Concrete Mix Design Data Required for Concrete Mix Design

(i) Concrete Mix Design Stipulation

(a) Characteristic compressive strength required in the field at 28 days grade designation — M 25
(b) Nominal maximum size of aggregate — 20 mm
(c) Shape of CA — Angular
(d) Degree of workability required at site — 50-75 mm (slump)
(e) Degree of quality control available at site — As per IS:456
(f) Type of exposure the structure will be subjected to (as defined in IS: 456) — Mild
(g) Type of cement: PSC conforming IS:455
(h) Method of concrete placing: pump able concrete

(ii) Test data of material (to be determined in the laboratory)

(a) Specific gravity of cement — 3.15
(b) Specific gravity of FA — 2.64
(c) Specific gravity of CA — 2.84
(d) Aggregate are assumed to be in saturated surface dry condition.
(e) Fine aggregates confirm to Zone II of IS – 383

Procedure for Concrete Mix Design of M25 Concrete

Step 1 — Determination Of Target Strength

Himsworth constant for 5% risk factor is 1.65. In this case standard deviation is taken from IS:456 against M 25
is 4.0.

ftarget = fck + 1.65 x S

= 25 + 1.65 x 4.0 = 31.6 N/mm2
Where, S = standard deviation in N/mm 2 = 4 (as per table -1 of IS 10262- 2009)

Step 2 — Selection of water / cement ratio:-

From Table 5 of IS 456, (page no 20)
Maximum water-cement ratio for Mild exposure condition = 0.55
Based on experience, adopt water-cement ratio as 0.5. 0.5<0.55, hence OK.

Step 3 — Selection of Water Content

From Table 2 of IS 10262- 2009,
Maximum water content = 186 Kg (for Nominal maximum size of aggregate — 20 mm)

Table for Correction in water content

Values as per Standard Values as per Correction in
Parameters Departure
reference condition Present Problem Water Content

Slump 25-50 mm 50-75 25 (+3/25) x 25 = +3

Shape of
Angular Angular Nil –
Aggregate

Total +3

3
Estimated water content = 186+ (3/100) x 186 = 191.6 kg /m
Step 4 — Selection of Cement Content
Water-cement ratio = 0.5
3
Corrected water content = 191.6 kg /m
Cement content = From Table 5 of IS 456,
 3
Minimum cement Content for mild exposure condition = 300 kg/m
3 3
383.2 kg/m > 300 kg/m , hence, OK.
This value is to be checked for durability requirement from IS: 456.
In the present example against mild exposure and for the case of reinforced concrete the minimum cement content is 300
3 3 3
kg/m which is less than 383.2 kg/m . Hence cement content adopted = 383.2 kg/m .
3
As per clause 8.2.4.2 of IS: 456 Maximum cement content = 450 kg/m .

Step 5: Estimation of Coarse Aggregate proportion:-

From Table 3 of IS 10262- 2009,
For Nominal maximum size of aggregate = 20 mm,
Zone of fine aggregate = Zone II
And For w/c = 0.5
Volume of coarse aggregate per unit volume of total aggregate = 0.62

Table for correction in estimation of coarse aggregate proportion

Values as per Correction in

Values as per
Parameter Standard reference Departure Coarse Aggregate Remarks
present problem
condition proportion

W/c 0.5 0.5 Nil – See Note 1

pump able
Workability – – -10% See Note 2
concrete

Total -10%

Note 1: For every ±0.05 change in w/c, the coarse aggregate proportion is to be changed by 0.01. If the w/c is less than 0.5
(standard value), volume of coarse aggregate is required to be increased to reduce the fine aggregate content. If the w/c is
more than 0.5, volume of coarse aggregate is to be reduced to increase the fine aggregate content. If coarse aggregate is not
angular, volume of coarse aggregate may be required to be increased suitably, based on experience.
Note 2: For pump able concrete or congested reinforcement the coarse aggregate proportion may be reduced up to 10%.
Hence,

Volume of coarse aggregate per unit volume of total aggregate = 0.62 x 90% = 0.558

