Optimizing Concrete Mix

Design

PowerPoint Prepared By Ir Sam Yip

Date: 29th April 2014
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Optimizing Concrete Mix Design

Content :
Introduction

Project Requirements in Concrete Design

Concrete Mix Design

Methodologies for Concrete Mix Design

Difficulties and Constraints

Quality Management System

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Introduction

Construction Industry is blooming in Hong Kong

recently. Numerous projects are in progress include
mega infrastructure project, MTRC Railway projects,
Hong Kong Housing Authority projects,
Government projects, high rise building etc.
There is an increase in concrete demand.
More stringent in concrete mix design criteria and
requirements.
Require higher quality of concrete mixes.

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Local Projects

Hong Kong – Zhuhai – Macao Bridge Project

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Local Projects

Hong Kong – Zhuhai – Macao Bridge Project

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Local Projects

Stonecutters Bridge Project

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Local Projects

Wan Chai Reclamation Project

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Local Projects

MTRC XRL Project

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Local Projects

Tunneling Works for XRL Project

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Local Projects

Highway Project

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Local Projects

International Commercial Centre at West Kowloon

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Local Projects

Foundation Project

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Project Requirements in Concrete Design
In Hong Kong, there are numerous specifications
for concrete, major specifications include
• General Specifications for CEW
• Building (Construction) Regulations
• Hong Kong Housing Authority
• Architectural Services Dept of HKSAR
• MTRC
• Hong Kong Electric & China Light Power
• Ove Arup, AECOM, BV…
• Various projects’ particular specifications……

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Project Requirements in Concrete Design
Different specifications have different concrete
design requirements.
There are inconsistent in the concrete requirements
among different specifications. Examples include:
• Max cementitious content for liquid retaining structure
• A Particular WSD project - 430kg/m3
• G.S. - 450kg/m3
• ASD - 440kg/m3
• Min cementitious content for Grade 20 Concrete
(plain concrete)
• B.D. - 290kg/m3
• G.S. - 270kg/m3
• ASD - 275kg/m3 14
Project Requirements in Concrete Design

Recent projects aim for high performance concrete

mix design to facilitate the concreting works to suit
specific applications.
Requirements include:
• High compressive strength
For skyscraper and high rise building to
maximize the useable floor area and slim structure
• Durability
For structure with long design life e.g. 120 years
and lower the maintenance cost

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Project Requirements in Concrete Design

• High workability concrete & retention properties

To facilitate the concreting works and for
environmental protection purpose
• Early strength concrete
To shorten the working cycle and demoulding
time
• Low heat of hydration
For massive structure and prevent thermal effect

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Project Requirements in Concrete Design

• Shrinkage reduction
To minimize shrinkage cracks in water retaining
structure
• Anti-corrosion behaviour
To protect the embedded rebar against corrosion
• Other project special requirements…..

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Project Requirements in Concrete Design

Examples
Hong Kong – Zhuhai – Macao Bridge Project
• Limitation in max cementitious content of
450kg/m3
• Limitation in max water cement ratio of 0.38
• Compliance in chloride diffusion test
• Long workability retention time for marine
transportation
• High PFA content (up to 40%) for durability
purpose

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Project Requirements in Concrete Design
Examples
HATS Project requirements
• Limitation in max cementitious content of
450kg/m3
• Limitation in max water cement ratio of 0.38
• RCPT ≤ 1000 coulombs
• Sorptivity ≤ 0.07 (mm/min1/2)
• Long workability retention time for concrete
transit
• Early strength for working cycle including
demoulding
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Project Requirements in Concrete Design
Examples
Highway Project requirements
• High compressive strength (50MPa)
• High early strength to reopen the road or
minimize the vibration effect (to achieve 12MPa
within 4 hours)

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Concrete Mix Design

Concrete mix design is the process to select

suitable constituent materials and determine
required and specified characteristics of a concrete
mixture.
• Prescriptive approach
• Performance approach
Mix design requirements are based on intended
use, exposure conditions etc.

