Confidential

Best Practice

on

Concrete Technology

Principles

Version 3.6

April 9th, 1998

Direction des Performances Bétons et Granulats Best Practice on Concrete Technology

Lafarge Mix Design Process Flow Chart

1.1.Requirements
Requirements 4. Mix Proportioning
•Customer
•Customerrequests
requests TARGET STRENGTH f cr
•Specifications
•Specifications
•National
•Nationalstandards
standards MPa
•Specified
•Specifiedstrength
strengthf’f’cc
•Durability
•Durability Main MISSING PROPORTIONS
Water Cement
2.2.Raw
RawMaterials
Materials kg/m3 kg/m3
•Characterization
•Characterization
•Selection
•Selection Cementitious
Additions
kg/m3
3.3.Mix
MixDesign
Design
•Risk
•RiskFactor
FactorRR Admixtures
•Max
•Maxwater/binder
water/binderratio
ratio l/m3
•Min.
•Min.cement
cementcontent
content
•Cementitious
•Cementitiousadditions
additions Air
•Admixture selection
•Admixture selection %
•Air
•Aircontent
contentrange
range
•Max
•Max Aggregatesize
Aggregate size
•Grading
•Gradingenveloppe
enveloppe
•Alkali AGGREGATE PROPORTIONS
•Alkalilimitations
limitations
Sand 1
Sand 2
Agg 1
Agg 2
Agg 3

8.8.Optimization
Optimization

5.5.Mix
MixActualization
Actualization
7.7.Control
Control
Determine x and σ
Ensure x − R ⋅ t ⋅σ ≥ f c′
6.6.Mixing
MixingProcedure
Procedure

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List of Principles

0. Quality Control Management ................................................................................... 5

Principle 0.1 Organize Quality Control in homogeneous zones................................................ 5
Principle 0.2 Use standardized data management systems accessible to first level
technicians .......................................................................................................... 5
Principle 0.3 Consolidate data in homogeneous zones ............................................................ 5
Principle 0.4 Use central laboratory for development activities ................................................ 5

1. Requirements ............................................................................................................ 5
Principle 1.1 Group Mix Design Requirements......................................................................... 5
Principle 1.2 Deal with special requirements............................................................................ 6

2. Raw Materials............................................................................................................ 6
Principle 2.1 Ensure daily information on cement properties from the cement plant ................ 6
Principle 2.2 Characterize raw materials.................................................................................. 6
Principle 2.3 Ensure regular survey of locally available raw material resources....................... 7
Principle 2.4 Select raw materials ............................................................................................ 7
Principle 2.5 Characterize admixtures...................................................................................... 7
Principle 2.6 Select admixtures................................................................................................ 7
Principle 2.7 Select supplier of admixtures .............................................................................. 8
Principle 2.8 Request production characteristics of raw materials............................................ 8

3. Mix Design ................................................................................................................. 8

Principle 3.1 Design the Risk Factor ........................................................................................ 8
Principle 3.2 Minimize overall cost of raw materials ................................................................. 8
Principle 3.3 Choose the proper air content range ................................................................... 9
Principle 3.4 Determine the maximum aggregate size ............................................................. 9
Principle 3.5 Determine the grading envelope.......................................................................... 9
Principle 3.6 Ensure communication between customer and mix designer .............................. 9
Principle 3.7 Report the consistency class or range................................................................ 9
Principle 3.8 Use Mix Design Cost Analysis............................................................................. 9

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4. Mix Proportioning ................................................................................................... 10

Principle 4.1 A recommended process for mix proportioning ................................................. 10
Principle 4.2 Calculate Target Strength.................................................................................. 10
Principle 4.3 Determine the water content ............................................................................. 10
Principle 4.4 Determine the cement content .......................................................................... 10
Principle 4.5 Maximize the compacity of the granular fraction................................................ 11
Principle 4.6 Use the overall grading as a guide for mix proportioning ................................... 11
Principle 4.7 Use air entraining agent as plasticizer in lean mixes ......................................... 11
Principle 4.8 Determine admixture dosage ............................................................................ 11
Principle 4.9 Maintain confidentiality of mix proportions ......................................................... 11

