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Unit-III: Concrete Mix Design
Unit-III: Concrete Mix Design
Unit-III
Syllabus
Concrete Mix Design
• Mix Design for compressive strength by I.S. Method, Road
Note Method, British method, Mix Design for flexural
Strength
Concrete Mix Design
• Concrete mix design may be defines as the art of selecting
suitable ingredients of concrete and determining their
relative proportions with the object of producing concrete of
certain minimum strength & durability as economically as
possible.
Objectives of Mix Design
• The purpose of concrete mix design is to ensure the most optimum
proportions of the constituent materials to fulfill the requirement of
the structure being built. Mix design should ensure following
objectives.
• To achieve the designed/ desired workability in the plastic stage
• To achieve the desired minimum strength in the hardened stage
• To achieve the desired durability in the given environment conditions
• To produce concrete as economically as possible.
Basic Considerations
• The following point must be considered while designing concrete
mixes
• Cost
• Specification
• Workability
• Strength and Durability
Basic Considerations
Cost
• The cost of concrete is made up of
• Material Cost
• Equipment Cost
• Labour Cost
• The variation in the cost of materials arises from the fact that cement is
several times costlier than aggregates. So it is natural in mix design to aim
at as lean a mix as possible. Therefore, all possible steps should be taken to
reduce the cement content of a concrete mixtures without sacrificing the
desirable properties of concrete such as strength and durability.
Basic Considerations
Specifications
• The following point may be kept in mind while designing concrete
mixes
• Minimum Compressive Strength required
• Minimum water/ cement ratio
• Maximum cement content to avoid shrinkage cracks
• Maximum aggregate / cement ratio
• Maximum density of concrete in case of gravity dams
Basic Considerations
Basic Considerations
Workability
• The following points related to workability shall be kept in mind while
designing concrete mixes.
• The consistency of concrete should no more than that necessary for placing,
compacting and finishing.
• For concrete mixes required high consistency at the time of placing, the use
of water-reducing and set-retarding admixtures should be used rather than
the addition of more water
• Wherever possible, the cohesiveness and finishibility of concrete should be
improved by increasing sand/ aggregate ratio than by increasing the
proportion of the fine particles in the sand.
Workability
Strength and Durability
• Fck= f ck + t.s
Where,
• Fck= target average compressive strength at 28 days
• F ck= characteristics compressive strength at 28 days
• s= Standard deviation
• t= a stastical value, depending upon the accepted proportion of low results and
the number of tests.
IS Method of Mix Design
• According to Is 456: 2000 and IS 1343:1980 te
characteristic strength is defined as the value below which
not more than 5 percent of results are expected to fall. In
such cases the above equation reduced to
• Fck= fck + 1.65 s
• The value of standard deviation is obtained from the table
IS Method of Mix Design
IS Method of Mix Design
Step-II
Selection of Water –Cement Ratio
• Since different cements and aggregates of different maximum sizes,
grading, surface texture shape and other characteristics may produce
concrete of different compressive strength for the same free water
cement ratio, the relationship between strength and free water
cement ratio should preferable be established for the material
actually to be used. In the absence of such data, the preliminary free
water-cement ratio corresponding to the target strength at 28 days
may be selected from the relationship shown below
IS Method of Mix Design
IS Method of Mix Design
• Alternatively, the preliminary free water cement ratio by
mass corresponding to the average strength may be selected
from the relationship shown below using the curve
corresponding to the 28 days cement strength to be used for
the purpose. However, this will need 28 days for testing of
cement.
IS Method of Mix Design
IS Method of Mix Design
• The free water-cement ratio thus selected should be checked
against limiting water-cement ratio for the requirements of
durability as per table 5.4 and the lower of the two values
should be adopted.
IS Method of Mix Design
IS Method of Mix Design
Step 3 Estimation of Air Content
• Approximate amount of entrapped air to be expected in normal
concrete is given in table 9.6
Nominal Maximum size Water Content per cubic Sand as percentage total
of Aggregates metre of concrete (kg) aggregate by absolute
volume of (%)
10 200 28
20 180 25
IS Method of Mix Design
• Adjustment of values in water content and sand percentage for other
conditions
Change in Condition Adjustment Required
Water Content Percentage sand in total aggregate
For sand confirming to 0 + 1.5 percent for zone I
grading Zones I , III -1.5 percent for zone III
and IV -3.0 for zone IV
Increase or decrease in ± 3 % 0
values of compacting
factor by 0.1
Each 0.05 increase or 0 ± 1%
decrease in free water -15 kg/m 3 -7 %
cement ratio
Calculation of Cement Content
• The cement content per unit volume of concrete may be
calculated from the free water-cement ratio obtained in
step- 2, and the quantity of water per unit volume of
concrete obtained in step-4
• The cement content so obtained should be checked against
the minimum cement content for the requirement of
durability as per table 5 IS 456:2000 and the greater of the
two value is adopted.
