UK term: Mix Design selection of mix ingredients and their
proportions (DOE approach) Ref: Design of normal concrete mixes, DOE, 1988)
American term: Mixture Proportioning (ACI approach) Ref: Standard practice for selecting proportions for normal, heavyweight, and mass concrete, ACI Manual of concrete practice, Part 1: Materials and general properties of concrete, ACI 211.1-91, 1994
The process aims to select constituent materials and their proportions for concrete to meet specified requirements, i.e. characteristic strength, consistence and durability for exposure conditions in service and any special needs The selected composition is adjusted based the results of a trial batch applying knowledge on influencing factors Page 1 of 62 Selection of Concrete Composition Important factors in selection of concrete composition: Compressive strength Commonly at 28-day characteristic value adopted in structural design (structural adequacy)
Consistence (depends on construction processes) Suitable for ease of placing, compacting and method of transporting to point of placing after delivery
Durability (intended working life for exposure condition) Currently deem-to-satisfied approach based on choice of types of cement, maximum w/c ratio, minimum cement and cover thickness based on qualitative classification of exposure condition
Cost and other special requirements, e.g. surface finish Page 2 of 62 Selection of Concrete Composition Exact determination of constituent proportions is NOT possible due to: Variability of materials of nominal qualitative classification e.g. shape, texture and grading of aggregates Lack of truly quantitative properties exactly linked to properties in quantitative terms e.g. water demand for given consistence Empirical methods adopt tables and charts to provide first approximation of proportions as these are prepared from past experience for initial estimation only For a new set of materials or requirements, initial test (trial mix) is conducted to assess resultant properties Adjustment to proportions as necessary to achieve and/or to optimize composition for desired concrete properties, checked with further trials often needed
Page 3 of 62 Fundamentals Concepts Duff Abrams (1918) formulated relationship between compressive strength of concrete and water-cement ratio in the form: o c = K 1 /K 2 (w/c)
o c = compressive strength A = empirical constant (96.5 MPa) B = Constant that depends on cement properties (~4) w/c = water to cement ratio by weight
B c w c A ) / ( 5 . 1 = o o c = 234 X 3 (MPa) reported by Powers (1958) Page 4 of 62 Fundamentals Concepts Feret (1896) established relationship:
o c = K [c/(c + w + a)] 2
where
o c = compressive strength
c, w, and a = absolute volumetric proportions of cement, water and air respectively K = constant
This relationship includes volume of air and has been applied to cementitious systems with high air content e.g. foamed concrete (aerated or cellular concrete)
Air content up to 3% by volume in normal concrete taken into consideration in empirical approach Higher air content by air-entraining admixture has to be compensated for reduction in compressive strength with lower water-cement ratio for similar strength
Page 5 of 62 Fundamentals Concepts Ideal aggregate grading Most dense aggregate-packing with a minimum content of voids will be the most economical in theory In practice, it is adequate to follow the grading limits specified by standards Some basic rules for consistence (workability) Flowability For a given slump, water requirement + when Max aggregate size | Content of angular or rough-textured aggregate particles + Content of entrained air | Cohesiveness Improve cohesiveness Increase sand/coarse aggregate ratio Partial replacement of coarse sand by a fine sand Increase cement/aggregate ratio (at given w/c) Water content is main factor influencing consistence Page 6 of 62 Mix Design Process Determine the job parameters Strength Durability requirements (if needed) Consistence (Slump) aggregate properties, max. aggregate size water/cement ratio Admixtures (for specific performance) Calculate batch weights Adjusting to the batch weights based on trial mix Comment: High durability concrete is expected to be also high in strength, may be higher than used in structural design Page 7 of 62 ACI Method (Mindess, 2002) Step 1: Required