Concrete Mix

Design
 Mix Design
References
IS 10262 : 2009 – CONCRETE MIX PROPORTIONING-
GUIDELINES (first revision) First published in 1982,
first revision in 2009
IS 456 : 2000 – Plain & reinforced cement concrete- code
of practice (forth revision) Amendments up to 4
CBC:2014– Code of practice for plain,reinforced &
prestressed concrete for general bridge construction
IS 2386 (Part 3) : 1963 – Method of test for aggregates
for concrete : part 3 specific gravity, density,
voids, absorption and bulking.
 Various Methods of Mix design
 Arbitrary proportion
 Fineness modulus method
 Maximum density method
 Surface are method
 Indian Road Congress, IRC 44 method
 High strength concrete mix design
 Mix design based on flexural strength
 Road note No.4 (Grading Curve method)
 ACI Committee 211 method
 DOE method
 Mix design for pumpable concrete
 Indian Standard Recommended method IS 10262:2009
 IS-10262 : 2009 (First Revision)
CONCRETE MIX PROPORTIONING - GUIDELINES

1. This standard applies to ordinary (M-10, 15 and 20) and

standard concrete grades (M-25 to 60) only. And not for
high strength concrete M65 to M100.(As per IS-456-
2000amendments)

2. All requirements of IS 456 is so far as they apply, shall be deemed

to form part of this standard.

3. Considering that the air content in normal concrete (Non air

entrained) is not of much significance in mix proportioning
procedure and it is also not a part of IS 456: 2000, the
consideration of air content has been deleted.

3. A new illustrative example of concrete mix proportioning

using fly ash as one of the ingredients has been added.
 Definition

DESIGN MIX
• It is a process of selecting suitable ingredients
and determining their relative proportions with
the objective of producing concrete of having
certain minimum workability, strength and
durability as economically as possible.
 Objective as per IS-10262 :
2009
The objective of proportioning concrete mixes
is to arrive at the most economical and
practical combinations of different ingredients
to produce concrete that will satisfy the
performance requirements under specified
conditions of use.

The proportioning is carried out to achieve

specified characteristics strength at specified
age, workability of fresh concrete and
durability requirements
 Types Of Mix Design
1. Nominal Mix:
a. Used for relatively unimportant and simpler works.
b. No scope for any deviation by the designer since
ingredients are prescribed and their proportions specified.
c. May be used for M-20 or lower.

Table 9 - IS 456

Kg
 Types Of Mix Design
2. Design Mix:

a. Performance based mix.

b. Choice of ingredients and proportioning are left to
designer.
c. User has to specify requirements of concrete in fresh as
well as in hardened state only.

Fresh concrete - workability & finishing characteristics

Hardened concrete – compressive strength & durability
 Sampling

1. One sample comprising of 3 cubes shall be taken from

each shift.
Quantity of concrete
2. Samples shouldin work
be takenNumber of samples
at random and should be
representative of actual concrete.
1-5 cum 1
6-15 2
16-30 3
31-50 4
51 and above 4 + 1 additional sample for
each additional 50 cum or
part thereof.
 Cube Casting

1. Concrete is filled in mould in 3 equal layers.

2. Each layer is tamped 35 times by bullet headed tamping
rod of 16 mm dia and 600 mm long.
3. Needle vibrator can also be used.
4. Light marking of date and number is done on green
concrete.
5. The cube in mould is covered with damp cloth and
stripped after 16-24 hrs and then submerged in pond till
testing.
 Cube Testing
1. 3 cubes constitute one sample.

2. The test result of the sample shall be the average of the

strength of three specimens.

3. Strength of individual cube should not vary by more than

+ 15% of average strength.

If more, the test results of the sample are invalid.

4. Smooth faces should face top and bottom during testing.

5. The rate of loading should not be more than 14 N/mm2

per minute.
 Importance Of Cube Test
1. It indicates potential strength of the mix.

