Gambella University

Department of Civil Engineering

Construction Material

Chapter Three (B) - Concrete

1
FRESH
CONCRETE

2
FRESH CONCRETE
• Fresh concrete is also known as plastic
concrete.
• The major Properties of concrete in its
plastic state are:
(1) workability,
(2) consistency,
(3) segregation,
(4) bleeding and
(5) Stiffening and Setting .
3
PROPERTIES OF FRESH CONCRETE

1. Workability
• Workability is ease (move gently) of placing and
resistance to segregation of concrete.
• Factors that affect workability are:
• Water content
• shape of aggregates
• Grading of Aggregates
• Size of Aggregates
• Surface Texture of Aggregates
• Air entraining Agents.
4
PROPERTIES OF FRESH CONCRETE …Cont.

• If water content is increased in the concrete:

• mix particles settle and bleeding occurs.
• cement slurry can escape through joints of
form works.
• Large sizes of aggregates consume less quantity
of water and less quantity of cement, and are
therefore economical.
• Appropriate sizes depend on handling, mixing
and placing equipment, thickness of section and
enforcement.
5
PROPERTIES OF FRESH CONCRETE …Cont.

• Angular shape, flakiness, and elongation of

aggregates reduce workability.
• Non­-absorbent aggregates and optimum
percentage of fine aggregate contributes to
workability.
• In concrete mass, air entraining agents
produce numerous air bubbles that act as
rollers to decrease bleeding and
segregation, and as a result increase
workability. 6
PROPERTIES OF FRESH CONCRETE …Cont.

2. Consistency
• refers to ease of flow of concrete and indicates
wetness of concrete, and thus workability.
• Concrete could have dry, plastic, semi-fluid, and
fluid consistency.
• Concrete of plastic consistency can be shaped into
ball, while that of semi-fluid consistency spreads
out slowly and with out segregation of aggregate.
• Concrete of fluid consistency spreads out fast and
results in segregation of aggregates, and hence
unacceptable.
7
PROPERTIES OF FRESH CONCRETE …Cont.

MEASUREMENT OF WORKABILITY

• The methods of measuring workability

that is wetness or fluidity are:
i. slump test and
ii. compacting factor test.
8
PROPERTIES OF FRESH CONCRETE …Cont.

Slump Test
• Slump is the subsidence of concrete cone after
mold is lifted up.
• Slump test is made in laboratory and on site to
measure subsidence of a pile of concrete in a
mold (slump test apparatus of dimensions:
– base = 20 cm,
– top diameter = 10cm ,and
– height =30 cm.)
– compacted with a steel rod
(16 mm long and 6Ocm long).
9
PROPERTIES OF FRESH CONCRETE …Cont.

Standard Size of slump cone

10
PROPERTIES OF FRESH CONCRETE …Cont.

• 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..

11
PROPERTIES OF FRESH CONCRETE …Cont.

• Permissible slumps for concrete mix are given as

standard for different types of construction
activities and placing conditions.
• The slump values shall be referred before using the
concrete mix.

12
PROPERTIES OF FRESH CONCRETE …Cont.

• Slump test gives the advantage of detecting water

content of successive batches of concrete of
identical mix.
• However, there are some limitations of slump
test. These are:­
• Not applicable for aggregates size greater than 40
mm.
• Applicability to plastic mixes only
• Not applicable to harsh and wet mixes

13
Process of measuring the slump of fresh
concrete

Measure the
slump

Trim the
concrete

Remove the
cone slowly
14
some examples of different measures of
slump

True slump Collapse slump

15
This drop in height is the slump measure of the degree of
workability of the mix.

16
• Preparation of test
• Procedure ….
Refer from manual

17
PROPERTIES OF FRESH CONCRETE …Cont.

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.
Compaction factor test
apparatus 18
PROPERTIES OF FRESH CONCRETE …Cont.

Compacting Factor = Weight of partially dry compacted concrete

Weight of fully compacted concrete

Table. Permissible Values of Compacting Factor

Workability Compacting factor

Good workability 0.95

Medium Workability 0.92
Low workability 0.85
19
PROPERTIES OF FRESH CONCRETE …Cont.

• For different placing conditions, degree of

workability (extremely low, very low, medium,
and high), and aggregate sizes, corresponding
values of Compacting factor are given as
standard to compare with.
• For compacting factor values between 0.75-0.80,
compacting concrete by had 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. 20
PROPERTIES OF FRESH CONCRETE …Cont.

3. Segregation or separation of coarse aggregates from

the mass of concrete results from: ­
• Uncontrolled pumping or falling
• Placing under waters
• Placing concrete in heavily reinforced members

Precautions to control segregation: ­

• Careful handling, placing, and consolidation of concrete
• Placing concrete near its final position, instead of falling
from greatest heights
• Applying air entraining agents
21
PROPERTIES OF FRESH CONCRETE …Cont.

4. Bleeding:
• is the appearance of water on concrete surface.
• As a consequence of bleeding, slum layer will be
formed making concrete weak and porous.
• Slum layer shall be removed before casting new
layer.
Measures to minimize bleeding: ­
• Using well graded and proportioned aggregates
• Increasing amount of cement
• Applying air entering agents
• Reducing amount of water
22
PROPERTIES OF FRESH CONCRETE …Cont.

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 while high
temperature accelerates the stiffening of
concrete.

23
Transportation of Fresh Concrete
i. Pans
ii. Wheel barrows
- When quantity is small
- When access to work is restricted - Moderate distance and
- Method is tedious, slow and costly
medium quantities

24
iii. Truck mixer …cont.
 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
25
…cont.
iv. 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

Chute

26
…cont.
v. 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

27
…cont.
vii. Helicopter transporting
vi. Belt conveyors

- When the concrete is to be

transported continuously
and to a higher level

- Could be a single unit or in

series
- Installed in an inclined
position 28
Placing of fresh 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)

29
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.

30
Compaction of Concrete …cont.
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. 31
Compaction of Concrete …cont.
Stages of Compaction
Compaction of concrete is a two-stage process.
1. First the aggregate particles are set in motion and slump to fill the
form giving a level top surface.
2. In the second stage, entrapped air is expelled.

32
Compaction of Concrete …cont.
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

33
Compaction of Concrete …cont.
Methods of compaction

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

34
Compaction of Concrete …cont.
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 Immersion Vibrator
mm. 35
Compaction of Concrete …cont.

Notes:
 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.
36
Compaction of Concrete …cont.
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.

37
Compaction of Concrete …cont.

Surface Vibrators
 Surface vibrators are
applied to the top surface
of concrete and act
downwards from there.
 They are very useful for
compacting slabs,
industrial floors, road
pavements, and similar
flat surfaces.
 They also aid in leveling
and finishing the surface.
Surface Vibrator
38
Compaction of Concrete …cont.
Consequences of Improper Vibration

(1) Honeycomb:
 results when the
spaces between
coarse aggregate
particles do not
become filled with
mortar.

39
Compaction of Concrete …cont.

(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.
(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.
40
Compaction of Concrete …cont.
Defects from over vibration :
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.
NB: Under vibration is more often a problem than
over vibration
41
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.

42
Curing …cont.
• Providing sufficient water to facilitate a proper curing process has
a significant impact on the quality of the concrete.
• Concrete which is allowed to dry out immediately after being
poured will only achieve 40 % of the strength it could reach if
properly cured.
• By providing proper water curing for three days will increase the
strength to more than 60 % of its full potential.
• This process continues over time reaching 95 % after 28 days.

43
Curing …cont.
Concrete can be kept moist 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.

Fogging Sprinkling 44
Curing …cont.
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 Plastic Sheets
with
 impervious paper or
 plastic sheets, or
 by applying membrane-
forming curing compounds.
45
Curing …cont.
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.
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
46
e a k
ea Br
T

47
HARDEN
CONCRETE

48
PROPERTIES OF HARDENED CONCRETE

 The compressive strength of concrete is usually at

least ten times its tensile strength, and five to six
times its flexural strength.
 The principal factors governing compressive
strength are given below:
• Water-cement ratio
• The age of the cured concrete
 Concrete gradually builds strength after mixing
due to the chemical interaction between the
cement and the water.
49
PROPERTIES OF HARDENED CONCRETE … cont.

 It is normally tested for its 28 day strength, but

the strength of the concrete may continue to
increase for a year after mixing.
 Air entrainment, the introduction of very small
air voids into the concrete mix, serves to greatly
increase the final product's resistance to
cracking from freezing-thawing cycles.
 Most outdoor structures today employ this
technique.

50
PROPERTIES OF HARDENED CONCRETE … cont.

The final strength of the finished concrete depends

on:
1. The proportions of the components
(i.e. whether the correct quantities of gravel,
sand, cement and water have been used)
2. The quality of the components
3. The distribution of the grain sizes of the gravel and
sand
4. The way the components are mixed
5. The way the mixture is transported, placed,
compacted and cured
51
PROPERTIES OF HARDENED CONCRETE … cont.
Hardened Concrete
1. Strength
i. Compressive strength
ii. Tensile strength
iii. Flexural strength
iv. Shear strength
2. Permeability
3. Durability
i. Weathering including disruption due to freezing and
thawing
ii. Mechanical wear  abrasion, wear,
iii. Chemical corrosion
- Sea water
- Sewage
- Acids- 52
PROPERTIES OF HARDENED CONCRETE … cont.
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).
53
Sulfate attack

54
Corrosion

55
Corrosion

56
CONCRETE
MIX DESIGN

57
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.
Goals:  Provide good durability
 Maximize strength  use well graded
 minimize water aggregates
 control bleeding & segregation  maximize void packing
 Reduce Cost
 reduced segregation
 use largest gravel possible for
the job
 minimize paste requirement 58
MIX DESIGN …cont.
Information required for mix design
The following information for available
materials will be useful:
 Sieve analyses of fine and coarse aggregates.

 Unit weight of coarse aggregate.

 specific gravities and absorption of aggregates.
 Specific gravity of Portland cement and other
cementations materials, if used.
59
EBCS
MIX DESIGN
METHODS

DOE ACI
60
EBCS MIX Design; Refer EBCS 2, 1995

61
EBCS MIX Design …cont.
Example
• Prepare 10 liter concrete and determine the
workability of the concrete by concrete slump test.
(use C-15) Based on EBCS-2, 1995 (standard mixes
for ordinary structural concrete per 50 k.g bag of
cement.)
– C-15
– Coarse aggregate size 20mm
– Workability = medium
– Cement = 50k.g
– Total aggregate = 320k.g
– Fine aggregate 30%-50% -------- take 40%
– Total volume of concrete = 0.178m3
62
EBCS MIX Design …cont.
Solution:
Fine aggregate 30%-50% -------- take 40%
i.e. F.A = 40*320/100
= 128k.g
C.A = Total aggregate – fine aggregate
= 320 – 128
= 192 k.g
Volume of the required concrete is
1m3 = 1000 lt
? = 10 lt
The required volume of concrete = 0.01m3
So, for 0.178 m3 volume of concrete 50 kg cement, 128 kg sand and
192 kg aggregate is used. Based on this information we can determine
the amount of cement, sand, and aggregate for 0.01m3 volume of
concrete. 63
EBCS MIX Design …cont.

Cement Sand Aggregate

0.178m3 = 50 k.g 0.178m3 = 128 0.178m3 = 192 k.g
0.01 m3 = ? k.g 0.01 m3 = ?
= 2.8 k.g 0.01 m3 = ? = 10.8 k.g
= 7.2 k.g

Therefore, for 0.01m3 volume of concrete use 2.8 k.g

cement, 7.2 k.g sand, and 10.8 k.g coarse aggregate.

64
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

65
ACI Mix Design Method …Cont.

Nominal maximum First estimate of concrete unit mass,

size of aggregate kg/m3
Non-air entrained Air entrained
concrete concrete
9.5 2280 2200
12.5 2310 2230
19 2345 2275
25 2380 2290
37.5 2410 2350
50 2445 2345
75 2490 2405
150 2530 2435
66
ACI Mix Design Method Steps:
Step 1. Choice of slump
• If slump is not specified, a value appropriate for the
work can be selected from the below Table which is
reproduced from the text book below*, (note that the
table numbers are given from the text book rather
than the ACI standard).

67
ACI Mix Design Method Steps …Cont.

Step 2. Choice of maximum size of aggregate

• Large maximum sizes of aggregates produce less voids
than smaller sizes.
• Hence, concretes with the larger-sized aggregates
require less mortar per unit volume of concrete, and of
coarse it is the mortar which contains the most
expensive ingredient, cement.
• Thus the ACI method is based on the principle that the
MAXIMUM SIZE OF AGGREGATE SHOULD BE THE LARGEST
AVAILABLE SO LONG IT IS CONSISTENT WITH THE DIMENSIONS
OF THE STRUCTURE.

68
ACI Mix Design Method Steps …Cont.

• In practice the dimensions of the forms or the

spacing of the rebar's controls the maximum CA size.
• ACI 211.1 states that the maximum CA size should
not exceed:

Special Note: When high strength concrete is desired, best results may be obtained with
reduced maximum sizes of aggregate since these produce higher strengths at a given w/c
ratio.
69
ACI Mix Design Method Steps …Cont.

Step 3. Estimation of mixing water and air content

• The ACI Method uses past experience to give a first
estimate for the quantity of water per unit volume of
concrete required to produce a given slump.
• In general the quantity of water per unit volume of
concrete required to produce a given slump is dependent
on:
– the maximum CA size,
– the shape and grading of both CA and FA,
– as well as the amount of entrained air.
• The approximate amount of water required for average
aggregates is given in Table below.
70
ACI Mix Design Method Steps …Cont.

Table:10.2: Approximate Mixing Water and Air Content

Requirements for Different Slumps and Maximum Aggregate Sizes.

71
ACI Mix Design Method Steps …Cont.

Step 4. Selection of water/cement ratio

• The required water/cement ratio is determined by
strength, durability and finish ability.
• The appropriate value is chosen from prior testing of a
given system of cement and aggregate or a value is
chosen from Table 10.3 and/or Table 10.4.

72
ACI Mix Design Method Steps …Cont.

Step 5. Calculation of cement content

• The amount of cement is fixed by the
determinations made in Steps 3 and 4 above

73
ACI Mix Design Method Steps …Cont.
Step 6. Estimation of coarse aggregate content
• The most economical concrete will have as much as
possible space occupied by CA since it will require
no cement in the space filled by CA.
Table 10.8. Estimation of coarse aggregate content

74
ACI Mix Design Method Steps …Cont.

Step 7. Estimation of Fine Aggregate Content

• At the completion of Step 6, all ingredients of the
concrete have been estimated except the fine
aggregate.
• Its quantity can be determined by difference if the
“absolute volume” displaced by the known ingredients-,
(i.e., water, air, cement, and coarse aggregate), is
subtracted from the unit volume of concrete to obtain
the required volume of fine aggregate.
• Then once the volumes are know the weights of each
ingredient can be calculated from the specific gravities.

75
ACI Mix Design Method Steps …Cont.

Step 8. Adjustments for Aggregate Moisture

• Aggregate weights. Aggregate volumes are calculated based
on oven dry unit weights, but aggregate is typically batched
based on actual weight. Therefore, any moisture in the
aggregate will increase its weight and stockpiled aggregates
almost always contain some moisture. 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 oven dry or
air 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.
76
ACI Mix Design Method Steps …Cont.

Step 9. Trial Batch Adjustments.

• The ACI method is written on the basis that a
trial batch of concrete will be prepared in the
laboratory, and adjusted to give the desired
slump, freedom from segregation, finish ability,
unit weight, air content and strength.

77
ACI Mix Design Method Steps …Cont.

Example 1 ACI Mix Design

Concrete is required for an exterior column to be
located above ground level in an area where it will be
wet and subjected to substantial freezing and thawing.
The concrete is required to have an average 28-days
compressive strength of 30 Mpa. For the condition of
placement, the slump should between 75 and 100
mm. The column is 625mm square with a minimum
clear space for aggregate of 50 mm.
The properties of the materials are as follows:

78
ACI Mix Design Method Steps …Cont.
• Cement • Coarse aggregate
– Type I – Maximum size = 19 mm
– Specific gravity = 3.15 – Bulk specific gravity (SSD) =
• Fine aggregate 2.68
– Bulk specific gravity (SSD) = – Absorption capacity = 1 %
2.63 – Surface moisture = 0.5 %
– Absorption capacity = 1.3 % based on SSD state
– Surface moisture = 4.2 % – Dry-rodded unit weight =
based on SSD state 1600 kg/m3
– Fineness modulus = 2.7

The sieve analysis of the coarse and fine aggregate fall within the
limits specified in ASTM C 33. with this information, the mix design
will now be carried through in detail, using the sequence of steps
outlined. 79
ACI Mix Design Method Steps …Cont.
Solution
Step 1: required material information
 This is already given
Step 2: choice of slump
 The slump is also given (refer the table)
Step 3: maximum aggregate size
 the maximum aggregate size = 19 mm
Step 4: Estimating of mixing water and air content
 Since the concrete will be exposed to freezing and thawing,
it must be air entrained. From the table the air content
recommended for severe exposure is 6.0 %; the water
requirement is 180 kg/m3
80
ACI Mix Design Method Steps …Cont.

Step 5: Water/cement ratio

 From the table 10.3 the (conservative) estimate of the
required w/c ratio to give a 28-day compressive strength of
30 Mpa is 0.45. this does not exceed the limits based on
durability in table 10.4.
Step 6: Calculation of cement content
 The required cement content, based on the results of
step 4 and 5, is 180/0.45 = 400kg/m3
Step 7: Estimation of coarse aggregate content
 Interpolating in table 10.8 for the fineness modulus of the
fine aggregate of 2.7, the volume of dry-rodded coarse
aggregate per unit volume of concrete is 0.63. Therefore,
the coarse aggregate will occupy 0.63 m3/m3.
81
ACI Mix Design Method Steps …Cont.

• The OD weight of the coarse aggregate is

0.63*1600 = 1008 kg.
• The SSD weight is
1008*1.01 = 1018 kg.
Step 8: Estimation of fine aggregate content
 The fine aggregate content can be
established either by mass (weight)
method or by the volume method.
82
ACI Mix Design Method Steps …Cont.

 Mass (weight) method:

 The estimated concrete weight is 2280 kg/m3.
 The weight already determined are;
 Water = 180 kg
 Cement = 400 kg
 Coarse aggregate (SSD) = 1018 kg.
Therefore, the weight of the fine aggregate (SSD) is
2280 – 180 – 400 – 1018 = 682 kg

83
ACI Mix Design Method Steps …Cont.

 Volume method:
 Knowing the weights and specific gravity of water,
cement, and coarse aggregate and knowing the air
volume, we can calculate the volume per m3
occupied by the different ingredients:
 Water = 180 /1000 = 0.18 m3
 Cement = 400/ (1000*3.15) = 0.127 m3
 Coarse aggregate = 1018/ (1000*2.68) = 0.379 m3
 Air = 6/100 = 0.06 m3
Total = 0.18 + 0.127 + 0.379 + 0.06 = 0.746
Therefore, the fine aggregate must occupy a volume of
1-0.747 = 0.253 m3
84
ACI Mix Design Method Steps …Cont.
Example 2 ACI Mix Design
Calculate the weight of all material required for the first
trial mix on the air entrained concrete details of which
are given below. Use ACI methods:
 Characteristic strength at 28 days = 40 N/mm2
 Coarse aggregate:
 Max. size = 20 mm
 Rodded bulk density = 1600 kg
 Rel. density = 2.65
 Fine aggregate:
 Fineness modulus = 2.40
 Rel. density = 2.5
 Air content = 3 %
 Slump = 25-50 mm 85
Solution
Step 1: Choice of slump
 50 mm, which mean between 25 and 75 mm
Step 2: Maximum aggregate size
 Max. size = 20 mm
Step 3: Estimation of mixing water and air content
 By interpolating (air entrained)
19 mm = 168
20 mm = x X = 167 kg/m3
25 mm = 160
Step 4: Selection of water cement ratio
 For 40 Mpa (air entrained) = 0.34
86
Solution ….Cont.
Step 5: Calculation of cement content
Cement content = 167 kg/m3 = 491 kg/m3
0.34
Step 6: Estimation of coarse aggregate content
 FM of sand = 2.40
By interpolating for 20 mm
19 mm = 0.66
20 mm = x X = 0.67
25 mm = 0.71
Coarse aggregate = 0.67 * 1600
= 1072 kg/m3

87
Solution ….Cont.

Step 7: Estimation of fine aggregate

 Estimated concrete unit mass (air entrained concrete) for 20 mm by
interpolating.
19 mm = 2275
20 mm = x X = 2277.5 kg/m3
25 mm = 2290
Therefore, F.A = 2277.5 – (167+491+1072)
= 547.5 kg/m3

• Mass (weight) method

– Water = 167 kg/m3
– Cement = 491 kg/m3
– Coarse aggregate = 1072 kg/m3
– Fine aggregate = 547.5 kg/m3 88
Solution ….Cont.

• Volume method
 Water = 167/1000 = 0.167 m3
 Cement = 491/(3.15*1000) = 0.155 m3
 Coarse aggregate = 1072/(2.65*1000) = 0.404 m3
 Air = 3/100 = 0.03 m3
 Fine aggregate = 547.5/(2.50*1000) = 0.235 m3
OR
• F.A = 1- (0.167+0.155+0.404+0.03)
= 0.244 m3

89
DOE Standard Mix Design Method
• The standard DOE mix design procedure can be
divided into 5 basic steps:
Step 1
1.1. characteristic strength
1.2. standard deviation
1.3. margin
1.4. target mean strength
1.5. cement strength class
1.6. aggregate type
1.7. free w/c ratio
1.8. maximum free w/c ratio

90
DOE mix design method …cont.
Step 2
2.1. slump or vebe time
2.2. maximum aggregate size
2.3. free-water content
Step 3
3.1. cement content
3.2.maximum cement content
3.3. minimum cement content
3.4. modified free-water/cement ratio
Step 4
4.1. relative density of aggregate
4.2. concrete density
4.3. total aggregate content
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DOE mix design method …cont.

Step 5
5.1. grading of fine aggregate
5.2. proportion of fine aggregate
5.3. fine aggregate content
5.4. coarse aggregate content

Finally, specify quantities of cement, water, fine

aggregate, coarse aggregate (10,20,40 mm) per m3
and then convert to trial mix of the required m3.

92
DOE mix design figures and tables
1.1. Characteristic strength ---(Specified)
1.2. Standard deviation (SD)

93
DOE mix design figures and tables …cont.
1.3. Margin (calculated or specified)

M=kxs
Where: M = the margin (Item 1.3)
k = a value appropriate to the ‘percentage
defectives’ permitted below the characteristic strength
(see 4.4)
s = the standard deviation.
4.4. margin for mix design
• k for 10% defectives = 1.28
• k for 5% defectives = 1.64
• k for 2.5% defectives = 1.96
• k for 1% defectives = 2.33
94
DOE mix design figures and tables …cont.

1.4. Target mean strength

fm = fc+ M or fm = fc+ ks
Where: fm= the target mean strength
fc = the specified characteristic strength
M = the margin
k = a constant
s = the standard deviation

where x = an individual result

n = the number of results
m= the mean of the n results
95
DOE mix design figures and tables …cont.

Example
For the 5% defective level
specified in BS 5328, k = 1.64
and thus fm= fc + 1.64s. Figure 1
relates to a concrete having a
specified characteristic strength
of 30 N/mm2 and a standard
deviation of 6.1 N/mm2. Hence:
Target mean strength (fm)
fm = 30 + (1.64 *6.1)
= 30 + 10
= 40 N/mm2
96
DOE mix design figures and tables …cont.

1.5. Cement strength class (specified)

• 42.5 or 52.5 … or
• OPC, PPC, RHPC…
1.6. Aggregate type
• Coarse aggregate
– Crushed or
– Uncrushed
• Fine aggregate
– Crushed or
– Uncrushed
97
DOE mix design figures and tables …cont.
1.7. Free-
water/cement
ratio

1.8. Max. free

w/c ratio
(specified)

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DOE mix design figures and tables …cont.
2.1. Slump (specified)
2.2. Max. aggregate size (specified)
2.3. Free-water content (table 3)
Note:
when CA & FA of different types
are used, the free-water content
is estimated by the expression:

Where:
Wf = free-water content appropriate
to type of fine aggregate and
Wc = free-water content appropriate
to type of coarse aggregate.
99
DOE mix design figures and tables …cont.

3.1. Cement content

3.2. Maximum cement content (specified)

3.3. Minimum cement content (specified)
Use 3.1 if < 3.2
Use 3.3 if > 3.1

100
DOE mix design figures and tables …cont.

4.1. Relative
density of
aggregate
(SSD)
(known)

4.2.
Concrete
density
(fig. 5)

Fig. 5 Estimated wet density of fully compacted

101
concrete
DOE mix design figures and tables …cont.

4.3. Total aggregate content

Total aggregate content = D—C—W
(saturated and surface-dry)

Where:
D = the wet density of concrete (kg/m3)
C = the cement content (kg/m3)
W = the free-water content (kg/m3)

102
DOE mix design figures and tables …cont.
5.1. Grading of fine aggregate
(percentage passing 600 micro sieve (%))
5.2. Proportion of fine aggregate (fig. 6)

103
DOE mix design figures and tables …cont.

104
DOE mix design figures and tables …cont.

105
DOE mix design figures and tables …cont.

5.3. Fine aggregate content

F.A content =
(total aggregate content) x (proportion of
fines)
5.4. Coarse aggregate content
C.A content =
(total aggregate content) — (fine aggregate
content)
106
DOE mix design method …cont.
Example 1- unrestricted design
 The following requirements are specified and thus
entered under the relevant item on the mix design
form, as shown in Table 4.
1. Characteristic compressive strength, 30 N/mm2 at 28
days, with a 2.5% defective rate (k = 1.96) ……...Item 1.1
2. Portland cement class 42.5 ……………………….…….Item 1.5
3. Slump required, 10–30 mm ……………………….……Item 2.1
4. Maximum aggregate size, 20 mm ………………..…..Item 2.2
5. Maximum free-water/cement ratio, 0.55 ………….Item 1.8
6. Minimum cement content, 290 kg/m3 ……………..Item 3.3
107
108
109
DOE mix design method …cont.

Example 2 - mix restricted by max. w/c ratio

The following requirements are specified and thus entered under the relevant
item on the mix design form, as shown in Table 5:
1. Characteristic comp. strength, 25 N/mm2 at 28 days .......Item 1.1
2. Portland cement class 42.5 …………………………………..…….…Item 1.5
3. Slump required, 30–60 mm …………………………………….….…Item 2.1
4. Maximum aggregate size, 40 mm …………..........................Item 2.2
5. Maximum free-water/cement ratio, 0.50 ……………………….Item 1.8
6. Minimum cement content, 290 kg/m3 ……………………….…Item 3.3
7. There are no previous control data but a margin of 10 N/mm 2
8. Aggregate type, uncrushed …………………………………………….Item 1.6
9. Aggregate relative density, 2.5 ………………………………………..Item 4.1
10. Fine aggregate, 90% passing a 600μm sieve …………………….Item 5.1

110
DOE mix design method …cont.

111
DOE mix design method …cont.

112
DOE mix design method …cont.
Example 3 – air entrained, using crushed and uncrushed aggregate
 This example deals with the case of designing an air-entrained concrete mix using a
crushed coarse aggregate with an uncrushed fine aggregate.
 The following requirements are specified and thus entered under the relevant item
on the mix design form, as shown in Table 8:
1. Characteristic compressive strength, 30 N/mm at 28 days, 1% defective rate
2 (k = 2.33)
……………………………………………………………………………….………Item 1.1
2. Portland cement class 42.5 ………………………………………………….Item 1.5
3. Slump required, 25 mm ………………………………………….…………….Item 2.1
4. Maximum aggregate size, 20 mm …………………………………….………Item 2.2
5. Maximum free-water/cement ratio, 0.55 …………………………………..Item 1.8
6. Minimum cement content, 285 kg/m2 ………………………………………Item 3.3
7. Air content, 4.5%............................................................................ Item 1.4.1
8. Previous control data gave a standard deviation of 5 N/mm2
9. Aggregate type: coarse, crushed
fine, uncrushed …………………………………………………Item 1.6
10. Aggregate relative density, 2.65 …………………………………………………..Item 4.1
11. Fine aggregate, 50% passing a 600 μm sieve ……………………………………Item 5.1
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DOE mix design method …cont.

114
DOE mix design method …cont.

115
IN DETAIL, REFER THE DOE
MIX DESIGN MANUAL…

116
End of Chapter
Three!!

117