Chapter 11
Concrete mix design
Brian Addis and John Goodman
11.1 Introduction
The ingredients of concrete, namely cementitious material,
water, sand, stone, and possibly admixture, must be
proportioned in a mixture that :
• in the fresh state, can, without segregating, be
transported, placed, fully compacted and finished
if necessary;
• in the hardened state, achieves the required strength,
adequate durability, and satisfactory dimensional
stability;
at the lowest cost.
Because of the large number of variables involved in
designing a mix theoretically, the use of approximations and
short-cut methods is justified and undue refinements may
be discarded.
According to McIntosh:[11.1]
"Precise relationships have not been established
between the properties of concrete, and even the
more specific characteristics of the mix such as water:
cement ratio, aggregate:cement ratio and grading
let alone such elusive qualities as aggregate particle
shape and texture. The data used in selecting mix
proportions should be expected to do no more than
serve as a guide. Mix design is a matter of trial and
error, and any calculations based on design data are
really only a means of making an intelligent guess at
a starting point for the first tests to be made."
A competent concrete technologist can combine the science
of mix design with experience and intuition and obtain
proportions which will be so close to the final figures that
only one or, at most, two trial mixes will be required.
Mixes are normally proportioned in the laboratory using
samples of specific materials to be used for the concrete.
Proper care during sampling is essential in order to obtain
a representative sample, but clearly it is also important for
the materials being used in the concrete to be as uniform as
possible.
This chapter describes a method of mix design used by the
Cement & Concrete Institute and gives guidelines for mixes
for some special applications. Worked examples are also
included.
219
Note on terminology
In this chapter, the word cement is used to indicate all the
cementitious material in a concrete mixture. Cement may
therefore be a “common cement” (see Chapter 1) or a blend
of common cement and one or more cement extender.
11.2 C&CI method
This method is derived from ACI Standard 211.1-91[11.2] and
is based on the following:
• The strength, at a given age, of fully compacted concrete,
cured under standard conditions, is governed by water:
cement ratio w:c and type of cementitious material
used. Note: w:c means the ratio of total mass of the
water in the mix, including water in the aggregates, to
the total mass of cementitious materials.
• The amount of water required per unit volume of
concrete for a given consistence and with given materials
is substantially constant regardless of cement content,
w:c or proportions of aggregates and cement. The
main factors determining the amount of water are
aggregate properties, cement properties, maximum
size of the stone and the selected workability range.
(This assumption is normally valid in the strength range
of 20 to 30 MPa, but the water requirement of concrete
of strengths outside this range should be determined.)
• For any particular concrete mix and combination of
materials, there is an optimum stone content which
depends on size, shape and compacted bulk density
of the stone, fineness modulus of the sand and desired
consistence of the concrete.
• The volume of compacted concrete produced by any
combination of materials is equal to the sum of the
absolute volumes of the cement and aggregates plus the
volume of water and that of any entrapped or entrained
air. The absolute volume of each material is calculated
from the mass and the relative density of the material (D).
Mass of material, kg . ..................(1)
Absolute volume, m3 =
D x 1 000
While all concrete mixtures contain some air, normally this
may be ignored when calculating the concrete yield, except
when air-entraining admixtures are used.
Fulton’s concrete technology • Concrete mix design

For practical purposes any discrepancies in the above • Select materials.

assumptions are normally small enough to be of no
• Characterise materials.
consequence. The purpose of the trial mix is to verify the
validity of the assumptions, and any significant inaccuracy • Proportion materials.
would be revealed at this stage. • Make and assess a trial mix.

• Specify mix proportions.

11.2.1 Applying the method
Practical mix design is a process involving the actions
In the figure, arrows indicate the inputs required for each
shown in Figure 11.1.
action. For the sake of simplicity, the use of admixtures is
not included.
Actions in the mix design process can be categorised as
follows:
The following notes refer to numbered actions in Figure
• Specify concrete properties and characteristics – the
11.1. Responsibilities are for conventional circumstances but
starting points for the process.
could be otherwise in specific cases.