5. Mix Actualization..................................................................................................... 12
Principle 5.1 Actualize Mix Designs ....................................................................................... 12
Principle 5.2 Actualize batch quantities.................................................................................. 12

6. Mixing Procedure.................................................................................................... 12
Principle 6.1 Optimize mixing procedure for special products ................................................ 12
Principle 6.2 Ensure proper slump adjustments by drivers/batchers ...................................... 12

7. Control ..................................................................................................................... 13
Principle 7.1 Implement statistical control processes ............................................................. 13
Principle 7.2 Update Statistical Control Processes ................................................................ 13
Principle 7.3 Calculate performance indicators monthly......................................................... 13

8. Optimization ............................................................................................................ 14
Principle 8.1 Optimize the cement efficiency and cost per unit strength................................. 14
Principle 8.2 Adjust Yield ....................................................................................................... 14

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0. Quality Control Management

Principle 0.1 Organize Quality Control in homogeneous zones

The Quality Control activities should be centralized in homogeneous zones in which the
elements of the following fields are to be standardized :
• software tools and methods for mix design
• data formats
• structure for human resources
Homogeneous zones may cover one or more Operational Units at the regional or national
scale.

Principle 0.2 Use standardized data management systems accessible to first level
technicians

First level technicians in a homogeneous zone must have access to a single computer-based
tool for QC data management allowing for the straightforward entry of data (test results).

Principle 0.3 Consolidate data in homogeneous zones

Quality Control data processed through the first level data management system must be
consolidated and rolled up to QC Managers in each homogeneous zone. This consolidation of
Quality Control data should enable benchmarking studies between the different homogeneous
zones.

Principle 0.4 Use central laboratory for development activities

Each homogeneous zone should have a central laboratory at its disposal for product
development, testing and demonstrations.

1. Requirements

Principle 1.1 Group Mix Design Requirements

All requirements should be obtained and written down on a standardized Mix Design
Requirements Check-List.
This check-list should propose 2 different sets of questions :
• a short set of questions for orders of « ready-to-deliver » mixes : this list is
intended to the batcher in order to determine which mix to deliver, chosen in the
plant’s mix design file,
• a complete set of questions for orders of « tailor-made » mixes requiring a new
mix design : this list is intended to the laboratory who designs the new mix.

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The following minimum information must be obtained :

1. Customer requests, such as intended use, specified strength, slump, aggregate
size, type of cement, etc.
2. Project specifications that interact with mix design,
3. Applicable constraints from local or national standards,
4. Durability requirements, if not already covered by standards.
The form for the Mix Design Requirements Check-List should be standardized to a national
level. Special sections in the form could be added to adapt to local specifications.

Principle 1.2 Deal with special requirements

Special requirements are properties or features of the mix that are not usual for a given
concrete plant.
When the customer asks for special requirements, test programs and technical meetings are
recommended.
A mix design provided by a customer should be in writing and should be signed by the
customer, especially if no previous history is available for this mix design, or if the mix design
does not conform to the standards relative to the specified concrete class.
If significant amounts of fly ash or slag are used, ask that 56-day and 90-day strengths be
considered (instead of 28 days).

2. Raw Materials

Principle 2.1 Ensure daily information on cement properties from the cement plant

Timely sharing of information on cement properties is necessary between cement plants and
concrete operations.
Concrete Technology Managers and cement suppliers should agree on limits for acceptable
variations in cement characteristics (these limits may not necessarily be those imposed by the
standards for the given characteristics). Cement plants must communicate changes instantly
whenever changes in cement exceed these limits.

Principle 2.2 Characterize raw materials

The characterization of raw materials aims at :

• verifying the conformity of these materials to applicable standards and Quality
Assurance plans,
• detecting any change in the properties of raw materials that may affect
performance of concrete in plastic and/or hardened state.
A Raw Material Characterization Table should :
• be written in the plant’s Quality-Assurance Plan,
• include at least the following elements :
1. the raw material identification (type and source),
2. the significant properties to characterize,
3. the testing methods to use,
4. the frequency of testing,

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5. the way to report the results (forms, graphs, table, calculations, etc.),
6. the parameter(s) to use to detect any change in the concrete properties,
7. guide values for the above mentioned parameters.

