Concrete Technology Seminar 2010 K.H.

Khayat

DAY 2 – Concrete Mix Design & Properties

(7 hours )
7. Quality controll testing (video- discussion – 0.5 hr)
8. Concrete mix design (2 hr)
9. Workability and testing of fresh concrete (2 hr)
10. Hardened properties: testing & influencing factors
(2 hr)
Compressive strength; Influencing factors
 Stress-strain behaviour; Elastic modulus

 Tensile and flexural strengths

 Effect of test parameters on mechanical properties

Open discussion (0.5 hr)

Designing and Proportioning

Normal Concrete Mixtures
Factors in the Proportioning of
Quality Concrete Mixtures
 Workability
 Durability
 Strength
 Appearance
 Economy

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Concrete Technology Seminar 2010 K.H. Khayat

Mix Characteristics
 Strength
 Water-cementing materials ratio
 Aggregate size and volume
 Air content
 Slump and workability
 Water content
 Cementing materials content
and type
 Admixtures

Balance Between Short-Term

and Long-Term Requirements
Long-Term Short-Term
Requirements Requirements
Strength Workability
Durability Compromise or Finishability
Volume Stability Mutual Benefit Pumpability

• Easily mixed, transported, fill forms

• Must be able to be finished properly
• Uniform throughout the mixture, not prone to
segregation

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Concrete Technology Seminar 2010 K.H. Khayat

Requirements for Exposure Conditions

Maximum w/c- Min. strength,
Exposure condition ratio by mass f'c, MPa (psi)
Select for strength, Select for
No freeze-thaw, deicers,
workability, and structural
aggressive substances
finishing needs requirements
Concrete with low permea-
0.50 28 (4000)
bility; exposed to water
Concrete exposed to
freezing and thawing in a 0.45 31 (4500)
moist condition or deicers
For corrosion protection for
reinforced concrete 0.40 35 (5000)
exposed to chlorides

Requirement for Concrete Exposed to Sulfates

Sulfate Sulfate Minimum
(SO4) in (SO4) in Maximum strength,
Sulfate soil, % by water, w/c, by f'c,
exposure mass ppm Cement type mass MPa (psi)
Less Less than No special
Negligible — —
than 0.10 150 type required
II, MS,
IP(MS),
0.10 to 150 to IS(MS),
Moderate 0.50 28 (4000)
0.20 1500 P(MS),
I(PM)(MS),
I(SM)(MS)
0.20 to 1500 to
Severe V, HS 0.45 31 (4500)
2.00 10,000
Very Over Over
V, HS 0.40 35 (5000)
severe 2.00 10,000

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Concrete Technology Seminar 2010 K.H. Khayat

Compressive Strength Vs. W/C

Bulk Volume of Coarse Aggregate

Maximum size Fineness modulus of sand
of aggregate,
2.40 2.60 2.80 3.00
mm (in.)
9.5 (3/8) 0.50 0.48 0.46 0.44
12.5 (1/2) 0.59 0.57 0.55 0.53
19 (3/4) 0.66 0.64 0.62 0.60
25 (1) 0.71 0.69 0.67 0.65
37.5 (1 1/2) 0.75 0.73 0.71 0.69
50 (2) 0.78 0.76 0.74 0.72
75 (3) 0.82 0.80 0.78 0.76
150 (6) 0.87 0.85 0.83 0.81

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Concrete Technology Seminar 2010 K.H. Khayat

Recommended Slump Ranges

Slump, mm (in.)
Concrete construction
Maximum Minimum
Reinforced foundation walls and
75 (3) 25 (1)
footings
Plain footings, caissons, and
75 (3) 25 (1)
substructure walls
Beams and reinforced walls 100 (4) 25 (1)
Building columns 100 (4) 25 (1)
Pavements and slabs 75 (3) 25 (1)
Mass concrete 75 (3) 25 (1)

Water and Air Requirements for

Different Slumps and Sizes of
Aggregate
Water, kilograms per cubic meter of concrete,
for indicated sizes of aggregate
9.5 12.5 19 25 37.5 50 75 150
Slump, mm mm mm mm mm mm mm mm mm
25 to 50 207 199 190 179 166 154 130 113
75 to 100 228 216 205 193 181 169 145 124
150 to 175 243 228 216 202 190 178 160 —
Approximate amount of
entrapped air in non-air- 3 2.5 2 1.5 1 0.5 0.3 0.2
entrained concrete, percent

Non-air-entrained concrete

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Concrete Technology Seminar 2010 K.H. Khayat

Water and Air Requirements for Different

Slumps and Sizes of Aggregate
Water, kilograms per cubic meter of concrete,
for indicated sizes of aggregate
9.5 12.5 19 25 37.5 50 75 150
Slump, mm mm mm mm mm mm mm mm mm
25 to 50 181 175 168 160 150 142 122 107
75 to 100 202 193 184 175 165 157 133 119
150 to 175 216 205 197 184 174 166 154 -
Recommended average total air content,
percent, for level of exposure
Mild exposure 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0
Moderate exposure 6.0 5.5 5.0 4.5 4.5 4.0 3.5 3.0
Severe exposure 7.5 7.0 6.0 6.0 5.5 5.0 4.5 4.0

