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2 Concrete Fundamentals
K L 3 10 6 C L AS S 0 2
S E M E S T E R I 2 0 10 / 2 0 11
Introduction
Concrete is one of the most versatile and universal
construction materials. construction materials.
Available all over the globe.
Can be developed into diverse forms of construction.
Can be built with all different levels of technology.
Excellent durability and fire resistance characteristics.
Requires substantially less maintenance than other materials.
b illi f d h About 260 million m
3
of concrete are used each year
in the US.
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Introduction
Concrete manufacturing process includes a number
of steps: of steps:
Proportioning
Batching
Mixing
Placing
Compacting
Fi i hi Finishing
Curing
Concrete
Concrete: rocklike
material produced by
i i d fi mixing coarse and fine
aggregates, hydraulic
cement (usually portland
cement) and water and
allowing the mixture to
harden.
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Aggregates
Fine aggregates consist
of sand with particles
ll h smaller than 5 mm.
Coarse aggregates are
generally gravel or
crushed stone larger than
5 mm (usually 9.5 mm
up to 37.5 mm).
Aggregates occupy 60-
75% of the concrete
volume or 70-85% of its
mass.
Cement
Hyd r a u lic cem en t s set and harden by reacting
chemically with water. The reaction is called chemically with water. The reaction is called
hydration.
During hydration, cement combines with water to
form paste, which bind aggregates into concrete as it
hardens.
Portland cement is the most common type of yp
hydraulic cement.
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Historical Overview
300 BC 476 AD: early form of concrete was used in
bridges, aqueducts, structures in Rome. g , q ,
The concrete used volcanic sand called pozzuolana
(available near Pozzuoli), which reacted with lime
and water to solidify into rock-like mass.
1824: Joseph Aspdin invented Portland cement.
1855: J. Lambot introduced reinforced concrete
concept The concept was then patented by Joseph concept. The concept was then patented by Joseph
Monier in 1867.
1930: Development of prestressed concrete by
Eugene Freyssinet.
Density of Concrete
Based on their density, fresh concrete are divided
into:
Lightweight concrete: 1350 1850 kg/m
3
Normal-weight concrete: 2200 2400 kg/m
3
Heavyweight concrete: 2800 6400 kg/m
3
Normal-weight concrete is the most commonly used
concrete in construction.
Lightweight concrete is used for light structures and Lightweight concrete is used for light structures and
heat / fire insulation.
Heavyweight concrete is used for radiation-shielding
and concrete coating for pipelines.
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Mechanical Properties of Concrete
Concrete has a high compressive strength; however,
its tensile strength is low (about 10% of its its tensile strength is low (about 10% of its
compressive strength).
Compressive strength of concrete (f
c
) is obtained by
uniaxial compression test of cylindrical concrete
samples.
There are two commonly used concrete samples: y p
15 cm diameter, 30 cm high, cylindrical sample (as in ACI and
current SNI).
15 cm 15 cm 15 cm cubic sample (as in PBI 1971).
Uniaxial Compression Test
f '
o
F bi l
c
f
c
For cubic samples:
0.83 *
c
f o ' =
where o* is the compressive strength
obtained from cubic samples.
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Aggregates
Requirements
Aggregate should be:
Clean Clean
Hard and strong
Free from absorbed chemicals
Free from coatings of clay
The distribution of aggregate size should follow the
grading limits (see tables in the next slide).
Grading is the particle-size distribution of aggregate
as determined by s ieve a n a lys is.
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Fin e Aggr ega t e Fin e Aggr ega t e
Coa r s e Aggr ega t e
( 25 m m m a x. s ize)
Coa r s e Aggr ega t e
( 25 m m m a x. s ize)
Grading Limits
Sieve s ize
[ m m ]
Per cen t p a s s in g,
by m a s s
9.5 100
4.75 (No. 4) 95 100
2.36 (No. 8) 80 100
1.18 (No. 16) 50 85
Sieve s ize
[ m m ]
Per cen t p a s s in g,
by m a s s
37.5 100
25 95 100
12.5 25 60
4.75 0 10
0.60 (No. 30) 25 60
0.30 (No. 50) 5 30
0.15 (No. 100) 0 10
2.36 0 5
Grading Limits
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Fineness Modulus
Calculated by adding the cumulative percentages of mass
retained on each of a specified series of sieves and
dividing the sum by 100.
The specified sieves for determining FM are:
150 m(No. 100)
300 m(No. 50)
600 m(No. 30)
1.18 mm (No. 16)
2 36 mm (No 8) 2.36 mm (No. 8)
4.75 mm (No. 4)
9.5 mm, 19.0 mm, 37.5 mm, 75 mm and 150 mm.
To be used in normal concrete, the fineness modulus of
fine aggregate should be between 2.3 3.1.
Example 1
A sample of fine aggregate is
passed through a series of sieves
Sieve s ize
[ m m ]
Ma s s r et a in ed
[ gr a m ]
passed through a series of sieves
and the masses retained on each
sieve are as shown.
Draw the grading of the fine
aggregate and determine the
fineness modulus.
9.5 0
4.75 9
2.36 68
1.18 101
0.6 102
0.3 121
0.15 93
0.075 10
Pan 5
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Sieve analysis is based on cumulative percentage of
aggregates that pass through the sieves, while fineness
modulus cumulative percentage of retained aggregates.
Sieve
s ize
[ m m ]
Ma s s
r et a in ed
[ gr a m ]
Cu m u la t ive
r et a in ed
Cu m u la t ive
p a s s
[ %]
[ gr a m ] [ %]
[ m m ] [ gr a m ] [ %]
[ gr a m ] [ %]
9.5 0 0 0 100
4.75 9 9 2 98
2.36 68 77 15 85
1.18 101 178 35 65
0.6 102 280 55 45
0.3 121 401 79 21
grading
0.3 121 401 79 21
0.15 93 494 97 3
0.075 10 504 99 1
Pan 5 509 100 0
grading
fineness modulus calculation
50
60
70
80
90
100
a
t
i
v
e

