CONCRETE

Introduction
Concrete a composite man-made material, is the most widely used building material in the
construction industry. It consists of a rationally chosen mixture of binding material such as
lime or cement, well graded fine and coarse aggregates, water and admixtures (to produce
concrete with special properties). In a concrete mix, cement and water form a paste or matrix
which in addition to filling the voids of the fine aggregate, coats the surface of fine and coarse
aggregates and binds them together. The matrix is usually 22-34% of the total volume. Freshly
mixed concrete before set is known as wet or green concrete whereas after setting and
hardening it is known as set or hardened concrete. The moulded concrete mix after sufficient
curing becomes hard like stone due to chemical action between the water and binding
material. It would be impossible to discuss all the aspects of this material in few pages and
the discussion is confined to the general characteristics and quality tests necessary for its use
by Civil Engineers. Most of the ancient structures and historical buildings had been
constructed with lime concrete. With the advent of cement, the use of lime concrete has been
confined to making bases for concrete foundations and roof terracing. The major factors
responsible for wide usage of cement-concrete are mouldability, early hardening, high early
compressive strength, development of desired properties with admixtures to be used in
adverse situations, suitability for guniting, pumpability and durability.
The simple reason for the extensive use of concrete in the construction of almost all civil
engineering works is that the properties can be controlled within a wide range by using
appropriate ingredients and by special mechanical, physical and chemical processing
techniques. Buildings—from single storey to multistorey, bridges, piers, dams, weirs, retaining
walls, liquid retaining structures, reservoirs, chimneys, bins, silos, runways, pavements, shells,
arches, railway sleepers are but a few examples of cement concrete applications.

Proportioning Concrete
The process of selection of relative proportion of cement, sand, coarse aggregate and water,
so as to obtain a concrete of desired quality is known as the proportioning of concrete.
The general expression for the proportions of cement, sand and coarse aggregate is 1:x:2x
by volume.
The recommended proportions are:
1:1:2 and 1:1.2:2.4 ---------for very high strength concrete
1:1.5:3 and 1:2:4 ------------- for nominal work
1:3:6 and 1:4:8 -------------- for foundations and mass concrete work
Recommended mixes of concrete

Proportion of concrete mix Maximum size of aggregate Nature of work

1:1:2 12 to 20 mm Heavily loaded R.C.C
columns
1:2:2 12 to 20 mm Small precast member of
concrete such as poles, long
piles
1 : 1.5 : 3 20 mm Water retaining structures,
Piles
1 : 2 : 3 or 1 : 1.666 : 3.333 80 mm Water tank, bridges etc.
 1 :2.5 :3.2 25 mm Foot paths and road works
1:2:4 40 mm For all general R.C.C works
in building such as stairs,
beams, column, Lintel etc.
1:3:6 50 mm Mass concrete work in
culvert, retaining walls e.t.c
1 : 4 : 8 or 1 : 5 : 10 or 1 : 6 : 60 mm Mass concrete work for
12 heavy walls, foundation
footing e.t.c

The concrete as per BIS: 456 – 1978 is designated in 7 grades, namely M10, M20, M25, M30,
M35 & M40
The letter M refers to the mix and the no. indicates the specified compressive strength of that
mix at 28 days expressed in N/mm2
The lean concrete bases and simple foundation for masonry walls, M5 and M7.5 grades of
concrete may be used.
M5 – 1: 5: 10; M7.5 – 1: 4: 8; M20 – 1: 1.5: 3; M10 – 1: 3: 6; M15 – 1: 2: 4; M25 – 1:1:2
The grade of cement lower than M15 are not to be used in RCC work

Quality of Mixing Water

This is the least expensive but more important ingredients of concrete. The water which is
used for making concrete, should be clean and free from harmful impurities such as oil, alkali,
acid etc. In general, the water which is fit for drinking should be used for making concrete.

