3

NPCA FOUNDATION SAFETY SUSTAINABILITY SHOP myNPCA CONTACT

UCTS PLANT RESOURCES CERTIFICATION EDUCATION MEETINGS PUBLICATIONS ABOUT NPCA

FIND PRECAST
Water-to-Cement Ratio and Aggregate Moisture
Corrections PRODUCTS & SUPPLIES

National Precast Concrete Association / Precast Magazines / Archive - 2004-2008 / Water-to-Cement Ratio and
Aggregate Moisture Corrections

May 28, 2010 — 41 Comments

r Q 8 X
By Adam D. Neuwald

Two of the most commonly specified requirements for concrete used in

the manufactured concrete products industry are the design
compressive strength (f’ c) and the maximum water-to-cement ratio
(w/c). These two values are inversely related, which means that as the
water-to-cement ratio increases, the compressive strength decreases.
Not only does the w/c ratio have a strong influence on compressive
strength, but it also affects the permeability and ultimately the
durability of the concrete. Both of these properties become extremely
important when the precast product will be subjected to a corrosive
environment or freeze-thaw conditions, or when it is required to
provide a watertight structure.

Concrete is designed to withstand a certain maximum load per area

before failing, known as compressive strength A number of factors
influence the concrete’s ability to withstand the force from an applied
load, such as the size, type, quantity and gradation of aggregates, the
type and quantity of cement and/or supplementary cementitious
materials, the amount of mix water, the age or maturity of the concrete,
and the production practices used in placing, consolidating and curing
the concrete. Small changes in any of these variables can have a
profound effect on the concrete’s compressive strength, permeability
and durability. To account for such variables, mixes are designed to
meet an average or required compressive strength (f’ cr), which is
greater than the design strength. Procedures for determining the
average or required compressive strength are addressed in chapter 5 of
ACI 318 and are covered in the May/June 2004 MC magazine article
titled “Standard Deviation” (available at www.precast.org).

Once general requirements such as the required compressive strength,

air content and slump have been established, initial mix designs may be
developed following the guidelines in ACI 211.1, “Standard Practice for
Selecting Proportions for Normal, Heavyweight and Mass Concrete.”

Water-to-cement ratio
The maximum water-to-cement ratio may be established by the
customer or authority having jurisdiction based on anticipated
exposure conditions. The target w/c ratio can also be selected from
available data on the actual materials that will be used. If no such data
is available the w/c ratio can be selected from table 6.3.4(a) of ACI 211.1
based on the required compressive strength. The lower of the two w/c
ratios should be used for the mix design.

The water-to-cement ratio is the weight of water provided in a mix

divided by the weight of cementitious materials. The total weight of
water includes all batch water and free water from the surface of
aggregates. If the amount of water is provided in gallons, it can easily be
converted to pounds by multiplying the total gallons by 8.34 pounds per
gallon. Cementitious materials include portland cement, blended
cements and supplementary cementitious materials such as fly ash,
silica fume and slag. Because of this, the water-to-cement ratio may be
referred to as the water-to-cementitious materials ratio (w/cm). When
calculating the w/c ratio, the total weight of all cementitious materials is
used in the denominator.
1 gallon of water = 8.34 pounds of water

Table 6.3.3 of ACI 211.1 may be used to select the required amount of
batch water based on the desired slump and maximum aggregate size.
The amount of cement and/or cementitious materials is then
determined by dividing the selected water weight by the w/c ratio. As
the amount of batch water is increased to achieve greater workability,
so is the amount of cement in order to maintain the required water-to-
cement ratio. The workability of a concrete mix is provided by the
paste, which fills the voids between aggregates. The paste acts as a
lubricant that reduces internal friction between aggregates while
increasing workability. As the aggregate decreases in size, the amount
of paste must increase to account for an increase in aggregate surface
area.

For both economical reasons and concerns with durability, it is often

desirable to use the largest size aggregate possible to minimize the
amount of paste in the system. Water-reducing chemical admixtures are
often incorporated into a mix to achieve the required fresh properties
for placing and consolidating concrete, ensuring that both a lower w/c
ratio and a paste content can be maintained. Water alone should never
be used to improve the workability of fresh concrete. Using water to
assist in finishing operations or working bleed water back into the top
surface of the concrete should also be avoided as these practices will
increase the water-to-cement ratio of the top layer of concrete, which
will lead to future durability problems.
Hydration is the result of a chemical reaction that occurs between the
cement and water. Initially the cement grains are dispersed throughout
the system and are separated by water (Fig. 1 at right). During this stage
of hydration, which typically occurs in the first 15 minutes, a rapid
exothermic chemical reaction takes place, which produces a
considerable amount of heat. Following this initial reaction, the
hydration process enters a dormant period of any where from two to
four hours. This dormant period allows for the transportation and
placement of the concrete.