Principle 2.3 Ensure regular survey of locally available raw material resources

The survey of the local raw material resources available in the plant area should be regularly
updated.
Continuously test new products and/or combination of admixtures to anticipate and react to
changes in properties of actual raw materials.
The decision to switch to other raw material suppliers or other materials from the same supplier
should be correctly evaluated in terms of overall costs.
The Concrete Technology Manager should provide the purchasers of raw materials with proper
technical data and advice.

Principle 2.4 Select raw materials

The selection of raw materials depends on the following locally balanced criteria :
1. price,
2. performance,
3. availability & stability,
4. strategy against competitors,
5. influence on the mix design and total cost.

Principle 2.5 Characterize admixtures

Depending on the intended use for the concrete mix design, the main parameters to consider
for the characterization of admixtures are :
1. water reduction capacity,
2. slump retention over time,
3. retardation / acceleration,
4. compatibility with cement and other admixtures,
5. air entrainment,
6. segregation / bleeding.
Characterization tests must be performed in the laboratory and confirmed at the plant.

Principle 2.6 Select admixtures

For plain concrete mixes, select admixtures that result in the lowest cost for acceptable
performance of the mix.
For special products, admixtures should be selected in terms of price vs. performance
indicators. Price of admixtures should always relate to the solid content. Possible indicators
are :
• price / volume of concrete
• MPa / kg of binder
• $ / MPa of resulting mix
• MPa/kg of admixture
• MPa/$ of admixture

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• Slump/kg of admixture
• Slump/$ of admixture
Laboratory trial tests should always be confirmed by field tests at the plant.

Principle 2.7 Select supplier of admixtures

For the concrete producer, it is essential that his supplier delivers products that are constant in
composition and readily available.
Select suppliers in terms of :
1. quality and consistency of the products,
2. quantity and capacity,
3. reliability of delivery,
4. services (assistance).

Principle 2.8 Request production characteristics of raw materials

Characterization, control and adjustments in the raw material properties are more efficient and
economical when performed at the production site prior to delivery to the concrete plant.
Raw material suppliers should be committed to Quality and conform to a Quality Assurance
plan.
Material suppliers shall conduct tests on their materials and forward results to Lafarge as stated
in the purchase order.

3. Mix Design

Principle 3.1 Design the Risk Factor

The Risk Factor is the additional margin added by the mix formulator to that of the local
standards in order to modulate the risk of non-conformance.

fcr = f’c + R*t*σ

where : fcr : Target Strength (specify age)
f’c : Specified Strength
R : Lafarge Risk Factor ≥ 1.0
t : Statistical factor from Standards
σ : Standard Deviation
A Risk Factor R > 1.0 may be appropriate where the consequence of failure warrants a more
conservative value of the Target Strength.

Principle 3.2 Minimize overall cost of raw materials

In an attempt to reduce the costs of a mix, it has proved efficient to consider the following steps
when designing a mix :
1. target the maximum efficient water / equivalent binder ratio as well as the
minimum cement content, consistent with requirements,

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2. use cheaper supplementary cementing materials to the maximum possible

extent,
3. use admixtures along with supplementary cementing materials to increase the
cement efficiency (MPa / kg of cement),
4. use aggregate gradations with the highest possible content of the cheapest
aggregates,
5. use the appropriate air content.

Principle 3.3 Choose the proper air content range

The mix formulator should choose an air content range that conforms to local standards,
especially those regarding durability aspects (freeze-thaw resistance, etc.)

Principle 3.4 Determine the maximum aggregate size

The mix formulator should choose a maximum aggregate size that conforms to customer
requirements and/or to local standards, especially regarding project specifications (workability
and placeability).
In order to reduce water demand, use the largest possible maximum aggregate size subject to
local availability, costs, and trends.

Principle 3.5 Determine the grading envelope

If mandatory, specify the combined grading or coarse grading envelope according to local
standards.
Ensure that in-house grading envelopes are kept confidential.