information on materials to be used, properties on fine and coarse aggregates, dimensions of structural elements, concrete strength and exposure conditions Step 2: Choice of slump guidance from Table 10.1 Step 3: Maximum aggregate size depends of bar spacing and cover Step 4: Estimation of mixing water (and air content if entrained air needed) guidance from Table 10.2 Step 5: Water/cement or water/cementitious material ratio guidance from Table 10.3 and Table 10.4 (severe exposure condition) [Tables 10.5, 10.6 and 10.7 from CSA for specific exposure class] Step 6: Calculation of cement or cementitious material content based on water content and water/cement ratio selected Step 7: Estimation of coarse aggregate content guidance from Table 10.8 Step 8: Estimation of fine aggregate content guidance from Table 10.9 for fresh concrete density or based on volume of each ingredient to make up 1 cubic meter Step 9: Adjustment for moisture in the aggregates for batching weights Step 10: Trial batch based on test results to adjust ingredient proportions to achieve required level Page 8 of 62 Required average strength ACI 214 (1) The probable frequency of the average of 3 consecutive tests below specified strength f c will not exceed 1 in 100 f cr = f c + 2.33 s/\3 = f c + 1.34 s where f cr = required average compressive strength f c = specified compressive strength s = standard deviation (2) (a) For f c s 35 MPa, the probable frequency of tests more than 3.5 MPa below f c should not exceed 1 in 100
f cr = f c + 2.33 s - 3.5 (MPa) (b) For f c > 35 MPa, the probable frequency of tests below 0.90f c should not exceed 1 in 100
f cr = 0.90 f c + 2.33 s The required average compressive strength f cr is determined as the larger value of the above (f cr and f c are cylinder compressive strength) Page 9 of 62 Required Average Strength (When Data Are Available to Establish a Standard Deviation) Specified compressive strength, f' c , MPa Required average compressive strength, f' cr , MPa s 35 f' cr = f' c + 1.34s f' cr = f' c + 2.33s 3.5 Use larger value > 35 f' cr = f' c + 1.34s f' cr = 0.90f' c + 2.33s Use larger value (ACI 214) Page 10 of 62 Number of tests Modification factor for standard deviation Less than 15 Use Table 15.3 15 1.16 20 1.08 25 1.03 30 or more 1.00 Modification Factor for Standard Deviation (s 30 Tests) s is multiplied by the above factor (ACI 318) Page 11 of 62 Required Average Strength (When There Are Insufficient Data to Establish s) Specified compressive strength, f' c , (MPa) Required average compressive strength, f' cr , (MPa) Less than 20 f' c + 7.0 20 to 35 f' c + 8.5 Over 35 1.1f' c + 5.0 These estimates are very conservative, and should not be used for large projects (over-design, non-economical) (ACI 318) Page 12 of 62 1. Required information Sieve analysis of fine and coarse aggregate, fineness modulus Dry-rodded unit weight of coarse aggregate Bulk specific gravity of materials Absorption capacity, or free moisture in the aggregate Information on structure including the type and dimensions of structural members, minimum space between reinforcing bars Required strength Exposure conditions Relationship between strength and w/c for available combinations of cement and aggregate Job specifications [e.g., max w/c, min. slump, strength at early age (normally 28d), early temperature] Page 13 of 62 2. Choice of slump
Recommended Slump Ranges Concrete construction Slump, mm Maximum Minimum Reinforced foundation walls and footings 75 25 Plain footings, caissons, and substructure walls 75 25 Beams and reinforced walls 100 25 Building columns 100 25 Pavements and slabs 75 25 Mass concrete 50 25 [(ACI 211.1) Table 10.1 Mindess] Page 14 of 62 3. Choice of maximum size of aggregate Using a large max size of a well-graded aggregate will produce less void space than using a smaller size Large aggregates minimize the amount of water required, therefore reduce the amount of cement required. The maximum allowable aggregate size is limited by the dimensions of the structural elements and space between reinforcement capabilities of construction equipment
Page 15 of 62 150 250 10 30 30 30 30 - Form: 150/5=30 mm - Space between bars =30x3/4=22.5 mm - Space between bar & form=25x3/4=19 mm (assume: cover thickness = 25 mm)
Select aggregate with max. size 19 mm (19 mm = 3/4 in. and 25 mm = 1 in.)
