Experiment 1

Concrete Mix Design

Objective: To design concrete mix to a strength of 25N/

at 28 days and to test the cube

strength of the mix design by mixing, casting and crushing a test cube.
Equipment: Cement, Shovel, Trowel, Tamping Bar, Cement Mixer, Moulds ( 150mm 150mm
150mm ), Compression Machine, Water Tank.
Procedure:
Step 1: Determining the free water / cement ratio
1. Given the required characteristics strength at a specified age, use Equation 1.0 to
obtain the target mean strength at that age, which is the compressive strength to be
used in the mix design.

Target mean strength = characteristic strength + 1.64

Where is the standard deviation of the strength of the strength tests. Typical values can
be obtained from Table 1.0.
Suppose the target mean strength to be obtained is 43 N/

at 28 days.

2. Given the type of cement and aggregate, use Table 1.1 to obtain the compressive
strength, at the specified age, that corresponds to a free water / cement (w/c) ratio of
0.5.

Suppose ordinary Portland cement and uncrushed aggregate are used. From the table 1.1
of the compressive strength of 40 N/

at 28 days (and 27N/

at 7 days and so on).

The pair of data (40 N/

, w/c ratio curve in Figure 2.0.9 method as explained below).

3. In figure 2.0, follow the starting line to locate the curve which passes through the
point (40 N/

, w/c ratio 0.5) in this particular case, it is the fourth curve from the
top of the figure. This curve shows that, to obtain our target mean strength of 43
N/

, we need a w/c ratio 0.47.

4. If the w/c ratio obtained in step 3 exceeds the max. w/c ratio specified for durability (
see table 1.2), then adopt the lower value resulting in a concrete having a higher
strength than required.

Step 2: Determining the water content
1. Given the slump or VB time, determine the water content from Table 2.0. Using Table
2.0, when coarse and fine aggregates of different types are used, the water content W is
estimated as follow :

W = 2/3

+ 1/3

Where ;

water content appropriate to the type of fine aggregate.

= water content appropriate to the type of coarse aggregate.

2. The aggregate type in Table 2.0 refers to all types of aggregates. Indeed, the fine
aggregate has a considerably greater specific surface area and hence has a greater
influence on the workability : this explains the greater weight, 2/3 assigned to

in
Equation 2.1
Step 3: Determining the cement content
1. The value given by Equation 3.1 should be checked against any maximum or minimum
cement contents that may have been specified, for durability. Refer Table 1.2.

Cement content (kg/

) =




If the cement content calculated from Eqn 3.1 is below a specified minimum, this
minimum must be used resulting in a reduced w/c ratio and hence has a higher strength
than the target mean strength. If the calculated cement content is higher than a specified
maximum, the specified strength and workability cannot be simultaneously met with the
selected materials, try to change the type and maximum size of aggregate.
Step 4: Determining the aggregate content
1. Having calculated the water content and the cement content, the total aggregate content in
practice is obtained from the chart in the DoE document (35). The value can also be
calculated from basic principles. For each cubic meter of fully compacted fresh concrete;

Volume occupied by the aggregate = 1-

(Equation 4.1)
Where

3150 kg/

is the density of the cement particles

= 1000 kg/

is the density of water.

Therefore total aggregate content (kg/

) =

(volume occupied by aggregates)
(Equation 4.2)
Where

is the density of the aggregate particles. The DoE (35) recommends that if no
information is available,

should be taken 2600 kg/

for uncrushed aggregates and

2700 kg/

for crushed aggregates.

Step 5: Determination of the fine and coarse aggregate contents
1. How much of the total aggregate content should consist of fine aggregate depends on the
grading zones 1, 2, 3, and 4. The general principle in mix design is : the finer the grading
of the fine aggregate i.e. the larger its structure area per unit weight, the lower will be the
proportion, expressed as a percentage of the total aggregate required to produce a
concrete of otherwise similar properties.
2. For a given slump and w/c ratio, the proportion of fine aggregate can be determined from
Figure 3.0 in which the grading zones are those of Table 3.0. For example, for a specified
slump of 10-30mm, w/c ratio 0.47 and fine aggregate in grading zone 3, Figure 3.0 will
give the proportion of fine aggregate as between 32 and 38% by weight, say 35%.
Therefore, for this particular example:
Fine aggregate content = 35% of total aggregate content
Coarse aggregate content = 100 35% of total aggregate content
Solution:
The solution will follow the data listed above
Step 1: Determination of required w/c ratio
From Table 1.1, at the standard water cement ratio of 0.5, the 28 days strength is 40N

