Mix Design as per ACI 211.

1-91
Dr. Md. Jahangir Alam
Assistant Professor, CE, BUET, Dhaka

• ACI = American Concrete Institute

• ACI 211.1-91 is part of ACI Manual published by American Concrete Institute.
• Standard practice for selecting proportions for normal, heavyweight and mass
concrete is described here.
• Guide for selecting proportions for high-strength concrete is described in ACI
211.4R-93.
• Mean target strength upto 6000 psi (41 MPa) is considered as normal strength
concrete and mean target strength above 6000 psi is considered as high-
strength.
• Smaller size aggregates have been shown to provide higher strength potential.
• Exposure condition of concrete limits the w/c ratio to ensure durability of
concrete in adverse environment.

Table 6.3.4(b) – Maximum permissible water-cement or water-cementitious

material ratios for concrete in severe exposures
Types of structure Structure wet continuously Structures exposed to sea
or frequently and exposed water or sulfates
to freezing and thawing*
Thin sections (railings,
curbs, sills, ledges,
ornamental work) and 0.45 0.40**
Sections with less than 1”
clear cover over steel
All other structures 0.50 0.45**
*Concrete should also be air entrained
**If sulfate resisting cement (Type II or Type V of ASTM C 150) is used, permissible water-cement
ratio may be increased by 0.05

• Slump value of concrete should be selected based on scope of compaction

during casting, for example, to make flowing concrete slump should be in the
range of 100 – 150 mm, concrete for cast in situ piles should have slump value
in the range of 150-175 mm. In addition, ACI recommended slump values are
given below.

Table 6.3.1 – Recommended slumps for various types of construction

Types of construction Slump, in.
Maximum Minimum
Reinforced foundation walls 3 1
and footings
Plain footings, caissons and 3 1
substructure walls
Beams and reinforced walls 4 1
Building columns 4 1
Pavements and slabs 3 1
Mass concrete 2 1

Updated in July 2009

 • Concrete mix proportion should be such that compressive strength of most of
the concretes would be more than design strength of the structure. To achieve
this, a safety margin is added to design strength to get target mean strength of
concrete mix. Detail description of this is available in ACI 318 – 02. The
simplest one is to use the following table to calculate mean target strength or
required average compressive strength.

Mix Design Example

• ACI method
• Composite cement
• Ready mixed concrete will be cast by pumping
• Admixture (Super Plasticizer) will be used to make flowing concrete
• Concrete will remain under sea water (i.e. offshore structure)
• Design strength of concrete is 35 MPa
• All necessary data are given in the following tables

Table 1: Properties of fine aggregate

Sl.
No. Property Test Method Value Unit
1 Bulk Specific Gravity (OD basis) ASTM C127 2.54 -
2 Apparent Specific Gravity (OD basis) ASTM C127 2.60 -
3 Absorption Capacity ASTM C127 1.34 %
4 Dry Rodded Unit Weight ASTM C29 1590 kg/m3
5 Moisture Content of FA in Laboratory - 4.00 %
6 Fineness Modulus (FM) ASTM C136 2.62

Updated in July 2009

Table 2: Properties of coarse aggregate
Sl.
No. Property Test Method Value Unit
1 Bulk Specific Gravity (OD basis) ASTM C127 2.66 -
2 Apparent Specific Gravity (OD basis) ASTM C127 2.68 -
3 Absorption Capacity ASTM C127 0.69 %
4 Dry Rodded Unit Weight ASTM C29 1550 kg/m3
5 Moisture Content of CA in Laboratory - 0.38 %
6 Maximum Size - 20 mm

Table 3: Properties of cement

Sl.
No. Property Test Method Value Unit
Supercrete
1 Brand name (composite) -
2 Clinker 80 %
3 Fly ash 20 %
4 Compacted Unit Weight 1400 kg/m3
5 Loose Unit Weight - 1100 kg/m3
6 Specific gravity of clinker 3.15
7 Specific gravity of fly ash 2.40

Table 4: Properties of water reducing admixture

Sl. Test
No. Property Method Value Unit
1 Brand name Megaflow230 -
500-1500 ml per 100
2 Recommended dose kg cement
3 Expected water reduction 15-20 %
4 Specific gravity 1.2 -

Table 5: ACI recommended w/c ratio for normal strength concrete

Mean target strength
psi MPa w/c ratio
6000 41 0.41
5000 34 0.48
4000 28 0.57
3000 21 0.68
2000 14 0.82