25 mm Situation Maximum aggregate size Form dimensions 1/5 of minimum clear distance Clear space between reinforcement or prestressing tendons 3/4 of minimum clear space Clear space between reinforcement and form 3/4 of minimum clear space Unreinforced slab 1/3 of thickness Mindess Page 16 of 62 4. Estimation of mixing water & air content The quantity of water required to produce a given slump is dependent on the max size, shape and grading of aggregate, amount of entrained air not greatly affected by cement content Estimation of water from Table 10.2 if no data are available for a given aggregate The recommendations in Table 10.2 are reduced for other aggregate shapes than angular:
Shape Reduction in kg/m 3
Sub-angular 12 Gravel with crushed particles 21 Round gravel 27 Page 17 of 62 Water and Air Requirements for Different Slumps and Sizes of Aggregate Water, kg/m 3 of concrete, for indicated sizes of aggregate Slump, mm 9.5 mm 12.5 mm 19 mm 25 mm 37.5 mm 50 mm 75 mm 150 mm 25 to 50 210 200 185 180 160 155 130 113 75 to 100 225 215 200 195 175 170 145 124 150 to 175 240 230 210 205 185 180 160 Approximate amount of entrapped air in non-air- entrained concrete, percent 3 2.5 2 1.5 1 0.5 0.3 0.2 Non-air-entrained concrete (Extra from Table 10.2) Based on well-shaped, angular coarse aggregate [(ACI 211.1) Table 10.2 Mindess] Page 18 of 62 Air entrainment requirements Air entrainment is required whenever concrete is exposed to freeze-thaw conditions Air entrainment is also used for workability The amount of the air required varies with exposure conditions mild: indoor or outdoor service where concrete is not exposed to freezing and de-icing salts. AEA may be used to improve workability moderate: some freezing exposure occurs but concrete not exposed to moisture severe size of the aggregates
Page 19 of 62 Water and Air Requirements for Different Slumps and Sizes of Aggregate Water, kg/m 3 of concrete, for indicated sizes of aggregate Slump, mm 9.5 mm 12.5 mm 19 mm 25 mm 37.5 mm 50 mm 75 mm 150 mm 25 to 50 180 175 165 160 145 140 120 107 75 to 100 200 190 180 175 160 155 135 119 150 to 175 215 205 190 185 170 165 155 - Recommended average total air content, percent, for level of exposure Mild exposure 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 Moderate exposure 6.0 5.5 5.0 4.5 4.5 4.0 3.5 3.0 Severe exposure 7.5 7.0 6.0 6.0 5.5 5.0 4.5 4.0 Air-entrained concrete (Extract from Table 10.2 [(ACI 211.1) Table 10.2 Mindess] Page 20 of 62 5. Selection of w/c or w/cm Strength (Comment: Cylinder compressive strength) Page 21 of 62 Cylinder Compressive strength at 28 days, MPa Water/Cement Ratio by mass Non-air-entrained concrete Air-entrained concrete 45 0.37 - 40 0.42 - 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 If no historical data are available - make trial batches with different w/c, establish a relationship between strength and w/c - estimation of w/c for the trial mixes from Table 10.3 Not applicable to ASTM Type II, III, IV, and V cements and blended cements with very high quantities of pozzolans or GGBFS [(ACI 211.1) Table 10.3 Mindess] Page 22 of 62 5. Selection of w/c or w/cm Durability Checking w/c against the max. allowable w/c for exposure conditions Generally, more severe exposure conditions require lower w/c The minimum of the w/c for strength and durability is selected for proportioning of the concrete
Page 23 of 62 6. Calculation of cement or cementitious material content = mixing water (step 4) divided by the w/c (step 5) if the concrete is used in flatwork, check minimum cement content requirement
Nominal maximum size of aggregate, mm Cementing materials, kg/m 3
