Chapter three

Concrete Technology

1
 1.1 Definition of Concrete
Concrete is a composite material made
up of inert materials of varying sizes, which
are bound together by a binding medium.

The strength of concrete is dependent on
the strength of the aggregates & paste
bond.
 Concrete is often looked upon as “man
made rock”.

2
 constituents of Concrete

Portland Cement
Paste
Water
Air (entrapped or entrained)
Concrete
Fine Aggregate (Sand)
Aggregate
Coarse Aggregate (Gravel)

Admixture (If required)

3
 Portlandcement 7% to 15% by Vol.
 Water 14% to 21% by Vol.
 Aggregates 60% to 75%
 coarse aggregates
 Fine aggregates

 Up to 8% air (depending on top size

of coarse aggregate)

4
1.2 Types and Uses of Concrete
Concrete is a very versatile material and can be made to
satisfy a large variety of requirements.

1. Plain (mass) concrete

2. No-fines concrete
3. Lightweight aggregate concrete
4. Aerated concrete
5.Steel reinforced concrete
6.High strength concrete
7.Pre-fabrecated concrete
8.Pre-stressed concrete
9.Fiber reinforced concrete

5
No-fines concrete

 with only single size coarse aggregate (dense

or lightweight) leaving voids between them.
 provides
-an excellent key for rendering,
-good thermal insulation (due to air gaps), and
-low drying shrinkage

6
Lightweight aggregate concrete
 using expanded clay, foamed blast furnace
slag, sintered fly ash, pumice, or other
light aggregate, for thermal insulating
walls and components, and for lightweight
building blocks.

7
Aerated concrete
 made by introducing air or gas into a
cement-sand mix (without coarse
aggregate)
 for thermal insulating, non-structural uses
and lightweight building blocks.
 are low resistance to abrasion, excessive
shrinkage and permeability.

8
Pre-stressed concrete

 Pre-stressing of concrete is made for

overcoming the concretes’ natural weakness
in tensioning.

It can be used to produce beams, floors,
or bridges with a longer span than is
practical with ordinary reinforced concrete.

9
10
 Fiber reinforced concrete

 Concrete containing a hydraulic cement,

water, fine or fine and coarse
aggregate, and discontinuous discrete
fibers is
called fiber-reinforced concrete (FRC).
It may also contain pozzolans and other

admixtures commonly used in

conventional concrete.
11
Fibers of various shapes and sizes
produced from steel, plastic, glass, and
natural materials are being used;
however, for most structural and

nonstructural purposes, steel fiber is the

most commonly used of all the fibers
 Compared to plain concrete, fiber-
reinforced concrete is much tougher
and more resistant to impact.

12
High strength concrete

 High-strength concrete has a compressive

strength generally greater than 40 Mpa.

High-strength concrete is made by
lowering the water-cement (W/C) ratio to
0.35 or lower.

13
 Uses of Concrete

 Concrete is versatile material & can be

used for :
 foundations of structures
 The walls of ordinary houses, as well as the
more massive walls of engineering structures
eg Dam.
 For arches, stairs, flooring of different kinds and
roofs.
 Drainage pipes etc

14
Advantages of Concrete

Good-quality concrete has many advantages:

 Its long life and relatively low maintenance
requirements increase its economic benefits.
 It is not as likely to rot, corrode, or decay as
other building materials.

15
 It has the ability to be molded or cast into
almost any desired shape.

 It is a non-combustible material which

makes it fire-safe and able withstand high
temperatures.

16
 It is resistant to wind, water, rodents, and
insects. Hence, concrete is often used
for storm shelters.

 It has high compressive strength, resistance

to weathering, impact and abrasion.

17
 Disadvantages of Concrete

Some of disadvantages of concrete are:

 High cost of cement, steel and formwork ( in

developing countries).

 Difficult quality control on building sites, with the

risk of cracking and gradual deterioration, if
wrongly mixed, placed and insufficiently cured with
water.

18
 In moist climates or coastal regions, corrosion of
reinforcement (if insufficiently protected),
leading to expansion cracks.

 Low tensile strength (but can be overcome

with steel reinforcement).

 Demolishing concrete is difficult.

19
Ingredients of Concrete

 Portland Cement
 Water
 Aggregates
 Admixtures (Additives)

20
 Portland Cement

 Dry power of very fine particles

 Forms a paste when mixed with water
 Chemical reaction –Hydration
 Paste coats all the aggregates together
 Hardens and forms solid mass

Various types of Portland cement as well as

physical & chemical requirements were discussed
in the previous course.

21
 Water Water that is safe to drink is safe to use
in concrete.

 is needed for
two purposes:
 chemical reaction with
cement
 Workability
 only 1/3 of the water
is needed for
chemical reaction
 extra water remains in
pores and holes

22
Water:
 Is Good for preventing plastic shrinkage
cracking and workability
 Is Bad for permeability, strength,
durability.
 any impurities present will affect bond
strength between the paste and aggregate.

23
Undesirable effects of impurities in mixing water:
Impurities in mixing water may cause any one or
all of the following:
 Abnormal setting time
 Decreased strength
 Volume changes
 Efflorescence
 Corrosion of reinforcement

24
Some of the impurities in mixing water that
cause undesirable effects in the final
concrete:
1.ALKALI CARBONATE AND BICARBONATE
 Carbonates and bicarbonates of sodium and
potassium have different effects on the setting
times of different cements.
 Sodium carbonate can cause very rapid
setting.
 In large concentrations, these salts can materially
reduce concrete strength.
 Can attack the cement-aggregate bond, leading to
early disintegration of the concrete.
25
2. CHLORIDE
 Concern over a high chloride content in
mixing water is chiefly due to the possible
adverse effect of chloride ions on the
corrosion of reinforcing steel.
 Chloride ions attack the protective oxide
film formed on the steel by the highly
alkaline (pH greater than12.5) chemical
environment present in concrete.

26
3.SULFATE
 Concern over a high sulfate content in mix
water due to possible
reactions expansive
is deterioration by
and sulfate
attack, especially in areas where the
concrete will be exposed to high sulfate
soils or water.

27
4. Seawater

 Seawater containing less than three percent

salt is generally acceptable for plain
concrete but not for reinforced concrete.
 The presence of salt can lead to corrosion of
the reinforcing bars and a decrease in
concrete strength by some 10-15%.

28
5. Algae
 Can cause a reduction in the strength of
concrete by increasing the amount of air
captured in the paste and
 Reduce the bond strength between the
paste and the aggregate.
6. Sugar
If sugar is present in even small amounts, it
can cause rapid setting and reduced
concrete strength.
29
Aggregates

Aggregates are the

filler materials which
make up a large
portion (roughly 65-
80%) of the concrete
volume. Considerable
care should be taken
to provide the best
aggregates available.

30
Classification of aggregates based on
source
Natural aggregates are taken from natural
deposits without change in their nature during
production, with the exception of crushing,
sizing, grading, or during production. In this
group crushed stone, gravel, and sand are the
most common.
Manufactured aggregates include blast
furnace slag and lightweight aggregates.

