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CEMENT
WHAT IS CEMENT
4. Easily workable.
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TYPES OF CEMENT
1) Lime (CaO)
2) Silica (SiO2)
3) Alumina (Al2O3)
4) Iron oxide ((Fe2O3)
5) Magnesium oxide (MgO)
6) Sulphur trioxide (SO3)
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PRINCIPAL MINERALS IN CEMENT
13
PORTLAND CEMENT
The rotation and shape of kiln allow the blend to flow down
the kiln, submitting it to gradually increasing temperature.
27
ASTM CLASSIFICATION
Type I-For use in general concrete construction where the special properties specified for
types II, III, IV, and V are not required. Type I is also called ordinary Portland cement (OPC).
Type II-For use in general concrete construction exposed to moderate sulphate action, or
where moderate heat of hydration is required.
Type III For use when high early strength is required (Rapid hardening cement).
Type IV-For use when low heat of hydration is required (Low Heat Cement)
Type V-For use when high sulphate resistance is required (Sulphate resisting cement).
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TYPES OF CEMENT
1. Ordinary Portland Cement 10. Coloured Cement
2. Rapid Hardening Cement 11. Hydrophobic cement
3. Extra Rapid Hardening 12. Masonry Cement
Cement 13. Expansive Cement
4. Sulphate Resisting Cement 14. IRS-T 40 Special Grade
5. Quick Setting Cement Cement
6. Super Sulphated Cement 15. Oil-Well Cement
7. Low Heat Cement 16. Rediset Cement
8. Portland Pozzolana Cement 17. High Alumina Cement
9. Air-Entraining Cement 18. High Early Strength
Cement
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ORDINARY PORTLAND CEMENT
Ordinary Portland cement (OPC) is the most important type of
cement.
The OPC was classified into three grades, namely 33 grade, 43
grade and 53 grade depending upon the strength of the
cement at 28 days when tested as per IS 4031-1988.
If the 28 days strength is not less than 33 N/mm2, it is called
33 grade cement,
if the strength is not less than 43 N/mm2, it is called 43 grade
cement, and
If the strength is not less than 53 N/mm2, it is called 53 grade
cement.
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MANUFACTURING OF PORTLAND CEMENT
33
EXTRA RAPID HARDENING CEMENT
34
EXTRA RAPID HARDENING CEMENT
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SULPHATE RESISTING CEMENT
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SULPHATE RESISTING CEMENT
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QUICK SETTING CEMENT
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LOW HEAT CEMENT
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SIEVES
40
SIEVES
41
CEMENT MANUFACTURING
42
EXTRACTION OF RAW MATERIALS
43
GRINDING AND STORAGE OF RAW MATERIALS
44
THE FIRING OF RAW MATERIALS
45
CEMENT CLINKERS
STORAGE AND GRINDING OF CEMENT
47
CEMENT
48
PACKING
49
PACKING AND SHIPMENT
50
SETTING AND HARDENING OF CEMENT
When cement is mixed with water a stiff and sticky paste is formed, which
remains plastic for a short period. With the passage of time the plasticity
gradually disappears and the cement paste become stiff due to initial
hydration of cement. This phenomenon by virtue of which the plastic cement
changes into a soil mass is known as setting of cement.
Cement sets when mixed with water by way of a complex series of chemical
reactions still only partly understood. The different constituents slowly
crystallise and the interlocking of their crystals gives cement its strength.
Carbon dioxide is slowly absorbed to convert the portlandite (Ca(OH)2) into
insoluble calcium carbonate. After the initial setting, immersion in warm
water will speed up setting. In Portland cement, gypsum is added as a
compound preventing cement flash setting.
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SETTING AND HARDENING OF CEMENT
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STANDARD CONSISTENCY TEST
53
SETTING TIME TEST
Prepare a cement paste by gauging the cement with 0.85 times the
water required to give a paste of standard consistency.
Fill the Vicat mould completely with the cement paste gauged as
above, the mould resting on a non-porous plate and smooth off the
surface of the paste making it level with the top of the mould. The
cement block thus prepared in the mould is the test block.