Step -6 Calculation of Aggregate Content
• With the quantities of water and cement per unit volume of concrete and
the ratio of fine to total aggregate already determined, the total aggregate
content per unit volume of concrete may be calculated from the
following equations
• V= [ W + C + 1 x fa ] x 1 for fine aggregate …………………………
1
Sc p Sfa 1000
And
V=[W+ C+ 1 x Ca ] x 1 for coarse aggregate …………..2
Sc (1-p) Sca 1000
Step -6 Calculation of Aggregate Content
Where,
• V= Absolute volume of fresh concrete (m3)
• W= Mass of Water (kg) per m3 of concrete
• C= Mass of Cement (Kg) per m3 of concrete
• Sc= Specific gravity of cement say 3.15
• P= ratio of fine aggregate to total aggregate by absolute volume
• Fa and Ca = Total masses of fine aggregate and coarse aggregate (kg) / m 3 of concrete
mass respectively
• Sfa, Sca= Specific gravities of saturated surface dry fine aggregate and coarse
aggregate respectively
• Normally Sfa= 2.6 and Sca= 2.7
Trial Mixes
• The Calculated mix proportions shall be checked by means
of trial batches. The quantity of material should be sufficient
for at least three 150 mm size cube concrete specimens
Example
• Using I.S Method design a concrete mix for reinforced concrete
structure for the following requirement.
• Design data
• Characteristic compressive strength= 20 N/mm 2
• Maximum size of aggregates= 20 mm (angular)
• Degree of workability= 0.9 CF
• Degree of quality Control= Good
• Type of exposure= Mild
Example
• Test data for Material
• Cement used= Ordinary Portland cement of grade 43 with 28 days strength 51
N/mm2
• SG= 3.15
• Bulk Density = 1450 kg/m3
• Aggregate Fine Aggregate Coarse Aggregate
• SG 2.66 2.75
• Bulk Density 1700 1800
• Water absorption 1 0.5
• Free Moisture 2 Nil
Example
Step-I Target Mean Strength
• Fck= fck + ts
• fck= 20 N/mm2
• T= 1.65
• S= 4 from table 9.5 for M 20
• Therefore
• Fck= 20 + 1.65 x 4
• = 26.6 N/mm2 (Mpa)
Example
Step-II
• Selection of Water Cement Ratio
• From the fig the free water cement ratio required for the target mean
strength of 26.6 N/ mm2 is 0.5
• From fig, for 28 days strength of cement 51 N/mm2, for curve D the free
water cement ratio is 0.52
• From table the maximum free water cement ratio for mild exposure is
0.55
• Hence the free water cement ratio is taken as the minimum of above
three values i.e. w/c = 0.5
Example
Step –III
• Estimation of Air Content
• For maximum Size of aggregate of 20 mm, the air content is taken as
2%
Example
Step-4 Selection of water and Sand Content
• From table 9.7 for 20 mm nominal maximum size aggregate and
sand confirming to grading zone –II water content per cubic metre of
concrete = 186 kg and sand content as percentage of total aggregate
by absolute volume= 35 %
• Water= 186 kg/m3 of concrete
• Sand= 35 % of total aggregate by absolute volume
Example
• For change in values in water cement ratio, compaction factor and
sand belonging to zone III the following adjustments required.
Change in Condition Water Content Percentage Sand in
total aggregate
For Decrease in water cement ratio 0 -2.0
(0.6-0.5) that is 0.1
0.1 x 1 = 2.0
0.05
For increase in compacting factor (0.9 + 3 0
-0.8) = 0.1
0.1 x 3 = 3
0.1
Example
• Required Water Content = 186 + ( 186 x 3 / 100)
• = 186 + 5.58
• = 191.6 lit /m3
=
required sand content as percentage of total aggregate by absolute
volume= 35 – 3.5
=
31.5 %
Example
Determination of Cement Content
• Water Cement ratio= 0.5
• Water = 191.6 lit= 191.6 kg
• Therefore W/c = 0.5
• 191.6 = 0.5
•C
• C=383.4 kg/m3
• = 383kg/m3 > 300 kg / m3 therefore O.K.
