BATCHING OF FRESH CONCRETE

The measurement of materials for making concrete is known as batching.

There are two methods of batching:
 Volume batching
 Weight batching
Weight batching is preferred over volume batching especially on important jobs. This is
because of the fact that the quantity of solid materials in a container very much depends on
its degree of compaction i.e. on the closeness with which the material packs. If the material
packs closely with few air voids the solid volume of the materials is greater than if the
material is packed loosely. However, because it is convenient volume batching is used at
most construction sites.

Volume batching of cement should be avoided because being a very fine material, its
volume is greatly affected by the way it is filled in the gauge box. It is more accurately
measured by weight. Ordinarily cement is batched by the bag. Each cement bag is packed to
contain a net weight of 50Kg, which is approximately 35 liter in volume. The quantity of
aggregate to be batched with each bag of cement would then be easily measured by using a
measuring box of 35 liter. One such a box would measure internally 40 X 35 X 25 cm.

Water is usually measured by volume in a calibrated tank or by means of flow type water
meters.
Proportions by volume are usually specified in terms of aggregates in a dry-rodded
condition, but the batch quantities must be given in the loose condition. Care must be taken
in the case of wet sand, which might bulk.

CONCRETE MIX DESIGN

It is the process of selecting suitable ingredients of concrete and determining their relative
proportions with the object of producing concrete of certain minimum strength and
durability as economically as possible.

Variables in proportioning
In connection with specifying a concrete mix, four variable factors to be considered are
 Water-cement ratio.
 Cement content or cement-aggregate ratio.
 Gradation of the aggregates.
 Consistency.
Usually two or three factors are specified, and the others are adjusted to give minimum
workability and economy. Water/cement ratio expresses the dilution of the paste - cement
content varies directly with the amount of paste. Gradation of aggregate is controlled by
varying the amount of given fine and coarse aggregate. Consistency is established by
practical requirements of placing.

In brief, the effort in proportioning is to use a minimum amount of paste (and therefore
cement) that will lubricate the mass while fresh and after hardening will bind the aggregate
particles together and fill the space between them. Any excess of paste involves greater cost,
greater drying shrinkage, greater susceptibility to percolation of water and therefore attack
by aggressive waters and weathering action. This is achieved by minimising the voids by
good gradation.

Page 1
 Design Mean Strength
The assumption of a normal distribution of concrete strengths forms the basis of mix design
and statistical quality control procedures for satisfying the strength requirement. For a
normal distribution, the probability of a strength lying outside specified limits either side of
the mean strength can be determined. These limits (fig. below) are usually expressed in
terms of the standard deviation s defined by,

 
1/ 2
 
 fc   c
2
1/ 2 f
   f c  f cm 
2
2
 
s   n  N / mm2
 n1   n1 
 
Where fc = observed strength
fcm = best estimate of the mean strength
=   fc n
n = the number of observations.

Probability values

Probability of an observed strength Probability of an observed strength

lying outside the range  being less than (fcm - s)
(fcm  s)
1 in 50 2.33 1 in 100
1 in 20 1.96 1 in 40
1 in 10 1.64 1 in 20

The probabilities of a strength lying outside the range (f cm  s) for different values of  are
given in the above table, in which of probabilities of strengths falling below the lower limit
(fcm - s) are also given.

If the specified characteristic strength fcu is the strength below which not more than
1 in 20 of the population of strengths shall fall, it follows that,
fcu = fcm - 1.64s
Or fcm = fcu + 1.64s

Hence if the standard deviation likely to be obtained on site can be assessed, the mean
strength for which the concrete must be designed can be determined.