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VICAT APPARATUS
56
VICAT APPARATUS
57
SETTING TIME TEST
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SETTING TIME TEST
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AGGREGATES
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AGGREGATES
Essentially aggregates can refer to any granular material formed from a
natural rock substance. It is usually further defined either:
63
TERMINOLOGIES
Workability
Flowability
Compactability
Stability
Pumpability
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WORKABILITY
65
WORKABILITY
68
FLOWABILITY
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COMPOSITION OF CONCRETE
Water
Chemical admixtures
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MIXING CONCRETE
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MIXING CONCRETE
Separate paste mixing has shown that the mixing
of cement and water into a paste before
combining these materials with aggregates can
increase the compressive strength of the
resulting concrete. The paste is generally mixed
in a high-speed, shear-type mixer at a w/cm
(water to cement ratio) of 0.30 to 0.45 by mass.
The cement paste premix may include admixtures
such as accelerators or retarders,
superplasticizers, pigments, or silica fume.
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MIXING CONCRETE
The premixed paste is then blended with
aggregates and any remaining batch water and
final mixing is completed in conventional
concrete mixing equipment.
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CONCRETE MIXING
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CONCRETE MIXING
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PLACING AND COMPACTION
The methods chosen for placing and compacting
the concrete will depend on the type of
construction, the total volume to be placed, the
required rate of placing and the preferences and
expertise of the construction companies involved.
There are, however, several basic rules which
should be followed to ensure that the concrete is
properly placed and compacted into a uniform,
void free mass once it has been delivered to the
formwork in a satisfactory state:
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PLACING AND COMPACTION
With deep pours, the rate of placing should be such that the layer of
concrete below that being placed should not have set; this will ensure full
continuity between layers, and avoid cold joints and planes of weakness in
the hardened concrete;
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PLACING AND COMPACTION
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PLACING AND COMPACTION
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TYPES OF CONCRETE
1) Regular concrete
2) High-strength concrete
3) high-performance concrete
4) Self-consolidating concretes
5) Vacuum concretes
6) Shotcrete
7) Pervious concrete
8) Stamped concrete
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REGULAR CONCRETE
Regular concrete- is the lay term describing
concrete that is produced by following the mixing
instructions that are commonly published on
packets of cement, typically using sand or other
common material as the aggregate, and often
mixed in improvised containers. This concrete
can be produced to yield a varying strength from
about 10 MPa (1450 psi) to about 40 MPa (5800
psi), depending on the purpose, ranging from
blinding to structural concrete respectively.
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REGULAR CONCRETE
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HIGH STRENGTH CONCRETE
It is a type of high performance concrete
generally with a specified compressive strength
of 6000 psi (40 MPa) or greater. High strength
concrete is required to:
Put concrete into service at much earlier age,
for example opening the pavement at 3-days
To build high-rise buildings by reducing
columns sizes and increasing available space.
etc.
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High-Strength Concrete
90% of ready-mix concrete
20 MPa - 40 MPa (3000 –
6000 psi) @ 28-d
(most 30 MPa – 35 MPa)
High-strength concrete
by definition —
28 day – compr. strength
70 MPa (10,000 psi)
High-Value
Concrete
High-Strength Concrete Materials
Aggregates —
9.5 - 12.5 mm (3/8 - 1/2 in.) nominal
maximum size gives optimum
strength
Combining single sizes for required
grading allows for closer control and
reduced variability in concrete
For 70 MPa and greater, the FM of
the sand should be 2.8 – 3.2. (lower
may give lower strengths and sticky
High-Value mixes)
Concrete
High-Strength Concrete Materials
High-Value
Concrete
High-Strength Concrete Materials
Admixtures —
Use of water reducers, retarders,
HRWRs, or superplasticizers —
mandatory in high-strength concrete
Air-entraining admixtures not necessary
or desirable in protected high-strength
concrete.
