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CONC. MIX design pdf Raph 2 for beginers

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The document presents mix design calculations for concrete achieving a characteristic strength of 40 N/mm² at 28 days, following the BRE 1992 method as recommended by the UK Department of the Environment. It includes detailed components such as cement content, water-cement ratios, aggregate proportions, and densities, with summaries for different concrete mixtures. Various trials and their respective quantities for materials per cubic meter are also provided to ensure accurate mixing for desired concrete performance.

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APPENDIX 2 MIX DESIGNS All mixes in this study were designed in accordance with the Building Research Establishment (BRE 1992) method, recommended by the UK Department of the Environment. Reference should be made therein to tables and graphs alluded to and available for use in this design method. All abbreviations and acronyms in the mix design sheets are those used in BRE’s 1992 method. Chapter 4: mix design calculation sheet for 40 N/mm2 concrete mix (28 day strength) A) NA 1-Characteristic strength at 28 days 40 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS = not specified) M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 53 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Crushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 53 N/mm2 w/c 0.46 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.46 7-Free-water content (W) Use Table 3 Slump 60-180 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Crushed Wf = 195 kg/m3 Wc = 225 kg/m3 W = 2/3Wf + 1/3Wc = 205 kg/m3
[When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 205 kg/m3 8-Cement content w/c ratio 0.46 (Fig. 4) Free-water content 205 kg/m3 8.1-Cement content 446 kg/m3 Say 445 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 445 kg/m3 Modified free-water to cement content 0.46 9-Concrete density Relative density of aggregate (SSD) = 2.65 (Known ) Free-water content = 205 kg/m3 Wet concrete density of the mix = 2360 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content - Cement content TAC = 1710 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 54 Modified free-water content to cement ratio 0.46 Proportion of fine aggregate (%) 41 (Graph 6) TAC = 1710 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 701.1 kg/m3 Say FAC= 700 kg/m3 Coarse aggregate content = TAC - FAC = 1010 kg/m3 13-Summary of quantities for 1 m3 (SSD) Cement = 445 kg/m3 Water = 205 kg/m3 Fine aggregate = 700 kg/m3 Coarse aggregate = 1010 kg/m3 Wet density = 2360 kg/m3 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.7 kg Water = 1.7 kg Fine aggregate = 5.8 kg Coarse aggregate = 8.4 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.7 2.6
15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 445 0.141 14 19 Water 205 0.210 21 9 Coarse agg. 1010 0.370 37 43 Fine agg. 700 0.269 27 30 Total agg. 1710 0.658 64 72 Total 2360 0.990 97 - Paste volume - 0.346 - - % PV - 35.6 - - Mortar volume - 0.616 - - % MV - 62 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.46 0.30 - 0.60 Coarse agg. / Total agg. ( %) 59 60 - 75% Fine agg. / Total agg. (%) 41 30- 45% Total agg. / Cement 3.8 2-5 Density (kg/m3 ) 2360 2200-2500 B) RA 1-Characteristic strength at 28 days 40 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS= not specified) M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 53 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Crushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu)) = 49 N/mm2 (Table 2) Target mean strength (fm) = 53 N/mm2 w/c 0.46 (Graph 4) w/c NS (S-specified, NS-not specified) (Use the lower value as w/c) w/c = 0.46 7-Free-water content (W)
Use Table 3 Slump 60-180 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Crushed Wf = 195 kg/m3 Wc = 225 kg/m3 W = 2/3Wf + 1/3Wc = 205 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 205 kg/m3 8-Cement content w/c ratio 0.46 (Fig. 4) Free-water content 205 kg/m3 8.1-Cement content 446 kg/m3 Say 445 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 445 kg/m3 Modified free-water to cement content 0.46 9-Concrete density Relative density of aggregate (SSD) = 2.55 (Known ) Free-water content = 205 kg/m3 Wet concrete density of the mix = 2325 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1675 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 54 Modified free-water content to cement ratio 0.46 Proportion of fine aggregate (%) 41 (Graph 6) TAC = 1675 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 686.75 kg/m3 Say FAC= 685 kg/m3 Coarse aggregate content = TAC - FAC = 990 kg/m3 13-Summary of quantities for 1 m3 (SSD) Cement = 445 kg/m3 Water = 205 kg/m3 Fine aggregate = 685 kg/m3 Coarse aggregate = 990 kg/m3 Wet density = 2325 kg/m3
14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.7 kg Water = 1.7 kg Fine aggregate = 5.7 kg Coarse aggregate = 8.2 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.5 2.6 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 445 0.141 14 19 Water 205 0.210 21 9 Coarse agg. 990 0.400 37 43 Fine agg. 685 0.263 26 30 Total agg. 1675 0.644 63 72 Total 2325 1.006 96 - Paste volume - 0.346 - - % PV - 34.6 - - Mortar volume - 0.610 - - % MV - 61 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.46 0.30 - 0.60 Coarse agg. / Total agg. (%) 59 60 - 75% Fine agg. / Total agg. (%) 41 30- 45% Total agg. / Cement 3.8 2-5 Density (kg/m3 ) 2360 2200-2500
Chapter 5: mix design calculation sheet for 40 N/mm2 concrete mix (28 day strength) A) NA 1-Characteristic strength at 28 days 40 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS = not specified) M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 53 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Crushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 53 N/mm2 w/c 0.46 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.46 7-Free-water content (W) Use Table 3 Slump 30-60 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Crushed Wf = 210 kg/m3 Wc = 210 kg/m3 W = 2/3Wf + 1/3Wc = 210 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 210 kg/m3 8-Cement content w/c ratio 0.46 (Fig. 4) Free-water content 210 kg/m3 8.1-Cement content 457 kg/m3 Say 457 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 457 kg/m3
Modified free-water to cement content 0.46 9-Concrete density Relative density of aggregate (SSD) = 2.65 (Known ) Free-water content = 210 kg/m3 Wet concrete density of the mix = 2400 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1733 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 42 Modified free-water content to cement ratio 0.46 Proportion of fine aggregate (%) 38 (Graph 6) TAC = 1733 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 658.5 kg/m3 Say FAC= 660 kg/m3 Coarse aggregate content = TAC - FAC = 1073 kg/m3 13-Summary of quantities for 1 m3 (SSD) Cement = 457 kg/m3 Water = 210 kg/m3 Fine aggregate = 660 kg/m3 Coarse aggregate = 1073 kg/m3 Wet density = 2400 kg/m3 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.8 kg Water = 1.7 kg Fine aggregate = 5.5 kg Coarse aggregate = 8.9 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.7 2.6
15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 457 0.145 15 19 Water 210 0.210 21 9 Coarse agg. 1073 0.400 40 45 Fine agg. 660 0.254 25 28 Total agg. 1733 0.667 65 72 Total 2400 1.006 99 - Paste volume - 0.355 - - % PV - 35.5 - - Mortar volume - 0.609 - - % MV - 61 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.46 0.30 - 0.60 Coarse agg. / Total agg. (%) 62 60 - 75% Fine agg. / Total agg. (%) 38 30- 45% Total agg. / Cement 3.8 2-5 Density (kg/m3 ) 2400 2200-2500 B) RA 1-Characteristic strength at 28 days 40 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS = not specified) M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 53 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Crushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 Target mean strength (fm) = 53 N/mm2 (Table 2) w/c 0.46 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.46