American Method of Mix Design

In practice the most widely used method of mix design is that of the American Concrete
Institute, given in ACI Standards. The ACI method utilizes the fact that, for a given
maximum size of aggregate, the water content in kilogram per cubic meter determines the
workability of the mix, largely independently of the mix proportions. The relative water
content for various workabilities is given in Table 3.1a and Table 3.1b gives the actual
content for a reference (plastic) consistence. It is thus possible to start the mix design by
selecting the water content from these two tables. The values given are for well-shaped
angular coarse aggregates, and in practice there would be some variations due to differences
in aggregate shape and texture. It should also be added that in mixes with a cement content
in excess of about 360 or 390 kg/m3 the water requirement is greater.
Page 2
 A further assumption is made that the optimum ratio of the bulk volume of coarse aggregate
to the total volume of concrete depends only on the maximum size of aggregate and on the
grading of fine aggregate. The shape of the coarse aggregate particles does not directly
enters the relation since, for instance, a crushed aggregate has a greater bulk volume for the
same weight (i.e. a lower bulk density) than a well rounded

Table 4.1a: Relative Mixing Water Requirements for Different Consistencies of concrete

Consistence Relative Water

Content
Description Slump Compacting Vebe
(mm) factor (s) (Per cent)
Extremely dry _ _ 32 - 18 78
Very stiff _ 0.70 18 -10 83
Stiff 0 - 30 0.75 10 - 5 88
Stiff plastic 30 - 80 0.85 5 -3 92
Plastic (reference) 80 - 130 0.91 3-0 100
Fluid 130 - 180 0.95 _ 106

Table 4.1b: Approximate Mixing Water Content for the Reference (Plastic) Mix of Table
3.1a for different maximum sizes of Aggregate

Maximum size of Non-air-entrained Entrapped air content Air-entrained water

aggregate water content (Per cent) content
(mm) (Kg/m3) (Kg/m3)
10 225 3 200
12.5 215 2.5 190
20 200 2 180
25 195 1.5 175
40 175 1 160
50$ 170 0.5 155
70$ 160 0.3 150
150$ 140 0.2 135

$ Water contents of concretes with aggregates sizes greater than 40 mm are not given
For mixes with a slump of less than 30 mm.

Table 4.2. Bulk Volume of Coarse Aggregate per Unit Volume of Concrete.

Page 3
Maximum size of Bulk volume of dry rodded coarse aggregate per unit volume of concrete for
aggregate fineness modulus of sand of: __
(mm)
2.40* 2.60* 2.80* 3.00*
10 0.50 0.48 0.46 0.44
12.5 0.59 0.57 0.55 0.53
20 0.66 0.64 0.62 0.60
25 0.71 0.69 0.67 0.65
40 0.75 0.73 0.71 0.69
50 0.78 0.76 0.74 0.72
70 0.82 0.80 0.78 0.76
150 0.87 0.85 0.83 0.81

 Fineness modulus of sand.

Table 4.3. Factors to be applied to the Volume of Coarse Aggregate Calculated on the
basis of Table 3.2. for Mixes of Consistence other than Plastic.

Consistence Factor for maximum size of aggregate of _

10mm 12.5mm 20mm 25mm 40mm

Extremely dry 1.90 1.70 1.45 1.40 1.30
Very stiff 1.60 1.45 1.30 1.25 1.25
Stiff 1.35 1.30 1.15 1.15 1.20
Stiff plastic 1.08 1.06 1.04 1.06 1.09
Plastic (reference) 1.00 1.00 1.00 1.00 1.00
Fluid 0.97 0.98 1.00 1.00 1.00

Table 4.4. Relation between Water/Cement Ratio and Compressive Strength of

Concrete According to ACI Standard

Compressive strength at Water/cement ratio (by weight)

28 days*
(Mpa.)
Non-air-entrained concrete Air-entrained concrete
48 0.33 _
41 0.41 0.32
34 0.48 0.40
28 0.57 0.48
21 0.68 0.59
14 0.82 0.74

*Measured on standard cylinders. The values given are for maximum size of aggregate of
20 to 25mm.

Table 4.5. Maximum Permissible Water/Cement Ratios for Different Types of

Page 4
 Structures in Severe Exposure, Prescribed by ACI Standard.

