CH07 PC Concrete

Mamlouk/Zaniewski, Materials for Civil and Construction Engineers, Third Edition. Copyright 2011 Pearson Education, Inc.
Materials for Civil and

Construction Engineers

CHAPTER 7
Portland Cement Concrete

2
Introduction
Many types of concrete
Portland Cement Concrete (PCC) prevalent
! concrete = PC Concrete
Engineers are directly responsible for the
! Design of the mix
! Final quality of concrete

3
Concrete Ingredients
Aggregates
! Fine
! Coarse
Portland Cement (PC)
Water
Admixtures
! Paste = PC + Water
! Mortar = PC + Water + Fine aggregate
! Concrete = PC + Water + Coarse and Fine
aggregates

Quality of Concrete
chemical composition
aggregate
water
admixtures
proportions
mixing
transporting
hydration
placing
vibrating
curing
depends on:
4

5
Order of Operations for Concrete
specific operations must be performed in a certain order
final quality is influenced by every step

I. mix design (proportioning)
II. trial mixes & testing
III. batching
------------------------------------------------------------start the clock
IV. mixing
V. transporting
VI. pouring (placing)
VII. vibrating (consolidating)
-------------------------------------------------------------initial set here
VIII. finishing
-------------------------------------------------------------final set here
IX. curing
X. maintenance
Sampllng and Lesung

6
7.1 Proportioning of Concrete Mixes
(Mix Design)
Determine proportions of mix ingredients that will:
! be economical
! be practical
! use available materials
! satisfy requirements & specs
acceptable workability of fresh mix
quality (durability, strength, appearance) of
hardened concrete
economy

7
Several Methods
Depends on project size:
Arbitrary volume method (1:2:3 =
PC:sand:coarse agg.)
Weight method easiest design method
Absolute volume method most accurate
Small jobs, non-critical

8
Mix Design: Volumetric Method
1. Strength requirements
2. Determine W/C
3. Estimate coarse aggregate mass
4. Air entrainment requirements
5. Workability needs
6. Estimate water content
7. Determine cement content requirements
8. Evaluate admixture needs
9. Estimate fine aggregate mass
10. Determine moisture corrections
11. Trial Mix

9
Step 1. Strength Requirements
Design engineer specifies a strength of
concrete used for design calculations f
c
Concrete strength is variable
Material engineer designs concrete so only a
small proportion of the concrete will have a
strength less than the strength assumed by the
design engineer.

Strength Requirements
normal dlsLrlbuuon
lncreaslng sLrengLh
Average sLrengLh
x Lhe concreLe has
a sLrengLh less Lhan
average
SLandard devlauons
1.34s
f
cr
= f
c
+ 1.34s
f
cr
- average sLrengLh
for mlx deslgn

Addlng 1.34s Lo f
c
-
90 of Lhe concreLe wlll
be sLronger Lhan specled
sLrengLh
f
cr
f
c

11
Strength Requirements
f
cr
= f
c
+ (1.34 s) when s < 500 psi
If s > 500 psi :
f
cr
= f
c
+ (2.33 s) - 500 psi
s = standard deviation of f
c
for a particular mixing
plant
! If s is based on fewer than 30 samples, then the
standard deviation of the population is
underestimated

Adjustments for Small Number of Samples
13 Lo 30 LesLs
mulupllcauon
ad[usLmenL facLor
e.g. 13 samples
muluply s by 1.16

fewer Lhan 13 LesLs:
!""#$%& (!)*+, -!.&" +/ ()
very conservauve: /+* (+, 0!,1& 2,+3&)*.
12

13
Step 2. Determine Water-Cement Ratio
hlsLorlcal records of sLrengLh are used Lo ploL f
c
vs. w/c
f
cr
w/c Ratio
13

.&%&,& &42+.5,& )+/"#$+/. ,&65#,& 0+7&, 78) ,!$+.
5.& 0+7&.* 78) ,!$+ +( !00 !220#)!-0& )+/"#$+/.
&42+.5,& )+/"#$+/.
.50(!*& &42+.5,&
Water-Cement Ratio
check for maximum allowed
14

w/c ad[usLmenL - exposure
15

w/c ad[usLmenL - sulfaLes
16

17
Step 3. Coarse Aggregate Requirements
gradation & maximum size
! use large most dense gradation for economy & specs
large aggregate improves workability (or less water &
cement)
nature of particles (shape, texture, porosity)
! round shape and smooth texture are workability (or less
water & cement)