7-Free-water content (W) Use Table 3 Slump 30-60 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Crushed Wf = 210 kg/m3 Wc = 210 kg/m3 W =2/3Wf + 1/3Wc = 210 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 210 kg/m3 8-Cement content w/c ratio 0.46 (Fig. 4) Free-water content 210 kg/m3 8.1-Cement content 457 kg/m3 Say 457 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 457 kg/m3 Modified free-water to cement content 0.46 9-Concrete density Relative density of aggregate (SSD) = 2.55 (Known ) Free-water content = 210 kg/m3 Wet concrete density of the mix = 2350 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1683 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 42 Modified free-water content to cement ratio 0.46 Proportion of fine aggregate (%) 38 (Graph 6) TAC = 1683 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 589.05 kg/m3 Say FAC= 590 kg/m3 Coarse aggregate content = TAC - FAC = 1073 kg/m3 13-Summary of quantities for 1 m3 (SSD) Cement = 457 kg/m3 Water = 210 kg/m3 Fine aggregate = 590 kg/m3 Coarse aggregate = 1093 kg/m3 Wet density = 2350 kg/m3
14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.8 kg Water = 1.7 kg Fine aggregate = 4.9 kg Coarse aggregate = 9.1 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.5 2.6 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 457 0.145 15 19 Water 210 0.210 21 9 Coarse agg. 1093 0.440 44 47 Fine agg. 590 0.227 23 25 Total agg. 1683 0.647 66 72 Total 2350 1.019 100 - Paste volume - 0.355 - - % PV - 35.5 - - Mortar volume - 0.582 - - % MV - 58 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.46 0.30 - 0.60 Coarse agg. / Total agg. (%) 65 60 - 75% Fine agg. / Total agg. (%) 35 30- 45% Total agg. / Cement 3.7 2-5 Density (kg/m3 ) 2350 2200-2500
Chapter 5: mix design calculation sheet for 50 N/mm2 concrete mix (28 day strength) A) NA 1-Characteristic strength at 28 days 50 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS = not specified) M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 63 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Crushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 63 N/mm2 w/c 0.4 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.4 7-Free-water content (W) Use Table 3 Slump 10-30 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Unrushed Wf = 160 kg/m3 Wc = 190 kg/m3 W = 2/3Wf + 1/3Wc = 170 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 170 kg/m3 8-Cement content w/c ratio 0.4 (Fig. 4) Free-water content 170 kg/m3 8.1-Cement content 425 kg/m3 Say 425 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 425 kg/m3
Modified free-water to cement content 0.40 9-Concrete density Relative density of aggregate (SSD) = 2.65 (Known ) Free-water content = 170 kg/m3 Wet concrete density of the mix = 2430 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1835 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 53 Modified free-water content to cement ratio 0.40 Proportion of fine aggregate (%) 30 (Graph 6) TAC = 1835 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 550.5 kg/m3 Say FAC= 550 kg/m3 Coarse aggregate content = TAC - FAC = 1285 kg/m3 13-Summary of quantities for 1m3 (SSD) Cement = 425 kg/m3 Water = 170 kg/m3 Fine aggregate = 550 kg/m3 Coarse aggregate = 1285 kg/m3 Wet density = 2430 kg/m3 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.5 kg Water = 1.4 kg Fine aggregate = 4.6 kg Coarse aggregate = 10.7 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.7 2.6
15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 425 0.135 13 17 Water 170 0.170 17 7 Coarse agg. 1285 0.480 48 53 Fine agg. 550 0.212 21 23 Total agg. 1835 0.706 69 76 Total 2430 0.992 97 - Paste volume - 0.305 - - % PV - 30.5 - - Mortar volume - 0.516 - - % MV - 52 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.4 0.30 - 0.60 Coarse agg. / Total agg.(%) 70 60 - 75% Fine agg. / Total agg. (%) 30 30- 45% Total agg. / Cement 4.3 2-5 Density (kg/m3 ) 2430 2200-2500 A) RA 1-Characteristic strength at 28 days 50 N/mm2 2-Margin strength (M) M-specified NS N/mm2 [NS= not specified] M-calculated = 1.64  S S = Standard Deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 63 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Crushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 63 N/mm2 w/c 0.4 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.4 7-Free-water content (W)
Use Table 3 Slump 10-30 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Unrushed Wf = 160 kg/m3 Wc = 190 kg/m3 W = 2/3Wf + 1/3Wc = 170 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 170 kg/m3 8-Cement content w/c ratio 0.4 (Fig. 4) Free-water content 170 kg/m3 8.1-Cement content 425 kg/m3 Say 425 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 425 kg/m3 Modified free-water to cement content 0.40 9-Concrete density Relative density of aggregate (SSD) = 2.55 (Known ) Free-water content = 170 kg/m3 Wet concrete density of the mix = 2365 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1770 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 53 Modified free-water content to cement ratio 0.40 Proportion of fine aggregate (%) 30 (Graph 6) TAC = 1770 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 531 kg/m3 Say FAC= 530 kg/m3 Coarse aggregate content = TAC - FAC = 1240 kg/m3 13-Summary of quantities for 1m3 (SSD) Cement = 425 kg/m3 Water = 170 kg/m3 Fine aggregate = 530 kg/m3 Coarse aggregate = 1240 kg/m3 Wet density = 2365 kg/m3
14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.5 kg Water = 1.4 kg Fine aggregate = 4.4 kg Coarse aggregate = 10.3 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.5 2.6 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 425 0.135 13 18 Water 170 0.170 17 7 Coarse agg. 1240 0.500 50 52 Fine agg. 530 0.204 20 22 Total agg. 1770 0.681 70 75 Total 2365 1.005 98 - Paste volume - 0.305 - - % PV - 30.5 - - Mortar volume - 0.509 - - % MV - 51 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.4 0.30 - 0.60 Coarse agg. / Total agg. (%) 70 60 - 75% Fine agg. / Total agg. (%) 30 30- 45% Total agg. / Cement 4.2 2-5 Density (kg/m3 ) 2365 2200-2500
Chapter 5: mix design calculation sheet for 60 N/mm2 concrete mix (28 day strength) A) NA 1-Characteristic strength at 28 days 60 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS = not specified) M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 73 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Crushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 73 N/mm2 w/c 0.33 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.33 7-Free-water content (W) Use Table 3 Slump 30-60 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Unrushed Wf = 210 kg/m3 Wc = 210 kg/m3 W = 2/3Wf + 1/3Wc = 210 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 210 kg/m3 8-Cement content w/c ratio 0.4 (Fig. 4) Free-water content 210 kg/m3 8.1-Cement content 636 kg/m3 Say 636 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 636 kg/m3
