Spin Practical Aspects in Concrete Mix Design

PRACTICAL ASPECTS IN
CONCRETE MIX DESIGN

Prof. Dubravka Bjegovi, Ph.D.C.E.
University of Zagreb, Faculty of Civil Enginering, Department for
Materials
Institut IGH, d.d., Zagreb, Croatia
Assis.prof. Irina Stipanovi Oslakovi, Ph.D.C.E.

Institut IGH d.d., Zagreb, Croatia
University of Twente, Faculty of Engineering and Technology,
Construction Management and Engineering Department, Netherlands
1
1
CONCRETE IN EUROPE
Yearly production of concrete in Europe - 750
millions m3 (around 4 tonnes per EU citizen)
In the European Union (EU27 countries), total
cement production in 2007 is estimated at 283
million tonnes, representing 10.5% of world
production.
Cement production in the EU is dominated by
Spain, at over 19% of the EU total, followed by Italy
and Germany.
Natural resources consumation - 9 billion tonnes of
sand and rock and 0.9 billion tonnes of mixing water
annually
2
Concrete construction
Concrete construction is
becoming increasingly
complex and the importance
of producing structures that
meet required performances
or that satisfies their
strength, that are cost
effective and durable has
never been higher.
3
Concrete mix design

The process of selecting suitable
ingredients of concrete and determining
their relative amounts with the objective of
producing a concrete of the required,
strength, durability, and workability as
economically as possible, is termed the
concrete mix design.
CONCRETE building product produced

from:
cement c= 3 t/m3
aggregate a= 2.65 t/m3
water w= 1 t/m3
concrete
chemical and/or mineral
addmixtures
con= 2.4 t/m3
Concrete mix design

The various factors affecting the mix design
are:
Compressive strength
Workability
Durability
Cost
It is one of the most important
properties of concrete and
influences many other
describable properties of the
hardened concrete.
The mean compressive strength
required at a specific age, usually
28 days.
7
Two states of concrete

The proportioning of ingredient of
concrete is governed by the
required performance of concrete
in 2 states:
the plastic and
the hardened states.
If the plastic concrete is not

workable, it cannot be properly
placed and compacted. The
property of workability, therefore,
becomes of vital importance.
8
Workability
The degree of workability required depends on three

factors:
the size of the section to be concreted,
the amount of reinforcement, and
the method of compaction to be used.
The desired workability depends on the compacting

equipment available at the site.
9
Workability
For the narrow and complicated section with

numerous corners or inaccessible parts, the concrete
must have a high workability so that full compaction
can be achieved with a reasonable amount of effort.
This also applies to the embedded steel sections.
10
Concrete durability
Concrete durability is one of the most
important considerations in the design
of new structures and when assessing
the condition of existing structures.
Concrete durability: its resistance to
weathering action, chemical attack,
abrasion and other degradation
processes.
11
Concrete durability
Different concretes require different degrees
of durability depending on the exposure
environment and the properties desired.
12
Concrete durability
Durability of concrete can be addressed by
two approaches:
the prescriptive approach,
the performance based approach.
13
Concrete durability
Prescriptive approach
In the prescriptive approach, designers
specify materials, proportions, and
construction methods based on fundamental
principles and practices that exhibit
satisfactory performance.
14
Concrete durability
Performance based approach
In the performance based approach,
designers identify functional requirements
such as strength, durability, and volume
changes, and rely on concrete producers and
contractors to develop concrete mixtures to
meet those requirements.
15
Concrete durability
High strength concrete is generally more
durable than low strength concrete.
In the situations when the high strength is not
necessary but the conditions of exposure are
such that high durability is vital, the durability
requirement will be determined by concrete
penetrability (absorption, diffusion,
permeability).
P
H2O
C1
C2
C1 > C2
16
Performance specifications
Performance specifications define
performance for a given exposure and life
expectancy, and include tests, which are tied
not only in the laboratory but also to the field
performance of concrete.
17
Cost of concrete
The cost of
concrete is made
up of the cost of
materials, plant
and labour.
18
Concrete service life

Concrete ingredients, their proportioning,
interactions between them, placing and curing
practices, and the service environment
determine the ultimate durability and service
life of the concrete.
19
Variables in the concrete mix

proportioning -1
The actual cement strength is not necessarily the
one expressed by the grade of cement.
There are now a variety of supplementary
cementitious materials like fly ash, ggbs, micro
silica and metakaolin.
The supplementary cementitious materials not
only influence the strength of concrete, but also
the water demand, workability and the ability to
retain workability of the mix!
20
Variables in the concrete mix

proportioning -2
Admixtures continue to evolve, each generation of
these bringing in greater complexity in the
interplay of the constituents of concrete.
The transportation and placing methods have
their own demand on the properties of fresh
concrete at different stages.
Designers (both structural and concrete mix) have
the confidence, (sometimes a need) to use 56
days or even 90 days strength as against 28 days
strength.
21
Information for materials -1

