Fundamentals of Concrete

There is No such Animal as a Cement @$&!*^#%

Composition of Concrete

PC + Water + Aggregates (FA & CA) + Voids Properties of Fresh Concrete and Hardened Concrete

Fresh Properties - ASTM

Slump Temperature Density & Yield Air Content Time of Setting

Hardened Properties - ASTM

Strength Air Content Density, Absorption and Voids Volume Change Durability Permeability

Strength

Durability

Freeze Thaw Chloride-Ion Alkali-Aggregate Sulfate

How does Concrete Get Its Strength

PC + water = hydration reaction > GLUE + Heat Cementitious material literally glues all of the inert (non-reactive) aggregates together to produce a solid load bearing mass that we call PCC Strength is inversely proportional to the water-to-cement ratio

Strength vs. w/c Ratio for PCC

Strength, psi

w/c ratio

Whats Important

Good quality materials

PC, water, coarse aggregate, and fine aggregate

Proper Proportioning of the Materials Proper Mixing Placing and Finishing Proper Curing QC Testing

Other Types of Concrete

Lightweight Concrete

Structural and Non-structural (120 50 pcf)

High Density Concrete (400 pcf) Mass Concrete Pre-placed Concrete No Slump Concrete Roller-Compacted Concrete Shotcrete (Wet and Dry)

PC does NOT come from Portland Oregon

History Portland Cement

Limestone + Sand + Clay + Iron ore + heat(1500 C) = PC Clinker + Grinding = PC powder

Dry process and wet process (p. 22 and 23)

Hydraulic Cement hardens in air and under water Types I, II, III, IV and V What does 1 bag of PC weigh?

Cement kilns are HUGE ... A cement kiln is the word's largest moving manufacturing machine. Typically, they are a huge cylindrical furnace 12 to 25 feet in diameter and 450 to 1,000 feet in length. They are set on a slight incline and rotate from 1 to 4 RPM. Cement kilns can process up 200 tons of raw material such as limestone, clay, and sand each hour. Cement kilns are HOT ... Internal temperatures exceed 3,000F, nearly one third the temperature of the sun's surface. Cement kilns are HUNGRY ... The cement industry is the world's third largest consumer of energy and typically uses 12 tons of fuel each hour..

General Types of Cement

Type I General Purpose Type II Moderate Heat, Moderate Sulfate Resistance Type III High Early Strength Type IV Very Low Heat Type V High Sulfate Resistance

Blended Cements

Type IP or P Portland Pozzolan Cement

Moderate heat and moderate sulfate resistance

Class F Fly Ash 15 to 25% (FDOT 18-22%) Class C Fly Ash 15 to 40%

High Early Strength

Blended Cements

Type IS or S - Portland Blast Furnace Slag Cement

Low Heat (FDOT)

25 70%

Other Types of Cement

High Early Strength Cements RR

Magnesium Phosphate SET-45 Calcium Aluminate Cements- Cement Fondu Calcium Sulfoaluminate Rapid Set

RR Mixing Equipment

Mixing Water

Potable

ie. Water suitable for drinking Chloride < 0.05% Sulfate < 0.08% Organic salts < 0.05% sugar

Strength vs. w/c Ratio for PCC

Strength, psi

w/c ratio

Aggregates

Coarse Aggregate

Retained on #4 Sieve

0.187 in (3/16) or 4.76 mm Granite Limestone River gravel

Igneous, Sedimentary and Metamorphic rock

CA continued

Maximum size from 6-in to 3/8-in

Max size governed by ACI code Graded down to #4 sieve according to ASTM C136 Standard Specification for Concrete Aggregates ASTM C33 (Table 5.5, p. 84-5).

Common gradations, #467, #57, #67 and #8 (#89-FL) 1-1/2 in max, 1-in max, -in max, and 3/8-in max respectively

Aggregate Testing according ASTM Standards

TABLE 5.2 (Page 81), Table 5.6 and 5.7, (page. 92).

Dry-Rodded Unit Weight test of coarse aggregate ASTM C29

Dry-Rodded Unit Weight of CA Test

Aggregates

Fine Aggregate

Passing #4 Sieve <3/16 - in. Natural Siliceous and Crushed Limestone Fines Aggregate Testing according to ASTM

TABLE 5.2 (Page 81)

Graded according to ASTM C33 OR FDOT 902

Table 5.3

See next slide Indication of the average particle size (2.0 to 3.0)

Fineness modulus

Fine Aggregate Grading Limits (ASTM and FDOT)

Sieve size No. 4 No. 8 No. 16 No. 30 No. 50 No. 100 ASTM C33 95-100 80-100 50-85 25-60 5-30 0-10 % Passing FDOT 902 95 - 100 85 - 100 65 - 97 25 - 70 5 - 35 0-7