Modified free-water to cement content 0.33 9- Concrete density Relative density of aggregate (SSD) = 2.65 (Known ) Free-water content = 210 kg/m3 Wet concrete density of the mix = 2400 kg/m3 (Graph 5) 10-Total aggregate content, TAC (Coarse and fine aggregate) TAC = Wet density - Free-water content -Cement content TAC = 1554 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 50 Modified free-water content to cement ratio 0.33 Proportion of fine aggregate (%) 31 (Graph 6) TAC = 1554 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 481.74 kg/m3 Say FAC= 480 kg/m3 Coarse aggregate content = TAC - FAC = 1074 kg/m3 13-Summary of quantities for 1 m3 (SSD) Cement = 636 kg/m3 Water = 210 kg/m3 Fine aggregate = 480 kg/m3 Coarse aggregate = 1074 kg/m3 Wet density = 2400 kg/m3 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 5.3 kg Water = 1.7 kg Fine aggregate = 4.0 kg Coarse aggregate = 8.9 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.7 2.6
15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 636 0.202 20 27 Water 210 0.210 21 9 Coarse agg. 1074 0.400 40 45 Fine agg. 480 0.185 18 20 Total agg. 1554 0.598 58 65 Total 2400 0.994 97 - Paste volume - 0.412 - - % PV - 41.2 - - Mortar volume - 0.597 - - % MV - 60 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.33 0.30 - 0.60 Coarse agg. / Total agg.(%) 69 60 - 75% Fine agg. / Total agg. (%) 31 30- 45% Total agg. / Cement 2.4 2-5 Density (kg/m3 ) 2400 2200-2500 A) RA 1-Characteristic strength at 28 days 60 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS = not specified) M-calculated = 1.64  S S = Standard Deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 73 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Crushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 73 N/mm2 w/c 0.33 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.33
7-Free-water content (W) Use Table 3 Slump 30-60 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Unrushed Wf = 210 kg/m3 Wc = 210 kg/m3 W = 2/3Wf + 1/3Wc = 210 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 210 kg/m3 8-Cement content w/c ratio 0.4 (Fig. 4) Free-water content 210 kg/m3 8.1-Cement content 636 kg/m3 Say 636 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 636 kg/m3 Modified free-water to cement content 0.33 9-Concrete density Relative density of aggregate (SSD) = 2.55 (Known ) Free-water content = 210 kg/m3 Wet concrete density of the mix = 2350 kg/m3 (Graph 5) 10-Total aggregate content, TAC (Coarse and fine aggregate) TAC = Wet density - Free-water content -Cement content TAC = 1504 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 50 Modified free-water content to cement ratio 0.33 Proportion of fine aggregate (%) 31% (Graph 6) TAC = 1504 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 466.24 kg/m3 Say FAC= 465 kg/m3 Coarse aggregate content = TAC - FAC = 1039 kg/m3 13-Summary of quantities for 1 m3 (SSD) Cement = 636 kg/m3 Water = 210 kg/m3 Fine aggregate = 465 kg/m3 Coarse aggregate = 1039 kg/m3 Wet density = 2350 kg/m3
14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 5.3 kg Water = 1.7 kg Fine aggregate = 3.9 kg Coarse aggregate = 8.6 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.5 2.6 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 636 0.202 20 27 Water 210 0.210 21 9 Coarse agg. 1039 0.420 42 44 Fine agg. 465 0.179 18 20 Total agg. 1504 0.578 59 64 Total 2350 1.006 99 - Paste volume - 0.412 - - % PV - 41.2 - - Mortar volume - 0.591 - - % MV - 59 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.33 0.30 - 0.60 Coarse agg. / Total agg. (%) 69 60 - 75% Fine agg. / Total agg. (%) 31 30- 45% Total agg. / Cement 2.4 2-5 Density (kg/m3 ) 2350 2200-2500
Chapter 6: mix design calculation sheet for 40 N/mm2 concrete mix (28 day strength) A) NA 1-Characteristic strength at 28 days 40 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS = not specified) M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm ) fm = 53 N/mm2 (fcu + M) 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Uncrushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 53 N/mm2 w/c 0.4 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.4 7-Free-water content (W) Use Table 3 Slump 30-60 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Unrushed Wf = 180 kg/m3 Wc = 210 kg/m3 W =2/3Wf + 1/3Wc = 190 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 190 kg/m3 8-Cement content w/c ratio 0.4 (Fig. 4) Free-water content 190 kg/m3 8.1-Cement content 475 kg/m3 Say 475 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 475 kg/m3
Modified free-water to cement content 0.4 9-Concrete density Relative density of aggregate (SSD) = 2.65 (Known ) Free-water content = 190 kg/m3 Wet concrete density of the mix = 2400 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1735 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 20 Percentage of fine aggregate passing 600 µm sieve (%) 54 Modified free-water content to cement ratio 0.4 Proportion of fine aggregate (%) 35 (Graph 6) TAC = 1735 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 607.25 kg/m3 Say FAC= 610 kg/m3 Coarse aggregate content = TAC - FAC = 1125 kg/m3 13-Summary of quantities for 1 m3 (SSD) Cement = 475 kg/m3 Water = 190 kg/m3 Fine aggregate = 610 kg/m3 Coarse aggregate = 1125 kg/m3 Wet density = 2400 kg/m3 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.9 kg Water = 1.6 kg Fine aggregate = 5.1 kg Coarse aggregate = 9.3 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.7 2.6
15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 475 0.151 15 19 Water 190 0.190 19 9 Coarse agg. 1125 0.420 42 43 Fine agg. 610 0.235 23 30 Total agg. 1735 0.667 65 72 Total 2400 0.992 97 - Paste volume - 0.341 - - % PV - 34.1 - - Mortar volume - 0.575 - - % MV - 58 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.4 0.30 - 0.60 Coarse agg. / Total agg. (%) 65 60 - 75% Fine agg. / Total agg. (%) 35 30- 45% Total agg. / Cement 3.7 2-5 Density (kg/m3 ) 2400 2200-2500 B) RA 1-Characteristic strength at 28 days 40 N/mm2 2-Margin strength (M) M-specified NS N/mm2 [NS = not specified] M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm ) fm = 53 N/mm2 (fcu + M) 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Uncrushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 53 N/mm2 w/c 0.4 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.4
7-Free-water content (W) Use Table 3 Slump 30-60 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Unrushed Wf = 180 kg/m3 Wc = 210 kg/m3 W =2/3Wf + 1/3Wc = 190 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 190 kg/m3 8-Cement content w/c ratio 0.4 (Fig. 4) Free-water content 190 kg/m3 8.1-Cement content 475 kg/m3 Say 475 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 475 kg/m3 Modified free-water to cement content 0.4 9-Concrete density Relative density of aggregate (SSD) = 2.55 (Known ) Free-water content = 190 kg/m3 Wet concrete density of the mix = 2325 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1660 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 54 Modified free-water content to cement ratio 0.4 Proportion of fine aggregate (%) 35 (Graph 6) TAC = 1660 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 581 kg/m3 Say FAC= 580 kg/m3 Coarse aggregate content = TAC - FAC = 1080 kg/m3 13-Summary of quantities for 1m3 (SSD) Cement = 475 kg/m3 Water = 190 kg/m3 Fine aggregate = 580 kg/m3 Coarse aggregate = 1080 kg/m3 Wet density = 2325 kg/m3
14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.9 kg Water = 1.6 kg Fine aggregate = 4.8 kg Coarse aggregate = 9.0 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.5 2.6 14.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 475 0.151 15 20 Water 190 0.190 19 8 Coarse agg. 1080 0.430 43 46 Fine agg. 580 0.223 22 25 Total agg. 1660 0.638 66 71 Total 2325 0.996 98 - Paste volume - 0.341 - - % PV - 34.1 - - Mortar volume - 0.564 - - % MV - 56 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.4 0.30 - 0.60 Coarse agg. / Total agg. (%) 65 60 - 75% Fine agg. / Total agg. (%) 35 30- 45% Total agg. / Cement 3.5 2-5 Density (kg/m3 ) 2325 2200-2500