Figure 11.1: Mix design process: actions and inputs

220

1 and 2: Specify strength of concrete and stone size
By the designer of the structure. Optimum stone size
depends on the dimensions of structural elements, depth of
cover and spacing of reinforcement.
3: Specify slump
By the contractor to suit methods of transporting, placing
and compacting.
4, 5 and 6: Specify cement type, maximum w:c ratio and
minimum cement content
By the designer/consultant to meet durability requirements.
Not done in all cases. Sometimes these items alone are
insufficient to provide adequate durability and additional
protective measures, eg a protective coating, may have to be
used. Specification should be in line with the latest relevant
code or technical literature.
7: Select cement type and source
By the mix designer for maximum economy but choice
could be overridden by action 4 above. (See Table 11.7 for
guidelines for selecting cements and blends for specific
applications.) Consider all requirements for the concrete,
eg any requirement for early strength.
8 and 9: Select stone and sand
By the mix designer for maximum economy of overall mix
while still meeting any aggregate specification requirements.
Use concrete technology knowledge to select appropriate
aggregates for the application. In South Africa sands are often
blended to achieve better concrete properties (see Chapter 3).
Note: The cheapest materials do not necessarily produce the
cheapest concrete (see actions 14 and 15).
10: Characterise cement
This includes:
• Strength performance, needed to select w:c
• Particle relative density, needed to calculate solid volume
• Possible effect on workability of concrete
The strength performances of South African cements may be
obtained from cement producers.
Particle relative densities of some cementitious materials are
shown in Table 11.1.
Table 11.1: Particle relative densities of cementitious materials
Material Particle relative density
CEM I 3,14
GGBS 2,9
FA 2,3
CSF 2,1
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Fulton’s concrete technology • Concrete mix design
Effective particle relative densities of blends of different
materials should be calculated as follows.
D= 100
. .........................................(2)
%X %Y
Dx + Dy + ...
where D is the effective particle relative density of the
blend; %X and %Y are percentages by mass of materials X
and Y respectively in the blend; and Dx and Dy are particle
relative densities of materials X and Y respectively.
Values for factory-blended cements may be obtained from
cement producers.
FA blends tend to reduce the quantity of water required for a
given consistence and permit higher stone contents.
11: Characterise stone
CBD – Compacted bulk density is a measure of
packing capacity.
RD – Particle relative density is needed to
calculate solid volume.
Grading – A sieve analysis is done to determine or
verify nominal size.
12: Characterise sand
RD – Particle relative density is needed to
calculate solid volume.
Grading – A sieve analysis is done to determine
distribution of particle sizes.
FM – Fineness modulus is calculated from the
sieve analysis.
Particle shape – Assess by eye, eg rounded, cubical, flaky,
elongated.
Surface texture – Affects water requirement of concrete.
13: Select w:c ratio
To achieve a target strength to satisfy a specified strength
requirement, based on the performance of the specific
cement. The selection may possibly be overridden by
requirements of actions 5 and 6.
Note that the compressive strength of site-made, 150-mm cubes
may be about 2 MPa lower than that of 100-mm laboratory
specimens. This difference is small and may be ignored.
14: Estimate water requirement, W
Depends on:
• Particle shape and surface texture of sand
• Stone size
• Required slump
• Type of cementitious material (The inclusion of FA
tends to reduce water requirement.)
Fulton’s concrete technology • Concrete mix design