Rather than adding additional water to increase the concrete’s

workability, water-reducing admixtures can improve the dispersion of
the cement particles to increase the workability.

Following the dormant period, the

cement will continue to hydrate,
producing reaction products that
will begin to fill the voids between
the cement particles (Fig. 2 at right).
The formation of reaction products
ultimately creates the binding
material between aggregates. A
basic mix will typically reach its
initial set after about four hours of hydration. At this time, concrete is
no longer workable and will typically have a compressive strength of
about 500 psi. The cement will continue to hydrate, producing
additional reaction products that will fill the voids provided by the
initial mix water. As long as there is available room for the reaction
products to form and water present to further hydration, the hydration
reaction will persist and the concrete will continue to gain strength.
However, once the available water has been exhausted or the voids
have been filled, the hydration of the cement will cease and the strength
gain of the concrete will plateau.

In theory, 100 percent hydration of cement can be

achieved when enough water has been provided to
react with the available cement and enough space
has been provided by the initial mix water for the
hydration products to form. Although 100 percent
cement hydration does not actually occur, we will
proceed as if it does. Roughly 1.1 unit volumes of
water are required to completely hydrate 1 unit
volume of cement, meaning that 1 cubic foot of
cement will produce 2.1 cubic feet of hydration
product formed from the available cement and
water. This translates to a w/c ratio of 0.36.
However, in order to achieve complete hydration,
all the pores within the system must be completely
filled with water throughout the hydration reaction. If a w/c ratio of 0.36
were used, the pores would not remain full during the entire reaction;
thus to achieve 100 percent hydration, a w/c ratio of 0.42 is required.

Some concretes are produced with w/c ratios lower than 0.2 and as high
as 0.7, although these ratios are not recommended for quality concrete.
Concretes with higher water-to-cement ratios ultimately contain more
water than is required for complete hydration of the available cement.
This additional water creates additional voids known as capillary pores.
As the w/c ratio increases, so does the capillary porosity, and it has a
strong influence on the strength and permeability of the concrete as
illustrated in the following graphs. A concrete with a high porosity will
not provide a watertight structure and will likely deteriorate at an
accelerated rate when exposed to severe freeze-thaw conditions or a
corrosive environment.

Because of this effect, both the American Concrete Institute (ACI) and
the National Precast Concrete Association have established maximum
w/c ratio limits for various applications. The “NPCA Quality Control
Manual for Precast Products” sets a maximum w/c ratio of 0.45 for
concrete exposed to freezing and thawing and a maximum limit of 0.40
for concrete that will be exposed to deicer salts, brackish water or
seawater. A maximum w/c ratio of 0.48 is set for watertight products
containing fresh water. In order to produce concrete with a lower
water-to-cement ratio, chemical admixtures can reduce the required
amount of mixing water and still obtain the desired fresh properties to
facilitate the placement and consolidation of the concrete.

One of the key parameters in producing

high-strength concrete is the use of a low
w/c ratio. As explained earlier, this
means that not all of the cement will
hydrate because of the lack of available
space within the system for hydration
products to form and because of the lack of free water available to
hydrate all of the cement (Fig. 3 at right). This is why moisture curing of
high-strength concrete is extremely important.

Aggregate moisture corrections

Aggregates are not completely solid but rather contain a certain level of
porosity. Pores may be located in the center of the aggregate, while
others may actually connect to the surface of the aggregate. When
calculating the bulk specific gravity of an aggregate, take both the
volume of the aggregate and all its pores into consideration. These pores
will likely contain a certain level of moisture that will affect the
performance of the concrete if appropriate corrections are not made to
account for the actual moisture content of the aggregates. There are
four different moisture conditions for aggregates, two of which may be
achieved in a laboratory, while the other two occur naturally on a daily
basis in aggregate stockpiles.

Oven-dry (OD): This is achieved under laboratory conditions when the

aggregate is heated to 220 F (105 C) for an extended period. Under this
condition, all moisture is removed from the aggregate’s pores.

Air-dry (AD): The surface of the aggregate is dry and the internal pores
may be partially filled with water. This condition may occur on a hot
summer day or in an arid region. The aggregates will likely absorb
water from the mix, which may affect the workability of the concrete
unless proper adjustments are made to the aggregate and water batch
weights.

Saturated surface-dry (SSD): This is achieved under laboratory

conditions when all the pores are completely filled with water but no
free water remains on the surface of the aggregate. Aggregates in this
condition will not contribute free water nor absorb water from the mix.

Damp or Wet: All the pores are completely filled with water and the
surface of the aggregate contains free water. Aggregates in a stockpile
will typically be in this condition, meaning additional water will be
added to the mix unless proper adjustments are made to the aggregate
and water batch weights.