Chapter 7: mix design calculation sheet for standard 50 N/mm2 (28 day strength) concrete mix (0% PFA) A) NA 1-Characteristic strength at 28 days 50 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS = not specified) M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm ) (fcu + M) fm = 63 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Uncrushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 63 N/mm2 w/c 0.4 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.4 7-Free-water content (W) Use Table 3 Slump 10-30 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Unrushed Wf = 160 kg/m3 Wc = 190 kg/m3 W = 2/3Wf + 1/3Wc = 170 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 170 kg/m3 8-Cement content w/c ratio 0.4 (Fig. 4) Free-water content 170 kg/m3 8.1-Cement content 425 kg/m3 Say 425 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 425 kg/m3
Modified free-water to cement content 0.40 9-Concrete density Relative density of aggregate (SSD) = 2.65 (Known ) Free-water content = 170 kg/m3 Wet concrete density of the mix = 2420 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1825 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 20 Percentage of fine aggregate passing 600 µm sieve (%) 53 Modified Free-water content to cement ratio 0.40 Proportion of fine aggregate (%) 30 (Graph 6) TAC = 1825 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 547.5 kg/m3 Say FAC= 545 kg/m3 Coarse aggregate content = TAC - FAC = 1280 kg/m3 13-Summary of quantities for 1 m3 (SSD) Cement = 425 kg/m3 Water = 170 kg/m3 Fine aggregate = 545 kg/m3 Coarse aggregate = 1280 kg/m3 Wet density = 2420 kg/m3 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.5 kg Water = 1.4 kg Fine aggregate = 4.5 kg Coarse aggregate = 10.6 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.7 2.6
15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 425 0.135 13 18 Water 170 0.170 17 7 Coarse agg. 1280 0.470 47 53 Fine agg. 545 0.210 21 23 Total agg. 1825 0.702 68 75 Total 2420 0.989 97 - Paste volume - 0.305 - - % PV - 30.5 - - Mortar volume - 0.515 - - % MV - 51 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.4 0.30 - 0.60 Coarse agg. / Total agg. (%) 70 60 - 75% Fine agg. / Total agg.(%) 30 30- 45% Total agg. / Cement 4.3 2-5 Density (kg/m3 ) 2420 2200-2500 A) RA 1-Characteristic strength at 28 days 50 N/mm2 2-Margin strength (M) M-specified NS N/mm2 [NS = not specified] M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 63 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Uncrushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 63 N/mm2 w/c 0.4 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.4
7-Free-water content (W) Use Table 3 Slump 10-30 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Unrushed Wf = 160 kg/m3 Wc = 190 kg/m3 W = 2/3Wf + 1/3Wc = 170 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 170 kg/m3 8-Cement content w/c ratio 0.4 (Fig. 4) Free-water content 170 kg/m3 8.1-Cement content 425 kg/m3 Say 425 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 425 kg/m3 Modified free-water to cement content 0.40 9-Concrete density Relative density of aggregate (SSD) = 2.55 (Known ) Free-water content = 170 kg/m3 Wet concrete density of the mix = 2360 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1765 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 53 Modified free-water content to cement ratio 0.40 Proportion of fine aggregate (%) 30 (Graph 6) TAC = 1765 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 529.5 kg/m3 Say FAC= 530 kg/m3 Coarse aggregate content = TAC - FAC = 1235 kg/m3 13-Summary of quantities for one cubic meter (SSD) Cement = 425 kg/m3 Water = 170 kg/m3 Fine aggregate = 530 kg/m3 Coarse aggregate = 1235 kg/m3 Wet density = 2360 kg/m3
14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.5 kg Water = 1.4 kg Fine aggregate = 4.4 kg Coarse aggregate = 10.3 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.5 2.6 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 425 0.135 13 18 Water 170 0.170 17 7 Coarse agg. 1235 0.460 46 52 Fine agg. 530 0.204 20 22 Total agg. 1765 0.679 66 75 Total 2360 0.966 99 - Paste volume - 0.305 - - % PV - 30.5 - - Mortar volume - 0.509 - - % MV - 51 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.4 0.30 - 0.60 Coarse agg. / Total agg.(%) 70 60 - 75% Fine agg. / Total agg. (%) 30 30- 45% Total agg. / Cement 4.2 2-5 Density (kg/m3 ) 2360 2200-2500
Chapter 8: mix design calculation sheet for standard 50 N/mm2 (28 day strength) concrete mix (0% PFA) A) NA 1-Characteristic strength at 28 days = 50 N/mm2 2-Margin strength (M) M-Specified NS N/mm2 (NS= Not Specified) M-calculated = 1.64 x S S = Standard Deviation = 8 N/mm2 M-calculated 1.64 x 8 (Fig. 3) M = 13 N/mm2 3-Target Mean strength fm (fm = fc+M) fm = 63 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Uncrushed (Crushed or Uncrushed) 6-Free-Water cement ratio (W/C) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength fcu 49 N/mm2 Target Mean strength fm = 63 N/mm2 (Table 2) w/c 0.4 (Graph No 4) (Use the lower value as w/c) w/c = 0.4 7-Free-water content W UseTable No 3 Slump 60 to 180 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed (Crushed or Uncrushed) Type of fine aggregate Unrushed (Crushed or Uncrushed)
Wf = 195 kg/m3 Wc = 225 kg/m3 W =2/3Wf +1/3Wc = 205 kg/m3 [When coarse and fine aggregates are of different types] W = Values in Table 3 [When coarse and fine aggregates are of the same types- use values in table 3] Free-water content W = 205 kg/m3 8-Relative density Relative density of aggregate (SSD) = 2.55 (Known) PFA percentage 30 % Amount of water reduced for PFA (Table 9) 20 kg/m3 Free-water content adjusted for PFA = 185 kg/m3 Wet density of the mix = 2340 kg/m3 (Graph 5) 9-Cement and PFA content Cement content = 409.8 kg/m3 Say 410 kg/m3 RGD content = 176 kg/m3 Say 175 kg/m3 C+RGD = 585 w/b = w/ (C+RGD) = 0.32 10-Total aggregate content ,TAC (Coarse and fine aggregate) TAC = Wet density - Free-water content -Cement content TAC = 1570 kg/m3 11-Proportion of fine and coarse aggregate Graph 6 Maximum aggregate size 20 mm Percentage of fine aggregate passing 600µm sieve 53 % Modified Free-water content to cement ratio 0.32 Proportion of fine aggregate (%) 38 (graph 6) TAC = 1570 kg/m3 Fine aggregate content = FAC = % Fine agg. x TAC = 596.6 kg/m3 Say FAC= 600 kg/m3 Coarse aggregate content = TAC - FAC = 970 kg/m3 13-Summary of quantities for one cubic meter (SSD) Cement = 410 kg/m3 PFA = 175 Water = 185 kg/m3 Fine aggregate = 600 kg/m3
Coarse aggregate = 970 kg/m3 14-Proportion of gradients per trial mix (SSD) of 0.0083 (For Small mixer) Cement = 3.4 kg PFA = 1.45 kg Water = 1.5 kg Fine aggregate = 5.0 kg Coarse aggregate = 8.1 kg This trial will make about 20 kg concrete, enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. PFA RD 3.15 1 2.5 2.6 2.25 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) Vol. (%) % by mass Cement 410 0.130 13 18 PFA 175 0.078 8 7 Water 185 0.19 19 8 Coarse agg. 970 0.39 39 41 Fine agg. 600 0.231 23 26 Total agg. 1570 0.604 62 67 Total 2340 1.012 99 - Paste volume - 0.393 - - % PV - 39 - - Mortar volume - 0.624 - - % MV - 62 - - Mortar 1370 ( RD = Relative Density, PV= Paste Volume, MV= Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range Powder content kg/m3 585 400-600 w/b - 0.32 0.28-0.42 % Coarse aggregate content (%) 39 29-35 % (by vol.) PV. (%) 39 30-42 % (by vol.) Fine agg./ Mortar (%) 44 40-52% Density Kg/m3 2340 2200-2500

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CONC. MIX design pdf Raph 2 for beginers