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Typical Concrete Mix Design Process

Review of specification requirements for all

constraints, e.g. materials, production, and
construction methodologies
Assessing availability of materials
Selection of materials to ensure the conformity with
standard and specifications
Obtaining data and/or testing of materials
Identifying influencing of mix design on concrete
production and construction materials
Obtaining approval for mix design

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Basic Factors for Concrete Mix Design

Grade and strength

Water cement ratio
Limitation in max / min cementitious content
Workability
Max aggregate size
Aggregate cement ratio
Durability considerations (exposure conditions)
Plastic density
Applications and construction methods including
the spacing of rebar
Etc.. 23
Methods for Concrete Mix Design

There are many concrete mix design methods and

commonly adopted methods include:
• Building Research Establishment of UK (BRE)
• America Concrete Institute (ACI)
• Volumetric Method

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BRE Method
Formerly developed by British Department of
Environment (DOE)
Applied only for normal weight concrete
High performance concrete is not covered
Principle:
- Use historical and available data
- Adopt charts and tables
BRE Method

Example:
Specified Requirement
For “OPC” Concrete:
• Characteristic compressive str. (fc) = 45MPa at 28-day with
a 5% defective rate (k = 1.64)
• Design Slump = 100mm
• OPC Class = 52.5N
• Max. aggregate size = 20mm
• Type of fine aggregates = Crushed rock fines
• Relative density of aggregate = 2.7 (SSD condition)
• Past cube compression test result or production data is not available

For “OPC + PFA” concrete:

• Same as above with PFA of proportion (p) = 30%
BRE Method

fc=45
BRE Method

Mix with Mix with

OPC OPC + PFA (30%)

Step 1: (Fig. 3) (Fig. 3)

Target mean Margin M = k x s Margin M = k x s
strength fm = 1.64 x 8 = 1.64 x 8
= 13 MPa = 13 MPa

Target mean strength Target mean strength

fm = fc + M fm = fc + M
= 45 + 13 = 45 + 13
= 58 MPa = 58 MPa
BRE Method
(OPC & OPC+PFA Concrete)

fm=58
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0.48
BRE Method

Mix with Mix with

OPC OPC + PFA (30%)

Step 2: (Table 2 ; Fig. 4) (Table 10 ; Fig. 4)

Selection of Target free-water/cement W/(C+eF)
target free- ratio where e is cementing
water/ = 0.48 efficiency factor = 0.30
cement ratio F = PFA content
Target free W/(C+0.30F)
= 0.48
BRE Method
BRE Method

Mix with Mix with

OPC OPC + PFA (30%)

Step 3: (Table 3) (Table 9)

Selection of free Free water content Free water content
water content (W) W = 225 kg/m3 W = 225 - 20
= 205 kg/m3
BRE Method

Mix with Mix with

OPC OPC + PFA (30%)

Step 4: Cement content Cement content (C)

Determination of C = 225/0.48 0.48 = 205 / (C+0.3F)
cement content (C) = 469 kg/m3 Since F = C /0.7 x 0.3
C = 378 kg/m3
PFA content (F)
W/(C+F) ratio PFA content (F)
F = C/ 0.7 x 0.3
= 162 kg/m3

Thus,
W/(C+F) =
205/(378+162) = 0.38
BRE Method

2405

2385

205 225
BRE Method

Mix with Mix with

OPC OPC + PFA (30%)

Step 5: (Fig. 5) (Fig. 5)

Determination of Wet density of Wet density of concrete
total aggregate concrete D = 2405 kg/m3
content (SSD D = 2385 kg/m3
condition)
Total aggregate Total aggregate content
content (SSD) (SSD)
=D-C-W =D-C-F-W
= 2385 - 469 – 225 = 2405 - 378 - 162 - 205
= 1691 kg/m3 = 1660 kg/m3
BRE Method

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0.38 0.48
BRE Method
Mix with Mix with
OPC OPC + PFA (30%)

Step 6: (Fig. 6) (Fig. 6)

Selection of Proportion of fine aggregate Proportion of fine aggregate =
fine and coarse = 47% 44%
aggregate
contents Fine aggregate content Fine aggregate content
= 1691 x 0.47 = 795 kg/m3 = 1660 x 0.44 = 730 kg/m3

Coarse aggregate content = Coarse aggregate content

1691 - 795 = 896 kg/m3 = 1660 - 730 = 930 kg/m3

20mm : 10mm ~ 2 : 1 20mm : 10mm ~ 2 : 1

20mm = 896 x 2/3 20mm = 930 x 2/3
= 597 kg/m3 = 620 kg/m3
10mm = 896 x 1/3 10mm = 930 x 1/3
= 299 kg/m3 = 310 kg/m3
BRE Method

Mix with Mix with

OPC OPC + PFA (30%)

Preliminary OPC = 469 kg/m3 OPC = 378 kg/m3

Mix Design 20mm = 597 kg/m3 PFA = 162 kg/m3
Proportion 10mm = 299 kg/m3 20mm = 620 kg/m3
CRF = 795 kg/m3 10mm = 310 kg/m3
Water = 225 kg/m3 CRF = 730 kg/m3
Water = 205 kg/m3

Wet density = 2385 Wet density = 2405 kg/m3

kg/m3 W/(C+F) = 0.38
W/C = 0.48
ACI Mix Design

The most common method adopted in North

America which is established by American
Concrete Institute.