,
then the w/c ratio required to obtain target mean strength (43 N/

is approximately 0.47.
This is within permitted maximum w/c ratio of 0.60. Therefore, adopt a w/c ratio of 0.47.
Step 2: Determination of required water content
From table 2.0, water content for 10mm nominal maximum size uncrushed aggregate with 10-
30mm slump is 180 kg/

.
Step 3: Determination of cement ratio
From Equation 3.1
Cement ratio =

= 385 kg/

> 300 kg/

Step 4: Determination of total aggregate content
From Equation 4.1 and Equation 4.2, total aggregate content = 2600 (1-

) = 1815kg/

Step 5: Determination of fine and coarse aggregate content
From figure 3.0, for a slump of 10-30mm, w/c ratio of 0.47 and fine aggregate in grading zone 4,
the proportion of the fine aggregate is 27.5 to 32% by weight, say 30%.
Fine aggregate content = 0.30 x 1815 = 545 kg/

Coarse aggregate content = (1-0.30) x 1815 = 1270 kg/

Answer:
The required mix proportions are:
Cement: 385 kg/

Water content: 180 kg/

Fine aggregate content: 545 kg/

Coarse aggregate content: 1270 kg/

Calculation
1. Determining the target mean strength:
Target mean strength = 25 + (1.6*4)
= 31.4 N/

2. Determining the water/cement ratio
From table 1.1, at the standard water cement ratio of 0.58, the 28 days strength is
40 N/

. Figure 1.0 shows that if a w/c ratio of 0.58 give 40 N/

, then the
w/c ratio required to obtain the target mean strength ( 31.4 N/

) is
approximately 0.58. This is within the permitted maximum w/c ratio of 0.65.
Therefore, adopt a w/c ratio of 0.58.
3. Determining the water and cement content
From table 2.0, water cement for this experiment is 180 kg/

Therefore, 0.58=

Cement content=

= 310.345 kg/

(acceptable because >275 (minimum cement

content))
4. Determining fine and coarse aggregate content


+


+


= 1

= 1
Aggregate content = 1875.842 kg/

.
From figure 2, fine aggregate (%) vs water cement ratio, the percentage of the fine
aggregate is 38%

Therefore, total fine aggregate content = 1875.842 *

= 721.947 kg/

.
Therefore, total coarse aggregate content = 1875.842 *

= 1163.022 kg/

.
Cube Test
1. Fill mould in 3 layers, tamper each layer for 35 times with tamping bar.
2. Finish top of mould with trowel. Mark date and numbers.
3. Strike formwork in 24 hours, during which damp socking is used over cube.
4. Cure in water for 7 days, 14 days, 21 days and 28 days.
5. Test 2 cubes for compressive strength on the 7
th
, 14
th
, 21
st
, and 28
th
day.
Precautions
1. Coat mould with mould oil black oil.
2. Bolt tightly.
3. User scoop and not shovel so that larges stones drop off.
4. Leave mix proud out of mould and allow for water separation.
5. Take mould apart completely when removing cube.
6. Clean mould as soon as it is stripped.
7. Dont scoop top; dig hold and trowel flat.
Calculation
1. The concrete strength,

