JOB MIX FORMULA FOR CONCRETE

Presented By: Irfan Khan

JOB MIX FORMULA FOR CONCRETE
Job Mix Concrete Volume
A trial batch of concrete can be tested to determine how much
concrete is to be delivered by the job mix. To determine the
volume obtained for the job, add the absolute volume Va of the
four components—cements, gravel, sand, and water.
Find the Va for each component from
Va = WL / ( SG ) Wu
Where Va = absolute volume, ft3 (m3)
WL = weight of material, lb (kg)
SG = specific gravity of the material
Wu = density of water at atmospheric condition (62.4 lb/ft3 or
1000 kg/m3)
Then, job yield equals the sum of Va for cement, gravel, sand,
and water.
CONCRETE MIX DESIGN PROCEDURE
Concrete mix designs is best defined as a process in selecting
suitable ingredients, which is cement, aggregate, sand and
water, and determining their relative proportions to give the
required strength, workability and durability. It is
performance specification and minimum cement.
The main changes in terminology are
mix → concrete or design
trial mix → initial test
workability → consistence and consistence class
free water → effective water
trans grade → compressive strength class
MIX DESIGN PROCESS
The mix design process may be required to include
1 Appraisal of the specification for any constraints, e.g.
materials, production and construction conditions
2 Assessing availability of materials
3 Selection of materials
4 Obtaining data and/or testing of materials
5 Identifying influences of mix design on concrete production
and construction methods
6 Economic analyses concerning material and/or concrete
production costs
7 Obtaining approval for designs
8 Recommending changes to specifications
PROPERTIES OF CONCRETE
The aspects of the fresh and hardened concrete to be covered
by the design may include a selection of the following either
because they are specified or because they are needed for
production or construction purposes:
1 Consistence
2 Rate of stiffening
3 Cohesion
4 Plastic density and yield
5 Mix proportions
6 Batch quantities for production
7 Strength
8 Durability parameters
9 Air content
10 Special types of concrete or special properties, e.g. s
IMPORTANT FACTORS
Important factors which are taken into account in the process of mix
design applied to designed mixes, rather than prescribed, standard
or designated mixes, specifications lay down limiting values for a
range of properties that must be satisfied . These properties are
usually: the maximum Water/cement ratio, minimum cement
content, minimum strength, minimum workability, and
maximum size of aggregate, and air content with in specified
limits.
OBJECTIVE OF CONCRETE MIX DESIGN
Two main objectives for concrete mix design:
 To determine the proportions of concrete mix constituents of;
Cement, Fine aggregate (or normally Sand), Coarse aggregate,
and Water.
 To produce concrete of the specified properties.

 To produce a satisfactory of end product, such as beam, column or

slab as economically as possible.
THEORY OF MIX DESIGNS
The Process of Concrete Mix Design
The method of concrete mix design applied here is in accordance to
the method published by the Department of Environment, United
Kingdom (in year 1988).
There are two categories of initial information required:
 Specified variables; the values that are usually found in
specifications.
 Additional information, the values normally available from the
material supplier.
 Reference data consists of published figures and tables is
required to determine the design values including;
 Mix parameters such as target mean strength, water-cement ratio
and concrete density.
 Unit proportions such as the weight of materials.
 The design process can be divided into 5 primary stages. Each
stage deals with a particular aspect of the concrete mix design:
WATER/CEMENT RATIO
Stage 1: Determining the Free Water/ Cement Ratio
i) Specify the required characteristic strength at a specified age, fc
ii) Calculate the margin, M.
M = k x s ….. [ F1 ]
k = A value appropriate to the defect percentage permitted below the
characteristic strength. [ k = 1.64 for 5 % defect ]
s = The standard deviation.

CCS 1: Approximate compressive strength (N/mm2) of concrete mixes

made with a free-water/cement ratio of 0.5
 WATER/CEMENT RATIO
iii) Calculate the target mean strength, fm
fm = fc + M ….. [ F2 ]
where;
fm = Target mean strength
fc = The specified characteristic strength
iv) Given the type of cement and aggregate, use the table of CCS 4to
obtain the compressive strength, at the specified age that corresponds
to a free water/cement ratio of 0.5.

CCS 4: Relationship between compressive strength and free-water/

cement ratio.
WATER/CEMENT RATIO
v) In figure CCS 4, follow the ‘starting line’ to locate the curve which
passes through the point (the compressive strength for
water/cement ratio of 0.5). To obtain the required curve
representing the strength, it is necessary to interpolate between the
two curves in the figure. At the target mean strength draw
horizontal line crossing the curve. From this point the required free
water/cement ratio can be determined.
WATER CONTENT
Stage 2: Determining the Free-Water Content

