CEMB 113

CIVIL ENGINEERING MATERIALS

CHAPTER 3
Portland Cement Concrete
Dr. Salmia Beddu
BN-3-027
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 Introduction
 Many types of concrete
 Portland Cement Concrete (PCC)
prevalent
 “concrete” = PC Concrete
 Engineers are directly responsible for the
 Design of the mix
 Final quality of concrete

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 Concrete Ingredients
• Aggregates
 Fine
 Coarse

• Portland Cement (PC)

• Water
• Admixtures

 Paste = PC + Water
 Mortar = PC + Water + Fine aggregate
 Concrete = PC + Water + Coarse and Fine
aggregates
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 Quality of Concrete
depends on:
 chemical composition  transporting

 aggregate  hydration

 water  placing

 admixtures  vibrating

 proportions  curing

 mixing

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

I. mix design (proportioning)

II. trial mixes & testing
III. batching
------------------------------------------------------------start the clock
IV. mixing
V. transporting
VI. pouring (placing)
Sampling and testing
VII. vibrating (consolidating)
-------------------------------------------------------------initial set here
VIII. finishing
-------------------------------------------------------------final set here
IX. curing
X.maintenance
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 7.1 Proportioning of Concrete Mixes
(Mix Design)
Determine proportions of mix ingredients that
will:
 be economical
 be practical
 use available materials
 satisfy requirements & specs
 acceptable workability of fresh mix
 quality (durability, strength, look) of hardened concrete
 economy
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 Several Methods
Depends on project size:
 Arbitrary volume method (1:2:3 =
PC:sand:coarse agg.)
 Weight method – easiest design method
 Absolute volume method – most accurate
 Small jobs, non-critical

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 Mix Design: Volumetric Method

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

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 BRE Mix Design Method
(Formerly DoE Method)

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

I. mix design (proportioning)

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

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 7.2 Mixing, Placing, & Handling of PCC
Batching
 Measuring correct proportions of components and placing

in the mixer
 By weight is more accurate because air voids don't matter

Mixing
 Until uniform appearance

 Usually batch mixers (one at a time), but sometimes

continuous (conveyors automatically feed components into

mixer)
 Usually start with 10% of the water in the mixer, then solids

with 80% of the water, and then remaining water

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Central Batch Concrete Plant

Mix ingredients in
predetermined
proportions

Place in trucks

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Slipform Paver

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

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 Mixing
 until uniform appearance
 usually batch mixers but sometimes continuous
(conveyors automatically feed components into
mixer)
 usually start with 10% of the water in the mixer,
then solids with 80% of the water, and then mix
in the remaining 10% of the water
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 Mixing
 specs. limit the revs. of the
 Ready Mixed truck barrel to avoid
 in a central plant and segregation
delivered in an agitator truck  max. 90 minutes from start
(2 - 6 rpm) of mixing to discharge, even
 Shrink-mixed with retarders
 partially mixed in plant and
delivered in a mixer truck
(4 - 16 rpm)
 Truck-mixed
 mixed completely in a mixer
truck (4 - 16 rpm)
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 Order of Operations for Concrete
Specific operations must be performed in a certain order
• final quality is influenced by every step

I. mix design (proportioning)

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

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 Sampling and Testing
 Pull samples at the job site
 Test on site
 Slump
 Air content

 Prepare samples for later

testing
 Cylinders
 Beams

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

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 Air Content Test for Fresh Concrete

 Measures total air content (entrapped and entrained)

 Only entrained is good but we can't tell the difference from
this test
1) Pressure Method
2) Volumetric Method
3) Gravimetric Method
4) Chase Air Indicator

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 Cylinders
 6 x12 Standard
 Place concrete in
three lifts, rod each
25 times
 Cure on site 24 hrs
– Temperature
– Humidity /
submerged in lime
water
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 Order of Operations for
Concrete
Specific operations must be performed in a certain order
• final quality is influenced by every step

I. mix design (proportioning)

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

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 Placing Concrete
Transfer From Truck….

