Designing and Proportioning

Concrete Mixtures
Design and Control of Concrete Mixtures – Chapter 12
Overview
 Mix Design
 Proportioning
 Concrete for Small Jobs
 Mixture Review
Designing and Proportioning
Concrete Mixtures
Designing and
Proportioning
Concrete Mixtures
Mix Design
 Characteristics selected based on:
 Intended use
 Exposure conditions
 Dimensions of elements
 Required physical properties
 Strength and durability
Water-
Cementitious
Materials Ratio
Aggregates
Air Content
Slump
 Measures mixture specific consistency
 No correlation between different mixtures
 Specified as a range or not-to-exceed value
 Examples:
 Mechanical paving: 25-75 mm (1-3 in.)
 Floors: 75-125 mm (3-5 in.)
 Walls/foundations: 100-200 mm (4-8 in.)
Water Content
Cementing Materials Content
Cementing Materials Content
Chemical Admixtures
Proportioning

Discussed later
Proportioning
 Equation 1: cr= c + 1.34S
 Equation 2: cr= c + 2.33S – 3.45 (MPa)
 Equation 2: cr= c + 2.33S – 500 (psi)
 Equation 3: cr= 0.90 c + 2.33S

 Larger of Eq. 1 or 2 for c ≤ 35 MPa (5000 psi)

 Larger of Eq. 1 or 3 for c > 35 MPa (5000 psi)
Proportioning
Proportioning
 Trial-mixture method – used when field test
records are insufficient
 3 mixtures made to produce a range of
strengths.
 Based on w/cm or cementitious content
 Strength results plotted vs. w/cm to produce
a curve
Measurements and Calculations
Example 1: Absolute Volume Method
(Metric)
 Givens:
 Severe freeze-thaw environment
 c = 35 MPa at 28 days
 Air-entrained concrete
 Slump of 25-75 mm
 Nom. Max. Size Aggregate = 25 mm
 No statistical data available
Example 1: Absolute Volume Method
(Metric)
 Available materials:
 Type GU cement per ASTM C1157
 Well-graded, 25-mm, rounded gravel
 Relative density = 2.68, absorption = 0.5%, bulk
density = 1600 kg/m3, moisture content = 2%