2. It detects variation in quality control at site.

3. It helps in determining the rate of gain of strength.

4. It helps in determining the time of removal of form work.

 Statistical Interpretation Of Cube Results
• Result of cube test is influenced by number of factors like material,
their proportions, various processes like mixing, compaction,
curing and finally the testing procedure of cubes.

• Even the results of different cubes, cast from the same concrete at
the same time, cured and tested in similar way may also show
different results.

• Therefore for evaluation of the test results, the help of statistical

approach is required.
 Statistical Interpretation Of Cube Results
(Histogram/Normal distribution curve)
 Different Degree of Control
Degree of Control Site Conditions for production of Concrete
Very Good Fresh cement from single source and regular tests, weight
batching of all materials, aggregate supplied in single sizes,
control of aggregate grading and moisture content, control
of water added, frequent supervision, regular workability
and strength tests, and field laboratory facilities.

Good Carefully stored cement and periodic test, weight batching

of all materials, controlled water, graded aggregate
supplied, occasional grading and moisture tests, periodic
check of workability and strength, intermittent supervision
and experienced workers.

Fair Proper storage of cement, volume batching of all aggregates

allowing for bulking of sand, weight batching of cement,
water content controlled by inspection of mix and
occasional supervision and tests.
 Standard deviation (S.D.) :

S.D. (σ ) = ∑ (x- µ)²

n-1

Wherex = Individual cube strength value

n = total no. of cubes
µ = Arithmetic mean of strength
of ‘n’ cubes
S.D. will be less if the quality control at site is better.
 Target Mean Strength
• From the experiments it is found that the area under the ‘Normal
distribution curve’ follows certain behavior such that area covered within
a distance equal to one S.D. on either side from mean will be equal to
34.1% of total area. Similarly 2nd & 3rd S.D. will cover additional area of
13.6% & 2.2% respectively. Approximately 99.9% area will be covered
within distance equal to (3 x S.D) on each side from mean value.

• From this it is clear that if we require the strength equal to mean value,
probability is that only 50% cubes will have strength equal to or more than
the required strength. If we want to increase the % of cubes having
strength equal or more than the required strength, we will have to target
for higher strength.
Target Mean Strength
 Target Mean Strength
• So instead of placing the desired strength at mean value, it is placed on left side
of mean value by a distance equal to k x S.D, where k will depend upon the %
of cubes we want to have strength equal or more than the desired strength.
As per IS 456-2000, this % is 95% and therefore desired strength has to be
placed at 1.65 times S.D. left of mean.
i.e. mean = desired strength + 1.65 x S.D.
f’ck = fck + 1.65 σ
Here, desired strength is called ‘Characteristic strength’(fck)
& mean value is called ‘Target mean trength’(f’ck)
f’ck & fck at 28 days in N/mm², S.D. in N/mm²
The value of 1.65 is based upon the provision that 5% of the test results can be
accepted having lower than the required strength.
Target Mean Strength
 Understanding Of Normal Distribution Curve

 Shows the probability of concentration of test results at

this strength.
 Concentration at mean value depends upon ‘Quality
control’ & S.D.
 If S.D. is less, probability of concentration of test results
will be higher at the mean value.
 Acceptance Criteria (As per IS-456:2000)
• While designing the mix, it should be targeted for
higher strength called ‘Target mean strength’ (f’ck) so
that not more than 5% test results fall below a desired
strength ‘fck’ i.e. characteristics strength (CS).

• Few cube test results may show less strength below CS

value. This is in accordance with the design criteria of
mix and acceptable.

• Therefore manipulation of results shall not be

attempted.
 Acceptance Criteria As per IS-456:2000
(Para 16,table 11)

a. Compressive strength-
Specified Mean of the group of 4 non overlapping Individual test results in
Grade consecutive test results in N/mm2 N/mm2

M-15 ≥ fck + 0.825 x S.D. ≥ fck - 3 N/mm2

or
fck + 3 N/mm2, whichever is greater.