Volume of fine aggregate = 1 – 0.558 = 0.442

Step 6: Estimation of the mix ingredients

3
a) Volume of concrete = 1 m
b) Volume of cement = (Mass of cement / Specific gravity of cement) x (1/100)
3
= (383.2/3.15) x (1/1000) = 0.122 m
c) Volume of water = (Mass of water / Specific gravity of water) x (1/1000)
3
= (191.6/1) x (1/1000) = 0.1916 m
3
d) Volume of total aggregates = a – (b + c ) = 1 – (0.122 + 0.1916) = 0.6864 m
3
e) Mass of coarse aggregates = 0.6864 x 0.558 x 2.84 x 1000 = 1087.75 kg/m
3
f) Mass of fine aggregates = 0.6864 x 0.442 x 2.64 x 1000 = 800.94 kg/m
Concrete Mix proportions for Trial Mix 1
3
Cement = 383.2 kg/m
3
Water = 191.6 kg/m
3
Fine aggregates = 800.94 kg/m
3
Coarse aggregate = 1087.75 kg/m
W/c = 0.5
For trial -1 casting of concrete in lab, to check its properties.
It will satisfy durability & economy.
For casting trial -1, mass of ingredients required will be calculated for 4 no’s cube assuming 25% wastage.
3 3
Volume of concrete required for 4 cubes = 4 x (0.15 x1.25) = 0.016878 m
3
Cement = (383.2 x 0.016878) kg/m = 6.47 kg
3
Water = (191.6 x 0.016878) kg/m =3.23 kg
3
Coarse aggregate = (1087.75 x 0.016878) kg/m =18.36 kg
3=
Fine aggregates = (800.94 x 0.016878) kg/m 13.52 kg

Step 7: Correction due to absorbing / moist aggregate:-

Since the aggregate is saturated surface dry condition hence no correction is required.

Step 8: Concrete Trial Mixes:-

Concrete Trial Mix 1:
The mix proportion as calculated in Step 6 forms trial mix1. With this proportion, concrete is manufactured and tested for
fresh concrete properties requirement i.e. workability, bleeding and finishing qualities.
In this case,
Slump value = 25 mm
Compaction Factor = 0.844
So, from slump test we can say,
Mix is cohesive, workable and had a true slump of about 25 mm and it is free from segregation and bleeding.
Desired slump = 50-75 mm
So modifications are needed in trial mix 1 to arrive at the desired workability.

Concrete Trial Mix 2:

To increase the workability from 25 mm to 50-75 mm an increase in water content by +3% is to be made.
The corrected water content = 191.6 x 1.03 = 197.4 kg.
As mentioned earlier to adjust fresh concrete properties the water cement ratio will not be changed. Hence
3
Cement Content = (197.4/0.5) = 394.8 kg/m
Which also satisfies durability requirement.
3
Volume of all in aggregate = 1 – [{394.8/(3.15×1000)} + {197.4/(1 x 1000)}] = 0.6773 m
3
Mass of coarse aggregate = 0.6773 x 0.558 x 2.84 x 1000 = 1073.33 kg/m
3
Mass of fine aggregate = 0.6773 x 0.442 x 2.64 x 1000 = 790.3 kg/m

Concrete Mix Proportions

3 for Trial Mix 2
Cement = 384.8 kg/m
3
Water = 197.4 kg/m 3
Fine aggregate =790.3 kg/m
3
Coarse aggregate = 1073.33 kg/m
For casting trial -2, mass of ingredients required will be calculated for 4 no’s cube assuming 25% wastage.
 3 3
Volume of concrete required for 4 cubes = 4 x (0.15 x1.25) = 0.016878 m
3
Cement = (384.8 x 0.016878) kg/m = 6.66 kg
3
Water = (197.4 x 0.016878) kg/m =3.33 kg
3
Coarse aggregate = (1073.33 x 0.016878) kg/m =18.11 kg
3=
Fine aggregates = (790.3 x 0.016878) kg/m 13.34 kg
In this case,
Slump value = 60 mm
Compaction Factor = 0.852
So, from slump test we can say,
Mix is very cohesive, workable and had a true slump of about 60 mm.
It virtually flowed during vibration but did not exhibit any segregation and bleeding.
Desired slump = 50-75 mm
So , it has achieved desired workability by satisfying the requirement of 50-75 mm slump value .
Now , we need to go for trial mix-3 .