For the concrete mix proportioning the
following information for available materials
will be useful:
Sieve analyses of fine and coarse aggregates.
Unit weight of coarse aggregate.
Bulk specific gravities and absorption of
aggregates.
Mixing-water requirements of concrete developed
from experience with available aggregates.
22
Information for materials -2

Relationship between strength and water-cement
ratio or ratio of water-to-cement plus other
cementitious materials.
Specific gravity of Portland cement and other
cementitious materials, if used.
Optimum combination of coarse aggregates to
meet the maximum density grading for mass
concrete.
23
Examples:
(prescriptive approach)
Simple one
Complex one
24
EXAMPLES
based on EN norms related to concrete structures:
EUROCODES and EN 206-1
1. CONCRETE REINFORCED ROOF PLATE
2. PRESTRESSED BEAM IN BRIDGE
25
1. REINFORCED CONCRETE ROOF PLATE
26
1. REINFORCED CONCRETE ROOF PLATE

Basic data about structural element
Concrete mix design has to be done for reinforced
concrete roof plate situated in the appartement
house
From structure design:
plate height is 20 cm, and surface area 135 m2.
27
STEPS IN QA/QC PROCEDURES

DURABILITY
STRENGTH
WORKABILITY
ADDITIONAL
REQUIREMENTS
GEOMETRICAL
CHARACTERISTICS
QUALITY CONTROL
AT THE SITE (BEFORE
POURING CONCRETE)
POURING
CONCRETE
C
O
S
T
CONTROL AFTER
POURING
28
Requirements for concrete are

defined in structural design project
ENVIRONMENTAL CLASSES
Corrosion induced by carbonation
XC1
Dry or
permanently
wet
Concrete in structures with low RH or dry air

Concrete permanently submerged
XC2
Humid, rarely dry
Concrete surface exposed to long-term contact with water

Most foundations
XC3
Moderate wet
Concrete in structures with moderate to high RH of air

Outer concrete protected from rain
XC4
Changing dry
and wet
conditions
Concrete surface in contact with water but different from

XC2
Plate is in the environment class XC1
29
Requirements for concrete mix design based on durability
DURABILITY CONDITION
Recommended limit values for concrete mix design for XC1
Exposure
class
Max w/c
ratio
Min
concrete
strength
class
Min. amount of
cement (kg/m3)
Min air
content (%)
Other
requirements
Degradation process: Carbonation
XC 1
0,65
C25/30
260
XC 2
0,60
C30/37
280
XC 3
0,55
C30/37
280
XC 4
0,50
C30/37
300
30

DURABILITY
STRENGTH
WORKABILITY
ADDITIONAL
REQUIREMENTS
GEOMETRICAL
PARAMETERS
QUALITY CONTROL
AT THE SITE (BEFORE
POURING CONCRETE)
IDENTITY TEST
POURING
C
O
S
T
CONTROL AFTER POURING
31
Requirements for concrete mix design based on structural design project
CONCRETE STRENGTH
Concrete must be of at least compressive
strength class C25/30.
Testing according HRN EN 12390-3
32
CEMENT
For construction of concrete plate following cement
may be used:
cement for general purpose, strength class 32,5.
It has to satisfy specifiations given in HRN EN 197-1.
Before using cement in the concrete production, it is

necessary to prove (certify) cements declared
properties
33
Requirements for concrete mix design based on cements strength and

type
STRENGTH REQUIREMENTS
fc(MPa)
C25/30
fc,m > fck + (6 do 12) N/mm2
fc,m > 30 + 8 = 38 N/mm2
for fc,m = 38 N/mm2 cement class 32,5

From the diagram w/c ratio can be
read and it is recommended to use:
w/c 0,55
w/c
34

STRENGTH
WORKABILITY
ADDITIONAL
REQUIREMENTS
GEOMETRICAL
PARAMETERS
QUALITY CONTROL
AT THE SITE (BEFORE
POURING CONCRETE)
C
O
S
T
POURING
35
CONCRETE COVER
Nominal concrete cover depth (cnom) is determined
from:
cnom=cmin + c
(mm)
where:
cmin minimum concrete cover depth depending on
environment class and i requirements for adhesion
properties
c allowed deviation (tolerance) in concrete cover
depth
Nominal concrete cover depth is cnom je 20 mm.