Updated in July 2009

Table 6: ACI recommended dry rodded bulk volume of coarse aggregate per unit
volume of concrete
max size
of agg FM of fine aggregate
mm 2.40 2.60 2.80 3.00
9.5 0.50 0.48 0.46 0.44
12.5 0.59 0.57 0.55 0.53
19 0.66 0.64 0.62 0.60
25 0.71 0.69 0.67 0.65
37.5 0.75 0.73 0.71 0.69
50 0.78 0.76 0.74 0.72
75 0.82 0.80 0.78 0.76
150 0.87 0.85 0.83 0.81

Table 7: First estimate of density of fresh concrete

nominal
max Density of fresh concrete
size (kg/m3)
9.5 2280
12.5 2310
19 2345
25 2380
37.5 2410
50 2445
75 2490
150 2530

Table 8: ACI recommended mixing water content for 1 m3 fresh concrete

Max size of
aggregate (mm) 10 12.5 20 25 40 50 70 150
Slump value (mm) Amount of mixing water in kg per 1 m3 concrete
25 to 50 207 199 190 179 166 154 130 113
75 to 100 228 216 205 193 181 169 145 124
150 to 175 243 228 216 202 190 178 160 -
Entrapped air (%) 3 2.5 2 1.5 1 0.5 0.3 0.2

Table 9: Properties of aggregates in site

Sl.
No. Property Test Method Value Unit
1 Moisture content of fine aggregate 5.0 %
2 Moisture content of coarse aggregate 1.0 %
3 Loose Unit Weight of fine aggregate 1280 kg/m3
4 Loose Unit Weight of coarse aggregate 1330 kg/m3
5 Loose Unit Weight of Cement 1100 kg/m3

Table 10: First trial mix result

0.3 kg more water was added than

Water added calculated for first trial mix
Slump measured 100 mm
Measured density
of fresh concrete 2390 kg/m3

Updated in July 2009

Step 1: Selection of slump value

To make flowing concrete, slump = 100 – 150 mm

Step 2: Selection of maximum size of coarse aggregate

(a) Nominal maximum size of coarse aggregate should be the largest

possible which is economically available.

(b) Maximum size of coarse aggregate should be less than

• One-fifth of the narrowest dimension of the structure
• One-third of the depth of slab
• Three-fourth of minimum clear spacing between bars
• Clear cover

Here, we have no information about size of structure and maximum size

of available aggregate is 20 mm.

So, maximum size of CA = 20 mm

Step 3: Estimation of mixing water content and air content

Usually for concrete structures exposed to severe weathering, air-

entrained concrete is needed. As air-entraining admixture is expensive
and not readily available in Bangladesh, non air-entrained concrete will be
used.

Using Table 8, for slump = 100 – 150 mm and maximum size of CA = 20 mm,
205 + 216
Mixing water = = 210.5 kg per 1 m3 fresh concrete
2
Entrapped air content = 2 % (Table 8)

Super plasticizer Megaflow230 will be used to increase workability.

Megaflow230 can reduce mixing water content upto 20% depending on its
dose.

If we use the dose of Megaflow230 = 1000 ml per 100 kg cement and

assume that it would reduce water content by 15%,

So, Mixing water = 210.5 x 0.85 = 179 kg per 1 m3 fresh concrete

Updated in July 2009

Step 4: Selection of w/c ratio

(a) Considering durability of concrete which is exposed to sea water,

maximum permissible w/c ratio is 0.45 (see Table 6.3.4(b) of ACI 211.1-
91)

w
So, ≤ 0.45
c

(b) Considering strength of concrete

Design compressive strength = 35.0 MPa
Safety margin = 8.5 MPa
Target Mean Strength = 43.5 MPa

For 41 MPa w/c ratio = 0.41

For 34 MPa w/c ratio = 0.48
For 7 MPa difference in strength, diff in w/c ratio = 0.07

For (43.5-41.0 = ) 2.5 MPa diff in strength, diff in w/c ratio =

⎛ 0.07 ⎞
⎜ ⎟.(2.5) = 0.025
⎝ 7 ⎠

So, for 43.5 MPa, w/c ratio = 0.41 – 0.025 = 0.385 = 0.38

w
i.e. ≤ 0.38 (governs)
c

or to avoid interpolation or extrapolation, we can use following formula to

get w/c ratio
w
= 1.1734e − 0.0259 f c '
c

Step 5: Calculation of cement content and admixture

w 179
Cementitious material or binder = = = 471 kg
w 0.38
c
Where, clinker = 465 x 0.8 = 377 kg
Fly ash = 465 x 0.2 = 94 kg

Updated in July 2009

Dose of admixture depends on the requirement of workability and past
experience of using the same admixture.