Air is mandatory, where durability in a
freeze-thaw environment is required (i.e..
bridges, piers, parking structures)
Recent studies:
w/cm ≥ 0.30—air required
High-Value w/cm < 0.25—no air needed
Concrete
High-Strength Concrete
Placing, Consolidation, and Curing
Delays in delivery and placing
must be eliminated
Consolidation very important to
achieve strength
Slump generally 180 to 220 mm (7 to 9
in.)
Little if any bleeding—fog or
evaporation retarders have to be
applied immediately after strike off to
minimize plastic shrinkage and crusting
High-Value 7 days moist curing
Concrete
HIGH STRENGTH CONCRETE
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HIGH-PERFORMANCE CONCRETE
High performance concrete (HPC) has been defined as concrete
that possesses high workability, high strength and high
durability.
High Performance Concrete (HPC) is a concrete made with
appropriate materials combined according to a selected mix
design; properly mixed, transported, placed, consolidated and
cured so that the resulting concrete will give excellent
performance in the structure in which it is placed, in the
environment to which it is exposed and with the loads to which
it will be subject for its design life.
The primary application for HPC have been structures requiring
long service lives such as oil drilling platform, long span bridges
and parking structures. HPC still requires good construction
practice and good curing to deliver high performance.
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HIGH-PERFORMANCE CONCRETE
High-Value
Concrete
Selected Properties of High-
Performance Concrete
Property Test Method Criteria that may be specified
High Strength ASTM C 39 70-140 MPa @ 28 to 91 days
H-E Comp. Strength ASTM C 39 20-30 MPa @ 3-12 hrs or 1-3 days
H-E Flex. Strength ASTM C 78 2-4 MPa @ 3-12 hrs or 1-3 days
Abrasion Resistance ASTM C 944 0-1 mm depth of wear
Low Permeability ASTM C 1202 500 to 2000 coulombs
AASHTO T
Chloride Penetration Less than 0.07% Cl at 6 months
259/260
Low Absorption ASTM C 642 2% to 5%
High Mod.of Elast. ASTM C 469 More than 40 GPa
High-Value
Concrete
Self-consolidating
concrete
Self-consolidating concrete
(SCC) is characterized by a low
yield, high deformability, and
moderate viscosity necessary
to ensure uniform suspension
of solid particles during
transportation, placement
(without external compaction),
and thereafter until the concrete
sets.
High-Value
Concrete
Self-Consolidating Concrete
High-Value
Concrete
Self-consolidating
concrete
Self-consolidating
Concrete
Vacuum concrete
It is a well known fact that excessive w/c
ratio is detrimental for concrete. We always
try to restrict the w/c ratio in order to
achieve higher strength. The chemical
reaction of cement with water requires a
w/c ratio of less than 0.38, whereas the
adopted w/c ratio is generally much more
than that mainly because of the
requirement of workability. Workability is
also important for concrete, so that it can
be placed in the formwork easily without
High-Value
Concrete
honeycombing.
Vacuum concrete
After the requirement of workability
is over, this excess water will
eventually evaporate leaving
capillary pores in the concrete.
These pores result into high
permeability and less strength in
the concrete. Therefore, workability
and high strength don't go together
as their requirements are
contradictory to each other.
High-Value
Concrete
Vacuum concrete
Vacuum concreting is the effective
technique used to overcome this
contradiction of opposite
requirements of workability and high
strength. With this technique both
these are possible at the same time.
In this technique, the excess water
after placement and compaction of
concrete is sucked out with the help
of vacuum pumps. This technique is
effectively used in industrial floors,
parking lots and deck slabs of bridges
High-Value
etc.
Concrete
Vacuum concrete
The magnitude of applied vacuum is
usually about 0.08 MPa and the water
content is reduced by up to 20-25%.
The reduction is effective up to a
depth of about 100 to 150 mm only.
High-Value
Concrete
Shotcrete
Shotcrete refers to a process in
which compressed air forces mortar
or concrete through a hose and
nozzle onto a surface at a high
velocity and forms structural or non-
structural components of buildings.