Properties of concrete
Concrete has altogether different properties when it is in plastic stage (known a green
concrete) and when it is hardened.
Properties of green concrete
i. Important properties of fresh concrete or green concrete are
- Workability
- Segregation
- Bleeding

ii. Properties of hardened concrete

Important properties of hardened concrete are
iii. Strength
iv. Shrinkage
v. Creep
vi. Thermal expansion
vii. Durability
viii. Imperviousness
Workability
The workability is a very important quality of concrete and it can be defined as the difficulty
with which the concrete is handled, transferred and placed between the forms and with
minimum loss of homogeneity.
A concrete is said to be workable when it can be easily mixed, handled, transported, placed
in position and compacted.
Several tests which have been developed to measure the workability of concrete are
i. Slump test
ii. Compaction factor test
iii. Flow table.
Factors affecting workability
The various factors which are influence the workability of concrete are:
- Water content
- Mix proportion
- Size of aggregate
- Shape of aggregate
- Surface texture
- Grading of aggregate
- Use of admixture
Water content
- Water content in a given volume of concrete will have significant influences on the
workability.
- The higher the water content per cubic meter of concrete, the higher will be the fluidity
of concrete, which is one of the important factors affecting workability
- The fluidity of concrete increases with water content
Mix proportion
- Aggregate cement ratio is an important factor influencing workability. The higher the
ratio, the leaner the concrete will be.
- In a lean concrete, paste available for lubrication of per unit surface of aggregate will
be less and hence, the workability is reduced.
Size of aggregate
For big size of aggregate, the total surface area to be wetted is less, also less paste is required
for lubrication the surface to reduce internal friction
For a given water content, big size aggregate give high workability.
Surface texture
The influence of surface texture on workability is due to fact that the total surface area of rough
textured aggregate is more than the surface area of smooth rounded aggregate of the same
volume.
Grading of aggregate
A well graded aggregate is one which has minimum amount of void in a given volume. This
directly affects the durability of concrete after casting.
Segregation
Segregation is defined as the separation of coarse material at one side and fine material at
the other side in the concrete. Such concrete contains large voids and are less durable.
Segregation occurs due to
ix. Lack of sufficient fine particles in the mix
x. Over vibration
xi. Dropping of the concrete from a high distance
Bleeding
The process of rese of water along with the cement particles to the surface of freshly laid
concrete is known as bleeding. This occurs due to the excessive quantity of water on the mix
or excessive compaction. it causes formation of pores on the surface and makes the concrete
weak.
It can be controlled by
xii. Proper mix design and using lesser water/cement (w/c) ratio.
xiii. Increasing the quality of fine aggregate
xiv. Mixing air resisting agents

STRENGTH OF CONCRETE

The strength of concrete is normally measured by compressing 100 mm or 150 mm (4 inch

or 6 inch) cubes or cylinders in a hydraulic testing machine. The maximum stress recorded
before crushing is the strength “grade,” typically 15–40 MPa. The cubes are cast in metal or
plastic moulds that are struck (removed) the day after casting. Once struck from the moulds,
the cubes are stored in water until testing (normally at 28 days). If a series of cubes from the
same batch of concrete are stored at different temperatures, strength gain curves, may be
obtained. High temperatures will give high early strengths; low temperatures will give the
best long-term strength.
In order to achieve the best strength from concrete, it must be cured well. This involves
keeping it at the right temperature and protected from frost, and, very importantly, preventing
it from drying out too quickly before the hydration reaction has completed. Concrete should
be kept as wet as possible after casting.
The strength of concrete can be increased by reducing the amount of water in the mix, and
thus reducing the water to cement (w/c) ratio. Unfortunately, reducing the water content will
reduce the workability, which means it will prevent the mix from flowing, and make it hard to
place properly
Uniformity of mixing
The process of rolling, folding and spreading of cement and aggregate of measured proportion
is called mixing of concrete

Mixing

Hand Mixing Machine Mixing

Hand Mixing
i. Materials are stacked on a water-tight solid platform (surface), which may be either
of solid-compacted earth, brick or steel
ii. Materials are thoroughly mixed three times in dry condition with trowel or shovel
iii. The prepared mix should be consumed within 30 mins after adding water
Machine mixing
i. It is more efficient and produces better quality concrete.
ii. The machine used for the mixing of concrete is called a Concrete Mixer (“Mixer” in
short)
iii. Material including water are collected in the drum of the mixer and rotated
thoroughly.
iv. Coarse aggregate should be fed first and then cement and sand is added and
thoroughly mixed.
v. The water should be poured into the mixer at the same time or before the other
materials are placed. This ensures even distribution of water
vi. The concrete discharge by the mixer should be consumed within 30 mins.

