CEMENT CONCRETE MIX DESIGN

Cement Concrete Mix Design means, determination of the proportion of the concrete ingredients i.e. Cement, Water, Fine Aggregate,Coarse Aggregate which would produce concrete possessing specified properties such as workability, strength and durability with maximum overall economy.
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Methods of Concrete Mix Design

I.S. Method British Method A.C.I. Method etc.

These Methods are based on two basic assumptions Compressive Strength of Concrete is governed by its Water-Cement Ratio Workability of Concrete is governed by its Water Content
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Data required for concrete mix design

1. 2. 3. 4. 5. Grade of Concrete Eg: RCC-M30-A20 Slump required in mm Eg: 25 75 mm Degree of Site Control Eg: Good Type of Exposure Eg: Moderate Grade of Cement Eg: OPC 43 Grade

Placing Conditions 1 Blinding Concrete; Shallow Sections; Pavements using pavers Mass Concrete; Lightly reinforced sections in Slabs, Beams, Walls, Columns; Floors; Hand placed Pavements; Canal lining; Strip Footings Heavily reinforced sections in Slabs, Beams, Walls, Columns; Slip form work; Pumped Concrete. Trench fill; In-Situ Piling; Tremie Concrete

Degree of Workability 2 Very Low

Slump (mm) 3 See 7.1.1

Low

25-75

Medium High

50-100 100-150

Site control having proper storage of cement; weigh batching of all materials; Controlled addition of water, regular checking of all materials, Good aggregate grading and moisture content; And periodical checking of workability and strength. Fair Site control having deviation from the above.
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Sl. No.
1 i)

Environment
2 Mild

Exposure Conditions
3

Concrete surfaces protected against weather or aggressive conditions, except those situated in coastal area.
Concrete surfaces sheltered from severe rain or freezing whilst wet. Concrete exposed to condensation and rain. Concrete continuously under water. Concrete in contact or buried under non-aggressive soil/ground water. Concrete surfaces sheltered from saturated salt air in coastal area. Concrete surfaces exposed to severe rain, alternate wetting and drying or occasional freezing whilst wet or severe condensation. Concrete completely immersed in sea water. Concrete exposed to coastal environment. Concrete exposed to sea water spray, corrosive fumes or severe freezing conditions whilst wet. Concrete in contact with or buried under aggressive sub-soil/ground water. Surface of members in tidal zone. Members in direct contact with liquid/solid aggressive 9 chemicals.

ii)

Moderate

iii)

Severe

iv)

Very Severe

v)

Extreme

Approximate Quantity of Materials required for concrete mix design

1. 2. 3. Cement : 200 Kg. Fine Aggregate : 240 Kg. Coarse Aggregate : 180 Kg. (20 mm) 180 Kg. (10 mm)

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STEPS INVOLVED IN CONCRETE MIX DESIGN

Step I:- Determine the physical properties of concrete ingredients.

I. CEMENT (OPC 43 Grade)

Sl. No. 1
2

Particulars of Test
Standard consistency (% by weight) Setting Time in minutes a) Initial b) Final Compressive Strength in N/sq.mm at the age of a) 3 days b) 7 days c) 28 days Specific Gravity Fineness in Sq.m/Kg

Result
25.6

Specifications As per IS:8112-1976

95 210

30 Minimum 600 Maximum

4 5

24 35 46 3.00 337

23 Minimum 33 Minimum 43 Minimum 225 Minimum

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II. 1.

FINE AGGREGATE Sieve Analysis

Sieve Size % Passing 100 100 98 65 42 8 0 Specifications for ZoneII As per IS:383-1970 100 90-100 75-100 55-90 35-59 8-30 0-10

10.0 mm 4.75 mm 2.36 mm 1.18 mm 600 micron 300 micron 150 micron

2. 3.

Specific Gravity Unit Weight in Kg/Cu.m a) Loose b) Rodded Materials Finer than 75 micron (% by weight)

2.60

: : :

1460 1580 1.00 3 Max

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4.

III. 20.0mm COARSE AGGREGATE 1. Sieve Analysis

Sieve Size % Passing Specifications As per IS:383-1970 Graded 100 95-100 25-55 0-10 Single Sized 100 85-100 0-20 0-5

40.00mm 20.00mm 10.00mm 4.75mm

100 90 3 0

2. 3.

Specific Gravity Unit Weight in Kg/Cu.m a) Loose b) Rodded

2.65

: :

1467 1633

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IV. MECHANICAL PROPERTIES

Sl. No. 1 Particulars of Test Crushing Value in % Result 28 Specifications As per IS: 383-1970 For For 2 Impact Value in % 24 For For 3 Los Angeles Abrasion Value in % 30 For For 30 Maximum wearing surfaces 45 Maximum other concrete 30 Maximum wearing surfaces 45 Maximum other concrete 30 Maximum wearing surfaces 50 Maximum other concrete

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V. 1.