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ACI Method
Example
To design a concrete mix for an exterior column located
above ground where substantial freezing and thawing may
occur.
• Grade : 35MPa (~5000PSi)
• Slump ~ 50mm (1 – 2 inch)
• Max size aggregate: 20mm (~0.75 inch)
• Cement: Type I, SG: 3.15
• Coarse aggregate:
Bulk density (SSD) = 2.7; Absorption capacity = 1%,
Oven dried unit weight = 100 lb/ft3; Surface moisture = 0
• Fine aggregate:
Bulk density (SSD) = 2.65; Absorption capacity = 1.3%,
Fineness modulus = 2.7, Surface moisture = 3%
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ACI Mix Design

Mix Design Procedure

Step 1 - Required material information
• Including sieve analysis for both coarse and fine
aggregate, specific gravity etc.

Step 2 – Choice of slump

• Normally it is specified by the project. If not, it
can be chosen from Table to suit the application.

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ACI Mix Design
Recommended slumps for various types of
construction

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ACI Mix Design

Step 3 - Maximum aggregate size

• Maximum size should not be larger than:
• 1/5 the minimum dimension of structural members
• 1/3 the thickness of a slab
• 3/4 the clearance between reinforcement and
formwork

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ACI Mix Design

Step 4 - Estimating of mixing water and air content

• An estimation of the amount of water required for
air entrained and non-air entrained concrete can
be obtained from Table.
• Concrete is routinely air entrained in North
America.

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ACI Mix Design

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ACI Mix Design

Step 5 – Water / Cement Ratio

• This component is governed by strength and
durability requirements.
• Strength – Related to water cement ratio and
referred to 28 days compressive strength.
• Durability – If there are severe exposure
conditions, such as freezing and thawing,
exposure to seawater, or sulfates, the w/c ratio
requirements may have to be adjusted.

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ACI Mix Design

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ACI Mix Design

Step 6 - Calculation of cement content

• Once the water content and the w/c ratio is
determined, the amount of cement per unit
volume of the concrete is found by dividing the
estimated water content by the w/c ratio.
• Weight of cement = Weight of water / (w/c)
• Weight of cement = 280/0.4 = 700 (lb/yd3)
= 415 (kg/m3)
Note:
A minimum cement content is required to ensure
good finishability, workability and strength.
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ACI Mix Design

Step 7 - Estimation of coarse aggregate content

• The percent of coarse aggregate to concrete for
a given maximum size and fineness modulus is
given in Table.
• The value from the table multiplied by oven dried
weight of coarse aggregate required per cubic
foot of concrete.
• Volume of coarse aggregate = 0.63 x 27 (ft3/yd3)
= 17.01 (ft3/yd3)
• The oven dried weight of coarse aggregate
= 17.01 (ft3/yd3) x 100 lb/ft3
= 1,701 lb/yd3 (1,009 kg/m3) 49
ACI Mix Design

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ACI Mix Design

Step 8 - Estimation of fine aggregate content

• There are two standard methods to establish the
fine aggregate content, the mass method and
the volume method.
• Volume method – This method is the preferred
method, as it is a somewhat more exact
procedure.
• The volume of fine aggregate is found by
subtracting the volume of cement, water, air and
coarse aggregate from the total concrete volume.

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ACI Mix Design

Step 8 - Estimation of fine aggregate content

• Water: 280 lb/ 62.4 lb/ft3 = 4.49 ft3
= 0.1271 m3
• Cement: 700 lb/(3.15 x 62.4 lb/ft3) = 3.56 ft3
= 0.1008 m3
• Coarse Agg: 1701 lb/(2.7 x 62.4 lb/ft3) = 10.10 ft3
= 0.2860 m3
• Air: 6% x 27ft3/yd3 = 1.62 ft3
= 0.0459 m3
Total = 19.77 ft3
= 0.5598 m3

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ACI Mix Design

Step 8 - Estimation of fine aggregate content

• Fine aggregate occupied a volume of:
= 27 ft3 – 19.77 ft3 = 7.23 ft3 (0.2047m3)
= 0.1271 m3
• Oven dried weight of fine aggregate:
7.23 ft3 x 2.65 (SG) x 62.4 lb/ft3 (Unit weight of water)
= 1,196 lb (544kg)

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ACI Mix Design

Step 9 - Adjustment for Moisture in the aggregate

• The water content of the concrete will be
affected by the moisture content of the
aggregate.