31
 Aggregate Terms and Types
The terms used to describe aggregates are
many and varied. These descriptive terms are
based on source, size, shape, type, use and
other properties.
Some typical terms used in describing
aggregates are:
1.Fine aggregate- aggregate particles passing
the No. 4 (4.75mm) sieve and retained on the
No. 200 (0.075mm) sieve.

32
2. Coarse aggregate- aggregate
predominantly retained on the No.4 (4.75mm)
sieve.

3.Crushed gravel (gravel and sand)- that

has been put through a crusher either to
break many of the rounded gravel particles to
a smaller size or to produce rough surfaces.

33
4. Crushed rock- aggregate from the
crushing of rock. All particles are angular,
not rounded as in gravel.

5. Screenings- the chips and dust or powder

that are produced in the crushing of rock for
aggregates.

34
6. All-in-aggregate- aggregate composed
of both fine and coarse aggregate.

7. Concrete sand- sand that has been

washed (usually) to remove dust & fines.

8. Fines- silty-clay or dust particles smaller

than 75 micro m (No. 200 sieve) usually
undesirable impurities in aggregates.

35
Properties of Aggregates
Important properties of aggregates include:
 Gradation (grain size distribution)

 Shape and surface texture

 Bulk unit weight

 Specific gravity (relative density)

 Absorption

 Hardness (resistance to abrasion or wear)

 Durability (resistance to weathering)

 Crushing strength

 Cleanliness (deleterious substances)

 Chemical stability

36
Gradation of Aggregates

37
Grading: is the distribution of particles of
angular materials among various sizes

38
The gradation of aggregates influences:
 the amount of paste required
 the workability of the concrete

 the strength and

 water tightness of the finished product

In general, it is desirable that the size increase

uniformly from fine sand to the maximum
allowed for a given job.
Most specifications for concrete require a grain
size distribution that will provide a dense and
strong mixture.

39
Gradation Classifications
 Well-graded:
maximum density, high stability, low permeability
 One-sized (uniformly graded):

particles same diameter, low stability, permeable

 Gap-graded:

Missing one or more sizes, stable, average permeability

 Open-graded:

Mostly large sizes, unstable, high permeability

40
Gradation Classifications ctd.

 Dense
Well-graded
 Well graded
 Gap-graded
 Uniform Poorly graded
 Open-graded

41
 Grading of aggregates
Well graded Uniform graded Gap
graded

The range of size Most particles Most particles

are approximately in are of the are of large
equal amounts
same size or small size

42
 Well graded aggregates:

 Improve workability of the concrete and

economy of the cement.
(Such aggregate has a decreased amount
of voids between the particles and
consequently requires less cement paste).
 Produces a stronger concrete than a poorly
graded one (less water is required to give
suitable workability)

43
Proper selection of various sizes will be very effective in
reducing the total volume of voids between aggregates

The cement paste requirement is related to the void

content of the combined aggregates.

44
SIEVE ANALYSIS
The grading or particle size distribution of
aggregate is determined by sieve analysis.

45
Sampling

46
Quartering Riffling

47
Standard size and square openings
Sieve Designation
Traditional Metric
 3” 75mm
 2” 50mm
 1 ½” 37.5mm
 1” 25mm
 ¾” 19mm 7 standard sieves
 ½” 12.5mm ranging from 150 μm
to 9.5 mm (No. 100
 3/8” 9.5mm
 No 4 4.75mm to 3/8 in) for fine
 No 8 2.36mm aggregates
 No 16 1.18mm
 No 30 600
 No 50 micro m
 No 100 300
 No 200 micro m
150
micro m
75
48
micro m
 Well-graded
(Coarse agg.)
One-sized

Well-graded Gap-graded
(Fine agg.)

Size (Log Scale)

49
 Different standards and specifications specify
grading limits for both fine and coarse aggregates.

There are several reasons for specifying grading

limits and maximum aggregate size, they
affect:
 Cement and water requirement
 Workability
 Economy
 Pumpability
 Relative aggregate proportions
 Shrinkage and durability of concrete
50
The following table shows the limits of ASTM C 33
with respect to fine aggregates, these limits are
generally satisfactory for most concretes:
Sieve size Percentage passing by mass

9.5 mm (3/4 in) 100

4.75 mm (No. 4) 95 to 100
2.36 mm (No. 8) 80 to 100
1.18 mm (No. 16) 50 to 85
600 μm (No. 30) 25 to 60
300 μm (No. 50) 5 to 30
150 μm (No. 100) 0 to 10

51
Other requirements by ASTM C 33
 The fineness modulus (FM) must not be
less than 2.3 nor more than 3.1

 The fine aggregate must not have more

than 45% retained between two
consecutive standard sieves.

52
 Fineness Modulus (ASTM C 125)
 The fineness modulus (FM) for both fine & coarse
aggregates is obtained by adding the cum’ve %
by mass retained on each of a specified series of
sieves and dividing the sum by 100.
 The FM is an index of the fineness of the aggre.
The higher the FM, the coarser the aggregate.
 FM of fine aggregate is useful in estimating
proportions of fine and coarse aggregate in
concrete mixtures. (Note: Intermediate Sieves of
2”, 1” and 1/2” are not included in the analysis)

53
Coarse Aggregate Grading
 ASTM C 33 permits a wide range in
grading and variety of grading sizes

 Usually more water and cement is

required for small-size aggregate than
for large sizes, due to an increase in
total aggregate surface area.

54
 Maximum size of aggregate: the smallest
sieve that all of a particular aggregate
must pass through.

 Nominal maximum size of an aggregate:

the smallest sieve size through which
the major portion of the aggregate must
pass (90%-100%).

55
 The maximum size of aggregate that must be
used generally depends on the following:
 Size and shape of the concrete member
 The amount and distribution of reinforcing steel

 In general the maximum size of aggregate

particles should not exceed:
 1/5 of the narrowest dimension of a concrete
member
 3/4 the clear spacing between reinforcing bars
and
between the reinforcing bars and forms
 1/3 the depth of slabs

56
Special Use Gap-Graded aggregates
 When certain particle sizes are
intentionally omitted. Ex., for an
aggregate of 19 mm maximum size, the
4.75 mm to 9.5 mm particles can be
omitted without making the concrete
harsh subject to segregation. Gap-
graded mixes are used in architectural
concrete to obtain uniform textures in
exposed –aggregate finishes.
57
Shape and Surface Texture of
Aggregates

58
Aggregate Shapes

Rounded and angular Rounded

59
Aggregate Shapes

Elongated Angular

60
Aggregate Shapes

Flaky Flaky and Elongated

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62
 The particle shape and the surface texture of
aggregates influence the properties of fresh
concrete more than those of hardened concrete.
 Rough-textured, angular, and elongated
particles require more water to produce
workable than smooth, rounded
concrete aggregate. Consequently, the cement
compact
content must also be increased to maintain the
water-cement ratio.