10.0mm COARSE AGGREGATE Sieve Analysis

Sieve Size % Passing Specifications As per IS:383-1970
Graded Single Sized 100 85-100 0-20 0-5

12.50mm 10.00mm 4.75mm 2.36mm

100 85 19 0

2.

Unit Weight in Kg/Cu.m a) Loose b) Rodded

: :

1427 1587

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VI. BLENDING OF COARSE AGGREGATE:

Sieve size (mm)

IS:383-1970 Specifications (Graded)

% Passing

20 mm 100 90 3 0

10 mm 100 100 85 19

60%+40% 100 94 40 7

50%+50% 100 95 44 10

40 20 10 4.75

100 95-100 25-55 0-10

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Fck Fck fck

Step II:= = =

Compute Target Mean Compressive Strength:

fck + t * S Target Mean Compressive Strength at 28 days in N/Sq.mm Characteristic Compressive Strength at 28 days in N/Sq.mm Standard Deviation in N/Sq.mm A Statistic, depending on accepeted proportion of low results. 1.65 for 1 in 20 accepted proportion of low results

S t

= =

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Values of Accepted proportion of low results

1 in 5,

20%

0.84
1.28 1.50 1.65

1 in 10, 10% 1 in 15, 6.7% 1 in 20, 5%

1in 40,

2.5%

1.86
2.33

1 in 100, 1%

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Assumed Standard Deviation (Table 8, IS:456-2000)

Grade of Concrete
M10, M15

Assumed Standard Deviation (N/Sq.mm)

Good Site Control Fair Site Control

3.5

4.5

M20, M25
M30, M35 M,40,M45 M50

4.0
5.0

5.0
6.0

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Step III:- Select the Water-Cement ratio of trial mix from experience
S. No. 1 Concrete Grade M10 Minimum expected W/C 0.9

2
3 4 5 6 7

M15
M20 M25 M30 M35 M40

0.7
0.55 0.50 0.45 0.40 0.35

M45

0.30

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Step IV:- Select the water content per cubic metre of concrete from table2 of I.S: 10262-2009.

Maximum size of Aggregate (mm) 10 20 40

Water Content per cubic metre of concrete (Kg) 208 186 165

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Approximate water content (Kg) per cubic metre of concrete (Table 32, SP:23-1982) Maximum Size of Aggregate (mm)

Slump (mm) 30-50 80-100 150-180

10
205 225 240

20
185 200 210

40
160 175 185
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Volume of Coarse Aggregate per Unit Volume of Total Aggregate (Table 3, IS:10262-2009) Maximum Volume of Coarse Aggregate per Unit Size of Volume of Total Aggregate Aggregate Zone IV Zone III Zone II Zone I (mm) 10 20 0.50 0.66 0.48 0.64 0.46 0.62 0.44 0.60

40

0.75

0.73

0.71

0.69

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Step VI:- Then we find the quantities of Fine & Coarse aggregate by absolute volume method.
V = (W+C/Sc+(1/p) * (fa/Sfa)) * (1/1000) and V = (W+C/Sc+(1/(1-p)) * (ca/Sca)) * (1/1000) Where V = Absolute volume of fresh concrete = 1 m3 W = Mass of Water (Kg) per m3 of concrete C = Mass of Cement (Kg) per m3 of concrete p = Percentage of fine aggregate. fa = Mass of fine aggregate ca = Mass of coarse aggregate Sc = Specific gravity of cement. Sfa = Specific gravity of fine aggregate. Sca = Specific gravity of coarse aggregate.
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- (Eq.1) - (Eq.2)

Substituting the values in Eq(1), we get 1000 = 185 + 411/3.0 + (1/0.36) * fa /2.6) = 185 + 137 + fa/0.936 = 322 + fa/0.936 fa = (1000 322) * 0.936 = 678 * 0.936 = 635 Kg.

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Substituting the values in Eq(2), we get 1000 = 185 + 411/3.0 + (1/0.64) * ca /2.65) = 185 + 137 + ca/1.696 = 322 + ca/1.696 ca = (1000 322) * 1.696 = 678 * 1.696 = 1150 Kg.

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So the mix proportion works out to be W : C : fa : ca = 185 : 411 : 635 : 1150 = 0.45 : 1 : 1.55 : 2.80 This mix will be considered as Trial Mix No.2

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Step VII:- Make slump trials to find out the actual weight of water to get required slump. Make corrections to the water content & %FA, if required. Step VIII:- Compute 2 more trial mixes with W/C ratios as 0.40 & 0.50, taking %FA as 34% and 38% respectively.