Air-entrained concrete

Air Content and Aggregate Size

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Concrete Technology Seminar 2010 K.H. Khayat

Approx. Water Requirements for

Various Agg. Sizes and Slumps

Minimum Cementing Materials

Content for Flatwork
Nominal maximum size Cementing materials,
of aggregate, mm (in.) kg/m3 (lb/yd3)
37.5 (1½) 280 (470)
25 (1) 310 (520)
19 (¾) 320 (540)
12.5 (½) 350 (590)
9.5 (3/8) 360 (610)

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Concrete Technology Seminar 2010 K.H. Khayat

Determination of Cement
Content
Required Water Content
Cement Content =
Water-Cement Ratio

Example: air-entrained concrete

25-mm max. size aggregate
75-mm slump

175 kg/m3 Water

= 330 kg cement per
0.53 W/C-ratio m3 of concrete

Approx. Water Requirements for

Various Agg. Sizes and Slumps

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Concrete Technology Seminar 2010 K.H. Khayat

Relationship
between:
 Slump
 Agg. Size
 W/C
 Cement
content

Bulk Volume of Coarse Aggregate

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Concrete Technology Seminar 2010 K.H. Khayat

Absolute Volume of Coarse

Aggregate per m3 of Concrete
Given: 0.46 m3 of coarse aggregate
1 m3 Bulk density = 1567 kg/m3, rodded
Relative density = 2.65
Water = 1000 kg/m3

0.46 m3 • 1567 kg/m3 = 715.5 kg

0.46 m3
Absolute volume =
715.5/(2.65 • 1000) = 0.27 m3

So the coarse aggregate is 27% of the

absolute volume of the concrete

Cementitious Materials
Requirements for Concrete
Exposed to Deicing Chemicals
Maximum of cementi-
Cementitious materials tious materials, %
Fly ash and natural pozzolans 25
Slag 50
Silica fume 10
Total of fly ash, slag, silica
50
fume and natural pozzolans
Total of natural pozzolans and
35
silica fume

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Concrete Technology Seminar 2010 K.H. Khayat

Maximum Chloride-Ion Content

for Corrosion Protection
Maximum chloride ion
content in concrete,
Type of member % by mass of cement
Prestressed concrete 0.06
Reinforced concrete exposed
0.15
to chloride in service
Reinforced concrete that will be
dry or protected from moisture 1.00
in service
Other reinforced concrete
0.30
construction

Methods for Proportioning

Concrete Mixtures
 Water-cement ratio method

 Weight method

 Absolute volume method

 Field experience (statistical data)

 Trial mixtures

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Concrete Technology Seminar 2010 K.H. Khayat

Proportioning from Field Data

Modification Factor for Standard
Deviation ( 30 Tests)

Modification factor for

Number of tests standard deviation
Less than 15 see next slide
15 1.16
20 1.08
25 1.03
30 or more 1.00

Proportioning from Field Data

Required Strength When Data Are
Available to Establish a Standard
Deviation
Specified compressive Required average
strength, f'c, MPa compressive strength, f'cr, MPa
f'cr = f'c+ 1.34s
 35 f'cr = f'c + 2.33s – 3.45
Use larger value
f'cr = f'c+ 1.34s
Over 35 f'cr = 0.90f'c + 2.33s
Use larger value

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Concrete Technology Seminar 2010 K.H. Khayat

Proportioning from Field Data

Required Strength When Data Are
Not Available to Establish a
Standard Deviation
Specified Required average
compressive strength, compressive strength,
f'c, MPa f'cr, MPa
Less than 21 f'c + 7.0

21 to 35 f'c + 8.5

Over 35 1.10f'c + 5.0

Absolute Volume Computation for

Fine Aggregate Content
135
Water = = 0.135 m3
1 • 1000
435 = 0.145 m3
Cement =
3.0 • 1000
8.0 = 0.080 m3
Air =
100
Coarse 1072
aggregate = = 0.400 m3
2.68 • 1000
Subtotal = 0.760 m3
Fine aggregate volume = 1 - 0.76 = 0.24 m3
Fine aggregate mass = 0.24 • 2.64 • 1000
= 634 kg

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Concrete Technology Seminar 2010 K.H. Khayat

Proportioning by Trial Mixtures

Trial batching
verifies that a
concrete mixture
meets design
requirements prior
to use in
construction.

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Concrete Technology Seminar 2010 K.H. Khayat

Result of Laboratory Trial

Mixtures
Air Cement Fine aggregate,
Batch Slump, content, Density, content, percent of total Worka-
no. mm percent kg/m3 kg/m3 aggregate bility
1 50 5.7 2341 346 28.6 Harsh

2 40 6.2 2332 337 33.3 Fair

3 45 7.5 2313 341 38.0 Good

4 36 6.8 2324 348 40.2 Good

Water-Cement ratio was 0.45

Common Mix Design Mistakes

 Not varying water-cement ratio
(3 point curve)
 Not monitoring slump loss
during mix design to identify
false setting tendency in
cement
 Not monitoring early age
concrete temperatures to
identify retardation effects of
water reducers

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