Here, let us use 700 ml Megaflow230 per 100 kg cement

700
So, amount of admixture = (471) ml per 1 m3 concrete
100
= 3297 ml = 3297 cm3 = 3297(1.2) gm
= 3956 gm = 3.956 kg

Admixture is generally water based solution. Amount of mixing water will

be changed
Mixing water = 179 – 4 = 175 kg

Step 6: Estimation of coarse aggregate content

Using Table 6,
Dry rodded bulk volume of CA = 0.64 m3 per 1 m3 concrete
Dry mass of CA = 0.64 x 1550 kg
= 992 kg per 1 m3 concrete

⎛ 0.69 ⎞
SSD mass of CA = 992⎜1 + ⎟
⎝ 100 ⎠
= 999 kg

Step 7: Calculation of fine aggregate content

Fine aggregate content can be calculated using mass method or volume

method.

(a) Mass method

Using Table 7, approximate density of fresh concrete = 2345 kg/m3

So SSD mass of FA = 2345 – W – C – CA(SSD) - Adm
= 2345 – 175 – 471 – 999 - 4
= 696 kg
= 696 kg
696
OD mass of FA = = 687 kg
1 + 1.34
100

Updated in July 2009

(b) Volume method

Total volume of concrete is 1 m3 which must be equal to sum of solid

volumes of all ingredients.

W C FlyAsh FA(OD ) CA(OD ) Adm A

+ + + + + + (1) = 1
1000 (3.15)1000 (2.40)1000 ( BSGFA− OD )1000 ( BSGCA− OD )1000 ( SG )1000 100

175 377 94 FA( OD ) 992 3.956 2

+ + + + + + (1) = 1
1000 (3.15)1000 (2.40)1000 (2.54)1000 (2.66)1000 (1.2)1000 100

FA (OD) = 686 kg
⎛ 1.34 ⎞
FA (SSD) = 686⎜1 + ⎟ =695 kg
⎝ 100 ⎠

Volume method does not require assumption of density of fresh concrete,

so it is more rational than mass method

So, FA (OD) = 686 kg

FA (SSD) = 695 kg

Basic mix design is complete here.

Mix proportion for 1 m3 fresh concrete

Water = 175 kg
Cement = 471 kg
FA (SSD) = 695 kg
CA (SSD) = 999 kg
Megaflow230 = 3.956 kg
Total = 2344 kg

Step 8: Adjustment and First Lab Trial Mix

⎛ 4.0 − 1.34 ⎞
Surface moisture or free moisture in FA = 686⎜ ⎟ = 18.2 kg
⎝ 100 ⎠
⎛ 0.38 − 0.69 ⎞
Surface moisture or free moisture in CA = 992⎜ ⎟ = −3.1 kg
⎝ 100 ⎠

Adjusted mixing water = 175 – 18.2 – ( - 3.1) = 159.9 kg = 160 kg

Updated in July 2009

Adjusted FA = 695 + 18.2 = 713.2 kg = 713 kg
Adjusted CA = 999 – 3.1 = 995.9 kg = 996 kg

Mix proportion for 1 m3 fresh concrete

SSD mass (kg) Adjusted wet mass (kg)
Water 175 160
Cement 471 471
Fine Aggregate 695 713
Coarse Aggregate 999 996
Megaflow230 3.956 3.956
Total 2344 2344

Using first lab trial mix, we have to measure density of fresh concrete
and slump value. In the laboratory we have cylindrical mold of diameter 6”
and 4”. We shall use three cylindrical mold of diameter 6” and height 12”.
⎛π ⎞
Volume of 3 cylinders = 3⎜ (0.150) 2 (0.300) ⎟ = 0.0159 m3
⎝4 ⎠
Consider 25% loss during handling,
So, volume of fresh concrete needed for first lab trial mix
= 1.25*0.0159 = 0.0199 m3 = 0.02 m3

Mix proportion for 0.02 m3 fresh concrete

Adjusted wet mass (kg) Adjusted wet mass (kg)
Water 160 x 0.02 = 3.20
Cement 471 x 0.02 = 9.42
Fine Aggregate 713 x 0.02 = 14.26
Coarse Aggregate 996 x 0.02 = 19.92
Megaflow230 3.956 x 0.02 = 0.079

All the ingredients as calculated above are mixed in mixer machine. From
visual observation it seems that more water is necessary to get required
slump. 0.3 kg more water is added and concrete is mixed again. Freshly
mixed concrete is taken out of mixer machine and slump test is
performed.

Slump value = 100 mm found from slump test.

To measure density of fresh concrete, 3 empty cylinders are weighed,

filled with concrete, compacted, leveled and cleaned outside of mold.
Then filled up molds are weighed. Density of concrete is calculated as
follows.