The relatively dry mixture is
consolidated by the force of impact
and develops a compressive
strength similar to normal- and high-
strength concrete.
High-Value
Concrete
Shotcrete
Shotcrete may be applied to
surfaces using a dry- or wet-mix
method. The wet-mix concrete
method consists of Portland cement
and aggregate premixed with water
before the pump pushes the mixture
though the hose. Additional
compressed air is added at the
nozzle to increase the velocity of the
mixture.
High-Value
Concrete
Shotcrete
In the dry-mix process, compressed
air propels a premixed blend of
Portland cement and damp
aggregate through the hose to the
nozzle. In the nozzle, water is added
from a separate hose and
completely mixed with the dry
mixture just as both streams are
being projected onto the prepared
surface.
High-Value
Concrete
Shotcrete
Shotcrete
Shaft
Shotcrete
Shotcrete
Shotcrete
Tunnel
Pervious concrete
Pervious concrete is a
special type of concrete with
a high porosity used for
concrete flatwork applications
that allows water from
precipitation and other
sources to pass directly
through, thereby reducing the
runoff from a site and
allowing groundwater
recharge.
Pervious
Concrete
Pervious concrete
The high porosity is attained by a highly interconnected
void content. Typically pervious concrete has little or no
fine aggregate and has just enough cementitious paste to
coat the coarse aggregate particles while preserving the
interconnectivity of the voids. Pervious concrete is
traditionally used in parking areas, areas with light traffic,
residential streets, pedestrian walkways, and
greenhouses. It is an important application for sustainable
construction and is one of many low impact development
techniques used by builders to protect water quality.
Pervious concrete
Pervious
Concrete
Architecture
Stamped concrete
Stamped concrete is concrete that is
patterned and/or textured or embossed
to resemble brick, slate, flagstone,
stone, tile, wood, and various other
patterns and textures. Stamped
concrete is commonly used for patios,
sidewalks, driveways, pool decks, and
interior flooring. The ability of stamped
concrete to resemble other building
materials makes stamped concrete a
less expensive alternative to using
those other authentic materials such as
stone, slate or brick.
High-Value
Concrete
Stamped concrete
There are three procedures used in
stamped concrete which separate it
from other concrete procedures; the
addition of a base colour, the
addition of an accent colour, and
stamping a pattern into the
concrete. These three procedures
provide stamped concrete with a
colour and shape similar to the
natural building material. It also is
longer lasting than paved stone,
High-Value and still resembles the look.
Concrete
Stamped concrete
Stamped
Concrete
Slump Test
The concrete slump test is used for the
measurement of a property of fresh
concrete. The test is an empirical test that
measures the workability of fresh
concrete. More specifically, it measures
consistency between batches. The slump
test is a means of assessing the
consistency of fresh concrete. It is used,
indirectly, as a means of checking that the
correct amount of water has been added
to the mix. The slump test is used to
ensure uniformity for different batches of
similar concrete under field conditions,
and to ascertain the effects of plasticizers
Slump test of on their introduction.
Concrete
Slump test procedure
The steel slump cone is placed on a solid,
impermeable, level base and filled with the fresh
concrete in three equal layers. Each layer is rodded
25 times to ensure compaction. The third layer is
finished off level with the top of the cone. The cone is
carefully lifted up, leaving a heap of concrete that
settles or ‘slumps’ slightly. The upturned slump cone
is placed on the base to act as a reference, and the
difference in level between its top and the top of the
concrete is measured and recorded to the nearest 5
mm to give the slump of the concrete.
Slump test procedure
When the cone is removed, the slump may take one
of three forms. In a true slump the concrete simply
subsides, keeping more or less to shape. In a shear
slump the top portion of the concrete shears off and
slips sideways. In a collapse slump the concrete
collapses completely. Only a true slump is of any
use in the test. If a shear or collapse slump is
achieved, a fresh sample should be taken and the
test repeated. A collapse slump will generally mean
that the mix is too wet or that it is a high workability
mix, for which the flow test is more appropriate.