#100

#4

ASTM C33 Grading Limits

Sieve Analysis Test

Aggregate Testing
AASHTO Standards

T11, Materials Finer Than 75 m (No. 200) Sieve in Mineral Aggregates by Washing T19/ T 19M-00, Bulk Density (Unit Weight) and voids in Aggregate T21, Organic Impurities in Fine Aggregates for Concrete T27, Sieve analysis of Fine and Coarse Aggregates T84, Specific Gravity and Absorption of Fine Aggregate T85, Specific Gravity and Absorption of Coarse Aggregate T96, Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

ASTM Standards ASTM D4791, Standard Test Method for Flat Particles, Elongated Particles, or Flat and Elongated Particles in Coarse Aggregate ASTM D5821, Standard Test Method for Determining the Percentage of Fractured Particles in Coarse Aggregate

500 g sample

Fineness Modulus Calculation

Sieve Size
No. 4 No. 8 No. 16 No. 30 No. 50 No. 100 Pan Total FM

% Retained
0 10 25 24 26 11 4

Cum. %Retained
0 10 35 59 85 96 100 285 2.85

Cum. %Passing
100 90 65 41 15 4 0

Lab 1 Information

Handouts Unit Weight of CA Gradation and FM of Fine Aggregate NO OPEN TOE SHOES

Unit Weight of CA ASTM C29

Volume of Measure Unit Weight loose condition Unit Weight compacted condition

Calculation 1) Calculate the unit weight in both the loose and compact (dense) conditions for the coarse aggregate. gbulk = (G - T) / V where: gbulk = unit weight of the aggregate, lb/ft3 G = mass of the aggregate plus the measure, lb T = mass of the measure, lb V = volume of the measure, ft3

Gradation and FM of Fine Aggregate ASTM C136

500 g sample

Fineness Modulus Calculation

Sieve Size
No. 4 No. 8 No. 16 No. 30 No. 50 No. 100 Pan Total FM

% Retained
0 10 25 24 26 11 4

Cum. %Retained
0 10 35 59 85 96 100 285 2.85

Cum. %Passing
100 90 65 41 15 4 0

Fine Aggregate Grading Limits (ASTM and FDOT)

Sieve size No. 4 No. 8 No. 16 No. 30 No. 50 No. 100 ASTM C33 95-100 80-100 50-85 25-60 5-30 0-10 % Passing FDOT 902 95 - 100 85 - 100 65 - 97 25 - 70 5 - 35 0-7

Recycled Concrete Aggregate

Old concrete that has been removed and crushed to produce aggregate.

Coarse aggregate in new concrete Fine aggregate in new concrete

Best combination is CA with natural fine aggregate

Good strength Drying shrinkage problem

Base-coarse replacement for natural limestone Pervious concrete pavement using recycled concrete as coarse aggregate.

Pervious Concrete

Mineral Admixtures

Pozzolanic (cement replacement)

Class F Fly ash 15 to 25% bwc Class C Fly ash 15 to 40% bwc 25 to 70% bwc

Blast Furnace Slag (cement replacement)

Silica Fume (cement addition)

6 to 12% bwc

Chemical Admixtures ASTM C-494 (Ch. 6)

Table 6-1 Water Reducing Type A Set Retarding Type B Set Accelerating Type C Water Reducer-Set Retarding Type D Water Reducer-Accelerating Type E High Range Water Reducers Type F HR Water Reducer-Set Retarding -Type G

Air-Entraining Agents ASTM C260 (Ch. 8)

Admix that produces stable bubble system Liquid and solid Low dosage rates relative to other chemical admixtures (0.005 to 0.05% bwc). Increase in durability @freeze/thaw Reduces compressive strength

3-5% per percent of entrained air

Fibers (see Table 7-1)

Natural Egyptian pyramids

Straw, bamboo, and wood

Glass alkali attack Steel

Fibers polypropylene nylon

Synthetic 1 to 1.5 lb per cu. yd.

Ethics and Safety

PC The most expensive component of the mix

Dont get shorted on this material Life Cycle Costs vs. Material Costs Highly alkaline

PCC inherently a safe material considering:

Eye protection Skin irritations

How about the Costs?

Item % of Total Cost Concrete 24% Materials Labor & 8% Equipment Reinforcing Steel 12% Labor & Equipment Formwork Materials Labor & Equipment 7%

10%
39%

ASTM C143

Size of slump cone Time to complete test

Sampling 5 min Start of test 2.5 min

Read to nearest in Rodding 25 times per layer = 75 times

ASTM C138

Bucket size Unit wt calc. Yield calc Rodding procedure

ASTM C231

Air content by pressure method Rodding procedure Procedure Aggregate correction factor results

ASTM C173

Air content volumetric Rodding technique Method results