37.5 280 25 310 19 320 12.5 350 9.5 360 (ACI 318) Page 24 of 62 Cementitious Materials Requirements for Concrete Exposed to Deicing Chemicals Cementitious materials Maximum % of cementitious materials Fly ash and natural pozzolans 25 Slag 50 Silica fume 10 Total of fly ash, slag, silica fume and natural pozzolans 50 Total of natural pozzolans and silica fume 35 (ACI 318) Page 25 of 62 7. Estimation of coarse aggregate content increase V, less workability (pavement) reduce V, increased workability (pumping, shotcrete) Maximum size of aggregate, mm Volume of dry-rodded coarse aggregate for different fineness moduli of sand 2.40 2.60 2.80 3.00 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 25 0.71 0.69 0.67 0.65 37.5 0.76 0.74 0.72 0.70 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 Volume of Coarse Aggregate per Unit volume of Concrete [(ACI 211.1) Table 10.8 Mindess Page 26 of 62 Coarse Aggregate Content per m 3 of Concrete Assume: Max. aggregate size = 9.5 mm Fineness modulus of sand = 2.8
Volume of coarse aggregate in concrete = 0.46 m 3 of coarse aggregate/m 3 concrete
Coarse aggregate content (SSD) = 715.5 x (1+ A/100) [ A = Absorption capacity in %] Page 27 of 62 8. Estimation of fine aggregate content Mass (Weight) method W fa = W c - Weight of other ingredients W fa = weight of fine aggregate W c = unit weight of concrete Estimate according to Table 10.9
[(ACI 211.1) Table 10.9 Mindess] Page 28 of 62 8. Estimation of fine aggregate content Volume method The components weight and specific gravity are used to determine the volumes of the water, coarse aggregate, and cement. These volume + volume of air are subtracted from a unit volume of concrete to determine the V of fine aggregate
1000 liters kg kg/l
convert the V to weight (generally using bulk SSD specific gravity) a w ca cem con a w ca cem con fa V W W W V V V V V V V = = 1 / 65 . 2 / 15 . 3 / Page 29 of 62 9. Adjustments for aggregate moisture The mix proportions determined by steps 1 to 7 are assumed to be on a saturated surface dry (SSD) basis. If aggregate contains free moisture, the mixing water should be + and aggregates correspondingly | according to the amount of free moisture in the aggregates. If aggregate is air dry, the mixing water should be | and aggregates correspondingly + Total water in aggregate absorption = free moisture
Page 30 of 62 Example: Coarse aggregate, absorption capacity = 1%, effective absorption = 0.5% (from air-dry to SSD) Fine aggregate, absorption capacity = 1.3%, total moisture content 4.5% Assume a concrete mix proportion based on SSD: Cement = 400 kg/m 3 , Water = 200 kg/m 3 , Coarse aggregate = 1050 kg/m 3 , Fine aggregate = 710 kg/m 3 Estimated unit weight = 2360 kg/m 3 Actual mix proportion with the given aggregates CA: 1050 1050x0.5% = 1045 kg/m 3 (diff. = 5 kg/m 3 )
Water: 200 + 1050x0.5% - 710x3.2% = 182 kg/m 3 Estimated unit weight = 2360 kg/m 3 (Batching tolerance: 3% for aggregates, ?% for water)
Page 31 of 62 10. Trial batch Purpose Verifies that a concrete mixture meets design requirements prior to use in construction.
Determine Fresh concrete: slump, cohesiveness, segregation tendency, unit weight, air content, finishing Hardened concrete: strength 28 days or other ages Durability parameters if specified
Adjust concrete mixture accordingly Strength does not meet requirement (workability ok) Reduce w/c - Keep water content unaltered - Increase cement, reduce aggregate Page 32 of 62 10. Trial batch - continued Adjust concrete mixture accordingly (contd) Workability does not meet requirement (strength ok) Keep w/c unaltered - Slump too low Increase water and cement content (| 6 kg/m 3 water will | slump by ~25 mm) Use WRA or superplasticizer - Slump too high Reduce water and cement content Reduce the dosage of WRA or SP Segregation Increase fine aggregate and reduce coarse aggregate accordingly Replace coarse sand with a finer sand Air content: | 1% air, reduce water by 3 kg/m 3 Page 33 of 62 UK Approach DOE Method (Neville, 2011) Step 1: Water/cement ratio based on typical relationships between compressive strength and water/cement ratio in Fig. 14.12, curve for use selected from past experience of 28 day compressive strength of concrete at water/cement of 0.5 Step 2: Water content for required consistence (slump) from Table 14.10 related to type