  • 1. APPENDIX 2 MIX DESIGNS All mixes in this study were designed in accordance with the Building Research Establishment (BRE 1992) method, recommended by the UK Department of the Environment. Reference should be made therein to tables and graphs alluded to and available for use in this design method. All abbreviations and acronyms in the mix design sheets are those used in BRE’s 1992 method. Chapter 4: mix design calculation sheet for 40 N/mm2 concrete mix (28 day strength) A) NA 1-Characteristic strength at 28 days 40 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS = not specified) M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 53 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Crushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 53 N/mm2 w/c 0.46 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.46 7-Free-water content (W) Use Table 3 Slump 60-180 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Crushed Wf = 195 kg/m3 Wc = 225 kg/m3 W = 2/3Wf + 1/3Wc = 205 kg/m3
  • 2. [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 205 kg/m3 8-Cement content w/c ratio 0.46 (Fig. 4) Free-water content 205 kg/m3 8.1-Cement content 446 kg/m3 Say 445 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 445 kg/m3 Modified free-water to cement content 0.46 9-Concrete density Relative density of aggregate (SSD) = 2.65 (Known ) Free-water content = 205 kg/m3 Wet concrete density of the mix = 2360 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content - Cement content TAC = 1710 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 54 Modified free-water content to cement ratio 0.46 Proportion of fine aggregate (%) 41 (Graph 6) TAC = 1710 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 701.1 kg/m3 Say FAC= 700 kg/m3 Coarse aggregate content = TAC - FAC = 1010 kg/m3 13-Summary of quantities for 1 m3 (SSD) Cement = 445 kg/m3 Water = 205 kg/m3 Fine aggregate = 700 kg/m3 Coarse aggregate = 1010 kg/m3 Wet density = 2360 kg/m3 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.7 kg Water = 1.7 kg Fine aggregate = 5.8 kg Coarse aggregate = 8.4 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.7 2.6
  • 3. 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 445 0.141 14 19 Water 205 0.210 21 9 Coarse agg. 1010 0.370 37 43 Fine agg. 700 0.269 27 30 Total agg. 1710 0.658 64 72 Total 2360 0.990 97 - Paste volume - 0.346 - - % PV - 35.6 - - Mortar volume - 0.616 - - % MV - 62 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.46 0.30 - 0.60 Coarse agg. / Total agg. ( %) 59 60 - 75% Fine agg. / Total agg. (%) 41 30- 45% Total agg. / Cement 3.8 2-5 Density (kg/m3 ) 2360 2200-2500 B) RA 1-Characteristic strength at 28 days 40 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS= not specified) M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 53 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Crushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu)) = 49 N/mm2 (Table 2) Target mean strength (fm) = 53 N/mm2 w/c 0.46 (Graph 4) w/c NS (S-specified, NS-not specified) (Use the lower value as w/c) w/c = 0.46 7-Free-water content (W)
  • 4. Use Table 3 Slump 60-180 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Crushed Wf = 195 kg/m3 Wc = 225 kg/m3 W = 2/3Wf + 1/3Wc = 205 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 205 kg/m3 8-Cement content w/c ratio 0.46 (Fig. 4) Free-water content 205 kg/m3 8.1-Cement content 446 kg/m3 Say 445 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 445 kg/m3 Modified free-water to cement content 0.46 9-Concrete density Relative density of aggregate (SSD) = 2.55 (Known ) Free-water content = 205 kg/m3 Wet concrete density of the mix = 2325 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1675 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 54 Modified free-water content to cement ratio 0.46 Proportion of fine aggregate (%) 41 (Graph 6) TAC = 1675 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 686.75 kg/m3 Say FAC= 685 kg/m3 Coarse aggregate content = TAC - FAC = 990 kg/m3 13-Summary of quantities for 1 m3 (SSD) Cement = 445 kg/m3 Water = 205 kg/m3 Fine aggregate = 685 kg/m3 Coarse aggregate = 990 kg/m3 Wet density = 2325 kg/m3
  • 5. 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.7 kg Water = 1.7 kg Fine aggregate = 5.7 kg Coarse aggregate = 8.2 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.5 2.6 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 445 0.141 14 19 Water 205 0.210 21 9 Coarse agg. 990 0.400 37 43 Fine agg. 685 0.263 26 30 Total agg. 1675 0.644 63 72 Total 2325 1.006 96 - Paste volume - 0.346 - - % PV - 34.6 - - Mortar volume - 0.610 - - % MV - 61 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.46 0.30 - 0.60 Coarse agg. / Total agg. (%) 59 60 - 75% Fine agg. / Total agg. (%) 41 30- 45% Total agg. / Cement 3.8 2-5 Density (kg/m3 ) 2360 2200-2500
  • 6. Chapter 5: mix design calculation sheet for 40 N/mm2 concrete mix (28 day strength) A) NA 1-Characteristic strength at 28 days 40 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS = not specified) M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 53 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Crushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 53 N/mm2 w/c 0.46 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.46 7-Free-water content (W) Use Table 3 Slump 30-60 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Crushed Wf = 210 kg/m3 Wc = 210 kg/m3 W = 2/3Wf + 1/3Wc = 210 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 210 kg/m3 8-Cement content w/c ratio 0.46 (Fig. 4) Free-water content 210 kg/m3 8.1-Cement content 457 kg/m3 Say 457 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 457 kg/m3
  • 7. Modified free-water to cement content 0.46 9-Concrete density Relative density of aggregate (SSD) = 2.65 (Known ) Free-water content = 210 kg/m3 Wet concrete density of the mix = 2400 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1733 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 42 Modified free-water content to cement ratio 0.46 Proportion of fine aggregate (%) 38 (Graph 6) TAC = 1733 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 658.5 kg/m3 Say FAC= 660 kg/m3 Coarse aggregate content = TAC - FAC = 1073 kg/m3 13-Summary of quantities for 1 m3 (SSD) Cement = 457 kg/m3 Water = 210 kg/m3 Fine aggregate = 660 kg/m3 Coarse aggregate = 1073 kg/m3 Wet density = 2400 kg/m3 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.8 kg Water = 1.7 kg Fine aggregate = 5.5 kg Coarse aggregate = 8.9 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.7 2.6
  • 8. 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 457 0.145 15 19 Water 210 0.210 21 9 Coarse agg. 1073 0.400 40 45 Fine agg. 660 0.254 25 28 Total agg. 1733 0.667 65 72 Total 2400 1.006 99 - Paste volume - 0.355 - - % PV - 35.5 - - Mortar volume - 0.609 - - % MV - 61 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.46 0.30 - 0.60 Coarse agg. / Total agg. (%) 62 60 - 75% Fine agg. / Total agg. (%) 38 30- 45% Total agg. / Cement 3.8 2-5 Density (kg/m3 ) 2400 2200-2500 B) RA 1-Characteristic strength at 28 days 40 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS = not specified) M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 53 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Crushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 Target mean strength (fm) = 53 N/mm2 (Table 2) w/c 0.46 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.46