Principle 3.6 Ensure communication between customer and mix designer

Communication is essential and is the best way to avoid litigation between customer and mix
designer.
Our customer should:
1. be well informed on the standards : specifications, tolerances, and allowances,
2. be informed of the mix design – but not of the mix proportions! –,
3. if appropriate, receive quality reports that:
• are standardized,
• are properly tabulated for clear presentation,
• highlight significant quality features.

Principle 3.7 Report the consistency class or range

Clearly report the specified slump range and tolerances. Note if specified values are limit
values or average values.

Principle 3. 8 Use Mix Design Cost Analysis

To help design mixes with the lowest overall cost, use a mix design software that automatically
indicates the cost of the resulting mix as the mix proportions are changed.

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4. Mix Proportioning

Principle 4.1 A recommended process for mix proportioning

Mix Proportioning has proved effective when based on the following 3-step process:
1. determination of the Target Strength ;
2. determination of the proportions of water, cement, admixtures, supplement
cementing materials, and air content ;
3. determination of the individual aggregate proportions by targeting a pre-
determined overall grading curve or envelope (including aggregates, cement,
and additions) depending on the job specifications.

Principle 4.2 Calculate Target Strength

Determine and record the Target Strength fcr = f’c + R*t*σ based on :
1. the Risk Factor R adopted in Section 3 - Mix Design,
2. the statistical factor t specified by the standards,
3. the current value of the standard deviation σ for the appropriate mix design and
plant.
Our Target Strength should not be divulged to our customer.

Principle 4.3 Determine the water content

The water content should be determined based on locally updated experimental data.
The statistical control process of information is the best way to produce locally updated data
relating the necessary amount of water to obtain a given slump, with or without plasticizer, at a
given temperature and with given aggregate characteristics (gradation, shape, roundness,
fineness, specific surface, etc.)
For special mixes with no local previous experience, the water content can be reasonably
estimated on the basis of theoretical curves relating the necessary amount of water to obtain a
given slump.

Principle 4.4 Determine the cement content

The cement content should be determined based on locally updated experimental data.
The statistical control process of information is the best way to produce locally updated data
relating cement content to concrete compressive strength for different cement classes, air
contents and admixtures.
For special mixes with no local previous experience, the cement content can be reasonably
estimated on the basis of theoretical curves relating cement content to concrete compressive
strength for different cement classes. Other methods, such as the Feret and Bolomey
equations, may also be used to estimate the cement content.
Concrete Strength to water/cement ratio or water/binder ratio curves for different cement types
should be plotted for each plant or group of plants using the same raw materials.

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Principle 4.5 Maximize the compacity of the granular fraction

It has been established that a higher compacity of the granular fraction of concrete (all grains
from silica fume to coarse aggregates, including cement) leads to a higher compressive
strength and, at the same time, to a better workability.
To optimize the compacity of concrete mixtures, the formulator should use a software tool using
a method such as :
1. the Faury method,
2. RENE-LCPC,
3. the ACI method.

Principle 4.6 Use the overall grading as a guide for mix proportioning

The overall grading (all grains from silica fume to coarse aggregates, including cement) is one
of the key features of a concrete mixture. When a given concrete mixture is to be reproduced
in a different location, experience has proven that the same overall grading curve should be
targeted at the new location.
When a concrete mixture is performing well, the overall grading should be accurately
determined and filed for future use as a reference overall grading curve.
LBG’s SIMPLEX software is an efficient tool to compare the overall grading of a blend of
various raw materials to reference curves. These reference curves could be theoretical (such
as the Faury curve) or come from a library of reference overall grading curves.

Principle 4.7 Use air entraining agent as plasticizer in lean mixes

In lean mixes, experience has shown that the entrainment of a moderate air volume (3% - 4%)
is an efficient way to reduce water, and thus save cement. In most cases, this is cheaper than
using a conventional water reducer.
Thus, the use of air entraining should be examined as an opportunity to reduce water in lean
mixes.

Principle 4.8 Determine admixture dosage

Admixture dosage should be determined according to the supplier’s technical data on the
product, including efficiency range and maximum dosage.
Always perform trial tests in the laboratory and on site.

Principle 4.9 Maintain confidentiality of mix proportions

Our mix proportions and Target Strength should not be divulged to the customer.
If communication of mix proportions is imposed by the standards, a confidentiality agreement
should be signed by the customer.

