Concrete Mix Design – M40, M60 as per IS [Update-2019]

Concrete mix design is all about finding perfect proportions of Cement, Sand, and Aggregate to produce good concrete to achieve target strength. Here we described the full procedure of concrete mix design calculation and formula with ratio for M40 and M60 grade of concrete as per IS Codes and MORTH.

 

CONCRETE MIX DESIGN OF M40 GRADE WITH OPC 53 GRADE CEMENT

CONCRETE MIX DESIGN IS CODE

For Concrete mix design we use MoRTH, IS 456 and IS 10262.

Concrete Mix Design Calculation for M40, M60 full Procedure as per IS Code | Grade of Concrete

 

REQUIRED DATA FOR CONCRETE MIX DESIGN CALCULATION

Characteristic Compressive Strength                                        :      40 Mpa

Maximum Size of Aggregate                                                       :     20 mm

Work-ability, Slump                                                                      :     125 – 150 mm

Degree of Quality Control                                                            :     Good

Type of Exposure as per MoRTH Table – 1700-2                    :     Severe

Minimum Target Mean Strength as per MoRTH Table: 1700-8 : 52 Mpa (40+12)

Max. Water   Cement Ratio as per MoRTH Clause –   1715.2         :      0.4

Minimum Cement Content as per MoRTH Clause – 1715.2           :      360 Kgs

Maximum Cement Content as per MoRTH Clause – 1715.2           :      450 Kgs

 

REQUIRED TEST DATA FOR MATERIALS

Type of Cement                                             :      OPC 53 Grade

Specific Gravity Details of Materials:

Cement                                                           :       3.15

Coarse Aggregate 20mm                              :      2.885

Coarse Aggregate 12.5mm                             :      2.857

Fine Aggregate                                                :      2.723

 

Water Absorption Details of Materials:

Coarse Aggregate 20 mm                             :      0.42%

Coarse Aggregate 12.5 m                             :      0.47%

Fine Aggregate                                              :      1.38%

 

CALCULATION FOR TARGET MEAN STRENGTH

Target Mean Strength as per MoRTH   Table 1700-8 specification ( 5th revision )

Margine For M40                    :       12   Mpa

                                                  :       40+12   = 52 Mpa

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SELECTION OF FREE WATER CEMENT RATIO

Maximum Water Cement Ratio Permitted As per MoRTH Clause – 1715.2   :     0.40

W/c Ratio Selected As                                                                                          :     0.35

 

SELECTION OF WATER

Water Content as per Table 2 , of IS : 10262 2009 for 20 mm maximum size of aggregate is

                                                                                 :     186   litre.

The above-estimated water is suggested for a slump range of 25 to 50 mm in the above mentioned IS code. For each 25 mm increase in slump 3% water can be increased as per clause No. 4.2 IS 10262 : 2009

Required slump is 150 mm, so

     for 50 mm slump water required = 186 litre

     for 75 mm slump  = 186 * 3% = 5.58 ltr

          186 + 5.58 = 191.58 ltr.

     for 100 mm slump = 186 * 6% = 11.16 ltr

          186 + 11.16 = 197.16 ltr

     for 125 mm slump = 186 * 9% = 16.74 ltr

          186 + 16.74 = 202.74 ltr

     for 150 mm slump = 186 * 12% = 22.32 ltr

          186 + 22.32 = 208.32 ltr.

Hence water requirement calculated as             :      208.32 ltr.

As Superplasticizer is used in the mix. The water content can be reduced up to 35 Percent and above as per IS: 10262 – 2009 Based on trials with Superplasticizer water content reduction of 21.51 percent has been Achieved with the same dose.

                                                                                 :      140.0

                                        Say       140.0

 

CEMENT CONTENT

Water Cement Ratio                               :       0.35

Hence   Cement content                        :       140.0 / 0.35 =   400.00 Kg

Say                                                            :        400 Kg

Hence Cement Content                       :         400 Kg

 

PROPORTION OF VOLUME OF COARSE AND FINE AGGREGATE CONTENT

Hence   Coarse aggregate content for MSA 20 mm     :       60%

Sand content can be adopted Max.                               :       40%

Course Aggregate Proportions  ( 20 mm : 10 mm )     :       50%   :     50%

 

CONCRETE MIX DESIGN CALCULATION FORMULA

Formula :   Volume of material content = material weight / ( material specific gravity * total volume )

Volume of concrete = 1  Cu.M.

