Mix Design by Various Methods

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A Project Report on

Submitted By
RAHUL DAS BISWAS
(CE- 20105040)



MIX DESIGN OF CONCRETE BY VARIOUS
METHODS

A Project Report
Submitted By
RAHUL DAS BISWAS
I n partial fulfillment for the award of the degree
Of
BACHELOR OF ENGINEEREING
IN
CIVIL ENGINEERING

Under The Guidance of
Prof. SANTOSH KUMAR DAS


Department of Civil Engineering
UNIVERSITY INSTITUTE OF TECHNOLOGY
BURDWAN UNIVERSITY
SESSION: 2010-2014




CERTIFICATE



This is to certify that the project entitled Mix Design of Concrete by
Various Methods is the bonafide work carried out by Rahul Das Biswas,
student of University Institute of Technology, Burdwan University, under
my supervision and guidance in partial fulfillment of the requirements for
the award of the Degree of Bachelor of Engineering in Civil Engineering.









_____________________________ _______________________________
Prof. Aparna Roy Prof. Santosh Kumar Das
Head of the Department, (Project Guide)
Department of Civil Engineering, Department of Civil Engineering,
University Institute of Technology, University Institute of Technology,
Burdwan University Burdwan University

















ACKNOWLEDGEMENT




We deem it a pleasure to acknowledge our sense of gratitude to our project
guide Prof. Santosh Kumar Das, Department of Civil Engineering,University
Institute of Technology,Burdwan University, under whom we have carried out
the project work. His incisive and objective guidance and timely advice
encouraged us with constant flow of energy to continue the work.

I would like to place on record my deep sense of gratitude to Prof. Aparna Roy,
Head of the Department,Department of Civil Engineering,University Institute of
Technology,Burdwan University, for his generous guidance, help and useful
suggestions.

I would like to thank my group co-workersfor their support and contributions
during the period of project work.




__________________________
(Rahul Das Biswas)










TABLE OF CONTENTS


Introduction
Literature Review
Concrete Mix Design According to IS: 10262-1982
o Introduction
o Basic Data required for Mix Design
o Standard deviation (s) of compressive strength of concrete
o Degree of quality control expected under different site conditions
o Procedure
o Trial Mix
Concrete Mix Design According to IS: 10262-2009
o Introduction
o Scope
o Standard deviation
o Selection of mix proportions
o Trial mixes
o Steps for design
American Concrete Institute(ACI) 211.1-91 Method of Mix-Design
Introduction
Assumptions
Design procedure
Road Note No. 4 Method
DOE Method of Concrete Mix Design
Mix Design of Concrete by IS: 10262-1982
M-25 Grade of Concrete
M-30 Grade of Concrete
M-35 Grade of Concrete
M-40 Grade of Concrete
M-45 Grade of Concrete


Design of concrete mix using IS 10262:2009
M-25 Grade of Concrete
M-30 Grade of Concrete
M-35 Grade of Concrete
M-40 Grade of Concrete
Mix design of concrete according to ACI-211.1-1991 method
M-25 Grade of Concrete
M-30 Grade of Concrete
M-35 Grade of Concrete
M-40 Grade of Concrete
M-45 Grade of Concrete
Mix Design of Concrete by DOE method
o M-25 Grade of Concrete
o M-30 Grade of Concrete
o M-35 Grade of Concrete
o M-40 Grade of Concrete
o M-45 Grade of Concrete
Comparison between the Quantities of the Design Parameters for
o M-25 Grade of Concrete
M-30 Grade of Concrete
M-35 Grade of Concrete
M-40 Grade of Concrete
M-45 Grade of Concrete
Conclusion
General
Basic Data Used In Different Codes
Similarities between the mix design processes
Differences between the mix design processes
References



Introduction

Concrete is the basic engineering material used in most of the civil engineering structures. Its
popularity as basic building material in construction is because of, its economy of use, good
durability and ease with which it can be manufactured at site. The ability to mould it into any
shape and size, because of its plasticity in green stage and its subsequent hardening to achieve
strength, is particularly useful. Generally concrete is used to build protective structures,
which are subjected to several extreme stress conditions. Concrete is the most widely used
construction material manufactured at the site.
Like other engineering materials, concrete also needs to be designed for properties like
strength, durability, workability.
Concrete mix design is the science of deciding relative proportions of ingredients of concrete
to achieve the desired workability with optimum strength and durability in the most
economical way.

The advantages of mix design of concrete are:
I. Quality:
Better strength
Better imperviousness and durability
Dense and homogeneous concrete
II. Economy:
Economy in cement consumption: It is possible to save up to 15% of
cement for M20 grade of concrete with the help of concrete mix
design. In fact higher the grade of concrete more are the savings.
Lower cement content also results in lower heat of hydration and hence
reduces shrinkage cracks.
Best use of available materials: Site conditions often restrict the quality
and quantity of ingredient materials. Concrete mix design offers a lot
of flexibility on type of aggregates to be used in mix design. Mix
design can give an economical solution based on the available
materials if they meet the basic IS requirements. This can lead to
saving in transportation costs from longer distances.
Other properties: Mix design can help us to achieve form finishes, high
early strengths for early deshuttering, concrete with better flexural
strengths, concrete with pump ability and concrete with lower
densities.

Mix design is carried out using certain empirical relationships among design parameters,
developed from the past experience. There are several codes which give empirical formula
and directed some methods for the mix design of concrete.

In this context we are trying to show some of the research work results, analyzing the
methods used in several codes, design mix for a grade of concrete by the codes and
comparing the results, also the comparison between the codes.



Literature Review

Bruce Patterson and Keith Johnston
1
have done a research work onseveral aspects of
Concrete Mix Design on Federal Highway Administration at Washington D.C. 20590; at
the year of 1991.This study investigates different aspects of concrete mix design. The
variability of compressive strength, slump and air content from batch to batch is examined.
The effect of increasing the sand content per cubic yard of concrete on the compressive
strength is studied with another series of laboratory batches. Finally, the effect of the
maximum coarse aggregate size on compressive strength is evaluated with a third set of
laboratory batches. The differences between the mean compressive strength of batches were
evaluated using statistics. Some of the findings were:
1. Variability in average 28-day compressive strength between laboratory batches of the
same design is very low.
2. The average 28-day compressive strength of concrete made with a 10% increase in the
sand content is higher than that of concrete made with standard mix proportions. The
workability of the former as measured by the slump is lower.
3. The average 28-day compressive strength of concrete made with 3/4 inch maximum size
aggregate is significantly higher than concrete made with 1 inch maximum size aggregate.
Proportioning and testing of concrete mixtures has followed certain procedures within the
Oregon State Highway Division. They have always accepted some unexamined assumptions
which were never tested for the local materials and equipments.

H. M. A. Al-Mattarneh, A. H. Hassan, M. H. Abu Hassan, B. S. Mohammed
2
from
university Tenaga National, at Malaysia, through investigating found an expert system for
concrete mix design. According to them, Actually these systems were developed mainly for
the reduction of time and wastage of material for determining optimum mixture proportion by
conventional method. Our codes are based on the data gathered from experience at a certain
region or place and therefore simultaneously find a limitation on being used at other places.
This serious problem was eliminated by this report. This report was mainly based on design
codes, technical literatures, surveys and interviews as well.

ParupalliRaghuver, K.Nagaraju, S.Chandrashekar Reddy, SpandanaMrudula
3

researched on mix design entitled as Study Of Mix Design On Self Compacting Concrete Of
M30 Grade, Under the guidance of V.Mallikarjuna Reddy
3
and submitted in the fulfillment
of the requirements. This was a bonafide work carried out by them and the results embodied
in this project report had been very much unique. Concrete occupies unique position among
the modern construction materials, Concrete is a material used in building construction,
consisting of a hard, chemically inert particulate substance, known as a aggregate (usually
made for different types of sand and gravel), that is bond by cement and water.
Self compacting concrete (SCC) is a high performance concrete that can flow under its
own weight to completely fill the form work and self-consolidates without any mechanical
vibration. Such concrete can accelerate the placement, reduce the labor requirements needed
for consolidation, finishing and eliminate environmental pollution. The so called first
generation SCC is used mainly for repair application and for casting concrete in restricted
areas, including sections that present limited access to vibrate. Such value added construction
material has been used in applications justifying the higher material and quality control cost
when considering the simplified placement and handling requirements of the concrete.
The successful production of self compacting concrete (SCC) for use, is depended on
arriving at an appropriate balance between the yield stress and the viscosity of the paste.
Specially formulated high range water reducers are used to reduce the yield stress to point to
allow the designed free flowing characteristics of the concrete. However, this alone may
result in segregation if the viscosity of the paste is not sufficient to support the aggregate
particles in suspension.
The process of selecting suitable ingredients of concrete and determining their relative
amounts with an objective of producing a concrete of required strength, durability, and
workability as economically as possible is termed as concrete mix design.
The Mix Design for concrete M30 grade is being done as per the Indian Standard Code IS:
10262-1982.


Izhar Ahmed andDr S.S.Jamkar
4
carried out a study on Effects of Fly Ash on Properties
of Concrete as Per IS: 10262-2009 on IOSR Journal of Mechanical and Civil
Engineering (IOSR-JMCE).According to them, properties of concrete depend up on
properties of ingredients and their relative proportion. Due to addition of mineral as well as
chemical admixture in concrete design of concrete mixes has become increasingly complex.
BIS has rationalized concrete mix proportioning code in Dec 2009, which is used to design
standard concrete mixes using both mineral as well as chemical admixtures. By considering
the code, the present work deals with the development of fly ash based concrete mix
proportion. This paper presents the results of an investigation dealing with Concrete cubes of
100 mm size, to replace 0%, 5%, 10% and 15% cement with fly ash. To cover a wide range
of concrete mixes water cementitious material ratio (W/C) of 0.3, 0.4 and 0.5 were used for
water content of 186 kg/m3, 191.58 kg/m3 and 197.16 kg/m3 each. The effect of various
parameters such as replacement of cement by fly ash, water to cementitious material ratio and
water content is studied on fresh and hardened properties of concrete. The study mainly
consisted of establishing relation between these parameters in the form of Graphs to specify
proportioning of required fly ash based concrete. Both workability and strength aspects are
considered.
To analyze the behavior of concrete in fresh state, three different water content i.e. 186
kg/m3, 191.58 kg/m3 and 197.16 kg/m3 were selected for each W/C ratio. Graph 1 and
Graph 2 shows the behavior of workability in terms of slump, for W/C ratio of 0.4 and 0.5.





It is observed that for a given W/C ratio and for given water content, addition of fly ash
increases the workability. Workability goes on increasing with increase in percentage of fly
ash from 5% to 15%. This trend is consistent for W/C ratio of 0.4 and 0.5. For W/C ratio of
0.3, mixes with and without fly ash is very low workable as per IS 456-2000. Hence a higher
dosage of superplasticizer (SP) is required to achieve desired workability. The workability of
fly ash based concrete is improved in following ways: a) As fly ash has lower specific
weight, the resultant cement paste results in a bigger volume of cementing materials which is
easy to handle and compacted.(b) The very fine particles existing in fly ash are attached by
cement particles, forming a structure similar to a ball bearing, which reduces friction and
improves workability.(c) The perfect spherical shaped fly ash particles are not able to
interlock between themselves or with the cement particles, providing lubricating effect to
fresh binder matrix. To achieve desired workability for a particular water cement ratio, water
content can be selected from Graph 1 and Graph 2, for different percentages of fly ash.


The results for compressive strength for 7 days, 28 days and 56 days, obtained from the
experimental investigation are represented graphically in Graph 3, Graph 4 and Graph 5
respectively.









It is seen from the graph, the mixes containing 5%, 10% and 15% fly ash, gain compressive
strength more slowly as compare to reference mix (0% fly ash) up to 28 days. Beyond 28
days concrete containing fly ash will ultimately exceeds the strength.

From the above Graphs it is observed that for all W/C ratios and percentage replacement of
fly ash with OPC, increase in compressive strength tremendously from 7 to 56 days. Graph 6,
Graph 7 and Graph 8 shows the relation between age of concrete and compressive strength in
MPa for 0.3, 0.4 and 0.5 W/C ratio respectively.





It is observed from the above Graph for all W/C ratio considered, concrete containing fly ash
has very low early age compressive strength i.e. at 7 days. But at the age of 28 days the
strength is increased which is nearly equals to reference concrete. Observations of 56 days
compressive strength shows much better results than reference mix. Concrete containing 10
% replacement of fly ash by weight of cement gives better results than 5 % and 15 %
replacement.


M.C. Nataraja and Lelin Das
5
had carried out a study on Concrete mix design based on the
ACI(211.1-1991) method, the old and new BIS method (IS 10262: 1982 & IS 10262: 2009)
upon M-20 grade of concrete using OPC-43 grade of cement. They reported that basic
differences among them depending upon the following aspects-
Selection of water cement ratio
Cement content
Fine & coarse aggregate content
Measure of workability
Strength & durability
Use of supplementary material such as chemical and mineral admixtures

R. Anuradha, V. Sreevidiy, R. Venkatassubramani and B.V. Rangan
6
carried out an
experimental study on Geo-polymer Concrete which is relevant to Indian Standard (IS 10262-
2009). Two kinds of systems were considered in this study using 100% replacement of
cement by ASTM class F low calcium fly ash (Sp gravity 2.3) and 100% replacement of sand
by M-sand which is crushed aggregates produced from hard granite. Sodium hydroxide,
Sodium silicate and alkaline liquids were also used. They used IS 10262-2009 for mix design
of this concrete. This concrete was cured for 24 hours at 60
o
c. It is an excellent alternative
solution to the CO
2
producing cement concrete. The results of this study show that the
workability increases with higher amount of fly ash but strength decreases. On the other hand
M-sand increases the strength of concrete as compare to the river sand.

S.Yuvaraj, Dr.Sujimohankumar, N. Dinesh and Karthic
7
had carried out an experimental
study in the field of Nanotechnology implementation in concrete using IS 10262-2009. In
order to reduce the carbon emission due to the cement manufacturing the fly ash was partially
used in place of OPC cement. It was found that it not only reduces the emission of CO
2
but
also improves the workability, corrosion strength and long term strength of the concrete. The
use of nano silica as an additive to fill up the deviation, and it is possible because the silica(S)
in the sand reacts with calcium hydrate in (CH) the cement at nano scale to form C-S-H bond
and its improve the strengthening factor of concrete which helps to achieve high compressive
strength of concrete. The results of this study show that there is frequently use of fly ash in
modern version of code to get optimum strength and durability of concrete and to reduce
CO
2
& cost of concrete.

B. Bhattacharjee
8
had carried out a study on Concrete mix design and optimization using
different grades of concretes in both old and new code of Bureau of Indian Standards. They
concluded that mix design is the mix proportion cement, sand, coarse aggregate, water and
admixture (if necessary) to get proper strength, durability & workability. In the modified
version of code the exposed conditions, air/non air content cement, surface texture (smooth or
crushed) and angularity of aggregate had taken into consideration. The calculation of coarse
aggregate is first calculated then the fine aggregate in new code and the selection of starting
W/C ratio is also quite different from the previous one. There is provision of frequently use
of fly ash in steed of cement to minimize the cost and to reduce CO
2
emission.

Prince Arulraj and Sruthi Rajam
9
carried out a study on Concrete mix design based on the
old and the new Indian codes. They reported that Mix design is the process of determining
the appropriate proportions of cement, fine aggregate, coarse aggregate, water and admixtures
if any which will satisfy the requirements of compressive strength, workability and durability.
IS10262-1982 is the relevant code for the design of Concrete mixes. Bureau of Indian
Standards has revised this code in the year 2009. An attempt has been made to determine the
effect of revision on the proportioning concrete the mixes. Concrete of grades M20, M25,
M30, M30, M40 were designed by varying all the parameters as per the old and new codes.

GenadijShakhmenko and Juris Birsh
10
carried out a study on Concrete mix design and
optimization. They reported that determination of ingredients of aggregate mixes is an
important part of concrete mix design. A concrete mix design method is used taking into
account granulation parameters of aggregates. The task of concrete mix optimization implies
selecting the most suitable concrete aggregates from the Data Base. The following properties
are to be optimized: cost of raw materials, quality of aggregate packing, water and cement
consumption. Computer programs for aggregate and concrete mix design as well as for
concrete mix optimization have been worked out.
MostafaA.M.Abdeen and Hossam Hodhod
11
carried out a study on Analytic Formulae for
Concrete Mix Design based on experimental data base and predicting the concrete behavior
using ANN technique. They reported that an experimental investigation of concrete
properties was made using two types of cement. Slump, compressive strength, rebound
number and ultrasonic pulse velocities were investigated. The main parameters were type of
cement, cement content, water content, and fine/coarse aggregate ratio. Data base was
established for the mix proportions and corresponding properties. Artificial Neural
Network(ANN) technique was developed in the work to simulate the concrete slump and
concrete compressive strength for different mix proportions at different ages for the two types
of cement and then predict the concrete behavior for different mix proportions at ages rather
than those investigated in the experimental work.

Chris C. Ramseyer and Roozbeh Kiamanesh
12
carried out a study on Optimizing concrete
mix designs to produce cost effective paving mixes. The research was designed to determine
the effect of the mechanically activated fly ash on fresh concrete properties and the ultimate
strength of the hardened concrete. The activation of the fly ash was performed with a
modified ball mill to increase the hydration reaction rate of the fly ash particles. Two primary
variables were studied in this research: Grinding duration and the percentage of fly ash as a
portion of cementitious material. The results of this study show that the concrete with higher
proportions of fly ash has higher workability, although the strength of the samples decreases
in most cases if high volume of fly ash is used.
Concrete Mix Design According to IS: 10262-1982

Introduction

The proportioning of concrete mixes consists of determination of the quantities of respective
ingredients necessary to produce concrete having adequate, but not excessive, workability
and strength for the particular loading and durability for the exposure to which it will be
subjected. Emphasis is laid on making the most economical use of available material so as to
produce concrete of the required attributes at the minimum cost.
Concrete has to be of satisfactory quality in both the fresh and hardened states. The task of
proportioning concrete mixes is accomplished by the use of certain established relationships
which afford reasonably accurate guidance for selecting the best combination of ingredients
so as to achieve the desirable properties of the fresh and hardened concrete. Out of all the
Physical characteristics of concrete, compressive strength is often taken as an index of its
quality in terms of durability, impermeability and water tightness and is easily measurable.
Therefore, the mix design is generally carried out for a particular compressive strength of
concrete, coupled with adequate workability, so that the fresh concrete can be properly placed
and compacted.
The basic assumption made in mix design is that the compressive strength of
workable concrete is, by and large, governed by the water-cement ratio. Another most
convenient relationship applicable to normal concretes is that for a given type, shape, size and
grading of aggregates, the amount of water determines its workability. However, there are
various other factors which affect the properties of concrete, for example, the quality and
quantity of cement, water and aggregates; batching; transportation; placing; compaction;
curing; etc. Therefore, the specific relationships that are used in proportioning concrete mixes
should be considered only as a basis for trial,, subject to modifications in the light of
experience as well as for the particular materials used at the site in each case.