SLUMP MOULD (ABRAMS CONE )
121
SLUMP TYPES
122
SLUMP MEASUREMENT
123
SLUMP TESTING
124
SLUMP CLASS
S1 10 ~ 40 20
S2 50 ~ 90 70
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CURING METHODS
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CURING OF CONCRETE
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CURING OF CONCRETE
129
CONCRETE MIX DESIGN
Concrete mix designs is best defined as a
process in selecting suitable ingredients, which is
cement, aggregate, sand and water, and
determining their relative proportions to give the
required strength, workability and durability.
To find a combination of constituents that would
give concrete of properties complying with certain
specifications, economically. Mix design
properties are selected depending on the
application and expected performance.
130
OBJECTIVE OF CONCRETE MIX DESIGN
131
METHODS OF MIX PROPORTIONING
1) Arbitrary proportion
2) Fineness modulus method
3) Surface area method
4) High strength concrete mix design
5) Mix design based on flexural strength
6) Road note No. 4 (grading curve method)
7) ACI Committee 211 method
8) DOE Method
9) Mix design for pumpable concrete
132
VARIABLES IN MIX PROPORTIONING
133
METHODS OF MIX PROPORTIONING
1) Arbitrary proportion
2) Fineness modulus method
3) Surface area method
4) High strength concrete mix design
5) Mix design based on flexural strength
6) Road note No. 4 (grading curve method)
7) ACI Committee 211 method
8) DOE Method
9) Mix design for pumpable concrete
134
SELECTION OF TARGET PARAMETERS
Selection of target parameters by the contractor
for any mix design must consider the influence of
the following:
1) material availability and economics
2) variability of each material throughout period
of usage
3) Control capability of production plant
4) Ambient conditions expected at the time(s) of
concrete placement
135
SELECTION OF TARGET PARAMETERS
136
COMMON TERMINOLOGIES OF MIX DESIGN
137
AGGREGATES
138
DRY RODDED UNIT WEIGHT
139
BULK SPECIFIC GRAVITY
140
FINENESS MODULUS(FM)
141
FINENESS MODULUS(FM)
%
Sieve sieve opening mass retaine cummulative % Cummulative %
No. (mm) retained (g) d retained Passing
ABSORPTION
Absorption is the process by which a liquid is
drawn into and tends to fill permeable pores in a
porous solid body. It is expressed as a percentage
of the dry weight of the body. For example, the
oven dry weight of a sample of sand is 60-pounds
and its absorption is 5%. The weight of the
sample after it has absorbed all of the moisture it
can absorb is:
143
ABSORPTION
60 lb x 1.05 = 63 lbs
The amount of water absorbed by the 60-pound
sample is:
63 lb - 60 lb = 3 lbs
144
AIR ENTRAINMENT
Air entrainment is the intentional creation of tiny air
bubbles in concrete. The bubbles are introduced into
the concrete by the addition to the mix of an air
entraining agent, a surfactant (surface-active
substance, a type of chemical that includes
detergents). The air bubbles are created during
mixing of the plastic (flowable, not hardened)
concrete, and most of them survive to be part of the
hardened concrete. The primary purpose of air
entrainment is to increase the durability of the
hardened concrete, especially in climates subject to
freeze-thaw; the secondary purpose is to increase
workability of the concrete while in a plastic state.
145
AIR ENTRAINMENT
146
BULK VOLUME
147
ABSOLUTE VOLUME
148
EXAMPLE 1
149
EXAMPLE 2
150
EXAMPLE 2
CA = 90 lb / (2.65 x 62.4 lb/cu ft) = 0.544 cu ft
FA = 60 lb / (2.63 x 62.4 lb/cu ft) = 0.366 cu ft
Cement = 25 lb / (3.15 x 62.4 lb/cu ft) = 0.127 cu ft
Water = 12 lb / (1 x 62.4 lb/cu ft) = 0.192 cu ft
Total Volume = 1.229 cu ft.