= 25/

is design by calculated the water, cement,

coarse and fine aggregate content.
2. The water content; 180 kg/

* 0.02835 = 5.13 kg
3. The cement content; 310.345 kg/

* 0.02835 = 8.845 kg
4. The fine aggregate content; 721.847 kg/

* 0.02835 = 20.573 kg
5. The coarse aggregate content; 1163.022 kg/

* 0.02835 = 33.146 kg
Total volume = 8*

* 5%
= 0.02836
Results
Day 7
th
14
th
21
st
28
th

Compression strength (kN) 170.00 209.15 270.00 183.50



Durability of concrete
The durability of concrete refers to its ability to withstand the environmental conditions to which
it is exposed. There is need to emphasize durability in the design and construction of concrete
structures. The I.Struc.E.Manual has summed up the main requirements for durability such as :
a) An upper limit to the w/c ratio (see table 1.2)
b) A lower limit to the cement content (see table 1.2)
c) A lower limit to the concrete cover to reinforcement (see table 1.2)
d) Good compaction
e) Adequate curing
The durability of concrete is intimately to its permeability, which terms refers to The ease with
which water can pass through the concrete. A low permeability makes the concrete better able to
withstand the effects of weathering, inculding the effects of driving rain and the distruptive
action of freezing and thawing, in connection with the strength of concrete, evaporable water and
the bubbles of trapped air occupy spaces called voids. As expected, therefore the permeability
increase rapidly with the w/c ratio and broadly speaking, factors which increase the strength of
the concrete would reduce its permeability and improve its durability : low w/c ratio, good
compaction and adequate curing. Indeed, the authors own experience with permeability is what
when the absorption of water in a sample of concrete exceeeds 7%, there is bound to be
corrosion of the reinforcement.
Corrosion of reinforcement can seriously affect the service life of a concrete structure. The
mechanisms of reinforcement corrosion are explained in an ACI Committee report, which also
gives guidance on the protective measure for new concrete construction, on the procedures for
identifying corrosive environments and active corrosion in concrete, and on remedial measures.
Broadly speaking, the factors which reduce the permeability of the concrete (and protect the
reinforcement from the ingress of external moisture) will help to inhibit reinforcement corrosion :
low w/c ratio, good compaction, adequate curing and an adequate concrete cover. The chloride
contents of the concrete must be held down, marine aggregate must be washed and sea-water
should not be used in concrete making.
Experience has shown that too low a cement content makes it more difficulty to obtain durable
concrete. Hence is often considered desirable in practice to specify a minimum cement content
(see table 1.2). It should also be pointed out what, while a higher cement content usually
improves the quality of the concrete, this is no longer so if the cement content exceeds a certain
limit. Too high a cement content increase the risk of cracking due to drying shrinkage in thin
section sections or to thermal stresses in thicker sections. It is therefore necessary to specify
maximum cement content: BS 8110 recommends that the cement should never exceed 550
kg/

Table 1.0 : Standard deviations under different conditions
Conditions Standard Deviation (N/mm2)
Good control with weight batching, use of
graded aggregates ,etc. Constant supervision
4-5
Fair control with weight batching.Use of two
sizes of aggregates.Occasional supervision
5-7
Poor control.Inaccurate volume batching of all
in aggregates. No supervision.
7-8 and above

Table 1.1 : Standard deviations under different conditions
Type of Cement Type of coarse Aggregate Compressive strength
(N/mm2)
Age (Days)
3 7 28 91
Ordinary Portland Uncrushed
Crushed
18 27 40 48
23 33 47 55

Rapid-Hardening Portland Uncrushed
Crushed
25 34 46 53
30 40 53 60

Table 1.2 : Durability requirements
Exposure condition Nominal Cover (mm)
Mild 20 20 20 20
Moderate - 35 30 20
Severe - - 40 25
Very severe - - 50 30
Maximum free w/c ratio 0.65 0.60 0.55 0.45
Minimum cement content (kg/m3) 275 300 325 400
Concrete fcu (N/mm2) 30 35 40 50







Table 2.0 : Approximate free-water contents (kg/m3) required to give various Level of
workability (after DoE[35]
Slump(mm)
VB time (seconds)
0-10
>12
10-30
12-6
30-60
6-3
60-180
3-0
Maximum Type of
Size of
aggregate
Aggregate(mm)

10
Uncrushed
Crushed
150
180
180
205
205
230
225
250
20
Uncrushed
Crushed
135
170
160
190
180
210
195
225
40
Uncrushed
Crushed
115
155
140
175
160
190
175
205

Table 3.0 : Grading limits for DoE mix design procedure
Standard Sieve
sizes
Percentage by weight passing standard sieves
Grading Zone
1
Grading Zone
2
Grading Zone
3

Grading Zone
4


10mm 100 100 100 100
5mm 90-100 90-100 90-100 95-100
No.7(2.36mm) 60-95 75-100 85-100 95-100
No.14(1.18mm) 30-70 55-90 75-100 90-100
No.25(600 micro
m)
15-34 35-59 60-79 80-100
No.52(300 micro
m)
5-20 8-30 12-40 15-50
No.100(150
micro m)
0-10 0-10 0-10 0-15