Basic Data required for Mix Design

The following basic data are required to be specified for design of a concrete mix:
a) Characteristic compressive strength of concrete at 28 days (f
ck
),
b) Degree of workability desired,
c) Limitations on the water-cement ratio and the minimum cement content to ensure adequate
durability,
d) Type and maximum size of aggregate to be used,

and
e) Standard deviation (s) of compressive strength of concrete.



Standard deviation (s) of compressive strength of concrete:

This is the root mean square deviation of all the results. This is denoted by s.
Numerically it can be explained as,
S =
()


Where, s = Standard deviation,
n = number of observations
X = particular value of observations
X
m
= arithmetic mean.

Concrete like most other construction material having certain amount of variability in
strength according to its mixing methods and proportion. And can be vary from batch to
batch and some time also within the batch. If, compressive strength test cubes results in a
random tests is plotted on Histrogram the results follow a bell shaped curve which is called
normal distribution curve, which is shown below. (Fig-A.1)




Fig-A.1

Fig-A.2
Standard deviation increases with increasing variability. The characteristics of the normal
distribution curve are fixed by the average value and the standard deviation. The spread ofthe
curve along the horizontal scale is governed by the standard deviation, while the position of
the curve along the vertical scale is fixed by the mean value.
The value of standard deviation has to be worked out from the trials conducted in lab or field
but when, results of sufficient number of teats (at least 30) are notavailable, then, depending
upon thedegree of quality control expected to be exercised at .the site, the value of standard
deviation given in Table below (Table A.1) may be adopted for guidance.

Table: A.1
Suggested values of Standard Deviation

GRADE OF
CONCRETE
Standard Deviation For Different Degree of Control in N/mm
2

Very Good Good Fair
M 10 2 2.3 3.3
M 15 2.5 3.5 4.5
M 20 3.6 4.6 5.6
M 25 4.3 5.3 6.3
M 30 5 6 7.0
M 35 5.3 6.3 7.3
M 40 5.6 6.6 7.6
M 45 6.0 7 8.0
M 50 6.4 7.4 8.4
M 55 6.7 7.7 8.7
M 60 6.8 7.8 8.8
DEGREE OF QUALITY CONTROL EXPECTED UNDER DIFFERENT
SITE CONDITIONS

Degree of Control Conditions ofproduction

Very good Fresh cement from single source and regular tests, weighbatching
of all materials, aggregates supplied in single sizes, control of
aggregate grading and moisture content, control of water added,
frequent supervision, regular workability and strength tests, and
field laboratory facilities.

Good Carefully stored cement and periodic tests, weigh batching of all
materials, controlled water, graded aggregate supplied, occasional
grading and moisture tests, periodic check of workability and
strength, intermittent supervision, and experienced workers.

Fair Proper storage of cement, volume batching of all
aggregatesallowing for bulking of sand, weigh-batching of cement,
water content controlled by inspection of mix, and occasional
supervision and tests.


PROCEDURE

The Bureau of Indian Standards recommended a set of procedure for design of concrete mix
mainly based on the work done in national laboratories. The mix design procedures are
Covered in IS 1026282. The methods given can be applied for both medium strength
andhigh strength concrete. Here the method described below step by step-

(a)Target mean strength for mix design:The target mean compressive ( f
ck
) strength at
28 days is given by
F
ck
= f
ck
+ tS

Where,
F
ck
= characteristic compressive strength at 28 days.
S= standard deviation. (As said earlier it is taken from the table given above
according to IS 10262:1982)
t = a statistical value depending on expected proportion of low results (risk factor).


Table: A.2
VALUES OF t (risk factor)

Accepted proportions of low results t
1 in 5 0.84
1 in 10 1.28
1 in 15 1.5
1 in 20 1.65
1 in 40 1.86
1 in 100 2.33

According to IS: 4562000 the characteristic strength is defined as that value below which
not more than 5 per cent results are expected to fall, in which case the above equation reduces
toF
ck
= f
ck
+ 1.65 S

(b) Selection of Water/Cement ratio: Various parameters like types of cement, aggregate,
maximum size of aggregate, surface texture of aggregate etc. are influencing the strength of
concrete, when water/cement ratio remain constant, hence it is desirable to establish a relation
between concrete strength and free water cement ratio with materials and condition to be used
actually at site. In absence of such relationship it is determined from the following graph.
Fig: A.3


Fig: A.3
Alternately, the preliminary free water-cement ratio (by mass) corresponding to the target
average strength,may be selected from the relationships shown in next figure (fig. A.4) using
the curve corresponding to the 28 days cement strength to be used for the purpose.



Fig- A.4

28 day Strength of cement tested according to IS: 4031-1968
A= 31.9-36.8 N/mm
2

B = 36.8-41.7 N/ mm
2

C = 41.7-46.6 N/ mm
2

D= 46.6-51.5 N/ mm
2

E = 51.5-56.4 N/ mm
2

F =56.4-61.3 N/ mm
2


(c) Estimation of Air Content: Approximate amount of entrapped air to be expected in
normal (non-air-entrained) concrete is given in Table below (Table A.3).





Table: A.3
APPROXIMATE AIR CONTENT

NOMINAL MAXIMUM SIZE
OF AGGREGATE(mm)
ENTRAPPED AIR, AS PERCENTAGE
OF VOLUME OF CONCRETE
10 3
20 2
40 1

(d)Selection of Water Content and Fine to Total Aggregate Ratio:
For the desired workability, the quantity of mixing water per unit volume of concrete and the
ratio of fine aggregate to total aggregate by absolute volume are to be estimated from Table-
A.4&Table-A.5 as applicable, depending upon the nominal maximum size and type of
aggregates.

TABLE: A.4
APPROXIMATE SAND AND WATER CONTENTS PER CUBIC
METRE OF CONCRETE FOR GRADES UPTO M 35

NOMINAL MAXIMUM
SIZE OF AGGREGATE
(mm)
WATER CONTENT PER
CUBIC METER OF
CONCRETE
SAND AS PERCENTAGE
OF TOTAL VOLUME BY
ABSOLUTE VOLUME
10 208 40
20 186 35
40 165 30

TABLE: A.5
APPROXIMATE SAND AND WATER CONTENTS PER CUBIC
METRE OF CONCRETE FOR GRADES ABOVE M 35

NOMINAL MAXIMUM
SIZE OF AGGREGATE
(mm)
WATER CONTENT PER
CUBIC METER OF
CONCRETE
SAND AS PERCENTAGE
OF TOTAL VOLUME BY
ABSOLUTE VOLUME
10 200 28
20 180 25



N.B: Water content corresponding to saturated surface dry aggregate.If otherwise, when
computing the requirement of mixing water, allowance shall be made for the free (surface)
moisture contributed by the fine and coarse aggregates. The amount of mixing water obtained
from Tables A.4 and A.5 shall be reduced by an amount equal to the free moisture
contributed by the coarse and fine aggregates. On the other hand, if the aggregates are dry,
the amount of mixing water should be increased by an amount equal to the moisture likely to
be absorbed by the aggregates.

Table: A.4is to be used for concretes grade up to M 35 and is based on the following
conditions:
(a) Crushed (Angular) coarse aggregate, conforming to IS: 3831970.
(b) Fine aggregate consisting of natural sand conforming to grading zone II of Table of 4,
IS: 3831970.
(c) Water-cement ratio of 0.6 (by mass), and
(d) Workability corresponds to compacting factor of 0.80
Table: A.5is to be used for concretes grade above M 35 and is based on the following
conditions:
(a) Crushed (Angular) coarse aggregate, conforming to IS: 3831970.
(b) Fine aggregate consisting of natural sand conforming to grading zone II of Table of 4,
IS: 3831970.
(c) Water-cement ratio of 0.35 (by mass), and
(d) Workability corresponds to compacting factor of 0.80

For other conditions of workability, water-cement ratio, grading of fine aggregate, and for
rounded aggregates, certain adjustments in the quantity of mixing water and fine to total
aggregate ratio given in Tables A.4 and A.5 are to be made, according to Table A.6 given
below.












Table: A.6
Adjustment of Values in Water Content and Sand Percentage for Other
Conditions

Change in conditions
stipulated for tables
Adjustment Required in
Water Content % Sand in Total Aggregate
For sand conforming to grade
Zones I, Zone III or Zone IV
of table 4, IS:383-1979
0
+ 1.5% for Zone I
-1.5% for Zone III
-3% for Zone IV
Increase or decrease in the
value of compacting factor
by 0.1
3% 0
Each 0.05 increase or
decrease in water-cement
ratio
0 1%
For rounded aggregate -15 kg -7 %

(e) Calculation of Cement Content: The cement content per unit volume of concrete may be
calculated from the free water-cement ratio and the quantity of water per unit volume of
concrete. The cement content so calculated shall be checked against the minimum cement
content for the requirements of durability and the greater of the two values adopted.

(f) 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:
[



Where,
V = absolute volume of fresh concrete, which is equal to gross volume (m
3
) minus the
volume of entrapped air,
W = Mass of water (kg) per m
3
of concrete,
C = Mass of cement (kg) per m
3
of concrete
Sc = Specific gravity of cement
p = Ratio of FA to total aggregate by absolute volume
f
a
, C
a
= Total masses of FA and CA (kg) per m3 of concrete respectively and
S
fa
, S
ca
= Specific gravities of saturated, surface dry fine aggregate and coarse
Aggregate respectively.
Trial Mix

The calculated mix proportions shall be checked by means of trial batches. Quantities of
materials worked out shall comprise Trial Mix No. 1. The quantity of materials for each trial
shall be sufficient for at least three 150 mm size cube concrete specimens and concrete
required to carry out workability test according to IS : 1199-1959.
Workability of the Trial Mix No. 1 shall be measured. The mix shall be carefully
observed for freedom from segregation and bleeding and its finishing properties. If the
measured workability of Trial Mix No. 1 is different from the stipulated value, the water
content shall be adjusted according to Table A.6 corresponding to the required change in
compacting factor. With this adjusted water content, the mix proportions shall be recalculated
keeping the free water-cement ratio at the pre-selected value which will comprise Trial Mix
No. 2. In addition, two more Trial Mixes No. 3 and 4 shall be made with the water content
same as Trial Mix No. 2 and varying the free water cement ratio by 10 percent of the pre-
selected value. For these two additional Trial Mixes No. 3 and 4, the mix proportions are to
be recalculated for the altered condition of free water-cement ratio with suitable adjustments
in accordance with Table A.6.
Mix No. 2 to 4 normally provides sufficient information, including the relationship
between compressive strength and water-cement ratio, from which the mix proportions for
field trials may be arrived at. Using the relationship so obtained between the compressive
strength and water-cement ratio, any change needed in the water-cement ratio to get the
required target compressive strength may be easily obtained. The concrete mix proportions
shall, however, be recalculated for this changed water-cement ratio, taking the water content
same as that determined in Trial Mix No. 2. If the size and special requirement of the work so
warrant, the trial may be extended to cover larger ranges of mix proportions as well as other
variables, such as alternative sources of aggregates, maximum sizes and grading of
aggregates, and different types and brands of cements.














Concrete Mix Design According to IS: 10262-2009

Introduction

Concrete has become an indispensable construction material. According to the present state
of the art, concrete has bypassed the stage of mere four component system that is cement,
water, coarse aggregate and fine aggregate. It can be a combination of far more number of
ingredients, as many as ten to be precise. Apart from the common four ingredients, fly ash,
ground granulated blast furnace slag, silica fume, rice husk ash; metakaoline and super
plasticizer are the six new ingredients which are being increasingly used nowadays in
concrete produced as and when required. Hence it has become quite necessary to introduce
these new aspects in the concrete mix design code as these must be given their due
importance as they have become an inseparable part of concrete in the present. Further, a lot
more emphasis is given on IS 456:2000 and concrete mix proportioning has been done
according to its norms.

Concrete is most commonly used material in civil construction work all over the country.
There is hardly any major original civil construction work where structural concrete is not
used. Nowadays concrete is produced in batch mixing plants located either at site of
construction or away from the site in a location from where concrete is carried in transit
mixers to the site. The later one is commonly called Ready MixConcrete (RMC). The
proportion of various ingredients of concrete made in batch mixing plants mentioned above is
usually determined in laboratory. This process is called designing (proportioning) of concrete
mix and such a concrete is called design mix concrete. The designing process is a trial and
error method in which right proportion of ingredients is sought to be determined so as to
achieve targeted mean strength which is kept somewhat higher than the characteristic
compressive strength of the concrete. Besides achieving the targeted strength, the workability
and durability requirements are also required to be ensured while designing the concrete mix.
All this has to be done keeping in mind the objective of achieving overall economy by
reducing the content of costliest material in the concrete, i.e. the cement. The designing
process in most of the major projects is usually carried out through reputed laboratories. IS
10262:2009 is the relevant Indian standard stipulating guidelines for concrete mix
proportioning. In the recent past, concrete has become one of the most important construction
material for buildings and other works.

In the beginning, concrete was only manufactured using ordinary Portland cement but now as
time passes newer cement varieties are developing, thus leading to development of newer
concrete varieties.



We know that the main objective behind concrete mixing is to make the choose the right
proportion of all the ingredients that are required to make concrete ,which are practically and
economically feasible to the client as well as the constructors, and which will serve the mere
purpose of it without any extra burden of cost and maintenance. This is basically archived by
using trial and error method, that is my making trial mixes and getting the correct result.
Understanding the basic principles of mixture design is as important as the actual calculations
used toestablish mix proportions. Only with proper selection of materials and mixture
characteristics can the abovequalities be obtained in concrete construction. (Abrams 1918,
Hover 1998 and Shilstone 1990). ACI 211.1-91, DOE 1988 and IS 10262 are the procedures
widely used for proportioning concrete mix. The IS 10262 is primarily based on the basic
assumption that the compressive strength of concrete is governed generally, by the water-
cement ratio. The recent development of using chemical and mineral admixtures in concrete
has not altered the applicability of the age-old Abrams water-cement ratio law', and the
compressive strength of concrete is governed by the water-cementitious materials ratio used
in concrete (S.C. Maiti 2006). The cementitious materials include cement and mineral
admixtures like fly ash, granulated blast furnace slag and silica fume etc. The strength of the
cementitious paste binder in concrete depends on the quality and quantity of the reacting
paste components and on the degree to which the hydration reaction has progressed. Concrete
becomes stronger with time as long as there is moisture and a favorable temperature
available. Therefore, the strength at any particular age is both a function of the original water-
cementitious material ratio and the degree to which the cementitious materials have hydrated.

Concrete needs to serve its purpose in its fresh and hardened state. The basic principles which
govern the proportioning of the mixes are Abrams law and Lysesrule.In general, the
compressive strength of concrete is taken as the index of acceptability and grades are
determined in order of that only.
The earlier code published in 1982 considered only basic four elements of concrete viz.
cement, sand, course aggregate and water. In this code we will see that a very much wider
spectrum of concrete is under radar and hence a large and relatively newer portions of this
part of civil is henceforth cultured in this code

Scope

It is known that the properties of concrete depend up on properties of ingredients and their
relative proportion. Due to addition of mineral as well as chemical admixture in concrete
design of concrete mixes has become increasingly complex. BIS has rationalized concrete
mix proportioning code in Dec 2009, which is used to design standard concrete mixes using
both mineral as well as chemical admixtures.

This standard applies all the requirements of IS 456 and provides the guidelines for concrete
proportioning mixes as per the requirements using the basic concrete making materials as
well as other supplementary materials which are in use nowadays. This standard has been so
modified that it is applicable to only ordinary and standard concrete grades only.
The basic data required for concrete mix proportioning are:-
1. Grade designation.
2. Type of cement to be used.
3. Maximum nominal size of aggregate to be used.
4. Maximum and minimum cement content.
5. Maximum water cement ratio.
6. Workability.
7. Exposure conditions.
8. Maximum temperature of concrete at the time of placing.
9. Method of transporting and placing
10. Early age strength requirements (if required).
11. About admixtures (if used).

In general we know that concrete has got two different strength criteria , the target mean
strength and the characteristic mean strength, the former being higher in value than the latter
always, and the design has always been done on the basis of the target mean strength which is
given by the formula:-

f
ck
= f
ck
+1.65
*
s

Where, f
ck
= target mean compressive strength at 28 days in N/mm
2
.
f
ck
= characteristic compressive strength at 28 days in N/mm
2
.
S = standard deviation in N/mm
2
.
Now a days design of concrete mixes has become increasingly complex with the addition of
mineral aswell as chemical admixture in concrete. There for BIS has rationalized concrete
mix proportioning code in Dec 2009. This code is now in use to design concrete mixes using
both mineral as well as chemical admixtures.

Standard deviation

Standard deviation is calculated separately for each grade of concrete and it is based on test
strength of the sample.
Now, the total number of test strength of samples required to constitute an acceptable record
for calculation of standard deviation shall not be less than 30, and attempts must be made to
obtain the required number of samples as early as possible, during the time of the first
mixing.
The standard deviation of a particular batch of concrete needs to separately evaluated every
time the batch is liable to addition of certain different items to it apart from the regular items,
such as any sort of admixtures etc and it must be up to date always.
Sometimes, it happens that the value of standard deviation of a particular grade of concrete is
unavailable, then a value is assumed in order to solve the problem and to continue the mix
proportioning until and unless the actual test results are coming, and when the actual result
comes, that value is taken into account. The following table TABLE B.1 shows the assumed
values of the standard deviation (according to CLAUSES 3.2.1.2, A-3 AND B-3)
TABLE: B(1)
FOR ASSUMED STANDARD DEVIATION


Selection of mix proportions

(a) Water cement ratio:The relationship between strength and free water-cement ratio
always needs to be established for the materials in use at site because even for the same
water-cement ratio the strength of concrete may be different as it depends on the shape and
size of aggregate, grading, surface texture etc., which may give a completely different result,
far apart from what the expectation.