Check maximum aggregate size (use smallest)

1hls ls Lhe only place ln Lhe mlx deslgn
process where maxlmum aggregaLe slze
ls used. nomlnal maxlmum aggregaLe
slze ls used ln all oLher places.
8emember Lhe maxlmum aggregaLe slze
ls generally one s|eve s|ze |arger Lhan Lhe
nomlnal maxlmum aggregaLe slze.

Coarse aggregaLe bulk volume
nMAS 19 mm
lM = 2.7
ury rodded unlL welghL = 120 lb/
3
0.63 of Lhe bulk
volume of Lhe
concreLe wlll be
coarse aggregaLe
Muluply 0.63 by Lhe
dry rodded unlL
welghL of Lhe coarse
aggregaLe Lo
deLermlne Lhe mass
of coarse aggregaLe.
Mass CA = 120*0.63
= 73.6 lb/
3

x27
= 2041 lb/yd
3
lb of coarse aggregaLe
per cublc yard of concreLe

19
Coarse Aggregate Adjustment
! increase CA volume by 10% to reduce slump:
e.g., pavement construction
! decrease CA volume by 10% to increase
slump:
e.g., for placement by pumping

20
Step 4. Air Entrainment Requirements
19 mm
ModeraLe exposure
Nom|na|
LsumaLed alr for non-alr-enLralned
needed for volumeLrlc analysls

21
Step 5. Workability Requirements
Slump is ease of placing, consolidating, and finishing.
highest slump with no segregation or excessive
bleeding
! CA migrates to bottom & water migrates to top
Increase slump with
! admixtures
! rounded aggregates

22
Step 6. Water Content
For a given slump it depends on maximum size and
shape of aggregates
Table 7.8: for angular shaped CA
! reduce water requirement for other shapes
Considers SSD condition (adjust in step 10)
Never let workers add water in truck or at the jobsite
Oven Dry Air Dry SSD Moist

CLher AggregaLe Shapes
19 mm nMAS 1.3 slump
Alr enLralned
280 lb waLer per cublc yard of concreLe
Angu|ar Aggregates
Step 6. Water Content (Cont.)
23

Step 7. Cement Content
Check mlnlmum requlremenLs
llaLwork
severe exposure - mlnlmum
of 334 kg/m
3
(364 lb/yd
3
)
under waLer mlnlmum of
383 kg/m
3
(630 lb/yd
3
)
c
w
W
W
water
cement
=
622
45 . 0
280
= =
cement
W
lb/yd
3
24

25
Step 8. Admixtures

follow instructions from manufacturers
generally small quantities
! volume or mass should be considered in mix
proportioning

26
Step 9. Fine Aggregate Requirements
aggregate coarse air cement water aggregate fine
V V V V V ! ! ! ! =1
Assume v
concreLe
= 1 elLher m
3
or yd
3
of concreLe
aggregate fine aggregate coarse air cement water concrete
V V V V V V + + + + =
Mass (or welghL) of componenLs used wlLh denslLy
(unlL welghL) Lo deLermlne volume of each componenL

V V V V V ! ! ! ! = 27
u.S. cusLomary
meLrlc
3
/yd
3

V V V V V ! ! ! ! = 27
3 3
/ 487 . 4 4 . 62 / 280 yd ft V
water
= =
( )
3 3
/ 165 . 3 4 . 62 15 . 3 / 622 yd ft V
cement
= ! =
3 3
/ 350 . 1 27 % 5 yd ft V
air
= ! =
( )
3 3
/ 959 . 11 4 . 62 735 . 2 / 2041 yd ft V
aggregate coarse
= ! =
3 3
/ 039 . 6
959 . 11 350 . 1 165 . 3 487 . 4 27
yd ft V
V
aggregate fine
aggregate fine
=
! ! ! ! =
3
waLer
yd
3
concreLe
3 3
/ 1019 4 . 62 705 . 2 039 . 6 yd lb M
aggregate fine
= ! ! =
lb ne agg. per yd
3
concreLe

28
Step 10. Moisture Corrections
Adjust the weight of water and aggregates to account for
the existing moisture content of the aggregate
! wet aggregate weighs more than dry agg. (we used dry
density)
! we assumed SSD and must adjust free mix water if not
SSD.