Chute Conveyor
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 Directly into form

Pump

Wheel barrow/ buggy Bucket

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 Placing Issues
 Drop height
 < 3 ft
 Horizontal movement
 Limit to prevent segregation
 Pumping
 Adjust mix design

tremie chute to limit drop height

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 Vibration of Concrete
 Consolidation (compaction)
complete before initial set
 Manually by
– ramming
– tamping
 Mechanically using vibrators
– Internal – poker
 5 sec to 2 min in one spot
 <10 sec. typical
 avoid segregation
 through entire depth
 penetrate layer below if still plastic
– External –
 tables and rollers for precast concrete USC
 SEGREGATION
 Tendency for separation of large and fine particles in fresh
concrete mix due to method of handling and placing
concrete
 Results in non-homogenous mix - affects the strength and
durability of hardened concrete
 Causes pores and honeycombed surface
 Air entrainment agent : decrease segregation tendency

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HONEYCOMBED CONCRETE DUE TO SEGREGATION

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 Factors influenced
 Aggregate gradation segregation
: well graded, no segregation
 Concrete moisture :
 Too dry : segregation between aggregates

 Too wet : segregation between grout and aggregate

 Dropping of fresh concrete from considerable height

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
Factors influenced segregation
Improper use of concrete vibrator : moved concrete to
another adjacent location
 Prolonged vibration : coarse aggregate may settle to
bottom, grout rise to top surface

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Proper handling and placing of concrete, and concrete
vibration technique is essential to prevent segregation

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Concrete handling techniques to prevent
segregation

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 BLEEDING
Water gain in concrete – some of water in concrete mix
tends to rise to the surface of freshly placed concrete
 Inability of solid constituents in concrete mix to hold all of
the mixing water, which then slowly displaced and rises to
top of the form
 Bleeding can continue to occur until the cement paste has
stiffened sufficiently

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 How to control bleeding?
Reduction of water
 Introduction of fines and air
 Proper Compaction (too much compaction causes
bleeding)

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 Concrete bleeding at wall surface

Concrete bleeding on
slab

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 Plastic Shrinkage
 Contraction that occur while the concrete in a fresh state
 Depends on rigidity of mix amount

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

I. mix design (proportioning)

II. trial mixes & testing
III. batching
------------------------------------------------------------start the clock
IV. mixing
V. transporting Sampling and testing
VI. pouring (placing) Complete
VII. vibrating (consolidating)
-------------------------------------------------------------initial set here
VIII. finishing
-------------------------------------------------------------final set here
IX. curing
X.maintenance
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 Finishing Concrete
smoothing and imprinting the surface of the
concrete with the desired texture
 must be completed before final set
 many types of colors and textures
available these days
 stamped concrete uses rubber stamps to
create the look of stone, tile, etc.

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Screeding – strike concrete
off to desired level

Bullfloating eliminates high

and low spots and embeds
large aggregate particles
Power float immediately after strikeoff.
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 Order of Operations for Concrete
Specific operations must be performed in a certain order
• final quality is influenced by every step

I. mix design (proportioning)

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

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 7.3 Curing Concrete
 Maintain moisture and
 Curing affects:
 durability
temperature in the
concrete to promote  strength

continued hydration  water-tightness

and strength gain  abrasion resistance

 hydration will resume  volumetric stability

if curing is stopped  resistance to

and resumed freezing and

thawing
 resistance to de-

icing chemicals
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Compressive strength of PCC at different ages &
curing levels
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 Curing Approaches

1. Maintaining presence of water in the

concrete
2. Seal the surface so mix water can’t
escape
3. Heat & additional moisture

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 Approach 1. Maintaining
Presence of Water
 Must water periodically
 Also provides cooling

 Methods
 ponding: smaller jobs flat-work (floors and
pavement) and laboratory
 spraying or fogging: expensive and a lot of

water
 wet coverings: burlap, cotton, rugs, etc.