Concrete Trial Mix 3:

In case of trial mix 3 water cement ratio is varied by +10% keeping water content constant. In the present example water
cement ratio is raised to 0.55 from 0.5.
An increase of 0.05 in the w/c will entail a reduction in the coarse aggregate fraction by 0.01.
Hence the coarse aggregate as percentage of total aggregate = 0.558 – 0.01 = 0.548
W/c = 0.55
Water content will be kept constant.
3
Cement content = (197.4/0.55) = 358.9 kg/m
Hence, volume of all in aggregate
3
= 1 – [{(358.9/(3.15 x 1000)} + (197.4/1000)] =0.688 m
3
Mass of coarse aggregate = 0.688 x 0.548 x 2.84 x 1000 = 1070.75 kg/m
3
Mass of fine aggregate = 0.688 x 0.452 x 2.64 x 1000 = 821 kg/m

Concrete Mix Proportions of Trial Mix 3

3
Cement = 358.9 kg/m
3
Water = 197.4 kg/m
3
FA = 821 kg/m
3
CA = 1070.75 kg/m
For casting trial -3, mass of ingredients required will be calculated for 4 no’s cube assuming 25% wastage.
3 3
Volume of concrete required for 4 cubes = 4 x (0.15 x1.25) = 0.016878 m
3
Cement = (358.9 x 0.016878) kg/m = 6.06 kg
3
Water = (197.4 x 0.016878) kg/m =3.33 kg
3
Coarse aggregate = (1070.75 x 0.016878) kg/m =18.07 kg
3=
Fine aggregates = (821 x 0.016878) kg/m 13.85 kg
In this case,
Slump value = 75 mm
Compaction Factor = 0.89
So, from slump test we can say,
Mix is stable, cohesive, and workable and had a true slump of about 75 mm.
Desired slump = 50-75 mm
So , it has achieved desired workability by satisfying the requirement of 50-75 mm slump value .
Now , we need to go for trial mix-4.

Concrete Trial Mix 4:

In this case water / cement ratio is decreased by 10% keeping water content constant.
W/c = 0.45
A reduction of 0.05 in w/c will entail and increase of coarse aggregate fraction by 0.01.
Coarse aggregate fraction = 0.558 +.01 =.568
3
W/c = 0.45 and water content = 197.4 kg/m
3
Cement content = (197.4/0.45) = 438.7 kg/m
Volume of all in aggregate
3
= 1 – [{438.7/(3.15 x 1000)} + (197.4/1000)] = 0.664 m
3
Mass of coarse aggregate = 0.664 x 0.568 x 2.84 x 1000 = 1071.11 kg/m
3
Mass of fine aggregate = 0.664 x 0.432 x 2.64 x 1000 = 757.28 kg/m
Concrete Mix Proportions of Trial Mix 4
3
Cement = 438.7 kg/m
3
Water = 197.4 kg/m
3
FA = 757.28 kg/m
3
CA = 1071.11 kg/m
For casting trial -4, mass of ingredients required will be calculated for 4 no’s cube assuming 25% wastage.
3 3
Volume of concrete required for 4 cubes = 4 x (0.15 x1.25) = 0.016878 m
3
Cement = (438.7 x 0.016878) kg/m = 7.4 kg
3
Water = (197.4 x 0.016878) kg/m =3.33 kg
3
Coarse aggregate = (1071.11 x 0.016878) kg/m =18.07 kg
3=
Fine aggregates = (757.28 x 0.016878) kg/m 12.78 kg
A local correction due to moisture condition of aggregate is again applied on this proportions. With corrected proportions
three concrete cubes are cast and tested for 28 days compressive strength.
A summary of all the trial mixes is given in the following Table.