36
AGGREGATE
It is chosen to use natural river aggregate due to the source and
proved quality
Has to be certified and tested according HRN EN 12620.
Requirement Property
Class SI20
Shape index
Class LA35
Course aggregate resistance to grinding
Class FNR
Frost resistance
< 0,06 %
Chlorides content
AS0,2
Maximum sulpfate content dissolved in acid
1%
Total suplhate content
37
MAXIMUM GRAIN SIZE

Maximum grain size Dmax may not be greater than:
1)
2)
3)
concrete cover depth cnom

1/3 of plate height
0.8 horizontal distance of reinforcing bars
cnom concrete cover depth = 20 mm

d plate height = 20 cm
a horizontal distance between reinforcing bars = 125 mm
1)
2)
3)
Dmax c = 20 mm
Dmax 1/3d = 1/3200 = 66,7 mm
Dmax 0,8a = 0,8125 = 100 mm
Selected:
Dmax=16 mm
38
Requirements for concrete mix design based on maximum grain size Dmax
CHOICE OF CONCRETE ADMIXTURES

Concrete will be produced without admixtures
DETERMINATION OF PORE AMOUNT IN CONCRETE
(assumed values for design procedure)

Max grain size (mm)
The amount of air in

non-aerated concrete
(%)
The amount of entrained

air - pores (%)
32-63
0,4
2-3
16-32
1,5
3-5
8-16
2,5
5-7
4-8
7-10
39

WORKABILITY
ADDITIONAL
REQUIREMENTS
GEOMETRICAL
PARAMETERS
QUALITY CONTROL
AT THE SITE (BEFORE
POURING CONCRETE)
C
O
S
T
POURING
40
WORKABILITY REQUIREMENTS
SLUMP VALUES
Structure type
Transport type
Slump (mm)
Not reinforced or weak

reinforced concrete foundations
Straps, special containers
10 - 50
Reinforced foundations, walls,

plates, columns
Pumps, container on crane
60 - 120
Heavily reinforced columns and

beams
80 - 160
Industrial floors, roads
Straps, trucks
10 - 50
Concreting under water
Pumps, tubes
120 - 180
Mass concrete
Straps, trucks, sylobus
Anchoring pouring, casting

plates of machines
Containers
10 - 50
130 - 200
41
Class of workability
slump 60 -120 mm selected S2 (50-90 mm)
Slump class
(mm)
Vebe class
(s)
Compaction
class
Spread class
(mm)
S1
10 - 40
V0
31
C0
1,46
F1
340
S2
50 - 90
V1
30 - 21
C1
1,45 - 1,26
F2
350 - 410
S3
100 - 150
V2
20 - 11
C2
1,25 - 1,11
F3
420 - 480
S4
160 - 210
V3
10 - 6
C3
1,10 - 1,04
F4
490 - 550
S5
220
V4
5-3
C4
< 1,04
F5
560 - 620
F6
630
42
Requirements for concrete mix design based on workability
Water amount for 1m3 of fresh concrete (l)
Workabillity condition
Choice of demanded
amouont of water
for achieving slump
class S2
Curve
Crushed aggregate
River aggregate
S1
S2
S3
S1
S2
S3
A63
120
145
160
95
125
140
A32
130
155
175
105
135
150
A16
140
170
190
120
155
175
A8
155
190
210
150
185
205
B63
135
160
180
115
145
165
B32
140
175
195
130
165
185
B16
150
185
205
140
180
200
B8
175
205
225
170
200
220
C63
145
180
200
135
175
190
C32
165
200
220
160
195
215
C16
185
215
235
175
205
225
C8
200
230
250
185
215
235
43

WORKABILITY
IDENTITY CONTROL
ADDITIONAL
REQUIREMENTS
POURING
C
O
S
T
44

DURABILITY
DURABILITY
WORKABILITY
ADDITIONAL
REQUIREMENTS
CONCRETE MIX DEISGN
GEOMETRICAL
PROPERTIES
IDENTITY CONTROL
POURING
C
O
S
T
45
CONCRETE MIX DESIGN

SELECTED VALUES
Type of cement
Cement
CEM I 32,5
Type of aggregate
Natural river
aggregate
Max grain size (mm)
16
Pores (%)
2,5
w/c ratio
Strength condition
Durability condition
0,55
0,65
Selected
0,55
Amount of water for 1 m3 concrete ( l )