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Trial Mix No. 1:Cement = 185 / 0.4 = 462.5 Kg. Substituting the values in Eq(1), we get 1000 = 185 + 462.5/3.0 + (1/0.34) * fa /2.6) fa = 584 Kg. Substituting the values in Eq(2), we get 1000 = 185 + 462.5/3.0 + (1/0.66) * ca /2.65) ca = 1156 Kg. So the mix proportion works out to be W : C : fa : ca = 185 : 462.5 : 584 : 1156 = 0.4 : 1 : 1.26 : 2.50
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Trial Mix No. 3:Cement = 185 / 0.5 = 370 Kg. Substituting the values in Eq(1), we get 1000 = 185 + 370/3.0 + (1/0.38) * fa /2.6) fa = 683 Kg. Substituting the values in Eq(2), we get 1000 = 185 + 370/3.0 + (1/0.62) * ca /2.65) ca = 1136 Kg. So the mix proportion works out to be W : C : fa : ca = 185 : 370 : 683 : 1136 = 0.5 : 1 : 1.85 : 3.07
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Step IX:- Cast atleast 3 cubes for each trial mix. Step X:- Test the cubes for compressive strength at 28 days.

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28 Days Compressive Strengths of Trial Mixes

W/C Ratio 0.40 0.45 0.50

C/W Ratio 2.50 2.22 2.00

Compressive Strength (Kg/Cm2) 457 420 360

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Step XI:- Draw a graph between compressive strength Vs C/W Ratio.

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Step XII:- From the graph, find the W/C ratio for the required target mean compressive strength.

Step XIII:- Calculate the mix proportions corresponding to the W/C ratio, obtained from the graph.

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Final Mix:From the graph, for a target strength of 390 Kg/Cm2, W/C ratio = 0.47 Cement = 185 / 0.47 = 394 Kg. Substituting the values in Eq(1), we get 1000 = 185 + 394/3.0 + (1/0.38) * fa /2.6) fa = 675 Kg. Substituting the values in Eq(2), we get 1000 = 185 + 394/3.0 + (1/0.62) * ca /2.65) ca = 1123 Kg. So the mix proportion works out to be W : C : fa : ca = 185 : 394 : 675 : 1123 = 0.47 : 1 : 1.71 : 2.85
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Step XIV:- Check the cement content & W/C ratio against the limiting values given in Table-5 of I.S: 456-2000 for given type of exposure & type of Concrete.

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Table-5 Minimum Cement content Maximum Water-Cement ratio and Minimum Grade of Concrete for different exposures with normal weight of aggregate of 20mm nominal maximum size.
Plain Concrete Sl. No. Exposure Minimum Cement Content kg/m3 Maximum Free Water Cement Ratio Minimum Grade of Concrete Reinforced Concrete Minimum Cement Content kg/m3 Maximum Free Water Cement Ratio Minimum Grade of Concrete

i)
ii) iii) iv) v)

Mild
Moderate Severe Very Severe Extreme

220
240 250 260 280

0.60
0.60 0.50 0.45 0.40

M15 M20 M20 M25

300
300 320 340 360

0.55
0.50 0.45 0.45 0.40

M20
M25 M30 M35 M40
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From the table 5 of IS: 4562000, the minimum Cement content & W/C ratio, For moderate, for RCC are 300Kgs. & 0.5
The Cement content = 394Kgs. > 300Kgs. Hence Ok

The W/C Ratio = 0.47 < 0.5 Hence Ok

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TEST REPORT Concrete Mix RCC M30 with 20.0mm M.S.A.

Sl. No. 1 Particulars Characteristic Compressive strength in N/Sq.mm Result 30

2
3 4 5 6 7 8

Maximum size of Aggregate in mm

Type of Exposure Type of Site control Target Average Compressive Strength in N/Sq.mm Workability in terms of Slump in mm Mode of Compaction Mix Partiuclars: a. Water-Cement Ratio b. Materials per cubic metre of concrete in Kg. i) Water ii) Cement (OPC 43 Grade) iii) Fine Aggregate iv) Coarse Aggregate c. Mix Portion by weight

20.0
Moderate Good 38.2 25-75 Vibration 0.47 185 394 675 1123 1:1.71:2.85

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 Secondary Slides:

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Sieve Analysis of Fine Aggregate

Weight of sample = 500g (approx) Observations:

Weight retained(g) Sieve size Trail 1 Trail2 Total Cumulative weight retained (g) % Cumulative weight retained (g) 0 0 2 35 % Passing IS:383-1970 Specifications Zone =II