Exposure conditions
Type of structure
Structure wet continuously Structure exposed to
or frequently and exposed sea water or
to freezing and thawing* sulphates
Thin sections, such as railings,
kerbs, sills, ledges, ornamental
work, and sections with less
than 25mm cover to the
reinforcement.
0.45 0.40$
All other structures 0.50 0.45$

* Air-entrained concrete should be used under all conditions involving severe exposure.
$
When Type II or Type V cement is used, maximum water/cement ratio may be increased
by 0.05.

ACI method of mix design

The first step in mix design is to establish the design strength from the project requirement
and the over design factor.
The following mix design procedure is based on the ACI manual of concrete practice
standard ACI 211.1-91, using metric units.
1. Choose slump from Table 3.1a
2. Choose the maximum size of the aggregate. The largest size that is economically
available in the area is usually chosen, subject to the following maximums:
 One-fifth of the width of the forms
 One-third of the depth of the slabs
 Three-fourths of the space between reinforcing bars
3. Estimate the amount of mixing water and air required from Table 3.1b. Admixtures,
if used, are added to the water.
4. Select the W/C or W/CM ratio from Table 3.4 (for design strength), and Table 3.5
(for exposure). (Use lowest).
5. Calculate the cement content from the W/C ratio and water-content values.
6. Estimate the proportion of coarse aggregate from Table 3.3, and its mass using the dry-
rodded density.
7. Estimate the mass of fine aggregate using the estimated total mass shown in Table 3.2.
8. Calculate the adjustments required for aggregate moisture. Usually the aggregates are wet
and therefore the mass of water that they contain, both absorbed and surface water must be
added to the required mass of aggregates, and the mass of surface water subtracted from the
water requirement.
9. Make trial batches. Only sufficient water should be used to produce the desired
slump. Test for slump, air, and density, and cast cylinders for strength, if required. If
specifications are not met, new batches should be prepared with adjusted
proportions. If the mix is satisfactory, design quantities, corrected for moisture
contents of the aggregates, should be recorded for use.

Page 5
Table 4.6a
RECOMMENDED SLUMPS FOR VARIOUS TYPES OF CONSTRUCTION (SI)
Types of Construction Slump, mm
Maximum Minimum
Reinforced foundation walls and footings 75 25
Plain footings, caissons, and substructure walls 75 25
Beams and reinforced walls 100 25
Building columns 100 25
Pavements and slabs 75 25
Mass concrete 75 25

Table 4.6b
APPROXIMATE MIXING-WATER AND AIR-CONTENT REQUIREMENTS

Water, kg/m3, for Indicated Nominal Sizes of Aggregates (mm)

Slump mm 9.5 12.5 19 25 37.5 50 75 150
Non-Air-Entrained Concrete
25 – 50 207 199 190 179 166 154 130 113
75 – 100 228 216 205 193 181 169 145 124
150 - 175 242 228 216 202 190 178 160 -
Approximate 3 2.5 2 1.5 1 0.5 0.3 0.2
entrapped air (%)
Air-Entrained Concrete
25 – 50 181 175 168 160 150 142 122 107
75 – 100 202 193 184 175 165 157 133 119
150 – 175 216 205 197 184 174 166 145 -
Recommended air
content (%)
Mild exposure 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0
Moderate exposure 6.0 5.5 5.0 4.5 4.5 4.0 3.5 3.0
Severe Exposure 7.5 7.0 6.0 6.0 5.5 5.0 4.5 4.0

Note: Mild exposure-where air entrainment is not required for durability.

Moderate exposure where concrete will not be continually exposed to water before freezing or
to deicing agents.
Severe exposure – where deicing or similar agents are used or where concrete may be highly
saturated before freezing.