Amount of
cement (kg)
155
Lowest amount of cement durability condition:

Amount of cement from w/c strength condition:
260
281,8
Selected amount of cement:
282
46
Concrete mix design

Calculated values
ma
md
mw mc
Vz 1000
w c z ZPS d
Component
mass
(kg/m3)
Cement
282,0
Water
155,0
w/c = 0,55
Air 2,5 %
Aggregate
1924,0
TOTAL
2361,0
47
CALCULATION OF TOTAL CONCRETE

NEEDED
Plate dimensions:
Depth 20 cm
Surface 135 m2
Needed concrete total volume:

Vbet = 0,2 x 135 = 27 m3
Needed amount of each component:
Cement:
Water:
Aggregate:
7614 kg
4185 l
51945 kg
48

DURABILITY
DURABILITY
WORKABILITY
ADDITIONAL
REQUIREMENTS
GEOMETRICAL
PROPERTIES
IDENTITY CONTROL
C
O
S
T
POURING
49
Quality control for determination of

concrete mix design
Quality control during production of concrete
at the concrete plant
Qulity control at site before pouring concrete

identity control testing
50
QUALITY CONTROL AT THE SITE

IDENTITY TESTING
Testing of fresh concrete properties
workability - slump
pore amount
temperature
51

IDENTITY TESTING
Sampling in order to make control of
hardenet concrete propestries:
Identity of compressive strength
52

IDENTITY TESTING
Program for sampling for test on hardened concrete
in order to prove identity of compressive strength
and other required properties
Criteria:
Certified production of concrete

Uncertified production of concrete
Property
Number of samples
3 samples
53

DURABILITY
STRENGTH
WORKABILITY
ADDITIONAL
REQUIREMENTS
GEOMETRICAL
PROPERTIES
IDENTITY CONTROL
C
O
S
T
POURING
54

DURABILITY
STRENGTH
WORKABILITY
ADDITIONAL
REQUIREMENTS
GEOMETRICAL
CHARACTERISTICS
QUALITY CONTROL
AT THE SITE
(IDENTITY TEST)
POURING
C
O
S
T
55
56

Concrete mix design for 2 prestressed beams in
longitudinal direction, freely supported on ends, for
train bridge
Data from structure design project
Beam height 130 cm,

width 420 cm,
length 24,60 m,
span 23,00 m.
Beam cross section

57
Reinforcement
Beam is heavily reinforced, and
post-tensioned prestressed in
longitudinal direction
Grouting of tendons after
prestressing.
58

DURABILITY
STRENGTH
WORKABILITY
ADDITIONAL
REQUIREMENTS
GEOMETRICAL
CHARACTERISTICS
QUALITY CONTROL
AT THE SITE (BEFORE
POURING CONCRETE)
POURING
CONCRETE
C
O
S
T
CONTROL AFTER
POURING
59
Requirements for concrete based on

structural design project
Asset type
Bridge for 2-track-railway
Main span is over the river
vale.
Environment class
Outer element.
Frost action.
Atmospheric action.
60
Exposure classes
Corrosion caused by carbonation
XC1
Dry or permanently
wet
Reinforced and prestressed concrete surfaces inside enclosed structures except areas of structures
with high humidity
Reinforced and prestressed concrete surfaces permanently submerged in non-aggressive water
XC2
Wet, rarely dry
Reinforced and prestressed concrete completely buried in soil, foundations
Moderate humidity
External reinforced and prestressed concrete surfaces sheltered from, or exposed to, direct rain
Reinforced and prestressed concrete surfaces subject to high humidity (e.g. poorly ventilated
bathrooms, kitchens)
Moderate humidity
or cyclic wet and
dry
Reinforced and prestressed concrete surfaces exposed to alternate wetting and

drying
Interior concrete surfaces of pedestrian subways not subject to de-icing salts,
voided superstructures or cellular abutments
Reinforced or prestressed concrete beneath waterproofing
XC3
XC4
Corrosion caused by freezing/thawing with or without de-icing salts
Moderate water
saturation without
de-icing agent
Vertical concrete surfaces such as faades and columns exposed to rain and freezing
Non-vertical concrete surfaces not highly saturated, but exposed to freezing and to
rain or water
XF2
Moderate water
saturation with de-icing
agent
Concrete surfaces such as parts of bridges, which would otherwise be classified as XF1, but which
are exposed to de-icing salts either directly or as spray or run-off
XF3
High water saturation