 Natural sand
 Relative density = 2.64, absorption = 0.7%,
moisture content = 6%, fineness modulus = 2.80
Example 1: Absolute Volume Method
(Metric)
 Available materials:
 Wood-resin type air-entraining admixture
 Water-reducer – 10% reduction
Example 1: Absolute Volume Method
(Metric)
 No statistical data: cr = c + 8.5 MPa = 43.5 MPa
 W/cm = 0.31
 Batch for 8% air
 Target slump = 75 mm
 Water content = 175 kg/m3 - 25 kg/m3 (rounded
gravel) – 10% (water-reducer) = 135 kg/m3
Example 1: Absolute Volume Method
(Metric)
 Cement content = 135 kg/m3 / 0.31 = 435 kg/m3
 Bulk volume of coarse aggregate = 0.67
 OD mass (C.A.) = 0.67*1600 kg/m3 = 1072 kg
 AE admixture = 0.5 g/kg of cement for 8% air content
 0.5 g/kg * 435 kg = 218 g AE admixture
 WR admixture = 3 g/kg
Example 1: Absolute Volume Method
(Metric)
 Volumes:
 Water = 135 / 1 x 1000 = 0.135 m3
 Cement = 435 / 3.0 x 1000 = 0.145 m3
 Air = 8.0 / 100 = 0.080 m3
 Coarse aggregate = 1072 / 2.68 x 1000 = 0.4 m3
 Total volume of known ingredients = 0.760 m3
 Fine aggregate = 1 – 0.76 = 0.24 m3
 Fine aggregate mass: 0.24 x 2.64 x 1000 = 634 kg
Example 1: Absolute Volume Method
(Metric)
 Water 135 kg, Cement 435 kg
 Coarse aggregate (dry) 1072 kg, Fine aggregate
(dry) 634 kg
 Total mass 2276 kg
 Air-entraining admixture 0.218 kg, Water reducer
1.305 kg
 Slump 75 mm, Air content 8%
 Estimated concrete density= 135 + 435 + (1072 x
1.005) + (634 x 1.007) = 2286 kg/m3
Example 1: Absolute Volume Method
(Metric)
 Moisture corrections:
 Coarse aggregate (2% MC): 1072 x 1.02 =
1093 kg
 Fine aggregate (6% MC): 634 x 1.06 = 672
kg
 Water: 135 – (1072 x 0.015) – (634 x 0.053)
= 85 kg
Example 1: Absolute Volume Method
(Metric)
 First trial batch:
 Water 85 x 0.1 = 8.5 kg
 Cement 435 x 0.1 = 43.5 kg
 Coarse aggregate (wet) 1093 x 0.1 = 109.3 kg
 Fine aggregate (wet) 672 x 0.1 = 67.2 kg
 Total 228.5 kg
 Air-entraining admixture 218 g x 0.1 = 21.8 g or
21.8 mL
 Water reducer 1305 g x 0.1 = 130 g or 130 mL
Example 1: Absolute Volume Method
(Metric)
 First trial batch results:
 Slump = 100 mm
 Air content = 9%
 Density = 2274 kg/m3
 0.5 kg of water held back (129 kg effective)
 Yield = 228.0 kg / 2274 kg/m3 = 0.10026 m3
Example 1: Absolute Volume Method
(Metric)
 Water = 127 kg
 Cement = 410 kg
 Coarse aggregate (dry) = 1072 kg
 Fine aggregate (dry) = 676 kg
 Total = 2285 kg
 Air-entraining admixture 164 g or mL
 Water reducer 1230 g or mL
 Estimated concrete density (aggregates at SSD) = 127
+ 410 + (1072 x 1.005) + (676 x 1.007) = 2295 kg/m3
Example 2: Absolute Volume Method
(Inch-Pound)
 Givens:
 c = 3500 psi at 28 days
 Type I cement
 Minimum 3 in. cover
 Nom. Max. Size Aggregate = 25 mm
 No statistical data available
Example 2: Absolute Volume Method
(Inch-Pound)
 Available materials:
 Type I cement per ASTM C150
 ¾ in. Coarse aggregate – well-graded gravel
with some crushed particles, relative density
= 2.68, absorption = 0.5%, bulk density =
100 lb/ft3, moisture content = 2%
 Natural sand – relative density = 2.64,
absorption = 0.7%, moisture content = 6%,
fineness modulus = 2.8
Example 2: Absolute Volume Method
(Inch-Pound)
 cr = c + 1200 = 4700 psi
 No durability limit on w/cm
 W/cm = 0.42 (based on cr = 4700 psi)
 ¾-in. aggregate satisfies ¾ distance between
reinforcement and between the reinforcement
and forms
 Aim for 7% air for trial batch
 Slump = 3 in.
Example 2: Absolute Volume Method
(Inch-Pound)
 Water content = 305 lb/yd3 – 35 lb/yd3 = 270
lb/yd3

 Cement content = 270 lb/yd3 / 0.42 = 643 lb/yd3

 Bulk volume C.A. = 0.62 * 100 lb/ft3 * 27 ft3/yd3
 AEA = 0.9 fl oz/cwt * 6.43 cwt/yd3 = 5.8 fl oz/yd3
Example 2: Absolute Volume Method
(Inch-Pound)
 Volume computations:
 Water = 270 / 1 * 62.4 = 4.33 ft3
 Cement = 643 / 3.15 * 62.4 = 3.27 ft3
 Air = 7.0 / 100 * 27 = 1.89 ft3
 Coarse aggregate = 1674 / 2.68 * 62.4 = 10.01 ft3
 Total volume of known ingredients = 19.50 ft3.
 Fine aggregate = 27 – 19.50 = 7.50 ft3
 Weight = 7.50 * 2.64 * 62.4 = 1236 lb
Example 2: Absolute Volume Method
(Inch-Pound)
 Trial proportions:
 Water 270 lb
 Cement 643 lb
 Coarse aggregate (dry) 1674 lb
 Fine aggregate (dry) 1236 lb
 Total weight 3823 lb
 Air-entraining admixture 5.8 fl oz
 Slump 3 in. (±3⁄4 in. for trial batch)
 Air content 7% (±0.5% for trial batch)
 Estimated density = [270 + 643 + (1674 x 1.005) + (1236 x
1.007)] ÷ 27 = 142.22 lb/ft3
Example 2: Absolute Volume Method
(Inch-Pound)
 Coarse aggregate (2% MC) = 1674 x 1.02 =
1707 lb
 Fine aggregate (6% MC) = 1236 x 1.06 = 1310
lb
 Water = 270 – (1674 x 0.015) – (1236 x 0.053)
= 179 lb
Example 2: Absolute Volume Method
(Inch-Pound)
 Trial batch proportions:
 Water = 179 * 2 / 27 = 13.26 lb
 Cement = 643 * 2 / 27 = 47.63 lb
 Coarse aggregate (wet) = 1707 * 2 27 = 126.44 lb
 Fine aggregate (wet) = 1310 * 2 / 27 = 97.04 lb
 Total = 284.37 lb
 Air-entraining admixture = 5.8 * 2 / 27 = 0.43 fl oz
Example 2: Absolute Volume Method
(Inch-Pound)
 Results: 4-in. slump, 8% air content, density =
141.49 ft3
 Actual proportions used:
 water 13.12 lb
 cement 47.63 lb
 coarse aggregate (2% MC) 126.44 lb
 fine aggregate (6% MC) 97.04 lb
 total 284.23 lb
 Yield = 284.23 / 141.49 = 2.009 ft3
Example 2: Absolute Volume Method
(Inch-Pound)
 Mixing water content:
 Water added = 13.12 lb
 Free water on coarse aggregate = 126.44 / 1.02 *
0.015 = 1.86 lb
 Free water on fine aggregate = 97.04 / 1.06 * 0.053
= 4.85 lb
 Total = 19.83 lb
 Per cubic yard: 19.83 * 27 / 2.009 = 267 lb
Example 2: Absolute Volume Method
(Inch-Pound)
 Adjust water content: +5 lb for 1% air, -10 lb for 1-in. slump
reduction = 262 lb/yd3
 New cement content = 262 / 0.42 = 624 lb/yd3
 New batch volumes:
 Water = 262 / 1 x 62.4 = 4.20 ft3
 Cement = 624 / 3.15 x 62.4 = 3.17 ft3
 Coarse aggregate = 1674 / 2.68 x 62.4 = 10.01 ft3
 Air = 7.0 / 100 x 27 = 1.89 ft3
 Total = 19.27 ft3
 Fine aggregate volume = 27 – 19.27 = 7.73 ft3