An estimate of the water content of the mix, using the 15: Calculate cement content, C
particular aggregate and cement combination selected, may C = W ÷ w:c from actions 13 and 14. May be overridden by
be made in one of three ways: requirement of action 6.
• By using figures obtained from mixes previously made
with the same materials 16: Calculate stone content
The formula for stone content is:
• By estimating, based on experience of similar materials
Ma = CBD (K - 0,1 FM) . . . . . . . . (3)
• By using average figures from Tables 11.2 and 11.3
where
The water contents given in Table 11.2 are for concrete made
Ma = mass of stone in one cubic metre of concrete, kg
with an optimum quantity of 19-mm stone and having a
slump of 75 mm. CBD = dry compacted bulk density of stone, kg/m3,
determined in accordance with SANS 5845 [11.3]
For other sizes of stone, adjust the water content by the K = a factor which depends on the maximum size
amount shown in Table 11.3. of the stone and the workability of the concrete
(Values for K are given in Table 11.4.)
A difference in water content of between 10 and 15 l/m3 will
FM = fineness modulus of sand determined in
normally halve or double the slump.
accordance with SANS 201[11.4]

Note that there are limits to stone content for workable

Table 11.2: Water requirements of concrete mixes (19-mm
stone, 75-mm slump) concrete. At Ma = CBD x 1,0, for example, concrete would
be completely unworkable. Approximate maximum
3
Water content, l/m Ma = CBD x 0,8 for general-purpose concrete.
Sand quality
Natural Crusher

Very poor 240 235 If a FA blend is used, calculated stone content may be
Poor 225 225
increased as shown in Table 11.5.

Average 210 215

Good 195 205

Table 11.5: Increase of stone content when using FA
Excellent 180 195
FA content as %
Percentage
by mass of total
additional stone
Table 11.3: Adjustments to water content to compensate cementitious material

for stone sizes other than 19 mm 15 3

Maximum 25 4
size of 9,5 13,2 19,0 26,5 37,5
stone, mm 30 5

Correction, 40 6
3 +20 +10 0 -10 -20
l/m 50 7

Table 11.4: Values of K for determining stone content

K
Approximate
slump range, Placing
Maximum size of stone, mm
requirement
mm
9,5 13,2 19,0 26,5 37,5