In the absence of data, the preliminary data may be selected which is based on the
relationship according to the target strength after 28 days. If that is also not available, then the
starting value of water cement ratio can be adopted from Table 5, IS 456:2000 which is based
on different exposure conditions. If any separate mineral admixtures or other cementing
materials are used then its calculation has to be separately made according to IS 456:2000,
table 5.

The checking of the above value needs to be done for the limiting value for the durability
criteria and hence the lesser value of the two will be taken into consideration.
The water content in concrete mix dcpends on many factors viz. shape, size and texture of
aggregates, water cement ratio, type of cement and other materials used and of course
environmental conditions especially temperature.

The following table TABLE B.2 shows the maximum or limiting value of water that can be
used per volume of concrete:-
SERIAL NO.
GRADE OF
CONCRETE
ASSUMED STANDARD DEVIATION
1. M10 3.5
2. M15 3.5
3. M20 4.0
4. M25 4.0
5. M30 5.0
6. M35 5.0
7. M40 5.0
8. M45 5.0
9. M50 5.0
10. M55 5.0
TABLE: B.2
FOR MAXIMUM WATER CONTENT

SERIAL NO.
NOMINAL MAX. SIZE
OF AGGREGATE (mm)
MAXIMUM WATER CONTENT
(kg)
1. 10 208
2. 20 186
3. 40 165

According to this code, the water content can further be reduced approximately by 10 kg for
sub angular aggregates, 20 kg for gravel with some crushed particles and 25 kg for fully
rounded gravels, and the results are the same i.e. the workability remains the same. Now the
slump value of 25 to 50 mm is considered as standard and with further increase in slump
value, the water content is increased by 3 percent with every additional 25 mm slump value.
Water content can also be increased or decreased confirming to IS 9103, following the use of
chemical admixtures.

(b) Coarse aggregate proportions:The aggregates are also an important part of the concrete
and the shape, size and texture of aggregate is responsible for many changes in the making of
concrete. Hence it is always advised to maintain a standard grade of aggregate to get the
required satisfactory workability.

Approximate values of the aggregate volume is given in the following table (Table B.3)

TABLE: B.3
FOR MAXIMUM COARSE AGGREGATE VALUE


SERIAL
NO.
NOMINAL MAX.
SIZE OF
AGGREGATE
(mm)
VOLUME OF COARSE AGGREGATE PER UNIT
VOLUME OF TOTAL AGGREGATE FOR
DIFFERENT ZONES OF FINE AGGREGATE
ZONE I ZONE II ZONE III ZONE IV
1. 10 0.50 0.48 0.46 0.44
2. 20 0.66 0.64 0.62 0.60
3. 40 0.75 0.73 0.71 0.69



The above given values are for a particular water cement ratio, which is 0.5, but this chart can
be suitably modified for other ratios also, as and when required. If, further an increase in
workability is required, then the coarse aggregate content can be further diminished up to 10
percent.
The coarse aggregate shall always confirm with IS 383. In general, only one size of aggregate
is not used but, a well graded range of different sizes of aggregate in certain proportions are
used to ensure better strength, bonding and overall result.

(c) Fine aggregate proportions:The coarse and fine aggregate content are calculated by the
following process:-
(i) The absolute volume of the cementitious material, water and chemical
admixture are found out.
(ii) The mass of the individual items are hen divided by their respective specific
gravities.
(iii) The results are multiplied by a constant factor 1/1000.
(iv) The summation result is subtracted from their unit volume.

The values so obtained are divided into coarse and fine aggregate fractions by volume in
accordance with the coarse aggregate proportion already determined. The final coarse and
fine aggregate values are obtained by multiplying the above values with their respective
specific gravities and 1000.


Trial mixes

The values so obtained from the mix design shall definitely be checked by making repetitive
trial mixes and any error needs to be adjusted.
Workability of the first trial mix shall be measured very much carefully and all sorts of
bleeding and segregation occurring in it shall be noted with care and precision, so that if the
result deviates from the anticipated value then the water or admixture or both quantities are
revised.
The second trial mix contains the pre-selected value of the free water cement ratio. In
addition a third and fourth trial mixes are also prepared with the water content kept constant
but the free water cement ratio being increased and decreased by ten percent respectively.
This generally provides with the required amount of information.






Steps for design

The basic steps for designing according to IS 10262:2009 are:-

1. Stipulations for proportioning: All the general data regarding the quality of the
materials are stated and hence the basic requirements of design are fulfilled.
2. Test data for materials: All the materials used are tested and the data of those tests
are presented in a tabular form in general.
3. Target strength for mix proportioning: The basic approach of the problem ways
itself through this step and hence this step is rendered as the first actual step towards
the solution of the design problem.
4. Selection of water-cement ratio: Another vital aspect of mix design without which
the problem even cannot be started. Generally done with the help of Table 5 from IS
456:2000.
5. Selection of water content: This is done with the help of Table 8 from IS
10262:2009.
6. Calculation of cement content: After the content of water is known, the cement can
be easily calculated. IS 456:2000 helps to determine the minimum cement content.
7. Proportion of volume of coarse and fine aggregate: Both these volumes are
calculated as they are very much necessary for the problem to step forward because
both these items are integral part of concrete mixture.
8. Mix calculations: The actual calculations are done and results are obtained.
9. Mix proportions for trial one: With the above values the first trial is done to obtain
the field results.
10. Measurement of slump and further trials: The slump shall be measured and
adjusted and accordingly further trials are done.















American Concrete Institute(ACI) 211.1-91 Method of Mix-
Design

INTODUCTION

This method of mix design was first established in the year of 1944 by ACI committee 613.In
the year 1954 this method was revised by the committee and the fact of entrained air was
included.In 1970 the mix design procedure was handed over to the ACI committee 211 this
committee had further modified the method (ACI 211.1)in the year 1991.Almost all the major
multipurpose concrete structures built during 1950 have been designed by using the method
of ACI committee method of mix design.

We shall now deal with the latest ACI committee 211.1 of 1991 method. It has the simplicity
regarding the design procedure for rounded and flaky aggregate, to regular or light weight
aggregates and to air entrained or non-air entrained concrete. In each of the cases the design
procedure is same. There are few assumptions regarding the method of design. The
assumptions are as follows:

ASSUMPTIONS

1.The method makes use of the established fact ,that over a considerable range of practical
proportions fresh concrete of a given slump containing a reasonably well graded aggregate of
given maximum size will have a constant water content regardless of variation in the water
cement ratio with the variation of cement content.

2. It makes use of the relation that the dry rodded volume of the coarse aggregate per unit
volume of the concrete depends upon the maximum size of the aggregate and the fineness
modulus of the fine aggregate regardless of the shape of the particles. That is why the angular
coarse aggregate require more mortar than the rounded coarse aggregate.

3. Irrespective of the methods of compaction, even after complete compaction is done a
definite percentage of the air remains which is inversely proportional to the size of the
aggregate.

4. We have to decide the maximum size of the coarse aggregate.Generally for the R.C.C.
work it is 20 and for pre-stressed concrete its value is 10.

5. For the design purpose of particular type of job we have to decide the value of workability
in terms of slump.ACI method has given various ranges of values of slump for various works
such as range of slump in mm for reinforced foundation walls and footings is 20-80.
6. The total water in kg/m
3
of concrete is selected as per ACI code depending upon the values
of the selected slump and the selected maximum size of the aggregate.In this method of
proportioning we consider the accidentally entrapped air in a non-air entraining agent.

7. From the above water content we find the cement content by dividing the water content by
the water cement ratio.

8. The bulk volume of the dry rodded coarse aggregate per unit volume of the concrete is
determined by using the maximum size of coarse aggregate and the fineness modulus of the
coarse aggregate.

9. The weight of the coarse aggregate per unit volume of the concrete is calculated by
multiplying the bulk volume with the bulk density.

10. The solid volume of the coarse aggregate in one cubic meter of concrete is calculated by
knowing the specific gravity of the coarse aggregate.

11. In the similar way we can calculate the solid volume of the cement, water and the volume
of the air entrapped.

12. The solid volume of the sand can be calculated by subtracting from the total volume the
volume of the cement,coarse aggregate, water and entrapped air.

13. The weight of the fine aggregate can be calculated by multiplying the solid volume of the
fine aggregate with its specific gravity.

DESIGN PROCEDURE AS PER ACI COMMITTEE 211.1-91 METHOD

(a) Assuming 5 per cent of results are allowed to fall below specified design strength,
The mean strength,
f
m
= f
min
+ ks
Where,
f
m
is the mean strength of concrete
f
min
is the characteristic strength of concrete
s is the standard deviation
k is the tolerance factor

(b) Assuming it that OPC has been used, from table C.1, we have to take the w/c ratio.
This w/c ratio from strength point of view is to be checked against maximum w/c ratiogiven
for special exposure condition given in Table C.2 and minimum of the two istobe adopted.
From exposure condition using Table C.2, we have to take the maximum w/c ratio.
Table:C.1
Relation between water/cement ratio and averagecompressive strength of
concrete, according to ACI 211.191

Average compressive strength at 28
days(MPa)

Effective water/cement ratio
(by mass)

Non-air
entrained concrete
Air-entrained
concrete
45 0.38 -
40 0.43 -
35 0.48 0.40
30 0.55 0.46
25 0.62 0.53
20 o.70 0.61
15 0.80 0.71

Table: C.2
Requirements of ACI 318-89 for W/C ratio and Strength for
Special Exposure Conditions

Exposure Condition
Maximum W/C ratio,
normal
density aggregate concrete
Maximum design
strength,low density
aggregate concrete (MPa)
1.Concrete Intended to
bewatertight

0.5

0.45

25

30
(a)Exposed to fresh water

(b)Exposed to brackish or sea
water
2.Concrete exposed to
freezing and thawing in a
moist condition:
0.45


0.50

0.45

30


25

30
(a) kerbs, gutters, guard rails
or thin sections

(b) other elements

(c) in presence of de-icing
chemicals



(c) From Table C.3, for a given slump and maximum size of aggregate, for no air-entrained
the mixing water content is to be taken per m
3
of concrete. Also the approximate entrappedair
content is 2 percent.


Table: C.3
Approximate requirements for mixing water and air content for different
workability and nominal maximum size of Aggregates according to ACI
211.1-91


Workability or
air content
Water content, kg/m
3
of concretefor indicated maximum aggregate
size
10mm 12.5mm 20mm 25mm 40mm 50mm 70mm 150mm
Non air-entrained concrete
Slump
30-50mm 205 200 185 180 160 155 145 125
80-100mm 225 215 200 195 175 170 160 140
150-180mm 240 230 210 205 185 180 170 -

Approximate
entrapped air
content per cent
3.0 2.5 2.0 1.5 1.0 0.5 0.3 0.2
Air entrained concrete
Slump
30-50mm 180 175 165 160 145 140 135 120
80-100mm 200 190 180 175 160 155 150 135
150-180mm 215 205 190 185 170 165 160 -
Recommendedaveragetotalair content per-cent
Mild exposure 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0
Moderate
exposure
6.0 5.5 5.0 4.5 4.5 4.0 3.5 3.0
Extreme
exposure
7.5 7.0 6.0 6.0 5.5 5.0 4.5 4.0


(d) From Table C.4 for a given maximum size of coarse aggregate and for given fineness
modulus the dry rodded bulk volume of C.A. per unit volume of concrete can be taken.







Table: C.4
Dry Bulk Volume of Coarse Aggregate per Unit Volume of
Concrete as given by ACI 211.191


Maximum size of aggregate
Bulk volume of dry rodded coarse aggregate of per
unit volume of concrete for fineness modulus of sand
F.M. 2.4 2.6 2.8 3.0
10 0.50 0.48 0.46 0.44
12.5 0.59 0.57 0.55 0.53
20 0.66 0.64 0.62 0.60
25 0.71 0.69 0.67 0.65
40 0.75 0.73 0.71 0.69
50 0.78 0.76 0.74 0.72
70 0.82 0.80 0.78 0.76
150 0.87 0.85 0.83 0.81

(e) Therefore the weight of C.A. can be calculated.

(f) From Table C5, the first estimate of density of fresh concrete for the givenmaximumsize
of aggregate and for non-air-entrained concrete can be adopted.



Table: C.5
First estimate of density (unit weight) of fresh concreteas given by ACI
211.1-91

Maximum size of aggregate
(mm)
First estimate of density (unit weight) of fresh concrete
Non air entrained (kg/m
3
) Air entrained(kg/m
3
)
10 2285 2190
12.5 2315 2235
20 2355 2280
25 2375 2315
40 2420 2355
50 2445 2375
70 2465 2400
150 2505 2435







(g) The weight of all the known ingredient of concrete is calculated.The weight of the F.A.
can be calculated by subtracting the weights of other ingredients from the total weight.

(h) Alternatively the weight of F.A. can also be found out by absolute volume methodwhich
is more accurate.

(i)Then we have to find the proportions of all ingredients from the estimated quantities.

(j)After that the proportions are required to be adjusted as per field conditions.As per ACI
211.1-91 the fine aggregate has surface moisture of 2 percent and for C.A. absorbs 1 percent
of water.On this regard the total amount of water which has to be supplied is determined.
(k) Quantities of materials to be used in field duly corrected for free surface moisture in F.A
and absorption characteristic of C.A.

(l) Field proportion as worked out above may not give the final answer. A trial mix is then
made to study the properties of such a concrete in respect of workability,cohesiveness,
finishing quality, yield and 28 days compressive strength. The mix may need grading
improvement, by way of change in proportion between various fractions of C.A. or change in
proportion between FA and CA. If feasible, change in the shape of C.A particularly 10 mm
fraction would greatly improve the situation. If F.A and C.A are having different specific
gravities, any change in their earlier calculated proportion, may affect the yield of concrete.
If all the avenues do not improve the qualities of the concrete designed for the work in hand,
then only, one must resort to increase in water content. If water content is increased,
corresponding increase in cement content is also made so that W/C ratio remains same.
When both water and cement is increased, it will affect the yield of concrete. Thereforeto
keep the yield constant, both the quantities of F.A and C.A is required to be
reducedcorrespondingly. All these needs a number of trials before one arrives at the final
proportions.
The mix designer must have sufficient experience, understanding and feel of concrete.










Road Note No. 4 Method

This method of designing concrete mix proportions is mainly based on the extensive
laboratory and field experiments carried out by the Road Research Laboratory, U.K. It was
first published in Road Note No 4 during 1950. They have established relationship between
various properties of concrete and variable parameters. A series of standard grading curves
have been established to give grading limits for all-in aggregates graded down from 20 mm
and 40 mm. The procedure of mix design by Road Note No 4 is also called Grading Curve
Method.
This method of mix design was popular and was widely used up to 1970s all over the world.
Most of our concrete roads and air field pavements were designed by this method. The
Building Research Establishment of Department of Environment (DOE) U.K. has evolved
another method called DOE method to replace the earlier Road Note No 4 method.


DOE Method of Concrete Mix Design

The DOE method was first published in 1975 and then revised in 1988. While Road Note No
4 or Grading Curve Method was specifically developed for concrete pavements, the DOE
method is applicable to concrete for most purposes, including roads. The method can be used
for concrete containing fly ash (in U.K. it is called pulverized fuel ash, PFA) or GGBFS.
Since DOE method presently is the standard British method of concrete mix design, the
procedure involved in this method is described instead of out dated Road Note No 4 method.







The following are the steps involved in DOE method:-

1. Find the target mean strength from the specified characteristic strength:-

Target mean strength = specified characteristic strength + (Standard deviation risk factor).

Standard deviation: The value of standard deviation has to be worked out from the trials
conducted at lab or field.

Risk factor: It is the valuesbelow which not more than 5% result are expected to fall.


Fig- D.1

2. Calculate the water/cement ratio:-This is done in a rather round about method, using
Table: D.1 and Fig. D.1
Table: D.1gives the approximate compressive strength of concretes made with a free w/c
ratio of 0.50. Using this table find out the 28 days strength for the approximate type of
cement and types of C.A. Mark a point on the ordinate in Fig- D.1 equal to the compressive
strength read form Table: D.1which is at a W/C ratio of 0.50.


TABLE: D.1
Approximate Compressive Strength of Concrete Made witha free
Water/Cement Ratio of 0.50 according to the 1988 BritishMethod

Through this intersection point, draw a parallel dotted curve nearest to the intersection point.
Using this new curve, we read off the W/C ratio as against target mean strength. This
Water/Cement ratio must be compared to the W/C requirement for durability according to
BS:8110:Part I:1985 Table: (1).

TABLE: D.2 [BS: 8110: Part I: 1985 Table: (1)]
Condition of Exposer Nominal cover of Concrete in mm
Mild 25 20 20 20 20
Moderate - 35 30 25 20
Severe - - 40 30 25
Very Severe - - 50 40 30
Extreme - - - 60 50
Maximum Water /
cementitious material ratio
0.65 0.6 0.55 0.5 .45
Minimum content of
cementitious material in kg/m
3
275 300 325 350 400
Minimum grade MPa 30 35 40 45 50

3. Determination of water content: -To decide water content for the required workability,
expressed in terms of slump or Vebe time, taking into consideration the size of aggregate and
its type from Table: D.3 below-



Days of calculating strength
Type of cement Type of C.A 3 7 28 91
Ordinary Portland cement(type I) Uncrushed 22 30 42 49
Sulphate resisting cement(type V) Crushed 27 36 49 56
Rapid hardening Portland
cement(type III)
Uncrushed 29 37 48 54
Crushed 34 43 55 61
Table: D.3
Approximate Free Water Contents Required to Give Various Levels of
Workability According to 1988 British method

Aggregate Water content (kg/m3)
Max-size
mm
Type
Slump 0-10 10-30 30-60 60-180
Vebe>12
seconds
6-12 3-6 0-3
10
crushed 150 180 205 225
uncrushed 180 205 230 250
20
crushed 135 160 180 195
uncrushed 170 190 210 225
40
crushed 115 140 160 175
uncrushed 155 175 190 205

Table: D.3.1
Table for Reduction in the free water contents of Table:D.3 when
using fly ash

Percentage of fly ash
in cementitious
material
Reduction in water Content in kg/m
3

Slump mm 0-10 10-30 30-60 60-180
Vebe
seconds
>12 6-12 3-6 0-3
10 5 5 5 10
20 10 10 10 15
30 15 15 20 20
40 20 20 25 25
50 25 25 30 30


4. Determination of cement content knowing the water/cement ratio and water content:-
Cement content is calculated simply dividing the water content by W/C ratio. The cement
content so calculated should be compared with the minimum cement content specified from
the durability consideration as per BS: 8110: Part I: 1985 and higher of the two should be
adopted. Sometime maximum cement content is also specified. The calculated cement
content must be less than the specified maximum cement content.

