CLASS NOTES

ON

CONCRETE TECHNOLOGY
MIX DESIGN

6.0 Mix Design of Portland Cement Concrete

Mix design is the process of determining relative quantity of concrete ingredients with the objective:
To ensure the desire workability of concrete at plastic stage (green stage).
To obtain the required strength, durability and surface finish at its hardened stage.
To achieve the economic mix.

6.1 Nominal & Design Mix of Concrete:

Nominal Mix: A concrete mix in which the proportions are adopted in generalized form irrespective
of its ingredient properties.
Design Mix: A concrete mix in which the proportions are adopted depending upon the ingredient
properties to obtain the desired workability, strength & durability of concrete.

6.2 Introduction to Nominal Mix:

Nominal mixes are suitable only upto the M20 grade concrete and desired strength / workability
cannot be guaranteed. But still useful if no any mix design data is available in site.

Concrete
Grade
M5
M7.5
M10
M15
M20

Table 6.1: Nominal Mix given by IS456:2000

Total dry Aggregate( in Kg )per
Fine: Coarse
50Kg Cement
(Proportion)
800
Generally 1:2 but
625
subjected to an upper
480
limit of 1:1.5 & lower
330
limit of 1:2.5
250

Water per 50Kg of

Cement
60
45
34
32
30

Example: For M15 grade concrete if we adopt,

Cement=50Kg,
Total Aggregate=330Kg,
Fine:Coarse =1:2,
Fine=330/(1+2)=110Kg,
Cement: Fine: Coarse = 50: 110: 220 = 1: 2.2: 4.4,
Nominal Mix = 1: 2.2: 4.4 and W/C =0.64

Water=32Kg
Coarse=2*330/(1+2)=220Kg
Water/Cement = 32/50 = 0.64

6.3 Mix Design of Concrete by DOE, ACI and Indian Standard Methods:
DOE Method
Developed by The Building Research Establishment Laboratory (BRE), Department of Environment
(DOE), U.K. DOE method outlines the procedure for design of concrete mix with 28 days cube
strength as high as 75Mpa.
The proportion of fine aggregate is determined depending upon the max. size of aggregate, degree
of workability, grading of fine aggregate & W/C ratio.
The degree of workability is indicated by specific value of slump & Vee -Bee time.

Class notes on Concrete Technology Mix Design (P -1)

Er. Sudip Karanjit

Design Steps:
Step1: Determine target mean strength (Fmean) from specified characteristic strength(Fck):
Fmean = Fck+ * K
= Standerd deviation (IS456:2000 page23 For M10/15=3.5, M20/25=4.0 M30-50=5.0)
K= Himsworth constant (1.64 for 95% confidence level)

Figure 6.1: Normal Distribution curve.

Step2: Determine Minimum W/C ratio based on Target Strength and compare with W/C
requirement for Durability consideration.

Table 6.2: Approximate compressive strength of

concrete with free water cement ratio W/C 0.5

1
2

Fig: 6.2: Compressive strength vs W/C ratio

Class notes on Concrete Technology Mix Design (P -2)

Er. Sudip Karanjit

Table 6.3: Minimum Cement Content & Max. W/C for Durability:
Exposure

Mild
Moderate
Severe
Very severe
Extreme

PCC
Min.
Cement
Kg/m3
220
240
250
260
280

RCC
Max. free
W/C

Min.
Cement
Kg/m3
300
300
320
340
360

0.6
0.6
0.5
0.4
0.4

Minimum Grade of
concrete
PCC
RCC

Max. free
W/C
0.55
0.5
0.45
0.45
0.4

M15
M20
M20
M25

M20
M25
M30
M35
M40

Step3: Determine free water content depending upon max size & type of aggregate and degree of
workability. Table 6.4: Approximate Water content (Kg/m3) for various degree of Workability:
Max. Size of
Aggregate
mm
10
20
40

Slump
Vee-Bee
Aggregate Type
Uncrushed
Crushed
Uncrushed
Crushed
Uncrushed
Crushed

0-10
>12

10-30
6-12

30-60
3-6

60-180
0-3

150
180
135
170
115
155

180
205
160
190
140
175

205
230
180
210
160
190

225
250
195
225
175
205

Step4: Calculate cement content from W/C ratio & water content of mix determined previously.
Compare value with min. / max. value of cement content of durability requirement (Table 6.3) &
modify if required.
Step5: Determine wet density of concrete depending upon free water content & relative density of
combine aggregate. Calculate Total aggregate content knowing the Wet density of concrete.