Table 4.7
FIRST ESTIMATE OF MASS OF FRESH CONCRETE (SI)

First Estimate of Concrete Unit mass, kg/m3

Nominal Maximum size
Non- Air Entrained Air Entrained Concrete
of aggregate, mm
Concrete
9.5 2280 2200
12.5 2310 2230
19 2345 2275
25 2380 2290
37.5 2410 2350
50 2445 2345
75 2490 2405
150 2530 2435

Table 4.8

Page 6
VOLUME OF COARSE AGGREGATE PER UNIT OF VOLUME OF CONCRETE

Volume of Dry-Rodded coarse Aggregate Per

Unit Volume of Concrete for Different Fineness
Moduli of Fine Aggregate
Nominal Maximum Size of 2.40 2.60 2.80 3.00
Aggregate, mm
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 4.9
ESTIMATED AVERAGE STRENGTHS FOR CONCRETE (MPa)

Water/Cement Ratio (by Mass)

Compressive Strength, 28 Non-Air Entrained Air-Entrained
Days (MPa) Concrete Concrete
40 0.42 -
35 0.47 0.39
30 0.54 0.45
25 0.61 0.52
20 0.69 0.60
15 0.79 0.70

Table 4.10
MAXIMUM WATER/CEMENT RATIOS FOR CONCRETE
IN SEVERE EXPOSURES

Type of Structure Structure Wet Continuously or Structure Exposed

Frequently and Exposed to to Seawater or
Freezing and Thawing Sulfates
Thin sections (railings, curbs,
sills, ledges, ornamental work)
and section with less than 25
mm. –cover over steel 0.45 0.40
All other structures 0.50 0.45

Page 7
Example 4.1 .A trial mix is required for a 150-mm pavement slab being constructed in an
area where exposure to seawater is expected. Strength required is 20 MPa. Trial mix design
strength is 28.5 MPa as previous test result are not available. For the sand, FM = 2.80 and
absorption is 1.2%. The absorption of the coarse aggregate is 1.6%, and its dry-rodded
density is 1730 kg/m3. Fine aggregate is dry and coarse aggregate contains 3.0% water.

Calculate
1. Slump allowed is 25-75 mm (Table 3.1a).
2. Maximum aggregate size is 50 mm (150/3). Size 37.5 mm is chosen, as it is
economically available in the area.
3. Mixing water required is 150 kg/m3 (for 25-50 mm slump). Air content required is
5.5% (Table 3.1b).
4. Maximum W/C is 0.47 for strength and 0.45 for exposure. Use 0.45 (Tables 3.4 and
3.5).
5. Cement content is 150 kg/m3/0.45 = 333 kg/m3.
6. Volume of dry coarse aggregate per volume of concrete is 0.71 (Table 3.3).
7. Materials per m3 (Estimate only as variation in aggregate densities and water
absorption not considered).
Coarse aggregate –0.71 x 1730 = 1228 kg
Water 150 kg
Cement 333 kg
Total 1711 kg
Estimated total mass of concrete is 2350 kg (Table 3.2).
 Dry mass of fine aggregate is 2350 kg-1711 kg = 639 kg

8. Adjust for moisture contents.

Extra water required for fine aggregate is 1.2% x 639 = 7.7 kg
Surplus water on coarse is 1.4% x 1228 kg = 17.2 kg
Corrected mix proportions:
Cement = 333 kg
Water 150 + 7.7 – 17.2 = 140 kg
Fine aggregate (dry) = 639 kg
Coarse aggregate = 1228 + 3.0% x 1228 = 1265 kg
9. Prepare trial mixes. A 150 x 300 mm standard cylinder contains 0.053 m 3. For a mix
making three cylinders plus enough for other tests, 0.03 m3 (3% of 1 m3) will be prepared.
Therefore, quantities are 3% of those required for 1m3.
Cement 9.99 kg
Water 4.20 kg
Fine aggregate 19.2 kg
Coarse aggregate 38.0 kg
Water is added to the mix only in sufficient quantities to give the desired slump. This could
be more or less than the amount prepared. If requirements have been met, corrected batch
quantities must be calculated. Results of the trial mix were: water used, 4.12 kg; air content,
5.2%; and density of the mix, 2340 kg/m3.

