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Introduction
-Process, Calculation in lab to find the amount of ingredients of Concrete
-process of finding the combination of constituents that would give
concrete of properties complying with certain specifications,
economically.
Ingredients/ constituents
- Cement
- Water
- Fine Aggregate ( Sand)
- Coarse Aggregate
- Admixture
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Mix Design Procedure
• Step 1
• Sampling
• The method of sampling shall
be in according to with IS:
2430-1986
• Collection of Sand and
Aggregate from Site
• Test of Ingredients (as per
spec)
• If not in the limit specified in
Code –reject Sample or modify
Sample
Mix Design Procedure Step 1 Continue
• Test on Ingredients
• Cement
Characteristics Requirement Remarks
OC HSC
Fineness , m2/Kg :( By Blaine's Air permeability Method 225
Minimum Setting Time ( Initial, Minutes) 45
Same in New Spec
Maximum Setting Time( Final, Minutes) 600
Soundness( by Le chatelier's method) mm,
Maximum 10
Minimum Average Compressive Strength of Three
Mortar Cubes
3 days 16 23 27
7 days 22 33 37
28 days 33 43 53
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Mix Design Procedure Step 1 Continue
• Test on Ingredients
• Fine Aggregate
FINE AGGREGATES As per IS Code 383
IS sieve Designation Percentage passing for(by weight)
Grading zone
Grading zone II Grading zone III Grading zone IV
I
10 mm 100 100 100 100
4.75 mm 90-100 90-100 90-100 95-100
2.36 mm 60-95 75-100 85-100 95-100
1.18 mm 30-70 55-90 75-100 90-100
600 mm 15-34 35-59 60-79 80-100
300 mm 5-20 8-30 12-40 15-50
150 mm 0-10 0-10 0-10 0-15
Fineness Modulus 2.71-4 2.11-3.37 1.71-2.72 1.35-2.25
Job mix Fineness Modulus ±0.3 for ordinary Concrete,
±0.2 high quality Concrete(in case of change in source)
Mix Design Procedure Step 1 Continue
• Test on Ingredients
• Coarse Aggregate
Characteristics Requirement Remarks
Class A, B, C, D, E OC HSC
Flakiness Index <25 <15
Water Absorption <2 %
Los Angeles Abrasion (LAA) <45% <35%
Aggregate Crushing Value ( ACV) <30%
Alkali Aggregate Reactivity
Physical Test
Chemical Test
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Mix Design Procedure Step 1 Continue
• Test on Ingredients
• Coarse Aggregate
The coarse aggregate shall be used conform to IS: 383 -1970. Table No. 2
Is sieve designation
Percentage passing for graded aggregate of Nominal Size
40 mm 20 mm 16 mm 12.5 mm
40 mm 95-100 100 -
20 mm 30-70 95-100 100 100
16 mm - - 90-100 -
12.5 mm - - - 90-100
10 mm 10-35 25-55 30-70 40-85
4.75 mm 0-5 0-10 0-10 0-10
2.36 mm - - -
Mix Design Procedure Step 1 Continue
• Test on Ingredients
• Coarse Aggregate
The coarse aggregate shall be used conform to IS: 383 -1970. Table No. 2
Is sieve designation
Percentage passing for graded aggregate of Nominal Size
40 mm 20 mm 16 mm 12.5 mm
40 mm 95-100 100 -
20 mm 30-70 95-100 100 100
16 mm - - 90-100 -
12.5 mm - - - 90-100
10 mm 10-35 25-55 30-70 40-85
4.75 mm 0-5 0-10 0-10 0-10
2.36 mm - - -
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Mix Design Procedure Step 1 Continue
• Test on Ingredients
• Coarse Aggregate
Is sieve designation Percentage passing for single sized aggregate of Nominal Size
12.5
63 mm 40 mm 20 mm 16 mm 10 mm
mm
80 mm 100 - - - - -
63 mm 85-100 100 - - -
40 mm 0-30 85-100 100 - - -
20 mm 0-5 0-20 85-100 100 - -
16 mm - - - 85-100 100 -
12.5 mm - - - - 85-100 100
10 mm 0-5 0-5 0-20 0-30 0-45 85-100
4.75 mm - - 0-5 0-5 0-10 0-20
2.36 mm - - - - 0-5
Job Mix ??
Mix Design Procedure
• Step 2
• Calculation of Target strength
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Step 2 Continue..
For Example
For M40
Ftg= 40+(1.65*5)
Ftg=48.25 N/mm2
Mix Design Procedure
• Step 3
• Selection of W/C Ratio and
Cement Content
• Choose exposure condition, Max. W/C ratio and
Minimum Cement Content
Minimum cement content, maximum water-cement ratio and minimum grade of concrete Adjustment to minimum
Nominal maximum size of
for different exposures S.N. cement content in table no 5
aggregate (mm)
(kg/m³)
Table no.5 IS 456:2000
Maximum nominal aggregates size 20 mm 1 10 +40
2 20 0
Minimum cement Maximum free Minimum grade
3 40 -30
content (kg/CUM) cement ratio of concrete
Mild 220 0.6 -
Plane concrete
moderate 240 0.6 M-15
Sever 250 0.5 M-20
Very sever 260 0.45 M-20
extreme 280 0.45 M-25
Mild 300 0.55 M-20
Reinforced
concrete
moderate 300 0.5 M-25
Sever 320 0.45 M-30
Very sever 340 0.45 M-35
extreme 360 0.4 M-40
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Mix Design Procedure
• Step 4
• Selection of Water Content
• Choose Nominal Size of Aggregate (Generally 20 mm)-
186 lit (Max.)