                 1 Cum = 1000 ltr ( in volume)

Volume of Materials:

Cement Content = 400 / 3.15 X 1000   =  0.127 Cu.M.

Water Content = 140 / 1.00 X 1000   =  0.140 Cu.M.

Admixture = 1.80 / 1.17 X 1000  =  0.0015 Cu.M.

Aggregate = 1- ( cement volume + water volume + admixture volume )

          = 1 – ( 0.127 + 0.140 + 0.0015 )  =   0.731 Cu.M.

Now we got volume of each material for use in concrete.

Now convert material volume into weight.

concrete mix design

 

FORMULA TO CONVERT VOLUME INTO WEIGHT FOR CONCRETE MIX

Formula = material weight = material volume * percentage of total volume * material sp. gravity * total volume.

Mass of coarse aggregates 20 mm  =  0.731 X 0.60 X 0.50 X 2.885 X 1000  = 633.1 Kg.

Say  :  633 Kg.

Mass of coarse aggregates 12.5 mm =  0.731 X 0.60 X 0.50 X 2.857 X 1000  = 626.9 kg

Say  :  627 Kg.

Mass of fine aggregates  =  0.731 X 0.40 X 1.00 X 2.723 X 1000  = 796.73 Kg

 Say  : 797 Kg

 

MIX PROPORTION PER CUM. FOR M40 GRADE OF CONCRETE

Cement          : 400 Kg

Water             : 140 Kg

20 mm            : 633 Kg

12.5 mm         : 627 Kg

sand                : 797 Kg

Dosage of admixture, by the Weight of Cement

0.45%  of cement weight: 1.80 Kg

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Note:

In moisture correction, Weights of Aggregate and water can be replaced by the weights of the free moisture on Aggregates.

 

 

Concrete Mix Design Report

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Concrete Mix Design Spreadsheet

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CONCRETE MIX DESIGN RATIO FOR M40

M40 mix ratio –  1 : 2 : 3

Concrete Mix Design Calculation for M40, M60 full Procedure as per IS Code | Grade of Concrete

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M60 GRADE OF CONCRETE DESIGN MIX PROCEDURE WITH OPC 53 GRADE CEMENT AND ALCCOFINE

REQUIRED DATA FOR CONCRETE MIX DESIGN CALCULATION

Characteristic Compressive Strength                                         :      60 Mpa

Maximum Size of Aggregate                                                         :     20 mm

Work-ability, Slump                                                                        :     125 – 150 mm

Degree of Quality Control                                                              :     Good

Type of Exposure as per MoRTH Table – 1700-2                         :     Severe

Minimum Target Mean Strength as per MoRTH Table: 1700-8  :  74 Mpa  ( 60 + 14 )

Max. Water   Cement Ratio as per MoRTH Clause –   1715.2           :      0.4

Minimum Cement Content as per MoRTH Clause – 1715.2             :      360 Kgs

Maximum Cement Content as per MoRTH Clause – 1715.2             :      450 Kgs

 

REQUIRED TEST DATA FOR MATERIALS

Type of Cement                                                                           :      OPC 53 Grade

Specific gravity values

Cement                                                        :       3.15,

Alccofine                                                     :      2.86,

Coarse Aggregate 20 mm                          :      2.88,

Coarse Aggregate 12.5 mm                        :      2.85,

Fine Aggregate                                              :      2.72,

 

Water absorption values

Coarse Aggregate 20 mm                         :      0.20%,

Coarse Aggregate 12.5 m                          :      0.09%,

Fine Aggregate                                            :      0.55%.

 

CALCULATION FOR TARGET MEAN STRENGTH

Target Mean Strength as per MoRTH   Table 1700-8 specification ( 5th revision )

Margine For M60                    :       14   Mpa

                                                  :       60+14   = 74 Mpa

 

SELECTION OF FREE WATER CEMENT RATIO

Maximum Water Cement Ratio Permitted As per MoRTH Clause – 1715.2         :     0.40

W/c Ratio Selected As                                                                        :     0.31

 

SELECTION OF WATER

Water Content as per Table 2 , of IS : 10262 2009 for 20 mm maximum size of aggregate is                                                                   :     186   litre.