Page 8
Cement 9.99 kg
Fine aggregate (SSD): 19.2 + 1.2% x 19.2 (absorption is 1.2%) = 19.2 + 0.23 = 19.43 kg
Coarse aggregate (SSD): 38.0 – 1.4% x 38.0 [excess moisture is total (3.0) – absorbed
(1.6) = 38.0 – 0.53 = 37.47 kg
Mix water; 4.12 – 0.23 + 0.53 = 4.42 kg
Total mass = 71.31 kg
Density was 2340 kg/m3.
Therefore, batch quantities per cubic meter are
Cement: 9.99 x (2340/71.31) = 9.99 x 32.814 = 328 kg/m3
Water: 4.42 x 32.814 = 145 kg/m3
Fine aggregate (SSD): 19.43 x 32.814 = 638 kg/m3
Coarse aggregate (SSD): 37.47 x 32.814 = 1230 kg/m3
Total: 2341 kg/m3

Actual W/C ratio = 145/328 = 0.44

The proportions of cementing materials can also be calculated using the volume occupied
by each component. In the ACI method illustrated in Section 7-6.2, the amount of fine
aggregate required is obtained using the masses of the components. An alternate method
uses the absolute volumes of the components. This method is also included in the CPCA
manual. The following example illustrates the calculations.

Example: 4.2. At step 7 of Example 7-8, these mix quantities were established (as summing
that cementing materials were specified instead of cement): water-150 kg, cementing
materials – 33 kg, and coarse aggregate – 1228 kg. The cm is to include 20% fly ash with
RD – 2.60. Design air content was 5.5%, and the RD values for the fine and coarse
aggregates in the dry (bulk) condition were 2.65 and 2.68 respectively. Calculate the amount
of fine aggregate required. Calculations:
Volumes occupied by the known components in 1 m3 of mix are

Air: 0.055 x 1 = 0.055 m3

Water; mass kg/(RD x 1000 kg/m3) = 150/(1 x 1000) = 0.15 m3
Cement: 80% x 333 = 266 kg, 266/(3.15 x 1000) = 0.084 m3
Fly ash: 20% x 333 = 67 kg, 67/(2.60 x 1000) = 0.026 m3
Coarse aggregate: 1228/(2.68 x 1000) = 0.458 m3
Total volume = 0.773 m3
Volume of fine aggregate required = 1 – 0.773 = 0.227 m3
Mass required = 0.227 m3 x 92.65 x 1000 kg/m3) = 602 kg.
(639 kg was obtained using the approximate mass method in the previous example)

A water/cement ratio method of mix design, using the specifications of the Canadian
standards association (CSA) has been described by the Canadian Portland Cement
Association.

1. Exposed concrete must be air entrained and meet the requirements shown in Table 7-
18. The minimum required strength for exposure and the project required strength, if
specified, must both be met. Using the governing value and the overdesign factor
(Section 7-6.1), the mix design strength is selected.
The design (W?CM ratio is found from Table 7-14 for the strength requirement, and
from Table 7-18 for exposure. The lower value is used.

Page 9
 2. The maximum aggregate size is chosen. It must not exceed the limits given in step 2
of the ACI method, Section 76.2.
3. Design slump is selected from Table 7-19.
4. Quantities for a trial mix are prepared. About 10.0 kg of cement usually results in a
quantity sufficient for the slump, air, and density tests, and the casting of three
strength cylinders. Extra aggregates, in the saturated, surface-dry condition, are
prepared. (Usually a mass of fine aggregate 5 times the mass of water, and a mass of
5,8, and 10 times for coarse aggregate of maximum size 10,20 and 40 mm
respectively will provide ample quantities.)
5. Cement, including any supplementary materials, and water, including additives, are
mixed. Aggregates are added until the desired slump and a workable mix are
reached. Tests are conducted and the quality of mix, whether it is too harsh or over
sanded (see figure 7-15), is assessed.