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5. Mix Actualization

Principle 5.1 Actualize Mix Designs

Actualization of Mix Designs should aim at :

1. managing and reducing the number of mix design codes,
2. transferring and actualizing mix designs directly from the laboratory to the plant,
3. enabling distant control over mix designs at the plant by the formulator.

Principle 5.2 Actualize batch quantities

Mix Actualization consists in adjusting batch quantities at time of batching, within :

a) tolerances allowed by the local standards,
b) average or range values set in Mix Design,
in order to compensate for changes in material characteristics or in environmental conditions
(mainly temperature).
The most common changes in material characteristics are :
1. moisture content of aggregates,
2. admixture sensitivity vs. temperature or additional water,
3. variations in weather conditions : dosage of supplementary cementing materials
vs. temperature.

6. Mixing Procedure

Principle 6.1 Optimize mixing procedure for special products

For special products, determine the best sequence and speed of addition and mixing of the
ingredients to optimize the efficiency of admixtures.
Trial batches should be performed prior to the project to determine the sequence and timing for
the addition of admixtures (air entraining, water reducers, retarders, and platicizers) into the
mix.
Once the sequence is chosen for the mix design, it should not be changed as this may change
setting times, strength development, etc.

Principle 6.2 Ensure proper slump adjustments by drivers / batchers

Communication between batchers and drivers is essential.

Batchers / drivers / inspectors need training for slump adjustment prior to delivery of the
concrete on site.
When water adjustments are requested by the ready-mix plant, they should only be performed
by trained personnel.

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7. Control

Principle 7.1 Implement statistical control processes

Reduction in variation through standardization is a fundamental prerequisite for quality

improvement.
In order to reduce variation, Operational Units should adopt the following policy :
A) Concrete plants producing volumes less than 10 000 m3 must implement and employ
appropriate Quality Assurance plans and control procedures adapted to the local
market (suppliers and customers).
B) Concrete plants producing volumes more than 10 000 m3 must employ statistical
control processes that are :
1. documented, controlled, and conform to Quality Assurance manuals and
training programs,
2. on the leading edge of equipment and computer technology,
3. structured for administration, development, edition, modification, or read-
only consultations;
and that can regularly do the following :
1. input and analyze databases,
2. characterize and determine performance indicators for raw materials, fresh
and hardened concrete properties,
3. output results that are predictable and reproducible in appropriate formats
that highlight significant results,
4. predict results,
5. output locally updated designs that conform to standards and customer
requirements,
6. determine whether each process is in control,
7. assist Lafarge personnel in the global Mix Design Process (Raw Materials,
Design, Proportioning, Procedure, Actualization, and Optimization).

Principle 7.2 Update Statistical Control Processes

In order to take advantage of the variations in data, the statistical control system should be
regularly fed with test results. The daily interpretation of data is mandatory.

Principle 7.3 Calculate performance indicators monthly

The following performance indicators of the produced mixes shall be calculated, updated,
reported, and compared on a monthly basis :
1. cementitious efficiency (MPa/kg of binder),
2. coefficients of variation in relevant statistics,
3. actual strength vs. target strength,
4. costs of Quality Control activities,
5. costs of non-conformance.

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8. Optimization

Principle 8.1 Optimize the cement efficiency and cost per unit strength

Mix formulators must use a Mix Optimization tool in order to :

1. maximize the cement efficiency (MPa / kg of cement) of our concrete mixes,
2. minimize our costs per unit strength ($/MPa).
This can be done by optimizing the nature, characteristics, and content of local materials :
1. aggregates,
2. cements and supplementary cementing materials,
3. admixtures.
Mix Optimization tools should rely on recently updated data of the following types :
1. raw material costs,
2. test results processed through statistical control,
3. risk factor associated with job delivered.
Mix Optimization should be carried out regularly to gain from changes in any of these 3 data
types.

Principle 8.2 Adjust Yield

Design yield of fresh concrete (ratio of actual to designed volume) to ensure conformity to the
local standards.
To ensure conformity to standards, all yields should be checked prior to delivery against actual
specific gravities and unit weights.

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