Mass

Absorption

Moisture
content

Mass
with
moisture

Free
moisture

CA 2041 0.80% 2.30% 2088 31
FA 1019 1.70% 4.50% 1065 29
Total
excess
moisture 60
new waLer welghL = 280 - 60 = 220
Ad[usLed
aggregaLe
welghLs

29
Step 11. Trial Mixes
check proportions with trial batches
! air content
! slump
! 28 day compressive strength:
3 cylinders 6! Dia. x 12! H
adjust for optimum workability & economy

30
Specific operations must be performed in a certain order

III. batching
------------------------------------------------------------start the clock
IV.mixing
V. transporting
-------------------------------------------------------------initial set here
VIII. finishing
-------------------------------------------------------------final set here
IX. curing
X. maintenance
CompleLe

31
7.2 Mixing, Placing, & Handling of PCC
Batching
Measuring correct proportions of components and
placing in the mixer
By weight is more accurate because air voids don't
matter
Mixing
Until uniform appearance
Usually batch mixers (one at a time), but sometimes
continuous (conveyors automatically feed components
into mixer)
Usually start with 10% of the water in the mixer, then
solids with 80% of the water, and then remaining water

Central Batch Concrete Plant
Mlx lngredlenLs ln
predeLermlned
proporuons
lace ln Lrucks
32

Slipform Paver
33

34
Mobile Plant
Batcher
! batcher mixer at (or
near) the jobsite

35
Mixing
until uniform appearance
usually batch mixers but sometimes continuous
(conveyors automatically feed components into mixer)
usually start with 10% of the water in the mixer, then
solids with 80% of the water, and then mix in the
remaining 10% of the water

Mixing
keady M|xed
ln a cenLral planL and
dellvered ln an aglLaLor Lruck
(2 - 6 rpm)
Shr|nk-m|xed
parually mlxed ln planL and
dellvered ln a mlxer Lruck
(4 - 16 rpm)
1ruck-m|xed
mlxed compleLely ln a mlxer
Lruck (4 - 16 rpm)
specs. llmlL Lhe revs. of Lhe
Lruck barrel Lo avold
segregauon
max. 90 mlnuLes from sLarL
of mlxlng Lo dlscharge, even
wlLh reLarders
36

37

III. batching
------------------------------------------------------------start the clock
IV. mixing
V. transporting
-------------------------------------------------------------initial set here
VIII. finishing
-------------------------------------------------------------final set here
IX. curing
X. maintenance
CompleLe
Sampllng and Lesung

38
Sampling and Testing
Pull samples at the job site
Test on site
! Slump
! Air content
Prepare samples for later
testing
! Cylinders
! Beams

39
Slump
Workability is measured by slump test
! fill a cone in 3 layers, 25 rods each layer
! lift cone off and measure distance it slumps from
original height

40
Air Content Test for Fresh Concrete
Measures total air content (entrapped and entrained)
Only entrained is good but we can't tell the difference
from this test
1) Pressure Method
2) Volumetric Method
3) Gravimetric Method
4) Chase Air Indicator

41
Cylinders
6 x12 Standard
Place concrete in
three lifts, rod each 25
times
Cure on site 24 hrs
Temperature
Humidity /
submerged in lime
water

42

III. batching
------------------------------------------------------------start the clock
IV. mixing
V. transporting
-------------------------------------------------------------initial set here
VIII. finishing
-------------------------------------------------------------final set here
IX. curing
X. maintenance
CompleLe
Sampllng and Lesung

43
Placing Concrete
Transfer From Truck.
ChuLe
Conveyor

ulrecLly lnLo form
Wheel barrow/ buggy
8uckeL
ump
44

45
Placing Issues
Drop height
! < 3 ft
Horizontal movement
! Limit to prevent segregation
Pumping
! Adjust mix design
trem|e chute to ||m|t drop he|ght