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 Spraying

Spraying

Fogging

Chapter 7 Portland USC 48

Cement Concrete
 Wet
Covering
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 Approach 2. Seal the Surface

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

Plastic Sheets
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Chapter 7 Portland USC 51
Cement Concrete
 Approach 3. Heat
 insulate
 steam
 good for early strength gain and in freezing
weather
 heating coils, electrically heated forms or
pads
 usually in precast plants only

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 Method Selection
 Considerations:
 availability of curing
materials
 size and shape of
structure
 production facilities (in-
place or precast)
 aesthetic appearance
 economics
 Curing – immediately
after final set to avoid
surface damage
 Curing period
 minimum 7 days
 70% of f’c (3 days for
high early strength)
 other job requirements
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 Order of Operations for
Concrete
Specific operations must be performed in a certain order
• final quality is influenced by every step

I. mix design (proportioning)

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

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 7.4 Properties of Hardened
Concrete
1. Early Volume Change
2. Creep
3. Permeability
4. Stress-Strain Relationship

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 Early Volume Change
 Plastic shrinkage – plastic
concrete – 1% shrinkage
from evaporation – cracking
 Drying shrinkage – after
setting if not cured –
cracking
 If wetted continuously –
very slight swelling
 Curling from non-uniform
drying
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 Creep
 long term, gradual, deformation under
sustained load
 small strain but transfers load from
concrete to steel in beams & columns

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

 Typical s-e of 28 day concrete

 Increasing w/c decreases both strength (f’ c) and
stiffness (E)
 Stronger concrete is more brittle
 Almost linear at small strains USC
 Usually use chord modulus for Ec
 Very small strain and 40% su or specific strain
(1%)
 3 or 4 loading cycles
 Ec = 2000 - 6000 ksi, Poisson's ratio, n = 0.11 - 0.21
 ACI building code: 
Ec  4,731 f c , MPa


Ec  57,000 f c , psi
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 7.5 Testing of Hardened Concrete
Compressive Strength (f’c) Test
 Most common test by far (even more than
slump)
 2:1 cylinders cast in 3 layers rodded 25
times each layer and cured at 95%
humidity
 Or specimens are cored from finished
structure
 7 day = 60% of 28 day and 28 day = 80%
ultimate strength
 Typical compressive strength is 3,000 -
6,000 psi USC
 6” diameter x 12” long is ASTM standard and
close approximate to actual structures
 Smaller sizes (4” x 8”, 3” x 6”)
 usuallystronger because smaller volume has fewer
defects in specimen
 usemore specimens because more variation and less
representative
 easeof handling, less accidental damage, less
concrete, smaller machine, less curing, & storage
space

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Split Tension Test
 To measure tensile strength

 about 10% of f'

c

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Flexural Strength
Important for pavements
Simply supported 6” x 6”
beam loaded on the 1/3
points

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Non-Destructive Tests

Rebound (Schmidt)
Hammer
 Measures energy
absorbed by concrete
 hardness of surface –
correlated to strength
 Not very accurate
 average of 10-12
readings in one area
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Penetration Resistance
(Windsor Probe)

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

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Ultrasonic Pulse Velocity

Transmitter, receiver, & clock

 piezoelectric crystals
 Velocity = distance / time
 faster = more dense like a
RR track
 cracks and weak spots are

slower
 Usually only used for finding
cracks and discontinuities
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Maturity Test
 Maturity is more than age since
hydration is a function of time &
temperature
 Maturity meter monitors
temperature over long periods

X-rays, wave refraction,

nuclear refraction, sonar,
radar
 Same principles as ultrasonic
velocity
 Darker areas are more dense
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 7.6 Some Alternative Concretes
 Self-Consolidating Concrete
 Highly flowable, nonsegregating concrete
 Can spread into place, fill the formwork, and
encapsulate the reinforcement, without any
mechanical consolidation

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

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

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Lightweight Concrete
 Floating concrete (ASCE concrete canoe)

 Costs more but need less because of

reduced weight
Heavyweight Concrete
 Massive walls for nuclear, medical, and

atomic shielding
 Very heavy weight aggregates (barite,

magnetite, hematite, lead, steel)

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

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Shrinkage Compensating
 Alumina causes a little expansion to
compensate for normal shrinkage
– Type K cement
Polymer Concrete
 Very quick set (1 hr.) or super high strength
( >20,000 psi)
 Polymer-PC concrete
– latex is mixed with Portland cement
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Fiber-reinforced Concrete
 Instead of rebar (for
corrosion) – becoming
more common
 Flexural strength increased
by up to 30%
 Reduces workability

 Steel, plastic, glass, etc.

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• Roller Compacted Concrete (RCC)

• No slump concrete compacted in-place by

heavy equipment
• Much cheaper for
many reasons
• Large dams
• Parking areas

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

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THANK YOU FOR YOUR
ATTENTION!!
..Have a Nice Day..

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