For the same mix containing 4% air the total volume
would be:
Total Volume = 1.229 cu ft x 1.04 = 1.278 cu ft.
The volume of air in the mix is:
Air = 1.278 cu ft - 1.229 cu ft = 0.049 cu ft.
151
POZZOLANA (P)
152
COMMON TERMINOLOGIES OF MIX DESIGN
153
VARIANCE
154
STANDARD DEVIATION
155
COEFFICIENT OF VARIATION
156
157
Number N Strength Average strength Deviation Deviation standard deviation
N x
1 43 2.8 7.84
2 48 7.8 60.84
3 40 -0.2 0.04
4 38 -2.2 4.84
5 36 -4.2 17.64
6 39 -1.2 1.44
7 42 1.8 3.24
8 45 4.8 23.04
9 37 -3.2 10.24
10 35 -5.2 27.04
40.2 4.36
11 39 -1.2 1.44
12 41 0.8 0.64
13 49 8.8 77.44
14 46 5.8 33.64
15 36 -4.2 17.64
16 38 -2.2 4.84
17 32 -8.2 67.24
18 39 -1.2 1.44
19 41 0.8 0.64
20 40 -0.2 0.04 158
EXAMPLE
159
160
TYPICAL VALUES OF STANDARD DEVIATION FOR DIFFERENT
CONDITIONS OF PLACING AND MIXING OF CONCRETE
161
TYPICAL VALUES OF STANDARD DEVIATION FOR DIFFERENT
CONDITIONS OF PLACING AND MIXING OF CONCRETE
162
SPECIMEN PREPARATION
SAND CEMENT PROPORTION
The following is the procedure for the
determination of the void ratio of a
cemented specimen, Determine
• The specific gravity of sand G sand
• The specific gravity of cement G cement
• The dry mass of specimen M dry i.e., the
mass of solid M solid
• Specimen dimensions i.e., height H and
diameter D
AVERAGE SPECIFIC GRAVITY
100 C C
G Gsoil Gcement
100 100
INITIAL VOID RATIO
2
VTotal D
4
The volume of voids V voids
Vvoids Vtotal Vsolid
INITIAL VOID RATIO
• The initial void ratio of the specimen e
Vvoids
e
Vsolid
CONSTANT DRY DENSITY WITH
INCREASING CEMENT CONTENT
d
1
ACI MIX DESIGN
171
MIX DESIGN PROCEDURES
173
MIX DESIGN PROCEDURES
Maximum aggregate size -- The largest maximum
aggregate size that will conform to the following
limitations:
Maximum size should not be larger than 1/5
the minimum dimension of structural members,
1/3 the thickness of a slab, or 3/4 the clearance
between reinforcing rods and forms. These
restrictions limit maximum aggregate size to 1.5
inches, except in mass applications.
174
MIX DESIGN PROCEDURES
175
MIX DESIGN PROCEDURES
176
177
WATER/CEMENT RATIO
178
Calculation of cement content -- Once the water
content and the w/c ratio is determined, the
amount of cement per unit volume of the
concrete is found by dividing the estimated water
content by the w/c ratio.
179
Estimation of coarse aggregate content - The
percept of coarse aggregate to concrete for a
given maximum size and fineness modulus is
given by Table
180
Volume of dry-rodded coarse aggregate per unit
volume of concrete for different coarse
aggregates and fineness moduli of fine
aggregates.
181
Estimation of fine aggregate content -- There are
two standard methods to establish the fine
aggregate content, the mass method and the
volume method. We will use the "volume"
method.
"Volume" Method -- This method is the preferred
method, as it is a somewhat more exact
procedure. The volume of fine aggregates is
found by subtracting the volume of cement,
water, air, and coarse aggregate from the total
concrete volume.
182
ACI MIX DESIGN EXAMPLE
183
ACI MIX DESIGN EXAMPLE
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MIX DESIGN CALCULATION
http://www.pensacolatesting.com/dirtknocker/beta.htm
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http://www.civilcraftstructures.com/materials-testing/steps-of-concrete-mix-design/
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