46
Vibration of Concrete
Consolidation (compaction)
complete before initial set
Manually by
ramming
tamping
Mechanically using vibrators
Internal poker
5 sec to 2 min in one spot
<10 sec. typical
avoid segregation
through entire depth
penetrate layer below if still plastic
External
tables and rollers for precast concrete

47

III. batching
------------------------------------------------------------start the clock
IV. mixing
V. transporting
-------------------------------------------------------------initial set here
VIII. finishing
-------------------------------------------------------------final set here
IX. curing
X. maintenance
CompleLe
Sampllng and Lesung

48
Finishing Concrete
smoothing and imprinting the surface of the
concrete with the desired texture
must be completed before final set
many types of colors and textures available
these days
! stamped concrete uses rubber stamps to
create the look of stone, tile, etc.

Screedlng - sLrlke concreLe
o Lo deslred level
8ulloaung ellmlnaLes hlgh
and low spoLs and embeds
large aggregaLe parucles
lmmedlaLely aer sLrlkeo.
ower oaL
49

50

III. batching
------------------------------------------------------------start the clock
IV. mixing
V. transporting
-------------------------------------------------------------initial set here
VIII. finishing
-------------------------------------------------------------final set here
IX. curing
X. maintenance
CompleLe
Sampllng and Lesung

7.3 Curing Concrete
Maintain moisture and
temperature in the
concrete to promote
continued hydration
and strength gain
hydration will resume
if curing is stopped
and resumed
Curing affects:
durability
strength
water-tightness
abrasion resistance
volumetric stability
resistance to
freezing and
thawing
resistance to de-
icing chemicals
51

Compressive strength of PCC at different ages &
curing levels
52

53
Curing Approaches
1. Maintaining presence of water in the
concrete
2. Seal the surface so mix water cant
escape
3. Heat & additional moisture


54
Approach 1. Maintaining Presence
of Water
Must water periodically
Also provides cooling
Methods
! ponding: smaller jobs flat-work (floors and
pavement) and laboratory
! spraying or fogging: expensive and a lot of
water
! wet coverings: burlap, cotton, rugs, etc.

55
ChapLer 7 orLland CemenL
ConcreLe
Spray|ng
logglng
Spraylng
55

56
Wet Covering

57
Approach 2. Seal the Surface

impervious paper or plastic
sheets
membrane forming
compounds
leave forms in place

lasuc SheeLs

58
ChapLer 7 orLland CemenL
ConcreLe 58

59
Approach 3. Heat
insulate
steam
! good for early strength gain and in freezing
weather
heating coils, electrically heated forms or pads
! usually in precast plants only

Method Selection
Conslderauons:
avallablllLy of curlng
maLerlals
slze and shape of
sLrucLure
producuon faclllues (ln-
place or precasL)
aesLheuc appearance
economlcs
Curlng - lmmedlaLely
aer nal seL Lo avold
surface damage
Curlng perlod
mlnlmum 7 days
70 of f
c
(3 days for
hlgh early sLrengLh)
oLher [ob requlremenLs
60

61

III. batching
------------------------------------------------------------start the clock
IV. mixing
V. transporting
-------------------------------------------------------------initial set here
VIII. finishing
-------------------------------------------------------------final set here
IX. curing
X. maintenance
Sampllng and Lesung

62
1. Early Volume Change
2. Creep
3. Permeability
4. Stress-Strain Relationship

7.4 Properties of Hardened
Concrete

63
Early Volume Change
Plastic shrinkage plastic
concrete 1% shrinkage from
evaporation cracking
Drying shrinkage after
setting if not cured cracking
If wetted continuously very
slight swelling
Curling from non-uniform
drying


64
long term, gradual, deformation under
sustained load
small strain but transfers load from
concrete to steel in beams & columns
Creep

65
Permeability
As w/c = 0.3 to 0.7:
coefficient of permeability
increases by a factor of 1000
Caused by voids: poor
consolidation & excess water
Allows water & chemicals to
penetrate
Reduces durability &
resistance to frost, alkali
reactivity, and other chemical
attacks

66
Typical !-" of 28 day concrete
Increasing w/c decreases both strength (f
c
) and
stiffness (E)
Stronger concrete is more brittle
Almost linear at small strains
Stress-Strain
Relationship