P
a
s
s

[
%
]
0
10
20
30
40
0.01 0.1 1 10
C
u
m
u
l
a
SieveSize [mm]
0 2 15 35 55 79 97
2.83
100
FM
+ + + + + +
= =
Note: The 0.075 mm sieve is not included in the FM calculation.
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Example 2
A sample of coarse aggregate is
passed through a series of
Sieve s ize
[ m m ]
Ma s s r et a in ed
[ gr a m ]
passed through a series of
sieves and the masses retained
on each sieve are as shown.
Draw the grading and
determine the fineness
modulus.
25 0
19 405
12.5 2850
9.5 2435
4.75 2030
2.36 375
Pan 35
Sieve
s ize
[ m m ]
Ma s s
r et a in ed
[ gr a m ]
Cu m u la t ive
r et a in ed
Cu m u la t ive
p a s s
[ %]
[ gr a m ] [ %]
25 0 0 0 100
19 405 405 5 95
12 5 2850 3255 40 60 12.5 2850 3255 40 60
9.5 2435 5690 70 30
4.75 2030 7720 95 5
2.36 375 8095 100 0
Pan 35 8130 100 0
Note: The 25 mm and 12.5 mm sieves are not included in the FM calculation.
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40
50
60
70
80
90
100
l
a
t
i
v
e

P
a
s
s

[
%
]
0
10
20
30
40
1 10 100
C
u
m
u
SieveSize [mm]
5 70 95 100 100 100 100 100
6.70
100
FM
+ + + + + + +
= =
80
90
100
Combined grading of fine and coarse aggregates from
Examples 1 and 2:
10
20
30
40
50
60
70
C
u
m
u
l
a
t
i
v
e