  • 9. 7-Free-water content (W) Use Table 3 Slump 30-60 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Crushed Wf = 210 kg/m3 Wc = 210 kg/m3 W =2/3Wf + 1/3Wc = 210 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 210 kg/m3 8-Cement content w/c ratio 0.46 (Fig. 4) Free-water content 210 kg/m3 8.1-Cement content 457 kg/m3 Say 457 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 457 kg/m3 Modified free-water to cement content 0.46 9-Concrete density Relative density of aggregate (SSD) = 2.55 (Known ) Free-water content = 210 kg/m3 Wet concrete density of the mix = 2350 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1683 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 42 Modified free-water content to cement ratio 0.46 Proportion of fine aggregate (%) 38 (Graph 6) TAC = 1683 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 589.05 kg/m3 Say FAC= 590 kg/m3 Coarse aggregate content = TAC - FAC = 1073 kg/m3 13-Summary of quantities for 1 m3 (SSD) Cement = 457 kg/m3 Water = 210 kg/m3 Fine aggregate = 590 kg/m3 Coarse aggregate = 1093 kg/m3 Wet density = 2350 kg/m3
  • 10. 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.8 kg Water = 1.7 kg Fine aggregate = 4.9 kg Coarse aggregate = 9.1 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.5 2.6 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 457 0.145 15 19 Water 210 0.210 21 9 Coarse agg. 1093 0.440 44 47 Fine agg. 590 0.227 23 25 Total agg. 1683 0.647 66 72 Total 2350 1.019 100 - Paste volume - 0.355 - - % PV - 35.5 - - Mortar volume - 0.582 - - % MV - 58 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.46 0.30 - 0.60 Coarse agg. / Total agg. (%) 65 60 - 75% Fine agg. / Total agg. (%) 35 30- 45% Total agg. / Cement 3.7 2-5 Density (kg/m3 ) 2350 2200-2500
  • 11. Chapter 5: mix design calculation sheet for 50 N/mm2 concrete mix (28 day strength) A) NA 1-Characteristic strength at 28 days 50 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS = not specified) M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 63 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Crushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 63 N/mm2 w/c 0.4 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.4 7-Free-water content (W) Use Table 3 Slump 10-30 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Unrushed Wf = 160 kg/m3 Wc = 190 kg/m3 W = 2/3Wf + 1/3Wc = 170 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 170 kg/m3 8-Cement content w/c ratio 0.4 (Fig. 4) Free-water content 170 kg/m3 8.1-Cement content 425 kg/m3 Say 425 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 425 kg/m3
  • 12. Modified free-water to cement content 0.40 9-Concrete density Relative density of aggregate (SSD) = 2.65 (Known ) Free-water content = 170 kg/m3 Wet concrete density of the mix = 2430 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1835 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 53 Modified free-water content to cement ratio 0.40 Proportion of fine aggregate (%) 30 (Graph 6) TAC = 1835 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 550.5 kg/m3 Say FAC= 550 kg/m3 Coarse aggregate content = TAC - FAC = 1285 kg/m3 13-Summary of quantities for 1m3 (SSD) Cement = 425 kg/m3 Water = 170 kg/m3 Fine aggregate = 550 kg/m3 Coarse aggregate = 1285 kg/m3 Wet density = 2430 kg/m3 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.5 kg Water = 1.4 kg Fine aggregate = 4.6 kg Coarse aggregate = 10.7 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.7 2.6
  • 13. 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 425 0.135 13 17 Water 170 0.170 17 7 Coarse agg. 1285 0.480 48 53 Fine agg. 550 0.212 21 23 Total agg. 1835 0.706 69 76 Total 2430 0.992 97 - Paste volume - 0.305 - - % PV - 30.5 - - Mortar volume - 0.516 - - % MV - 52 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.4 0.30 - 0.60 Coarse agg. / Total agg.(%) 70 60 - 75% Fine agg. / Total agg. (%) 30 30- 45% Total agg. / Cement 4.3 2-5 Density (kg/m3 ) 2430 2200-2500 A) RA 1-Characteristic strength at 28 days 50 N/mm2 2-Margin strength (M) M-specified NS N/mm2 [NS= not specified] M-calculated = 1.64  S S = Standard Deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 63 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Crushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 63 N/mm2 w/c 0.4 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.4 7-Free-water content (W)
  • 14. Use Table 3 Slump 10-30 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Unrushed Wf = 160 kg/m3 Wc = 190 kg/m3 W = 2/3Wf + 1/3Wc = 170 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 170 kg/m3 8-Cement content w/c ratio 0.4 (Fig. 4) Free-water content 170 kg/m3 8.1-Cement content 425 kg/m3 Say 425 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 425 kg/m3 Modified free-water to cement content 0.40 9-Concrete density Relative density of aggregate (SSD) = 2.55 (Known ) Free-water content = 170 kg/m3 Wet concrete density of the mix = 2365 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1770 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 53 Modified free-water content to cement ratio 0.40 Proportion of fine aggregate (%) 30 (Graph 6) TAC = 1770 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 531 kg/m3 Say FAC= 530 kg/m3 Coarse aggregate content = TAC - FAC = 1240 kg/m3 13-Summary of quantities for 1m3 (SSD) Cement = 425 kg/m3 Water = 170 kg/m3 Fine aggregate = 530 kg/m3 Coarse aggregate = 1240 kg/m3 Wet density = 2365 kg/m3
  • 15. 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.5 kg Water = 1.4 kg Fine aggregate = 4.4 kg Coarse aggregate = 10.3 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.5 2.6 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 425 0.135 13 18 Water 170 0.170 17 7 Coarse agg. 1240 0.500 50 52 Fine agg. 530 0.204 20 22 Total agg. 1770 0.681 70 75 Total 2365 1.005 98 - Paste volume - 0.305 - - % PV - 30.5 - - Mortar volume - 0.509 - - % MV - 51 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.4 0.30 - 0.60 Coarse agg. / Total agg. (%) 70 60 - 75% Fine agg. / Total agg. (%) 30 30- 45% Total agg. / Cement 4.2 2-5 Density (kg/m3 ) 2365 2200-2500
  • 16. Chapter 5: mix design calculation sheet for 60 N/mm2 concrete mix (28 day strength) A) NA 1-Characteristic strength at 28 days 60 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS = not specified) M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 73 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Crushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 73 N/mm2 w/c 0.33 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.33 7-Free-water content (W) Use Table 3 Slump 30-60 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Unrushed Wf = 210 kg/m3 Wc = 210 kg/m3 W = 2/3Wf + 1/3Wc = 210 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 210 kg/m3 8-Cement content w/c ratio 0.4 (Fig. 4) Free-water content 210 kg/m3 8.1-Cement content 636 kg/m3 Say 636 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 636 kg/m3
  • 17. Modified free-water to cement content 0.33 9- Concrete density Relative density of aggregate (SSD) = 2.65 (Known ) Free-water content = 210 kg/m3 Wet concrete density of the mix = 2400 kg/m3 (Graph 5) 10-Total aggregate content, TAC (Coarse and fine aggregate) TAC = Wet density - Free-water content -Cement content TAC = 1554 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 50 Modified free-water content to cement ratio 0.33 Proportion of fine aggregate (%) 31 (Graph 6) TAC = 1554 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 481.74 kg/m3 Say FAC= 480 kg/m3 Coarse aggregate content = TAC - FAC = 1074 kg/m3 13-Summary of quantities for 1 m3 (SSD) Cement = 636 kg/m3 Water = 210 kg/m3 Fine aggregate = 480 kg/m3 Coarse aggregate = 1074 kg/m3 Wet density = 2400 kg/m3 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 5.3 kg Water = 1.7 kg Fine aggregate = 4.0 kg Coarse aggregate = 8.9 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.7 2.6