 Flat, slivery pieces make concrete more difficult

to finish
63
 The increase in bond is important for selecting
aggregates for concrete where strength at
early age is important.

 Aggregate should be free of flat or elongated

particles. Because they require an increase
in mixing water and thus may affect the
strength of concrete particularly in flexure.

 Generally, flat and elongated particles are

avoided or are limited to about 15 percent by
weight of the total aggregate.

64
Bulk Unit Weight/Bulk Density
The bulk unit weight of an aggregate is the
weight of the aggregate divided by the
total volume occupied by it.
 The normal range of bulk unit weight for
aggregates for normal-weight concrete is
from 1200 to 1760 kg/m3.
 The range of aggregates that could be used
in concrete are:
Heavyweight, Lightweight, Normal Weight

65
The weight of the aggregate required to fill a container of a
specified unit volume.
• Volume is occupied by both the aggregates and
the voids between the aggregate particles.

• Depends on sizedistribution
and shape of
particles and how densely the aggregate is packed
• Loose bulk density
• Rodded or compact bulk density

66
 Examples of Uses for the
Weight
Aggregates Used Concrete
can be sawed or nailed,
ultra-lightweight vermiculite, ceramic also used for its insulating
properties

used primarily for making

expanded clay, shale or lightweight concrete for
lightweight slate, crushed brick structures, also used for its
insulating properties

crushed limestone, sand,

river gravel, used for normal concrete
normal weight projects
crushed recycled concrete

used for making high

steel or iron shot; steel density concrete for
heavyweight or iron pellets shielding against nuclear
radiation

67
 Specific Gravity (Relativedensity)
 The specific gravity of an aggregate is
another characteristic of the material which
needs to be determined.
 Specific gravity is not a measure of
aggregate quality but is used in making
calculations related to mix design.
 The specific gravity of most normal weight
aggregates will range from 2.4 to 2.9

68
Specific Gravity ctd
 Absolute: the ratio of the weight of the solid to the
weight of an equal volume of water (both at a stated
temperature)
• refers to volume of the material excluding all pores
Apparent: ratio of the weight of the aggregate (dried in
an oven 100- 110ºC for 24 hours) to the weight of
water occupying a volume equal to that of the solid
including the impermeable pores
. volume of solid includes impermeable pores (but not
capillary pores)

69
 Specific Gravity
Aggregate Type Specific Gravity
Granite Normal weight 2.65
Gravel Normal weight 2.70
Sand Normal weight 2.60
(For normal use)
Pumice Lightweight 0.75
Barite (barium sulphate) Heavyweight
(for
4.50special case e.g. heavy
concrete, nuclear-
radiation- shielding
concrete)
70
 Water Absorption
Aggregate have the ability to absorb water
based on its porosity.

Thus, it may have internal moisture and

external surface moisture.

Absorption of aggregate is important in

concrete and asphalt concrete.

71
Over a 24-hr period light weight aggregates
may absorb water in the amount of 5 to 20%
of their own dry weight, depending on the
type of aggregate and its pore structure .

A tendency of this sort must be taken into

account when concrete is made with
lightweight aggregate.

72
 Moisture Content
Two types of moisture are recognized in aggregates:
 Absorbed moisture
 Surface moisture
Absorbed moisture is that which is taken in by the voids
in aggregate particles and may not be apparent on the
surface.
Surface moisture is that which clings to the surface of
the
particle.
Total moisture content
 The total amount of water present on the external and
internal surfaces of aggregates.
= Surface moisture + absorbed moisture

73
The moisture conditions of aggregates
are designated as follows:
 Oven-Dry (OD): In this condition they are fully
absorbent.
 Air-Dry (AD): Particles are dry at the surface but
contain some interior moisture. They are therefore
somewhat absorbent.
 Saturated Surface Dry (SSD): In this condition there is
no water on the surface, but the particle contains all
the interior moisture it will hold. It will neither absorb
moisture from nor contribute moisture to the mix.

 Damp or Wet: The particles contain an excess of

moisture on the surface and will contribute moisture to a
mix.

74
75
Absorption Capacity: maximum amount of water aggregate
can absorb
• Absorption Capacity (%) = [(WSSD – WOD)/WOD] X
100

Surface Moisture: water on surface of aggregate particles

• Surface Moisture (%) = [(WWET – WSSD)/WSSD] X 100

Moisture Content: of an aggregate in any state

•Moisture Content (%) = [(WAGG – WOD)/WOD] X 100

76
The ideal moisture ????????????
The moisture present in the aggregate
affects the total water needed for the mix.
The ideal moisture is "saturated surface
dry" where in all pores of the material are
filled with water but no free moisture exists
on the surface.

90
 Bulking
 Surface moisture in fine aggregate is the cause of
a phenomenon known as bulking of sand.

 Surface moisture holds the particles apart,

causing an increase in volume over the same
amount of sand in a surface dry condition.

 The amount of bulking will depend on the fineness

of the sand.

91
Strength and Durability of Aggregates
 One measure of the strength of an
aggregate is its resistance to freeze-thaw
and ability to withstand compressive
stresses.

 Soluble, weak, or friable material must be

avoided.

92
Cleanliness (Deleterious Substances)
The cleanliness of the aggregate affects the bond
between the paste and the aggregate surface.
Deleterious (harmful substances) have the following
effects on concrete:
 Weaken bondage between cement paste and
aggregates
 Interfere with hydration
 Reduce of strength and durability
 Affect water tightness of the concrete
 Modify setting action and
 Cause efflorescence
8
Hardness of Aggregates
The hardness of aggregates is expressed
in terms of their resistance to abrasion.
This characteristic is important if the
aggregate is used in concrete intended for
such purposes as heavy-duty floors.
A common method of making this test is
the Loss Angeles abrasion test.

8
Chemical Stability
 Aggregates need to be chemically stable so
that they will neither react chemically with
cement nor be affected chemically by outside
influences.
 In some cases aggregates with certain
chemical constituents react with alkalis in
cement. This reaction may cause abnormal
expansion and resultant cracking of concrete.

8
Alkali-aggregate reaction
• Certain forms of silica and siliceous
material in aggregate (e.g. chert) interact
with alkalis released during the hydration of
Portland cement.
• This produces a gel like material which
increases in volume in the presence of
water causing expansion and cracking of
concrete.

8
Effects of Alkali-silica reaction (ASR)

Crack Popouts
8
HANDLING AND STOCKPILING OF AGGREGATES

The purpose of appropriate handling and stock piling of

aggregates is to avoid breakage, segregation, contamination,
and degradation.

Precautions:
 Storing on hard and dry ground or on platforms of planks,
sheets, lean concrete
 Storing separately each aggregate size in compartments
 Avoiding segregation of aggregates resulting from free fall
 Proper collection and mixing of test batches is important to
ensure that test samples accurately represent the aggregate
in the entire stockpile.