75 - 150 Hand compaction 0,75 0,84 0,94 1,00 1,05

25 - 100 Moderate vibration 0,80 0,90 1,00 1,06 1,10

0 - 25 Heavy vibration 1,00 1,05 1,08 1,10 1,15

60 - 125 Pumped - 0,83 0,86 0,87 -

25 - 50 Concrete roads * - - - - 1,2

* Calculated on CBD of 37,5-mm stone when using a blend of 37,5- and 19-mm stone

222

17: Calculate sand content
The sand content is calculated, assuming full compaction of
the concrete, from the fact that volume of concrete is equal
to the sum of absolute volumes of cement, sand, stone and
water.
For 1 m3 concrete (ignoring air content):
Mc Ms Ma Mw
1 = + + + ....... (4)
Dc x 1 000 Ds x 1 000 Da x 1 000 1 x 1 000
where M and D refer respectively to mass, kg and particle
relative density; subscripts c, s, a and w refer respectively to
cementitious material, sand, stone and water.
Ms =
Mc Ma Mw
Ds x 1 000 1 – – – ....... (5)
Dc x 1 000 Da x 1 000 1 x 1 000
The effective particle relative density of a blend of fine
aggregates of different RDs should be calculated from
equation (2) above.
18: Make trial mix
Done in a laboratory. A mix that yields 15 l is normally
enough.
19: Measure slump
20: Assess stone content and cohesiveness of concrete
This requires skill and experience. Some techniques are:
• Feel the resistance the concrete offers to the tamping rod
when doing the slump test. In a workable concrete, if
the slump is correct, the stones should move away easily
from the tip of the rod. A harsh grating sound indicates
that stone content is too high.
• After the slump has been measured, tap the base plate
with the end of the tamping rod. If the concrete is
cohesive, it will collapse in a solid mass. If it lacks
cohesion, it will break apart as it collapses.
• Smooth the surface of the concrete with a steel trowel.
A closed surface without voids should be achieved if
stone content is not too high.
• Compact some concrete at least 250 mm deep, eg in a
bucket. Scratch the surface of the concrete. Stones
should be a millimetre or so beneath the surface. If they
are deeper, stone content is too low. If stones protrude
above the surface, stone content is too high.
21: Approve mix
Approve the mix if results of actions 19 and 20 are acceptable.
Make cubes, preferably for crushing at seven and 28 days, to
check that strength development is normal.
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Fulton’s concrete technology • Concrete mix design
22: Reject mix
Reject the mix if results of actions 19 and 20 are not
acceptable.
23: Modify design
Reproportion the mix after doing one or more of the
following.
• If mix is too stony, reduce stone content by 100 kg/m3.
• If mix is too sandy, increase stone content by 100 kg/m3.
• If mix lacks cohesion, do one or more of the following:
– Use a finer sand.
– Use a sand with a higher percentage passing the
300-µm sieve. This may be achieved by sub-
stituting a finer sand for some of the original sand.
• Use a smaller stone. (If permitted. This will increase
water requirement and hence binder content and
increase material cost.)
• If mix is too sticky, use a coarser sand or a sand with a
lower percentage passing the 75-µm sieve.
• If slump is incorrect, adjust water content. A difference
of 10 to 15 l in 1 m3 of concrete will normally halve or
double the slump.
A practical short-cut method is to start with water
content higher than estimated, and then, after
measuring slump, effectively reduce water content
in stages by adding predetermined increments of
sand and stone. Thus the amount of water stays
constant but the yield of the trial mix increases.
In practice, initial amounts and aggregate increments
can be easily calculated using a computer spread-
sheet program.
Water content for the required slump may be
determined by interpolating between contents
straddling the required slump.
No attempt should ever be made to improve workability
simply by increasing the amount of mixing water.
24: Specify mix proportions for manufacture of concrete
Based on the outcome of the previous actions. If reactive
aggregates have been used, check that adequate precautions
are taken against deleterious ASR (see Chapter 10). To allow
for moisture in the sand, the mass of sand is increased
proportionally and the amount of added water decreased to
keep w:c ratio the same.
To calculate the yield of a batch, add the total water content
and solid volumes of cement, sand and stone.
Fulton’s concrete technology • Concrete mix design
11.3 Mix design for special applications
This section gives guidance on the design of mixes for the
following:
• Concrete mixes for pumping
• Air-entrained concrete
• High-density concrete
• Low-density concrete
• Mixes for compaction by heavy vibration
• Mixes made with very fine sand
• Shaft linings
• Sliding formwork
11.3.1 Concrete mixes for pumping
The method of design is similar to that used for conventional
concrete but, because of certain restrictions imposed by the
pump and pipeline system, there are some limitations to the
range of materials and concretes that can be used:
Cement content is usually in the range of 250 to 380 kg/m3,
however, concretes containing higher cement contents can
be pumped using suitable admixtures, if necessary. All
common cements are suitable for pumped concrete. The
inclusion of FA may improve pumpability.
Water content is normally about 10 to 15 l /m3 higher than
in conventional concrete when slump is 125 mm.
Sand of good particle shape should be selected. At least
20%, but preferably 30%, of the sand should pass the
300-micron sieve. Sand content, by mass of total aggregate,
is generally about 3 to 8% higher than that for conventional
mixes, and the fraction of sand by mass of total aggregate is
usually in a range of 38 to 55%.
Stone of good particle shape is recommended. The size
of stone for 100-mm delivery pipes should be limited to
26,5 mm but 19,0 mm is preferable. The stone content may
be estimated using the K factor given in Table 11.4.
Admixtures are beneficial in some instances but they should
be tested under site conditions.
A slump range of between 60 and 90 mm is regarded as
optimal for piston pumps, and 100 to 125 mm for pneumatic
pumps.
11.3.2 Air-entrained concrete (AEC)
It is preferable to use the proportions of a normal concrete
mix, made with the same materials and having the same
consistence in the fresh state and strength in the hardened
224
state, as a starting point for the design of AEC. To calculate
the proportions for the first trial mix of the AEC:
• Reduce the water content by 7%.
• Increase the cement content per m3 by 20 kg for lean
concrete (20 MPa or less at 28 days) to 40 kg for rich
concrete (30 MPa or more at 28 days).
• Use the same stone content.
• Include the volume of air expected to be entrained in
the calculation of absolute volumes.
The design of AEC may require several trial mixes to
verify air content and consistence of the fresh concrete, and
strength of the hardened concrete.
11.3.3 High-density concrete
Concrete with a high density may be produced by using
high-density aggregates as discussed in Chapter 18.
The methods of design of mixes for high-density concrete
are the same as for normal-density concrete.[11.2] High-
density concretes are, however, more prone to segregation,
particularly if there is a large difference in the particle
relative densities of the coarse and fine aggregates and if
mixes with a high slump are used. Often a number of trial
attempts are required in order to produce a cohesive mix
with minimal segregation and bleeding.
11.3.4 Low-density concrete
Because of the difficulty of estimating water contents
of mixes containing low-density aggregates, conventional
methods of mix design as described in this chapter are
usually unsatisfactory. Low-density mixes are often designed
on the basis of cement content rather than on w:c.
Useful data on methods of designing mixes for low-
density concretes are given in the ACI Guide for structural
lightweight aggregate concrete[11.5] and in the FIP Manual
of lightweight aggregate concrete.[11.6]
11.3.5 Mixes for compaction by heavy vibration
Mixes of very low workability that are suitable for intense
vibration are designed in the usual manner. Note that:
• Water content for very low workability will be about
20 l/m3 less than for medium workability.
• Stone content may be determined from equation (3)
and Table 11.4.
• The Vebe test may be used to assess consistence.
• The mix should be tested under site conditions.
A method of designing concrete mixes for intense vibration
was developed by Stewart and is described in reference 11.7.

