M6CCT19 ADVANCED CONCRETE TECHNOLOGY

Department of Civil Engineering Science

University of the Johannesburg

VOLUMETRIC MIX DESIGN

(By Prof. SO. Ekolu)

Consider one cubic metre of concrete divided into its absolute volumes of water, cement, sand,
stone:

Problem: Determine the mass of each component per

unit volume of concrete (kg/m3)

(1) W/C ratio: Water-cement ratio is selected on the basis of the required strength and the
required durability. Tables and design curves are consulted. In designing mixes, we aim at
some target or average strength higher than the characteristic strength i.e. Average (target)
strength = characteristic strength + 1.7 SD (SD = 5% for good control).

(a) W/C for strength: Table 1 may be used if required strength is not known. A target strength
greater than the minimum specified (characteristic) strength is normally used. Having
established the target strength, the W/C needed to obtain this strength is selected directly
using known relations such as curves in Figure 1.

(b) W/C for durability: Requirements for durability are recommended in the SANS 0100-2
design code, given in Table 2. The minimum strength grade, minimum cement content
along with minimum nominal cover are specified for each exposure condition.

The final W/C selected will be the lesser of that selected for strength and for durability.

(2) Water Content(W): Water content is determined mainly by workability requirements, and is
generally estimated from a visual examination of the aggregates concerned. Sand is the most
critical aggregate component affecting water requirement and figures of 180 to 240 kg/m3 are
common. As coarse aggregate size increases, so water content decreases. Table 3 may be used
to make an initial estimate of the water content, adjusted using values in Table 4 for stones other
than 19 mm.

(3) Cement Content (CC): CC is calculated from W / (W/C), and checked against requirements for
minimum CC in Table 2. The normal range is 200 to 450 kg/m3.
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(4) Stone Content: This is determined from its void content and a knowledge of the F.M. of the
sand. The lower the F.M. of sand, the higher the stone content can be since the finer sand gives a
greater “lubrication” of the mix. More stone can be provided in mixes which are to be
mechanically compacted than hand compacted. We normally want to maximize the stone
content of a mix to produce the best economy, minimum shrinkage, creep, etc. Values of 900 –
1200 kg/m3 are typical.
Stone content is calculated as Mst = CBD (K-0.1FM)
CBD = compacted bulk density of stone
FM = fineness modulus of sand
K = the factor for workability, obtained from Table 5

(5) Sand Content: This is determined by first calculating the absolute volumes occupied by the
water, cement and stone, and subtracting their sum from 1m3 to give the absolute volume of the
sand, which is then converted to a mass/m3.

Note that the Curves and Tables 3 to 5, apply to 75 mm slump concrete. Figure 2 is then used to
adjust slumps as required.

Typical Tables and Curves for Use in Mix Design

Table 1: Recommended characteristic concrete strengths for various purposes

Description and purpose Characteristic 28-day

compressive strength
(MPa)
Prestressed concrete 40
High-grade concrete for highly stressed reinforced concrete
members; concrete roads, paving and floors on the ground to
carry fork-lift trucks. Precast structural units; water-tight 30
walls and tanks; concrete subject to severe vibration and
shock
High-grade structural concrete for machine foundations
subject to vibration and shock; light-duty one-course floors
25
on the ground (no trucking) minimum for watertight
reinforced-concrete construction
Standard structural-grade concrete for: general reinforced
concrete construction in buildings, bridges, culverts, silos,
bins,etc; machine foundations; unrendered walls above 20
ground; base courses of lightly loaded floors on the ground
(no trucking)
Mass concrete for: basement and foundation walls; dams and
weirs; bridge piers, abutments and wing walls; large
15
foundations for non-vibrating machinery; footings for one
and two storey buildings
Mass concrete of roughest type for: large, lightly loaded
footings and foundations; retaining walls; making up over- 7-10
excavation in trenches; etc.
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Figure 1: Curves for selection of W/C for a

given strength
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Table 2: Nominal cover and strength grade for durability (SANS 0100-2)

MINIMUM NOMINAL COVER FOR

DURABILITY
Mild a) Exposed to only unpolluted air 20 20 20 20 20
-e.g. indoors, outdoors in Karoo
Moderate a) Sheltered from rain or - 35 30 25 20
b) Buried in non aggressive soil or
c) Subject to polluted air
- e.g indoors in industrial areas,
CONDITIONS

outdoors in rural highveld areas

Severe Exposed to - - 40 35 30
a) wet conditions
b) corrosive fumes
c) salt-laden air
d) buried in aggressive soil
- e.g. outdoors in industrial areas,
EXPOSURE

marine areas – 15km from sea

Very Exposed to: - - - 45 40
severe a) sea water
b) water containing sulphates or
chlorides
c) highly corrosive fumes
Extreme - - - - 50
Concrete Grade: 20 25 30-35 40-45 >45
Max W/C: 0,67 0,60 0,53 0,50  0,45
Minimum CC: 300 340 380 400 420

Table 3: Approx. water contents

for concrete mixes (19-mm, 75 mm slump)
Sand Quality Water content (l/m3)
Natural Crusher Table 4: Correction to water contents for stone
sizes other than 19 mm
Very poor 240 235 Max size of stone, mm 9.5 13.2 19.0 26.5 37.5
3
Poor 225 225 Correction, l/m +20 +10 0 -10 -20
Average 210 215
Good 195 205
Excellent 180 195
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Figure 2: Curves for changing

slump from one value to another

Table 5: K values

Values of K
Workability Maximum size of stone, mm
9.5 13.2 20 26.5 37.5
Very high (150 mm slump) 0.72 0.81 0.92 0.97 1.03
High (100 mm slump) 0.75 0.84 0.94 0.99 1.05
Medium (40 mm slump) 0.80 0.90 1.00 1.02 1.10
Low (25 mm slump) 1.00 1.05 1.05 1.10 1.15
Very low (15 mm slump) 1.20 1.20 1.15 1.15 1.15
Extremely low (0 slump) 1.40 1.40 1.30 1.30 1.25

References
Fulton’s concrete technology, 6th & 8th Ed., 1986; 2001.
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EXAMPLE: Determine a trial mix design

Requirements: Moderate exposure
Concrete grade: 30 MPa
Slump: 50 mm

Data: Cement: CEM II 42.5N, relative density (R.D) = 3,15

Stone: 20 mm size; R.D = 2,7; dry compacted bulk density (CBD) = 1530 kg/m3
Sand: R.D = 2,65; fineness modulus (FM) = 2,8

(1) Average (target) strength = …………………………………

W/C for strength = ……………………………………….…

W/C for durability =………………………………………...

(2) Estimate for sand of average quality

………………………………………………………………

(2) Cement content

………………………………………………………………

(4) Stone content:

……………………………………………………………..
……………………………………………………………..
……………………………………………………………..

(5) Sand content

Materials Mass Density Abs volume (m3)

(kg) (Kg/m3)
Cement, CEM II
Water
Stone
Sand

Trial mix (quantities per m3)

Cement ……….
Water ………..
Stone ………..
Sand ………..