5. Determination of the total aggregate content:-This requires an estimate of the wet
density of the fully compacted concrete. This can be found out from Fig. 2 for approximate
water content and specific gravity of aggregate. If sp. gr. is unknown, the value of 2.6 for
uncrushed aggregate and 2.7 for crushed aggregate can be assumed.

6. Determination of proportion of fine aggregate:-The total aggregate is determined using
Fig- D.3, Fig- D.4 is for 10 mm size, Fig- D.5 is for 20 mm size and Fig-D.6 is for 40 mm
size coarse aggregate. The parameters involved in Figure are maximum size of coarse
aggregate, the level of workability, the water/cement ratio, and the percentage of fines
passing 600 sieve. Once the proportion of F.A. is obtained, fractions depending on the
shape of aggregate. As a general guidance the figures given in Table D.4 can be used.
Multiplying by the weight of total aggregate gives the weight of fine aggregate. Then the
weight of the C.A. can be found out. Course aggregate can be further divided into different
fractions depending on the shape ofaggregate. As a general guidance the figures given in
Table D.4can be used.

Free water content in Kg/m
3

Fig- D.2Estimated wet density for fully compacted concrete
TABLE: D.4
Proportion of Coarse Aggregate Fractions According to the 1988 British
method

The proportion so worked out should be tried in a trial mix and confirmed about its suitability
for the given concrete structure. Table D.3.1 gives the reduction of free water contents from
the figures given in Table D.3 when fly ash is used in the mix. The proportion so worked out
should be tried in a trial mix and confirmed about its suitability for the given concrete
structure.

Fig- D.3 [for 10mm size]
Total C.A 510 mm 1020 mm 20-40mm
100 33 67 -
100 18 27 55

Fig- D.4 [for 10mm size]




















Fig- D.5[for 20mm size]


Fig- D .6[for 40mm size]


Mix Design of M-25 Grade of Concrete by IS: 10262-1982

Table: E.1
DESIGN STIPULATIONS

Characteristic compressive strength requiredin the field at 28 days 25 N/mm
2
(MPa)
Maximum size of aggregate 20mm
Type of aggregate Angular, Crushed
Degree of workability (Compacting Factor) 0.9
Degree of quality control Good
Type of exposure Mild

Table: E.2
TEST DATA FOR MATERIALS

Cement used OPC- 43
Specific gravity of cement 3.15
Specific gravity of coarse aggregates 2.7
Specific gravity of fine aggregates 2.7
Water absorption:Coarse aggregate 0.5%
Water absorption:Fine aggregate 1%
Free (surface) moisture:Coarse aggregate NIL
Free (surface) moisture:Fine aggregate NIL
Sieve analysis: Coarse aggregate
Conforming to grading
Zone III of Table 4 of
IS : 383- 1970

TARGET MEAN STRENGTH OF CONCRETE:

The target mean compressive ( Fck) strength at28 days is given by
F
ck
= f
ck
+ tS

Where,
F
ck
= characteristic compressive strength at 28 days = 25 MPa
S= standard deviation= 4.0 MPa
t = a statistical value depending on expected proportion of low results (risk factor)
= 1.65
F
Ck
= 25 + (4.0 X 1.65) = 31.6 MPa
SELECTION OF WATER CEMENT RATIO:

According to the graph for Cement Grade of OPC-43 and for target strength of 31.6 MPa the
water cement ratio is taken as 0.44.

Estimation of Air Content:

Approximate amount of entrapped air to be expected in normal is 2% of volume of concrete
for nominal maximum size of aggregate of 20mm.

SELECTION OF WATER AND SAND CONTENT:

For 20 mm maximum size aggregate, sand conforming to gradingZone II, water content per
cubic meter of concrete = 186 kg and sand content as percentageof total aggregate by
absolute volume = 35%.

ADJUSMENT:

For change in values in water-cement ratio, compacting factor and sand belonging to Zone
III, the following adjustment is required:

Change in conditions
stipulated for tables
Adjustment Required in
Water Content % Sand in Total Aggregate
For sand conforming to grade
Zone III of table 4, IS:383-
1979
0
-1.5%

Increase in the value of
compacting factor by 0.1
+ 3% 0
0.16 decrease in water-
cement ratio
0 -3.2%

Therefore, required sand content as percentage of total aggregate by absolute volume
= 35 1.5 3.2 = 30.3 %
Required water content = 186 + 5.58 = 191.6 kg/m
3

Determination of cement content:
Water-cement ratio = 0.44
Water content = 191.6 lt
Required cement content = 191.6/.44 = 435.5 kg/m
3

Determination of coarse and fine aggregate contents:

Our specified maximum size of aggregate of 20 mm, so the amount entrapped air in the wet
concrete is 2 per cent.

We know
[



Where,
V = absolute volume of fresh concrete, which is equal to gross volume (m
3
) - the
volume of entrapped air = .98
W = Mass of water (kg) per m
3
of concrete =191.6 kg/m
3

C = Mass of cement (kg) per m
3
of concrete = 435.5 kg/m
3

Sc = Specific gravity of cement = 3.15
p = Ratio of FA to total aggregate by absolute volume = .303
f
a
, C
a
= Total masses of FA and CA (kg) per m3 of concrete respectively and
S
fa
, S
ca
= Specific gravities of saturated, surface dry fine aggregate and coarse
Aggregate respectively = 2.7
So
[



f
a
= 531.9 kg/m
3
And,
[


C
a
= 1223.5 kg/m
3


But extra quantity of water to be added for absorption in case of CA, at 0.5 per cent mass,
So, the mass of water per m
3
= 191.6 + (1223.5*.5/100) = 191.6 + 6.1 = 197.7 kg/m
3

So, the mass of coarse aggregate per m
3
= 1223.5 6.1 = 1217.4 kg/m
3


Also,
Extra quantity of water to be added for absorption in case of FA, at 1.0 per cent mass,
So, the mass of water per m
3
= 197.7 + (531.9*1.0/100) = 197.7 + 5.32 = 203.02 kg/m
3

So, the mass of fine aggregate per m
3
= 531.9 5.32 = 526.58 kg/m
3



The mix proportion then becomes:
Cement: Fine aggregate: Coarse Aggregate

=435.5kg: 526.58 kg: 1217.4 kg

= 1 : 1.2 : 2.8

Actual quantities required for the mix per m
3
of concrete:

Cement 435.5 kg/m
3

Water 197.7 kg/m
3

Fine Aggregate 531.9 kg/m
3

Coarse Aggregate 1217.4kg/m
3





Mix Design of M-30 Grade of Concrete by IS: 10262-1982

Table: E.1
DESIGN STIPULATIONS

Characteristic compressive strength requiredin the field at 28 days 30 N/mm
2
(MPa)
Maximum size of aggregate 20mm
Type of aggregate Angular, Crushed
Degree of workability (Compacting Factor) 0.9
Degree of quality control Good
Type of exposure Mild

Table: E.2
TEST DATA FOR MATERIALS

Cement used OPC- 43
Specific gravity of cement 3.15
Specific gravity of coarse aggregates 2.7
Specific gravity of fine aggregates 2.7
Water absorption:Coarse aggregate 0.5%
Water absorption:Fine aggregate 1%
Free (surface) moisture:Coarse aggregate NIL
Free (surface) moisture:Fine aggregate NIL
Sieve analysis: Coarse aggregate
Conforming to grading
Zone III of Table 4 of
IS : 383- 1970

TARGET MEAN STRENGTH OF CONCRETE:

The target mean compressive ( Fck) strength at28 days is given by
F
ck
= f
ck
+ tS

Where,
F
ck
= characteristic compressive strength at 28 days = 30 MPa
S= standard deviation= 4.0 MPa
t = a statistical value depending on expected proportion of low results (risk factor)
= 1.65
F
Ck
= 30 + (4.0 X 1.65) = 36.6 MPa
SELECTION OF WATER CEMENT RATIO:

According to the graph for target strength of 36.6 MPa the water cement ratio is taken as
0.40.

Estimation of Air Content:

Approximate amount of entrapped air to be expected in normal is 2% of volume of concrete
for nominal maximum size of aggregate of 20mm.

SELECTION OF WATER AND SAND CONTENT:

For 20 mm maximum size aggregate, sand conforming to gradingZone II, water content per
cubic meter of concrete = 186 kg and sand content as percentageof total aggregate by
absolute volume = 35%.

ADJUSMENT:

For change in values in water-cement ratio, compacting factor and sand belonging to Zone
III, the following adjustment is required:

Change in conditions
stipulated for tables
Adjustment Required in
Water Content % Sand in Total Aggregate
For sand conforming to grade
Zone III of table 4, IS:383-
1979
0
-1.5%

Increase in the value of
compacting factor by 0.1
+ 3% 0
0.20 decrease in water-
cement ratio
0 -4%

Therefore, required sand content as percentage of total aggregate by absolute volume
= 35 1.5 4 = 29.5 %
Required water content = 186 + 5.58 = 191.6 kg/m
3

Determination of cement content:
Water-cement ratio = 0.40
Water content = 191.6 lt
Required cement content = 191.6/0.40 = 479.0 kg/m
3

Determination of coarse and fine aggregate contents:

Our specified maximum size of aggregate of 20 mm, so the amount entrapped air in the wet
concrete is 2 per cent.

We know
[



Where,
V = absolute volume of fresh concrete, which is equal to gross volume (m
3
) - the
volume of entrapped air = .98
W = Mass of water (kg) per m
3
of concrete =191.6 kg/m
3

C = Mass of cement (kg) per m
3
of concrete = 479.0 kg/m
3

Sc = Specific gravity of cement = 3.15
p = Ratio of FA to total aggregate by absolute volume = .295
f
a
, C
a
= Total masses of FA and CA (kg) per m
3
of concrete respectively and
S
fa
, S
ca
= Specific gravities of saturated, surface dry fine aggregate and coarse
Aggregate respectively = 2.7
So
[



f
a
= 506.84 kg/m
3
And,
[


C
a
= 1211.27 kg/m
3


But extra quantity of water to be added for absorption in case of CA, at 0.5 per cent mass,
So, the mass of water per m
3
= 191.6 + (1211.27*.5/100) = 191.6 + 6.1 = 197.7 kg/m
3

So, the mass of coarse aggregate per m
3
= 1211.27 6.1 = 1205.17 kg/m
3


Also,
Extra quantity of water to be added for absorption in case of FA, at 1.0 per cent mass,
So, the mass of water per m
3
= 197.7 + (506.84*1.0/100) = 197.7 + 5.07 = 202.77 kg/m
3

So, the mass of fine aggregate per m
3
= 506.84 5.07 = 501.77 kg/m
3



The mix proportion then becomes:
Cement: Fine aggregate: Coarse Aggregate

= 479.0 kg: 501.77 kg: 1205.17 kg

= 1 : 1.05 : 2.52

Actual quantities required for the mix per m
3
of concrete:

Cement 479.0 kg/m
3

Water 202.77 kg/m
3

Fine Aggregate 501.77kg/m
3

Coarse Aggregate 1205.17kg/m
3






Mix Design of M-35 Grade of Concrete by IS: 10262-1982

Table: E.1
DESIGN STIPULATIONS

Characteristic compressive strength requiredin the field at 28 days 35 N/mm
2
(MPa)
Maximum size of aggregate 20mm
Type of aggregate Angular, Crushed
Degree of workability (Compacting Factor) 0.9
Degree of quality control Good
Type of exposure Mild

Table: E.2
TEST DATA FOR MATERIALS

Cement used OPC- 43
Specific gravity of cement 3.15
Specific gravity of coarse aggregates 2.7
Specific gravity of fine aggregates 2.7
Water absorption:Coarse aggregate 0.5%
Water absorption:Fine aggregate 1%
Free (surface) moisture:Coarse aggregate NIL
Free (surface) moisture:Fine aggregate NIL
Sieve analysis: Coarse aggregate
Conforming to grading
Zone III of Table 4 of
IS : 383- 1970

TARGET MEAN STRENGTH OF CONCRETE:

The target mean compressive ( Fck) strength at28 days is given by
F
ck
= f
ck
+ tS

Where,
F
ck
= characteristic compressive strength at 28 days = 35 MPa
S= standard deviation= 4.0 MPa
t = a statistical value depending on expected proportion of low results (risk factor)
= 1.65
F
Ck
= 35 + (4.0 X 1.65) = 41.6 MPa
SELECTION OF WATER CEMENT RATIO:

According to the graph for target strength of 41.6 MPa the water cement ratio is taken as
0.36.

Estimation of Air Content:

Approximate amount of entrapped air to be expected in normal is 2% of volume of concrete
for nominal maximum size of aggregate of 20mm.

SELECTION OF WATER AND SAND CONTENT:

For 20 mm maximum size aggregate, sand conforming to gradingZone II, water content per
cubic meter of concrete = 186 kg and sand content as percentageof total aggregate by
absolute volume = 35%.

ADJUSMENT:

For change in values in water-cement ratio, compacting factor and sand belonging to Zone
III, the following adjustment is required:

Change in conditions
stipulated for tables
Adjustment Required in
Water Content % Sand in Total Aggregate
For sand conforming to grade
Zone III of table 4, IS:383-
1979
0
-1.5%

Increase in the value of
compacting factor by 0.1
+ 3% 0
0.24 decrease in water-
cement ratio
0 -4.8%

Therefore, required sand content as percentage of total aggregate by absolute volume
= 35 1.5 4.8 = 28.7 %
Required water content = 186 + 5.58 = 191.6 kg/m
3

Determination of cement content:
Water-cement ratio = 0.36
Water content = 191.6 lt
Required cement content = 191.6/0.36 = 532.2 kg/m
3

Determination of coarse and fine aggregate contents:

Our specified maximum size of aggregate of 20 mm, so the amount entrapped air in the wet
concrete is 2 per cent.

We know
[



Where,
V = absolute volume of fresh concrete, which is equal to gross volume (m
3
) - the
volume of entrapped air = .98
W = Mass of water (kg) per m
3
of concrete =191.6 kg/m
3

C = Mass of cement (kg) per m
3
of concrete = 532.2 kg/m
3

Sc = Specific gravity of cement = 3.15
p = Ratio of FA to total aggregate by absolute volume = .287
f
a
, C
a
= Total masses of FA and CA (kg) per m
3
of concrete respectively and
S
fa
, S
ca
= Specific gravities of saturated, surface dry fine aggregate and coarse
Aggregate respectively = 2.7
So
[



f
a
= 480.0 kg/m
3
And,
[


C
a
= 1192.5 kg/m
3


But extra quantity of water to be added for absorption in case of CA, at 0.5 per cent mass,
So, the mass of water per m
3
= 191.6 + (1192.5*.5/100) = 191.6 + 6.0 = 197.6 kg/m
3

So, the mass of coarse aggregate per m
3
= 1192.5 6.0 = 1186.5 kg/m
3


Also,
Extra quantity of water to be added for absorption in case of FA, at 1.0 per cent mass,
So, the mass of water per m
3
= 197.6 + (480.0*1.0/100) = 197.6 + 4.8 = 202.4 kg/m
3

So, the mass of fine aggregate per m
3
= 480.0 4.8 = 475.2 kg/m
3



The mix proportion then becomes:
Cement: Fine aggregate: Coarse Aggregate

= 532.2 kg: 480.0 kg: 1192.5 kg

= 1 : 0.9 : 2.24

Actual quantities required for the mix per m
3
of concrete:

Cement 532.2 kg/m
3

Water 202.4 kg/m
3

Fine Aggregate 480.0kg/m
3

Coarse Aggregate 1192.5kg/m
3






Mix Design of M-40 Grade of Concrete by IS: 10262-1982

Table: E.1
DESIGN STIPULATIONS

Characteristic compressive strength requiredin the field at 28 days 40 N/mm
2
(MPa)
Maximum size of aggregate 20mm
Type of aggregate Angular, Crushed
Degree of workability (Compacting Factor) 0.9
Degree of quality control Good
Type of exposure Mild

Table: E.2
TEST DATA FOR MATERIALS

Cement used OPC- 43
Specific gravity of cement 3.15
Specific gravity of coarse aggregates 2.7
Specific gravity of fine aggregates 2.7
Water absorption:Coarse aggregate 0.5%
Water absorption:Fine aggregate 1%
Free (surface) moisture:Coarse aggregate NIL
Free (surface) moisture:Fine aggregate NIL
Sieve analysis: Coarse aggregate
Conforming to grading
Zone III of Table 4 of
IS : 383- 1970

TARGET MEAN STRENGTH OF CONCRETE:

The target mean compressive ( Fck) strength at28 days is given by
F
ck
= f
ck
+ tS

Where,
F
ck
= characteristic compressive strength at 28 days = 40 MPa
S= standard deviation= 4.0 MPa
t = a statistical value depending on expected proportion of low results (risk factor)
= 1.65
F
Ck
= 40 + (4.0 X 1.65) = 46.6 MPa
SELECTION OF WATER CEMENT RATIO:

According to the graph for target strength of 46.6 MPa the water cement ratio is taken as
0.325.

Estimation of Air Content:

Approximate amount of entrapped air to be expected in normal is 2% of volume of concrete
for nominal maximum size of aggregate of 20mm.

SELECTION OF WATER AND SAND CONTENT:

For 20 mm maximum size aggregate, sand conforming to gradingZone II, water content per
cubic meter of concrete = 180 kg and sand content as percentageof total aggregate by
absolute volume = 25%.