 The weight of dry fine aggregate required is 7.73 x 2.64 x

62.4 = 1273 lb
Example 2: Absolute Volume Method
(Inch-Pound)
 Adjusted batch weights:
 Water - 262 lb
 Cement - 624 lb
 Coarse aggregate - 1682 lb (SSD)
 Fine aggregate - 1282 lb (SSD)
 Total - 3850 lb
 Air-entraining admixture - 5.0 fl oz
 Adjusted density = [262 + 624 + (1674 * 1.005) + (1273
x*1.007)] / 27 = 142.60 lb/ft3
Example 3:
Laboratory
Trial Mixture
(Metric)
Example 3: Laboratory Trial
Mixture (Metric)
Example 3:
Laboratory
Trial Mixture
(Metric)
Example 4: Laboratory Trial Mixture
(Inch-Pound)
Example 4:
Laboratory
Trial Mixture
(Inch-Pound)
Example 4:
Laboratory
Trial Mixture
(Inch-Pound)
Example 4: Laboratory Trial Mixture
(Inch-Pound)
Example 4:
Laboratory
Trial Mixture
(Inch-Pound)
Example 5: Absolute Volume Method –
Multiple Cementing Materials
 Givens:
 Design strength = 40 MPa
 Freeze/thaw, deicer, and very severe sulfate exposure
 Chloride permeability limit = 1500 coulombs
 Shrinkage limit = 300 millionths
 Heat control due to element thickness
 Concrete producer standard deviation = 2 MPa
 Slump = 200-250 mm
Example 5: Absolute Volume Method –
Multiple Cementing Materials
 Available materials:
 Cement – Type HS, relative density = 3.14, silica fume content = 5%
 Fly ash – Class F, relative density = 2.60
 Slag – Grade 120, relative density = 2.90
 Coarse aggregate – well-graded, 19-mm nom. max. size, crushed
rock; relative density = 2.68, absorption = 0.5%, moisture content =
2.0%, ovendry density = 1600 kg/m3, history of ASR
 Fine aggregate – natural sand with some crushed, relative density =
2.64, absorption = 0.7%, moisture content = 6%, fineness modulus =
2.80
 AEA – synthetic; Retarding water reducer – 3 g/kg cement; Plasticizer
– 30 g/kg cement; Shrinkage reducer – 15 g/kg cement
Example 5: Absolute Volume Method –
Multiple Cementing Materials
 cr is greater of:
 cr = c + 1.34S = 40 + 1.34(2) = 42.7 MPa
 cr = 0.9 c + 2.33S = 36 + 2.33(2) = 40.7 MPa
 Durability requirements = 35 MPa

 W/cm = 0.35 (to achieve 42.7 MPa)