of coarse aggregate (uncrushed or crushed) and maximum aggregate size Step 3: Cement content based on selected water/cement ratio and water content (at least equal to minimum cement content for durability, guidance not provided) Step 4: Total aggregate content for range of specific gravity of crushed or uncrushed coarse aggregate and fresh concrete density for water content and specific gravity of coarse aggregate in Fig. 14.13 Step 5: Proportions of fine aggregate in total aggregate based on level of slump and free water /cement ratio for different percentage of fine aggregate passing 600 m sieve and maximum aggregate size (20 mm or 40 mm) in Fig. 14.14
Comment: In both ACI and DOE approach, guidance not provided on use of chemical admixture and recommendations for different specific exposure conditions. Page 34 of 62 UK Approach Adopted in Singapore Target mean strength, = characteristic strength + margin f m = f cu,28 + ks where f m = mean cube compressive strength f cu,28 = specified characteristic cube compressive strength s = standard deviation k = constant (= 1.64 for 5% defective)
EN 206: 2013 Annex A (normative) Initial Test For initial testing, margin = 2 x standard deviation (6 to 12 MPa)
Comment: Typical values for standard deviation range from 3 to 5 MPa for most RMC plants. Common margin selected = 7.5 to 8 MPa (s ~ 4.5 to 5.0) Page 35 of 62 1. Selection of water/cement ratio Target mean strength is based on value adopted in design of concrete structure (may not be the same for all structural elements)
DOE method based on assuming certain strengths are related to water/cement ratio of 0.5 for different types of cements and aggregates Table 14.9 Neville
Current CEM l (42,5R) is similar to former rapid hardening Portland (ASTM Type lll) [w/c 0.5 50 MPa, approximately linear to w/c 0.3 80 MPa]
Fig. 14.12 Neville Comment: Cube compressive strength Page 36 of 62 2. Selection of free water content for consistence Free water content assumed main factor to achieve various levels of consistence (in terms of slump) (Table 14.10 Neville)
Three maximum size coarse aggregates : 10, 20, 40 mm
Two types of coarse aggregates considered: Uncrushed (e.g. river gravel) Crushed (higher water demand)
(Neville, 2011) Page 37 of 62 3. Determination of cement content Cement content = (water content)/ (water/cement ratio)
Limit for minimum cement content for durability (EN 206 Table F.1 Annex F (informative)
Cement is the most costly not only on per unit mass basis but also for the amount in each unit volume of concrete
Cement has highest carbon footprint of all constituent materials in concrete
Minimum cement content achieved with minimum water content for consistence (including use of superplasticizers)
Limit for maximum cement content for development of heat of hydration in thick sections
Page 38 of 62 Durability Design of Concrete Structures SS EN 206-1:2009 Clause 4.1 Exposure classes related to environmental actions NOTE The exposure classes to be selected depends on the provisions valid in the place of use of the concrete.
SS 544-1:2009 Concrete Complimentary Singapore Standard to SS EN 206-1 Part 1: Method of specifying and guidance for the specifier
Table A.2 Classification of ground conditions provides more detailed criteria for sulfate and Tables A.1, A.4 and A.5 for exposure classes (presentation on durability) Page 39 of 62 4. Determination of total aggregate content Estimate density of fully compacted fresh concrete indicated for selected water content (Step 2) and specific gravity of coarse aggregate from chart (Fig. 14.13 Neville) If specific gravity of coarse aggregate in not known, recommend value of 2.6 for uncrushed aggregate and 2.7 for crushed aggregate Total aggregate = concrete density cement content water content
(Neville, 2011) Page 40 of 62 5. Determination of proportion of fine aggregate Bases for selection include level of consistence, water/cement ratio and fineness of fine aggregate (percentage of fine aggregate passing 600 m sieve (likely range 40 to 60%)