Mixing time

Mixing time is determined based on twenty revolutions of any mixer. Therefore, as mixer
becomes bigger (in terms of capacity) the time needed for thorough mixing will be longer.
Below table is prepared for different mixer capacities.

Mixing times for various mixer capacities.

Capacity of mixer (m3) Mixing time (minutes)
0.8 1
1.5 1¼
2.3 1½
3.1 1¾
3.8 2
4.6 2¼
7.6 3
Vibration of concrete
In the process of mixing, transporting and placing of concrete, air is likely to get entrapped in
the concrete. Compaction of concrete is the process adopted for expelling the entrapped air
or voids/ for the concrete. Thus, vibration is one of the methods of concrete compaction and
it is achieved by the use of vibrators.
Types of vibrators
i. Internal or immersion vibrators
ii. Surface vibrators
iii. Form or shutter vibrators
iv. Vibrating tables
i. Internal or Immersion vibrations
These vibrators consist of a steel tube which is immersed in fresh concrete. The steel tube
is called the poker and it is connected to an electronic motor or a petrol engine through a
flexible tube. The frequency of vibration is about 3000 to 6000 r.p.m. This type of vibrator
is more efficient because used by immersing it in the concrete. Hence, it is more commonly
used.
ii. Surface Vibrators
Surface vibrators are found to be more effective for compacting of dry concrete. These
vibrators are mounted on a platform. They are used to finish concrete surfaces such as
bridge decks, road slabs, station platforms, etc.
iii. Form or shutter vibrators
These vibrators are attached to the formwork. They require more power because of loss
of some power to vibrating the rigid shutter.
iv. Vibrating tables
v. These are in the form of a rigidly built steel platform mounted on flexible springs
and they are operated by electromagnetic action or electric motor. The tables are
vibrated either mechanically or by placing the springs under the supports of tables.
The frequency of vibration of this machine varies from 3000 to 7200 vibrations per
minute.
Curing of Concrete
Curing means, the creation of an environment for a relatively short period,
immediately after placing of concrete. The desirable conditions of that environment
are suitable temperature and preventing the loss of moisture or providing moisture.

Common Techniques of Curing

1. Prevention of evaporation due to sun or drying wind: This is done by using
polythene sheeting, tarpaulins or waterproof paper. It is better to place these
materials after spraying some water on the surface.
2. Surface-spraying with a chemical composition: This chemical composition forms an
impervious layer. This is applied when the concrete is still moist but not wet. The
main disadvantage of this technique is that the composition layer prevents the
bonding between hardened concrete and any finishes or fresh concrete, which may
be applied. However, it is possible to remove that layer effectively.
3. Covering concrete surface with wet straw or hessian sacking after preliminary
hardening of concrete. This material may require to be damped periodically in hot
or windy conditions.
4. Flooding horizontal slabs with water.
5. The use of insulated formwork. Especially timber is a good insulated and
prolonging of stripping time is a method of curing.
6. Blowing warm air around concrete or employing electrically heated insulating mats (for very
cold weathers).

Selection of Curing Techniques

Selection of technique depends on economic consideration, which depends on labour,
material and plant available. Besides, environmental conditions, structural and visual
requirements affect the degree of curing to be applied.
Particular care is required when placing concrete in large pours, because of the high
temperature generated in the mass during hydration. Subsequent cooling is liable to
cause cracking. If it is possible applying of flooding technique is the best one for this
case. In very cold weather, insulating of both formwork and the surface may well be
needed. The use of water curing is obviously unsuitable. Applying of straw is the best.
When it is not very cold, polythene sheeting may be acceptable. Very low
temperatures may require the use of electrically heated insulation mats or the
discharge of warm air between the concrete surface and a cover. Accelerating
admixtures in the concrete help generation of heat, thereby helping the curing process
and shortening its duration. Curing and stripping periods must be considerably extended in
very cold weather. In very hot weather, curing membranes or polythene sheeting is particularly
necessary. The use of water is also a solution if it is applicable. Retarding admixtures
are particularly useful in assisting the effectiveness of curing.

