore.
Shetty, M. S., Concrete Technology, S. Chand and Company Ltd., New Delhi.
Gambir, M. L., Concrete Technology, Tata McGraw Hill Publishing Company
Ltd., New Delhi.
Metha, P. K., Paulo, J. M., Concrete : Micro Structure, Properties and Materials,
Monterio ICI Publication.

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 Concrete Mix Design
CONCRETE TECHNOLOGY
Concrete Technology has come a long way since portland cement and reinforced
concrete were started being used in construction. Concrete is a very versatile
material comprises cement, sand (fine aggregate), crushed stone chips or natural
stone (coarse aggregate) and potable water. Sometimes, admixtures are also
added to achieve the desired properties in concrete. The study of characteristics of
concrete; ingredients of concrete; their storing, batching and mixing procedures;
and their mix design, etc. apart from transportation, deposition and finishing of
concrete form the subject matter of this course. In fact, the knowledge and
practice of concrete technology forms an integral part of any civil engineering
curriculum.
This course comprises eight units.
Unit 1 deals with the definition, grades and importance of concrete, properties of
concrete in plastic and hardened stage. It also includes the process diagram of
concrete operation.
In Unit 2, you will be introduced to the most important binding material in
construction, i.e. cement. It discusses about the definitions of related terms,
chemical ingredients of cement, its manufacturing processes, types, properties
and testing procedures of cement.
Aggregates, the essential ingredient of concrete, are described in Unit 3. The unit
deals with the classifications and various properties of aggregates, which are
directly responsible to give quality to fresh and hardened concrete.
Unit 4 deals with the quality of water and various properties of fresh concrete,
namely, hydration of cement, workability, etc. You will also be introduced to
various tests used to measure the workability of concrete in the field as well as in
laboratory. The unit also describes the segregation and bleeding effects on
concrete and their remedial measures.
Unit 5 discusses about the storing, batching and mixing of concrete ingredients,
i.e. cement, sand and aggregate.
Transportation, deposition, compaction, curing and finishing of concrete are
discussed in Unit 6. The unit also introduces you to the different joints provided
in the concrete work and formwork.
In Unit 7, the light has been thrown on the advantages and field of application of
special types of concrete and concreting method under extreme environmental
conditions.
Unit 8 covers the important parameters that govern the design of a good mix of
concrete. Statistical quality control, blending of aggregates and design of a mix
with the desired properties have also been discussed at length.
The Self-Assessment Questions (SAQs), given in each unit, are intended to help
you in checking your own progress. You should study the text carefully, and then
try to solve the SAQs and verify your answers with those given at the end of each
unit. This will definitely develop your confidence.
At the end, we wish you all the best for your all future educational endeavours.

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