  • 18. 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 636 0.202 20 27 Water 210 0.210 21 9 Coarse agg. 1074 0.400 40 45 Fine agg. 480 0.185 18 20 Total agg. 1554 0.598 58 65 Total 2400 0.994 97 - Paste volume - 0.412 - - % PV - 41.2 - - Mortar volume - 0.597 - - % MV - 60 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.33 0.30 - 0.60 Coarse agg. / Total agg.(%) 69 60 - 75% Fine agg. / Total agg. (%) 31 30- 45% Total agg. / Cement 2.4 2-5 Density (kg/m3 ) 2400 2200-2500 A) RA 1-Characteristic strength at 28 days 60 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS = not specified) M-calculated = 1.64  S S = Standard Deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 73 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Crushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 73 N/mm2 w/c 0.33 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.33
  • 19. 7-Free-water content (W) Use Table 3 Slump 30-60 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Unrushed Wf = 210 kg/m3 Wc = 210 kg/m3 W = 2/3Wf + 1/3Wc = 210 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 210 kg/m3 8-Cement content w/c ratio 0.4 (Fig. 4) Free-water content 210 kg/m3 8.1-Cement content 636 kg/m3 Say 636 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 636 kg/m3 Modified free-water to cement content 0.33 9-Concrete density Relative density of aggregate (SSD) = 2.55 (Known ) Free-water content = 210 kg/m3 Wet concrete density of the mix = 2350 kg/m3 (Graph 5) 10-Total aggregate content, TAC (Coarse and fine aggregate) TAC = Wet density - Free-water content -Cement content TAC = 1504 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 50 Modified free-water content to cement ratio 0.33 Proportion of fine aggregate (%) 31% (Graph 6) TAC = 1504 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 466.24 kg/m3 Say FAC= 465 kg/m3 Coarse aggregate content = TAC - FAC = 1039 kg/m3 13-Summary of quantities for 1 m3 (SSD) Cement = 636 kg/m3 Water = 210 kg/m3 Fine aggregate = 465 kg/m3 Coarse aggregate = 1039 kg/m3 Wet density = 2350 kg/m3
  • 20. 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 5.3 kg Water = 1.7 kg Fine aggregate = 3.9 kg Coarse aggregate = 8.6 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.5 2.6 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 636 0.202 20 27 Water 210 0.210 21 9 Coarse agg. 1039 0.420 42 44 Fine agg. 465 0.179 18 20 Total agg. 1504 0.578 59 64 Total 2350 1.006 99 - Paste volume - 0.412 - - % PV - 41.2 - - Mortar volume - 0.591 - - % MV - 59 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.33 0.30 - 0.60 Coarse agg. / Total agg. (%) 69 60 - 75% Fine agg. / Total agg. (%) 31 30- 45% Total agg. / Cement 2.4 2-5 Density (kg/m3 ) 2350 2200-2500
  • 21. Chapter 6: mix design calculation sheet for 40 N/mm2 concrete mix (28 day strength) A) NA 1-Characteristic strength at 28 days 40 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS = not specified) M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm ) fm = 53 N/mm2 (fcu + M) 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Uncrushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 53 N/mm2 w/c 0.4 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.4 7-Free-water content (W) Use Table 3 Slump 30-60 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Unrushed Wf = 180 kg/m3 Wc = 210 kg/m3 W =2/3Wf + 1/3Wc = 190 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 190 kg/m3 8-Cement content w/c ratio 0.4 (Fig. 4) Free-water content 190 kg/m3 8.1-Cement content 475 kg/m3 Say 475 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 475 kg/m3
  • 22. Modified free-water to cement content 0.4 9-Concrete density Relative density of aggregate (SSD) = 2.65 (Known ) Free-water content = 190 kg/m3 Wet concrete density of the mix = 2400 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1735 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 20 Percentage of fine aggregate passing 600 µm sieve (%) 54 Modified free-water content to cement ratio 0.4 Proportion of fine aggregate (%) 35 (Graph 6) TAC = 1735 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 607.25 kg/m3 Say FAC= 610 kg/m3 Coarse aggregate content = TAC - FAC = 1125 kg/m3 13-Summary of quantities for 1 m3 (SSD) Cement = 475 kg/m3 Water = 190 kg/m3 Fine aggregate = 610 kg/m3 Coarse aggregate = 1125 kg/m3 Wet density = 2400 kg/m3 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.9 kg Water = 1.6 kg Fine aggregate = 5.1 kg Coarse aggregate = 9.3 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.7 2.6
  • 23. 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 475 0.151 15 19 Water 190 0.190 19 9 Coarse agg. 1125 0.420 42 43 Fine agg. 610 0.235 23 30 Total agg. 1735 0.667 65 72 Total 2400 0.992 97 - Paste volume - 0.341 - - % PV - 34.1 - - Mortar volume - 0.575 - - % MV - 58 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.4 0.30 - 0.60 Coarse agg. / Total agg. (%) 65 60 - 75% Fine agg. / Total agg. (%) 35 30- 45% Total agg. / Cement 3.7 2-5 Density (kg/m3 ) 2400 2200-2500 B) RA 1-Characteristic strength at 28 days 40 N/mm2 2-Margin strength (M) M-specified NS N/mm2 [NS = not specified] M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm ) fm = 53 N/mm2 (fcu + M) 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Uncrushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 53 N/mm2 w/c 0.4 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.4
  • 24. 7-Free-water content (W) Use Table 3 Slump 30-60 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Unrushed Wf = 180 kg/m3 Wc = 210 kg/m3 W =2/3Wf + 1/3Wc = 190 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 190 kg/m3 8-Cement content w/c ratio 0.4 (Fig. 4) Free-water content 190 kg/m3 8.1-Cement content 475 kg/m3 Say 475 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 475 kg/m3 Modified free-water to cement content 0.4 9-Concrete density Relative density of aggregate (SSD) = 2.55 (Known ) Free-water content = 190 kg/m3 Wet concrete density of the mix = 2325 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1660 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 54 Modified free-water content to cement ratio 0.4 Proportion of fine aggregate (%) 35 (Graph 6) TAC = 1660 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 581 kg/m3 Say FAC= 580 kg/m3 Coarse aggregate content = TAC - FAC = 1080 kg/m3 13-Summary of quantities for 1m3 (SSD) Cement = 475 kg/m3 Water = 190 kg/m3 Fine aggregate = 580 kg/m3 Coarse aggregate = 1080 kg/m3 Wet density = 2325 kg/m3
  • 25. 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.9 kg Water = 1.6 kg Fine aggregate = 4.8 kg Coarse aggregate = 9.0 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.5 2.6 14.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 475 0.151 15 20 Water 190 0.190 19 8 Coarse agg. 1080 0.430 43 46 Fine agg. 580 0.223 22 25 Total agg. 1660 0.638 66 71 Total 2325 0.996 98 - Paste volume - 0.341 - - % PV - 34.1 - - Mortar volume - 0.564 - - % MV - 56 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.4 0.30 - 0.60 Coarse agg. / Total agg. (%) 65 60 - 75% Fine agg. / Total agg. (%) 35 30- 45% Total agg. / Cement 3.5 2-5 Density (kg/m3 ) 2325 2200-2500
  • 26. Chapter 7: mix design calculation sheet for standard 50 N/mm2 (28 day strength) concrete mix (0% PFA) A) NA 1-Characteristic strength at 28 days 50 N/mm2 2-Margin strength (M) M-specified NS N/mm2 (NS = not specified) M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm ) (fcu + M) fm = 63 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Uncrushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 63 N/mm2 w/c 0.4 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.4 7-Free-water content (W) Use Table 3 Slump 10-30 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Unrushed Wf = 160 kg/m3 Wc = 190 kg/m3 W = 2/3Wf + 1/3Wc = 170 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 170 kg/m3 8-Cement content w/c ratio 0.4 (Fig. 4) Free-water content 170 kg/m3 8.1-Cement content 425 kg/m3 Say 425 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 425 kg/m3