8
Concrete Admixture

8
1. Definition
Admixtures are materials which are
added to concrete at the
stage mixing some of the
properties
to ofmodify
the mix.

8
2. Uses of admixtures
 To increase workability without changing
water content.
 To reduce water content without changing
workability.
 To adjust setting time.
 To reduce segregation and/or bleeding.
 To improve Pumpability.
 To accelerate the rate of strength
development at early ages.
8
 3. Types of admixtures
Admixtures are broadly classed as Chemical
admixtures and Mineral admixtures
There are five distinct classes of chemical
admixtures:
1. Plasticizers (water-reducing agents)
2. Superplasticizers
3. Air entrainers
4. Accelerators
5. Retarders
8
Mineral Admixtures:
- Used in concrete to replace part of cement
- Added in large quantities compared to
chemical admixtures.
Some of the mineral admixtures are:
i. Natural Pozzolans: Raw and calcined
natural materials such as shale, and
pumice
- Siliceous or siliceous and aluminous materials which by
themselves possess no cementing property, but in fine
pulverized form and in the presence of water can react
with lime in cement to form concrete

9
ii. Fly ash: By-product of coal from electrical power
plants
- - Finer than cement
- - Consists of complex compounds of silica, ferric
oxide and alumina
- - Increases the strength of concrete and
decreases the heat of hydration
- - Reduces alkali aggregate reaction.

-iii. Silica fume: By-product of electric arc

furnaces
- Size less than 0.1μm
- - Consists of non-crystalline silica

- - Increases the compressive strength 9

3.1
Plasticizers
 When added to a concrete mix, plasticizers
(water-reducing agents) are absorbed on the
surface of the binder particles, causing them to
repel each other and deflocculate.
 This results in improved workability and provides a
more even distribution of the binder particles
through the mix.
 Plasticizers Reduce the water requirement of a
concrete mix for a given workability by about 10%.

9
 Concrete containing a plasticizer (water-reducing
admixture) needs less water to reach a required
slump than untreated concrete.
 The treated concrete can have a lower water-
cement ratio. This usually indicates that a higher
strength concrete can be produced without
increasing the amount of cement.
 For concretes of equal cement content, air
content, and slump, the 28-day strength of a
water-reduced concrete containing a water
reducer can be 10% to 25% greater than concrete
without the admixture.

9
 Uses of
plasticizers
Increase the slump of concrete with a given
water content.
 Reduce the water requirement of a concrete
mix for a given workability by about 10%.
 The addition of a plasticizer makes it possible
to achieve a given strength with a lower
cement content.
 Improve pumpability.

9
 Problems associated with plasticizers
 Some plasticizers contain chlorides which
may increase danger ofcorrosion of
the
reinforcing steel.
 Where plasticizers are to increase
used
workability, the shrinkage and creep will
invariably be increased.

9
3.2 Superplasticizers


They can greatly reduce water demand
and cement contents and as a result;
 make low water-cement ratio,
 high-strength concrete with
 normal or enhanced workability.
 Also known as or high-range water reducers
(HRWR), reduce water content by 12 to 30
percent

9
 can be added to concrete with a low-to-
normal slump and water-cement ratio
to make high-slump flowing concrete.
 As a result of the slump loss, super
plasticizers are usually added to concrete
at the job site.

9
Uses of super
plasticizers
 In areas of congested (crowded number)
reinforcement.
 Where workable concrete that can be
placed with little or no vibration or
compaction.
 For high-strength concretes.

9
Flowable concrete with a high slump is easily placed,
even in areas of heavy reinforcing steel congestion.

9
 Problems associated with super
plasticizers
 The effect of a super plasticizer may
disappear as soon as 30-60
minutes after mixing.
 They have a relatively high unit
cost.
 Where super plasticizers are used to
produce very high workability, the
shrinkage and creep will be increased.
1
 3.3 Air entrainers
 An air-entraining agent introduces air in the
form of minute bubbles distributed uniformly
throughout the cement paste.
 Air entrainment will dramatically improve the
durability of concrete exposed to cycles of freezing
and thawing.
 Entrained air can be produced in concrete by use of
an air-entraining cement, by introduction of an air
entraining admixture, or by a combination of both
methods.
1
Uses of air-entertainers
 Where improved resistance of hardened
concrete to damage from freezing and
thawing is required.
 For improved workability, especially in
harsh or lean mixes.
 To reduce bleeding and segregation,
especially when a mix lacks fines.

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Air entrainment may reduce the strength of
concrete and overdosing can cause major loss of
strength. As a rule-of-thumb, 1% air may cause a
strength loss of 5%.
It is therefore important that mixes be specially
designed for air entrainment and that the
percentage of air entrained during construction
must be monitored.

1
3.4 Accelerators
Accelerators :
 speed up the chemical reaction of
the cement and water and so….
 accelerate the rate of setting and/or early
gain in strength of concrete.

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Uses of accelerators

 Where rapid setting and high early

strengths are required.
 Where rapid turnover of moulds or
formwork is required.
 Where concreting takes place under very
cold conditions.

1
 Problems associated with accelerators
 Certain accelerators may increase drying
shrinkage, cracking and creep.
 Many chloride-based accelerators promote
corrosion of reinforcing steel.
 Calcium chloride should not be used in
reinforced concrete
 An overdose can result in placement
problems and can be detrimental to concrete.

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3.5
Retarders

unlike the accelerators, these
admixtures slow the chemical reaction of
the cement and water leading to longer
setting times and slower initial strength
gain.

1
 Uses of retarders

 When placing concrete in hot weather,

particularly when the concrete is pumped.
 To prevent cold joints due to duration of
placing.
 In concrete which has to be transported for
a long time.

1
Problems associated with
retarders
 If a mix is overdosed beyond the limit
recommended by the supplier, retardat-
ion can last for days.
 Delay in adding of retarders can result in
extended retardation.

1
Fresh Concrete

1
1
 Transporting
Gathering
Ingredients Proportioning Mixing

finishing
n &
Compactio
Placing
Hardened
Concrete

Curing

1
Mixing

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 Major properties of fresh concrete
Definition: Fresh concrete is the stage of concrete
in which concrete can be molded in to any type of
shape and is in its plastic state. This is also called
"Green Concrete".
 The major Properties of concrete in its plastic
state are:
 Workability

 Consistency

 Segregation

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Properties of Fresh concrete Conti..

 Bleeding
 Stiffening and setting
 Hydration
 Air Entrainment
 Curing

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 1. Workability
Workability: is often referred to as the ease with which a
concrete can be transported, placed consolidated
and without excessive bleeding or
segregation.
 Hence, Workability means how easy it is to:
Transport / handle
 Place

 Compact and

 FINISH a concrete mix.

 Concrete that is stiff or
dry may be difficult to
Handle, Place, Compact, and Finish and will not
be as strong or durable when finally hardened.