Aggregate mixture proportions are developed using either the oven-dry

or saturated surface-dry condition. It is important to know this
information when adjusting mix designs to account for actual aggregate
moisture contents. Mix designs are typically developed using the oven-
dry condition, but some may be developed using the saturated surface-
dry condition. According to Ken Hover of Cornell University, one
advantage of designing a mix based on SSD conditions is that the total
weight of the batched materials will be the same before and after
aggregate moisture corrections. Corrections to aggregate batch weights
can be made using a correction factor, while the batch water weight is
easily calculated by subtracting the weight of the cement and adjusted
aggregates from the original design weight of all materials.

The actual aggregate moisture content and the absorption value of the
aggregates must be known in order to accurately adjust the batch
weights. The aggregate supplier should be able to provide you with the
absorption value for each aggregate; otherwise they may be calculated
following the procedures in ASTM C127 for coarse aggregates and ASTM
C128 fine aggregates.

A = Absorption

W SSD = Weight saturated surface-dry aggregate

W OD= Weight oven-dry aggregate

The moisture content for each aggregate must also be calculated.

Aggregate moisture contents will vary throughout a stockpile, with
wetter aggregates located near the bottom of the pile. It is extremely
important to calculate the aggregate moisture content at least once a
day and perhaps more frequently when producing self-consolidating
concrete (SCC), which is more sensitive to changes in aggregate
moisture contents. Some batching systems are equipped with probes
that read the moisture content of aggregates while being discharged
from the hopper. These systems are typically tied directly into the batch
computer and will automatically adjust the batch weights for correct
proportions and w/c ratio. For batching systems without moisture
meters or probes, the aggregate moisture content must be determined
manually.

ASTM C566, “Standard Test Method for Total Evaporable Moisture

Content of Aggregate by Drying,” should be followed when determining
the aggregate moisture content. Take a representative sample from the
aggregate stockpile, avoiding the first few inches as this material is
probably dry and not representative of the entire lot. Take the samples
in accordance with the procedures established in ASTM D75, “Standard
Practice for Sampling Aggregates,” except for the sample size.

Weigh the collected sample and record it prior to drying. Use a hot plate,
microwave oven or some other means of drying. Note that very rapid
heating may cause some particles to explode, resulting in the loss of
particles, which may render your calculations inaccurate. The sample is
considered dry when further heating would cause less than 0.1 percent
additional loss in mass. Allow the sample to cool to avoid damaging the
scale. Weigh the sample to the nearest 0.1 percent. Calculate the total
aggregate moisture content (MC) using the follow equation:

MC = Moisture Content

W initial = Weight of the sample prior to drying

W OD = Weight of the sample after drying

By using the moisture content and absorption of the aggregates, you can
adjust the batch weights to account for the actual moisture condition. If
the moisture content is higher than the aggregate’s absorption value,
the aggregates will contribute free water to the mix. If the moisture
content is below the absorption value, the aggregates will absorb a
portion of the mix water.

For mix designs based on raw materials in an oven-dry condition, make

the following adjustments.

Calculate the adjusted coarse aggregate (CA BW) and fine aggregate (FA
BW) batch weights using the following equation for each material:

AGG BW = Weight of adjusted aggregate to be batched (calculate for CA

BW and FA BW)

AGG DW = Mix design weight of aggregate (CA DW and FA DW)

MC = Moisture content as a percentage (MC CA and MC FA)

Calculate the adjusted water batch weight (W BW) using the following
equation:

W BW= Weight of water to be batched after adjustment

W DW= Mix design weight of water

CA DW = Mix design weight of coarse aggregate

MC CA = Moisture content of coarse aggregate as a percentage

A CA = Absorption of coarse aggregate as a percentage

FA DW = Mix design weight of fine aggregate

MC FA = Moisture content of fine aggregate as a percentage

A FA = Absorption of fine aggregate as a percentage

For mix designs based on raw materials in a saturated surface-dry

condition, make the following adjustments.

Calculate coarse aggregate (CA BW) and fine aggregate (FA BW) batch
weights by multiplying each aggregate design weight (AGG DW) by its
respective correction factor (CF) using the following equation:

CF = Correction factor must be calculated for each aggregate (CF CA and

CF FA)

MC = Moisture content of aggregate as a percentage (MC CA and MC FA)

A = Absorption of aggregate as a percentage (A CA and A FA)

AGG BW = Weight of adjusted aggregate to be batched (calculate for CA

BW and FA BW)

AGG DW = Mix design weight of aggregate (CA DW and FA DW)

CF = Correction factor must be calculated for each aggregate (CF CA and

CF FA)
Determine the amount of batch water by subtracting the sum of the
corrected batch weights (cement, CA BW and FA BW) from the sum of
all the initial design weights, including the water. This concept is
illustrated below.