ADJUSMENT:

For change in values in water-cement ratio, compacting factor and sand belonging to Zone
III, the following adjustment is required:

Change in conditions
stipulated for tables
Adjustment Required in
Water Content % Sand in Total Aggregate
For sand conforming to grade
Zone III of table 4, IS:383-
1979
0
-1.5%

Increase in the value of
compacting factor by 0.1
+ 3% 0
0.025 decrease in water-
cement ratio
0 -0.5%

Therefore, required sand content as percentage of total aggregate by absolute volume
= 25 1.5 0.5 = 23.0 %
Required water content = 180 + 5.4 = 185.4 kg/m
3

Determination of cement content:
Water-cement ratio = 0.325
Water content = 185.4 lt
Required cement content = 185.4/0.325 = 570.46 kg/m
3

Determination of coarse and fine aggregate contents:

Our specified maximum size of aggregate of 20 mm, so the amount entrapped air in the wet
concrete is 2 per cent.

We know
[



Where,
V = absolute volume of fresh concrete, which is equal to gross volume (m
3
) - the
volume of entrapped air = .98
W = Mass of water (kg) per m
3
of concrete =185.4 kg/m
3

C = Mass of cement (kg) per m
3
of concrete = 570.46 kg/m
3

Sc = Specific gravity of cement = 3.15
p = Ratio of FA to total aggregate by absolute volume = .23
f
a
, C
a
= Total masses of FA and CA (kg) per m
3
of concrete respectively and
S
fa
, S
ca
= Specific gravities of saturated, surface dry fine aggregate and coarse
Aggregate respectively = 2.7
So
[



f
a
= 381.0 kg/m
3
And,
[


C
a
= 1275.5 kg/m
3


But extra quantity of water to be added for absorption in case of CA, at 0.5 per cent mass,
So, the mass of water per m
3
= 185.4 + (1275.5*.5/100) = 185.4 + 6.4 = 191.8 kg/m
3

So, the mass of coarse aggregate per m
3
= 1275.5 6.4 = 1269.1 kg/m
3


Also,
Extra quantity of water to be added for absorption in case of FA, at 1.0 per cent mass,
So, the mass of water per m
3
= 191.8 + (381.0*1.0/100) = 191.8 + 3.81 = 195.61 kg/m
3

So, the mass of fine aggregate per m
3
= 381.0 3.81 = 377.2 kg/m
3



The mix proportion then becomes:
Cement: Fine aggregate: Coarse Aggregate

= 570.46 kg: 377.2 kg: 1269.1 kg

= 1 : 0.67 : 2.23

Actual quantities required for the mix per m
3
of concrete:

Cement 570.46 kg/m
3

Water 195.61 kg/m
3

Fine Aggregate 377.2kg/m
3

Coarse Aggregate 1269.1kg/m
3






Mix Design of M-45 Grade of Concrete by IS: 10262-1982

DESIGN STIPULATIONS:

Characteristic compressive strength requiredin the field at 28 days 45 N/mm
2
(MPa)
Maximum size of aggregate 20mm
Type of aggregate Angular, Crushed
Degree of workability (Compacting Factor) 0.9
Degree of quality control Good
Type of exposure Mild

TEST DATA FOR MATERIALS:

Cement used OPC- 43
Specific gravity of cement 3.15
Specific gravity of coarse aggregates 2.7
Specific gravity of fine aggregates 2.7
Water absorption:Coarse aggregate 5%
Water absorption:Fine aggregate 1%
Free (surface) moisture:Coarse aggregate NIL
Free (surface) moisture:Fine aggregate NIL
Sieve analysis: Coarse aggregate
Conforming to grading
Zone III of Table 4 of
IS : 383- 1970

TARGET MEAN STRENGTH OF CONCRETE:

The target mean compressive ( Fck) strength at28 days is given by
F
ck
= f
ck
+ tS

Where,
fck = characteristic compressive strength at 28 days = 45 MPa
S= standard deviation= 4 MPa
t = a statistical value depending on expected proportion of low results (risk factor)
= 1.65
F
Ck
= 45 + (4 X 1.65) = 51.6 MPa


SELECTION OF WATER CEMENT RATIO:

According to the graph for Cement Grade of OPC-43 and for target strength of 51.6 MPa the
water cement ratio is taken as 0.31.

Estimation of Air Content:

Approximate amount of entrapped air to be expected in normal is 2% of volume of concrete
for nominal maximum size of aggregate of 20mm.

SELECTION OF WATER AND SAND CONTENT:

For 20 mm maximum size aggregate, sand conforming to gradingZone II, water content per
cubic meter of concrete = 180 kg and sand content as percentageof total aggregate by
absolute volume =25 %.

ADJUSMENT:

For change in values in water-cement ratio, compacting factor and sand belonging to Zone
III, the following adjustment is required:

Change in conditions
stipulated for tables
Adjustment Required in
Water Content % Sand in Total Aggregate
For sand conforming to grade
Zone III of table 4, IS:383-
1979
0
-1.5%

Increase in the value of
compacting factor by 0.1
+ 3% 0
0.04 decrease in water-
cement ratio
0
-0.8%


Therefore, required sand content as percentage of total aggregate by absolute volume
= 25 1.5 0.8 = 22.7%
Required water content = 180 + 5.4 = 185.4 kg/m
3

Determination of cement content:

Water-cement ratio = 0.31
Water content =185.4lt
Required cement content = 185.4/.31 = 598.06 kg/m
3

Determination of coarse and fine aggregate contents:

Our specified maximum size of aggregate of 20 mm, so the amount entrapped air in the wet
concrete is 2 per cent.

We know

[



Where,
V = absolute volume of fresh concrete, which is equal to gross volume (m
3
) - the
volume of entrapped air = .98
W = Mass of water (kg) per m
3
of concrete =185.4 kg/m
3

C = Mass of cement (kg) per m
3
of concrete = 598.06 kg/m
3

Sc = Specific gravity of cement = 3.15
p = Ratio of FA to total aggregate by absolute volume = .227
f
a
, C
a
= Total masses of FA and CA (kg) per m3 of concrete respectively and
S
fa
, S
ca
= Specific gravities of saturated, surface dry fine aggregate and coarse
Aggregate respectively = 2.7
So
[



f
a
=370.6 kg/m
3
And,
[


C
a
= 1262.15kg/m
3

Water absorbed by coarse aggregate 5% = 1262.15 x 5/100 = 63 kg/m
3

So field weight of coarse aggregate = 1216.15-63 = 1153.15kg/m
3

And water absorbed by fine aggregate 1% = 370.6 x 1/100 = 3.706kg/m
3

So field weight of fine aggregate should be taken = 370.6-3.706 =366.89 kg/m
3

Now the water content = 185.4+63+3.706 = 252.1 kg/m
3

The mix proportion then becomes
Cement: Fine aggregate: Coarse Aggregate

=598.06 kg :366.89 kg:1153.15 kg

= 1 :0.6: 1.93

Actual quantities required for the mix per m
3
of concrete:

Cement 598.06 kg/m
3

Water 252.1 kg/m
3

Fine Aggregate 366.89kg/m
3

Coarse Aggregate 1153.15kg/m
3






Design of concrete mix of M25 grade using IS 10262:2009


1. STIPULATIONS FOR PROPORTIONING and TEST DATA FOR
MATERIALS:

Grade designation- M25
Type of cement used- OPC 43
Maximum nominal size of aggregate- 20 mm
Degree of quality control- Good
Exposure conditions- Mild (for PCC)
Specific gravity of cement- 3.15
Type of aggregate used- Angular, crushed
Degree of supervision- Good
Chemical admixture type- Super plasticizer (IS 9103)
Workability- 100 mm slump
Specific gravity of coarse aggregate- 2.7
Specific gravity of fine aggregate- 2.7
Water absorption of coarse aggregate- 0.5 percent
Water absorption of fine aggregate- 1.0 percent
Free surface moisture of coarse aggregate- Nil
Free surface moisture of fine aggregate- Nil
Zone of fine aggregate- Zone III (Table 4, IS 383)
Fineness modulus of fine aggregate- 2.8
Maximum free water cement ratio- 0.55
Minimum cement content- 300 kg/m
3





2. TARGET STRENGTH FOR MIX PROPORTIONING:
We know
f
ck
= f
ck
+1.65*s
here, f
ck
= 25 Mpa or 25 N/mm
2

s= 4.0 (according to Table 1 of IS 10262: 2009)
therefore, f
ck
= 25 + 1.65 * 4 = 31.6 N/mm
2
.


3. SELECTION OF WATER CEMENT RATIO ( first trial):
According to Table 5 of IS 456: 2000 , we get
The maximum free water cement ratio= 0.55
We are adopting the value as 0.5 which is less than 0.55.

4. SELECTION OF WATER CONTENT :
According to Table 2 of IS 10262: 2009,for 20 mm aggregatesthe maximum water content is
186 kg, for 25 to 50 mm slump.
Hence, estimated water content for 100 mm slump = (186 + 6% of 186) kg
= (186 + 11.16) kg
= 197.16 kg
Now, as super plasticizer is used, the water content can be reduced by 20 percent or above.
Therefore, for the first trial, we are assuming that the water content is reduced by 20 percent.
Hence the calculated water content is = 80% of 197.16 kg
= 157.728 kg



5. CALCULATION OF CEMENT CONTENT (first trial):
Water cement ratio= 0.50
Therefore, cement content = 157.728/0.5 = 315.456 kg/m
3

From Table 5 of IS 10262:2009
the minimum cement content for mild exposure condition is 300 kg/m
3
.
As, 315.456 kg/m
3
is greater than 300 kg/m
3

Hence, our assumption is O.K.

6. PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE
AGGREGATE CONTENT (first trial):
From Table 3, volume of coarse aggregate corresponding to 20 mm size aggregate and fine
aggregate (Zone III) for water cement ratio is 0.64.
Hence, volume of coarse aggregate = 0.64
Therefore, volume of fine aggregate = 1- 0.64= 0.36.



7. MIX CALCULATIONS (first trial):

a) Volume of concrete = 1m
3
.

b) Volume of cement= (Mass of cement/Specific gravity of cement)* (1/1000)
= ( 315.456 / 3.15) * (1/1000)
= 0.100145m
3



c) Volume of water =(Mass of water/Specific gravity of water)* (1/1000)
=(157.728/1)*(1/1000)
= 0.157728m
3


d) Volume of super plasticizer (@ 2 % by mass of cementitious material)
= (Mass of admixture/ Specific gravity) * (1/1000)
= (6.31/1.145) * (1/1000)
= 5.51 * 10
-3
m
3


e) Volume of all in aggregate = [ a ( b + c + d )]
= [ 1 ( 0.100145 + 0.157728 + 0.00551 )] m
3

= 0.736617 m
3



f) Mass of coarse aggregate = e * Volume of Coarse aggregate * Specific
gravity of Coarse aggregate * 1000
= 1272.87 kg

g) Mass of fine aggregate = e * Volume of Fine aggregate * Specific gravity of
Fine aggregate * 1000
= 716 kg

8. MIX PROPORTION VALUES FOR TRIAL 1:

a. Cement = 315.456 kg/m
3
.
b. Water = 157.728 kg/m
3
.
c. Fine aggregate = 716 kg/m
3
.
d. Coarse aggregate = 1272.87 kg/m
3
.
e. Chemical admixture = 6.31 kg/m
3
.
f. Water cement ratio = 0.5.

9. TRIAL 2:
In this trial, we assume a different water cement ratio value,
W/c ratio = w/c ratio of first trial 10% of w/c ratio of first trial
= 0.5 10 % of 0.5
= 0.45
The calculated water content will remain the same, provided the reduction in water
content due to the use of plasticizer remains the same.
Hence, the water content = 157.728 kg.
Therefore, cement content = 157.728/ 0.45 = 350.51 kg/m
3
. > 300 kg/m
3
.
We know, volume of coarse aggregate for w/c ratio of 0.5 is 0.64 for Zone III fine
aggregate.
But, as the w/c ratio is 0.45, so, the volume of coarse aggregate needs to be increased to
decrease the fine aggregate content. The volume of coarse aggregate is increased @ of
0.01 % for a decrease of 0.05 water cement ratio.
Therefore, volume of coarse aggregate = 0.64 + 0.01 = 0.65.
Therefore, volume of fine aggregate = 1- 0.65 = 0.35.

10. MIX CALCULATIONS (for second trial):

a. Volume of concrete = 1m
3
.
b. Volume of cement = ( 350.51/ 3.15) * (1/1000) m
3

= 0.11127 m
3
.
c. Volume of water = 0.157728 m
3
.
d. Volume of plasticizer = (7.0102 / 1.145 ) * (1/1000) m
3

= 0.006 m
3
.
e. Volume of all in aggregate = 1 ( 0.11127 + 0.157728 + 0.006) m
3

= 0.725 m
3
.
f. Mass of coarse aggregate = 1272.38 kg.
g. Mass of fine aggregate = 685.13 kg.


11. MIX PROPORTION VALUES FOR TRIAL 2:

a. Cement = 350.51 kg/m
3
.
b. Water = 157.728 kg/m
3
.
c. Fine aggregate = 685.13 kg/m
3
.
d. Coarse aggregate = 1272.38 kg/m
3
.
e. Chemical admixture = 7.0102 kg/m
3
.
f. Water cement ratio = 0.45

12. TRIAL 3:
In this trial, we assume yet another different water cement ratio value,
w/c ratio = w/c ratio of first trial + 10% of w/c ratio of first trial
= 0.5 + 10 % of 0.5
= 0.55
The calculated water content will remain the same, provided the reduction in water
content due to the use of plasticizer remains the same.
Hence, the water content = 157.728 kg.
Therefore, cement content = 157.728/ 0.55 = 286.78 kg/m
3
. < 300 kg/m
3
.
Hence, here we will use the minimum cement content that is 300 kg/m
3
.
we know, volume of coarse aggregate for w/c ratio of 0.5 is 0.64 for Zone III fine
aggregate.
But, as the w/c ratio is 0.55, so, the volume of coarse aggregate needs to be decreased to
increase the fine aggregate content. The volume of coarse aggregate is decreased @ of
0.01 % for a decrease of 0.05 water cement ratio.
Therefore, volume of coarse aggregate = 0.64 - 0.01 = 0.63.
Therefore, volume of fine aggregate = 1- 0.63 = 0.37.

13. MIX CALCULATIONS (for third trial):

a. Volume of concrete = 1m
3
.
b. Volume of cement = ( 286.78/ 3.15) * (1/1000) m
3

= 0.091 m
3
.
c. Volume of water = 0.157728 m
3
.
d. Volume of plasticizer = (5.7356 / 1.145 ) * (1/1000) m
3

= 0.005 m
3
.
e. Volume of all in aggregate = 1 ( 0.091 + 0.157728 + 0.005) m
3

= 0.746 m
3
.
f. Mass of coarse aggregate = 1268.95 kg.
g. Mass of fine aggregate = 745.25kg.

14. MIX PROPORTION VALUES FOR TRIAL 3:

a. Cement = 286.78 kg/m
3
.
b. Water = 157.728 kg/m
3
.
c. Fine aggregate = 745.25 kg/m
3
.
d. Coarse aggregate = 1268.95 kg/m
3
.
e. Chemical admixture = 5.7356 kg/m
3
.
f. Water cement ratio = 0.55.

Design of concrete mix of M30 grade using IS 10262:2009


15. STIPULATIONS FOR PROPORTIONING and TEST DATA FOR
MATERIALS:

Grade designation- M30
Type of cement used- OPC 43
Maximum nominal size of aggregate- 20 mm
Degree of quality control- Good
Exposure conditions- Severe (for PCC)
Specific gravity of cement- 3.15
Type of aggregate used- Angular, crushed
Degree of supervision- Good
Chemical admixture type- Super plasticizer (IS 9103)
Workability- 100 mm slump
Specific gravity of coarse aggregate- 2.7
Specific gravity of fine aggregate- 2.7
Water absorption of coarse aggregate- 0.5 percent
Water absorption of fine aggregate- 1.0 percent
Free surface moisture of coarse aggregate- Nil
Free surface moisture of fine aggregate- Nil
Zone of fine aggregate- Zone III (Table 4, IS 383)
Fineness modulus of fine aggregate- 2.8

16. TARGET STRENGTH FOR MIX PROPORTIONING:

We know,
f
ck
= f
ck
+1.65*s
Here, f
ck
= 30Mpa or 30 N/mm
2

s= 5.0 (according to Table 1 of IS 10262: 2009)
Therefore, f
ck
= 30 + 1.65 * 5 = 31.6 N/mm
2
.

17. SELECTION OF WATER CEMENT RATIO ( first trial):

According to Table 5 of IS 456: 2000, we get
The maximum free water cement ratio= 0.45
We are adopting the value as 0.4 which is less than 0.45


18. SELECTION OF WATER CONTENT :

According to Table 2 of IS 10262: 2009,for 20 mm aggregatesthe maximum water
content is 186 kg, for 25 to 50 mm slump.
Hence, estimated water content for 100 mm slump = (186 + 6% of 186) kg
= (186 + 11.16) kg
= 197.16 kg
Now, as super plasticizer is used, the water content can be reduced by 20 percent or
above.
Therefore, for the first trial, we are assuming that the water content is reduced by 20
percent.
Hence the calculated water content is = 80% of 197.16 kg
= 157.728 kg

19. CALCULATION OF CEMENT CONTENT (first trial):

Water cement ratio= 0.40
Therefore, cement content = 157.728/0.4 = 394.32 kg/m
3

From Table 5 of IS 10262:2009
The minimum cement content for severe exposure condition is 320 kg/m
3
.
As, 394.32 kg/m
3
is greater than 320 kg/m
3

Hence, our assumption is O.K.

20. PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE
AGGREGATE CONTENT (first trial):

From Table 3, volume of coarse aggregate corresponding to 20 mm size aggregate
and fine aggregate (Zone III) for ratio of volume of coarse aggregate to total
aggregate is 0.64.
In the present case water-cement ratio is 0.40. Therefore, volume of coarse aggregate
is required to be increased to decrease fine aggregate content. As the water-cement
ratio is lower by 0.10, the proportion of volume of coarse aggregate is increased by
0.02. Therefore, corrected proportion of volume of coarse aggregate for the water-
cement ratio of 0.40=0.66.
Hence, volume of coarse aggregate = 0.66
Therefore, volume of fine aggregate = 1- 0.66= 0.34.