Recommended mix proportion of ingredients for grade of concrete M25:

From Compressive Strength vs. c/w graph for target strength 31.6 MPa we get,
W/c = 0.44
3
water content = 197.4 kg/m
3
Cement content = (197.4/0.44) = 448.6 kg/m
Volume of all in aggregate
3
= 1 – [{448.6/(3.15 x 1000)} + (197.4/1000)] = 0.660 m
A reduction of 0.05 in w/c will entail and increase of coarse aggregate fraction by 0.01.
Coarse aggregate fraction = 0.558 +.01 =.568
Volume of fine aggregate = 1 – 0.568 = 0.432
3
Mass of coarse aggregate = 0.660 x 0.568 x 2.84 x 1000 = 1064.65 kg/m
3
Mass of fine aggregate = 0.660 x 0.432 x 2.64 x 1000 = 752.71 kg/m
Concrete Mix Design Example – M50 Grade Concrete

Grade Designation = M-50

Type of cement = O.P.C-43 grade
Brand of cement = Vikram ( Grasim )
Admixture = Sika [Sikament 170 ( H ) ]
Fine Aggregate = Zone-II
Sp. Gravity
Cement = 3.15
Fine Aggregate = 2.61
Coarse Aggregate (20mm) = 2.65
Coarse Aggregate (10mm) = 2.66
Minimum Cement (As per contract) =400 kg / m 3
Maximum water cement ratio (As per contract) = 0.45
Concrete Mix Design Calculation
1. Target Mean Strength = 50 + ( 5 X 1.65 ) = 58.25 Mpa
2. Selection of water cement ratio:
Assume water cement ratio = 0.35

3. Calculation of water content:

Approximate water content for 20mm max. Size of aggregate = 180 kg /m 3 (As per Table No. 5 , IS : 10262 ). As
plasticizer is proposed we can reduce water content by 20%.
Now water content = 180 X 0.8 = 144 kg /m 3
4. Calculation of cement content:
Water cement ratio = 0.35
Water content per m3 of concrete = 144 kg
Cement content = 144/0.35 = 411.4 kg / m3
Say cement content = 412 kg / m 3 (As per contract Minimum cement content 400 kg / m 3 )
Hence O.K.
5. Calculation of Sand & Coarse Aggregate Quantities:
Volume of concrete = 1 m 3
Volume of cement = 412 / ( 3.15 X 1000 ) = 0.1308 m 3
Volume of water = 144 / ( 1 X 1000 ) = 0.1440 m 3
Volume of Admixture = 4.994 / (1.145 X 1000 ) = 0.0043 m 3
Total weight of other materials except coarse aggregate = 0.1308 + 0.1440 +0.0043 = 0.2791 m 3
Volume of coarse and fine aggregate = 1 – 0.2791 = 0.7209 m3
Volume of F.A. = 0.7209 X 0.33 = 0.2379 m 3 (Assuming 33% by volume of total aggregate )
Volume of C.A. = 0.7209 – 0.2379 = 0.4830 m3
Therefore weight of F.A. = 0.2379 X 2.61 X 1000 = 620.919 kg/ m 3
Say weight of F.A. = 621 kg/ m 3
Therefore weight of C.A. = 0.4830 X 2.655 X 1000 = 1282.365 kg/ m 3
Say weight of C.A. = 1284 kg/ m 3
Considering 20 mm: 10mm = 0.55: 0.45
20mm = 706 kg .
10mm = 578 kg .
Hence Mix details per m 3
Increasing cement, water, admixture by 2.5% for this trial
Cement = 412 X 1.025 = 422 kg
Water = 144 X 1.025 = 147.6 kg
Fine aggregate = 621 kg
Coarse aggregate 20 mm = 706 kg
Coarse aggregate 10 mm = 578 kg
Admixture = 1.2 % by weight of cement = 5.064 kg.
Water: cement: F.A.: C.A. = 0.35: 1: 1.472: 3.043
Observations from Concrete Mix Design
A. Mix was cohesive and homogeneous.
B. Slump = 120 mm
C. No. of cube casted = 9 Nos.
7 days average compressive strength = 52.07 MPa.
28 days average compressive strength = 62.52 MPa which is greater than 58.25MPa
Hence the mix accepted.
Percentage strength of concrete at various ages
The strength of concrete increases with age. Table shows the strength of concrete different ages in comparison
with the strength at 28 days.

Age Strength per cent

1 day 16%

3 days 40%

7 days 65%

14 days 90%

28 days 99%