Fig: 6.3: Wet density of mix vs Free water content.

Class notes on Concrete Technology Mix Design (P -3)

Er. Sudip Karanjit

Calculate total aggregate content (Saturated surface dry): o-c-w

o= Wet density of concrete (Kg/m3)
c= Cement Content (Kg/m3)
w= Free Water Content (Kg/m3)
Step6: Determine Proportion of fine aggregate depending upon the W/C ratio, Max size of
aggregate, fine aggregate grading zone & workability level.
Fine Aggregate =Total Agg. * Proportion of Fine Agg.
Coarse Aggregate= Total Agg. Fine Agg.

Fig: 6.4 Recommended % of fine aggregate in total aggregate vs W/C ratio. (Nominal max. size 20mm)

Fig: 6.5 Recommended % of fine aggregate in total aggregate vs W/C ratio. (Nominal max. size
40mm)

Class notes on Concrete Technology Mix Design (P -4)

Er. Sudip Karanjit

EXAMPLE DOE METHOD: Design concrete mix for RCC work for the moderate exposure
environment. The characteristic strength required is 30Mpa. Max aggregate size = 20mm crushed.
Sieve analysis of fine aggregate shows 50% passing through 600 sieve. Average Sp. gr. of aggregate
is 2.65. Slump required 30-60 mm. OPC Cement (Type1) will be used.
Step1: Fmean = Fck+ * K = 30 + 1.64*5 = 38.2Mpa (For M30, =5 Ref; IS456:2000 page23)
Step2: Minimum W/C ratio based on Tar]\get Strength (Fig6.2 / Table 6.2) = 0.6
Minimum W/C ratio based on durability (Table 6.3) = 0.5
Adopt minimum W/C = 0.5
Step3: Free water content (Table 6.4) = 210kg/m3
Step4: Cement content (Step 2&3) = 210/0.5 = 420kg/m3 > min cement 300kg/m3 from Table 6.3

(OK)
Step5: Wet density of concrete for 210kg free water content & sp gr aggregate 2.65 (Fig 6.3) =
2375kg/m3
Total aggregate content = Total Concrete Cement Water = 2375 420 -210 = 1745kg/m3
Step6: % of fine aggregate (Fig 6.4 for slump 30-60 & W/C = 0.5 & FA 50% passing 600 sieve.) = 35%
of total aggregate
F A = 0.35 * 1745 = 610.75kg/m3
C A = 1745 610.75 = 1134.25kg/m3
Cement : Fine : Coarse = 420 : 610.75 : 1134.25 = 1 : 1.454 : 2.701

Class notes on Concrete Technology Mix Design (P -5)

Er. Sudip Karanjit

ACI METHOD

The American Concrete Institute mix design method is suggested by the ACI Committee 211.
One method is based on the estimated weight of the concrete per unit volume & the other
method is based on calculation of the absolute volume occupied by concrete ingredient.
This method consider the requirement for workability, consistency, strength and durability of
concrete.

Design Steps:
Collect the data required for mix design first:
-

Fineness modulus of fine aggregate, Sp. Gravity of fine & coarse agg. , Unit wt. of dry rodded
coarse agg. & Sp. Gr. of cement.