Determine proportion of fine aggregate in term of percent of total aggregate (Step 4) - Fig. 14.14 Neville
Fine aggregate content = % fine aggregate x total aggregate content
Coarse aggregate content = total aggregate content minus fine aggregate content
Recommend coarse aggregate divided into different single sized aggregates in proportions shown below
Total coarse aggregate 5 10 mm 10 20 mm 20 40 mm 100 33 67 - 100 18 27 55 Comment: approximately 1:2 between adjacent sizes Page 41 of 62 5. Determination of proportion of fine aggregate Neville, 2011 Comment: Commonly 20 mm max. size 60-180 mm slump Page 42 of 62 Volumetric Proportions of Concrete Mass proportions of concrete batching control
Volumetric proportions for consideration of contribution of components on properties of concrete
Density of concrete = M c + M w + M ca + M fa (M = mass content, kg/m 3 )
where c = cement, w = water, ca = coarse aggregate, fa = fine aggregate
Density of components: G c ,
G w , G ca , G fa are density of components with c = cement, w = water, ca = coarse aggregate, fa = fine aggregate Per cubic metre of concrete, V con
V c ,
V w , V ca , V fa and V air are volume of components with c = cement, w = water, ca = coarse aggregate, fa = fine aggregate
V con = V c + V w + V ca + V fa + V air = 1 m 3 V con = M c /G c + M w /G w + M ca /G ca + M fa /G fa + V air = 1 m 3
(Comment: Entrapped air content 2%, or max. 3% with chemical admixture) Nominal or determined density to indicate volume supplied in delivery truck
Page 43 of 62 Selection of Ingredient Proportions Both ACI and DOE approaches do not provide guidance on use of chemical admixtures (use manufacturers recommendation) The data used are based on experience in temperature climate and temperature effects for tropical climate not included In most RMC plants, past experience with available constituent materials for concrete has led to typical proportions for common range of characteristic strengths (C25/30 to C50/60) As set-retarding and plasticizing admixtures are typically used in tropical climatic conditions, adjustment of consistence is often provided by adjusting dosage of admixtures (Water reducing admixture: G1 10%, G2 20% and G3 30% or higher water reduction for similar slump) Typically strength/water-cement ratio is approximately linear over limited range of values, e.g. Fig. 14.12 (Neville 2011) shows approx. 10 MPa from w/c = 0.60 to 0.50 and approx. 15 MPa for each change in w/c = 0.10 between 0.50 and 0.30
Page 44 of 62 Durability Design of Concrete Structures - Sulfate SS EN 206-1:2009 Clause 4.1 Exposure classes related to environmental actions NOTE The exposure classes to be selected depends on the provisions valid in the place of use of the concrete.
SS 544-1:2009 Concrete Complimentary Singapore Standard to SS EN 206-1 Part 1: Method of specifying and guidance for the specifier
Table A.2 Classification of ground conditions provides more detailed criteria for sulfate attack Page 45 of 62 Durability Design of Concrete Structures - Sulfate SS 544-1: 2009 (BS 8500-1: 2006) Page 46 of 62 Durability Design of Concrete Structures - Sulfate SS 544-1: 2009 (BS 8500-1: 2006) Page 47 of 62 Durability Design of Concrete Structures - Sulfate SS 544-1: 2009 (BS 8500-1: 2006) Page 48 of 62 Durability Exposure classes related to environmental influence
Chemical attack (XA classes) BS EN 206-1: Where concrete is exposed to chemical attack from natural soils and ground water, the exposure shall be classified in Table 2. The classification of sea water depends on the geographical location, therefore the classification valid in the place of use of the concrete applies. Class designation Description of the environment Informative examples where exposure class may occur XA1 Slightly aggressive chemical environment according to Table 2
