Welcome to Online Live Class

CE 202 Construction Materials

11-Concrete / Mix Design
Mehmet Fatih KOCABEYLER
2022-2023 SPRING TERM
Engineering Faculty 1
NORMAL CONCRETE
MIX DESIGN

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Concrete Mix Design

▪ Concrete: a composite material that consists basically of cement,

water, fine and coarse aggregates.
▪ “The proportioning of a concrete mix” is the determination of the
amounts of cement, water, aggregates and admixtures to be used
in the production of concrete for a particular purpose.
▪ This process is commonly referred to as “concrete mix design”.

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Concrete Mix Design

▪ There are two sets of requirements which enable the engineer to

design a concrete mix:
1. The requirements of concrete in hardened state. These are
specified by the structural engineer.
2. The requirements of fresh concrete such as workability, setting
time. These are specified by the construction engineer (type of
construction, placing methods, compacting techniques and
transportation)
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Concrete Mix Design

≈Weight (%) ≈Volume (%)

Cement
Cement
0.15% 2%
Water 0.35% Water
15% 11%

7% Fine Agg. 18%

Fine Agg.
42% 37%
Coarse Agg.
Coarse Agg.
36% 32% Chemical Ad.
Chemical Ad.
Air

Weights / Volumes?

▪ Basically, we are trying to fit a specific amount of concrete

ingredients into a volume of 1 m3.

▪ Since the volume measurement of concrete ingredients is not

easy, we make a connection between the weights and the
volumes.

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Concrete Mix Design

▪ The “proportioning of a concrete mix” is the determination of the

amounts of cement, water, aggregates, and admixtures to be used
in the production of concrete for a particular purpose. The process
is commonly referred to as “concrete mix design”.

▪ Mix design is the process of

selecting suitable ingredients of
concrete & determining their
relative quantities with the
objective of producing concrete
of certain minimum properties
such as workability, strength &
durability.
▪ Concrete is to be as economical
as possible complying with all *All rights reserved by
Dr. Cagla Meral from
the criteria. METU-Civil
6 Dep.
Engineering
Concrete Mix Design

How is it done?
▪ There are three ways to do it:
o Ask an expert
(if you are not a civil engineer)
o Use predefined recipes and tables (prescriptive-based method)
(if you are a civil engineer)
o Make trial batches (performance-based method)
(if you are a construction materials expert)

▪ Using a prescriptive-based method, that depends on recipes and

tables, will save time and give acceptable results, but will limit the
usage to specific materials only.

▪ Using a performance-based method, by making trial batches, needs

more time, effort, experience and money, but will allow the use of
new materials and will give accurate results.
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Concrete Mix Design

Prescriptive based method

▪ Past specifications the ▪ Modern specifications specify

proportions of cement, fine & min. compressive strength, grading
coarse aggregate are given of agg, max W/C ratio, min/max
o By weight → cement content, min entrained air
Cement: 1 & etc.
Fine Agg : 2 o Max. W/C ratio
Coarse Agg : 4 o Slump
o Strength
▪ However, modern specifications o Max agg. size
do not use these fixed ratios. o Min. air content
o Min. cement content
o Durability
o Type of cement
o Admixtures
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Concrete Mix Design

Prescriptive based method- How is it done?

▪ In the scope of this course, prescriptive mix design method is

explained.
▪ Some of the fresh properties and the amounts and ratios of the
concrete batch will be chosen according to predefined tables.
▪ A total of 9 steps are used in this mix design procedure.
1. Choice of slump
2. Choice of max. size of aggregate
3. Estimation of mixing water and air content
4. Selection of w/c ratio
5. Calculation of cement content
6. Estimation of coarse aggregate content
7. Estimation of fine aggregate content
8. Adjustment for aggregate moisture
9. Trial batches
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Concrete Mix Design

1. Choosing Slump Value

▪ The slump value, that the concrete of a particular quality should have,
may be dictated by the job specification. If slump is not specified, an
appropriate slump value can be selected from table below (Table 14.5)

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Concrete Mix Design

2. Choosing Max. Agg. Size

▪ The max. size of aggregate in aggregate sample is determined by sieve
analysis; it is equal to the size of the minimum sieve through which
all the particles can pass.

▪ Max. Agg. Size ≤ 1/5 of the narrowest dimension of the mold

≤ 1/3 of the depth of the slab
≤ 3/4 of the clear spacing between individual
reinforcing bars
≤ 3/4 of the clear spacing between reinforcing bars
and form

▪ Concrete with well graded larger sized aggregate requires less mortar
per unit volume of concrete. Generally, the maximum size of
aggregate should be the largest that is economically available and
consistent with dimensions of the structure. 12
Concrete Mix Design

3. Estimating Mixing Water & Air Content

▪ The amount of water required and the air content per cubic meter of
non-air entrained concrete can be estimated by using the values given
in the table below.