  • 27. Modified free-water to cement content 0.40 9-Concrete density Relative density of aggregate (SSD) = 2.65 (Known ) Free-water content = 170 kg/m3 Wet concrete density of the mix = 2420 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1825 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 20 Percentage of fine aggregate passing 600 µm sieve (%) 53 Modified Free-water content to cement ratio 0.40 Proportion of fine aggregate (%) 30 (Graph 6) TAC = 1825 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 547.5 kg/m3 Say FAC= 545 kg/m3 Coarse aggregate content = TAC - FAC = 1280 kg/m3 13-Summary of quantities for 1 m3 (SSD) Cement = 425 kg/m3 Water = 170 kg/m3 Fine aggregate = 545 kg/m3 Coarse aggregate = 1280 kg/m3 Wet density = 2420 kg/m3 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.5 kg Water = 1.4 kg Fine aggregate = 4.5 kg Coarse aggregate = 10.6 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.7 2.6
  • 28. 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 425 0.135 13 18 Water 170 0.170 17 7 Coarse agg. 1280 0.470 47 53 Fine agg. 545 0.210 21 23 Total agg. 1825 0.702 68 75 Total 2420 0.989 97 - Paste volume - 0.305 - - % PV - 30.5 - - Mortar volume - 0.515 - - % MV - 51 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.4 0.30 - 0.60 Coarse agg. / Total agg. (%) 70 60 - 75% Fine agg. / Total agg.(%) 30 30- 45% Total agg. / Cement 4.3 2-5 Density (kg/m3 ) 2420 2200-2500 A) RA 1-Characteristic strength at 28 days 50 N/mm2 2-Margin strength (M) M-specified NS N/mm2 [NS = not specified] M-calculated = 1.64  S S = Standard deviation = 8 N/mm2 M-calculated 1.64  8 (Fig. 3) M = 13 N/mm2 3-Target mean strength (fm) (fcu + M) fm = 63 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Uncrushed (Crushed or Uncrushed) 6-Free-water cement ratio (w/c) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength (fcu) = 49 N/mm2 (Table 2) Target mean strength (fm) = 63 N/mm2 w/c 0.4 (Graph 4) w/c NS (Use the lower value as w/c) w/c = 0.4
  • 29. 7-Free-water content (W) Use Table 3 Slump 10-30 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed Type of fine aggregate Unrushed Wf = 160 kg/m3 Wc = 190 kg/m3 W = 2/3Wf + 1/3Wc = 170 kg/m3 [When coarse and fine aggregates are of different types] [When coarse and fine aggregates are of the same type - use values in Table 3] Free-water content W = 170 kg/m3 8-Cement content w/c ratio 0.4 (Fig. 4) Free-water content 170 kg/m3 8.1-Cement content 425 kg/m3 Say 425 kg/m3 8.2-Maximum specified cement content NS 8.3-Minimum specified cement content NS ( Use 8.1 if 8.1 ≤ 8.2, or use 8.3 if 8.3 > 8.1, use 8.2 if 8.2 < 8.1 ) Cement content 425 kg/m3 Modified free-water to cement content 0.40 9-Concrete density Relative density of aggregate (SSD) = 2.55 (Known ) Free-water content = 170 kg/m3 Wet concrete density of the mix = 2360 kg/m3 10-Total aggregate content, TAC (Coarse and fine aggregate) (Graph 5) TAC = Wet density - Free-water content -Cement content TAC = 1765 kg/m3 11-Proportion of fine and coarse aggregate (Graph 6) Maximum aggregate size (mm) 20 Percentage of fine aggregate passing 600 µm sieve (%) 53 Modified free-water content to cement ratio 0.40 Proportion of fine aggregate (%) 30 (Graph 6) TAC = 1765 kg/m3 Fine aggregate content = FAC = % Fine aggregate  TAC = 529.5 kg/m3 Say FAC= 530 kg/m3 Coarse aggregate content = TAC - FAC = 1235 kg/m3 13-Summary of quantities for one cubic meter (SSD) Cement = 425 kg/m3 Water = 170 kg/m3 Fine aggregate = 530 kg/m3 Coarse aggregate = 1235 kg/m3 Wet density = 2360 kg/m3
  • 30. 14-Proportion of gradients per trial mix (SSD) of : 0.0083m3 (For small mixer) Cement = 3.5 kg Water = 1.4 kg Fine aggregate = 4.4 kg Coarse aggregate = 10.3 kg This trial will make about 20 kg of concrete; enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. RD 3.15 1 2.5 2.6 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) % by Vol. % by mass Cement 425 0.135 13 18 Water 170 0.170 17 7 Coarse agg. 1235 0.460 46 52 Fine agg. 530 0.204 20 22 Total agg. 1765 0.679 66 75 Total 2360 0.966 99 - Paste volume - 0.305 - - % PV - 30.5 - - Mortar volume - 0.509 - - % MV - 51 - - (RD = Relative Density, PV = Paste Volume, MV = Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range w/c 0.4 0.30 - 0.60 Coarse agg. / Total agg.(%) 70 60 - 75% Fine agg. / Total agg. (%) 30 30- 45% Total agg. / Cement 4.2 2-5 Density (kg/m3 ) 2360 2200-2500
  • 31. Chapter 8: mix design calculation sheet for standard 50 N/mm2 (28 day strength) concrete mix (0% PFA) A) NA 1-Characteristic strength at 28 days = 50 N/mm2 2-Margin strength (M) M-Specified NS N/mm2 (NS= Not Specified) M-calculated = 1.64 x S S = Standard Deviation = 8 N/mm2 M-calculated 1.64 x 8 (Fig. 3) M = 13 N/mm2 3-Target Mean strength fm (fm = fc+M) fm = 63 N/mm2 4-Cement type OPC 5-Aggregate Coarse: Crushed (Crushed or Uncrushed) Fine: Uncrushed (Crushed or Uncrushed) 6-Free-Water cement ratio (W/C) Concrete age 28 days Type of cement OPC Coarse aggregate Crushed Estimated compressive strength fcu 49 N/mm2 Target Mean strength fm = 63 N/mm2 (Table 2) w/c 0.4 (Graph No 4) (Use the lower value as w/c) w/c = 0.4 7-Free-water content W UseTable No 3 Slump 60 to 180 mm Maximum aggregate size 20 mm Type of coarse aggregate Crushed (Crushed or Uncrushed) Type of fine aggregate Unrushed (Crushed or Uncrushed)
  • 32. Wf = 195 kg/m3 Wc = 225 kg/m3 W =2/3Wf +1/3Wc = 205 kg/m3 [When coarse and fine aggregates are of different types] W = Values in Table 3 [When coarse and fine aggregates are of the same types- use values in table 3] Free-water content W = 205 kg/m3 8-Relative density Relative density of aggregate (SSD) = 2.55 (Known) PFA percentage 30 % Amount of water reduced for PFA (Table 9) 20 kg/m3 Free-water content adjusted for PFA = 185 kg/m3 Wet density of the mix = 2340 kg/m3 (Graph 5) 9-Cement and PFA content Cement content = 409.8 kg/m3 Say 410 kg/m3 RGD content = 176 kg/m3 Say 175 kg/m3 C+RGD = 585 w/b = w/ (C+RGD) = 0.32 10-Total aggregate content ,TAC (Coarse and fine aggregate) TAC = Wet density - Free-water content -Cement content TAC = 1570 kg/m3 11-Proportion of fine and coarse aggregate Graph 6 Maximum aggregate size 20 mm Percentage of fine aggregate passing 600µm sieve 53 % Modified Free-water content to cement ratio 0.32 Proportion of fine aggregate (%) 38 (graph 6) TAC = 1570 kg/m3 Fine aggregate content = FAC = % Fine agg. x TAC = 596.6 kg/m3 Say FAC= 600 kg/m3 Coarse aggregate content = TAC - FAC = 970 kg/m3 13-Summary of quantities for one cubic meter (SSD) Cement = 410 kg/m3 PFA = 175 Water = 185 kg/m3 Fine aggregate = 600 kg/m3
  • 33. Coarse aggregate = 970 kg/m3 14-Proportion of gradients per trial mix (SSD) of 0.0083 (For Small mixer) Cement = 3.4 kg PFA = 1.45 kg Water = 1.5 kg Fine aggregate = 5.0 kg Coarse aggregate = 8.1 kg This trial will make about 20 kg concrete, enough for slump and Vebe tests. 15-Miscellaneous Material Cement Water Coarse agg. Fine agg. PFA RD 3.15 1 2.5 2.6 2.25 15.1-Volumes of the mixture components Material kg/m3 Vol. (m3 ) Vol. (%) % by mass Cement 410 0.130 13 18 PFA 175 0.078 8 7 Water 185 0.19 19 8 Coarse agg. 970 0.39 39 41 Fine agg. 600 0.231 23 26 Total agg. 1570 0.604 62 67 Total 2340 1.012 99 - Paste volume - 0.393 - - % PV - 39 - - Mortar volume - 0.624 - - % MV - 62 - - Mortar 1370 ( RD = Relative Density, PV= Paste Volume, MV= Mortar Volume) 15.2-Other important values and ratios Quantity Value Common range Powder content kg/m3 585 400-600 w/b - 0.32 0.28-0.42 % Coarse aggregate content (%) 39 29-35 % (by vol.) PV. (%) 39 30-42 % (by vol.) Fine agg./ Mortar (%) 44 40-52% Density Kg/m3 2340 2200-2500