XA2 Moderately aggressive chemical environment according to Table 2 XA3 Highly aggressive chemical environment according to Table 2 Replacement for XA classes in BS EN 206-1, Table (shown above) with BS 8500-1 Annex A (informative) Table A.2 to determine the ACEC-class (see BRE Special Digest 1 for guidance on site investigation) Refer in BS EN 206-1 Table 2 Limiting values for exposure classes for chemical attack from natural soil and ground water Page 49 of 62 Extract from Table A.2 of SS 544-1 Classification of ground conditions (refer to the BS 8500-1 for the details) Sulfate and magnesium Design sulfate class Natural soil Brownfield A) ACEC- class (design sulfate class) 2:1 water/soil extract Groundwater Total potential sulfate B) Static water Mobile water Static water Mobile water SO 4 Mg C) SO 4 Mg C) SO 4
400 to 1400 0.24 - 0.6 DS-2 > 3.5 AC-1s > 5.5 >6.5 AC-2 2.5 to 3.5 AC-2s 2.5 to 5.5 5.6 to 6.5 AC-3z 4.5 to 5.5 AC-4z 2.5 to 4.5 AC-5z 1600 to 3000
1500 to 3000 0.7 to 1.2 DS-3 > 3.5 > 5.5 AC-2s > 5.5 > 6.5 AC-3 2.5 to 3.5
2.5 to 5.5
AC- 3s 2.5 to 5.5 5.6 to 6.5 AC-4 2.5 to 5.5 AC-5 Page 50 of 62 Extract from Table A.9 of SS 544-1 Selection of the nominal cover and DC-class or designated concrete and the number of APM for in-situ concrete elements where the hydraulic gradient due to groundwater is five or less (refer to the BS for details)
ACEC-class Lowest nominal cover E) , mm Intended working life F) At least 50 years G), H) At least 100 years AC-1s, AC-1 50 I) , 75 J) DC-1 (RC25/30 if reinforced) DC-1 (RC25/30 if reinforced) AC-2s AC-2 50 I) , 75 J) DC-2 (FND2) DC-2 (FND2) AC-2z 50 I) , 75 J) DC-2z (FND2z) DC-2z (FND2z) AC-3s 50 I) , 75 J) DC-3 (FND3) DC-3 (FND3) AC-3z 50 I) , 75 J) DC-3z (FND3z) DC-3z (FND3z) AC-3 50 I) , 75 J) DC-3 (FND3) DC-3 + one APM of choice, FND3 + one APM or choice, DC-4 or FND4 AC-4 50 I) , 75 J) DC-4 (FND4) DC-4 + one APM from APM2 to APM5, or FND4 + one APM from APM2 to APM5 AC-5 50 I) , 75 J) DC-4 (FND4) + APM3 K) DC-4 (FND4) + APM3 K) I) For concrete cast against binding J) For concrete cast directly against the soil (Designation within brackets refers to Designated Concrete in BS 8500-1) Page 51 of 62 Extract from Table A.11 of BS 8500-1 Limiting values of composition and properties for concrete where a DC-class is specified DC- class Max. w/c ratio Min. cement or combination content (kg/m 3 ) for max. aggregate size Cement and combination types Grouping used in BRE SD1: 2005[1] 40 mm 20 mm 14 mm 10 mm DC-1 A) All in Table A.6 A to G DC-2 0.55 300 320 340 360 IIB-V+SR, IIIA+SR, IIIB+SR, IVB-V D, E, F 0.50 320 340 360 380 CEM I, SRPC, IIA-D, IIA-Q, IIA-S, IIA-V, IIB- S, IIB-V, IIIA, IIIB A, G 0.45 340 360 380 380 IIA-L or LL 42.5 B 0.40 360 380 380 380 IIA-L or LL 32.5 C DC-2z 0.55 300 320 340 360 All in Table A.6 A to G DC-3 0.50 320 340 360 380 IIIB+SR F 0.45 340 360 380 380 IVB-V E 0.40 360 380 380 380 IIB-V+SR, IIIA+SR, SRPC D, G DC-3z 0.50 320 340 360 380 All in Table A.6 A to G A) If the concrete is reinforced or contains embedded metal, the minimum concrete quality for 20 mm maximum aggregate size is C25/30, 0.65, 260 or designated concrete RC25/30. Page 52 of 62 Exposure Classes Page 53 of 62 Exposure Classes National Foreword to SS 544-1: 2009 Guidelines are highlighted to guide local users: Annex A (informative) Exposure classes related to environmental conditions In order to cater to the higher ambient temperatures in Singapore compared to UK, the recommendation is to consider the required concrete for at least one class higher than that based on exposure conditions in accordance with the requirements for UK exposure conditions (refer to Table A.3). The specifier should take into consideration the nature of the element, intended working life, its importance and the cost of maintenance and repair to select the same or higher performance concrete. Different elements in the same structure may be specified with different concrete to optimise cost-effectiveness. Page 54 of 62 SS EN 544-1: 2009 Annex A (informative) Page 55 of 62 SS EN 544-1: 2009 Annex A (informative) Page 56 of 62 SS EN 544-1: 2009 Annex A (informative) Page 57 of 62 SS EN 544-1: 2009 Annex A (informative) Page 58 of 62 Durability Design of Concrete Structures - Examples Example Prescribed limits on w/c, cement content and cement type