Form work
Most structural concrete is made by casting concrete into previously made boxes that are
called forms or shuttering. Usually wall, column, beam and slab forms are built by joining
wooden boards' edge on edge. Sometimes plywood may be nailed, for tighter and more
wrap resistant. In certain cases metal forms are used, e.g. when a large number of equal
structural members (pre-cast elements) have to be erected or when the parts should be
very exact in measurements.
The most suitable material for formwork is wood, in particular boards, rails, batten and
planks. All this timber is available in various qualities and dimensions. Hardwood should
not be used for parts where nailing is necessary. Boards of less quality and boards of rough
surface do not last very long for shuttering work. Using plastic or metal sheets are
economical and highs qualitative.
All form work material (planks, boards, steel etc.) and elements formwork (moulds) are
sprinkled with water before placing concrete. After striking or dismantling, the formwork
is cleaned and eventually oiled as well as properly stored and protected from sun and rain.
This will guarantee the use of frame work repetitively.
Formwork for pre-cast products like cover slabs, fence posts, well and culvert rings, and
element of formwork for standard structures like stand posts should be made of quality
timber or steel.
Removal of the formwork
Formwork should be left in place until the concrete is hardened enough to hold its own
weight and any other weight. The surface must be hard enough to remain unmarked while
stripping the forms.
Under ordinary circumstances, formwork for various types for construction may be
removed after intervals as follows:
Period for removal of formwork

Structural Element Period

Slabs, beams/ lintels with clear span 3m and 8 to 14 days
below
Slabs, beams/ lintels with clear span 3m- 6m 16 to 14 days
Slabs, beams/ lintels with clear span more than 24 to 35 days
6m
Cantilever As long as possible but minimum of 35
days (because of creeping of concrete)

CONCRETE MIX DESIGN

In designing a concrete mix, the primary objective is to select suitable constituent materials
and determine their required amounts in order to produce concrete of specific characteristics
and properties as economically as possible. The characteristics typically specified are
workability, strength and durability. Other characteristics that may be required includes;
density, thermal characteristics, elastic modulus etc. However, the mix design process only
considers the factors which have a major effect on the properties of concrete i.e. workability,
strength and durability.
The proportioning of the constituent materials of concrete is dependent on the required
performance of concrete in two states: the fresh/plastic and hardened states.
Four variable factors need to be considered in mix proportioning:
i. Water-cement ratio
ii. Cement content
iii. Gradation of aggregates
iv. Consistency

Typically, two or three factors are specified and the others are adjusted to achieve minimum
workability and economy. In summary, the goal of mix proportioning is to use the minimum
quantity of cement that will lubricate the mixture when fresh to allow for adequate placing and
at the same time, bind the aggregates together and fill up the voids between them when the
concrete has hardened. Any excess of paste results in a higher cost, higher drying shrinkage.
Requirements of Concrete Mix Design
The necessary data required can be classified into two categories viz a viz:
A. Specified variables: These are variables which are normally selected in the specifications
based on intended use of the concrete. They include:
· The minimum compressive strength required for the intended use of the concrete
· Adequate workability required for placement and full compaction with the available
compaction equipment
· Maximum water-cement ratio
· Maximum/minimum cement content required to provide adequate durability for the specified
exposure conditions
· Strength class of cement
· Maximum aggregate size

B. Additional information: This refers to data on the available materials required

for the concrete mix. They include:
· The standard deviation which is a measure of the variability from the specified
characteristic strength
· The type of aggregate
· Specific gravity of aggregate
· Grading of fine aggregate

