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ACI Mix Design Example
A concrete mix is to be designed for use in a 250 mm (10 inch) thick JPCP (https://
[Link]/reference-desk/pavement-types-and-history/pavement-
types/jointed-plain-concrete-pavement/) pavement. The desired properties are:
• Slump = 25 mm (1.0 inch)
• Average 28-day �exural strength of at least 4.5 MPa (650 psi)
• Coarse aggregate: nominal maximum size = 37.5 mm (1.5 inch), dry-rodded weight
= 1600 kg/m3 (100 lb/ft3), speci�c gravity = 2.68, moisture content = 1.0 percent,
absorption = 0.5 percent
• Fine aggregate: �neness modulus = 2.80, speci�c gravity = 2.64, moisture content =
5 percent, absorption = 0.7 percent
• Air content: 4.5 – 6.5 percent
• Maximum allowable water-cement ratio = 0.44
• Minimum cement content = 335 kg (565 lb)
• Density of water = 1000 kg/m3 (62.4 lb/ft3)
• Speci�c gravity of portland cement = 3.15 (typically assumed value)
Slump
Speci�ed as 25 mm (1.0 inch). This is typical for pavement PCC.
Maximum Aggregate Size
Speci�ed as 37.5 mm (1.5 inches). This is well within the general ACI recommendation
that the nominal maximum size be limited to 1/3 of slab depth. No reinforcing steel will
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be used so the thumbrule pertaining to clear space between reinforcing bars is not
applicable.
Mixing Water and Air Content Estimation
In order to achieve an air content above 2 – 3 percent, PCC must be air-entrained.
Therefore, using the mixing water and air content estimation table (https://
[Link]/reference-desk/design/mix-design/aci-mix-design/), air-
entrained PCC with a target 25 mm (1 inch) slump and a 37.5 mm (1.5 inch) nominal
maximum aggregate size will require about 148 kg/m3 (250 lb/yd3) of mixing water.
Enough air-entraining admixture will be added to achieve a 5.5 percent air content (in
the middle of the speci�ed 4.5 – 6.5 percent band). Keep in mind that water-reducing
admixtures can reduce water requirements by about 5 – 10 percent and several will also
increase the entrained air content by about 0.5 – 1 percent.
Converting weight to volume, the recommended volume of mixing water in one cubic
meter (one cubic yard) of PCC is 0.148 m3 (4.00 ft3). The amount of entrained air will be
5.5 percent of the total volume or 0.055 m3 (1.49 ft3).
Water-Cement Ratio
Since the speci�ed strength is �exural strength, a conversion factor must be used to
obtain an approximate compressive strength in order to use the water-cement ratio vs.
compressive strength table ([Link]
design/mix-design/aci-mix-design/). A good rule-of-thumb (as used in the ACI Code) is:
where:
equals
compressive strength
Solving for compressive strength, we get about 51.7 MPa (7,500 psi). This value is not
listed in Table 17 for determining water-cement ratios. Therefore, a more involved
determination of the water-cement ratio is needed. Water-cement ratios may also be
determined using local experience. Keep in mind that Table 4 is rarely used in pavement
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ACI Mix Design Example – Pavement Interactive [Link]
PCC mix design. Additionally, ACI recommends a maximum water-cement ratio for PCC
exposed to freezing and thawing in moist conditions (such as curbs and gutters) or PCC
in the presence of deicing chemicals (such as PCC pavement slabs) of 0.45. In this
instance, assume that local experience dictates a water-cement ratio of around 0.39.
Cement Content
Based on the previous mixing water content and water-cement ratio, cement content is
calculated to be:
The recommended volume of portland cement in one cubic meter (one cubic yard) of
PCC is:
Coarse Aggregate Content
Using the coarse aggregate content table ([Link]
reference-desk/design/mix-design/aci-mix-design/) with the given nominal maximum
aggregate size of 37.5 mm (1.5 inches) and the given �ne aggregate �neness modulus of
2.80, the recommended volume fraction of coarse aggregate is 0.71. This means that
the coarse aggregate should occupy 71 percent of the total volume. However, this
volume of aggregate includes the volume of air between the aggregate particles.
Therefore, this 71 percent volume must be converted to a weight of aggregate. Given
the 1600 kg/m3 (100 lb/ft3) dry-rodded unit weight, this equates to:
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ACI Mix Design Example – Pavement Interactive [Link]
Now, the recommended volume of coarse aggregate (which is now only the solid volume
of coarse aggregate) in one cubic meter (one cubic yard) of PCC is:
Fine Aggregate Content
The �ne aggregate content can be found by subtracting the other constituent volumes
from the unit volume:
Unit volume (1 m3 or yd3)
1.000 m3
27.00 ft3
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ACI Mix Design Example – Pavement Interactive [Link]
Volume of mixing water
0.148 m3
4.00 ft3
Volume of air
0.055 m3
1.49 ft3
Volume of portland cement
0.121 m3
3.26 ft3
Volume of coarse aggregate
0.424 m3
11.46 ft3
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ACI Mix Design Example – Pavement Interactive [Link]
equals
Volume of �ne aggregate
equals
0.252 m3
6.79 ft3
Therefore, the weight of �ne aggregate per unit volume is:
Adjustments for Aggregate Moisture
Since there is moisture in both the coarse and �ne aggregate their trial batch weights
must be adjusted.
Coarse aggregate:
1136 x 1.01 = 1147 kg/m3
1917 x 1.01 = 1936 lb/yd3
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ACI Mix Design Example – Pavement Interactive [Link]
Fine aggregate:
665 x 1.05 = 698 kg/m3
1119 x 1.05 = 1175 lb/yd3
Also, the amount of mixing water needs to be adjusted because both the coarse and �ne
aggregate are wet and will contribute water to the cement paste.
Coarse aggregate:
1136 x (0.01 - 0.005) = 5.7 kg/m3
1917 x (0.01 - 0.005) = 10 lb/yd3
Fine aggregate:
665 x (0.05 - 0.007) = 28.6 kg/m3
1119 x (0.05 - 0.007) = 48 lb/yd3
Therefore, the amount of mixing water to be added is:
148 kg - 5.7 kg - 28.6 kg
equals
113.7 kg
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ACI Mix Design Example – Pavement Interactive [Link]
250 lb - 10 lb - 48 lb
equals
192 lb
Summary
The �nal trial batch amounts per unit volume (1 m3 or yd3) are:
Mixing water
114 kg
192 lb
Portland cement
380 kg
641 lb
Coarse aggregate
1147 kg
1936 lb
Fine aggregate
698 kg
1175 lb
Usually, to make trial batches, something less than the unit volume is made – a typical
trial batch size is 0.03 m3 (1 ft3). Once the trial batch is made it can be tested for slump,
air content, �exural strength, compressive strength and any other required property.
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