W BW= Weight of water to be batched after adjustment

C DW = C BW ; The weight of the cement does not change form the

initial design

CA DW = Mix design weight of coarse aggregate

FA DW = Mix design weight of fine aggregate

CA BW = Adjusted batch weight of coarse aggregate

FA BW = Adjusted batch weight of fine aggregate

The following examples show to adjust how mix design weights to
account for aggregates of varying moisture contents.

Example 1: Adjusting Mix Designs Based on Oven-Dry Conditions

The following information is provided for the initial mix design:

Cement = 650 lbs

Coarse Aggregate (OD) = 1,836 lbs
Absorption = 0.5%
Moisture Content = 2.0%
Fine Aggregate (OD) = 1,243 lbs
Absorption = 0.7%
Moisture Content = 5.20%
Water = 315 lbs
Calculate the adjusted aggregate batch weights

Calculate the adjusted water batch weight:

The new batch weights are as follows:

Cement = 650 lbs

Coarse Aggregate = 1,873 lbs
Fine Aggregate = 1,308 lbs
Water = 231 lbs

Example 2: Adjusting Mix Designs Based on Saturated Surface-Dry

Conditions

The following information is provided for the initial mix design:

Cement = 650 lbs

Coarse Aggregate (SSD) = 1,610 lbs
Absorption = 0.5%
Moisture Content = 1.8%
Fine Aggregate (SSD) = 1,245 lbs
Absorption = 0.7%
Moisture Content = 4.8%
Water = 310 lbs
Total weight of materials = 

Calculate the adjusted aggregate batch weights

Calculate the adjusted water batch weight

The new batch weights are as follows:

Cement = 650 lbs

Coarse Aggregate = 1,631 lbs
Fine Aggregate = 1,296 lbs
Water = 237 lbs

What would happen if the design batch weights in the above examples
were used without making corrections to account for the actual
aggregate moisture contents? The w/c ratio in the first example would
have changed from roughly 0.48 to 0.61, and the w/c ratio in the second
example would have changed from roughly 0.48 to 0.59. This would
mean that the 28-day compressive strength of each mix would likely be
reduced by 1,000 psi, not to mention that the w/c ratios may no longer
comply with the limits established by the authority having jurisdiction.
 Whether you are using your own batch plant with automated moisture
probes or purchasing ready-mixed concrete, it is extremely important
that all individuals involved with the batching, mixing and casting of
concrete understand the importance of maintaining the specified water-
to-cement ratio. All additional water added to a mix should be
measured and accounted for by adjusting mix proportions to ensure the
maximum water-to-cement ratio is not exceeded. Having tight control
on the w/c ratio will remove one of the many variables that influence
the strength and durability of finished products.

Filed Under: Archive - 2004-2008

Tagged With: aggregate moisture, precast, precast concrete, water-to-cement ratio

Recommended For You

Reducing Shrinkage Cracking

Watertightness of Precast Concrete

Combating an Old Nemesis: Freeze/Thaw Cycles

Comments

jacqueline says
June 13, 2012 at 2:14 am

this is nice.:)..

Reply

Akondo says
January 8, 2013 at 2:46 am

Nice

Reply

Alberto Salazar says

July 8, 2014 at 5:29 pm

This was very helpful. Thank you.

Reply
 Bob says
July 22, 2014 at 2:17 am

Interesting comment regarding increased porosity degrading the freeze thaw resistance.

Reply

Muhammad Mohsan says

April 9, 2015 at 3:53 pm

nice job and thanks this is very helpfull

Reply

Jeffery S. says
April 23, 2015 at 2:50 am

What is the standard for achieving SSD aggregates?

Reply

Claude Goguen says

April 23, 2015 at 5:03 pm

Achieving SSD in aggregates can be done using methods ASTM C127 Standard Test
Method for Relative Density (Specific Gravity) and Absorption of Coarse Aggregate
and C128 Standard Test Method for Relative Density (Specific Gravity) and
Absorption of Fine Aggregate.
 Usually, SSD weights are given in the aggregate mill certificates through the
Absorption Capacity. Take the AC and multiply it by the oven dry weight, and you get
your SSD weight. I would happy to go over this with you in detail if need be.

Reply

Janagarajan.P says
July 4, 2015 at 3:59 am

How do you calculate for the moisture correction for hot aggregates which is lying open
yard at Batching plant site. Aggregates will drink more water because of hot. Then how
do you calculate that water content other than considering water absorption and
moisture content of aggregates.

Reply

Sara Geer says

July 6, 2015 at 3:40 pm

Thanks for the comment Janagarajan.P. I consulted with the technical department
here at NPCA, and they advised that determining water adjustments for aggregates
is usually only based on moisture content and absorption capacity. The aggregate
can only absorb as much water as its porosity will allow, regardless of temperature.
If the aggregate is so hot that it evaporates mix water that comes in contact, then
looking at ways to lower that temperature may be considered. Some precast
concrete companies will sprinkle aggregate with water. Others will erect means of
shading to keep temperatures down.