11.3.6 Mixes made with very fine sand
In cases where the only available sand is very fine
(FM < 1,7), a satisfactory mix may be designed by using one
of the following two approaches.
The first approach is to blend 6,7-mm stone with the sand.
The ratio of 6,7-mm stone to sand should be such that the
FM of the blend is about 2,5. Use equation (3) to determine
stone content.
The second approach is to use a blend of two sizes of stone
instead of a single size. The smaller stone should be about
half of the size of the larger stone. As a starting point, use
a ratio of one part of smaller stone to two parts of larger
stone.
Insert the CBD for the larger stone together with its K value
from Table 11.4 in equation (3) to determine total stone
content.
11.3.7 Mine-shaft linings
The use of 13,2-mm stone will in many cases be as economical
as 19,0-mm stone in these very wet mixes in a slump range of
150 to 200 mm. Flaky or elongated stone should be avoided.
Stone contents are similar to those used for pumped
mixes. The sand should have a low water requirement,
and sufficient material passing the 600-µm sieve to ensure
adequate cohesion.
For these mixes, accelerators and superplasticisers or high-
range water reducers are commonly used to reduce the
water and cement contents to acceptable levels.
Usually, the strength requirement is an average of 5,0 MPa
at eight hours. Suggested starting points for trial mixes are
w:c = 0,55 and 0,65 when cements of strength classes 42,5N
and higher, respectively, are used with calcium chloride as
an accelerating admixture (at 2% by mass of the cement
content). The calcium chloride flake should be dissolved as
a 30% solution in water before being added to the mix.
The flow table test may be used to assess consistence.
11.3.8 Sliding formwork
The mix is designed using the normal procedure and the
stone content is determined in the same way as that for
conventional concrete.
The grading of the sand, however, has a significant influence
on the success of the slide, and it is recommended that not
less than 30% of the sand should pass the 300-µm sieve.
11.4 Designing a mix by eye
This method of mix design is an effective laboratory
method requiring an experienced operator to produce a
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Fulton’s concrete technology • Concrete mix design
desired mix having characteristics not necessarily covered
by conventional methods. It should preferably be done in a
laboratory pan mixer having a watertight pan.
The method is especially suited to the design of mixes for:
• Exposed aggregate concrete
• High stone content and heavy vibration
• Special placing conditions such as pumping and placing
by tremie
• High-strength concrete
Method
1 . Select w:c.
2. Weigh the water (usually 1,5 or 2,0 kg) and the cement
and place them in the mixer.
3. Have ready sufficient sand and stone weighed in
containers in easily handled quantities (5 or 10 kg).
4. Add about 5 kg of sand to the pan and start the mixer
and add further sand until experience indicates that the
mortar part of the mix is still slightly too wet.
5. With the mixer still running, add stone and finally
correct the consistence with sand.
6. Record the quantities of sand and stone used.
7. Determine the slump or Vebe consistence, air content
and wet density and make the appropriate test
specimens.
8. Calculate the mix proportions per cubic metre using the
recorded quantities of materials used for the mix and
the measured air content and wet density.
11.5 Examples of calculations
Example 1: Determine the stone content of a mix
A concrete for hand compaction is to be made using a
19,0-mm stone with a compacted bulk density of 1 720 kg/m3.
The sand has a fineness modulus of 2,8.
From Table 11.4: K = 0,94
and substituting the values in equation (3):
Ma = 1 720 x (0,94 - 0,1 x 2,8) = 1 135 kg
Example 2: Calculate the particle relative density of a
blend of two aggregates with different densities
The blend consists of 60% of aggregate A with a particle
relative density of 2,65, and 40% of aggregate B with a
particle relative density of 4,55.
Fulton’s concrete technology • Concrete mix design