P
a
s
s

[
%
]
0
10
0.01 0.1 1 10 100
SieveSize [mm]
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Bulk Density and Voids
Bulk density (or unit weight): mass (or weight) of
aggregate required to fill a container of a specified aggregate required to fill a container of a specified
unit volume.
The volume above is occupied by aggregates and
voids between particles.
Aggregates commonly used in normal concrete have
bulk density in the range of 1200 1750 kg/m
3
. y g 75 g/
Void contents range from 30 45% for coarse
aggregates to 40 50% for fine aggregates.
Relative Density
Relative density (or specific gravity): ratio of
aggregate mass to the mass of equal absolute volume aggregate mass to the mass of equal absolute volume
of water.
Most aggregates have relative density between 2.4
2.9.
In concrete mix design, the density of aggregate is
calculated by multiplying its relative density with the y p y g y
density of water.
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Absorption and Surface Moisture
Moisture conditions of aggregates are designated as:
Ovendry: no moisture fully absorbent Ovendry: no moisture, fully absorbent
Air dry: dry at the surface, but contain some interior moisture,
absorbent.
Saturated surface dry (SSD): neither absorbent, nor
contributing water to the concrete mixture.
Damp or wet: containing excess moisture on the surface.
Portland Cement
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Main Ingredients
Raw materials
Limestone sand clay iron ore ground and burned into Limestone, sand, clay, iron ore ground and burned into
clinker
Gypsum
Important minerals
Calcium, iron, silica, alumina, sulfate
Primary chemical compounds
Tricalciumsilicate (3CaO-SiO
2
or C
3
S)
Dicalciumsilicate (2CaO-SiO
2
or C
2
S)
Tricalciumaluminate (3CaO-Al
2
O
3
or C
3
A)
Tetracalciumaluminoferrite (4CaO-Al
2
O
3
-Fe
2
O
3
or C
4
AF)
Type of Portland Cement
Type I : normal / general-purpose cement
Type II : moderate sulfate resistance Type II : moderate sulfate resistance
For concrete exposed to soil, ground water, or seawater where
sulfate concentration are higher than normal but not severe.
Must be used with low water-cement ratio.
Type III : high early strength
Physically and chemically similar to Type I, but the particles
have been ground finer.
Type IV : low hydration heat
Develop strength at slower rate than other types of cement.
Type V : sulfate resistant
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Mix Design
Required Strength
The required average strength , as the target
average strength in concrete mix design, is the larger
cr
f '
average strength in concrete mix design, is the larger
of the following equations:
where
1.34
2.33 3.45 for 35 MPa
0.9 2.33 for 35 MPa
cr c
c c
cr
c c
f f s
f s f
f
f s f
' ' = +
' ' + s

' =

' ' + >

where
= specified compressive strength (MPa)
s = standard deviation (MPa)
c
f '
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Required Strength
If there are no field strength test data available, the
following values of average compressive strength following values of average compressive strength
should be used (Table 9-11):
Sp ecified com p r es s ive
s t r en gt h , [ MPa ]
Requ ir ed a ver a ge
com p r es s ive s t r en gt h ,
[ MPa ]
21
cr
f ' c
f '
7 f ' + 21
21 35
> 35
7
c
f +
8.5
c
f ' +
1.1 5
c
f ' +
Water-Cement Ratio
Relationship between water-cement ratio and
concrete compressive strength (Table 9-3):
Com p r es s ive s t r en gt h
a t 28 d a ys [ MPa ]
Wa t er -cem en t r a t io
Non -a ir -en t r a in ed
con cr et e
Air -en t r a in ed
con cr et e
45 0.38 0.30
40 0.42 0.34
35 0 47 0 39
concrete compressive strength (Table 9 3):
35 0.47 0.39
30 0.54 0.45
25 0.61 0.52
20 0.69 0.60
15 0.79 0.70
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Slump
Recommended slumps for various types of
construction (Table 9-6): ( b 9 )
Con s t r u ct ion t yp e
Slu m p [ m m ]
Ma xim u m Min im u m
Reinforced foundation walls and footings 75 25
Plain footings, caissons, and substructure walls 75 25
B d i f d ll Beams and reinforced walls 100 25
Building columns 100 25
Pavements and slabs 75 25
Mass concrete 75 25
Mixing Water and Air Content
Mixing water and air content as a function of slump
and maximum aggregate size (Table 9-5), for non- and maximum aggregate size (Table 9 5), for non
air-entrained concrete:
Slu m p [ m m ]
Wa t er [ kg p er m
3
con cr et e] ,
for in d ica t ed m a x. a ggr ega t e s izes [ m m ]
9. 5 12. 5 19 25 37. 5 50 75 150
25-50 207 199 190 179 166 154 130 113
75-100 228 216 205 193 181 169 145 124
150-175 243 228 216 202 190 178 160 -
Air content [%] 3 2.5 2 1.5 1 0.5 0.3 0.2
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Coarse Aggregate Content
Bulk volume of dry coarse aggregate per unit volume
of concrete (Table 9-4): of concrete (Table 9 4):
Ma x. s ize of
a ggr ega t e [ m m ]
Bu lk volu m e p er u n it volu m e of con cr et e,
for d iffer en t FM of fin e a ggr ega t e
2. 40 2. 60 2. 8 0 3. 0 0
9.5 0.50 0.48 0.46 0.44
12.5 0.59 0.57 0.55 0.53
19 0.66 0.64 0.62 0.60 9
25 0.71 0.69 0.67 0.65
37.5 0.75 0.73 0.71 0.69
50 0.78 0.76 0.74 0.72
75 0.82 0.80 0.78 0.76
150 0.87 0.85 0.83 0.81
Mix-Design Procedure
(ACI 211.1, Absolute Volume Method)
Determine the required average strength, , using
ACI formula or Table 9-11.
cr
f '
9
Determine the water-cement ratio based on concrete
strength, using Table 9-3.
Choose an appropriate slump based on construction
type, using Table 9-6.
Determine mixing water and air content based on
slump and maximum aggregate size using Table 9 5 slump and maximum aggregate size, using Table 9-5.
Determine the coarse aggregate content based on
maximum aggregate size and FM of fine aggregate,
using Table 9-4.
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Mix-Design Procedure
(ACI 211.1, Absolute Volume Method)
By now, we have had the volume of cement, coarse
aggregate, air, and water per unit volume of aggregate, air, and water per unit volume of
concrete. The rest of the volume should be filled by
the fine aggregate.
Adjust the content of water, coarse aggregate, and
fine aggregate due to absorption or water content of
the aggregates.
Example 3
Design the proportioning of concrete for pavement
with compressive strength of 35 MPa. The nominal with compressive strength of 35 MPa. The nominal
maximum size of aggregate is 25 mm, and no
previous statistical data available are available.
The properties of the materials are as follows:
Cement: type I, with relative density of 3.15
Coarse aggregate: max. size 25 mm, ovendry density 2.68,
absorption 0.5%, bulk density 1600 kg/m
3
, moisture content
2%.
Fine aggregate: ovendry relative density 2.64, absorption
0,7%, fineness modulus 2.80, moisture content 6%.
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Required average strength:
8.5 35 8.5 43.5 MPa
cr c
f f ' ' = + = + =
Water-cement ratio (Table 9-3):
( )
45 43.5
0 42 0 38 0 38 0 392
w