10 mm 4.75 mm 2.36 mm 1.18 mm

0 2 6 166

0 2 7 165

0 4 13 331

0 4 17 348

100 100 98 65

100 90-100 75-100 55-90

600 micron
300 micron 150 micron

118
175 36

117
160 42

235
335 78

583
918 996

58
92 100

42
8 0

35-59
8-30 0-10

150 micron pass

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Zones of Fine Aggregate

IS : 383 1970 Sieve Size Zone I 10.00 mm 4.75 mm 2.36 mm 100 90-100 60-95 % Passing for Zone II 100 90-100 75-100 Zone III 100 90-100 85-100 Zone IV 100 95-100 95-100

1.18 mm
600 micron 300 micron

30-70
15-34 5-20 0-10

55-90
35-59 8-30 0-10

75-100
60-79 12-40 0-10

90-100
80-100 15-50 0-15
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150 micron

Sieve Analysis of Coarse Aggregate

2 20 mm aggregate : a. Minimum weight of sample = 25 Kg b. Observations :

Sieve size

Weight retained (Kg)

Cumulative weight retained (Kg) 0.0 4.7

% Cumulative weight retained (Kg) 0 10 97 100 -

IS:383-1970 Specifications % Passing Graded 100 90 3 0 100 95-100 25-55 0-10 Single sized 100 85-100 0-20 0-5 -

40 20 10 4.75 4.75 P

0.0 4.7 41.5 1.6 0

46.2 47.8 47.8

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Sieve Analysis of Coarse Aggregate

2 10 mm aggregate : a. Minimum weight of sample = 12 Kg b. Observations :

Sieve size

Weight retained (Kg)

Cumulative weight retained (Kg) 0.0 5.4

% Cumulative weight retained (Kg) 0 15 81 100 -

IS:383-1970 Specifications % Passing Single Sized 100 85-100 0-20 0-5 -

12.5 10 4.75 2.36 2.36 P

0.0 5.4 24.3 6.9 0

100 85 19 0 -

29.7 36.6 36.6

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Target mean compressive strength

N = 20 Avg = 30

N = 20 Avg = 35

27,30,30,32,35, 27,33,34,29,28, 30,28,31,32,26, 34,33,25,27,29

Total = 600

28, 32,35,38,40, 34,35,35,36,39, 33,32,32,34,37, 32,35,38,39,36

Total = 700

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The value of S depends on Degree of Site control and grade of concrete as given in I.S: 4562000 (Table.8)
Good Fair

Sl. No.

Concrete Grade

Fck
S 1.65XS N/mm
2

Fck
S 1.65XS N/mm2 Kg/cm2

Kg/cm2

1 2 3 4 5 6

M10 M15 M20 M25 M30 M35

3.5 3.5 4.0 4.0 5.0 5.0

58 58 6.6 6.6 8.3 8.3

15.8 20.8 26.6 31.6 38.3 43.3

161 212 271 322 390 441

4.5 4.5 5.0 5.0 6.0 6.0

7.4 7.4 8.3 8.3 9.9 9.9

17.4 22.4 28.3 33.3 39.9 44.9

178 229 288 339 407 458

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Step IV:-Fixation of Water Cement ratios for trial mixes.

Sl. No. 1 2

Required Grades M20, M15, M10 M25, M20, M15

Trial W/C

0.55, 0.6, 0.9 0.5, 0.6, 0.7

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Final Mix for RCC-M25:From the graph, for a target strength of 322 Kg/Cm2, W/C ratio = 0.57 which is > 0.5, So, limit W/C ratio to 0.5 only. Cement = 185 / 0.5 = 370 Kg. Substituting the values in Eq(1), we get 1000 = 185 + 370/3.0 + (1/0.38) * fa /2.6) fa = 683 Kg. Substituting the values in Eq(2), we get 1000 = 185 + 370/3.0 + (1/0.62) * ca /2.65) ca = 1136 Kg. So the mix proportion works out to be W : C : fa : ca = 185 : 370 : 683 : 1136 = 0.50 : 1 : 1.85 : 3.07

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Specific Gravity of Cement [ IS : 4031 1988]:

Specific gravity of cement (Sc) (W2 - W1) = ---------------------------- x 0.79 (W4 - W1) - (W3 - W2) Where, W1 = Weight of specific gravity bottle in g W2 = Weight of specific gravity bottle with about half filled cement in g W3 = Weight of specific gravity bottle with about half filled cement & rest is filled with kerosene in g. W4 = Weight of specific gravity bottle completely filled with kerosene in g 0.79 = Specific Gravity of Kerosene.

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Specific Gravity of Fine Aggregate & Coarse Aggregate [ IS : 2386 (Part.3) 1963]: D Specific gravity (Gs) = -------------C ( A B)

Where,
A = Weight of Pycnometer vessel containing sample & filled with distilled water in g B = Weight of Pycnometer completely filled with distilled water only in g C = Weight of saturated surface dry sample in g D = Weight of oven dried sample in g

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