Table 7-18
REQUIREMENTS FOR EXPOSED CONCRETE

Exposure Exposure Minimum 28 Maximum Air Content (%)

Classification* Condition* Day Strength, W/CM Max, Agg. Size mm
MPa 10 14-20 28-40
Concrete subjected to freezing and thawing, but not to chlorides
F–1 Saturated 30 0.50 6–9 5–8 4–7
F–2 Unsaturated 25 0.55 5–8 4–7 3–6
Concrete exposed to chlorides (including deicing chemicals or seawater)
C –1 Reinforced
(a) Freezing 35 0.40 6–9 5–8 4–7
(b) Other 35 0.40 5–8 4–7 3–6
C–2 Freezing 32 0.45 6–9 5–8 4–7
C–3 Saturated 30 0.50 5–8 4–7 3–6
C–4 Dry 25 0.55 5–9 4–7 3–6

*Exposure classifications and conditions:

F-1 – Concrete exposed to freezing and thawing in a saturated condition
F-2 – Concrete exposed to freezing and thawing in an unsaturated condition
C-1 – Reinforced concrete
(a) exposed to freezing and thawing
(b) not exposed to freezing and thawing
C-2 – Plain (unreinforced) concrete exposed to freezing and thawing
C-3 – submerged concrete not exposed to freezing and thawing
C-4 – Plain (unreinforced) concrete not exposed to freezing and thawing

With the permission of the Canadian Standards Association, material is reproduced from the CSA
Standard CAN/CSA A23.1-M94 (Concrete Materials and Methods of Concrete
Construction/.Methods of Test for Concrete), which is copyrighted by CSA, 178 Rexdale Blvd.,
Rexdale, Ontario, M9W 1R3. While use of this material has been authorized, CSA shall not be
responsible for the manner in which the information is presented, nor for any interpretation
thereof. This CSA material may not be updated to reflect amendments made to the original
content. For up-to-date information, contact CSA.

If the mix is suitable, batch quantities are calculated. Otherwise, changes are made in the
materials and/or proportions and additional trials conducted.

Page 10
Example 4.3 A trial mix is to be prepared for an un reinforced pavement requiring 25 MPa
concrete and subject to freezing and deicing chemicals. Ten kg of cement will be used. The
overdesign factor for these materials has been established as 3.0 MPa.

Table 7-19
SPECIFIED SLUMP
Type of Construction Slump (mm) Allowable Range (mm)
Mass concrete, pavements 40 20 – 60
Structural concrete, slabs on
ground, driveways, walks 80 50 – 110
Tremie concrete 170 140 - 200

With the permission of the Canadian Standards Association, materials is reproduced from the CSA
Standard CAN/CSA A23 1-M94 (Concrete Materials and Methods of Concrete
Construction/Methods of Test for Concrete), which is copyrighted by CSA, 178 Rexdale Blvd.,
Rexdale, Ontario, M9W 1R3. While use of this materials has been authorized, CSA shall not be
responsible for the manner in which the information is presented, nor for any interpretation thereof.
This CSA material may not be updated to reflect amendments made to the original content. For up-
to-date information, contact CSA.

1. The minimum strength required for this exposure (C-2) is 32 MP1. This is greater
than the project-specified strength, and will govern. With the overdesign factor, the
mix design strength is 35 MPa.
From Table 7-14, the maximum W/CM ratio is 0.39. This meets the requirements of
Table 7-18 for this exposure, 0.45, and will be used.

Fig.
Figure 7-15 Harshness of concrete: (a) harsh mix – not enough cement-sand mortar to fill
the spaces between the coarse aggregate particles; (b) good mix-with a light troweling, all
the spaces between the coarse particles are filled (note the good supply of coarse particles at
the edge of the pile); (c) overstanded mix-finishes well but with an excess of mortar, making
it an uneconomical and possibly porous mix.
2. A maximum aggregate size of 40 mm will be used although up to 200/3 = 67 mm
would be acceptable. The required air content is 4-7% (Table 7-18). This will be
used to calculate the amount of air-entrainment chemical to add to the mix water.
3. Required slump is 40 mm, with an allowable range of 20-60 mm (Table 7-19).
4. Quantities for mix:
Cement 10.0 kg
Water (10.0 x 0.39) 3.9 kg
Fine aggregate (SSD) 19.5 kg
Coarse aggregate (SSD) 39.0 kg
5. Actual aggregate quantities used were – fine 19.4k
- coarse 38.5 kg
Total mass of mix = 71.8 kg
Density as measured was 2290 kg/m
Batch quantities:
Cement = 10.0 (kg) x 2290 (kg/m)/71.8 kg = 319 kg/m
Water 3.9 x 2290/71.8 = 124 kg/m
Fine aggregate (SSD) 19.4 x 2290/71.8 = 619 kg/m
Coarse aggregate (SSD) 38.5 x 2290/71.8 = 1228 kg/m
Total 2290 kg/m