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Concrete Mix Design

3. Estimating Mixing Water & Air Content (cond`t)

▪ The amount of water required and the air content per cubic meter of
air entrained concrete can be estimated by using the values given in
the table below.

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Concrete Mix Design

3. Estimating Mixing Water & Air Content (cond`t)

▪ Mild exposure: This exposure includes indoor and outdoor services

where concrete will not be subjected to freezing or to deicing agents.

▪ Moderate exposure: This type of exposure includes service conditions

in a climate where some freezing is expected but where the concrete
will not be continually exposed to moisture for long periods.

▪ Severe exposure: This type of exposure includes service conditions

where concrete may be subjected to high saturation prior to freezing
or deicing agents.

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Concrete Mix Design

4. Selection of w/c ratio

▪ When the relationship between the strength and the w/c ratio has not
been found by conducting tests, the values given below can be used
for selecting proper w/c ratio that will lead to required minimum
strength of the concrete.

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Concrete Mix Design

4. Selection of w/c ratio (cont`d)

▪ For severe conditions of exposure, the w/c ratio can be selected from
the values given below.

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Concrete Mix Design

5. Calculation of cement content

▪ Since the amount of water per cubic meter of concrete is already

determined from Step 3 and the w/c ratio is already determined from
Step 4, the amount of cement per cubic meter of concrete can be
found by calculation:

o Cement content= (water amount)/(water-cement ratio)

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Concrete Mix Design

6. Estimation of coarse aggregate content

▪ The volume of dry coarse aggregate per cubic meter of concrete can
be estimated by using the table below.

▪ The volume of coarse aggregate per unit volume of concrete can be

converted to dry weight of coarse aggregate by multiplying it by the
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oven-dry-rodded unit weight of the coarse aggregate.
Concrete Mix Design

7. Calculation of fine aggregate content

▪ The volume of fine aggregate (SSD) per cubic meter of concrete is equal
to
= 1 - (volume of cement + volume of water + volume of coarse
aggregate (SSD) + volume of air)

• Volume of cement= weight of cement / specific gravity of

cement
• Volume of water= weight of water / specific gravity of water
• Volume of coarse aggregate = SSD weight of coarse aggregate
/ SSD specific gravity of coarse aggregate
• Volume of air comes from Step 3

▪ The calculated volume of fine aggregate can be converted to SSD weight

of fine aggregate by multiplying it by the SSD specific gravity of the fine
aggregate. 20
Concrete Mix Design

8. Adjustments for aggregate field moisture

▪ The weight of fine and coarse aggregates determined by the above

mentioned calculations are the weights in SSD state. However, the
aggregates actually to be used in concrete may not be in SSD state.

▪ If the actual aggregates are in moist state (MC>AC), it will lead to

inclusion of extra water in the concrete mix. Extra water will increase
the slump of the fresh concrete and decrease the strength of the
hardened concrete.

▪ If the actual aggregates are in oven or partially dry state (MC<AC), some
of the mixing water will be absorbed by the aggregates. This will lead to
decrease in workability.

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Concrete Mix Design

8. Adjustments for aggregate field moisture

▪ Therefore, adjustments need to be made to find the proportions of the

actual materials to be used in the concrete.
𝑊𝑆𝑆𝐷
𝑊𝐷𝑟𝑦 =
1 + 𝐴𝐶
𝑊𝐹𝑖𝑒𝑙𝑑 = 𝑊𝐷𝑟𝑦 𝑥 (1 + 𝑀𝐶)
100% + 𝑀𝐶𝐶𝐴
𝑊𝐶𝐴−𝐹𝑖𝑒𝑙𝑑 𝑚𝑖𝑥 = 𝑊𝐶𝐴−𝑆𝑆𝐷 𝑚𝑖𝑥 𝑥
100% + 𝐴𝐶𝐶𝐴

100% + 𝑀𝐶𝐹𝐴
𝑊𝐹𝐴−𝐹𝑖𝑒𝑙𝑑 𝑚𝑖𝑥 = 𝑊𝐹𝐴−𝑆𝑆𝐷 𝑚𝑖𝑥 𝑥
100% + 𝐴𝐶𝐹𝐴

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Concrete Mix Design

9. Trial Batch Adjustment

▪ The properties of the mixes in trial batches are checked and necessary
adjustments are made to end up with the minimum required properties
of concrete.

▪ 0.02 m3 of concrete is sufficient for such a trial batch. Therefore, the

weights of the materials should be divided by 50, and a trial batch
should be prepared with these smaller quantities of materials.

▪ Moreover, a lab trial batch may not always provide the final answer.

▪ Only the mix made and used at the construction site can guarantee that
all properties of concrete are satisfactory in every detail for the
particular job at hand.