Nominal Maximum size
S.N. Maximum water content KG
of aggregates
2
1 3
I 10 208
Ii 20 186
Iii 40 165
• Ideal Condition- Angular Agg, 25-50 mm Slump Value,
SSD Agg
• Make Adjustment as per IS Code (456-2000)
• Factors
• Slump Value –increase 3% for each 25 mm
slump value
• Aggregate –sub-agnular, rounded + crushed
particles, Rounded- Reduce %wc
• Admixture- reduces up to 20%
• Get final Value of Water Content
Mix Design Procedure
• Step 5
• Selection of Cement Content
• Choose W/C Ratio less than Max W/C as above
Step 3
• For Example
• W/C= .35 (Say), Adjusted Water Content say
180 , Than cement content= ?? (KG)
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Mix Design Procedure
• Step 6
• Quantity of Admixtures
• Find Quantity – Product/Company Specification
• Plasticizers- Flow gel +micro silica, Mark flow30
+ Micro silica, Normet ( Tamsen 53I) +
microsilica
• For Example
• Micro silica= 5% of By weight of Cement
• Mark flow 30= 0.6% By Weight of Cement
Mix Design Procedure
• Step 7
• Calculation of Volume of Coarse
and Fine aggregate
IS 10262:2009 Table 3 volume of coarse Aggregates per unit volume of total Aggregates for
Different Zones of fine aggregates (clauses 4.4, A-7 and B-7)
Nominal Volume of coarse aggregates per unit volume of
maximum size of total aggregates for different zones of fine
S.N.
Aggregates(mm) aggregates
Zone IV Zone III Zone II Zone I
1 10 0.5 0.48 0.46 0.44
2 20 0.66 0.64 0.62 0.6
3 40 0.75 0.73 0.71 0.69
Volumes are based on aggregates in saturated surface dry condition.
Adjustment should made in table no 3,it is only for w-c ratio 0.50 and if the water cement ratio change every -/+0.05 the coarse
aggregate change by +/- 0.01
Eg.. w/c=.35, difference =0.15 for W/C=0.5, Than,
(0.01*3)=.03 will be added on volume specified in table 3
i.E .62 (sand Zone ii) will be 0 .65
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Mix Design Procedure
• Step 7 Continue…
• From lS Table 3 10262-2000
• Find Volume of Coarse Aggregate
For Example
For 20 mm nominal size of Coarse Aggregate and
zone 2 of fine aggregate with w/c=0.5, is .62 Cum
(Coarse Aggregate)
. Adjustment
• Every ± 0.05 w/c change = ±0.01 (Inversely)
After Adjustment find the volume of fine
Aggregate i.e 1- [Link] Coarse Agg
Mix Design Procedure
• Step 8.
• Calculation of Mass of Coarse
Aggregate
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Mix Design Procedure
• Step 8.. Continue
• Calculation of Volume of fine
Aggregate
Mix Design Procedure
• Step 9 Aggregate moisture
correction
• Saturated surface dry condition up to this step
• In site, Aggregate are in dry Condition so
• the amount of mixing water should be
increased by amount equal to the moisture
likely to be absorbed by the aggregates
• Necessary adjustments are also required to
be made in mass of aggregates
• Lab input Data
• Water absorption and water content(
Free Surface Moisture) of Fine and
Course Aggregate
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Mix Design Procedure
• Step 9 Aggregate moisture
correction
Mix Design Procedure
• Step 9 Continue..
Now we get Final Values
Hence the Ratio
Water Cement Fine Agg Course Agg Remarks
KG 148.52 450.656 650.67 1229.83Per Cum
Ratio 0.329 1 1.443 2.729
Round off 0.32 1 1.4 2.7
Batching ??- for this case use .4x.4X.4 cube box- One bag
cement- 35 kg sand 2 times, 76.5 kg aggregate 2 times..
Batching by weight is best way to quality control,
Concrete batching plant is preferable
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Mix Design Procedure
• Step 10 Trail Mixes
Case Procedure Parameter Remarks
Change in Slump Value go
As per initial design Find Slump to Trail 2
Trail 1 step 1-9 Value Not Change in Slump Value
go to Trail 3
Change in Water Better to change water
W/C keep
Trail 2 Content and
Constant
content only and repeat
admixture step 4 to 9
Keep Water
Trail 3 Add 10% on W/C ratio Contain Repeat Step 5 to 9
Constant
keep Water
reduce 10% on W/C
Trail 4 ratio
Contain Repeat Step 5 to 10
Constant
Mix Design Procedure
Lab Test Equipment
• Slump apparatus set
• Mixer small capacity up to .5 cum
• Weight Balance ( capacity up to 20 kg)
accuracy up to 1 gram)
• Beaker capacity up to 1 litre
• Cube Mould ( min 30 nos) 15 cm
• Compressive strength Test machine capacity
up to 2000 KN
• Tray, shovel, gloves, gallon
Note : Test equipment on Cement, sand and
Aggregate are not included.
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Mix Design Procedure
Excel Sheet Exercise
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