Understanding the basic concept of mix design is as significant as the actual calculations
required for determining the mix proportions. In fact, the appropriate mix proportions are a
consequence of the concrete mix design.
Variability of Concrete Strength
In the production of concrete, there are inevitable variations in the properties of the materials
used as well as the construction methods. For instance, the quality of various
batches of cement supplied may vary, or the grading and particle shape of the aggregates
may vary. These variations may even be observed within a batch as a result of process of
sampling, production, curing and testing of specimens even if they are conducted in
accordance with the recommended standard. This results in variation of strength from batch
to batch and also within a batch. This makes the strength of the final product difficult to assess.
In concrete mix design, it is now generally accepted that the variation in concrete strengths
follow the normal distribution curve shown in Figure A. The area under the
curve represents the total number of test results. If a vertical line is drawn through a
specified value, the proportion of results less than that value is represented by the area
beneath the curve and to the left hand side of the vertical line as demonstrated in Figure A.
The normal distribution curve is defined by two parameters: its mean and standard deviation.
The curve is symmetrical about its mean and the standard deviation is a measure of the
variability. Typically at a given level of quality control, the standard deviation increases as the
specified characteristic strength.
 Figure A:

This statistical quality control method provides a scientific approach to understanding the
variations that are encountered on site so as to provide proper tolerance to allow for inevitable
variations. To obtain the standard deviation on site, the minimum number of test samples
should be between 20 to 30. The standard deviation used for any calculation should be based
on either result obtained from the site, or in the absence of such data, assumed values are
specified in different standards. Most producers of concrete in Nigeria do not have the quality
control ability to have small standard deviations. To this end it is suggested that producers
without adequate records start with a standard deviation of 8MPa, if thereafter a consecutive
result of 30 tests is available, the standard deviation should be based on the result
from the 30 consecutive tests. Whenever the producer is convinced that he can achieve a
lower standard deviation, he can use that new value for mix design.
Percentage of Results outside statistical limit

Defectiveness

Where k is the reliability index

Decision Variables in Mix Design

The following are the key decision variables when estimating the proportions in a concrete
mix:
Water Cement ratio
The water cement ratio is the single most important parameter that determines the strength
and durability of concrete. The strength of concrete is dependent on the water cement ratio
and not totally on the cement content. According to Abram's law, the higher the water
cement ratio, the lower the strength of concrete. It is generally accepted as a rule of thumb
that every 1% increase in quantity of water added reduces the strength of concrete by 5%.
Theoretically, a water cement ratio of 0.25 is required for the complete hydration of cement.
Hence, it is very important to control the water cement ratio on site.