Example
Determination of fine and coarse Aggregates
• Consider volume of Concrete= 1 m3
• But entrapped air in wet concrete = 2 %
• Therefore volume of fresh concrete= 1 – 2
100
1- 0.02
V= 0.98 m3
Example
• With the quantities of water and cement per unit volume of concrete and
the ratio of fine to total aggregate already determined, the total aggregate
content per unit volume of concrete may be calculated from the following
equations
• V= [ W + C + 1 x fa ] x 1 for fine aggregate ………………1
Sc p Sfa 1000
0.98 = [ 191.6 + 383 + 1 + fa ] x 1
3.15 0.315 2.66 1000
980 = 313.187 + 1.19 fa
fa= 558.75 kg mass of F.A
Example
And
V=[W+C+ 1 x Ca ] x 1 for coarse aggregate …………..2
Sc (1-p) Sca 1000
0.98 = [ 191.6 + 383 x 1 x Ca ] x 1
3.15 (1-0.315) 2.75 1000
980 = 313.187 + 0.5308 Ca
Ca= 1256.24 kg mass of C.A
Example
Water Cement F.A C.A
191.6 li 383 kg 558.75 kg 1256.24 kg
0.5 1 1.46 3.28
• W= 0.44
C
Example
Step III Estimation of air Content
• For maximum Size of Aggregate of 20 mm, the air content is taken as
2.0 %
Example
Step-4
• Selection of Water and Sand Content
• From table 9.7 for 20 mm nominal maximum size aggregates and
sand confirming to grading Zone-II, water content per cubic metre
of concrete = 186 kg and sand content as percentage of total
aggregate by absolute volume = 35 % i.e.
• Water = 186 kg/m3
• Sand = 35 % of total aggregate by absolute Volume.
Example
• For Change in values in water-Cement ratio, compaction factor and
sand belonging to zone I the following adjustments are required.
Change in Condition Adjustment Required
Water Content Percentage Sand in total
Aggregate
(i) For Decrease in Water-Cement ratio (0.6 0 -3.2
– 0.44) that is 0.16
Therefore 0.16 x 1 = 3.2
0.05
(ii) For Increase in Compacting factor (0.9 +3 0
-0.8)= 0.1
Therefore 0.1 x 3 = 3.0
0.1
(iii) For Sand Conforming to Zone-I of table 4 0 +1.5
of IS 383-1970
Example
• Required water Content = 186 + ( 186 x 3 )
100
= 191.6 lit / m3
Required Sand Content as Percentage of Total aggregate by absoluter
Volume
p= 35 – 1.7
=
33.3 %
Example
Step- V Determination of Cement Content
• Water Cement Ratio = 0.44
• Water = 191.6 lit = 191.6 kg
• Therefore,
• W= 0.44
C
191.6 = 0.44
C
C= 435.45 kg/m3 > 300 kg /m3
This cement content is adequate for ‘Moderate Exposure’ condition, according to table 5
IS 456-2000)
Example
Determination of fine and Coarse content:
• Consider volume of concrete = 1 m3
But, entrapped air in wet concrete= 2 %
Therefore, absolute volume of fresh concrete= 1 – 2
100
= 1 – 0.02
V= 0.98 m3
Therefore,
Example
• V= [ W + C + 1 x fa ] x 1 for fine aggregate…1
Sc p Sfa 1000
And
0.98= [ 191.6 + 436 + 1 + fa ] x 1
3.15 0.33 2.6 1000
980 = 191.6 + 138.41 + 1.15 fa
fa= 562.76 kg
= 563 kg mass of F.A.
Example
Similarly,
V=[W+C+ 1 x Ca ] x 1 for coarse aggregate……..2
Sc (1-p) Sca 1000
• 0.98 = [ 191.6 + 436 x 1 x Ca ] x 1
3.15 (1-0.333) 2.65 1000
980 = 191.6 + 138.41 + 0.5657 Ca
Ca= 1149 kg/m3 mass of C.A.