CCS 2: Approximate free-water contents (kg/m3) required to give

various levels of workability.
Given the Concrete Slump or Vebe time, determine the free water
content from table CCS 2.
CEMENT CONTENT
Stage 3: Determining the Cement Content
Cement Content = Free Water Content/Free-water or Cement Ratio…[F3]
 The resulting value should be checked against any maximum or
minimum value that may be specified. If the calculated cement content
from F3 is below a specified minimum, this minimum value must be
adopted resulting in a reduced water/cement ratio and hence a higher
strength than the target mean strength. If the calculated cement content
is higher than a specified maximum, then the specified strength and
workability simultaneously be met with the selected materials; try to
change the type of cement, the type and maximum size of the aggregate.
TOTAL AGGREGATE CONTENT
Stage 4: Determining the Total Aggregate Content
This stage required the estimate of the density of fully compacted
concrete which is obtained from figure CCS 5. This value depends
upon the free-water content and the relative density of the combined
aggregate in the saturated surface-dry condition. If no information
is available regarding the relative density of the aggregate, an
approximation can be made by assuming a value of 2.6 for un-
crushed aggregate and 2.7 for crushed aggregate.

CCS 5: Estimated wet density of fully compacted concrete.

TOTAL AGGREGATE CONTENT
With the estimate of the density of the concrete the total aggregate
content is calculated using equation F4:
Total Aggregate Content = D – C – W ….. [ F4 ]
where;
D = The wet density of concrete ( in kg/m3)
C = The cement content (in kg/m3)
W = The free-water content (in kg/m3)
AGGREGATE CONTENT
Stage 5: Determining of The Fine and Coarse Aggregate
Contents
This stage involves deciding how much of the total aggregate should
consist of materials smaller than 5 mm, i.e. the sand or fine
aggregate content. The figure CCS 6 shows recommended values for
the proportion of fine aggregate depending on the maximum size of
aggregate, the workability level, the grading of the fine aggregate
(defined by the percentage passing a 600 μm sieve) and the free-
water/ cement ratio. The best proportion of fines to use in a given
concrete mix design will depend on the shape of the particular
aggregate, the grading and the usage of the concrete.
AGGREGATE CONTENT

CCS 6: Recommended proportions of fine aggregate according to

percentage passing a 600 μm sieve.
AGGREGATE CONTENT
The final calculation, equation F5, to determine the fine and coarse aggregate
is made using the proportion of fine aggregate obtained from figure CCS 6
and the total aggregate content derived from Stage 4.
Fine Aggregate Content = Total Aggregate Content x Proportion of Fines..[F5]
Coarse Aggregate Content = Total Aggregate Content – Fine Aggregate
 PROCEDURES OF DESIGN MIXING
Production of Trial Mix Design
 The volume of mix, which needs to make three cubes of size 100 mm is
calculated. The volume of mix is sufficient to produce 3 numbers of cube
and to carry out the concrete slump test.
 The volume of mix is multiplied with the constituent contents obtained
from the concrete mix design process to get the batch weights for the
trial mix.
 The mixing of concrete is according to the procedures given in
laboratory guidelines.
 Firstly, cement, fine and course aggregate are mixed in a mixer for 1
minute.
 Then, water added and the cement, fine and course aggregate and
water mixed approximately for another 1 minute.
 When the mix is ready, the tests on mix are proceeding.
TESTS ON TRIAL MIX DESIGN
 The slump tests are conducted to determine the workability of
fresh concrete.
 Concrete is placed and compacted in three layers by a tamping
rod with 25 times, in a firmly held slump cone. On the removal of
the cone, the difference in height between the uppermost part of
the slumped concrete and the upturned cone is recorded in mm as
the slump.
 Three cubes are prepared in 100 mm x 100 mm each. The cubes
are cured before testing. The procedures for making and curing
are as given in laboratory guidelines. Thinly coat the interior
surfaces of the assembled mould with mould oil to prevent
adhesion of concrete. Each mould filled with two layers of
concrete, each layer tamped 25 times with a 25 mm square steel
rod. The top surface finished with a trowel and the date of
manufacturing is recorded in the surface of the concrete. The
cubes are stored undisturbed for 24 hours at a temperature of 18
to 220C and a relative humidity of not less than 90 %. The
concrete all are covered with wet gunny sacks. After 24 hours, the
mould is striped and the cubes are cured further by immersing
them in water at temperature 19 to 21oC until the testing date.
 Compressive strength tests are conducted on the cubes at the age
of 7 days. Then, the mean compressive strengths are calculated.
THE CALCULATIONS
Here is one example of calculation from one of the concrete mix
design obtained from the laboratory. We have to fill in all
particulars in the concrete mix design form with some
calculations…