Page 11
Note: The Canadian Portland Portland_Cement Association recommends minimum cement
content of 335 kg for this type of exposure.

Research conducted by SHRP has led to a recommendation that a revised method be used to
proportion the trial mix aggregates, in step 6 of the ACI design method.

Computer-generated tables have been used to find the optimum proportions of spheres of
two or three sizes. Voids in the aggregate mixture must be filled with the more expensive
paste fraction. Therefore the aggregate combination with the least volume of voids is the
most economical and densest.

To use the tables, two values for each aggregate are required. The cahract5eristic diameter
D, is found from the diameter at the 63% passing level of a straight-line plot of the grain-
size curve on specified graph. The dry-rodded density and voids content are obtained from a
standard test (AASHTO T19). The dry-packing density PH) is calculated from
PHI = 1 – (% voids/100)

Adjusted quantities
Cement _______ (A)
Water (B1 + excess – required) _______ (B2)
Fine aggregate (C2 – excess + required) _______ (C3)
Coarse aggregate (D2 – excess + required) _______ (D3)
Total _______ (T)
Air-entraining agent _______
Mass per cubic meter
Cement (A/T x ) _______
Water (B2/T x ) _______
Fine aggregate (C3/T x ) _______
Coarse aggregate (C3/T x ) _______
Strength test:
Age in days _______
Failure load _______
Area _______
Strength _______

Trial Mix – ACI Method

Purpose: To find the optimum proportions of cement, water, aggregates, and admixtures for
a concrete mixture.

Apparatus:
Mixing pan and tools (or a mechanical mixer)
Balances
Slump cone
Air meter
Volumetric container
Strength-test molds
Procedure:

Page 12
 1. Using given or established design criteria, find the estimated quantities per cubic
yard or cubic meter. If supplementary cementing materials are used, the mass of fly
ash or other SCM will also have to be determined. Slump can be found from Table 7
– 12, and amount of mixing water and air from Table 7-13. The W/C or W/Cm ratio
is obtained from Tables 7-14 and 7-15. The volume and mass of coarse aggregate is
calculated from the dry-rodded density and the proportion found in Table 7-16. The
amount of fine aggregate can be found by using the volume method or by using the
estimated total mass of the concrete (Table 7-17).
2. Calculate the amounts required fro a trial mix. A batch of about 0.25 ft 3 or 0.007m3
should be mixed for each standard-strength cylinder to be made.
3. If the aggregates are not in the saturated, surface-dry condition, correct the
calculated batch quantities.
4. Measure out the indicated amounts of each materials, adding the air-entraining
agent, if used, to the water.
5. Dampen the mixing pan (or mixer). Mix the cement and fine aggregates together.
Add the coarse aggregate and mix. Add about 50-75% of the water and mix
thoroughly. Add additional water, mixing constantly, until the desired consistency is
reached. 9This may require more or less water than measured out.) Note the actual
amount of water used an observe the quality of the mix.
6. Conduct a slump test and, if required, an air-content test. 9See sections 7-12.3 and 7-
12.4.)
7. Remix the concrete; place it in the volumetric container in three layers. Rodding
each layer 25 times; level the surface of the concrete flush with the top of the
container; and obtain the mss of the concrete in the container.
8. Remix the concrete and cast the strength-test cylinders. (See section 7-12.5.)
9. Calculations:
a. Find the density of the concrete.
b. Note the actual quantities used and calculate the adjusted amounts if the
aggregates were not in the saturated, surface-dry condition.
c. Calculate the mass per unit volume in 1b/yd 3 or kg/m3, and the actual W/C
ratio.
10. Cap and strength test the cylinders at the specified age. (See Section 7 – 12.6)

Note: For a second trial mix, if required, use the yield quantities for proportions of water
and fine and coarse aggregates, with any adjustments required to improve the workability or
finishing properties. Recalculate the amount of cement needed, used the required W/C
ration and the indicated water content.