Example
• Mix Proportions (By Mass)
45 0.38 -
40 0.43 -
35 0.48 0.4
30 0.55 0.46
25 0.62 0.53
20 0.7 0.61
15 0.8 0.71
The ACI Method of Mix Design
• The water Cement ratio obtained from Strength point of
view is to be checked against maximum W/C Ratio given for
special exposure condition given in table 9.11 and minimum
of the two is to be adopted.
The ACI Method of Mix Design
• Requirement of ACI for W/C Ratio and Strength for Special Exposure
Condition
Exposure Condition Maximum W/C ratio, normal density Minimum Design Strength, low
aggregate concrete Density aggregate Concrete, MPA
Concrete Intended to be Watertight
(a) Exposed to fresh Water 0.5 25
(b) Exposed to brackish or sea Water 0.45 30
Concrete Exposed to freezing and Thawing in a moist Condition:
45 0.38 -
40 0.43 -
35 0.48 0.4
30 0.55 0.46
25 0.62 0.53
20 0.7 0.61
15 0.8 0.71
Exposure Condition Maximum W/C ratio, normal density Minimum Design Strength, low
aggregate concrete Density aggregate Concrete, MPA
Concrete Intended to be Watertight
(a) Exposed to fresh Water 0.5 25
(b) Exposed to brackish or sea Water 0.45 30
Concrete Exposed to freezing and Thawing in a moist Condition:
• Check this w/c ratio for durability considerations and adopt the
lower value
Minimum 30 35 40 45 50
grade
Maximu 0.65 0.6 0.55 0.5 0.45
m w/c
ratio
Maximu 275 300 325 350 400
m cement
content
CONCRETE MIX DESIGN
Fig.1 Relation between
compressive strength and
free water cement ratio
mark a point corresponding to
strength f1, at water cement ratio 0.5.
draw a curve parallel to the nearest
curve, through this point
Using the new curve,
Read off ( abscissa) the water cement
ratio
corresponding to the target mean
strength (ordinate)
Introduction
In this method, the aggregate to cement ratios are worked out on the basis of type of
aggregate, max size of aggregate and different levels of workability.
The relative proportion of aggregates is worked on basis of combined grading curves. This
method facilitates use of different types of fine and coarse aggregates in the same mix.
The relative proportion of these can be easily calculated from combined grading curves.
The values of aggregate to cement ratio are available for angular rounded or irregular coarse
aggregate.
2. w/c ratio is read from compressive strength v/s w/c ratio graph.
3. Proportion of combined aggregates to cement is determined from tables, for maximum size 40 mm and 20
mm.
4. If the aggregate available differs from the standard grading, combine FA and CA so as to produce one of
the standard grading.
5. The proportion of cement, water, FA and CA is determined from knowing the water/cement ratio and the
aggregate/cement ratio.
6. Calculate the quantities of ingredients required to produce 1 m 3 of concrete, by the absolute volume
method, using the specific gravities of cement and aggregates.
Plastic Density
This method
This
method leads
leads to
to very
very high
high cement
cement contents
contents and
and thus
thus is
is becoming
becoming
obsolete.
obsolete.
In many
In
many cases
cases use
use of
of gap
gap graded
graded aggregate
aggregate becomes
becomes unavoidable.
unavoidable. In In many
many
parts of
parts of the
the country
country the
the practice
practice is
is to
to use
use 20mm
20mm coarse
coarse aggregates
aggregates without
without
10mm aggregates.
10mm aggregates. This
This is
is because
because ofof quality
quality of
of 10mm
10mm aggregates
aggregates produced
produced
from jaw
from jaw crusher
crusher is
is very
very poor
poor .Gap
.Gap grading
grading does
does not
not fit
fit in
in to
to the
the standard
standard
combined grading
combined grading curves
curves of
of RRL
RRL method.
method.
Sand available
Sand
available in
in some
some parts
parts of
of country
country is
is graded
graded that
that itit is
is high
high on
on coarse
coarse
fraction (1.18mm
fraction (1.18mm andand above)
above) and
and low
low on
on fines
fines (600micron
(600micron and and below).
below). ItIt
is difficult
is difficult to
to adjust
adjust the
the sand
sand content
content toto match
match anyany of of the
the standard
standard
combined grading
combined grading curves
curves .The
.The combined
combined grading
grading curve
curve often
often cuts
cuts across
across
more than
more than one
one standard
standard curves
curves inin such
such cases
cases
• Internet websites
• http://www.foundationsakc.org/
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