= + = ( ) 0.42 0.38 0.38 0.392
45 40
w
c
= + =

Slump (Table 9-6):

Slump for pavement: 25 75 mm, choose 75 mm.
Air and water content (Table 9-5):
Air content: 1.5% Air content: 1.5%
Water: 193 kg for 1 m
3
of concrete
Cement content:
193
0.392 ; 193 kg 492 kg
0.392
w
w c
c
= = = =
Coarse aggregate (Tabel 9-4):
Max. size 25 mm, FM of fine aggregate = 2.80
volume of coarse aggregate = 0.67 m
3
for 1 m
3
concrete.
Mass of coarse aggregate (ovendry):
Now, for 1 m
3
concrete we need:
Water: 193 kg 0.193 m
3
Cement: 492 kg 0.156 m
3
Coarse aggregate: 1072 kg 0.400 m
3
Ai %
3
1600 0.67 1072 kg w = =
Air: 1.5% 0.015 m
3
Total: 0.764 m
3
Fine aggregate content = 1 0.764 = 0.236 m
3
Mass of fine aggregate = 0.236 2.64 1000 = 623 kg
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Total mass = 193 + 492 + 1072 + 623 = 2380 kg
Estimated concrete density =
Adj f i
193 + 492 + (1072 1.005) + (623 1.007) = 2390 kg/m
3
Coarse aggregate: 1072 1.02 = 1093 kg
Fine aggregate: 623 1.06 = 660 kg
Water: 193 (1072 0.015) (623 0.053) = 144 kg
Adjustment for moisture content:
Concrete density =
144 + 492 + 1093 + 660 = 2389 kg/m
3
Admixtures
Cementitious materials
Fly ash: waste product from coal power plant; increase Fly ash: waste product from coal power plant; increase
strength, reduce permeability, improve workability, reduce
shrinkage and creep
Silica fume: byproduct of semiconductor, about 100 times
finer than cement; increase strength, reduce permeability.
Blast furnace slag: byproduct of iron manufacture; improve
workability, reduce temperature rise during curing, improve
sulfate resistance.
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Admixtures
Chemicals
Air-entraining Air entraining
Water-reducing
Superplasticizer (high range water reducing)
Accelerating / retardant
Shrinkage-reducing
Corrosion inhibitor
F t ti Freeze protection
Coloring agents
Curing
Concrete strength increases with age provided that:
Unhydrated cement is still available Unhydrated cement is still available.
The concrete remains moist (humidity > 80%).
The temperature remains favorable.
Sufficient space is available for the hydration product to form.