1
Factors that affect workability
 Water cement ratio
 Amount and Type of Aggregate
• shape of aggregates
Aggregate
• Grading of Aggregates Properties

• Size of Aggregates
• Surface Texture of Agg

1
Factors that affect workability (Cont…)
 Amount and type of Cement
 Weather conditions
 Temperature
 Wind
 Chemical Admixtures
 Sand to Aggregate ratio

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Water content

If water content is increased the

coarse particles settle and
bleeding occurs. Cement slurry
can escape through joints of
formworks.

1
Aggregate (types) properties
 shape of aggregates (Flakiness)
 Grading of Aggregates
 Size of Aggregates (Nominal Size)
 Surface Texture of Aggregates
Angular, flaky, and elongated aggregates
reduce workability.
Nonabsorbent aggregates and optimum
percentage of fine aggregate contributes to
workability .

1
Admixtures
 Workability admixtures improve the
workability of concrete
 Air entraining agents produce
numerous air bubbles that act as
rollers to decrease bleeding and
segregation, and as a result increase
workability
 Slump test can be used to find out the workability of concrete

1
2.
Consistency
Consistency refers to the
ability of
concrete to flow and indicates
wetness of concrete.
Concrete could have:
 Dry
 Plastic: can be shaped into ball

Semi-fluid: spreads out slowly and
with out segregation of aggregate
 Fluid consistency: spreads out fast and
results
in segregation of aggregates
1
3. Segregation
Segregation is separation of coarse
aggregates from the mass of concrete.

Segregation results from:

• Uncontrolled pumping or falling
• Placing under waters
• Placing concrete in heavily reinforced members

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Precautions to control segregation

Placing concrete near its final position,

instead of falling from greatest
heights
1
Precautions to control segregation

 Careful handling, pacing, and consolidation

of concrete
 Applying Admixtures : Plasticizer and air
entraining admixture.

1
4. Bleeding
Bleeding is the appearance of water on
concrete surface. As a consequence
of bleeding, slum layer will be formed
making concrete weak and porous.

1
 Interaction between bleeding and evaporation

Evaporation

surface water

Bleed

water

Bleed water = evaporation

 Too much evaporation leads to surface cracking

Evaporation

no surface water

drying

Bleed water < Evaporation

Measures to minimize bleeding

 Using well graded and

proportioned aggregates
 Increasing amount of
cement
 Applying air entering
agents
 Reducing amount of
1
5. Stiffening and setting
Concrete is required to remain plastic for
the time to be taken to transport, place,
and consolidate it.
Temperature influences the stiffening of
concrete. That is,
Low temperature delays
High temperature accelerates the
stiffening of
concrete.
1
MEASUREMENT OF WORKABILITY
Some of the methods of measuring
workability that is wetness or fluidity are:
 Slump test
 Compacting factor test

1
Slump is the subsidence of concrete cone after mold is lifted up.

1
1
1
1
1
Types of slump

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Types of slump (results of slump)
 True Slump - Has even subsidence

 Shear Slump - Half of the cone slides,

difficult to measure, and results from harsh
mixes deficient in fine aggregates.

 Collapse Slump - difficult to measure,

results from very wet mixes.

1
Slump test results
Slump (mm) Degree of workability
(Suitability) & Recom’d for
0-25 Very low
(Massive sections,
little reinforcement)
25-50 Low
( little reinforcement)
50-100 Medium
(Beam, columns)
100-175 High
(For heavily reinforced sections

1
Limitations of slump test

 Not applicable for aggregates size greater

than 40 mm .

 Applicable to plastic mixes only

 Not applicable to harsh and wet mixes

1
Compacting Factor Test

Drier mixes do not give slump. Therefore,

compaction factor test should be done to
determine degree of compaction
(compacting factor) by falling the mix
through successive hoppers with
standard height using a compaction
factor test apparatus.

1
Compaction factor test apparatus

1
Compacting Factor = Weight of partially dry compacted concrete
Weight of fully compacted concrete

Permissible Values of Compacting Factor

Workability Compacting factor

Good workability 0.95
Medium Workability 0.92
Low workability 0.85

1
Compacting factor values
 For compacting factor values between
0.75-0.80, compacting concrete by hand is
not permissible.
 For Compacting Values less than 0.75,
pressure should be exerted into concrete
to vibrate.
 Compacting factor test is suitable for both
dry and wet mixes, since it gives constant
results.
1
MIXING OF CONCRETE

1
Purpose of mixing
The purpose of concrete mixing is to
provide a uniformly blended product of
cement, water, and aggregates.

Basic requirement of mixing is to produce

concrete of uniform consistency from
beginning to end.

1
Methods of mixing
Two basic methods of mixing concrete;

i. Hand mixing
ii. Machine mixing

1
 Hand Mixing
Adopted for small works and quantity
of concrete used is small
Procedure:
a. Sand + cement  dry mix
b. Spread the sand -cement mix on a flat
platform
c. Spread the measured quantity of
coarse aggregate on the cement-sand
mix

1
d. Mix the cement + sand + c.agg. At least three
times by shovel from center to the side and
then back to the center and again to the side

e. Make a hallow in the middle of the mixed pile

and pour slowly into it half to three-quarter of the
total quantity of water required

f. Add the remainder of the water slowly,

turning the mixture over and again until the
color and consistency are uniform throughout
the pile

1
Hand Mix Conti...

Note:
1. Time of mixing should not exceed 3
minutes

2. Mixing platform is cleaned at the end of

the days work, so that it is ready for use
the next day

1
Machine mixing

 Used in case of a large quantity of concrete

is to be produced

 Concrete can be produced at a faster rate

at a lesser cost and of better quality

1
Note
- Care for mixer is very important!
1. Wash the mixer every day preferably with a hose
2.Hammering or hitting of the loading skip in order to
accelerate the discharge of adhering sand and cement should
not be permitted
3.When the mixer is installed at one place for a longer
periods, it should be ensured that wheels and axle of the
mixer do not get buried under accumulating materials
4.Before closing down a shift or day’s work, the
interiors of the drum and blades are flushed clean
5.General upkeep and maintenance of the mixer
engine be attended everyday, i.e., fuel, water, lubricant, etc.