Updated in July 2009

 weight of average
weight of cylinder + weight of diameter height volume density density
cylinder concrete concrete (mm) (mm) mold (m3) (kg/m3) (kg/m3)
Cylinder1 11.00 24.50 13.50 155 305 0.005755 2345.7
Cylinder2 10.99 24.67 13.68 153 305 0.005608 2439.6 2390
Cylinder3 10.88 24.60 13.72 155 305 0.005755 2384.0

Measured density of fresh concrete = 2390 kg/m3

Mass of water added = 3.20 + 0.30 = 3.50 kg

Mass of ingredients mixed

= 3.50 + 9.42 + 14.26 + 19.92 + 0.079
= 47.179 kg
47.179
So, yield of trial mix = = 0.01974 m3
2390

Surface moisture in 14.26 kg FA = ?

14.26
OD mass of FA = = 13.71 kg,
1+ 4
100
⎛ 4 − 1.34 ⎞
Surface moisture in FA = 13.71⎜ ⎟ = 0.365 kg
⎝ 100 ⎠

Surface moisture in 19.92 kg CA = ?

19.92
OD mass of CA = = 19.845 kg
1 + 0.38
100
⎛ 0.38 − 0.69 ⎞
Surface moisture in CA = 19.845⎜ ⎟ = 0.062 kg
⎝ 100 ⎠

So, mixing water in first lab trial mix = 3.50 +0.365 – 0.062 + 0.079
= 3.882 kg for 0.0197 m3 concrete
For 0.0197 m3 concrete, mixing water = 3.882 kg
3.882
For 1 m3 concrete, mixing water = = 197 kg
0.01974

Step 9: Revision of mix proportion based on First Lab Trial Mix result

ACI suggests that if the slump of the trial mix does not satisfy the
requirement, increase or decrease the re-estimated water content by 2
kg/m3 for each increase or decrease of 10 mm slump.

Slump required = (100+150)/2 = 125 mm

Slump found = = 100 mm
Slump to be increased = 25 mm

Updated in July 2009

 ⎛2⎞
Water to be increased = ⎜ ⎟25 = 5 kg
⎝ 10 ⎠
So, modified mixing water = 197 + 5 = 202 kg

To get target mean strength or same durability, we have to keep the w/c
ratio constant as calculated in step 4,

202
So, modified cement content = = 532 kg
0.38
19.92
CA (wet) for 1 m3 concrete = = 1009 kg
0.01974
1009
CA (OD) for 1 m3 concrete = = 1005 kg
1 + 0.38
100
⎛ 0.69 ⎞
CA (SSD) for 1 m3 concrete = 1005⎜1 + ⎟ = 1012 kg
⎝ 100 ⎠
Surface water in wet CA = 1009 - 1012 = -3 kg

FA (SSD) = 2390 – 202 – 532 – 1012 = 652.48 = 644 kg

644
FA (OD) = = 635 kg
1 + 1.34
100
⎛ 4 ⎞
FA (wet) = 635⎜1 + ⎟ = 660 kg
⎝ 100 ⎠
Surface water in wet FA = 660 - 644 = 16 kg

Mixing water = 202 – 4 = 198

Mixing water in adjusted wet masses = 198 – 16 + 3 = 185

Modified mix proportion for 1 m3 fresh concrete after first lab trial
SSD mass (kg) Adjusted wet mass (kg)
Water 198 185
Cement 532 532
Fine Aggregate 644 660
Coarse Aggregate 1012 1009
Megaflow230 3.956 3.956
Total 2390 2390

Updated in July 2009

Step 10: Final trial mix to confirm strength and slump

We need 9 cylinders to cast. If we use 4” diameter and 8” height cylinder,

⎛π ⎞
Volume of 9 cylinders = 9⎜ (0.100) 2 (0.200) ⎟ = 0.0141 m3
⎝4 ⎠
Consider 25% loss during handling,
Volume of fresh concrete needed for final trial mix
= 1.25*0.0141 = 0.0176 m3
This is very small amount of mix which may lead to significant errors due
to errors in measurement and loss in mixing. For this reason, it is wise to
make at least 0.025 m3 concrete for final trial mix.