without de-icing agent
Horizontal concrete surfaces, such as parts of buildings, where water accumulates and which are
exposed to freezing
Concrete surfaces subjected to frequent splashing with water and exposed to freezing
High water saturation

with de-icing agent or
sea water
Horizontal concrete surfaces, such as roads and

pavements, exposed to freezing and to de-icing salts either
directly or as spray or run-off
Concrete surfaces subjected to frequent splashing with
water containing de-icing agents and exposed to freezing
XF1
XF4
61
Requirements for concrete mix design based on durability
DURABILITY REQUIREMENTS
Recommended limit values for concrete composition for
clasess XC4 and XF1
Environment class
Max wc
ration
Min
strength
Min. amount of
cement (kg/m3)
Min air
content (%)
XC 4
0,50
C30/37
300
XF 1
0,55
C30/37
300
Additional
requirements
Aggregate
according
HRN EN 12620 has
to be frost resistant
62

DURABILITY
STRENGTH
WORKABILITY
ADDITIONAL
REQUIREMENTS
GEOMETRICAL
PARAMETERS
QUALITY CONTROL
AT THE SITE (BEFORE
POURING CONCRETE)
IDENTITY TEST
POURING
C
O
S
T
63
MECHANICAL PROPERTIES OF CONCRETE:

STRENGTH AND MODULUS OF ELASTICITY
Compressive strength class
(testing acc. HRN EN 12390-3)
C35/45
Average concrete tensile strength fctm

(testing acc. HRN EN 12390-6)
3,2 N/mm2
Static modulus of elasticity (Ecm)

(acc. HRN U.M1.025)
33500 N/mm2
Minimum compressive strength needed for prestressing

calculated on final force of prestressing (at the age of
concrete of 30 days tested on concrete cylinder)
34 N/mm2
64
CEMENT
It is possible to use:
Beam:
height 130
cm,
width 420
cm,
length
24,60 m
cement for general purpose,

Strength class 42,5,
With the condition of low hydration heat (sign LH).
Cement has to satisfy specifications according

norms HRN EN 197-1 and HRN EN 197-3.
Need to be certified
65
Requirements for concrete mix design based on

concrete strength required and chosen cement
Strength conditions
fc(MPa)
C35/45
fc,m > fck + (6 do 12) N/mm2
fc,m > 45 + 10 = 55 N/mm2
for fc,m = 55 N/mm2 and class of
cement 42,5
From diagram read value is:
w/c ratio of 0,45
w/c
66

STRENGTH
WORKABILITY
ADDITIONAL
REQUIREMENTS
GEOMETRICAL
PARAMETERS
QUALITY CONTROL
AT THE SITE (BEFORE
POURING CONCRETE)
C
O
S
T
POURING
67
Requirements for concrete mix design based on

structural design project
CONCRETE COVER
Nominal concrete cover depth (cnom) is determined
from:
cnom=cmin + c
(mm)
where:
cmin minimum concrete cover depth depending on
environment class and i requirements for adhesion
properties
c allowed deviation (tolerance) in concrete cover depth
cnom = 55 mm for ordinary steel reinforcement

cnom = 105 mm for prestressing steel
68
AGGREGATE
It is chosen to use crashed aggregate due to the source and proved
quality
Has to be certified and tested according HRN EN 12620.
Requirement
Property
Class SI20
Shape index
Class LA35
Course aggregate resistance to grinding
0,075 %
Volume stability shrinkaeg due to drying
Class F1
Frost resistance
< 0,03 %
Chlorides content
AS0,2
Maximum sulpfate content dissolved in acid
1%
Total suplhate content
69
MAXIMUM GRAIN SIZE
Maximum grain size Dmax may not be greater than:

1) concrete cover depth cnom
2) 1/4 of beam height
3) 0,8 horizontal distance of reinforcing bars minimum sistance is 90
mm accroding the project
cnom concrete cover depth = 50 mm
d plate height = 20 cm
a horizontal distance between reinforcing bars = 125 mm
1)
2)
3)
Dmax c = 550 mm
Dmax 1/4d = 1/3250 = 62,5 mm
Dmax 0,8a = 0,890 = 72 mm
Selected:
Dmax=32 mm
70
Requirements for concrete mix design based on maximum grain size Dmax
CHOICE OF CONCRETE ADMIXTURES

Concrete will be produced wit admixture AIR ENTRAINING
AGENT in order to ensure frost resistance of concrete
DETERMINATION OF PORE AMOUNT IN CONCRETE
(assumed values for design procedure)

Max grain size (mm)
The amount of air in

non-aerated concrete
(%)
The amount of
entrained air - pores
(%)
32-63
0,4
2-3
16-32
1,5
3-5
8-16
2,5
5-7
4-8
7-10
71
Choice of concrete admixtures and requirements
Pore content in fresh concrete (testing acc.