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ACI Mix Design

Step 9 - Adjustment for Moisture in the aggregate

• The weight of aggregate from the stockpile is:
Weight(stockpile) = Weight(Oven dried) (1 + Moisture Content)

• The change in the weight water due to the moisture

of the aggregate from the stockpile is:
∆Weight(water) = Weight(Oven dried) (Surface Moisture)

• Adjusted Weight(water) = Weight(water) – ∆Weight(water)

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ACI Mix Design

Step 9 - Adjustment for Moisture in the aggregate

• Fine aggregate required from the stockpile:
= 1,196 lb (1+3%+1.3%)
= 1,247 lb/yd3 (740 kg/m3)
• Coarse aggregate required from the stockpile:
= 1,701 (1 + 1%)
= 1,718 lb/yd3 (1,019 kg/m3)
• Required mixing water:
= 280 lb – 1,196 lb x (4.3% - 1.3%) -
1,718 lb x (1% - 1%)
= 244 lb/yd3 (145 kg/m3)
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ACI Mix Design

Estimated batch weight

• Cement: 700 lb/yd3 (415 kg/m3)
• Water: 244 lb/yd3 (145 kg/m3)
• Coarse Agg: 1,718 lb/yd3 (1,019 kg/m3)
• Fine Agg: 1,247 lb/yd3 (740 kg/m3)
• Total: 3,909 lb/yd3 (2,319 kg/m3)

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ACI Mix Design

Step 10 - Trial Batch

• Using the proportions developed in the
preceding steps to mix a trial batch of concrete.
• The fresh concrete shall be tested for slump, unit
weight, yield, air content, and its tendencies to
segregation, bleeding and finishing
characteristics.
• Hardened samples shall be tested by
compressive strength and other characteristics.

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Volumetric Method
Can be used to proportion high performance concrete
mixture by incorporating admixtures
Easily adopted from adequate past experiences and
knowledge in the properties of raw materials used
Volumetric Method
Past experiences and knowledge in:
• relationship between strength and w/c ratio
• grading and hardness of aggregates
• proportion of total fine content in different
workability
• suitably select admixture to minimize total
cementitious materials used
• matrix performance for different proportion of
cementitious materials used
Volumetric Method
The principal is the volume of compacted concrete
equal to the sum of the absolute volume of all
ingredients
Require to know the density of all ingredients used
Formula used:
Density = Mass/Volume
Volume (m3) = Mass (kg)/Density (kg/m3)
Volumetric Method

Included air content (entrained and entrapped air),

normally 0.8~1% in the mix design
Aggregates are based on saturated - surface-dry
(SSD) conditions
Volumetric Method
In general, density (kg/m3) of local raw materials used
in the mix design:
Cement (OPC) ~ 3,150
PFA ~ 2,400
GGBS ~ 2,900
Silica Fume (condensed) ~ 2,500

Coarse 20mm & 10mm in SSD ~ 2,600

Crushed rock fines in SSD
~ 2,600
condition
Potable water 1,000
Admixtures depends
Volumetric Method

General parameters (Examples) based on past

experiences/trial results
OPC 52.5N
PFA not included
Max. aggregate size is 20mm
Dosage of normal water-reducer (lignin based) admixture
in 0.8~0.9 L/100 kg cement)
Volumetric Method

Example:
Specified requirement: same as BRE method
mentioned above (i.e. Design 45D/20, 100mm slump)
Using the general parameters as the table listed
above and the following equation for 1m3 concrete,

(C/3150) + (Aggc/2600) + (Aggf/2600) + (W/1000)

+ (Am/1100) + Ac = 1 m3

where, C = cement content (kg)

Aggc = total “20mm + 10mm” aggregates content (SSD) (kg)
Aggf = crushed rock fine aggregate content (SSD) (kg)
W = water content (kg)
Am = admixture content (kg), use density = 1100 kg/m3
Ac = air content (0.8~1%)
Volumetric Method

Step 1: Water content is about 200 kg/m3

Determination of and W/C = 0.42, thus
cement content (C) Cement content C = 200 / 0.42
= 476 kg