Usually use chord modulus for E
c

Very small strain and 40% s
u
or specific strain
(1%)
3 or 4 loading cycles
E
c
= 2000 - 6000 ksi, Poisson's ratio, n = 0.11 - 0.21
ACI building code:
MPa f E
c c
, 731 , 4
!
=
psi f E
c c
, 000 , 57
!
=
67

68
Compressive Strength (f
c
) Test
Most common test by far (even more than
slump)
2:1 cylinders cast in 3 layers rodded 25
times each layer and cured at 95%
humidity
Or specimens are cored from finished
structure
7 day = 60% of 28 day and 28 day = 80%
ultimate strength
Typical compressive strength is 3,000 -
6,000 psi
7.5 Testing of Hardened Concrete

69
6 diameter x 12 long is ASTM standard and close
approximate to actual structures
! Smaller sizes (4 x 8, 3 x 6)
usually stronger because smaller volume has
fewer defects in specimen
use more specimens because more variation
and less representative
ease of handling, less accidental damage, less
concrete, smaller machine, less curing, &
storage space

70
Split Tension Test
To measure tensile strength
about 10% of f'
c


I|exura| Strength
lmporLanL for pavemenLs
Slmply supporLed 6 x 6
beam loaded on Lhe 1/3
polnLs
71

72
Non-Destructive Tests

Rebound (Schmidt)
Hammer
Measures energy absorbed
by concrete
! hardness of surface
correlated to strength
Not very accurate
! average of 10-12
readings in one area

73
Penetration Resistance
(Windsor Probe)

Measures penetration of a
probe into concrete (very
slightly destructive)
! hardness of surface:
correlated to strength
Average of 3 tests in
triangular template

74
Ultrasonic Pulse Velocity

Transmitter, receiver, & clock
! piezoelectric crystals
Velocity = distance / time
! faster = more dense like a RR
track
! cracks and weak spots are
slower
Usually only used for finding
cracks and discontinuities


75
Maturity Test
Maturity is more than age since
hydration is a function of time &
temperature
Maturity meter monitors
temperature over long periods

X-rays, wave refraction,
nuclear refraction, sonar,
radar
Same principles as ultrasonic
velocity
Darker areas are more dense

76
Self-Consolidating Concrete
Highly flowable, nonsegregating concrete
Can spread into place, fill the formwork, and
encapsulate the reinforcement, without any
mechanical consolidation
7.6 Alternative Concretes

77
Flowable Fill
Self-leveling and self-compacting, cementitious
material with low unconfined compressive
strength
Used as backfill material in lieu of compacted
granular fill

78
Shotcrete (Gunite or
Sprayed Concrete)
Mortar or small-aggregate
concrete that is sprayed at
high velocity onto a
surface

79
Lightweight Concrete
Floating concrete (ASCE concrete canoe)
Costs more but need less because of reduced
weight

Heavyweight Concrete
Massive walls for nuclear, medical, and atomic
shielding
Very heavy weight aggregates (barite, magnetite,
hematite, lead, steel)

80
High-Strength Concrete
At least 6,000 psi strength with normal
weight aggregates
Very low w/c with superplasticizers up to
20,000 psi


81
Shrinkage Compensating
Alumina causes a little expansion to compensate for
normal shrinkage
Type K cement

Polymer Concrete
Very quick set (1 hr.) or super high strength ( >20,000
psi)
Polymer-PC concrete
latex is mixed with Portland cement

82
Fiber-reinforced Concrete
Instead of rebar (for corrosion)
becoming more common
Flexural strength increased by
up to 30%
Reduces workability
Steel, plastic, glass, etc.

Roller Compacted Concrete (RCC)
No slump concrete compacted in-place by
heavy equipment
Much cheaper for
many reasons
Large dams
Parking areas
83

84
High Performance Concrete
High strength sacrifices other properties
By using special aggregate gradation, admixtures,
and techniques we can improve several properties
at once (workability, strength, toughness, volume
stability, and exposure resistance)

CH07 PC Concrete

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Mamlouk/Zaniewski, Materials for Civil and Construction Engineers, Third Edition. Copyright 2011 Pearson Education, Inc.

Materials for Civil and

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