1
Ready-mixed concrete
1. Central mixed - Mixed completely in a
stationary mixer (Batching Plant) and then
transported in a truck agitator

2. Transit mixed - Mixed completely

in a truck mixer
3. Shrink mixed - Mixed partially in a
stationary mixer and finally completed in a
truck mixer

1
Transporting Concrete
i. Pans
- When quantity is small
- When access to work is restricted
- Method is tedious, slow and costly

1
Transporting Concrete
ii. Wheel barrows
- Moderate distance and medium quantities
iii. Truck mixer
-When place of deposit of concrete is at a very
long distance from the mixer such that the concrete
cannot be transported and placed in the forms
within 30 minutes
- Happens in case of ready-mixed concrete
-Drum containing the concrete rotates
continuously to prevent the concrete from being
stiff and to prevent segregation

1
1
iv. Belt conveyors
- When the concrete is to be transported
a continuously
higher level and to
- Could be a single unit or in series
- Installed in an inclined position

v. Chutes

- When concrete is to be placed below ground level, the

mixer may be placed on an upper level and concrete
discharged to the lower level through a chute of corrugated
iron or timber
vi. Pumps
-When large quantity of concrete is to be transported
continuously to congested sites where mixing plant can not
be installed
- To a maximum of 300 m horizontally and 40m vertically

1
Placing of concrete
- Concrete should be placed and
compacted before setting commences
- Method of placing should be in
such a way as to prevent segregation (
should not be dropped from a height
more than about 1m)

1
 Formwork
Material
i. Timber  Most commonly
used
ii. Plywood  Bounded
with water proof synthetic
resin adhesives
iii. Hard board 
Manufactured from wood
fibers, usually impregnated
with drying oils and
factory applied plastic
coatings
iv. Metal forms 
very common
nowadays
1
Compaction of Concrete
When first placed in the form, normal
concrete excluding those with very low or
very high slumps will contain between 5%
and 20% by volume of entrapped air.
Compaction is the process which expels
entrapped air from freshly placed concrete
and packs the aggregate particles together
so as to increase the density of concrete.

1
Proper compaction:
 Increase significantly the ultimate strength of
concrete and
 Enhances the bond with reinforcement.
 Increases the abrasion resistance and general
durability of the concrete,
 Decreases the permeability and helps to
minimize its shrinkage-and-creep
characteristics.
 Also ensures that the formwork is completely
filled – i.e. there are no pockets of
honeycombed material – and that the required
finish is obtained on vertical surfaces.

1
Stages of Compaction
Compaction of concrete
is a two-stage process.
First the aggregate
particles are set in
motion and slump to fill
the form giving a level
top surface.
In the second stage,
entrapped air is expelled.

1
Effect of compaction on hardened
concrete
As may be seen from the
figure the effect of
compaction on
compressive strength is
dramatic. For example,
the strength of concrete
containing 10% of
entrapped air may be as
little as 50% that of the
concrete when fully
compacted.

Loss of strength through incomplete compaction

1
Methods of compaction
i. Hand compaction (Tamping)
ii. Vibrators
- Internal vibrators
- Form vibrators
- Surface vibrators

1
Types of vibrators
1. Immersion Vibrator(spud or
poker vibrators)

Immersion vibrators consist

essentially of a tubular housing
which contains a rotating
eccentric weight. The out-of-
balance rotating weight causes
the casing to vibrate and,
when immersed in concrete,
the concrete itself. Depending
on the diameter of the casing,
and on the frequency and the
amplitude of the vibration, an
immersion vibrator may have a
radius of action between 100
and 600 mm.
Immersion Vibrator
1
1
•Vibrators should not be used to move concrete
horizontally since this causes segregation.
•Whenever possible, the vibrator should be
lowered vertically into the concrete at regularly
spaced intervals and allowed to descend by
gravity.
•It should penetrate to the bottom of the layer
being placed and at least 150 mm (6 in.) into any
previously placed layer.
•The height of each layer or lift should be about
the length of the vibrator head or generally a
maximum of 500 mm (20 in.) in regular formwork.

1
2. External vibrators
 form vibrators,
 vibrating tables,
 surface vibrators
 Form vibrators, designed to be securely attached to the
outside of the forms, are especially useful
(1)for consolidating concrete in members that are very thin
or congested with reinforcement,
(2) to supplement internal vibration, and
(3) for stiff mixes where internal vibrators cannot be used.

1
 Surface Vibrators

Surface vibrators are

applied to the top
surface of concrete and
act downwards from
there.are very useful
They
for compacting slabs,
industrial floors, road
pavements, and similar
flat surfaces. They
also aid in leveling and
finishing the surface.

Surface Vibrator

1
Consequences of Improper Vibration
(1)honeycomb:

results when the spaces

between coarse
aggregate particles do
not become filled with
mortar.

1
(2) excessive amount of entrapped air voids, often
called bug holes:
 Excessive entrapped air voids are similar to, but not
as severe as honeycomb. Vibratory equipment and
operating procedures are the primary causes of
excessive entrapped air voids.
(3) Cold Joints:
 are a discontinuity resulting from a delay in placement
that allowed one layer to harden before the adjacent
concrete was placed. The discontinuity can reduce the
structural integrity of a concrete member if the
successive lifts did not properly bond together.
 The concrete can be kept alive by re vibrating it every
15 minutes or less depending on job conditions.

1
(4) placement lines;
 are dark lines between adjacent
placements of concrete batches.
 They may occur if, while vibrating the
overlying layer, the vibrator did not
penetrate the underlying layer enough to
knit the layers together.

1
Defects from overvibration :
(1)segregation as vibration and gravity causes heavier
aggregates to settle while lighter aggregates rise;
(2) loss of entrained air in air-entrained concrete;
(3) excessive form deflections or form damage; and
(4)form failure caused by excessive pressure from
vibrating the same location too long and/or placing
concrete more quickly than the designed rate of pour.
Undervibration is more often a problem than
overvibration

1
Curing Concrete
Curing is the process which controls the loss of
moisture from concrete either after it has been
placed in position (or during the manufacture of
concrete products), thereby providing time for the
hydration of the cement to occur.
Since the hydration of cement does take time –
days, and even weeks rather than hours – curing
must be undertaken for a reasonable period of
time if the concrete is to achieve its potential
strength and durability.

1
Concrete can be kept moist (and in some cases at
a favorable temperature) by three curing
methods:
1. Methods that maintain the presence of mixing
water in the concrete during the early hardening
period. These include ponding or immersion,
spraying or fogging, and saturated wet
coverings. These methods afford some cooling
through evaporation, which is beneficial in hot
weather.

1
Fogging Sprinkling

1
 Impervious curing paper
2. Methods that reduce
the loss of mixing
water from the
surface of the
concrete. This can be
done by covering the
concrete with
impervious paper or Plastic Sheets
plastic sheets, or by
applying membrane-
forming curing
compounds.

1
Liquid membrane-forming curing compounds

1
 3. Methods that accelerate strength gain by
supplying heat and additional moisture to
the concrete. This is usually accomplished
with live steam, heating coils, or electrically
heated forms or pads.

1
 Duration of curing

- Concrete shall be covered and kept constantly

wet for seven days from the date of placing

- Curing by sprinkling of water shall continue at

least up to 28 days of age

1
HARDENEDD CONCRETE

1
 Properties of Hardened Concrete
1. Strength of Concrete
i. Mainly Compressive strength
ii. Tensile strength
iii. Flexural strength
iv. Shear strength
2. Concrete Creep
3. Shrinkage
4. Water tightness (Impermeability)
5. Modules of Elasticity
6. Durability
i. Weathering including disruption due to freezing and thawing
ii. Mechanical wear  abrasion, wear,
iii. Chemical corrosion
- Sea water
- Sewage
- Acids-
1
1. Strength of Concrete

 The strength of concrete is basically

depends upon three factors.