Step1: Determine target mean strength (Fmean) from specified characteristic strength(Fck):
Fmean = Fck+ * K
= Standerd deviation (IS456:2000 page23 For M10/15=3.5, M20/25=4.0 M30-50=5.0)
K= Himsworth constant (1.64 for 95% confidence level)
Step2: Determine Minimum W/C ratio based on Target Strength and compare with W/C
requirement for Durability consideration.
Table 6.5: Relation between W/C ratio & Av. Compressive strength (ACI 211.1:91)

38.2

0.45

Class notes on Concrete Technology Mix Design (P -6)

Er. Sudip Karanjit

Table 6.6: Relation between W/C ratio & Exposure conditions (ACI 318-89)

Step3: Determine free water content depending upon max size & type of aggregate and degree of
workability.
Table 6.7: Water content determination depending upon slump & max. agg. size

Step4: Calculate cement content from W/C ratio & water content of mix determined previously.
Step5: Determine Bulk volume of dry rodded C A depending upon Max. Agg. size & Fineness
Modulus of fine aggregate (Table 6.8).
Calculate Wt. of C A = Bulk Volume * Bulk Density

Class notes on Concrete Technology Mix Design (P -7)

Er. Sudip Karanjit

Table: 6.8 Bulk Volume of Dry rodded Coarse Aggregate depending upon FM & Max Agg. size

Step6: Determine Wt. of Fresh concrete (Table 6.9) per m3:

Table 6.9:

OR

Wm = 10A(lOO-A)+c(1-A/ C) -w(A -1)

where
Wm = weight of fresh concrete, kg/m3
A = weighted average specific gravity of
combined fine and coarse aggregate
C = specific gravity of cement (= 3:15)
c = cement requirement, kg/m3
w = mixing water requirement, kg/m3
A = air content, percent

Step7: Determine Wt of F A required:

F. A. (wt.) = Total wt of concrete (step6) Cement (step4) Water (step3) C A (step5)
Now Mix proportion = Cement: FA: CA & W/C

Class notes on Concrete Technology Mix Design (P -8)

Er. Sudip Karanjit

EXAMPLE ACI METHOD: Design concrete mix for RCC underground water tank. The characteristic
strength required is 30Mpa at 28days. Max aggregate size = 20mm crushed. Sieve analysis of fine
aggregate shows Fineness modulus 2.6. Dry rodded bulk density of CA = 1600kg/m3. Average Sp. gr.
of aggregate is 2.65. Slump required 30-60 mm. OPC Cement (Type1) will be used.

Step1: Fmean = Fck+ * K = 30 + 1.64*5 = 38.2Mpa (For M30, =5 Ref; IS456:2000 page23)
Step2: Minimum W/C ratio based on Target Strength (Table 6.5) = 0.45
Minimum W/C ratio based on durability (Table 6.6) = 0.5
Adopt minimum W/C = 0.45
Step3: Free water content (Table 6.4) = 185kg/m3
Step4: Cement content (Step 2&3) = 185/0.45 = 411kg/m3
Step5: Bulk volume of dry rodded C A = 0.64 {depending upon Max. Agg. Size 20mm & Fineness
Modulus of fine aggregate 2.6 (Table 6.8)}
Calculate Wt. of C A = Bulk Volume * Bulk Density = 0.64m3 * 1600kg/m3 = 1024 kg/m3
Step6: Wet density of concrete for Max 20mm aggregate & Normal Concrete (Table 6.9) =
2355kg/m3
Step7: Determine Wt of F A required:
F A required: = F. A. (wt.) = Total wt of concrete (step6) Cement (step4) Water (step3) C A
(step5)
= 2355 411 - 185 1024 = 735kg/m3

Cement : Fine : Coarse = 411 : 735 : 1024 = 1 : 1.788 : 2.491

W/C = 0.45

Class notes on Concrete Technology Mix Design (P -9)

Er. Sudip Karanjit

IS METHOD OF MIX DESIGN

This method is recommended by the Bureau of Indian standards covered in IS10262: 1982. The
method given can be applied from medium to high strength concrete. As the procedure developed
in 1982 & since then lots of modification seen in concrete technology, code revision seems to be
required.
Design Steps:
Step1: Determine target mean strength (Fmean) from specified characteristic strength(Fck):
Fmean = Fck+ 1.65 * S
S = Standerd deviation (IS456:2000 page23 For M10/15=3.5, M20/25=4.0 M30-50=5.0)
Step2: Determine Minimum W/C ratio based on Target Strength & Cement type, and compare
with W/C requirement for Durability consideration.
Fig: 6.6: Compressive strength vs W/C ratio
IS10262:82