M-20 and ≥ fck +0.825 x S.D. ≥ fck - 3 N/mm2*

above or
fck + 3 N/mm2*, whichever is greater.

b. Flexural strength-
1. The mean determined from any group of 4
consecutive results > fck+ 0.30 N/mm2.
2. The individual strength ≥ fck - 0.30 N/mm2
* Values (≥ fck + 4 N/mm2 & fck -2 N/mm2 ) changed vide amendment no.4
May 2013 to IS 456.
 Acceptance Criteria (As per CBC)
1. Compressive strength-
(For M-20 above grade only)

a. The mean of 4 consecutive test results should exceed

fck by 3 N/mm2 i.e. fck+3 N/mm2 and

b. Any individual test result ≥ fck – 3 N/mm2.

2. Flexural strength-

1. The mean determined from any

group of 4 consecutive results > fck+ 0.30 N/mm2.

2. The individual strength ≥ fck - 0.30 N/mm2

 Data for Mix proportioning (IS-10262, 2009)
1. Grade designation,
2. Type of cement,
3. Maximum nominal size of aggregate,
4. Minimum cement content,
5. Maximum water cement ratio,
6. Workability,
7. Exposure conditions as per table 4 and 5 of IS-456,
8. Maximum temperature of concrete at the time of placing,
9. Method of transporting and placing,
10. Early age strength requirements, if required,
11. Type of aggregate,
12. Maximum cement content,
13. Whether an admixture shall or shall not be used and the type of
admixture and the condition of use.
 Procedure (IS-10262, 2009)
Table 1 Assumed Standard Deviation

SN Grade Of Concrete Assumed standard deviation in N/mm²

1. M-10
3.50
2. M-15
3. M-20
4.00
4. M-25
5. M-30
6. M-35
7. M-40
5.00
8. M-45
9. M-50
10 M-55
11. M-60
Note: The above values correspond to the site control with proper storage of cement,
weigh batching of all materials, controlled addition of water, regular checking of all
materials, aggregate grading and moisture content and periodical checking of
workability and strength. In case of deviation from above, values shall be increased by
1 N/mm2.
 Standard Deviation [IS 10262:2009]
As per para number3.2.1
The standard deviation for each grade of concrete shall be calculated
separately.
3.2.1.1 standard deviation based on test strength of sample
a) Number of test results of samples – The total number of test strength of
samples required to constitute an acceptable record for calculation of
standard deviation shall be not less than 30. attempts should be made to
obtain the 30 samples(taken from site), as early as possible, when a mix
is used for the first time.
b) In case of significant changes in concrete - The standard deviation value
shall be calculated separately for such batches of concrete
c) Standard deviation to be brought up-to-date.
 Procedure (IS-10262, 2009)
2. Selection Of Water-Cement Ratio.
Table-5 of IS-456 Min cement content, max W/C ratio and min
grade of concrete for different exposures with normal weight
aggregates of 20 mm nominal maximum size.

SN Exposure RCC
Minimum cement Maximum free Minimum grade of
content water cement ratio concrete

1 Mild 300 0.55 M-20

2 Moderate 300 0.50 M-25

3 Severe 320 0.45 M-30

4 Very Severe 340 0.45 M-35

5 Extreme 360 0.40 M-40

 Procedure (IS-10262, 2009)

1. The supplementary cementitious materials i.e. Mineral

admixtures shall also be considered in water cement ratio
calculations.

2. The free water-cement ratio selected should be checked

against the limiting water cement ratio for the requirement
of durability and lower of the 2 values adopted.
 Procedure (IS-10262, 2009)
4. Calculation of cementitious material content.

1. The cement and supplementary cementitious materials

content per cubic meter can be calculated from free
water cement ratio and the quantity of water per cubic
meter.