 Paste strength
 Interfacial bonding
 Aggregate strength

1
A. Paste strength:

 It is mainly due to the binding properties of

cement that the ingredients are
compact’d together.
 Therefore, If the paste has higher binding
strength, higher will be strength of
concrete.

1
B. Interfacial bonding:

 Interfacial bonding is very

necessary regarding strength.
the Clay
hampers/hinders the bonding
paste and aggregate. between
 Therefore, the aggregate should be
washed for a better bonding
paste and aggregate.
between

1
C. Aggregate strength:

 It is mainly the aggregate that provide

strength to concrete especially coarse
aggregates which act just like bones in the
body. Rough and angular aggregate
provides better bonding and high strength

1
Factors Affecting Strength
Following are the factors that affect the strength of
concrete:
 Water-Cement ratio
 Type of cementing material
 Amount of cementing material
 Type of aggregate
 Air content
 Admixtures

1
a. Water – Cement ratio
 It is water cement ratio that basically
governs the property of strength. Lesser
the water cement ratio, greater will be
strength.

1
b. Types of cement:

 Type of cement affect the hydration process and

therefore strength of concrete.

C. Amount of cementing material:

 it is the paste that holds or binds all the

ingredients. Thus greater amount of cementing
material greater will be strength.

1
 d. Types of Aggregate

 Rough and angular aggregates

are preferable as they provide greater
bonding.

1
e. Admixtures
 Chemical admixtures like plasticizers
 reduce the water cement ratio and
 increase the strength of concrete at same
w/c ratio.

 Mineral admixtures affect the strength at later

stage and increase the strength by increasing
the amount of cementing material.

1
 2. Creeps in Concrete

Definition:
creep is deformation of structure under sustained
load. Basically, long term pressure or stress on
concrete can make it change shape. This
deformation usually occurs in the direction the
force is being applied. Like a concrete column
getting more compressed, or a beam bending.

1
Creep Continued....
 Creep does not necessarily cause
concrete to fail or break apart. Creep is
factored in when concrete structures are
designed.

1
2.1 Factors Affecting Creep

 Aggregate
 Mix Proportions
 Age of concrete

1
Factors affecting Creep Conti.....
A. Influence of Aggregate
 Aggregate undergoes very little creep.

It is really the paste which is responsible
for the creep.
 However, the aggregate influences the
creep of concrete through a restraining
effect on the magnitude of creep.
 The paste which is creeping under load is
restrained by aggregate which do not
creep.
1
Factors affecting Creep Conti.....

B. Influence of Mix Proportions:

 The amount of paste content and its

quality is one of the most important
factors influencing creep.

 A poorer paste structure undergoes

higher creep. Therefore, it can be said
that creep increases with increase in 1
Factors affecting Creep Conti.....
C. Influence of Age:
 Age at which a concrete member is loaded
will have a predominant effect on the
magnitude of creep.

 The older the concrete the stronger it

becomes hence less creep occurs

1
2.2 Effects of Creep

 In reinforced concrete beams, creep

increases the deflection with time and may
be a critical consideration in design.

 In eccentrically loaded columns, creep

increases the deflection and can load to
buckling.

1
 Types of Shrinkage in Concrete
(Reading Assignment)
To understand this aspect more, shrinkage can
be classified in the following way:
 (a) Plastic Shrinkage
 (b) Drying Shrinkage
 (c) Auto-genius Shrinkage
 (d) Carbonation Shrinkage

1
Durability is :
- Performance of concrete for the purpose of its intended function.

-hence, maintaining its required strength and servicibility, during the

specified or traditionally expected service life

- Durability does not mean an indefinite life , nor does it mean

withstanding any action on concrete

-It is now well known that, for many conditions of exposure of

concrete structures, both strength and durability have to be
considered explicitly at the design stage

- Concrete durability has been defined by the American Concrete

Institute as its resistance to weathering action, chemical attack,
abrasion and other degradation processes

2
Mechanisms that affect durability

i. Freeze-thaw damage (physical effects, weathering).

ii. Alkali-aggregate reactions (chemical effects).

iii. Sulfate attack (chemical effects).

iv. Microbiological induced attack (chemical effects).

v. Corrosion of reinforcing steel embedded in concrete

(chemical effects).
a) carbonation of concrete
b) chloride induced
vi. Abrasion (physical effects).

vii. Mechanical loads (physical effects). 224

 Abrassion
- Concrete surfaces subjected to wear due to attrition by sliding,
scraping or purcussion

-in the case of hydraulic structures, the action of abrassive

materials carried by water leads to erosion

202
Action of frost
-As temperature of saturated concrete in service is lowered 
water held in the capillary pores freezes  expansion of concrete
takes place

-If subsequent thawing is followed by re-freezing, further

expansion takes place  repeated cycle have a commulative
effect

203
Assessment of Concrete
strength
1.Cube/ cylindrical strength

204
2.Using Nondestructive Tests
I. Rebound Number (Hammer)
 The rebound number is obtained by the use of a hammer
that consists of a steel mass and a tension spring in a
tubular frame.
 When the plunger of the hammer is pushed against the
surface of the concrete, the steel mass is retracted and the
spring is compressed.
 The rebound distance is indicated by a pointer on a scale
that is usually graduated from 0 to 100. The rebound
readings are termed R-values.
 Rebound numbers may be used to estimate the
uniformity
and quality of concrete
205
206
207
208
ii. Penetration Resistance (Probe)

 The apparatus most often used for penetration resistance

is the Windsor Probe, a special gun.

 A series of three measurements is made in each area

with the spacer plate.

 Penetration resistance can be used for assessing the

quality and uniformity of concrete because physical
differences in concrete will affect its resistance to
penetration.

 A probe will penetrate deeper as the density,

subsurface
hardness, and strength of the concrete decrease
209
 Windsor probe  Windsor probe in
apparatus
use
210
Compressive strength Vs depth of penetration

211
iii. Pull-Out Test

 This is a test which

measures ,by means of a
special tension jack, the
force required to pull out
a previously cast in metal
insert with an enlarged
end.

 The insert is pulled out

with a lump of concrete,
approximately in shape of
a frustum of cone.

247
iv. Ultrasonic Pulse-Velocity Method

  The method involves measurement of the time of

travel of electronically pulsed compression waves
through a known distance in concrete.

 From known TOA (time of arrival) and distance

traveled, the pulse velocity through the concrete
can be calculated

 Pulse-velocity measurements made through good-

quality, continuous concrete will normally produce
high velocities accompanied by good signal
strengths. Poor-quality or deteriorated concrete will
usually decrease velocity and signal strength.
213
 MIX DESIGN
 Mix design is the selection of mix ingredients
and their proportions.
 The purpose of a concrete mix design is to
have economical mix proportions for the
available concreting materials which has
adequate workability to be placed in its final
position on site.