Reply
 chaitanya says
August 6, 2015 at 3:43 pm

Thanku sir.Very useful information.

Reply

Manuel says
August 7, 2015 at 1:16 am

Very helpful for civil engineers, thanks

Reply

ejaznespak says
August 30, 2015 at 8:13 am

what is the normal slump of girders concrete to achieve a good strength for this
water cement ratio o.40?

i m waiting for your good response;;;;;;;;;;;;;;;;;;

AME NESPAK PAKISTAN

Reply

Sara Geer says

October 28, 2015 at 7:53 am

Thank you for the comment ejaznespak. Evan Gurley, one of our technical
engineers, has given the following response:
“Concrete must always be made with a workability, consistency and plasticity
suitable for job conditions. The slump test is generally used to measure
 concrete consistency. Consistency is the ability of freshly made concrete to
flow. When used with different batches of the same mix design, a change in
slump indicates a change in consistency and in the characteristics of the
materials, mixture proportions, water content, mixing, time of test or the
testing itself.

The reality is that if we measure the slump, the only thing we really know at
this point is the slump. The slump of a concrete mix is influenced by
everything. Changes in any of the following can change the slump of the
concrete:

– Content, proportions, chemistry, fineness particle size distribution, moisture

content and temperature of cementitious materials
– Content, proportions, size, texture, grading, cleanliness and moisture
contents of the aggregates
– Dosage, type, combination, interaction, sequence of addition of chemical
admixtures
– Air content
– Batching, mixing and delivery/placing methods
– Temperature of the concrete
– Sampling, slump-testing technique and the condition of the test equipment
– Amount of free water in the concrete
– Time since batching at the time of testing

Slump is usually indicated in the job specifications as a range or as a

maximum value not to be exceeded. If slump is not specified, ACI 211.1 Table
6.3.1 has established recommended slumps based on the various types of
construction.”

Reply

Rod Llanera says

 January 20, 2016 at 7:14 am

How to calculate the volumetric batch of 1:2:4, and how to apply corrections in moisture
of aggregates and bulking in sand.

Reply

Sara Geer says

February 9, 2016 at 8:13 am

Thank you for your comment Rod. Kayla Hanson, one of technical engineers, has
provided the following response.

“Volumetric Batching: First, the 1:2:4 ratio is the ratio of cement to fine aggregate
to coarse aggregate, by material volume. There are five parameters we need to
identify prior to calculating the mix proportions.

1. Required strength
2. Minimum cementitious materials content or maximum water-to-cementitious
materials ratio
3. Nominal maximum aggregate size
4. Air content
5. Desired slump

Next, ACI 318 outlines in detail numerous guidelines and requirements that dictate
certain factors. Additionally, you’ll need to refer to ACI 211.1, ACI 211.2, ACI 211.3 or
ACI 237R-07 for proportioning, depending on what type of mix you’re developing –
normal, heavyweight or mass concrete; structural lightweight concrete; no-slump
concrete; or self-consolidating concrete. If you have further questions after
reviewing the ACI codes, NPCA’s technical services is happy to answer them for you.

Moisture Adjustments: To determine moisture correction factors, we first need to

know the moisture content of both the coarse aggregate and fine aggregate. We
also need to know the certain inherent aggregate properties.
 For example, if the nominal maximum coarse aggregate size is 1 inch, and the fine
aggregate has a fineness modulus of 2.40, ACI 211.1 will tell us the recommended
bulk volume of coarse aggregate is 0.71. If the coarse aggregate has a unit weight
of 100 lb/ft3, this will require 1,917 pounds of coarse aggregate per cubic yard of
concrete (0.71 * 100 lb/ft3 * 27 ft3/yd3 = 1,917 lb/yd3). If the coarse aggregate has
a moisture content of 1.5%, we will instead need to batch about 1,946 pounds of
coarse aggregate per cubic yard of concrete (1,917 lb/yd3 * 1.015 = 1,946 lb/yd3).

Similar calculations also apply to fine aggregate moisture adjustments. Adjusting

any aspect of the batch will alter the characteristics of both plastic and hardened
concrete, so be sure to account for any and all adjustments that are made, and also
be aware of how those adjustments will affect other raw material quantities and the
fresh and hardened concrete properties.”

Reply

Coleridge Davis says

January 21, 2016 at 5:16 am

Thanks guys for your helpful information . You guys are on the ball with everything

Reply

Coleridge Davis says

January 21, 2016 at 5:22 am

Base on all the information that is been shade Is there anyone on your team have ever
achieve 4000 PSI in 24 hours ? If yes can someone explain to me how is it been done

What are the key factor in doing this design ?