▪ That’s why we take samples from the field mixes for checking the
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properties.
Mix Design – EXAMPLE-1

▪ Slump → 75-100 mm
▪ D max → 25 mm
▪ f’c,28 = 25 MPa
▪ Specific Gravity of cement = 3.15
▪ Non-air entrained concrete

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Concrete Mix Design-Example

Answer
1) Slump is given as 75-100 mm
2) Dmax is given as 25 mm
3) Estimate the water and air content (from Table 14.6)

Slump and Dmax→ W=193 kg/m3; Entrapped Air=1.5%

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Concrete Mix Design-Example

4) Estimate w/c ratio

o Non-air entrained concrete is specified
o f’c,28 = 25 MPa
o Estimate the w/c ratio (from Table 14.8)

f’c & non air entrained → w/c=0.61 (by weight)

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Concrete Mix Design-Example

5) Calculation of cement content

▪ W=193 kg/m3 and w/c= 0.61 are determined from step 3 and 4.

▪ Cement content= 193/0.61= 316.4 kg/m3

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Concrete Mix Design-Example

6) Estimation of coarse aggregate content

▪ D max is given as 25 mm.
▪ Fineness modulus of fine aggregate is given as 2.6.
▪ Estimate the coarse aggregate content from Table 14.10.

Volume of dry
rodded coarse
aggregate is 0.69

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Concrete Mix Design-Example

6) Estimation of coarse aggregate content-cont’d

▪ After the determination of volume of dry rodded coarse aggregate as

0.69, it can be converted to dry weight of coarse aggregate by
multiplying it by the dry-rodded unit weight of the coarse aggregate.
Dry-rodded unit weight of coarse aggregate is given as 1600 kg/m3 from
question.

o WCA-Dry = 1600*0.69 = 1104 kg/m3

▪ The dry weight of coarse aggregate can be converted to saturated

surface dry (SSD) weight by multiplying with “1+%AC”.

o WCA-SSD = 1104*(1+0.005) = 1109.5 kg/m3

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Concrete Mix Design-Example
7) Calculation of fine aggregate content
▪ The volume of fine aggregate (SSD) per cubic meter of concrete is equal
to
VFA-SSD= 1 - [(volume of cement + volume of water 𝑀
𝑉=
+ volume of coarse aggregate (SSD) 𝑆𝑝. 𝐺𝑟. 𝑥 𝑝𝑤
+ volume of air)] 𝑝𝑤 = 1000 𝑘𝑔/𝑚3

316.4
• 𝑉𝑐𝑒𝑚𝑒𝑛𝑡 = = 0.100 𝑚3
3.15𝑥1000

193 𝑉𝐹𝐴−𝑆𝑆𝐷 = 1 − 0.100 + 0.193 + 0.414 + 0.015

• 𝑉𝑤𝑎𝑡𝑒𝑟 = = 0.193 𝑚3
1𝑥1000
𝑉𝐹𝐴−𝑆𝑆𝐷 = 0.278 𝑚3
1109.5
• 𝑉𝐶𝐴−𝑆𝑆𝐷 = = 0.414 𝑚3 𝑊𝐹𝐴−𝑆𝑆𝐷 = 0.278 𝑥 2.62 𝑥 1000
2.68𝑥1000
= 727.2 𝑘𝑔/𝑚3
• 𝑉𝑎𝑖𝑟 = 1.5% 𝑥 1𝑚3 = 0.015 𝑚3
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Concrete Mix Design-Example

Summary of Mix Design

▪ The results based on SSD weight of aggregates are;
For SSD
state

▪ However, the aggregates actually to be used at the construction site are not in
SSD state.
Available Data

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Concrete Mix Design-Example

8) Adjustment for Moisture in Aggregates

𝑊𝑆𝑆𝐷
▪ Adjustments need to be made in the 𝑊𝐷𝑟𝑦 =
calculations to find the proportions of the 1 + 𝐴𝐶
actual materials to be used in the concrete.
▪ For coarse agg. adjustment 𝑊𝐹𝑖𝑒𝑙𝑑 = 𝑊𝐷𝑟𝑦 𝑥 (1 + 𝑀𝐶)
1109.5
𝑊𝐶𝐴−𝐷𝑟𝑦 = = 1104 𝑘𝑔/𝑚3
1 + 0.005 Coarse Fine
Agg. Agg.
𝑊𝐶𝐴−𝐹𝑖𝑒𝑙𝑑 = 1104𝑥 1 + 0.02
Absorption (AC) 0.5% 1.0%
= 1126.1 𝑘𝑔/𝑚3
Total Mois. Content (MC) 2.0% 5.0%
▪ For fine agg. adjustment SSD Weight (kg/m3) 1109.5 727.2
727.2
𝑊𝐹𝐴−𝐷𝑟𝑦 = = 720 𝑘𝑔/𝑚3 Dry Weight (kg/m3) 1104 720
1 + 0.01
Field Weight (kg/m3) 1126.1 756
𝑊𝐹𝐴−𝐹𝑖𝑒𝑙𝑑 = 720𝑥 1 + 0.05
= 756. 𝑘𝑔/𝑚3
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Concrete Mix Design-Example