CCS 3: Relationship between standard deviation and characteristic

strength
CONCRETE GRADES
 THE CALCULATIONS
Firstly, we specified 30 N/mm2 at 7 days for the characteristic
strength. Then, we obtained the standard deviation, s from the figure
CCS 3. So, s = 8 N/mm2.From the formula F1, k = 1.64 for 5 % defect.
The margin, M is calculated as below:
M = k x s = 1.64 x 8 = 13.12 N/mm2
With the formula F2, target mean strength, fm is calculated as below:
Target mean strength, fm = fc + M= 30 + 13.12 = 43.12 N/mm2
The type of cement is Ordinary Portland Cement (OPC). For the fine
and course aggregate, the laboratory’s fine aggregate is un-crushed
and for coarse aggregate is crushed before producing concrete.
THE CALCULATIONS
Then, we obtain the free-water/cement ratio from table CCS
1. For OPC (7 days) using crushed aggregate, water/cement
ratio = 36 N/mm2. After that, from the figure CCS 4, the
curve for 42 N/mm2 at 0.5 free-water ratio is plotted and
obtained the free-water ratio is 0.45 at the target mean
strength 43.12 N/mm2.
THE CALCULATIONS
Next, we specified the slump test for slump about 20 mm and the
maximum aggregate size we used in laboratory is 10 mm. For the
specified above, we can obtained the free-water content from table
CCS 2 at slump 10 – 30 mm and maximum size aggregate 10 mm,
the approximate free-water content for the un-crushed aggregates
is 180 kg/m3 and for the crushed aggregates is 205 kg/m3. Because
of the coarse and fine aggregates of different types are used, the
free-water content is estimated by the expression:
Free-water Content, W
= 2/3 Wf + 1/3 Wc
= (2/3 x 180) + (1/3 x 205)
= 188.33 kg/m3
where,
Wf = Free-water content appropriate to type of fine aggregate
Wc = Free-water content appropriate to type of coarse aggregate
THE CALCULATIONS
 Cement content also can obtained from the calculation with the
expression at F3:
Cement Content, C = Free Water Content / Free-water or Cement
Ratio= 188.33 / 0.45 = 418.52 kg/m3
 We assumed that the relative density of aggregate (SDD) is 2.7.
Then, from the figure CCS 5 with the free-water content 188.33
kg/m3, obtained that concrete density is 2450 kg/m3. The total
aggregate content can be calculated by:
Total Aggregate Content = D – C – W
= 2450 – 418.52 – 188.33 = 1843.15 kg/m3
THE CALCULATIONS
 The percentage passing 600 μm sieve for the grading of fine
aggregate is about 60%. The proportion of the fine
aggregate can be obtained from the figure CCS 6, which is
38 %. Then, the fine and course aggregate content can be
obtained by calculation:
 THE CALCULATIONS
Fine Aggregate Content
= Total Aggregate Content x Proportion of Fines
= 1868.74 x 0.38 = 700.40 kg/m3
Coarse Aggregate Content=Total Aggregate Content – Fine Aggregate
= 1843.15 – 700.40 = 1142.75 kg/m3
The quantity per m3 can be obtained, which is;
Cement = 418.52 kg
Water = 188.33 kg
Fine aggregate = 700.40 kg
Coarse aggregate (10 mm) = 1142.75 kg
The volume of trial mix for 3 cubes
= [(0.1 x 0.1 x 0.1) x 3] + [25% contingencies of trial mix volume]
= 0.006 + 0.00075= 0.00375 m3
The quantities of trial mix = 0.00375 m3, in which is;
Cement = 1.57 kg
Water = 0.71 kg
Fine aggregate = 2.61 kg
Coarse aggregate (10 mm) = 4.29 kg
THE RESULTS OF MIX DESIGN
 Slump Test = True Slump of 55 mm…
 All the 3 concrete cubes produced were then cured for 7
days. After that, the compressive cube test is carried out. The
results are as follows:
Sample 1 2 3
Compressive Strength 32.37 33.54 35.70
Average (32.37 + 33.54 + 35.70) / 3 =
33.87

 For cubes after 7 days of curing, compressive strength should not

be less than 2/3 target mean strength.
= 2/3 × 43.12 = 28.75 N/mm2 < 33.9 N/mm2
 After 7 days of curing, the compressive strength of concrete cubes
produced by the mix design method pass the specific strength
requirements.
DISCUSSIONS UPON CONCRETE MIX DESIGNS
 Although our compressive strength passes the specific requirements, we
still identified several factors which contribute to the lacking of
compressive strength of concrete mixes produced in the
experiment. However, the main factor is the condition of aggregates
whether it is exposed to sunlight or rainfall.
 When the free water/cement ration is high, workability of concrete is
improved. However, excessive water causes “honey-comb” effect in the
concrete produced. The concrete cubes become porous, and hence its
compressive strength is well below the design value. Other possible
reasons include over compaction, improper mixing methods and some
calculation errors.
 Few suggestion upon several steps to avoid the problems previously
faced:
 All the raw materials, which is cement, aggregates, and sand should be
protected from precipitation or other elements which may affect its
physical properties.
 The quantity of ingredients may be adjusted if necessary, theoretical
values are not always suitable. For example, if the aggregates are wet or
saturated, less amount of water should be added, vice versa.
CONCLUSIONS
 By using the concrete mix design method, we have
calculated the quantities of all ingredients, that is water,
cement, fine and coarse aggregate according to specified
proportion.