From equation (1): Step 5: Sand content

From equation (5):
100
D = = 3,18 315 1 185 210
60 40 Ms = 2,65 x 1 000 1– – –
+ 3 140 2 700 1 000
2,65 4,55

= 665 kg
(The result is very different from the intuitive
[0,6 x 2,65] + [0,4 x 4,55] = 3,41.)
The quantities per cubic metre of concrete are therefore:
Cement 315 kg
Example 3: Design a trial mix
Sand 665 kg
Type CEM I 42,5N Stone 1 185 kg
Cement
Dc 3,14 Water 210 l
Ds 2,65
Sand FM 2,30
Example 4: Design a trial mix
Quality Average Type CEM I 42,5N
Given
Cement
Da 2,70 Dc 3,14
Stone Size 19,0 mm
Ds 2,65
CBD 1 540 kg/m3
Sand FM 1,90
Degree of control “Average” Quality Excellent
Given
Characteristic Da 2,74
25 MPa
strength at 28 days Stone Size 26,5 mm
Required
75 mm CBD 1 460 kg/m3
slump for Degree of control
Consistence
moderate " Good"
vibration
Characteristic
35 MPa
strength at 28 days
Step 1: W:C 25 mm
Required
Consistence
For “average” degree of control, strength margin is slump
10 MPa (see Table 16.1). For characteristic strength of
Maximum w:c for durability 0,43
25 MPa, target strength is therefore 25 + 10 = 35 MPa. From
cement producer,w:c = say, 0,67.
Step 1: W:C
Step 2: Water content For “good” degree of control, strength margin is 8,5 MPa
The sand is of average quality. (see Table 16.1).

Either from Table 11.2 or by visual examination of the sand,
estimate the water content of the mix, say 210 l/m3. No
adjustment is necessary for size of stone (Table 11.3) because
the stone is 19,0 mm, or consistence because the required
consistence is 75-mm slump.
Therefore water content = 210 l/m3
For characteristic strength of 35 MPa, target strength is
therefore 35 + 8,5 = 43,5 MPa.
From cement producer: w:c for strength = 0,60.
But maximum w:c is specified as 0,43; this value must be
used.