Please help

Reply

McKenzie says
February 5, 2016 at 8:40 pm

I am not a concrete professional, but for that type of performance, I think you will
need to use calcium aluminate cement instead of portland cement.

Reply

Isah says
February 19, 2016 at 2:14 am

Thank you for the informative article.

β
Do you know what the standard or typical values for absorption of coarse aggregates that
are to be used in concrete mix design are?

Reply

Sara Geer says

May 11, 2016 at 8:56 am

Thank you for the comment Isah. Aggregate absorption values and specific gravities
can vary widely depending on the geology and geography of the aggregate site. This
can even vary within close regional pit locations. I suggest to contact your local
aggregate supplier to obtain absorption values, which would be valid for your mix
design.
 Reply

RHC says
May 4, 2016 at 6:11 pm

What if the materials are not in OD or SSD condition? Which adjustment do you make?

Reply

Sara Geer says

May 11, 2016 at 9:22 am

Thank you for the comment RHC. Eric Carleton, vice president of technical services,
provided the following response:

“The answer to your question is actual aggregate conditions are rarely oven dry or
surface-saturated dry. Those are laboratory established ideal conditions used to
develop the mix design. Prior to production, all aggregates need to be tested no less
than daily (and possibly more depending on local conditions) to determine the
actual moisture content of the stored aggregate. The mix water can then be
adjusted to match the original mix design water content developed for that
particular aggregate when in OD and SSD condition. The arithmetic adjustments
used, as described in the article, would depend on which way you want to develop
the original mix design.”

Reply

Ussu ajaib says

June 16, 2016 at 9:07 pm
Is it required to reduce the selection of water content in calculation of mixed design when
fine aggregate has a surface moisture content of 2%?if yes, then how?

Reply

Sara Geer says

June 21, 2016 at 7:32 am

Thank you for the comment Ussu. To answer your question, when aggregates are
wet beyond an SSD state, the excess surface water on the aggregates contributes
to the mix water. The amount of water batched into the mixer should be adjusted to
account for the aggregate moisture content (and the additional water added to the
mix by the wet aggregates) so that the total amount of water in the mix abides by
the mix design qualifications.

Reply

Richard Okura says

July 12, 2016 at 11:28 am

Why would two plants batching concrete using the same materials use different amount
of water, say 120litres and 146litres? More so when before the two plants were using the
same amount of water? (Please note that one of the plant is automated and the other is
not when it comes to making moisture corrections?).

Reply

Sara Geer says

July 26, 2016 at 12:35 pm
Thank you for your comment Richard. Eric Carleton, director of codes and
standards, provided the following response:

“Greetings Richard, you pose an interesting question. As you may know, water
serves two purposes in a concrete mix design. First, it starts the hydration process
with the cementitious materials. The minimum water-to-cementitious materials
ratio needed is between 0.19 and 0.26, depending on the materials, grind fineness,
etc. Second, water in excess amounts of the needed hydration minimum fill the
pores and provide lubricity or workability to the mix. This characteristic is measured
via a slump test. More water creates greater slump and workability. However, there
is diminishing returns because adding water beyond the optimized hydration
amount can lead to reduced compressive strength, possible aggregate segregation
and reduced durability. Many standards limit the maximum w/cm ratio for quality
concrete.Fortunately, modern chemical admixtures can increase concrete
workability as well without the need for excessive water.

Which now brings us back to your initial question, why would two plants using
identical raw materials have mix designs with different water quantities? When you
say “one plant is automated and the other is not when it comes to making moisture
corrections,” I assume the automation only applies to the mix and batch operation
and not that one plant manufactures products via an “automated” process. In that
case, “automated” would mean one plant employs a dry-cast automated production
method and the other doesn’t, which would explain everything.

However, assuming both plants use wet cast or SCC mixes, the answer could be a
number of reasons:

1. If the raw materials used are the same, each plant’s mix design may be slightly
different. It could be one plant is using more cement requiring greater amounts of
water to maintain a similar slump or slump flow range needed for casting. Note, the
added cement may not be intentional, so checking weigh scales or ensuring
material gates open and close properly, may also solve the problem.
2. The use of automated moisture controls when operating properly can provide
added consistency to batching. It is important moisture sensors are calibrated with
the aggregates being used. The NPCA Quality Control Manual for Precast concrete
 Plants, Section 5.2.2, “Moisture Content,” requires the calibration to occur weekly for
conventional, dry-cast and SCC mixes. This is typically accomplished by either
ASTM C70 or C566 and compares it to automated readings to ensure they are
within an acceptable range. If the moisture sensors are not reading properly that
could lead to varied water content. A slump test would stress this problem.
3. Are both plants maintaining identical slump or slump flow range for the produced
products? And are they actively testing fresh mixes? If not, that could also be the
reason for the water difference. Additionally, if one plant is using a water reducing
or plasticizer admixture in different proportions, that would account for different
batching weights of water.
4. Are both aggregates stored similarly? If a sand or course aggregate is stored
outside for one plant, it may dry out faster than a plant that keeps its aggregate
stored inside. This can have a greater water demand.