Mix proportion for 0.025 m3 fresh concrete

Adjusted wet mass (kg) Adjusted wet mass (kg)
Water 185 x 0.025 = 4.63
Cement 532 x 0.025 = 13.30
Fine Aggregate 660 x 0.025 = 16.50
Coarse Aggregate 1009 x 0.025 = 25.23
Megaflow230 3.956 x 0.025 = 0.099

At first coarse aggregate, fine aggregate and cement are weighed

separately and put into mixer machine. Mixer machine is rotated for 1-2
minutes. Then water and admixture are weighed separately and mixed
together before pouring into mixer machine. Admixture mixed water is
now poured into mixer machine. Mixer machine is rotated for more than 5
minutes to make homogeneous mix of concrete. Freshly mixed concrete is
taken out from mixer machine and slump test is performed. Then half of
9 molds are filled up and compacted. Compaction can be performed using
vibrator, rodding or vibratory table. Rest portion of molds are filled up,
compacted and leveled at top of mold. Next day, concrete cylinders are
taken out from molds and kept submerged into water or lime water for
curing.

Let us name this final trial mix as ASHA-01

Updated in July 2009

Test results of final trial mix:
Date of Casting: 1-Jul-09 Target Mean Stength: 43.5 MPa (C35)
Trial Mix No.: ASHA-01 Brand Name of Cement: Supercrete (Composite)
w/c: 0.38 Name of Admixture: Megaflow230
Fine and Coarse Aggregate: Sylhet sand and Stone chips
COMPRESSIVE STRENGTH OF TRIAL MIX CONCRETE CYLINDERS
3-days strength 7-days strength 28-days strength
Crushing Crushing Crushing Crushing Crushing Crushing
Type of Type of Type of
Sl. No strength strength strength strength strength strength
Failure Failure Failure
(psi) (MPa) (psi) (MPa) (psi) (MPa)

1 3720 25.6 Mortar 5140 35.4 Combined 6700 46.2 Combined

2 3350 23.1 Mortar 4990 34.4 Combined 6780 46.7 Combined

3 3570 24.6 Mortar 5210 35.9 Combined 6550 45.1 Combined

Mean 3550 24.5 - 5100 35.1 - 6700 46.2 -

4-Jul-09 56% 8-Jul-09 81% 29-Jul-09 106%

.
3
Materials requirement for 1 m of fresh concrete:

Water: 198 kg Initial setting time =

Cement: 532 kg - minutes
Fine Aggregate (SSD): 644 kg
Coarse Aggregate (SSD): 1012 kg
Admixture*: 3.96 kg
*( 0.74 % of cement mass)

Slump: 140 mm

Step 11: Adjustment for casting in site

Mix proportion is usually prescribed in SSD condition. Before concrete

mixing in site, moisture content of FA and CA should be determined and
mix proportions should be adjusted accordingly.

From table 9,
Moisture content in FA = 5%
Moisture content in CA = 1%

FA (OD) = 635 kg, CA (OD) = 1005

⎛ 5 − 1.34 ⎞
Surface moisture in FA = 635⎜ ⎟ = 23.2 kg
⎝ 100 ⎠
⎛ 1 − 0.69 ⎞
Surface moisture in CA = 1005⎜ ⎟ = 3.1 kg
⎝ 100 ⎠

Adjusted mixing water = 198 – 23.2 – 3.1 = 171.7 kg = 172 kg

Adjusted FA = 644 + 23.2 = 667 kg
Adjusted CA = 1012 + 3.1 = 1015 kg

Updated in July 2009

Mix proportion for 1 m3 fresh concrete in site
SSD mass (kg) Adjusted wet mass (kg)
Water 198 172
Cement 532 532
Fine Aggregate 644 667
Coarse Aggregate 1012 1015
Megaflow230 3.956 3.956
Total 2390 2390

Step 12: Conversion to volumetric ratio

Volumetric ratio is necessary where mass batching is not possible in site.

Adjusted masses are converted to bulk volume using loose unit weight as
shown below
Moisture Adjusted Loose unit Bulk Ingredients
SSD Mass Volumetric
content wet mass weight volume for 1 bag Unit
(kg) 3 3 ratio
(%) (kg) (kg/m ) (m ) cement
water 198 N/A 172 1000 0.172 0.36 0.57 cft
cement 532 N/A 532 1100 0.484 1.00 1.00 bag
FA (field) 644 5.00 667 1280 0.521 1.08 1.72 cft
CA (field) 1012 1.00 1015 1330 0.763 1.58 2.52 cft
adm 4.0 N/A 4 1200 - - - -

Note that generally

1 bag cement = 50 kg cement mass
= 1.25 cft compacted bulk volume of cement
= 1.60 cft loose bulk volume of cement

However, among practicing engineers in Bangladesh, 50 kg cement = 1.25

cft bulk volume of cement is known and used for calculating volumetric
ratio.

Volumetric ratios like 1:1.5:3 or 1:2:4 have no rational basis which is very
familiar to practicing engineers in Bangladesh. This kind of ratios should
not be used any more.

Updated in July 2009