The above-estimated water is suggested for a slump range of 25 to 50 mm in the above mentioned IS code. For each 25 mm increase in slump 3% water can be increased as per clause No. 4.2 IS 10262 : 2009

Required slump is 150 mm, so

     for 50 mm slump water required = 186 litre

     for 75 mm slump  = 186 * 3% = 5.58 ltr

          186 + 5.58 = 191.58 ltr.

     for 100 mm slump = 186 * 6% = 11.16 ltr

          186 + 11.16 = 197.16 ltr

     for 125 mm slump = 186 * 9% = 16.74 ltr

          186 + 16.74 = 202.74 ltr

     for 150 mm slump = 186 * 12% = 22.32 ltr

          186 + 22.32 = 208.32 ltr.

Hence water requirement calculated as             :      208.32 ltr.

As Superplasticizer is used in the mix. The water content can be reduced up to 35 Percent and above as per IS: 10262 – 2009 Based on trials with Superplasticizer water content reduction of 30.06 percent has been Achieved with the same dose.

                                                                                 :      145.7 ltr

                                        Say       146.0 ltr.

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MIX DESIGN MARGIN FOR EACH GRADE

Concrete Mix Design Calculation for M40, M60 full Procedure as per IS Code | Grade of Concrete

 

CEMENTITIOUS CONTENT

Water Cementitious Ratio                               :       0.31

Hence Cementitious material content           :       145.7 / 0.31 =   470.00 Kg

Say                                                                     :        470 Kg

Hence Cementitious Content                         :        470 Kg

 

PROPORTION OF VOLUME OF COARSE AND FINE AGGREGATES CONTENT

Hence Coarse aggregate content for MSA 20 mm      :       60%

Sand content can be adopted Max.                               :       40%

Course Aggregate Proportions  ( 20 mm : 10 mm )       :       45%  :   55%

 

CONCRETE MIX DESIGN CALCULATION FORMULA

Formula :   Volume of material content = material weight / ( material specific gravity * total volume )

Volume of concrete = 1  Cu.M.

 1 Cum = 1000 ltr ( in volume)

Volume of Cement Content = 450 / 3.15 X 1000   =  0.143 Cu.M.

then,

Volume of Alccofine = 20 / 2.86 X 1000   =  0.007 Cu.M.

then,

Volume of Water Content = 146 / 1.00 X 1000   =  0.146 Cu.M.

then,

Volume of Admixture = 3.67 / 1.17 X 1000  =  0.0031 Cu.M.

Now,

Aggregate = 1- ( cement volume + water volume + admixture volume )

          = 1 – ( 0.143 + 0.007 + 0.146 + 0.0031 )  =   0.701 Cu.M.

Now we got volume of each material for use in concrete.

Now convert material volume into weight.

 

FORMULA TO CONVERT VOLUME INTO WEIGHT FOR CONCRETE MIX

Formula = material weight = material volume * percentage of total volume * material sp. gravity * total volume.

Mass of coarse aggregates 20 mm  =  0.701 X 0.60 X 0.45 X 2.88 X 1000  = 545.3 Kg.

Say  :  545 Kg.

 

Mass of coarse aggregates 12.5 mm =  0.701 X 0.60 X 0.55 X 2.85 X 1000  = 659.6 kg

Say  :  660 Kg.

Mass of fine aggregates  =  0.701 X 0.40 X 1.00 X 2.72 X 1000  = 763.03 Kg

 Say  : 763 Kg

 

CONCRETE MIX PROPORTION PER CUM. FOR M60 GRADE OF CONCRETE

Cement          : 450 Kg

Water             : 140 Kg

Alccofine        : 20 Kg

20 mm            : 545 Kg

12.5 mm         : 660 Kg

sand                : 763 Kg

Dosage of admixture, by the Weight of Cement

0.78%  of cement weight  :        3.67 Kg

Note:

In moisture correction, Weights of Aggregate and water can be replaced by the weights of the free moisture on Aggregates.

 

CONCRETE MIX DESIGN RATIO FOR M60

M60 mix ratio –  1 : 1.5 : 2.5

 

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Read More:

Concrete – Grade, Types and Uses in 2019

M30 Grade of Concrete Mix Design Calculation Procedure

Compressive Strength of Concrete at 7 days, 28 days Calculation & Formula

Initial and Final Setting Time of Cement by Vicat [Update-2019]

CBR Test of Soil Procedure, Calculation & Graph

 

Students Corner

Concrete mixing design determines the right proportions of cement, sand and concrete aggregates to achieve target strength in structures. 