8) Adjustment for Moisture in Aggregates- cont’d

▪ Correction for mixing water are required. Because the coarse

aggregate is in a wet state since its total moisture is greater than its
absorption capacity (MC>AC). The amount of free water in the
coarse aggregate;
o WCA-free-water = (MC-AC) x WCA-Dry
= (2%-0.5%) x 1104 = 16.6 kg
o WCA-free-water =WCA-Field-WCA-SSD
= 1126.1 – 1109.5 = 16.6 kg
45.4 kg extra
▪ The fine aggregate is in a wet state, too. water
o WFA-free-water =WFA-Field-WFA-SSD
= 756 – 727.2 = 28.8 kg

Corrected water amount = 193- 45.4 = 147.6 kg 33

Concrete Mix Design-Example

Answer: Summary of Concrete Mix Design

▪ The final proportions of materials are estimated as follows:

Ingredients Field Weight-

kg/m3
Cement 316
Water 148
Coarse Agg. 1126
Fine Agg. 756
Total 2346

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Concrete Mix Design-Example

9) Trial Batch

▪ The calculated mixture proportions should be checked by means of tests

conducted on a trial batches.
▪ Usually, a 0.02 m3 of concrete is sufficient to verify the slump and air
content of the mix. If the slump and air content are different
readjustments of the proportions should be made.
Trial Batch Weights

Ingredients Field Weight-

kg/0.02m3
Cement 6.32
Water 2.96
Coarse Agg. 22.52
Fine Agg. 15.12
Total 46.92
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Mix Design – EXAMPLE-2

Available Data
▪ Slump → 75-100 mm
▪ D max → 37.5 mm
▪ f’c,28 = 24 MPa
▪ Dry rodded UW of CA: 1600 kg/m3
▪ Type I [Link]. of cement = 3.15
▪ CA →
o Sp. Gr. (SSD)= 2.68, Absorption = 0.5%, Total Moisture content =
2.0%,
▪ FA →
o Sp. Gr. (SSD)= 2.64, Absorption = 0.7%, Total Moisture content =
6.0%, Fineness modulus = 2.8

▪ No severe weather condition ( that is, non-air entrained concrete)

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Mix Design – EXAMPLE-2

Answer
▪ Step 1: Slump → 75-100 mm
▪ Step 2: D max → 37.5 mm
▪ Step 3: Estimate the water and air content (from Table 14.6)
o Water = 181 kg/m3 , Air content = 1 %,
▪ Step 4: Estimate w/c ratio (from Table 14.8)
o w/c = 0.63 ( by interpolation)
▪ Step 5: Calculation of Cement content
o Cement content = 181/0.63 = 287.3 kg/m3
▪ Step 6: Estimate the coarse aggregate content (from Table 14.10)
o VCA = 0.71
o WCA-Dry = 1600*0.71 = 1136 kg/m3
o WCA-SSD = 1136*(1+0.005) = 1142 kg/m3

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Mix Design – EXAMPLE-2

Answer-cont’d
▪ Step 7: Calculation of fine aggregate content
o Vwater=181/1000=0.181 m3
o Vcement=287.3/(3.15x1000)=0.091 m3
o VCA=1142/(2.68x1000)=0.426 m3
o Vair=0.01m3
𝑉𝐹𝐴−𝑆𝑆𝐷 = 1 − 0.181 + 0.091 + 0.426 + 0.01 = 0.292m3
𝑊𝐹𝐴−𝑆𝑆𝐷 = 0.292 𝑥 2.64 𝑥 1000 = 771 𝑘𝑔/𝑚3

▪ Step 8: Adjustment for moisture in aggregates

o WCA-Dry = 1142/(1+0.005) = 1136 kg/m3
o WCA-Field = 1136*(1+0.02) = 1159 kg/m3
o WCA-free-water =WCA-Field-WCA-SSD = 1159 – 1142 = 17 kg
o WFA-Dry = 771/(1+0.007) = 766 kg/m3
o WFA-Field = 766*(1+0.06) = 812 kg/m3 58 kg extra
o WFA-free-water =WFA-Field-WFA-SSD = 812 – 771 = 41 kg water
Corrected water amount = 181- 58 = 123 kg 38
Mix Design – EXAMPLE-2

Answer-cont’d
▪ Summary of Concrete Mix Design
Ingredients Field Weight-
kg/m3
Cement 287
Water 123
Coarse Agg. 1159
Fine Agg. 812
Total 2381

▪ Step 9: For the lab trial batch, the weights for 0.02m3 are used.

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