2. The cementitious material should be checked against

minimum content for the requirement of durability and
greater of the two should be adopted.
 Procedure (IS-10262, 2009)
3. Selection Of Water Content. Table-2 of IS-10262
Maximum water content per cubic meter of concrete for
nominal maximum size of aggregate.
SN Nominal maximum size of Maximum water content
aggregate (mm) (Kg)
1 10 208
2 20 186
3 40 165
Note:
1. These quantities of mixing water are for use in computing cementitious material
contents for trial batches.
2. Water content corresponds to SSD aggregate.(saturated surface odry) 3. The
water content is for angular CA and for 25-50 mm slump range. 4. For ther than 25-50
mm slump range, the water content can be
established by trial or an increase by about 3% for every additional 25 mm slump or
alternatively by use of chemical admixtures.
5. Water reducing admixtures usually decrease water content by 5-10% and
superplasticizers by 20% and above.
 Procedure (IS-10262, 2009)
5. Estimation of coarse aggregate proportion.
Table-3 of IS-10262 Volume of CA per unit volume of total
aggregate for different zones of FA.
SN Nominal Volume of CA per unit volume of total aggregate for
maximum size of different zones of fine aggregate
aggregate
(mm) Zone IV Zone III Zone II Zone I

1 10 0.50 0.48 0.46 0.44

2 20 0.66 0.64 0.62 0.60
3 40 0.75 0.73 0.71 0.69

Note: 1. The approximate values of aggregate volume are for a water cement
ratio of 0.50 which may be suitably adjusted for other water cement ratios.
2. For pumpable concrete or when the concrete is required to be
worked around congested steel, it may be desirable to reduce the CA upto
10%.
 6. Estimation of FA proportion.

Volume-

a. Cement = Mass x 1
SG 1000

b. Water = Mass x 1
SG 1000

c. Chemical Adm. = Mass x 1

SG 1000

d. Volume of CA+FA = 1- (a+b+c) m³

 6. Estimation of FA proportion.

e. The value so obtained is divided into CA and FA

fractions by volume in accordance with CA proportion
already determined.

f. Mass of CA = Volume x SG x 1000

g. Mass of FA = Volume x SG x 1000

 Quantities per 1 m³ of concrete:
1. Cement - kg/m3
2. Water - kg/m3
3. CA - Kg/m3
4. FA - Kg/m3
5. Chemical admixture - Kg/m3
6. Water cement ratio -

This is first trial mix, TM – 0

Note- 1. Aggregate should be used in SSD condition.
2. If otherwise, allowance shall be made for free(surface) moisture
contributed by the CA and FA.
3. On the other hand, if the aggregates are dry, the amount of
mixing water should be increased equal to the moisture likely to
be absorbed.
4. Necessary adjustments are also required in mass of
aggregates.
7. Trial Mixes-
1. Workability of TM-0 will be measured.
2. The mix will be carefully observed for freedom from
segregation, bleeding and finishing properties.
3. If the workability of TM-0 is different from the
stipulated value, the water and/or admixture content
shall be adjusted suitably.
4. With this adjustment, the mix proportions will be
calculated again keeping same W/C ratio.
This will be TM-01.
5. In addition, 2 more TM no 2 and 3 will be made with
same water content and varying the W/C ratio by
+10%.
6. A graph between 3 W/C ratios and their corresponding
strengths at 28 days will be plotted to work out the
mix proportions for the given Target mean strengthTMS.
7. However, durability requirement shall be met.
 MIX DESIGN EXAMPLE
• Input Data :
(a) concrete requirements :
Grade of concrete = M20 (for RCC)
Workability = 25 to 50mm slump
Exposure condition = Moderate
(b) Material :
Grade of cement OPC 43 satisfying IS:8112:1989
Max. size of Aggregate (MSA) = 20mm
Sand = zone – I (As per IS 383-1970)
Type of aggregate – Angular
Specific Gravity of Cement = 3.15
Specific Gravity of Course Aggregate = 2.5
Specific Gravity of Fine Aggregate = 2.7
Step-1 Target Mean Strength (3.2)
TMS = fck+1.65 x S.D.
Here, fck = 20 N/mm2, S.D. = 4.0 N/mm2
Therefore, TMS = 20 + 1.65x4
= 26.60 N/mm2 or 27 N/mm2

Step-2 Water- Cement ratio (4.1,4.1.1)