The concrete mix design includes various steps, calculations, and laboratory tests to find the right mixing ratios.

The benefits of concrete mix design are that it provides the right material ratios, making the concrete structure economical to achieve the required strength of the components. 

 

Concrete is a composite mixture consisting of cement, sand and aggregates. 

 

Concrete mixing design is the process to find the right amounts of these materials to achieve the desired strength. 

 

Large structures such as bridges or dams require a large amount of concrete, and using the right amount of components makes the structure economical.

 

The main component of the concrete is cement, aggregates, water, and additives.

Due to the different material properties of concrete, the design of concrete is not an easy task. 

The aim of the mixture design is to produce a concrete with the required strength, durability and processability as economically as possible.

 

The process for selecting suitable concrete constituents and determining their relative amounts in order to produce a concrete with the required strength, durability and processability as economically as possible is referred to as a concrete mix design. 

 

The admixture of concrete components depends on the required performance of concrete in two states, namely the plastic and the cured state. 

If the plastic concrete is not processable, it can not be properly placed and compacted.

 

In the following courses, we will discuss the steps that need to be taken to complete a concrete mix design. 

The aim of this course is also to analyze the properties of the freshly formed concrete based on the design and not the hardened concrete. 

As explained in lecture 2, the two types of property categories are not independent of each other, rather they are directly linked together, and the failure to comply with the new properties results in poor concrete quality in the cured state. 

 

Basically, the design of concrete mixes is done by careful selection of the quantities of concrete constituents with the aim of producing cost-effective concrete with a minimum of properties such as processability, compressive strength, and durability (Neville 1995).

 

Once we have determined all mixing ratios, we need to make samples from the resulting concrete mix, which are subjected to various tests and conditions to determine the suitability of hardened concrete. 

 

Admixtures are regarded as secondary components of concrete and do not belong to the class of importance such as water or cement. 

 

There are various types of additives, depending on their effect on concrete, and also their use is considered from the point of view of economy and increase of concrete quality.

 

HPC’s basic blend design has not yet been determined as it contains other admixtures that meet the requirements of fresh and hardened concrete. 

In recent years, the problem of metering concrete mixes, which involves more variables than before, has become more and more complicated. 

For high-strength concretes (HSC), however, all components of the concrete mix have reached their limits. 

After all these failed calculations, the conclusion is that concrete is still constructed by experience with previousblends or by making experimental approaches in a laboratory and testing the concrete. 

Many decorative contractors have 4 or 5 blends that they use for different applications or weather conditions. 

The standard for designing a concrete mix is ​​ACI 211.1, proportions for normal, heavy and mass concrete. 

 

In a mix design process, test runs are made in the laboratory and processability is measured after all the constituents of the concrete have been achieved. 

If the processability criterion is met, cubes or cylinders are poured for the compression strength test. 

If the desired processability is not achieved, the concrete components are set again and prepared a trial batch.

The fact that rheological parameters are fundamental properties of fresh concrete and compressive strength is the most important hardened property of concrete.

The correlation curves between rheological properties and compressive strength of concrete were used in the mixture design.

The thus obtained masterbatch fractions obtained following the guidelines of the existing Is-Code process were used to prepare HPC trial blends by obtaining the desired levels of micro silica and SP with a view to achieving the desired processability and strength properties were incorporated.

 

Based on the experimental observations, the base mix ratios used to make HPC trial mixes were modified by changing the ratio of coarse aggregate to fine aggregate and incorporating appropriate levels of micro silica and SP to provide the desired processability and compressive strength for various combinations of moisture and temperature receive.

 

The proposed blend design method for HPC thus provides the final blend ratios, taking into account the parameters or variables required to achieve the desired machinability and strength properties for different types of HPC blends.

 

The proposed method for admixing HPC blends provides the blending ratios for different moisture and temperature combinations for the grades of m50 to m90 HPC blends. 

 

To verify the validity of the proposed mix design method, a sample M50 grade HPC blend was prepared using the blend proportion obtained by the proposed method.

 

Since it has been found that the HPC compounding test produced gives satisfactory processability with good flow properties, and this also in a single trial for the blend fraction obtained by the proposed process, it can be seen that the proposed blend design process for blending HPCMixtures for validly specified humidity and temperature conditions. 