21. MIX CALCULATIONS (first trial):
h) Volume of concrete = 1m
3
.
i) Volume of cement= (Mass of cement/Specific gravity of cement)* (1/1000)
= (394.32 / 3.15) * (1/1000)
= 0.125181m3
j) Volume of water =(Mass of water/Specific gravity of water)* (1/1000)
=(157.728/1)*(1/1000)
= 0.157728m
3


k) Volume of super plasticizer (@ 2 % by mass of cementitious material)
= (Mass of admixture/ Specific gravity) * (1/1000)
= (6.31/1.145) * (1/1000)
= 5.51 * 10
-3
m
3


l) Volume of all in aggregate = [ a ( b + c + d )]
= [ 1 ( 0.125181 + 0.157728 + 0.00551 )] m
3

= 0.711581 m
3



m) Mass of coarse aggregate = e * Volume of Coarse aggregate * Specific gravity
of Coarse aggregate * 1000 = 0.66*2.7*1000 = 1782 kg

n) Mass of fine aggregate = e * Volume of Fine aggregate * Specific gravity of
Fine aggregate * 1000= 0.34*2.7*1000 = 918 kg

22. MIX PROPORTION VALUES FOR TRIAL 1:

g. Cement = 394.32 kg/m
3
.
h. Water = 157.728 kg/m
3
.
i. Fine aggregate = 918 kg/m
3
.
j. Coarse aggregate = 1782 kg/m
3
.
k. Chemical admixture = 6.31 kg/m
3
.
l. Water cement ratio = 0.4.








23. TRIAL 2:
In this trial, we assume a different water cement ratio value,
W/c ratio = w/c ratio of first trial 10% of w/c ratio of first trial
= 0.4 10 % of 0.5
= 0.35
The calculated water content will remain the same, provided the reduction in water
content due to the use of plasticizer remains the same.
Hence, the water content = 157.728 kg.
Therefore, cement content = 157.728/ 0.45 = 450.65 kg/m
3
. >450 kg/m
3
.
So, we adopt 450 kg/m
3
We know, volume of coarse aggregate for w/c ratio of 0.4 is 0.66 for Zone III fine
aggregate.
But, as the w/c ratio is 0.35, so, the volume of coarse aggregate needs to be increased to
decrease the fine aggregate content. The volume of coarse aggregate is increased @ of
0.01 % for a decrease of 0.05 water cement ratio.
Therefore, volume of coarse aggregate = 0.66 + 0.01 = 0.67.
Therefore, volume of fine aggregate = 1- 0.67 = 0.33.

24. MIX CALCULATIONS (for second trial):

h. Volume of concrete = 1m
3
.
i. Volume of cement = ( 450/ 3.15) * (1/1000) m
3

= 0.142857 m
3
.
j. Volume of water = 0.157728 m
3
.
k. Volume of plasticizer = (7.0102 / 1.145 ) * (1/1000) m
3

= 0.006 m
3
.
l. Volume of all in aggregate = 1 ( 0.142857 + 0.157728 + 0.006) m
3

= 0.6934 m
3
.
m. Mass of coarse aggregate = 1809 kg.
n. Mass of fine aggregate = 891 kg

25. MIX PROPORTION VALUES FOR TRIAL 2:

g. Cement = 450 kg/m
3
.
h. Water = 157.728 kg/m
3
.
i. Fine aggregate = 891 kg/m
3
.
j. Coarse aggregate = 1809 kg/m
3
.
k. Chemical admixture = 7.0102 kg/m
3
.
l. Water cement ratio = 0.35

26. TRIAL 3:
In this trial, we assume yet another different water cement ratio value,
w/c ratio = w/c ratio of first trial + 10% of w/c ratio of first trial
= 0.5 + 10 % of 0.5
= 0.45
The calculated water content will remain the same, provided the reduction in water
content due to the use of plasticizer remains the same.
Hence, the water content = 157.728 kg.
Therefore, cement content = 157.728/ 0.45 = 350.5067 kg/m
3
. > 320 kg/m
3
.
Hence, here we will use the cement content 350 kg/m
3
.
We know, volume of coarse aggregate for w/c ratio of 0.4 is 0.66 for Zone III fine
aggregate.
But, as the w/c ratio is 0.45, so, the volume of coarse aggregate needs to be decreased to
increase the fine aggregate content. The volume of coarse aggregate is decreased @ of
0.01 % for a decrease of 0.05 water cement ratio.
Therefore, volume of coarse aggregate = 0.66 - 0.01 = 0.65.
Therefore, volume of fine aggregate = 1- 0.65 = 0.35.

27. MIX CALCULATIONS (for third trial):

h. Volume of concrete = 1m
3
.
i. Volume of cement = ( 350/ 3.15) * (1/1000) m
3

= 0.1111 m
3
.
j. Volume of water = 0.157728 m
3
.
k. Volume of plasticizer = (5.7356 / 1.145 ) * (1/1000) m
3

= 0.005 m
3
.
l. Volume of all in aggregate = 1 ( 0.1111 + 0.157728 + 0.005) m
3

= 0.726 m
3
.
m. Mass of coarse aggregate = 1755 kg.
n. Mass of fine aggregate = 945 kg.

28. MIX PROPORTION VALUES FOR TRIAL 3:

g. Cement = 350 kg/m
3
.
h. Water = 157.728 kg/m
3
.
i. Fine aggregate = 945kg/m
3
.
j. Coarse aggregate = 1755 kg/m
3
.
k. Chemical admixture = 5.7356 kg/m
3
.
Water cement ratio = 0.45.

Design of concrete mix of M35 grade using IS 10262:2009

1. STIPULATIONS FOR PROPORTIONING and TEST DATA FOR MATERIALS:

Grade designation- M35
Type of cement used- OPC 43
Maximum nominal size of aggregate- 20 mm
Degree of quality control- Good
Exposure conditions- Very Severe (for RCC)
Specific gravity of cement- 3.15
Type of aggregate used- Angular, crushed
Degree of supervision- Good
Chemical admixture type- Super plasticizer (IS 9103)
Workability- 100 mm slump
Specific gravity of coarse aggregate- 2.7
Specific gravity of fine aggregate- 2.7
Water absorption of coarse aggregate- 0.5 percent
Water absorption of fine aggregate- 1.0 percent
Free surface moisture of coarse aggregate- Nil
Free surface moisture of fine aggregate- Nil
Zone of fine aggregate- Zone III (Table 4, IS 383)
Fineness modulus of fine aggregate- 2.8
Maximum free water cement ratio- 0.45 ( IS 456,table 5)
Minimum cement content- 340 kg/m
3
( IS 456,table
5)


2.TARGET STRENGTH FOR MIX PROPORTIONING:
We know
f
ck
= f
ck
+1.65*s
here, f
ck
= 35 Mpa or 35 N/mm
2

s= 5.0 (according to Table 1 of IS 10262: 2009)
Therefore, f
ck
= 25 + 1.65 * 5 = 43.25 N/mm
2
.


3. SELECTION OF WATER CEMENT RATIO :
According to Table 5 of IS 456: 2000 , we get
The maximum free water cement ratio= 0.45
We are adopting the value as 0.4 which is less than 0.45.
4. SELECTION OF WATER CONTENT :
According to Table 2 of IS 10262: 2009,for 20 mm aggregatesthe maximum water content is
186 kg, for 25 to 50 mm slump.
Hence, estimated water content for 100 mm slump = (186 + 6% of 186) kg
= (186 + 11.16) kg
= 197.16 kg
Now, as super plasticizer is used, the water content can be reduced by 20 percent or above.
Therefore, we are assuming that the water content is reduced by 20 percent.
Hence the calculated water content is = 80% of 197.16 kg
= 157.728 kg

5.CALCULATION OF CEMENT CONTENT:
Water cement ratio= 0.40
Therefore, cement content = 157.728/0.5 = 394.32 kg/m
3

From Table 5 of IS 456:2000 ,
the minimum cement content for very severe exposure condition is 340 kg/m
3
.
As, 394.32 kg/m
3
is greater than 340 kg/m
3

Hence, our assumption is O.K.

6. PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE
AGGREGATE CONTENT (first trial):
From Table 3 of IS 10262:2009, volume of coarse aggregate corresponding to 20 mm size
aggregate and fine aggregate (Zone III) for water cement ratio of 0.5 is 0.64.But ,as the w/c
ratio is 0.4,so the volume of course aggregate needs to be increased to decrease the fine
aggregate content. The volume of course aggregate is increased @ 0.01 for a decrease of 0.05
w/c ratio.
Hence, volume of coarse aggregate = 0.64+0.02=0.66
Therefore, volume of fine aggregate = 1- 0.66= 0.34.

7. MIX CALCULATIONS :

a) Volume of concrete = 1m
3
.

b) Volume of cement= (Mass of cement/Specific gravity of cement)* (1/1000)
= ( 394.32 / 3.15) * (1/1000)
= 0.125181m
3


c) Volume of water =(Mass of water/Specific gravity of water)* (1/1000)
=(157.728/1)*(1/1000)
= 0.157728m
3


d) Volume of super plasticizer (@ 2 % by mass of cementitious material)
= (Mass of admixture/ Specific gravity) * (1/1000)
= (7.88/1.145) * (1/1000)
= 6.887 * 10
-3
m
3


e) Volume of all in aggregate = [ a ( b + c + d )]
= [ 1 ( 0.125181 + 0.157728 + 0.006887 )] m
3

= 0.710204 m
3



f) Mass of coarse aggregate = e * Volume of Coarse aggregate * Specific
gravity of Coarse aggregate * 1000
=0.710204*0.66*2.7*1000
= 1265.58 kg

g) Mass of fine aggregate = e * Volume of Fine aggregate * Specific gravity of
Fine aggregate * 1000
=0.710204*0.34*2.7*1000
= 651.97 kg

29. MIX PROPORTION VALUES :

a. Cement = 394.32kg/m
3
.
b. Water = 157.728 kg/m
3
.
c. Fine aggregate = 651.97 kg/m
3
.
d. Coarse aggregate = 1265.58 kg/m
3
.
e. Chemical admixture = 7.886 kg/m
3
.
Water cement ratio = 0.4.







Design of concrete mix of M40 grade using IS 10262:2009

1. STIPULATIONS FOR PROPORTIONING and TEST DATA FOR MATERIALS:

Grade designation- M40
Type of cement used- OPC 43
Maximum nominal size of aggregate- 20 mm
Degree of quality control- Good
Exposure conditions- Extreme (for RCC)
Specific gravity of cement- 3.15
Type of aggregate used- Angular, crushed
Degree of supervision- Good
Chemical admixture type- Super plasticizer (IS 9103)
Workability- 100 mm slump
Specific gravity of coarse aggregate- 2.7
Specific gravity of fine aggregate- 2.7
Water absorption of coarse aggregate- 0.5 percent
Water absorption of fine aggregate- 1.0 percent
Free surface moisture of coarse aggregate- Nil
Free surface moisture of fine aggregate- Nil
Zone of fine aggregate- Zone III (Table 4, IS 383)
Fineness modulus of fine aggregate- 2.8
Maximum free water cement ratio- 0.40
Minimum cement content- 360 kg/m
3



2. TARGET STRENGTH FOR MIX PROPORTIONING:
We know
f
ck
= f
ck
+1.65*s
Here, f
ck
= 40 Mpa or 40 N/mm
2

s= 5.0 (according to Table 1 of IS 10262: 2009)
Therefore, f
ck
= 40 + 1.65 * 5 = 48.25 N/mm
2
.


3. SELECTION OF WATER CEMENT RATIO:
According to Table 5 of IS 456: 2000 , we get
The maximum free water cement ratio= 0.40
We are adopting the value as 0.35 which is less than 0.40.
4. SELECTION OF WATER CONTENT :
According to Table 2 of IS 10262: 2009 , for 20 mm aggregates
the maximum water content is 186 kg, for 25 to 50 mm slump
hence, estimated water content for 100 mm slump = (186 + 6% of 186) kg
= (186 + 11.16) kg
= 197.16 kg
Now, as super plasticizer is used, the water content can be reduced by 20 percent or above.
Therefore, for the first trial, we are assuming that the water content is reduced by 20 percent.
Hence the calculated water content is = 80% of 197.16 kg
= 157.728 kg



5. CALCULATION OF CEMENT CONTENT:
Water cement ratio= 0.35
Therefore, cement content = 157.728/0.35 = 450.651 kg/m
3

From Table 5 of IS 456:2000
the minimum cement content for extreme exposure condition is 360 kg/m
3
.
As, 450.651 kg/m
3
is greater than 360 kg/m
3
.
Hence, our assumption is O.K.

6. PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE
AGGREGATE CONTENT:
From Table 3 of IS 10262:2009, volume of coarse aggregate corresponding to 20 mm size
aggregate and fine aggregate (Zone III) for water cement ratio of 0.5 is 0.64.
But, as the w/c ratio is 0.35, so, the volume of coarse aggregate needs to be increased to
decrease the fine aggregate content. The volume of coarse aggregate is increased @ of 0.01
for a decrease of 0.05 water cement ratio.
Hence, volume of coarse aggregate = 0.64 + 0.03 = 0.67
Therefore, volume of fine aggregate = 1- 0.67= 0.33.

7. MIX CALCULATIONS:

a) Volume of concrete = 1m
3
.

b) Volume of cement= (Mass of cement/Specific gravity of cement)* (1/1000)
= ( 450.651 / 3.15) * (1/1000)
= 0.143064m
3

c) Volume of water =(Mass of water/Specific gravity of water)* (1/1000)
=(157.728/1)*(1/1000)
= 0.157728m
3


d) Volume of super plasticizer (@ 2 % by mass of cementitious material)
= (Mass of admixture/ Specific gravity) * (1/1000)
= (9.013/1.145) * (1/1000)
= 7.8716 * 10
-3
m
3


e) Volume of all in aggregate = [ a ( b + c + d )]
= [ 1 ( 0.143064 + 0.157728 + 0.0078716 )] m
3

= 0.69134 m
3



f) Mass of coarse aggregate = e * Volume of Coarse aggregate * Specific gravity
of Coarse aggregate * 1000
= 1250.63 kg

g) Mass of fine aggregate = e * Volume of Fine aggregate * Specific gravity of
Fine aggregate * 1000
= 616 kg


8. MIX PROPORTION VALUES :

a. Cement = 450.651 kg/m
3
.
b. Water = 157.728 kg/m
3
.
c. Fine aggregate = 616 kg/m
3
.
d. Coarse aggregate = 1250.63 kg/m
3
.
e. Chemical admixture = 9.013 kg/m
3
.
Water cement ratio = 0.35.







Mix design of M25 grade of concrete according to ACI-211.1-1991
method

The specified design strength of concrete (characteristic strength) is 25MPa at 28 days
measurement. The specific gravity of the C.A. and F.A. is 2.7. The dry rodded bulk density of
the C.A. is 1600kg/m
3
and the fineness modulus of the F.A.is 2.8. The ordinary Portland
cement will be used for this purpose. The degree of quality control is good. The degree of
workibility is 100mm slump. The water absorption capacity of the C.A. is 0.5% and that of
the F.A. is 1%.It has been given that the free surface moisture of C.A. and F.A. is nil.

The step by step procedure of mix design with the given data is shown
below:

Step 1: Assuming that 5% of the test results are to fall below the specified design strength,the
mean strength,
F
m
=f
min
+k*s
=25+1.65*4 (The value of s is taken as per IS 456-2000)
=31.6MPa

Step2: As we have used OPC we have to take the w/c ratio fromstrength point of view and
from the special exposure condition also.
From strength of view, w/c=0.53 (according to table C(1) ACI 211.1-91)
From the exposure condition, w/c=0.5(according to table C(2)ACI211.1-91)
So according to the above mentioned code we have to take the least value of the w/c among
these two values.
Therefore the value w/c=0.5

Step3: For the slump of 100mm and the maximum size of the aggregate =20mm for air
entered concrete,
The mixing water content is=180kg/m
3
(According totable C(3) ACI211.1-91)
Therefore the required cement cont=180/0.5=360kg/m
3

Step 4: The given F.M. of the F.A. is 2.8 and the maximum size of the coarse aggregate is
20mm.Then according totable C(4) ACI211.1-91 the bulk volume of the coarse aggregate is
0.62per unit volume of the concrete.

Step5: Therefore the weight of the coarse aggregate is =0.62*1600=992kg/m
3
(as the bulk
density of the coarse aggregate is 1600kg/m
3
)

Step6: According to table C(5) ACI211.1-91 the first estimate of fresh concrete for 20 mm
maximum size of aggregate and for air entrained concrete=2280kg/m
3

Step7: Therefore the weight of the fine aggregate =2280-(180+360+992)=748kg/m
3


Step8: Alternatively the weight of F.A. can also be found out by absolute volume method
which is more accurate.
Absolute volume of the cement=(360/3.15)*10
3
=114.3*10
3
cm
3

Absolute volume of the water=(180/1)*10
3
=180*10
3
cm
3

Absolute volume of the C.A.=(992/2.7)*10
3
=367.4*10
3
cm
3

Absolute volume of the air=(2/100)*10
6
=20*10
3
cm
3

So the total absolute volume =681.7*10
3
cm
3

Therefore the absolute volume of the F.A.=(1000-681.7)*10
3
=318.3*10
3
cm
3

Therefore the weight of the F.A.=318.3*2.7*10
3
=859.4kg/m
3
So will take 859.4kg/m
3
of F.A.

Step9: Estimated quantities of of materials per cubic meter of concrete are
Cement=3600kg
F.A.=859.4kg
C.A.=992kg
Water=180kg
Therefore the density of fresh concrete 2391.4kg/m
3
as against 2280 according to table
C(5)ACI211.1-91.