W/C ratio for moderate exposure = 0.50
Max W/C ratio for RCC from durability Consideration as per para
5.4.3 of Concrete bridge code(CBC) for moderate exposure
= 0.45
lower of above values w/c = 0.45
 Step 3 Estimation of water in concrete
For MSA = 20mm, grade of concrete = M20,
from table Table-2 of IS-10262
Quantity of water ‘w’ = 186 kg/m3 of concrete
Step 4 Calculation of cement quantity
C = w/(w/c) = 186/0.45 = 413 kg
This Qty of cement needs to be checked against requirement
from durability consideration.
From CBC for RCC structure & moderate exposure
Min. cement = 300 kg
Max. cement = 500 kg
Hence C = 413 kg is adopted
Step 5 Calculation of aggregate content
p = Volume of FA / Volume of total aggregate OR Volume of total
aggregate (CA+FA)= 1/p x Volume of FA
Therefore ,Total Volume = V of water + V of cement + (V of FA + V of
CA)
V = (Wt. of water/sp. gravity) + (Wt. of cement/sp.gravity of cement)
+ 1/p x Volume of fine aggregate/Sfa
V = w/1 + C/Sc + 1/p x FA/Sfa
All variables are known except FA, i.e. total weight of fine
aggregate per m3 of concrete.
1000 = 186/1.0 + 413/3.15 + FA/0.39x2.7
Therefore, FA = 719.08 kg say 719 kg
Course aggregate CA
V = w/1 + C/Sc + (1/1-p) x CA/Sca
1000 = 186/1.0 + 413/3.15 + (1/1-0.39) x CA/2.5
Therefore, CA = 1041.62 kg say 1043 kg
Therefore values obtained per cum of concrete are-
cement = 413 kg
water content = 186 kg/m3
fine aggregate = 738 kg
coarse aggregate = 1043 kg
W/C ratio = 0.45
• Prepare the concrete mix with the above proportion of
ingredients. (Trial mix TM-0)
• Find out workability.

• If workability is exactly same as required, i.e. 25 to 50 mm slump,

then no further adjustment is made.

• If measured workability is different from initially assumed, then

water content adjustment will again be made keeping w/c ratio
same. Final qty. of materials will again be calculated. (Trial mix
TM-1)

• Two more trial mixes TM-2 & TM-3 will be made, one with 10%
less w/c and other with 10% more w/c but keeping water content
same.
• Now one sample (three cubes) with each trial mix is casted.

• 28 days compressive strength is found out.

• This strength is plotted against w/c ratio and a curve will be obtained.

• From this curve, w/c ratio for the required TMS is found out for our design mix.

• This w/c ratio is used to calculate again the ingredient quantities using
equation (1) & (2) so that the mix prepared with these quantities will satisfy
the requirements of not only strength but workability also.

• The entire process is a DESIGN MIX.

 80

70
NUMBER OF SPECIMENS IN 70

60
60
55
52
50
50
INTERVAL

40
35 35

30 30
30

20
15

10 10
10 7
4 5
2 3 3 3 2
0 1 1 1
0
40 41 42 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65

COMPRESSIVE
STRENGTH IN MPa
Target Mean Strength
 Acceptance Criteria As per IS-456:2000
(Para 16,table 11)(Latest Amendments)
a. Characteristic Compressive strength Compliance
Requirement
Specified Mean of the group of 4 non Individual test results in
Grade overlapping consecutive test results N/mm2
in N/mm2
M-15 ≥ fck + 0.825 x established standard ≥ fck - 3 N/mm2
And above deviation(rounded off to nearest 0.5
N/mm2)
or

fck + 3 N/mm2, whichever is greater.

Note: 1. In the absence of established value of standard deviation, the values given
table 8 may be assumed, the attempt should be made to obtain results of 30
samples as early as possible to establish the value of standard deviation.
2.For concrete of quantity up to 30m3, (where the number of sample to be taken is
less than four as per the frequency of sampling given in 15.2.2)the mean of the test
result of all such samples shall be fck+4 N/mm2 ,minimum and the requirement of
minimum individual test results shall be fck-2 N/mm2 , minimum. However when the
number of sample is only one as per 15.2.2, the requirement shall be fck+4 N/mm2
,minimum .
THANKS