214
 Goals:
 Maximize strength by
= minimize water
= hence, control bleeding & segregation
 Reduce Cost
= use largest gravel possible for the job
= hence, minimize paste requirement
 Provide good durability
= use well graded aggregates
= maximize void packing
= reduced segregation

215
 Information required for mix design
The Basic information of the Concrete Ingredients
Required for Concrete Mix Design are:

 Sieve analyses of fine and coarse aggregates.

 Fineness Modules of Fine Aggregate (Reading)
 Unit weight of coarse aggregate.
 specific gravities of Aggregates (Cement,
Fine aggregate and Coarse Aggregate)
 Specific gravity of other cementations materials, if
used.
 Water absorption value of aggregates.
 Moisture content of Aggregates
216
ACI Standard Mix Design Method
 The standard ACI mix design procedure
can be divided into 8 basic steps:
1. Choice of slump
2. Mixing water and air content selection
3. Maximum aggregate size selection
4. Water-cement ratio
5. Cement content
6. Coarse aggregate content
7. Fine aggregate content
8. Adjustments for aggregate moisture

217
 Step #1: Select
Table 1 Slump

218
 Step #2: Determination the
Maximum Aggregate Size
 DEFINITION: Nominal maximum aggregate size is the largest sieve that retains
some of the aggregate particles.

 ACI Limits:
 1/3 of the slab depth

3/4 of the minimum clear space
between bars/form
 Aggregate larger than these dimensions may be difficult to
consolidate and compact resulting in a honeycombed structure
or large air pockets.

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Step #3:Determine Mixing
Water Amount and Air
Content
Table 2

256
 Step #4: W/C Ratio Determination
(From the Structural design)
Table 3

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 Step #5: Evaluation of Cement
Content & Entrained Air
 The calculated cement amount is based on
the selected mixing water content and
water-cement ratio.
 W/C= Wt. of Water

Wt. of Cement
 Amt of Entrained Air

=% of Entrained
Air* 1m3
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Step #6: Coarse Aggregate.
Content
Table 4

223
Step #7: Determination of Fine
Aggregate. Content

224
VCon = Va + Vw + Vc + Vfa + Vca
Where:
Vcon = Volume of the fresh concrete
Va = Volume of the air
Vw = volume of the water
Vc= absolute volume of the cement
Vfa = absolute volume of the fine
aggregate
Vca = absolute volume of the
coarse
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 Step #8: Batch Weight & Water
Adjustment
 Aggregate weights.
 Aggregate volumes are calculated based on oven dry unit weights, but
aggregate is batched in the field by actual weight.
 Any moisture in the stockpiled aggregate will increase its weight.
 Without correcting for this, the batched aggregate volumes will be
incorrect.

 Amount of mixing water.

 If the batched aggregate is anything but saturated surface dry it will absorb
water (if dry) or give up water (if wet) to the cement paste.
 This causes a net change in the amount of water available in the mix and
must be compensated for by adjusting the amount of mixing water added.

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Mix Design Example No. 1:
25cm Thick Un reinforced Pavement Slab

227
Properties of Footing Concrete Specified
By Eng.

 Slump = 2.5cm
 28-day strength of 34.5MPa
 Air content: 4.5 - 6.5 percent

228
Information About Materials:
 Coarse aggregate :
 nominal maximum size = 37.5mm
 dry-rodded weight = 1600 kg/m3
 specific gravity = 2.68
 moisture content = 1.0 percent
 absorption Value= 0.5 percent
 Fine aggregate:
 fineness modulus = 2.80
 specific gravity = 2.64
 moisture content = 5 percent
 Absorption Value = 0.7 percent

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 Step #1: Check the Slump (Given)

Conclusion: the Slump size is with in the

standard
Table:1

 Engineer Specified 2.5cm (correlates w/table)

230
 Step #2: Check for
Maximum
Aggregate
Note: The plain Size is a slab of
concrete structure
25cm hick (Given)
 And according to ACI Limits:
 1/3 of the slab depth
=>250mm/3 =83.33mm > 37.5mm (OK!!!)

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 Step #3:Determine Amount of Mixing Water from
Nominal size and Slump Amount for Air Entertained
37.5mm Stone (Given)
Table:2

5 cm Slump (Given)

232
Step 3:Determining Volume of Water (Con..)

Analysis:

Weight of Water = 148 kg/m3

Volume of Water = 148 kg/m3 = 0.148m3
1000 kg/m3
Volume of Water = 148liters per cubic meter of
concrete

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 Step #4: Determining W/C Ratio
Note: 28 day Comp strength is 34.5MPa and the
Concrete is Air Entrained (Given). Hence from
the ACI Table below the W/C ratio is 0.40
Table:4

234
Step #5: Determining Amount of
Cement Content
Analysis
 W/C= Wt. of Water

Wt. of Cement
 Wt. of Cement = 148 kg/m3

0.40
=370kg/m3

Volume of Cement = 370 kg/m3 (Concrete)

3.15 x 1000kg/m3
SG Cement
Volume of Cement = 0.117m3 per cubic meter of concrete

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 Step #6: Determination of
Coarse Aggregate
Content
Table:5

236
Analysis

Note: the Maximum Aggregate size is 37.5mm and the

FM=2.8 (Given). Hence from the ACI Table above the
volume of Coarse Aggregate is 0.71
Weight (Dry) =0.71 x 1600 kg/m3 = 1,136 kg

Dry Rodded Unit Wt of Stone (Given)

Volume = 1,136 kg = 0.42 m3

2.68 x 1000kg/m3
SG Stone

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 Step #7: Determination of
Fine Aggregate
Content
1m3 Cubic meter of Concrete
0.148m3 Water
0.055m3 Air
0.117m3 Cement
0.42m3 Stone
0.26m3 Sand

Analysis:
Wt of Sand(Dry) = 0.26m3 x 2.64 x 1000kg/m3 = 686.4 kg.

SG Sand
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Step #8: Aggregate Batch Weights &
Water Adjustment

 Wt of Stone(Wet) = 1,136 kg x 1.01= 1,147.4kg

1% Moisture

 Wt of Sand(Wet) =686.4 kgx 1.05= 720.7kg

5% Moisture

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Step #8: Aggregate Batch Weights &
Water Adjustment
(Continued…….)
B. Mixing Water Amount Adjustment:
Since Both the coarse and fine aggregate are wet of
SSD and will contribute water to the cement paste.
Water from Stone = 1,136 kg x (0.01-0.005) =
5.68kg
Dry Wt. Moisture Absorption

Water from Sand= 686.4 kg x (0.05-0.007) = 29.52kg

Dry Wt. Moisture Absorption
Water = 148kg – 5.68kg– 29.52kg= 112.8kg

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Final Batch by Weight per1
Cubic meter of Concrete

Water 112.8kg

Cement 370kg

Stone(aggregate) 1,147.4kg

Sand 720.7kg

241