Step10: Therefore the proportions are,
Cement : F.A. : C.A. : Water
360 : 859.4 : 992 : 180
1 : 2.4 : 2.75 : 0.5

Step11: According to the given data the C.A. is 0.5% water absorptive. So the quantity of
water absorbed by the C.A.=(0.5/100)*992=4.96kg/m
3

Therefore the weight of the C.A. in field condition=(992-4.96)=987.04kg/m
3

As the F.A. is 1% absorptive so quantity of water absorbed by
F.A.=(1/100)*859.4=8.594kg/m
3

Therefore the weight of the F.A,in field condition=(859.4-8.594)=850.8kg/m
3

The total amount of water absorption=(4.96+8.594)=13.554kg/m
3

Therefore the total amount of water required = (180+13.554)=193.554kg/m
3

So in the field the actual amounts of cement, F.A., C.A. and water is,
Cement=360kg/m
3
, F.A.=850.8 kg/m
3
,C.A.=987.04 kg/m
3
and water=193.554 kg/m
3

So the field density of the fresh concrete=2391.4 kg/m
3















Mix design of M30 grade of concrete according to ACI-211.1-1991
method

The specified design strength of concrete (characteristic strength) is 30MPa at 28 days
measurement. The specific gravity of the C.A. and F.A. is 2.7. The dry rodded bulk density of
the C.A. is 1600kg/m
3
and the fineness modulus of the F.A.is 2.8. The ordinary Portland
cement will be used for this purpose. The degree of quality control is good. The degree of
workibilty is 100mm slump. The water absorption capacity of the C.A. is 0.5% and that of the
F.A. is 1%.It has been given that the free surface moisture of C.A. and F.A. is nil.

The step by step procedure of mix design with the given data is shown below:

Step 1: Assuming that 5% of the test results are to fall below the specified design strength,
the mean strength,
F
m
=f
min
+k*s
=30+1.65*4
=36.6MPa

Step2: As we have used OPC we have to take the w/c ratio from strength point of view and
from the special exposure condition also.
From strength of view ,w/c=0.46 (according to ACI 211.1-91)
From the exposure condition ,w/c=0.5(according to ACI211.1-91)
So according to the above mentioned code we have to take the least value of the w/c among
these two values.
Therefore the value w/c=0.46

Step3: For the slump of 100mm and the maximum size of the aggregate =20mm for
airentrened concrete,
The mixing water content is=180kg/m
3

Therefore the required cement cont=180/0.46=391.3kg/m
3

Step 4: The given F.M. of the F.A. is 2.8 and the maximum size of the coarse aggregate is
20mm.Then according to ACI211.1-91 the bulk volume of the coarse aggregate is 0.62per
unit volume of the concrete.

Step5: Therefore the weight of the coarse aggregate is =0.62*1600=992kg/m
3
(as the bulk
density of the coarse aggregate is 1600kg/m
3
)

Step6: According to ACI211.1-91 the first estimate of fresh concrete for 20 mm maximum
size of aggregate and for air entrained concrete=2280kg/m
3

Step7: Therefore the weight of the fine aggregate =2280-(180+391.3+992)=716.7kg/m
3


Step8: Alternatively the weight of F.A. can also be found out by absolute volume method
which is more accurate.
Absolute volume of the cement=(391.3/3.15)*10
3
=124.2*10
3
cm
3

Absolute volume of the water=(180/1)*10
3
=180*10
3
cm
3

Absolute volume of the C.A.=(992/2.7)*10
3
=367.4*10
3
cm
3

Absolute volume of the air=(2/100)*10
6
=20*10
3
cm
3

So the total absolute volume =691.6*10
3
cm
3

Therefore the absolute volume of the F.A.=(1000-691.6)*10
3
=308.4*10
3
cm
3

Therefore the weight of the F.A.=308.4*2.7*10
3
=832.7kg/m
3
So will take 832.7kg/m
3
of F.A.

Step9: Estimated quantities of of materials per cubic meter of concrete are
Cement=391.3kg
F.A.=832.7kg
C.A.=992kg
Water=180kg
Therefore the density of fresh concrete 2396kg/m
3
as against 2280 according to ACI211.1-91.



Step10: Therefore the proportions are,
Cement : F.A. : C.A. : Water
391.3 : 832.7 : 992 : 180
1 : 2.13 : 2.53 : 0.46

Step11: According to the given data the C.A. is 0.5% water absorptive. So the quantity of
water absorbed by the C.A.=(0.5/100)*992=4.96kg/m
3

Therefore the weight of the C.A. in field condition=(992-4.96)=987.04kg/m
3

As the F.A. is 1% absorptive so quantity of water absorbed by
F.A.=(1/100)*832.7=8.327kg/m
3

Therefore the weight of the F.A, in field condition=(832.7-8.327)=824.37kg/m
3

The total amount of water absorption=(4.96+8.327)=13.287kg/m
3

Therefore the total amount of water required = (180+13.287)=193.287kg/m
3

So in the field the actual amounts of cement, F.A.,C.A. and water is,
Cement=391.3kg/m
3
, F.A.=824.3 kg/m
3
,C.A.=987.04 kg/m
3
and water=193.287 kg/m
3

So the field density of the fresh concrete=2396 kg/m
3





















Mix design of M35 grade of concrete according to ACI-211.1-1991
method

The specified design strength of concrete (characteristic strength) is 35MPa at 28 days
measurement. The specific gravity of the C.A. and F.A. is 2.7. The dry rodded bulk density of
the C.A. is 1600kg/m
3
and the fineness modulus of the F.A.is 2.8. The ordinary Portland
cement will be used for this purpose. The degree of quality control is good. The degree of
workibilty is 100mm slump. The water absorption capacity of the C.A. is 0.5% and that of the
F.A. is 1%.It has been given that the free surface moisture of C.A. and F.A. is nil.

The step by step procedure of mix design with the given data is shown
below:

Step 1: Assuming that 5% of the test results are to fall below the specified design strength,
the mean strength,
F
m
=f
min
+k*s
=35+1.65*4
=41.6MPa

Step2: As we have used OPC we have to take the w/c ratio from strength point of view and
from the special exposure condition also.
From strength of view ,w/c=0.4 (according to ACI 211.1-91)
From the exposure condition ,w/c=0.5(according to ACI211.1-91)
So according to the above mentioned code we have to take the least value of the w/c among
these two values.
Therefore the value w/c=0.4

Step3: For the slump of 100mm and the maximum size of the aggregate =20mm for
airentrened concrete,
The mixing water content is=180kg/m
3

Therefore the required cement cont=180/0.4=450kg/m
3

Step 4: The given F.M. of the F.A. is 2.8 and the maximum size of the coarse aggregate is
20mm.Then according to ACI211.1-91 the bulk volume of the coarse aggregate is 0.62per
unit volume of the concrete.

Step5: Therefore the weight of the coarse aggregate is =0.62*1600=992kg/m
3
(as the bulk
density of the coarse aggregate is 1600kg/m
3
)

Step6: According to ACI211.1-91 the first estimate of fresh concrete for 20 mm maximum
size of aggregate and for air entrained concrete=2280kg/m
3

Step7: Therefore the weight of the fine aggregate =2280-(180+450+992)=658kg/m
3


Step8: Alternatively the weight of F.A. can also be found out by absolute volume method
which is more accurate.
Absolute volume of the cement=(450/3.15)*10
3
=142.85*10
3
cm
3

Absolute volume of the water=(180/1)*10
3
=180*10
3
cm
3

Absolute volume of the C.A.=(992/2.7)*10
3
=367.4*10
3
cm
3

Absolute volume of the air=(2/100)*10
6
=20*10
3
cm
3

So the total absolute volume =710.25*10
3
cm
3

Therefore the absolute volume of the F.A.=(1000-710.25)*10
3
=289.75*10
3
cm
3

Therefore the weight of the F.A.=289.75*2.7*10
3
=782.32kg/m
3
So will take 782.32kg/m
3
of F.A.

Step9: Estimated quantities of of materials per cubic meter of concrete are
Cement=450kg
F.A.=782.32kg
C.A.=992kg
Water=180kg
Therefore the density of fresh concrete 2404.32kg/m
3
as against 2280 according to ACI211.1-
91.


Step10: Therefore the proportions are,
Cement : F.A. : C.A. : Water
450 : 782.32 : 992 : 180
1 : 1.74 : 2.2 : 0.4

Step11: According to the given data the C.A. is 0.5% water absorptive. So the quantity of
water absorbed by the C.A.=(0.5/100)*992=4.96kg/m
3

Therefore the weight of the C.A. in field condition=(992-4.96)=987.04kg/m
3

As the F.A. is 1% absorptive so quantity of water absorbed by
F.A.=(1/100)*782.32=7.823kg/m
3

Therefore the weight of the F.A,in field condition=(782.32-7.823)=774.5kg/m
3

The total amount of water absorption=(4.96+7.823)=12.783kg/m
3

Therefore the total amount of water required = (180+12.783)=192.783kg/m
3

So in the field the actual amounts of cement ,F.A.,C.A. and water is,
Cement=450kg/m
3
, F.A.=774.5 kg/m
3
,C.A.=987.04 kg/m
3
and water=192.783 kg/m
3

So the field density of the fresh concrete=2404.32 kg/m
3














Mix design of M40 grade of concrete according to ACI-211.1-1991
method

The specified design strength of concrete (characteristic strength) is 25MPa at 28 days
measurement. The specific gravity of the C.A. and F.A. is 2.7. The dry rodded bulk density of
the C.A. is 1600kg/m
3
and the fineness modulus of the F.A.is 2.8. The ordinary Portland
cement will be used for this purpose. The degree of quality control is good. The degree of
workibilty is 100mm slump. The water absorption capacity of the C.A. is 0.5% and that of the
F.A. is 1%.It has been given that the free surface moisture of C.A. and F.A. is nil.

The step by step procedure of mix design with the given data is shown below:
Step 1: Assuming that 5% of the test results are to fall below the specified design strength,
the mean strength,
F
m
=f
min
+k*s
=40+1.65*4
=46.6MPa

Step2: As we have used OPC we have to take the w/c ratio from strength point of view and
from the special exposure condition also.
From strength of view, w/c=0.43 (according to ACI 211.1-91)
From the exposure condition, w/c=0.5(according to ACI211.1-91)
So according to the above mentioned code we have to take the least value of the w/c among
these two values.
Therefore the value w/c=0.43

Step3: For the slump of 100mm and the maximum size of the aggregate =20mm for non
airentrened concrete,
The mixing water content is=200kg/m
3

Therefore the required cement cont=200/0.43=465kg/m
3


Step 4: The given F.M. of the F.A. is 2.8 and the maximum size of the coarse aggregate is
20mm.Then according to ACI211.1-91 the bulk volume of the coarse aggregate is 0.62per
unit volume of the concrete.
Step5: Therefore the weight of the coarse aggregate is =0.62*1600=992kg/m
3
(as the bulk
density of the coarse aggregate is 1600kg/m
3
)

Step6: According to ACI211.1-91 the first estimate of fresh concrete for 20 mm maximum
size of aggregate and fornon air entrained concrete=2355kg/m
3

Step7: Therefore the weight of the fine aggregate =2355-(200+465+992)=698kg/m
3


Step8: Alternatively the weight of F.A. can also be found out by absolute volume method
which is more accurate.
Absolute volume of the cement=(465/3.15)*10
3
=147.62*10
3
cm
3

Absolute volume of the water=(200/1)*10
3
=200*10
3
cm
3

Absolute volume of the C.A.=(992/2.7)*10
3
=367.4*10
3
cm
3

Absolute volume of the air=(2/100)*10
6
=20*10
3
cm
3

So the total absolute volume =735*10
3
cm
3

Therefore the absolute volume of the F.A.=(1000-735)*10
3
=265*10
3
cm
3

Therefore the weight of the F.A.=265*2.7*10
3
=715.5kg/m
3
So will take 715.5kg/m
3
of F.A.

Step9: Estimated quantities of of materials per cubic meter of concrete are
Cement=465kg
F.A.=715.5kg
C.A.=992kg
Water=200kg
Therefore the density of fresh concrete 2372.5kg/m
3
as against 2355 according to ACI211.1-
91.


Step10: Therefore the proportions are,
Cement : F.A. : C.A. : Water
465 : 715.5 : 992 : 200
1 : 1.54 : 2.13 : 0.43
Step11: According to the given data the C.A. is 0.5% water absorptive. So the quantity of
water absorbed by the C.A.= (0.5/100)*992=4.96kg/m
3

Therefore the weight of the C.A. in field condition= (992-4.96)= 987.04kg/m
3

As the F.A. is 1% absorptive so quantity of water absorbed by
F.A.=(1/100)*715.5=7.155kg/m
3

Therefore the weight of the F.A, in field condition= (715.5-7.155)=708.345kg/m
3

The total amount of water absorption= (4.96+7.155)=12.115kg/m
3

Therefore the total amount of water required = (200+12.115)=212.115kg/m
3

So in the field the actual amounts of cement, F.A., C.A. and water is,
Cement=465kg/m
3
, F.A.=708.345 kg/m
3
,C.A.=987.04 kg/m
3
and water=212.115 kg/m
3

So the field density of the fresh concrete=2372.5 kg/m
3



























Mix design of M45 grade of concrete according to ACI-211.1-1991
method

The specified design strength of concrete (characteristic strength) is 45MPa at 28 days
measurement. The specific gravity of the C.A. and F.A. is 2.7. The dry rodded bulk density of
the C.A. is 1600kg/m
3
and the fineness modulus of the F.A.is 2.8. The ordinary Portland
cement will be used for this purpose. The degree of quality control is good. The degree of
workability is 100mm slump. The water absorption capacity of the C.A. is 0.5% and that of
the F.A. is 1%.It has been given that the free surface moisture of C.A. and F.A. is nil.

The step by step procedure of mix design with the given data is shown below:
Step 1: Assuming that 5% of the test results are to fall below the specified design strength,
the mean strength,
F
m
=f
min
+ k*s
=45+1.65*5 (The value of s is taken as per IS 456-2000)
=53.25MPa

Step2: As we have used OPC we have to take the w/c ratio from strength point of view and
from the special exposure condition also.
From strength of view, w/c=0.38 (according to table C(1) ACI 211.1-91)
From the exposure condition, w/c=0.5(according to table C(2)ACI211.1-91)
So according to the above mentioned code we have to take the minimum value of the w/c
among these two values.
Therefore adopt the value of w/c= 0.38

Step3: For the slump of 100mm and the maximum size of the aggregate =20mm for non-air
entered concrete,
The mixing water content is=200kg/m
3
(According to table C(3) ACI211.1-91)
Therefore the required cement cont=200/0.38=526kg/m
3

Step 4: The given F.M. of the F.A. is 2.8 and the maximum size of the coarse aggregate is
20mm.Then according to table C(4) ACI211.1-91 the bulk volume of the coarse aggregate is
0.62per unit volume of the concrete.
Step5: Therefore the weight of the coarse aggregate is =0.62*1600=992kg/m
3
(as the bulk
density of the coarse aggregate is 1600kg/m
3
)

Step6: According to table C(5) ACI211.1-91 the first estimate of fresh concrete for 20 mm
maximum size of aggregate and for non-air entrained concrete=2355kg/m
3

Step7: Therefore the weight of the fine aggregate =2355-(200+526+992)= 637kg/m
3


Step8: Alternatively the weight of F.A. can also be found out by absolute volume method
which is more accurate.
Absolute volume of the cement= (526/3.15)*10
3
=166.98*10
3
cm
3

Absolute volume of the water= (200/1)*10
3
=200*10
3
cm
3

Absolute volume of the C.A.= (992/2.7)*10
3
=367.4*10
3
cm
3

Absolute volume of the air= (2/100)*10
6
=20*10
3
cm
3

So the total absolute volume = 754.38*10
3
cm
3

Therefore the absolute volume of the F.A.=(1000-754.38)*10
3
=245.62*10
3
cm
3

Therefore the weight of the F.A.=245.62*2.7*10
3
=663.174kg/m
3
So, we will take 663.174kg/m
3
of F.A.

Step9: Estimated quantities of of materials per cubic meter of concrete are
Cement=526kg
F.A.=663.174kg
C.A.=992kg
Water=200kg
Therefore the density of fresh concrete 2381.174kg/m
3
as against 2355 according to table
C(5)ACI211.1-91.

Step10: Therefore the proportions are,
Cement : F.A. : C.A. : Water
526 : 663.174 : 992 : 200
1 : 1.26: 1.89 : 0.38
Step11: According to the given data the C.A. is 0.5% water absorptive. So the quantity of
water absorbed by the C.A.= (0.5/100)*992=4.96kg/m
3

Therefore the weight of the C.A. in field condition=(992-4.96)=987.04kg/m
3

As the F.A. is 1% absorptive so quantity of water absorbed by F.A.=(1/100)*663.174
=0.66kg/m
3

Therefore the weight of the F.A, in field condition= (663.174-0.66)=662.514kg/m
3

The total amount of water absorption= (4.96+0.66) =5.62kg/m
3

Therefore the total amount of water required = (200+5.62)=205.62kg/m
3

So in the field the actual amounts of cement, F.A., C.A. and water is,
Cement=526kg/m
3
, F.A.=662.514kg/m
3
,C.A.=987.04 kg/m
3
and water=205.62 kg/m
3

So the field density of the fresh concrete=2381.174 kg/m
3



























Mix Design of M-25 Grade of Concrete by DOE method

Characteristic Strength = 25 MPa

According to DOE Method of Mix Design,

Step 1:Target Mean Strength = Characteristic Strength + Standard Deviation Risk Factor
= 25+(4.0 )= 30 N/mm
2

Step 2:For O.P.C and Cursed Aggregate:28 days Strength = 49 MPa
Now, from the graph compressive strength vs. water/cement ratio,
We get, W/C ratio = 0.67

Step 3: According to condition of exposure (Mild) and nominal cover of Concrete = 25mm.
Maximum water Cement ratio = 0.65
[From durability Consideration, From BS 8100: Part I: 1985]
Now we should adopt the smaller of the two values,
W/C ratio will be 0.65.