Class notes on Concrete Technology Mix Design (P -10)

Fig 6.7: Compressive strength of concrete various

cement type IS10262:82

Er. Sudip Karanjit

Fig 6.7: Compressive strength of concrete various cement type (Germany)

Table 6.10: Minimum Cement Content & Max. W/C for Durability (IS456:2000):
Exposure

Mild
Moderate
Severe
Very severe
Extreme

PCC
Min.
Cement
Kg/m3
220
240
250
260
280

RCC
Max. free
W/C
0.6
0.6
0.5
0.4
0.4

Min.
Cement
Kg/m3
300
300
320
340
360

Max. free
W/C
0.55
0.5
0.45
0.45
0.4

Minimum Grade of
concrete
PCC
RCC

M15
M20
M20
M25

M20
M25
M30
M35
M40

Step3: Determine free water content & Fine to total Agg. ratio depending upon max size of
aggregate & concrete Strength for standard condition.
Make the adjustment depending upon Ingredient properties.
Table 6.11: Approximate Sand & Water content (Kg/m3) for Compaction Factor CF =0.8
(approximate slump 30mm), Angular coarse aggregate & Sand zone II as per IS383:1970

Upto M35
W/C - 0.6
CF =0.8

> M35
W/C 0.35
CF =0.8

Class notes on Concrete Technology Mix Design (P -11)

Er. Sudip Karanjit

Table 6.12: Adjustment table for water content & % sand in total aggregate.

Step4: Calculate cement content from W/C ratio & water content of mix determined previously.
Compare value with min. / max. value of cement content of durability requirement (Table 6.10) &
modify if required.
Step5: Calculate Aggregate content:

Step6: The mix proportion above obtained by the assumption that the aggregates are saturated &
surface dry if any deviation, make adjustment in water & aggregate content.

Class notes on Concrete Technology Mix Design (P -12)

Er. Sudip Karanjit

EXAMPLE IS METHOD: Design concrete mix for RCC Silo. The characteristic strength required is
30Mpa at 28days. Max aggregate size = 20mm crushed. Sieve analysis of fine aggregate shows Sand
zone III. Workability required compaction factor 0.9. Exposure condition moderate. Cement Type E 53Mpa will be used. Sp. gr. of CA = 2.7 / FA = 2.6 / Cement = 3.15.

Step1: Fmean = Fck+ 1.65*S = 30 + 1.65*5 = 38.25Mpa (For M30, =5 Ref; IS456:2000 page23)
Step2: Minimum W/C ratio based on Target Strength (Fig 6.7) = 0.45
Minimum W/C ratio based on durability (Table 6.10) = 0.5
Adopt minimum W/C = 0.45
Step3: Free water content (Table 6.11) = 186kg/m3 & F A = 35% of Total Agg.
Adjustments (Table 6.12):
Condition Change

Water Content % adjustment Sand content % Adjustment

Sand confirming Zone III

Increase in Compaction Factor

+ 3%

(0.9-0.8) = 0.1
Decrease in W/C ratio (0.45-0.6)

= -0.15
Total

+3%

1.5%
0

(0.15/0.05)
= - 3%
-4.5%

F A content = 35 -4.5 = 30.5%

Water content =186 +3% *186 = 191.6kg
Step4: Cement content (Step 2&3) = 191.6/0.45 = 425.8kg/m3 > 240kg ok
Step5: Calculate Aggregate content:

Air content
425.8
(1 0.02) = (191.6 +
+
3.15

.3052.6

1
1000

fa = 518kg/m3
=

10.305
0.305

518

2.7
2.6

Ca= 1225.8kg/m3

Cement : Fine : Coarse = 425.8 : 518 : 1225.8 = 1 : 1.217 : 2.879 & W/C = 0.45

Class notes on Concrete Technology Mix Design (P -13)

Er. Sudip Karanjit

Class notes on Concrete Technology Mix Design (P -14)

Er. Sudip Karanjit