Cement Content
Cement is the binder material in concrete which imparts strength to the concrete. With
regards to durability, conditions of exposure govern the maximum cement contents required.
For a given workability, a certain water content is required. This implies that a higher cement
content would be required to achieve a desired workability at a lower water cement ratio.
Based on the relationship between cement content and water cement ratio, we see that a
greater water cement ratio would require a lower cement content. Details on properties and
types of cement and how they relate to concrete properties are presented in chapter two of
this manual.
Relative Proportion of Aggregates
Aggregates in concrete are of two types: Coarse aggregates which refer to materials retained
on 4.75mm sieve size; and Fine aggregates which are materials passing through 4.75mm
sieve size. The proportion of fine aggregates to coarse aggregate in a concrete mix depend
on the fineness of the fine aggregate, size/shape of coarse aggregates and the cement
content. Details of the effect of properties of aggregates on properties of concrete mixes are
presented in chapter three
Factors Affecting Concrete Mix Proportions
The process of designing a concrete mix consists of selecting the appropriate proportions of
cement, fine aggregate, coarse aggregate and water to produce concrete having specified
properties. The most fundamental way of specifying mix proportions is in terms of the mass of
material in a unit volume of fully compacted concrete. The various factors affecting the choice
of mix proportions include:
Compressive Strength
The compressive strength of concrete is the most universally used measure for concrete
quality. It influences other properties of hardened concrete. Studies have shown that the
compressive strength of concrete is inversely proportional to the water cement ratio within
practical limit. The strength of the cement paste binder in concrete is dependent on the quality
and quantity of the reaction of the paste components and the extent to which the hydration
reaction has progressed. The strength of concrete increases with time as long as there is
sufficient hydration water/moisture at a favourable temperature. Hence, the strength at a
particular age is dependent on both the original water-cement ratio as well as the degree to
which the cementitious materials have hydrated. The mean compressive strength at a specific
age, typically 28 days, determines the water-cement ratio of the mix. (Except in pozzolanic
cement where ages 56 to 90 days may be specified)
Workability
The workability required for various types of construction is dependent on various factors. The
Slump test is typically used to determine the degree of workability. For a given proportion of
cement and aggregates, the higher the slump, the wetter the mixture and higher the
workability.
Durability
Typically, high strength concrete is generally more resistant to adverse conditions as
compared to low strength concrete. However, in conditions where high strength is not required
but the concrete would be exposed to adverse conditions, the durability requirement will
determine the water-cement ratio to be used.
Maximum Size of Aggregate
Maximum size of aggregate, MSA, influences workability, strength, shrinkage, and
permeability. Mixtures with large maximum size of coarse aggregate tend to produce concrete
with better workability, probably because of the decrease in specific surface. There is an
optimal maximum size of coarse aggregate that produces the highest strength for a given
consistency and cement content. In high performance concrete (HPC) with low water-cement
ratio and high cement content, a high value of MSA tends to reduce strength. This can be
explained by the observation that bond with large particles tends to be weaker than with small
particles due to smaller surface area-to-volume ratios. Mixtures with coarse aggregates having
large maximum size tends to have reduced shrinkage and creep. Finally, for a given water-
cement ratio, the permeability increases as the maximum size of the aggregate increases.
Maximum Nominal Size of Aggregate
The maximum size of coarse aggregate is the standard sieve size through which at least 90%
of the coarse aggregates would pass. Typical maximum sizes of aggregate in use in Nigeria
are 40mm, 20mm and 10mm with 20mm being the most common. The maximum size of
aggregate affects the workability and strength of the concrete. It also affects the required water
content for a certain workability and fine aggregate content required for achieving a cohesive
mix.
The larger the size of the maximum aggregate, the lower the surface area of the coarse
aggregates. With a higher surface area, a higher water content is required to coat the particles
and develop workability. Also, a higher maximum size of aggregate would require a lower fine
aggregate content to coat the particles and maintain cohesiveness of the concrete mix. This
implies that for the same workability, coarse aggregate with maximum size of 40mm could
require a lower water cement ratio and thus higher strength compared to coarse aggregate
with maximum size of 20mm. However, maximum size of aggregate is restricted by the clear
cover and the minimum distance between reinforcement bars.
Grading and Type of Aggregate
Typically, aggregates can be single sized or graded in terms of particle size distribution. The
grading of aggregate is significant in achieving a dense and cohesive concrete mix. The voids
created by the larger coarse aggregates are filled by the smaller coarse aggregates and
hence, the volume of cement-sand-water paste required to fill the final voids is minimum. By
proper
grading of coarse aggregate, the compactibility of concrete is improved and segregation is
minimized especially for higher workability. The type and source of aggregate also has a
significant effect on the compressive strength of concrete. Typical aggregates in use in Nigeria
can be categorized in the crushed and uncrushed classes. It is widely accepted that
concrete produced from crushed aggregate has a higher strength compared to concrete
produced from uncrushed aggregates. This can be attributed to the rough surface texture of
the crushed aggregates which gives it a better bonding with the cement gel. The grading of
aggregate is significant in attaining an economical mix as it affects the amount of concrete that
can be obtained with a given amount of cement and water.
MIX DESIGN PROCEDURE
There are two main methods of mix design; the first is common in the United Kingdom (Design
of Normal Concrete Mixes, Building Research Establishment report BR331), and the second
in the United States (Standard Practice for Selecting Proportions for Normal, Heavyweight,
and Mass Concrete, American Concrete Institute Standard 211.1). Although, in the month of
August, 2017, the Council for the Regulation of Engineering in Nigeria published a concrete
mix design manual to be used in the Nigerian industry, but as at now (2018), the Nigerian
industry has not gotten used to it.
For ease of calculation, the mix design procedure is divided into eleven stages. Each step
by step procedure deals with a particular aspect and ends with an important parameter.