In a perfect world theoretically both mixes of “identical materials” should have

identical water demand. However, concrete batching is not a perfect science and
there are minor variables to always be considered. Therefore, the answer to your
question boils down to either: mix design differences, equipment error or human
error.”

Reply

John says
September 8, 2016 at 9:12 am

Is there a formula or estimate for the impact on cement requirements to maintain

required strength when additional fine aggregate is added. With a known surface area for
the additional sand can I calculate the additional cement required to avoid strength loss?

Reply
 Ahortu derrick says
October 9, 2016 at 11:15 am

Nice job:):D

Reply

Jorge Cifuentes says

November 7, 2016 at 1:28 pm

I am trying to determine the range or spec. of the W/C ratios on 2 machines that we run
in a dry cast processing plant. What we call our Columbia is the 50 machine running 307
lbs. cement with 8.7 gallons of water, my calculation comes to 0.263 W/C ratio.
On the Teksam machine we are running 413 lbs. cement with 12.2 gallons of water with
my calculation of 0.246 W/C ratio. Remember this is a dry cast plant. Is there a specific
range that we should be in as far as WC as I see it vary from week to week? Most of the
info I get is pertained to wet cast.

Thank you in advance,

Jorge

Reply

Mason Nichols says

November 10, 2016 at 9:37 am

Hi Jorge,

Thank you for submitting your question! We passed it along to our technical
services engineers, and Kayla Hanson has this response for you:
If we assume one gallon of water weighs 8.36 pounds, aggregate at SSD and no
admixtures, we get the following values for situation #1, where you’re using 307 lb
of cement and 8.7 gallons of water: It appears that you may have transposed the
decimal numbers in your inquiry.

8.7 gal x 8.36 lb/gal = 72.732 lb water

72.732 lb water / 307 lb cement = 0.2369

We get the following values for situation #2, where you’re using 413 lb of cement
and 12.2 gallons of water:

12.2 gal x 8.36 lb/gal = 101.992 lb water

101.992 lb water / 412 lb cement = 0.2476

The reason you don’t get exactly these water-cement ratios for every batch of dry
cast concrete you produce could be due to a variety of reasons. Is your water meter
calibration up to date? Is it functioning within appropriate limits? Do you use
supplementary cementitious materials in your mix designs? Do you monitor both
the fine aggregate and coarse aggregate moisture contents accurately and
consistently with probes or by moisture burns (ASTM C70 or ASTM C566)? Are your
aggregates clean? Do you adjust your mix water depending on how wet/dry your
aggregates are? Do you use chemical admixtures in your mix designs? The water in
the admixtures may actually count toward the total amount of mix water in your
concrete. This isn’t an exhaustive list of the possible causes, but these could be
good places to check first.

As far as an appropriate w/c ratio range is concerned, that will depend on what the
design calls for and how much variance can occur in the w/c while still producing
the same strengths, same durability, same performance, etc. ACI 211.3, “Guide for
Selecting Proportions for No-Slump Concrete,” will provide valuable information and
guidelines for you.

Reply
 leslie says
April 18, 2017 at 8:51 am

are both examples based on trial mixes done in the lab ? cause they have me confused?

Reply

Sara Geer says

April 21, 2017 at 12:38 pm

Thank you for your comment Leslie. I forward your question to our Technical
Services engineers. The following response is from Kayla Hanson.

The examples use sample values that one might see either in a plant or in a lab
setting. Example 1 shows how to adjust for aggregate moisture if a mix design is
proportioned based on oven dry aggregate, and Example 2 shows how to adjust for
aggregate moisture if a mix design is proportioned based on saturated surface dry
aggregate. Further information on concrete mix design, adjustments, and examples
can be found in ACI 211, “Standard Practice for Selecting Proportions for Normal,
Heavyweight, and Mass Concrete.”

It’s important to remember that aggregates have pores that can hold water. Oven
dry (OD) describes the state where the aggregate surface is completely dry and the
pores/internal structure of the aggregate are also completely dry. Air dry (AD)
describes the state where the surface of the aggregate is dry and the internal pores
are partially filled with water. Saturated surface dry (SSD) describes the state where
the surface of the aggregate is dry, but the internal pores are completely full of
water. Wet describes the state where all the internal pores are fully saturated plus
the surface of the aggregate is fully saturated.