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TRIAL MIX-ACI METHOD DATA SHEET

Design Criteria: Specified strength _________ Design strength _________

W/CM _________ Slump __________ Max. agg. Size ________________
Air entrainment _____ yes __________ % or no __________ (% entrapped = ________)
Fine aggregate ____ RDSSD ___________ Dry-rodded density __________
Estimted proportions _______ per cubic yard ________ or cubic meter _________
Water (Table 7-13) _________ (A)
Cement  (water W/C) _________ (B)
Coarse aggregate [volume (Table 7-16) x dry- _________ (C)
rodded density]
Air-entraining agent ______
Total mass _________ (M)
Fine aggregate
(a) Volume method
Volume water _________
Volume cement _________
Volume coarse aggregate _________
Volume air _________
Total ________(V)
Volume fine aggregate (1m3 – V) _________
Mass fine aggregate (volume x RDSSD x w) _________ (D)
(b) Mass method
Estimated mass of concrete (Table 7-17) _________(M1)
Mass of fine aggregate (M1-M) _________(D)
Batch quantities – batch size _________
Water _________(A1)
Cement _________(B1)
Coarse aggregate _________(C1)
Fine aggregate _________(D1)
Air-enteraining agent _________
Corrections for water content
Fine Coarse
Water content, % ______ ______
Absorption, % ______ ______
Excess or required water, % ______ ______
Amount of excess water (% x mass of aggregate) ______ ______
Amount of required water (% x mass of aggregate) ______ ______
Revised quantities
Water (A1 – excess or + required) _________(A2)
Cement _________(B2)
Coarse aggregate (C1 + excess or – required water) _________(C2)
Fine aggregate (D1 + excess or – required _________(D2)
water)
Mixture:
Water used ______(A3)
Appearance-stony, good, or sandy ______
Finishability-good, fair, or poor ______
Density:
Volume of container ______
Mass of concrete density ______
Density ______
Slump: _______
Air content: _____
Calculations:
Water used ______ (A3)
Correction for aggregates ______

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 + excess water ______
- required water ______
Mix water ______ (A4)
Total mix (A4 + B1 + C1 + D1) ______ (T)
Mass per unit volume
Water (A4/T x ) ______
Cement (B1/T x ) ______
Coarse aggregate (C1/T x ) ______
Fine aggregate (D1/T x ) ______
Actual W/C ratio (A4/B1) ______
Strength test:
Age in days ______
Failure load ______
Area ______
Strength ______

PROBLEMS

1. What are the main compounds in Portland cement? Which one is most important for
early strength? For subsequent strength gain?
2. What is meant by hydration of Portland cement? How does hydration affect the
temperature of the material? How Much water is required?
3. Name the types of Portland cement. In what situation would each of these types of
cement be used?
4. The strength of a normal concrete is found to b3 24.7 MPa (3580 psi) at 28 day’s
age. Estimate the strength of this concrete at 6 months if it is moist cured.
5. What is cement clinker?
6. What are the main differences in chemical composition between Type I (10) and
Type III (30) Portland cement? Why are there thee differences?
7. What is meant by water cement ratio? What effect does the value of the water
cement ratio have on the strength of concrete? Why?
8. What is air-entrained concrete? When it is used? Why is it effective? What property
of the mix governs the amount of air required? Why?
9. Estimate the percentage increase in 28-day strength for air-entrained concrete made
with normal cement if the W/C ratio is reduced from 0.63 to 0.55.

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