Step 4: Now water content for the slump 100mm, 20mm down crushed aggregate,
From table D.1 = 225 kg / m
3
Cement Content will be (225/ 0.65) =346.15 kg/m
3

Now we have to check this cement content for durability condition,
Now from BS 8110: Part I: 1985
Minimum Content of Cement = 275 kg/ m
3

So, we should adopt the greater of two.
Cement Content = 346.15 kg/m
3
Step 5: Now we have to find out the density of fresh concrete for water content of 225 kg/m
3

For 20mm of aggregate size of specific gravity=2.7= 2380kg / m
3

[From graph of wet density of concrete mixture Vs free water content]
Weight of total aggregate = 23802-(346.15+225) = 1808.85kg/ m
3


Step 6: Now we assume that 65% fines are passing through 600 micron sieve.
Then from the figure: D.5 we obtain the percentage of the fine aggregate=34%
Now the amount of the fine aggregate= (1808.8534%) =615.009 Kg/m
3
Percentage of coarse aggregate= (100%-34%) =66%
So, the amount of the coarse aggregate= (1808.8566%) =1193.84 Kg/m
3
The estimated quantities are as below-
i)Cement content=346 Kg/m
3
ii)Water content=225 Kg/m
3

iii)Coarse aggregate amount=1193.84 Kg/m
3

iv)Fine aggregate amount=615.009 Kg/m
3

So,the ratio of cement:fineaggregate:coarse aggregate=346:615.009:1193.84
=1:1.77:3.45























Mix Design of M-30 Grade of Concrete by DOE method

Characteristic Strength = 30MPa

According to DOE Method of Mix Design,

Step 1:Target Mean Strength = Characteristic Strength + Standard Deviation Risk Factor
= 30+(4.0 ) = 35 N/mm
2

Step 2:For O.P.C and Cursed Aggregate:28 days Strength = 49 MPa
Now, from the graph compressive strength vs. water/cement ratio,
We get, W/C ratio = 0.61

Step 3: According to condition of exposure (Mild) and nominal cover of Concrete = 25mm.
Maximum water Cement ratio = 0.65
[From durability Consideration, From BS 8100: Part I: 1985]
Now we should adopt the smaller of the two values,
W/C ratio will be 0.61

Step 4: Now water content for the slump 100mm, 20mm down crushed aggregate,
From table D.1 = 225 kg / m
3
Cement Content will be (225/ 0.61) =368.8 kg/m
3

Now we have to check this cement content for durability condition,
Now from BS 8110: Part I: 1985
Minimum Content of Cement = 275 kg/ m
3

So, we should adopt the greater of two.
Cement Content = 368.8 kg/m
3

Step 5: Now we have to find out the density of fresh concrete for water content of 225 kg/m
3

For 20mm of aggregate size of specific gravity=2.7= 2380kg / m
3

[From graph of wet density of concrete mixture Vs free water content]
Weight of total aggregate = 2420-(368.8+225) = 1826.2 kg/ m
3

Step 6: Now we assume that 65% fines are passing through 600 micron sieve.
Then from the figure: D.5 we obtain the percentage of the fine aggregate=32%
Now the amount of the fine aggregate= (1808.8532%) =584.32 Kg/m
3
Percentage of coarse aggregate= (100%-32%) =68%
So, the amount of the coarse aggregate= (1808.8568%) =1242.62 Kg/m
3
The estimated quantities are as below-
i)Cement content=368.8Kg/m
3
ii)Water content=225 Kg/m
3

iii)Coarse aggregate amount=1242.62 Kg/m
3

iv)Fine aggregate amount=571.28 Kg/m
3

So,the ratio of cement:fine aggregate:coarse aggregate= 368.8:584.32:1242.62
=1:1.58:3.36

Mix Design of M-35 Grade of Concrete by DOE method

Characteristic Strength = 35MPa

According to DOE Method of Mix Design,

Step 1:Target Mean Strength = Characteristic Strength + Standard Deviation Risk Factor
= 35+(4.0 ) = 40 N/mm
2

Step 2:For O.P.C and Cursed Aggregate:28 days Strength = 49 MPa
Now, from the graph compressive strength vs. water/cement ratio,
We get, W/C ratio = 0.56

Step 3: According to condition of exposure (Mild) and nominal cover of Concrete = 25mm.
Maximum water Cement ratio = 0.65
[From durability Consideration, From BS 8100: Part I: 1985]
Now we should adopt the smaller of the two values,
W/C ratio will be 0.56
Step 4: Now water content for the slump 100mm, 20mm down crushed aggregate,
From table D.1 = 225 kg / m
3
Cement Content will be (225/ 0.56) =401.78 kg/m
3

Now we have to check this cement content for durability condition,
Now from BS 8110: Part I: 1985
Minimum Content of Cement = 275 kg/ m
3

So, we should adopt the greater of two.
Cement Content = 401.78 kg/m
3

Step 5: Now we have to find out the density of fresh concrete for water content of 225 kg/m
3

For 20mm of aggregate size of specific gravity=2.7= 2420 kg / m
3

[From graph of wet density of concrete mixture Vs free water content]
Weight of total aggregate = 2420-(401.78+225) = 1793.22 kg/ m
3

Step 6: Now we assume that 65% fines are passing through 600 micron sieve.
Then from the figure: D.5 we obtain the percentage of the fine aggregate=30.5%
Now the amount of the fine aggregate= (1793.2230.5%) =546.9 Kg/m
3
Percentage of coarse aggregate= (100%-30.5%) =69.5%
So, the amount of the coarse aggregate= (1793.2269.5%) =1246 Kg/m
3
The estimated quantities are as below-
i)Cement content=402 Kg/m
3
ii)Water content=225 Kg/m
3

iii)Coarse aggregate amount=1246 Kg/m
3

iv)Fine aggregate amount=546.9 Kg/m
3

So,the ratio of cement:fine aggregate:coarse aggregate= 402:547:1246
=1:1.36:3.1







Mix Design of M-40 Grade of Concrete by DOE method

Characteristic Strength = 40 MPa

According to DOE Method of Mix Design,

Step 1:Target Mean Strength = Characteristic Strength + Standard Deviation Risk Factor
= 40+(4.0 ) = 45 N/mm
2

Step 2:For O.P.C and Cursed Aggregate:28 days Strength = 49 MPa
Now, from the graph compressive strength vs. water/cement ratio,
We get, W/C ratio = 0.51

Step 3: According to condition of exposure (Mild) and nominal cover of Concrete = 25mm.
Maximum water Cement ratio = 0.65
[From durability Consideration, From BS 8100: Part I: 1985]
Now we should adopt the smaller of the two values,
W/C ratio will be 0.51

Step 4: Now water content for the slump 100mm, 20mm down crushed aggregate,
From table D.1 = 225 kg / m
3
Cement Content will be (225/ 0.51) =441 kg/m
3

Now we have to check this cement content for durability condition,
Now from BS 8110: Part I: 1985
Minimum Content of Cement = 275 kg/ m
3

So, we should adopt the greater of two.
Cement Content = 441 kg/m
3

Step 5: Now we have to find out the density of fresh concrete for water content of 225 kg/m
3

For 20mm of aggregate size of specific gravity=2.7= 2420 kg / m
3

[From graph of wet density of concrete mixture Vs free water content]
Weight of total aggregate = 2420-(441+225) = 1754 kg/ m
3

Step 6: Now we assume that 65% fines are passing through 600 micron sieve.
Then from the figure: D.5 we obtain the percentage of the fine aggregate=29.5%
Now the amount of the fine aggregate= (175429.5%) =517.43 Kg/m
3
Percentage of coarse aggregate= (100%-29.5%) =70.5%
So, the amount of the coarse aggregate= (1793.2270.5%) =1236.57Kg/m
3
The estimated quantities are as below-
i)Cement content=441 Kg/m
3
ii)Water content=225 Kg/m
3

iii)Coarse aggregate amount=1236.57 Kg/m
3

iv)Fine aggregate amount=517.43 Kg/m
3

So,the ratio of cement:fine aggregate:coarse aggregate= 441:517.43:1236.57
=1:1.17:2.8




Mix Design of M-45 Grade of Concrete by DOE method

Characteristic Strength = 45 MPa

According to DOE Method of Mix Design,

Step 1:Target Mean Strength = Characteristic Strength + Standard Deviation Risk Factor
= 45+(4.0 ) = 50 N/mm
2

Step 2:For O.P.C and Cursed Aggregate:28 days Strength = 49 MPa
Now, from the graph compressive strength vs. water/cement ratio,
We get, W/C ratio = 0.48

Step 3: According to condition of exposure (Mild) and nominal cover of Concrete = 25mm.
Maximum water Cement ratio = 0.65
[From durability Consideration, From BS 8100: Part I: 1985]
Now we should adopt the smaller of the two values,
W/C ratio will be 0.48
Step 4: Now water content for the slump 100mm, 20mm down crushed aggregate,
From table D.1 = 225 kg / m
3
Cement Content will be (225/ 0.48) =468.75 kg/m
3

Now we have to check this cement content for durability condition,
Now from BS 8110: Part I: 1985
Minimum Content of Cement = 275 kg/ m
3

So, we should adopt the greater of two.
Cement Content = 468.75 kg/m
3

Step 5: Now we have to find out the density of fresh concrete for water content of 225 kg/m
3

For 20mm of aggregate size of specific gravity=2.7= 2380kg / m
3

[From graph of wet density of concrete mixture Vs free water content]
Weight of total aggregate = 2420-(468.75 + 225) = 1726.25 kg/ m
3

Step 6: Now we assume that 65% fines are passing through 600 micron sieve.
Then from the figure: D.5 we obtain the percentage of the fine aggregate=29%
Now the amount of the fine aggregate= (1808.8529%) =500 Kg/m
3
Percentage of coarse aggregate= (100%-29%) =71%
So, the amount of the coarse aggregate= (1808.8571%) =1226.25Kg/m
3
The estimated quantities are as below-
i)Cement content=468.75Kg/m
3
ii)Water content=225 Kg/m
3

iii)Coarse aggregate amount=1226.25 Kg/m
3

iv)Fine aggregate amount=500 Kg/m
3

So,the ratio of cement:fine aggregate:coarse aggregate=468:500:1226
=1:1.07:2.62

Comparison between the Quantities of the Design Parameters for All
Methods for M25 grade of Concrete

IS:10262-1982 IS:10262-2009 ACI-211.1-1991 DOE METHOD
Cement
435.5 kg/m
3
286.78 kg/m
3
360 kg/m
3
346 Kg/m
3

Water
197.7 kg/m
3
157.728 kg/m
3
193.554 kg/m
3
225 Kg/m
3

Fine Aggregate
531.9 kg/m
3
745.25 kg/m
3
850.8 kg/m
3
615.009 Kg/m
3

Coarse Aggregate
1217.4kg/m
3
1268.95 kg/m
3
987.04 kg/m
3
1193.84 Kg/m
3

Cement: F.A: C.A
1: 1.2: 2.8 1: 2.6: 4.4 1: 2.4: 2.75 1:1.77:3.45




Comparison between the Quantities of the Design Parameters for All
Methods for M30 grade of Concrete

IS:10262-1982 IS:10262-2009 ACI-211.1-1991 DOE METHOD
Cement
479.0 kg/m
3
350 391.3 368.8
Water
202.77 kg/m
3
157.728 193.287 225
Fine Aggregate
501.77kg/m
3
945 824.3 571.28
Coarse Aggregate
1205.17kg/m
3
1755 987.04 1242.62
Cement: F.A: C.A
1: 1.05: 2.52 1: 2.7: 5 1: 2.13: 2.53 1: 1.58: 3.36




Comparison between the Quantities of the Design Parameters for All
Methods for M35 grade of Concrete

IS:10262-1982 IS:10262-2009 ACI-211.1-1991 DOE METHOD
Cement
532.2 kg/m
3
394.32 450 402
Water
202.4 kg/m
3
157.728 192.783 225
Fine Aggregate
480.0kg/m
3
651.97 774.5 546.9
Coarse Aggregate
1192.5kg/m
3
1265.85 987.04 1246
Cement: F.A: C.A
1: 0.9: 2.24 1: 1.65: 3.2 1: 1.74: 2.2 1: 1.36 :3.1
Comparison between the Quantities of the Design Parameters for All
Methods for M40 grade of Concrete

IS:10262-1982 IS:10262-2009 ACI-211.1-1991 DOE METHOD
Cement
570.46 kg/m
3
450.651 465 441
Water
195.61 kg/m
3
157.728 212.115 225
Fine Aggregate
377.2kg/m
3
616 708.345 517.43
Coarse Aggregate
1269.1kg/m
3
1250.63 987.04 1236.57
Cement: F.A: C.A
1: 0.67: 2.23 1: 1.37: 2.78 1: 1.54: 2.13 1: 1.17: 2.8






Comparison between the Quantities of the Design Parameters for All
Methods for M45 grade of Concrete

IS:10262-1982 IS:10262-2009 ACI-211.1-1991 DOE METHOD
Cement
598.06 kg/m
3
- 526 468.75
Water
252.1 kg/m
3
- 205.62 225
Fine Aggregate
366.89kg/m
3
- 662.514 500
Coarse Aggregate
1153.15kg/m
3
- 987.04 1226.25
Cement: F.A: C.A 1: 1.06: 1.93
- 1: 1.26: 1.89 1:1.07:2.62











Conclusion

So it is seen that there are some problems in every method while designing a concrete mix.
As the amount of aggregate is increased, the concrete becomes lean. Lean concrete means
plain concrete with a large ratio aggregate tocement than structural concrete. The workability
of the concrete also decreases. Mainly concrete mix design is done in a conventional method.
The conventional ways determine the amount of aggregate or concrete that is mixed together
while preparing a concrete mix. But the methods cant be used after the grade of concrete
exceeds M35 or M40. It happens because the test results changes abruptly after the particular
grade of concrete. So as the grade of the concrete exceeds that particular limit, conventional
method of designing a concrete mix is avoided and mix design is done from the past
experiences. Mainly D.O.E method contents several graphs which are used designing
concrete mix. So in many cases, evaluating exact values from the graph becomes difficult and
hence error occurs. According to A.C.I method silica fume, fly ash and super plasticizer may
be used. But it causes decrease in workability, increase in cost, delay in strength gain etc. But
there are no such considerable problems that occur in the old or new code of concrete mix
design.
























Basic Data Used In Different Codes


Parameter IS-10262:1982 IS- 10262:2009 ACI- 211.1-91 DOE METHOD
Characteristic compressive
strength at 28 days
YES YES YES YES
Standard deviation of
compressive strength
YES YES YES YES
Degree of workability
Compacting
factor
Slump Slump Slump/ Vebe time
Type and maximum size of
aggregates
YES YES YES YES
Nominal maximum size of
coarse aggregates (NMSA)
YES YES YES YES
Dry rodded unit weight of
coarse aggregates (DRUW)
NO YES YES NO
Fine aggregates (sand) Grading zone
Fineness
modulus
(FM), Zone
Fineness
modulus
(FM)
Graph, depending
on W/C ratio &
max. size of the
coarse aggregate
Specific gravity of cement,
coarse and fine aggregates
YES YES YES YES
Water absorption
and moisture content
adjustment
YES YES YES NO
Type of construction/ Degree
of control
YES YES YES YES
Exposure condition NO YES YES YES
Air/Non-air entrainment NO NO YES NO
Super plasticizer, mineral
admixtures
NO YES YES NO
Risk factor/ tolerance factor YES YES YES YES









Similarities between the mix design processes (IS-10262:1982,
IS-10262:2009, ACI-211.1-91, DOE method):

All these methods are based on the empirical relations.

All the relations are derived from extensive experiments done with the locally
available materials.


All the methods extensively use tables and graphs and follow logical determination of
the ingredients by establishing the targeted strength for trial batch.

Trial batch strength is derived from the required design strength of the structural
concrete and statistical analysis, ensuring that the mix design meets or exceeds the
design strength.


Once the target mix design strength is established, all methods determine the w/c
ratio.

It is common in both methods that the cement content is calculated based on the
relationships of two parameters, the w/c ratio and the water content.


In all methods w/c ratio and the water content are checked against the limiting values
in order to ensure compliance with durability conditions.


Differences between the mix design processes (IS-10262:1982,
IS-10262:2009, ACI-211.1-91, DOE method):

Target strength: All the methods use different formula to determine the target
average compressive strength. Although all methods utilize standard deviation to
calculate the target strength, techniques of calculation is not the same. When
sufficient data are not available to establish standard deviation, the ACI method
recommends empirical values to determine the target calculating strength. On the
other hand, the old BIS method suggests the value of standard deviation to be based
on the quality control. In the new BIS method, standard deviation is to be calculated
separately for each grade of concrete. In DOE method suggest the value of standard
deviation to be based on the quality control.

Measure of workability: The old BIS Method uses the compacting factor as a
measure of workability, whereas the new BIS and ACI use the slump, DOE method
use either slump or vebe time as a measure of workability.

W/C Ratio: In the ACI method, w/c ratio is determined in combination with the
target strength and the type of concrete (air/non-air entrainment). Although, old BIS
method discusses the air entrainment, the selection of w/c ratio in this method is a
function of target strength. W/C specific curves are given for different cements based
on their strengths. Generalized w/c curve is also proposed. However, the new BIS
suggests that the w/c curve be developed based on the type of materials to be used in
the project. In DOE method w/c ratio is determined in combination with the target
strength and type of cement and coarse aggregate used.

Water content: The old BIS method determines the water content based on target
strength, type of aggregates, Nominal maximum size of aggregate (NMSA) and
compacting factor. Different tables are given for medium and high strength concretes.
In the case of the ACI method, water content is dependent on air-entrainment, types of
aggregates, slump, and NMSA. However, water content can be determined
independent of target strength, whereas in the old BIS method, target strength
influences the water content. The new BIS is similar to ACI method wherein a table
for maximum water content per cubic meter of concrete for nominal maximum size of
aggregate is given. In the case of DOE method, water content is dependent on
workability i.e. on slump or vebe time, type and size of aggregate.

Coarse and fine aggregate content: In the ACI method, coarse aggregate content is
determined without knowing the absolute volume of fine aggregates. Contrary to the
ACI method, the old BIS method determines the fine aggregate content, as percentage
of total aggregate by absolute volume, first, and the coarse aggregate content is then
determined once the proportion of all other ingredients are known. In the new BIS
method, sand grading zones are used as the governing parameter for sand content
determination, whereas the fineness modulus is used in the ACI method for selecting
the bulk volume of dry rodded coarse aggregate. The old BIS method does not utilize
fineness modulus and dry rodded unit weight of aggregates. The new BIS procedure is
same as that of ACI method, wherein the volume of coarse aggregate per unit volume
of total aggregate for different zones of fine aggregate is calculated based on
maximum size of aggregate. In DOE method the total aggregate content is determined
with the help of estimated wet density of fully compacted concrete. Then for different
size of aggregate and required workability the proportion of the fine aggregate
percentage is calculated. Then from the proportion fine aggregate content can be
calculated and also the difference between the total and fine aggregate content gives
the coarse aggregate content.




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26. Nataraja, M. C., Dhang, N and Gupta, A. P., A Simple Equation for Concrete
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28. Nataraja, M. C and PatilGopal Reddy, Proportioning of High Strength Concrete
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