If aggregates are dryer than SSD, they can absorb mix water because their pores are
not full, and the aggregate tries to get to a state of equilibrium. If aggregates are
more wet than SSD, they can contribute water to the mix because there is excess
water (no matter how little) on the aggregate surface. Because of this, aggregate
moisture contents can affect the water-to-cementitious materials ratio of a mix.
 However, aggregates are never going to be in a perfect SSD state, and rarely will the
entire stockpile of aggregate be in an OD state. Therefore, we need to determine the
absorption capacity of each aggregate type. Before making the first batch of the
day, we measure the aggregate’s actual moisture content at that time and compare
it to its absorption capacity. The values will indicate what state the aggregate is in,
and from that we can either batch additional water into the mixer or hold back some
of the water to ensure we will have the appropriate w/cm ratio.

Reply

Pavan says
April 22, 2017 at 8:32 am

What are the main differences between IS method and the ACI method of concrete mix
design?

Which is more affordable one?

Reply

Sara Geer says

April 27, 2017 at 8:21 am

Thank you for your comment Paven. Since we primarily represent North American
precasters, we are unfamiliar with Indian Standard codes. I’d suggest contacting the
Bureau of Indian Standards to get a more accurate response to your questions. If
you are needing information about precast concrete mix design, we have many
helpful resources on our website. Search “mix design” in the main search bar for
case studies, technical documents and more. If you have anymore questions,
please let me know.

Reply
 jun says
May 8, 2017 at 12:15 am

Our design mix is suppose to be for 80mm slump, the w/c ratio is 0.35. The slump we got
was 40mm. how are we going to adjust the slump to 80mm without altering the w/c
ratio? Is the batch adjustment for wet aggregates only? how about if the aggregates are
dry. Are we going to use batch adjustment even the aggregates are dry?

Reply

Sara Geer says

May 8, 2017 at 10:40 am

Thank you for your comment Jun. I forwarded your question to our Technical
Services engineers. The following response is from Kayla Hanson.

If the aggregates are dry, they will absorb the mix water and reduce your slump and
water-cement ratio. Prior to batching, you should check your aggregate moisture
content and compare it to how the mix design was proportioned. If your mix design
assumes you’ll be using aggregates in a saturated surface dry state, but the
aggregates you actually use are dryer than SSD, they will absorb mix water. Dry
aggregates can also absorb any liquid admixtures in the mix, which can greatly
reduce their effectiveness. Similarly, if your aggregates are wet, they will add water
to your mix, resulting in greater slump and greater w/c. ACI 211.1, “Standard
Practice for Selecting Proportions for Normal, Heavyweight, and Mass Concrete”
provides further information.

Reply
 Jun says
May 9, 2017 at 6:55 pm

we are using sand, 20mm and 10mm aggregates. do we still have to get the moisture
content of 10mm?

Reply

Sara Geer says

May 11, 2017 at 8:54 am

Thank you for your comment Jun. I forwarded your question to our Technical
Services engineers. The following response is from Kayla Hanson.

Yes. The absorption capacity and moisture content of each aggregate needs to be
determined (sand, 20 millimeter and 10 millimeter). Each ingredient in the mix,
including each aggregate type and size, can affect the mix and its fresh and
hardened properties and behavior.

Reply

Ken Uber says

June 18, 2017 at 6:25 pm

I would like to know just what aggregate particle shape, round versus fractured face play
in the water demand in a given mix design?

Reply

Sara Geer says

 June 26, 2017 at 12:31 pm

Thank you for your comment Ken. I forwarded your inquiry to our technical services
engineers. The following response is from Eric Carleton, P.E., director of codes and
standards.

Many concrete design documents acknowledge that rounded course aggregates

have a reduced water demand than crushed angular. This statement has been
repeatedly verified through physical concrete batching, but the answer to “why” lies
in the surface area of the two shapes. Rounded aggregate of similar gradation sizes
has less exposed surface area than jagged faced aggregate. More surface area
requires more paste to cover the area. Also, on a microscopic level, angular
aggregate can have slightly increased void space between them then rounded
aggregate. This leads to increasing the requirements of fine aggregate or concrete
paste to fill this void and increases water demand.

Reply

Joey Suklaru says

March 16, 2018 at 1:23 pm

I have this bookmarked on my computer, absolute gold.

Reply

Leave a Reply
Your email address will not be published. Required fields are marked *
 Comment

Name *

Email *

Website

Post Comment

CATEGORIES

NPCA Blog (457)

NPCA News (103)

From NPCA Board Chair (15)
From NPCA President Ty Gable (46)
Building (1)
Case Studies (9)
Education (4)
Manhole (1)
Marketing (24)
Meet a Precaster (48)
Precast Products (78)
Precast Concrete Paving Slabs (2)
Safety (56)

Bi-Monthly Safety Training (47)

Safety Hot Topics (7)
Stormwater Management (12)
Sustainability (7)
The Precast Show (11)
Utility Structures (3)
Water and Wastewater (5)
Quality Assurance (1)

Sponsors

r Q X U " L
© 2018 National Precast Concrete Association