Step 3: Cement content Step 2: Water content

Mc = Water content The sand appears to be of excellent quality, therefore say
w:c 180 l/m3 (for 75-mm slump). See Table 11.2.
= 210/0,67
= 313 kg/m3, say 315 kg/m3 Adjustment for size of stone from Table 11.3 is minus 10 l.

Step 4: Stone content Adjustment for slump is minus 10 l (roughly, slump halves
From equation (3) and Table 11.4: for each 10 l reduction).
Ma = CBD (K - 0,1 FM)
= 1 540 (1,0 - 0,1 x 2,30) Water content = 180 - 10 - 10 = 160 l/m3
= 1 186 kg/m3, say 1 185 kg/m3

226
 Fulton’s concrete technology • Concrete mix design

Step 3: Cement content The amount of moisture in the stone is usually very small
Mc = Water content and it is customary to ignore it.
w:c
= 160/0,43 Assume that the sand in Example 4 contains an estimated
= say 370 kg/m3 4% of moisture by mass. Adjustments are made as follows:

Step 4: Stone content Mass of dry sand = 93 kg

From equation (3) and Table 11.4: 4% moisture = 93 x 4/100 = 3,7 kg,
Ma = CBD (K - 0,1 FM) say 4 kg
= 1 460 (1,06 - 0,1 x 1,9)
Mass of damp sand to be used = 93 + 4 = 97 kg
= 1 270 kg
Say gross volume of water = 22 l
Step 5: Sand content Water in sand = 4 kg = 4 l
From equation (5):
Net water required = 22 - 4 = 18 l
370 1 270 160
Ms = 2,65 x 1 000 1– – – Example 6: Calculate volume proportions and quantities
3 140 2 740 1 000
If the loose bulk densities of the aggregates are known, in
= 685 kg either the dry or damp state, the masses of the materials
may be converted to volumes.
The quantities per cubic metre are:
Cement 370 kg In Example 4 above, assume that the loose bulk densities are:
Sand 685 kg Stone: 1 410 kg/m3
Stone 1 270 kg Sand: Dry 1 640 kg/m3
Water 160 l Sand: Damp 1 360 kg/m3 (this lower density is due to
the bulking of sand caused by dampness)
The above mix contains 370 kg cement = 370/50 bags
= 7,4 bags The quantities of aggregates per cubic metre are therefore:
Stone: 1 270/1 410 kg/m3 = 0,90 m3
Sand: Dry 685/1 640 kg/m 3 = 0,42 m3
The proportions by mass for a one-bag mix are therefore:
Cement 370/7,4 = 50 kg Sand: Damp 1,04 x 685/1 360 = 0,52 m3
Sand 685/7,4 = 93 kg
Stone 1 270/7,4 = 172 kg These figures are used for calculating quantities or for
ordering materials.
Water 160/7,4 = 22 l
and yield (per one-bag batch) = 1/7,4 = 0,135 m3 = 135 l If the damp bulk density of the sand is not known, the dry
density may be used and the volume so obtained increased
Example 5: Correct mix proportions for moisture content by between 20 and 30% to allow for bulking:
of aggregates
The steps described in section 11.2.1 are based on the use of Volume of damp bulked sand = (93/1 640) x 1,20 = 0,068 m3
dry aggregates. If the aggregates contain moisture this must
be taken into account in the proportions for the mix.

Table 11.6: Batching quantities for Example 6

By volume, aggregates rounded to nearest 5 l

Material By mass
Dry sand Damp sand

Cement 50 kg 1 bag 1 bag

Sand 93 kg 93/1 640 = 0,055 m3 97/1 360 = 0,070 m3
Stone 172 kg 172/1 410 = 0,120 m3 172/1 410 = 0,120 m3
Water 22 kg 22 l 22 - (93 x 0,04) = 18 l

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Fulton’s concrete technology • Concrete mix design

Table 11.7: Guidelines for selecting cements for concrete

Note: The guidelines given below assume appropriate proportioning of mixes and that good practice is followed.