Exposure class: Corrosion induced by carbonation (XC classes) Concrete for nominal cover of 25+Ac (mm) Exposure class: XC3/4: (intended working life of at least 50 years, 20 mm maximum size aggregate) Cement type: All in Table 6, except IVB-V Strength class SS 544-1 Table A.4 With + 2 MPa With + 5 MPa Designation C30/37-XC3/4 (0.55 300) C32/40-XC3/4 (0.52 310) C35/45-XC3/4 (0.50 320) Comment UK conditions May not be adequate Preferred Increase nominal cover to 30+Ac (mm) Exposure class: XC3/4: (intended working life of at least 50 years, 20 mm maximum size aggregate) Cement type: All in Table 6, except IVB-V Strength class SS 544-1 Table A.4 With + 2 MPa With + 4 MPa Designation C28/35-XC3/4 (0.60 280) C30/37-XC3/4 (0.55 300) C32/40-XC3/4 (0.52 310) Comment UK conditions May not be adequate Preferred Concrete for nominal cover of 30+Ac (mm) Exposure class: XC3/4: (intended working life of at least 100 years, 20 mm maximum size aggregate) Cement type: All in Table 6, except IVB-V Strength class SS 544-1 Table A.5 With + 5 MPa With + 10 MPa Designation C40/50-XC3/4 (0.45 340) C45/55-XC3/4 (0.40 380) C50/60-XC3/4 (0.35 380) Comment UK conditions Preferred For off-form finish Page 59 of 62 Durability Design of Concrete Structures - Examples Example Prescribed limits on w/c, cement content and cement type Exposure class: Corrosion induced by carbonation (XC classes) Concrete for nominal cover of 25+Ac (mm) Exposure class: XC2: (intended working life of at least 50 years, 20 mm maximum size aggregate) Cement type: All in Table 6 Strength class SS 544-1 Table A.4 With + 3 MPa With + 5 MPa Designation C25/30-XC2 (0.65 260) C28/30-XC2 (0.60 280) C30/37-XC2 (0.55 300) Comment UK conditions, same for higher covers May not be adequate Preferred Concrete for nominal cover of 30+Ac (mm) Exposure class : XC2: (intended working life of at least 100 years, 20 mm maximum size aggregate) Cement type: All in Table 6 Strength class SS 544-1 Table A.5 With + 3 MPa With + 5 MPa Designation C25/30-XC2 (0.65 260) C28/30-XC2 (0.60 280) C30/37-XC2 (0.55 300) Comment As for 50 years, but with larger cover May not be adequate Preferred Note: XC2: for foundations, often with nominal cover of 50 mm XC3/XC4: for above ground structures (see also XS1 airborne salts) Page 60 of 62 Comparison of Approach Information provided:
S.G. (SSD) = 2.65, Absorption 1%, Effective absorption = 0.5% Fine aggregate: Free moisture content 8% (total 9.5% absorption 1.5%) S.G. (SSD) = 2.50 Fineness modulus = 2.60, % passing 600 m = 50% CEM I (ASTM Type 1), S.G. = 3.15 Durability: XO (no special requirement)
(a) Select concrete composition without admixture (SSD aggregates) (b) Select concrete composition with admixture (SSD aggregates) Admixture to be taken as part of added water (dosage < 2 kg/m 3 ) Water reduction = 15% when added at recommended dosage Compute batch quantities for 1m 3 in each case (adjusted for moisture) Comment on differences in composition between ACI and DOE methods
Page 61 of 62 Review of Results Each method is based on different approaches to the selection of values to arrive at the concrete composition.
The results may differ within a narrow range between different persons as interpolation may be needed using the tables and figures provided in the presentation
You are encouraged to carry out case (a) for both approaches and send their compositions by e-mail to tamct@nus.edu.sg
A summary of submitted results will be presented for review at the end of the next presentation
Adjust concrete composition if Initial Test show: (Each case taken separately, all others data remain as before) (a) Mean cube compressive strength is 5 MPa below target (b) Fineness modulus changed to 2.30 (% passing 600 m = 60%) (c) Fine aggregate total moisture content = 12%