 Air content = 8±0.5%
 Slump = 250 ±20 mm
Example 5: Absolute Volume Method –
Multiple Cementing Materials
 Water content:
 Base = 168 kg/m3
 15% water reduction = 168 * 0.85 = 143 kg/m3
 Cement content = 143 / 0.35 = 409 kg/m3
 55% Type HS = 225 kg/m3
 30% Slag cement = 123 kg/m3
 15% Fly ash = 61 kg/m3
Example 5: Absolute Volume Method –
Multiple Cementing Materials
 Coarse aggregate: 1600 kg/m3 * 0.62 m3 = 992 kg/m3
 AEA = 0.5 x 409 = 205 g = 0.205 kg
 Water-reducer = 3 x 409 = 1227 g = 1.227 kg
 Plasticizer = 30 x 409 = 12,270 g = 12.270 kg
 Shrinkage-reducer = 15 x 409 = 6135 g = 6.135 kg
Example 5: Absolute Volume Method –
Multiple Cementing Materials
 Volume computations:
 Water (including chemical admixtures) = 143 / 1.0 x 997.75 = 0.143 m3
 Cement = 225 / 3.14 x 997.75 = 0.072 m3
 Fly ash = 61 / 2.60 x 997.75 = 0.024 m3
 Slag = 123 / 2.90 x 997.75 = 0.043 m3
 Air = 8.0 / 100 = 0.080 m3
 Coarse aggregate = 992 / 2.68 x 997.75 = 0.371 m3
 Total = 0.733 m3
 Fine aggregate = 1 – 0.733 = 0.267 m3
 Mass of fine aggregate = 0.267 x 2.64 x 997.75 = 703 kg
 Air entrainer = 0.205 / (1.0 x 997.75) = 0.0002 m3
 Water reducer = 1.227 / (1.0 x 997.75) = 0.0012 m3
 Plasticizer = 12.270 / (1.0 x 997.75) = 0.0123 m3
 Shrinkage reducer = 6.135 / (1.0 x 997.75) = 0.0062 m3
 Total = 19.84 kg of admixture with a volume of 0.0199 m3.
Example 5: Absolute Volume Method –
Multiple Cementing Materials
 Proportions:  Slump = 250±20 mm for
 Water 123 kg; trial batch
 Cement 225 kg;
 Air content = 8±0.5% for
 Fly ash 61 kg;
trial batch
 Slag 123 kg;
 Coarse aggregate (dry) 992 kg;  Estimated concrete density
 Fine aggregate (dry) 703 kg; = 123 + 225 + 61 + 123 +
 Air entrainer 0.205 kg; (992 x 1.005) + (703 x
 Water reducer 1.227 kg; 1.007) + 20 (admixtures) =
 Plasticizer 12.27 kg; 2257 kg/m3
 Shrinkage reducer 6.135 kg;
 Total = 2247 kg
Example 5: Absolute Volume Method –
Multiple Cementing Materials
 Moisture corrections:  New batch quantities:
 Water 71 kg
 Coarse aggregate (2%
 Cement 225 kg
MC) = 992 x 1.02 =
1012 kg  Fly ash 61 kg;
 Slag 123 kg;
 Fine aggregate (6% MC)
 Coarse aggregate 1012 kg
= 703 x 1.06 = 745 kg
 Fine aggregate 745 kg
 Water = 123 – (992 x
 Air entrainer 0.205 kg
0.015) – (703 x 0.053) =
 Water reducer 1.227 kg
71 kg
 Plasticizer 12.27 kg
 Shrinkage reducer 6.14 kg
Example 5: Absolute Volume Method –
Multiple Cementing Materials
 0.1 m3 test batch results:
 Air content = 7.8%  ASR testing = 0.02% expansion

 Slump = 240 mm  Temperature rise = acceptable

 Density = 2257 kg/m3  Shrinkage = below 300 millionths

 Yield = 0.1 m3  Water-soluble chloride content =

0.06%
 Strength = 44 MPa
 RCPT testing = 990
coulombs
Example 5: Absolute Volume Method –
Multiple Cementing Materials
 Mixture for submission:
 Water 123 kg
 Cement, Type HS 225 kg
 Fly ash, Class F 61 kg
 Slag, Grade 120 123 kg
 Coarse aggregate 997 kg (SSD)
 Fine aggregate 708 kg (SSD)
 Air entrainer 0.205 kg
 Water reducer 1.227 kg
 Plasticizer 12.27 kg
 Shrinkage reducer 6.14 kg
 Slump 200-250 mm
 Air content 5-8%
 Density (SSD) = 2257 kg/m3
 Yield = 1 m3
 w/cm 0.35
Mixture Review
Summary
 Mix Design
 Proportioning
 Concrete for Small Jobs
 Mixture Review
Questions