HRN EN 12350-7):
Tested mix 2,5% of the value in the control mix
Total content of air should be 4-6% of volume
Pores in hardened concrete (testing acc. HRN

EN 480-11):
Air spacing ratio in tested mix has to be 0,200 mm
Compressive strenght at 28th day

(teseted acc. HRN EN 12350-3):
Tested mix 75% of control mix
72

WORKABILITY
ADDITIONAL
REQUIREMENTS
GEOMETRICAL
PARAMETERS
QUALITY CONTROL
AT THE SITE (BEFORE
POURING CONCRETE)
C
O
S
T
POURING
73
WORKABILITY REQUIREMENTS
SLUMP VALUES
Structure type
Transport type
Slump (mm)
Not reinforced or weak

reinforced concrete foundations
Straps, special containers
10 - 50
Reinforced foundations, walls,

plates, columns
60 - 120
Heavily reinforced columns

and beams
80 - 160
Industrial floors, roads
Straps, trucks
10 - 50
Concreting under water
Pumps, tubes
120 - 180
Mass concrete
Straps, trucks, sylobus
Anchoring pouring, casting

plates of machines
Containers
10 - 50
130 - 200
74
Class of workability
slump 80 -160 mm selected S3 (100-150 mm)
Slump class
(mm)
Vebe class
(s)
Compaction
class
Spread class
(mm)
S1
10 - 40
V0
31
C0
1,46
F1
340
S2
50 - 90
V1
30 - 21
C1
1,45 - 1,26
F2
350 - 410
S3
100 - 150
V2
20 - 11
C2
1,25 - 1,11
F3
420 - 480
S4
160 - 210
V3
10 - 6
C3
1,10 - 1,04
F4
490 - 550
S5
220
V4
5-3
C4
< 1,04
F5
560 - 620
F6
630
75
Requirements for concrete mix design based on workability
Water amount for 1m3 of fresh concrete (l)
Workabillity condition
Choice of demanded
amouont of water
for achieving slump
class S3
Curve
Crushed
aggregate
River aggregate
S1
S2
S3
S1
S2
S3
A63
120
145
160
95
125
140
A32
130
155
175
105
135
150
A16
140
170
190
120
155
175
A8
155
190
210
150
185
205
B63
135
160
180
115
145
165
B32
140
175
195
130
165
185
B16
150
185
205
140
180
200
B8
175
205
225
170
200
220
C63
145
180
200
135
175
190
C32
165
200
220
160
195
215
C16
185
215
235
175
205
225
C8
200
230
250
185
215
235
76

WORKABILITY
IDENTITY CONTROL
ADDITIONAL
REQUIREMENTS
POURING
C
O
S
T
77
Requirements for concrete mix design based on structure design project
Special conditions by the construction of structural

element
Due to large dimensions of this beam (130x420
cm) it can be expected a high temperature in the
middle of cross section due to the heat hydration
development.
It is recommended to:
use cement of low hydration heat during mix design
preliminary testing of heat development during hydration on
concrete for the prestressed beam
78
Requirements for concrete mix design based on structure design project
Special conditions by the construction of structural element
Due to the post-tensioning of tendons it is necessary to determine:

Shrinkage of concrete (HRN U.M1.029) and
Creep coefficient of concrete (HRN U.M1.027).
Design values of shrinkage and creep

Basic deformation of shrinkage cs (mm/m)
- At the age of t1 = 30 days
cs(t1, ts) = -0,8410-5
- At the age of t = 30000 days
cs(t, ts) = -20,3910-5
Creep coefficient (t, t0)

- At the age of t1 = 30 days
(t1, t0) = 0,423
- At the age of t = 30000 days
(t, t0) = 1,610

79
Requirements for concrete

Additional requirements for fresh concrete
Cement of low hydration:
sign LH
Hydration heat:
270 J/g
Temperature of fresh concrete:
5-25 C
Pore content in fresh concrete:
4%
80
Requirements for concrete

Additional requirements for hardened concrete
Freezing thawing test (frost resistance): 100 cycles
Tensile strength:
3,2 N/mm2
Static modulus of elasticity:
33500 N/mm2
Maximum shrinkage at the age of t1 = 30 days:

cs(t1, ts)= -0,8410-5 mm/m
Maximum creep coefficient at the age t1 = 30 days:
(t1, t0) = 0,423
81