STAGE 1. CALCULATING THE TARGET MEAN STRENGTH

From the specified proportion of defectives, and the known or assumed standard deviation
(see Fig. 1), calculate the margin and add this to the characteristic strength to obtain the target
mean strength using equation:

fcr = fc + 1.64s.
Where
fcr = Target mean strength (Required strength)
fc = Design strength
1.64 = Reliability index (modification factor)
S = standard deviation
 1

STAGE 2. INITIAL STRENGTH VALUE

For the specified materials and test age, find the strength that would be expected with a w/c
ratio of 0.5from Table 1.
STAGE 3. DRAW THE CURVE FOR THE W/C RATIO
On Fig. 2 plot the point found at stage 2 above. Draw a curve through this point parallel to the
existing curves on the figure. These curves represent the relationship between strength and
w/c ratio for the particular materials, and test age, being used.
STAGE 4. OBTAIN THE W/C RATIO
On the curve drawn in Fig. 2, locate the target mean strength, and read off from the bottom
axis the required water/cement ratio.

1
 2

STAGE 5. CHOICE OF WATER CONTENT

From Table 2, obtain the free water content required to give the specified workability.
STAGE 6. CALCULATE CEMENT CONTENT
Calculate the cement content as the water content divided by the w/c ratio.

2
STAGE 6. CALCULATE CEMENT CONTENT
Calculate the cement content as the water content divided by the w/c ratio.
STAGE 7. ESTIMATE WET DENSITY
Using the known or assumed value for relative density (specific gravity) of aggregate, from
Fig. 3, obtain an estimate of the wet density of the concrete. Note that a given aggregate
density of 2500 kg/m would be used in Fig. 3 as a relative density of 2.5

STAGE 8. CALCULATE AGGREGATE CONTENT

Calculate the total aggregate content by subtracting cement and water content from the
concrete density.
STAGE 9. OBTAIN PROPORTION OF FINE AGGREGATE
For the specified fine aggregate grading (given as the percentage passing a 600 mm sieve),
obtain an estimate for the proportion of fine aggregate in the total aggregate, depending on
the maximum aggregate size, workability, and w/c ratio from Fig. 4.
4
STAGE 10. CALCULATE FINE AND COARSE AGGREGATE QUANTITIES
Calculate the fine aggregate content by multiplying the total aggregate content by the
proportion of fine aggregate. Calculate the coarse aggregate content by subtracting fine
aggregate content from total aggregate content.
STAGE 11. CALCULATE QUANTITIES FOR REQUIRED VOLUME
The quantities for each material are multiplied by the volume required for use.

Example
Calculate the quantities for a 0.15 m3 trial concrete mix to the following specification using the
UK method:
Characteristic strength: 35 MPa at 28 days
Cement: OPC (EN class 42.5)
Percent defectives: 5%
No. of test samples: 5
Target slump: 50 mm
Coarse aggregate: 10 mm uncrushed
Fine aggregate: Uncrushed 50% passing a 600 mm sieve

Solution:
Stage 1. Standard deviation = 8 MPa (Fig. 1 with five results)
Target mean strength = 35 + 8 × 1.64 = 48.12 MPa
Stage 2. Starting point for Fig. 3 = 42 MPa (Table 1)
Stage 3 and 4. w/c = 0.45
Stage 5. Water content = 205 kg/m3 (Table 2)
Stage 6. Cement content = 205/0.45 = 455 kg/m3
Stage 7. Density = 2340 (Fig. 4 using the assumed relative density of 2.6 for uncrushed
aggregate)
Stage 8. Aggregate content = 2340 - 205 - 455 = 1680 kg/m3
Stage 9. Percentage fne aggregate = 44% (Fig. 2 for 10 mm aggregate and 30–60 mm
slump). A line for 50% passing a 600 mm sieve is assumed between 40% and 60% lines.
Stage 10. Fine aggregate content = 1680 × 44% = 739 kg/m3

Coarse aggregate content = 1680 - 739 = 941 kg/m3

Stage 11. The final quantities in kg/m3 are: