Concrete Methods and principles

Concrete ingredients

By

Moayyad Al Nasra, PhD,PE

.
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Concrete Ingredients
Aggregate
Fine Aggregate Course Aggregate

Cement Water Air Admixture

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AGGREGATES
Types by source / method of manufacture
The source refers to where obtained The method refers to how they are made

Natural Mineral Aggregates (Often Smooth) Sand Gravel / River Sand Manufactured Mineral Aggregates (Typically More Angular) Crushed Stone (Coarse Aggregate) Sand from Crushing Stone / Gravel Crushed Concrete or Clay Bricks / Blocks

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AGGREGATES
Types - size
Fine Aggregate: Passing No. 4 (4.75mm) and predominantly retained on No. 200 (0.075 mm), approximately 0.006 3/16 Course Aggregate: Predominantly retained on No. 4 (4.75mm), 3/16 3

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AGGREGATES
Types - Shape
Round : Disintegration and abrasion of rocks naturally

Angular: Usually from crushed stones, artificial crushing

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Aggregates
Types Unit Weight
Light weight: FA: < 70 pcf CA: < 55 pcf
Concrete: c =( 120 - 140 pcf )
Two types of Lightweight Aggregates: Natural (i.e. Pumice, volcanic rock)

Manufactured (i.e. Fly Ash, blast-furnace slag)

Normal-weight:
FA: < 105 pcf CA: < 95 pcf Concrete: c = (140 - 150 pcf)

Heavyweight: Variable Agg. Weight

(Heavy Rock / Steel) FYI: SGsteel 7.0

Concrete: c =( 150 - 400 pcf )

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AGGREGATES
Gradation: The gradual gradation in size from coarse to fine is a key property of aggregates. The effects are:
Workability Stability Drainage Frost resistance Others: mix proportioning, economy, porosity, durability, shrinkage, strength
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Types of Aggregate Gradation

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Aggregate Gradation
Normally Graded Aggregate is one that conforms to the grading limits specified by an agency such as ASTM. Open-Graded Aggregate has a particle-size distribution that results in large voids or void content. Dense-Graded Aggregate has a particle-size distribution that results in the least voids or lowest void content. Gaped-Grades Aggregate has a particle-size distribution that results in a missing some particle sizes

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AGGREGATES
Types of Aggregate Mixture
Aggregates with no fines. Its strength from grain-tograin contact of aggregate particles. Unstable, excellent drainage, completely non-frost susceptible. Fines just filling the voids of aggregate fraction. Its strength from grain-to-grain contact of aggregate particles. Stable base coarse material because of fine content, adequate drainage and can be non-frost susceptible. Fines overfilling the voids of aggregate fraction. Strength is from grain-to-grain contact of fines rather than the aggregate particles. Reduction in strength, poor drainage, very frost susceptible.
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Aggregate Mixture
Aggregates with no fines

Aggregates with just filling the voids Aggregates overfilling the voids
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Angularity and surface texture of aggregates

angular and rough aggregate

smooth aggregate river gravel

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AGGREGATES
Surface Texture Property Smooth Rough ___________________________________ Bond Strength Weaker Stronger Water Demand Less Higher W/C Less Higher Overall Strength Almost equal = Workability Good More Mortar
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AGGREGATES
Freezing and Thawing
Saturated aggregates of low porosity may accommodate pore-water freezing by simple elastic expansion. Saturated aggregates of moderate to high porosity may fail because the particle dimension exceeds a certain critical size or may cause failure in the paste immediately adjacent to the aggregate particle because of aggregate pore-water displacement

Aggregate

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AGGREGATES
Freezing and Thawing
The disruption of concrete by aggregates is a result of hydraulic pressures. The hydraulic pressure is a result of the degree of saturation (proportional to total void space filled with water) and permeability and size of the aggregate particles. Upon freezing, water expands 9 percent, and if the degree of saturation of the aggregate particles, 91.7 percent, water will be expelled into the paste surrounding the aggregate particle, and potentially destructive hydraulic pressure may develop there also. So the properties of paste, its permeability, air content, and porosity are also involved in the problem. Three additional factors; composition, texture, and structure, also play important roles in freezing and thawing of concrete.

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Properties of Aggregates

Properties of aggregate affect the properties of the products made from aggregate (i.e. Portland cement concrete, asphalt concrete, road subbase, railroad ballast) Some important aggregate properties are: specific gravity bulk density porosity voids absorption moisture content shrinkage gradation / fineness modulus (FM) Youngs modulus (E) compressive strength others: toughness, hardness, shape, texture, chemical reactivity
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Testing Aggregates
Sieve Analysis simplified procedure
Record empty weight of sieves Assemble sieve stack Place a known weight of aggregate in top sieve Shake sample with mechanical shaker Weigh each sieve with retained aggregate Perform calculations to produce gradation curves / fineness modulus Compare with ASTM specified grading limits Report will contain at least the following: 2 semi-log graphs (fine & coarse) containing ASTM limits and test sample 2 Tables (fine & coarse) Calculation of FM Calculation of % Passing Calculation of % Retained
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Testing Aggregates
Sieve Analysis Fineness Modulus
Fineness Modulus (FM) is a factor representative of the sieve analysis. It is a number obtained by adding the values of the percentages coarser than each sieve in the set and dividing by 100. For use in concrete, the FM ranges between 2.3 3.1. A higher FM means more coarse particles and less fine particles. A lower FM means more fine particles and less coarse particles. 4/13/2013 Concrete Methods and Principles,
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Testing Aggregates
Sieve Analysis Example
Sieve No. Sieve Size (mm) Wt of Sieve (g) Sieve + Mat (g) Wt Ret. (g) % Ret. % Coar. % Finer

3/8 4 8 pan
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19 12.5
9.5 4.75 2.36 0

350 350
350 340 340 300

400 600
650 630 440 400

50 250
300 290 100 10

5 25
30 29 10 1

5 30
60 89 99 100

95 70
40 11 1 0
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Sieve Analysis Example contd

Sample weight = 1000 g Add all the numbers in the column % coarser = 283 FM=283/100 = 2.83

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AGGREGATE UNIT WEIGHT

Oven dried condition

From ASTM C29: M = (G-T)/V

where: M = unit weight of aggregate (pcf) G = mass of aggregate and measure (lb) T = mass of measure (lb) V = volume of measure (ft3)
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AGGREGATE UNIT WEIGHT

(SSD Condition)

SSD = saturated surface dry This represents the state of moisture when all the pores of the aggregate are filled with water and the surface of the aggregate is dry. It is assumed in this state that neither water absorption nor water contribution to the surroundings (i.e. the concrete mix) occurs. From ASTM C29:
M,SSD = M [1 + (AB / 100)]

where:
M,SSD = unit weight of aggregate (pcf) AB = % absorption (ASTM C127)

AB = [(B A) / A] * 100 where:

A = weight of oven dry sample in air B = weight of SSD sample in air

* Equation also used for Absorption Content *

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AGGREGATE MOISTURE CONDITIONS

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AGGREGATE MOISTURE
CONTD

All aggregate has internal pores. Oven dry = no moisture present Air dry = some moisture (water) present in pores Saturated surface dry = all pores contain water; surface of aggregate is dry (no further absorption capacity) Wet = all pores filled with water and surface moisture present Moisture Content , MC, (%) MC = (WAGG with Moisture) (WAGG OD) * 100 WAGG OD Surface Moisture (%) SM = MC - AB
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AGGREGATE SPECIFIC GRAVITY

(SG)
Definition the ratio of the mass of a unit volume of material to the mass of the same volume of fresh water. In equation form, SG =,AGG / ,WATER, with ,WATER = 62.4 pcf
OR

W,AGG / (V,AGG * ,WATER) = W,AGG / W,WATER or Bulk SG = A / (B-C) where:

A = weight of OD sample in air B = weight of SSD sample in air C = weight of SSD sample in water

Bulk SGSSD = B / (B-C) Apparent SG = A / (A-C)

or or

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AGGREGATE SPECIFIC GRAVITY (SG) CONTD

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AGGREGATE SPECIFIC GRAVITY (SG) CONTD

The difference between B and C is the weight of water displaced by the solid part of the sample (= buoyancy force). Fb=Buoyancy Force, weight of displaced water B-C=B-(B-Fb)=Fb C-B+Fb=0, C=B-Fb
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VOID CONTENT
The space between aggregate particles % VOIDS = 100 [(S * W) M] / (S * W) where:
S = dry bulk SG W = density of water (62.4 pcf) M = unit weight of aggregate (pcf)

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CEMENT
Cement is made from a mixture of clay and calcareous materials. The essential ingredients are lime and silica, abundantly found in chalk ( or limestone) and clay. The silica- and calcareous-rich materials are mixed at around 1500 C (2732 F), which is one of the sources of carbon dioxide emission. The energy stored at 1500 C in cement is frozen in a chemical equilibrium state into clinkers phases of cement. The stored energy is released upon mixing with water to form cement paste.
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CEMENT
Cements are materials that exhibit characteristic properties of setting and hardening Groups
Hydraulic Cements: Ability to set and harden under water Non-hydraulic: Do not have the ability to set and harden under water, but requires air to harden
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Lime
Lime is a cementing material. It is produced by burning limestone ( Calcium Carbonates) with impurities to about 1800 F CaCO3 Heat CaO + CO2 Calcium Carbonate Calcium mono-oxide + Carbon di-oxide Quick lime) CaO + H2O Ca(OH)2 + Heat The setting of lime mortar is the result of the loss of water from the slaked lime Ca(OH)2 Ca(OH)2 + CO2 CaCO3 + H2O This results in the formation of calcium carbonate crystals, which bind the heterogeneous mixture into a coherent mass
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Pozzolan Cements
Siliceous or siliceous and aluminous material which possesses little or no cementitious value, but will react chemically with calcium hydrooxide at ordinary temperatures to form compounds possessing cementitious properties Artificial pozzolans include fly ash, boiler slag, and by-products from the treatment of bauxite ore. Pozzolan cements are manufactures by direct grinding of volcanic rocks or by calcining and grinding clays, shale, and diatomaceous earth.
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Portland Cements
Main Compounds of Portland Cement

Name of compound Tricalcium Silicate Dicalcium Silicate Tricalcium Aluminates Tetra calcium Aluminoferrite

Oxide Composition 3CaO.SiO2 2CaO.SiO2 3CaO.Al2O3 4CaO.Al2O3.Fe2O3

Abbreviation C3S C2S C3A C4Af

Minor compounds such as MgO, TiO2, MnO3, K2O and Na2O Raw Materials
Lime Silica Iron Oxide Alumina Gypsum (added after burning)
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Approximate Composition Limits of Portland Cement

Oxide CaO SiO2 Al2O3 FeO3 MgO SO3 Content, % 60-67 17-25 3-8 0.5-6.0 0.1-4.0 1-3
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Types of Portland Cement

Type I: No specific properties required Type IA: Air-entraining cement Type I Type II: Moderate sulfate resistance, moderate heat of hydration Type IIA: Air-entraining type ii cement Type III: High early strength Type IIIA: Air-entraining type iii cement Type IV: Low heat of hydration Type V: High sulfate resistance
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Special Portland Cements

White Portland Cement: is used for decorative displays. Low in iron and manganese. Colored Cements: used for decorative purposes, made by inter-grinding a chemically inert pigment such as metallic oxide in the amount of 3 to 10 percent to Portland cement. Oil-well Cement: Slow setting cement which are used to seal deep wells. Regulated Cement: rapid setting and hardening cements. They are used in the manufacture of blocks, pipes, prestressed, and pre-cast concrete, and for patch work. Waterproofed Cement: is a portland cement inter-ground with water repelled materials, such as calcium stearate. Hydrophobic Cement: similar to waterproofed cement, but with the purpose of the life of the cement during storage, or being transported to long distances. Antibacterial Cement: portland cement inter-ground with an antibacterial agent with the intention of reducing harmful micro-organisms. Barium and Strontium Cement: Portland cement in which the calcium oxide is replaced completely or in part by barium oxide or strontium oxide. Their purpose is to act as concrete shield in which the barium and strontium absorb x-rays and gamma rays.

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WATER
Water containing less than 2000 parts per million (ppm) of total dissolved solids can generally be used satisfactorily for making concrete. Water containing more than 2000 ppm of dissolved solids should be tested for its effect on strength and time of set.

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Impurities in Water
Alkali Carbonate and Bicarbonate: Different effects on setting times of different cement. Chloride: Possible effect of chloride ions on corrosion of reinforcing steel or pre-stressing strands. Concentrations of 20,000 ppm of sodium chloride are generally tolerable in concrete that will be dry in service and has low potential for corrosive reactions. Sulfate: Possible expansive reactions and deterioration by sulfate attach. 10,000 ppm is generally tolerable. Ion Salt: 40,000 ppm do not usually affect strength adversely. Inorganic Salts: Salts of magnesium, tin, zinc, copper, and lead in mixing water can cause significant reduction in strength and large variations in setting time
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Impurities in Mixing water continued

Seawater: Up to 35,000 ppm of dissolved solids is generally suitable as mixing water for unreinforced concrete. Sea water is not suitable for use in making steel reinforced concrete and should not be used for prestresses concrete. Acid Water: Acid waters with PH 3.0 or less may create handling problems and should be avoided. Sugar: Small amount of sucrose, as little as 0.03% to 0.15% by weight of cement, usually retard the setting of cement. Silt or suspended particles: 2000 ppm of suspended clay of fine rock particles can be tolerated.
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Air-Entrained Concrete Effects

Freeze-Thaw Resistance: Significantly improved by the use intentionally entrained air. Resistance to Deicers and Salts: Deicer scaling is believed to be caused by buildup of osmotic and hydraulic pressures in excess of normal hydraulic pressures produced when water in concrete freezes. Sulfate resistance: Improved Resistance to Alkali-Silica Reactivity: The reactivity is reduced through the use of air entrainment. Workability: Entrained air improves the workability.

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Recommended Air Contents

The amount of air to be used in air entrained concrete depends on:
Type of structure Climate conditions Number of freeze-thaw cycles Extent of exposure to deicers Extent of exposure to sulfates or other aggressive chemicals in soil or water
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ADMIXTURE Classified by Function

Air-entraining: Improve durability in environment of freeze-thaw, deicers, sulfate, and alkali reactivity. Also improves workability. Material (salts of wood resinVinsol resin, some synthetic detergents, salts of sulfonated lignin, fatty and resinous acids and their salts, ) Water-reducing: Reduce water demand. Material (lignosufonates, Hydroxylated carboxylic acids, carbohydrates, ) Retarding: Retard setting time. Material (lignin, borax, sugar, tartaric acid and salts, ) Accelerating: Accelerate setting time and early-strength development. Material (Calcium cloraide, triethanolamine, sodium thiocyanate, calcium formate, calcium nitrite, calcium nitrate, )

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Admixture: Classified by Function Continued

Superplasticiers: Flowing concrete, reduce water-cement ratio. Material (sulfonated melamine formaldehyde condensates, sulfonated naphthalene formaldehyde condensate, lignosulfonates) Finely divided mineral: Partial cement replacement, improves workability, plasticity, sulfate resistance, reduce alkali reactivity, permeability, heat of hydration, filler. Material (ground granulated blast-furnace slag, pozzolans diatomaceous earth, opaline cherts, clays, shale, volcanic tuffs, pumicites, fly ash, silica fume, ) Miscellaneous admixtures: Bonding, damp-proofing, permeabilityreducing, grouting, gas-forming, coloring, corrosion inhibiting, and pumping admixture. Material (bonding rubber, polyvinyl chloride, poly vinyl acitate,, damp-proofing soaps of calcium or ammonium stearate or oleats, butyl stearate, , permeability reducer silica fume, fly ash, , gas former aluminum powder, , coloring modified carbon black, iron oxide, phthalocyanin, umber, , , )
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Major reason for using admixtures

Reduce the cost of concrete construction Achieve certain properties in concrete Ensure quality in adverse weather conditions Overcome certain emergencies during concreting operation

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