DURABILITY
DURABILITY
WORKABILITY
ADDITIONAL
REQUIREMENTS
CONCRETE MIX DEISGN
GEOMETRICAL
PROPERTIES
IDENTITY CONTROL
POURING
C
O
S
T
82
CONCRETE MIX DESIGN

recommended and selected values
Type of cement PC, low hydration cement
CEM I 42,5 LH
Aggregate type
Drobljeni agregat
Maximum grain size (mm)
32
Admixture
aerant
Air content (%)
w/c ratio
Strength requirement
Durability risk - frost (XF1)
Durability risk - carbonation (XC4)
0,45
0,55
0,50
Selected
0,45
Amount of water on 1 m3 of concrete ( l )

Cement
amount (kg)
195
Lowest amount of cement durability condition:

Amount of cement from w/c strength condition:
300
433,3
Selected value of cements::
433
83
CALCULATION OF
CONCRETE MIX DESIGN
ma
md
mw mc
Vz 1000
w c z ZPS d
COMPONENT
MASS
(kg/m3)
Cement
433,0
Water
195,0
w/c = 0,45
Air entrainer 0,5% on
mc
Air 4 %
~2,0
-
Agreggate
1708,0
TOTAL
2338,0
84
CALCULATION OF TOTAL CONCRETE

NEEDED
Beam dimensions:
Beam length 24,6 m
Cross section surface 5,76 m2
Concrete needed for 2 beams:

Vbet = 24,6 x 5,76 x 2 = 283,4 m3
Needed amount of each component:
Cement:
Water:
Agreggate:
Air entraining agent:
122.712 kg
55.263 l
484.025 kg
615 kg
85

DURABILITY
STRENGTH
WORKABILITY
ADDITIONAL
REQUIREMENTS
GEOMETRICAL
PROPERTIES
IDENTITY TESTING
C
O
S
T
POORING
CONTROL AFTER POORING
86
Quality control for determination of

concrete mix design
Quality control during production of concrete
at the concrete plant
Quality control at site before pouring concrete

identity control testing
87

IDENTITY TESTING
Testing of fresh concrete properties
workability - slump
pore amount
temperature
88

IDENTITY TESTING
Quality control of hardened concrete
identity tests of:
Tensile strength by splitting
Static modulus of elasticity
Freezing/thawing
Shrinkage
Creep
89

IDENTITY TESTING
Program for sampling concrete
property
Broj i uestalost uzimanja uzoraka
At least 1 sample on a day of concreting

At least 1 sample on each 100 m3 poored concrete
Tensile strength
At least 1 sample on a day of concreting

At least 1 sample on each 200 m3 poored concrete
Static modulus of
elasticity
3 samples for compressive strength determination

3 samples for static modulus of elasticity
Freezing thawing
resistance
15 samples
Shrinkage
At least 3 samples
Creep
3 samples for deformations due to shrinkage

3 samples for compressive strength
3 samples for meausirng total deformations under a constant load
90

IDENTITY TESTING
CRITERIA FOR COMPRESSIVE STRENGTH
For certified production of concrete
Number of tested samples for
declared amount of concrete
production
Criteria 1
Criteria 2
Average from n results (fcm)

(N/mm2)
Each single result (fci) (N/mm2)
fck + 1
fck - 4
2-4
For uncertified concrete production
Initial
Continuous
Number of tested
samples, n, for
the assesment of
strength in the
group
Criteria 1
Criteria 2
Average from n results

(fcm) (N/mm2)
Each single result (fci)

(N/mm2)
fck + 4
fck - 4
Not less than 15
fck +1,48
fck - 4
91

IDENTITY TESTING
CRITERIA FOR TENSILE STRENGTH
Production
Initial
Continuous
Number of tested
samples, n, for
the assesment of
strength
Criteria 1
Criteria 2
Average from n
results (ftm)
(N/mm2)
Each single result

(fti) (N/mm2)
fck + 0,5
fck 0,5
Not less than 15
fck + 1,48
fck 0,5
92

IDENTITY TESTING
CRITERIA
PROPERTY
CRITERIA
Freezing / thawing resistance
Loss of compressive strength after 100

cycles has to be less than 25%
Modulus of elasticity
33.500 N/mm2
Maximum shrinkage at t1 = 30
days (cs(t1, ts))
-0,8410-5 mm/m
Maximum creep at t1 = 30 days