 

The sensitivity analysis of the cspnn or spnn can be used to assess the effect of various concrete mix components (water, cement, ground granulated blast furnace slag, fly ash, coarse aggregate, fine aggregate and superplasticizer) on compressive strength and to assess break-in of concrete.

 

The distribution of burglary and sp for the training patterns of the spnn shows that the burglary increases with increasing sp-amount in the concrete mix.

 

Burglary is proportional to SP, and the slope of the fitted simple regression line is a positive value (0.6246). 

 

The reason for this may be that SP is a material with greater variance and the characteristics of different SP marks are different.

 

preparation for Concrete Mix Design

In order to prepare a data set for the metering of pozzolanic concrete mixtures, which is practical and appropriate for technical applications, it is further classified Engineers can use the classified data set to easily predict mixture proportionate based on the required compressive strength of concrete, the replacement rate of pozzolanic admixture, and the required concrete cost. 

 

The first step is to create a set of pozzolanic concrete mixes that conforms to the ACI code and consists of experimental data from the literature and numerical data generated by a computer program. 

The second step is the classification of the data set for the dosage of pozzolanic concrete mixtures. 

A classification method is used to categorize data on the compressive strength of concrete, the replacement rate of pozzolanic additives and the cost of materials in 360 clusters.

Schematic representation of the proposed approach for the design of pozzolanic concrete mixtures.

Experimental samples were also prepared in the laboratory to investigate the predictive accuracy of cspnn and spnnwith respect to pozzolanic concrete according to the Aci concrete mix code. 

Twelve concrete mixes were randomly generated by a computer program according to the concrete mix in the ACI code.  

Twelve experimental concrete mixes and their accurate and predicted compressive strength and sinking. 

Uses of concrete strengths in excess of 10,000 psi are easily accessible on each building. 

The standard blend of cement, water, stone, and sand, regularly perfected by the Romans, contains a variety of chemical additives that can significantly improve the composition, strength, and performance of the concrete.

 

While the laboratory, the plant and the contractor may be directly responsible for ensuring that the concrete meets the specified design strengths, it is often up to the designer responsible to control the variables under field conditions, to help with troubleshooting and to make suggestions for improvement. 

 

For high strength concrete, it is common to use this test for every concrete laying. Other projects may not use microwave tests, but they can be used as an aid in solving on-the-spot problems. 

If the number of concrete breaks in a project is low, conducting on-site microwave tests can provide information on the ratio of water to cementitious material and help pinpoint the problem, or at least eliminate the concrete’s water content as a potential problem. 

 

The most common reason for low concrete test results is the addition of unauthorized water to the concrete mix on the job site. 

Concrete may not contain more water than specified in the approved mix design. The best way to ensure this is to stop adding water to the site. 

Unfortunately, if the transit time to the job site is too long and sagging until the completion of the concrete, the most common reaction is the addition of water. 

 

The method of the American Concrete Institute (ACI) is based on the fact that the water content in kilograms per cubic meter of concrete for a given maximum aggregate size determines the processability of the concrete mix, usually independent of the mixing ratios.

It is, therefore, possible to start the mix design by selecting the water content from these tables.

Furthermore, it is also assumed that the optimum ratio of the bulk volume of the coarse aggregate to the total volume of the concrete depends only on the maximum size of the aggregate and on the grading of the fine aggregate.

 

A Little About Concrete

Concrete is a composite mixture consisting of cement, sand, and aggregates.

Concrete mixing design is the process to find the right amounts of these materials to achieve the desired strength.

 Large structures such as bridges or dams require a large amount of concrete, and using the right amount of components makes the structure economical.

Concrete mixing design determines the right proportions of cement, sand and concrete aggregates to achieve target strength in structures. 

The concrete mix design includes various steps, calculations, and laboratory tests to find the right mixing ratios.

The benefits of concrete mix design are that it provides the right material ratios, making the concrete structure economical to achieve the required strength of the components.

 

Based on the tables and calculations included in the standard, a concrete mix can be created. Because all concrete mixes have unique properties, the design process can be time-consuming and challenging.

 

However, the Concrete Hub app solves the challenges associated with creating a unique concrete mix.

After all these failed calculations, the conclusion is that concrete is still constructed by experience with previous blends or by making experimental approaches in a laboratory and testing the concrete.

Many decorative contractors have 4 or 5 blends that they use for different applications or weather conditions. 

The standard for designing a concrete mix is ​​ACI 211.1, proportions for normal, heavy and mass concrete. 

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