Step 2: Provide 0.85 L/100 kg cement of

Determination of admixture, where S.G.= 1.10,
admixture content thus
(Am) Admixture content
Am = (0.85 x 4.76) x 1.10
= 4.45 kg
Volumetric Method

Step 3: The cohesiveness and workability

Determination of required in the mix depends also on
crushed rock fines the total fine content (i.e. all
content (Aggf) cementitious materials + total fine
aggregates content).
In general, for 100mm slump, total
fine content is about 0.40
(~40% in volume).
That is
(C/3150) + (Aggf/2600) = 0.4
(476/3150) + (Aggf/2600) = 0.4
Aggf = 647 kg
Volumetric Method

Step 4: (C/3150) + (Aggc/2600) +

Determination of total (Aggf/2600) + (W/1000)
coarse aggregates + (Am/1100) + Ac = 1 m3
(20mm+10mm)
content (Aggc) For air content Ac = 0.9% =
0.009, thus, we have,

(476/3150) + (Aggc/2600) +
(647/2600) + (200/1000) +
(4.45/1100) + 0.009 = 1 m3
Aggc (20mm+10mm) = 1,006 kg
Volumetric Method

Step 5: Generally, 10mm aggregates

Determination of each (Agg10) is about ~20% to total
20mm (Agg20) & aggregates content (i.e. coarse
10mm (Agg10) + fine)
contents Using 20%, we have,
Agg10/(Aggc + Aggf) = 0.2
Agg10/(1006 + 647) = 0.2
Agg10 = 331

So, Agg20 = 1,006 – 331

= 675 kg
Volumetric Method

Mix with OPC

Preliminary Mix OPC = 476 kg/m3

Design Proportion 20mm = 675 kg/m3
10mm = 331 kg/m3
CRF = 647 kg/m3
Water = 200 kg/m3
Admixture = 4.45 kg/m3
Wet density = 2,333 kg/m3
W/C = 0.42
Design Verification
No matter using which concrete mix design method,
trial mix is required to verify the design proportion.
Design the mix proportions is a starting point.
During trial mix stage, adjustment may be required to
optimize the design mix proportion to suit the actual
materials performance and specific applications.
Further test to determine compatibility of materials
and confirm the mix design.
Field trial for final verification.
Validate through production.

Theoretical Vs Laboratory Vs Field

Factors Affecting Mix Design

Materials fluctuations
Insufficient batching & placing
Improper curing
Poor compaction
Testing
Site condition and malpractice

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Difficulties & Constraints

Concrete is not magic and still have its limitations

although there is great improvement in concrete
technology
Concrete gain strength through cement hydration
process and it takes time.
Contradictory specification requirements
e.g. high compressive strength but low tensile splitting
strength
high PFA content but have to achieve high early
strength
…
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Difficulties & Constraints

Limited space in concrete batching plant for storage

and handling of constituent materials.
Stringent regulatory requirements and approval
process for relevant permit and license.
Sustainable materials supply e.g. aggregate supply.

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Quality Management System

• Good quality concrete not only the responsibility of

Concrete Producers.
• Concrete Producers have the ability to design and
produce high standard concrete comply with
specifications and requirements to suit the site
applications.
• However, workmanship of concreting, compacting,
curing cause significant impact to the performance of
concrete.

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Quality Management System

Consultant
& Engineer

Architect Good Contractor

Quality
Concrete
Mix

Concrete Testing
Producer Laboratory

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Quality Management System

• A stringent and high degree of quality control system

among the Concrete Producers, Architects,
Consultants, Engineers and Contractors shall be
established
• The system ensure the high standard concrete to be
specified, produced, placed, compacted and cured
properly to achieve the desire performance and long
term engineering benefits

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Quality Management System

• Improper curing cause deterioration of strength

development and durability of concrete

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Quality Management System

• Impact of poor compaction

• The presence of voids in concrete greatly reduces its
strength
• Indicative figure show that 5% of voids can lower the
strength by as much as 30% even 2% voids can
result in a drop of strength of more than 10%.

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Final Words

• Concrete Producers in Hong Kong are capable for

design and production of concrete mixes which fully
comply with project requirements
• However, since the overall process is under very
strict control, production rate is quite often
compromised substantially and higher cost is
thereby incurred.
• The concrete performance not only the concrete
itself.
• A stringent and higher degree of quality control
system among the Concrete Producers, Architects,
Consultants, Engineers and Contractors is required
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~ End ~

Thank You

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