0,423
((t1, t0))
93
REQUIRED PROPERTIES
FOR THE GROUT
TESTING
PROPERTY
METHOD
HRN EN 445
DESCRIPTION
Fluidity / flowability
Cone method
Time needed for flow of 1L of grout

through the cone
Bleeding
Gauge glass
The amount of bleeded water after 3

hours
Volume deformations
metoda s
limenkom
Compressive
strentgh
prisms
Volume deformations within 24 hours

On prisms 4x4x16 cm, after 28 days
CRITERIA
HRN EN 447
25 s
<2% from
initial volume
>-1%; < +5%
> 30 MPa
94

DURABILITY
STRENGTH
WORKABILITY
ADDITIONAL
REQUIREMENTS
GEOMETRICAL
CHARACTERISTICS
QUALITY CONTROL
AT THE SITE
(IDENTITY TEST)
POORING
C
O
S
T
QUALITY CONTROL
AFTER POORING
95

DURABILITY
STRENGTH
WORKABILITY
ADDITIONAL
REQUIREMENTS
GEOMETRICAL
CHARACTERISTICS
QUALITY CONTROL
AT THE SITE
(IDENTITY TEST)
POORING
C
O
S
T
CONTROL AFTER POORING
96
SUMMARY- 1
Durability of concrete in 21st century:
carefully selected materials
control and optimization of their properties
reduction of varaiblity in mixing, transport,
placement and curing of concrete
performance-based specifications to control insitu concrete
real-time monitoring, NDT evaluation
understanding reaction between concrete and its
environment
97
SUMMARY - 2
It is surely within the capability of the modern
day IT systems to capture all these variables in
a complicated mix design software.
However, the trial mix would not necessarily
follow the predicted results as the numbers of
independent variables contributing to the
single outcome are too many!
98
SUMMARY -3
The journey from the calculated mix
proportion to the final proportion would
require judgment and experience, and
laboratory trials.
99
100
Thank you
for
your attention!
101

Spin Practical Aspects in Concrete Mix Design

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Spin Practical Aspects in Concrete Mix Design

Hochgeladen von

Copyright:

Verfügbare Formate

PRACTICAL ASPECTS IN

CONCRETE MIX DESIGN

Assis.prof. Irina Stipanovi Oslakovi, Ph.D.C.E.

Concrete mix design

CONCRETE building product produced

aggregate a= 2.65 t/m3

con= 2.4 t/m3

Concrete mix design

Two states of concrete

If the plastic concrete is not

The degree of workability required depends on three

The desired workability depends on the compacting

For the narrow and complicated section with

Concrete service life

Variables in the concrete mix

Variables in the concrete mix

Information for materials -1

Information for materials -2

1. REINFORCED CONCRETE ROOF PLATE

1. REINFORCED CONCRETE ROOF PLATE

STEPS IN QA/QC PROCEDURES

Requirements for concrete are

Concrete in structures with low RH or dry air

Humid, rarely dry

Concrete surface exposed to long-term contact with water

Concrete in structures with moderate to high RH of air

Concrete surface in contact with water but different from

Plate is in the environment class XC1

Requirements for concrete mix design based on durability

Degradation process: Carbonation

STEPS IN QA/QC PROCEDURES

CONTROL AFTER POURING

Requirements for concrete mix design based on structural design project

Requirements for concrete mix design based on structural design project

It has to satisfy specifiations given in HRN EN 197-1.

Before using cement in the concrete production, it is

Requirements for concrete mix design based on cements strength and

for fc,m = 38 N/mm2 cement class 32,5

STEPS IN QA/QC PROCEDURES

CONTROL AFTER POURING

Requirements for concrete mix design based on structural design project

Nominal concrete cover depth is cnom je 20 mm.

Requirements for concrete mix design based on structural design project

Course aggregate resistance to grinding

Maximum sulpfate content dissolved in acid

Total suplhate content

Requirements for concrete mix design based on structural design project

MAXIMUM GRAIN SIZE

concrete cover depth cnom

cnom concrete cover depth = 20 mm

CHOICE OF CONCRETE ADMIXTURES

DETERMINATION OF PORE AMOUNT IN CONCRETE

(assumed values for design procedure)

The amount of air in

The amount of entrained

STEPS IN QA/QC PROCEDURES

CONTROL AFTER POURING

Requirements for concrete mix design based on structural design project

Not reinforced or weak

Straps, special containers

Reinforced foundations, walls,

Pumps, container on crane

Heavily reinforced columns and

Pumps, container on crane