Application Comments

The cement is normally selected for economy.

Conventional structural SANS 50197-1 common cements should be suitable.
concrete in a non- Site blends of CEM I cement with 50% GGBS or 30% FA have been extensively and successfully used in South Africa.
aggressive environment A site blend of CEM I cement and about 8% CSF is technically feasible but there is relatively little local experience of its use.
Blends with more than one extender have been used successfully.
Large placements where
temperature rise, due to Best results are likely to be achieved with cements with extender contents in excess of 50% GGBS or 30% FA.
heat of reaction, is to be See section 15.3.2.
kept as low as possible
Choice of cement will depend mainly on strength requirements at early ages.
High early strengths, without steam curing, may be achieved most economically with cements of strength grade 42,5R and
Structural precast
higher and with low extender content.
Cements with high extender content are better suited to steam curing.
Precast bricks, blocks
The cement should meet durability requirements, if any, and ensure sufficient strength to allow handling at an early age,
and pavers
typically the day after casting.
(See Chapter 22)
Strength class should be 42,5N or higher.
The inclusion of about 8% CSF is common practice in this application.
High-performance
Other cement extenders may also be used for technical or economic benefits.
concrete (See Chapter 17)
Superplasticiser is an essential ingredient in high-performance concrete.
The compatibility of the specific cement and superplasticiser is important.
Concrete for these applications must develop strength rapidly enough to permit joint sawing before the concrete cracks due
Floors, roads and
to restrained drying shrinkage. The mature concrete must have good abrasion resistance.
pavements with sawn
These properties are likely to be achieved most economically with cements of strength grade 42,5N or higher, with extender
joints
content not greater than 30%.
Reinforced concrete in Based on research done with South African materials,cements containing 30% FA, 50% GGBS or 10% CSF are
marine environment recommended. See Chaper 9.
Concrete made with The total alkali content in pore solution of the concrete should be maitained below limits (See Table 10.1) or the cement
alkali-reactive aggregate should contain not less than 40% GGBS, or 20% FA, or 15% CSF. However the use of 15% CSF usually results in a sticky
(See section 10.6) concrete requiring the use of a superplasticiser.
Caution should be exercised with concrete in sulphate environments and it is recommended that C&CI, specialist literature,
Concrete exposed to
relevant codes or a cement manufacturer should be consulted for guidance. Concrete made with 70/30 CEM II/FA blends
sulphate attack
normally gives better sulphate resistance than an equivalent CEM I concrete.
Extenders should meet the requirements of SANS 1491 parts 1-3[11.8] as relevant

References
11.1 Mclntosh, J.D. Basic principles of concrete mix
design, Proceedings of a Cement and Concrete
Association symposium on mix design and
quality control of concrete, London, May 1954,
pp.3-27.
11.2 ACI 211.1-91, Standard practice for selecting
proportions for normal, heavyweight, and mass
concrete, Farmington Hills, Michigan: American
Concrete Institute, 1999.
11.5 ACI 213R-03, Guide for structural lightweight-
aggregate concrete, Farmington Hills, Michigan:
American Concrete Institute, 2003.
11.6 Federation Internationale de la Precontraint
(FIP), FIP manual of lightweight aggregate
concrete, 2nd ed. Glasgow: Surrey University
Press, 1983.
11.7 Stewart, D. A. The design and placing of high
quality concrete, London: Spon, 1951.

11.3 SANS 5845:2006, Bulk densities and voids
content of aggregates, Pretoria, South African
Bureau of Standards, 2006.
11.4 SANS 201:2008, Sieve analysis, fines content
and dust content of aggregates, Pretoria: South
African Bureau of Standards, 2002.
11.8 SANS 1491:1, 2 and 3:2005-2006, Standard
specification for portland cement extenders.
Part 1: Ground granulated blastfurnace slag.
Part 2: Fly ash. Part 3: Condensed silica fume,
Pretoria: South African Bureau of Standards,
2005-2006.

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