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HANSON CONCRETE
PHILIPPINES
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CONCRETE
FUNDAMENTALS &
TROUBLESHOOTING GUIDE

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Presentation Summary

FUNDAMENTALS OF CONCRETE
CEMENT

COMMON CONCRETE
PROBLEM

AGGREGATES

FRESH CONCRETE

WATER

HARDENED CONCRETE

MINERAL ADDITIVES
ADMIXTURES

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FUNDAMENTALS OF
CONCRETE

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CONCRETE IS A MIX OF:

cement

aggregates
Coarse
Fine

water

mineral additives

chemical admixtures

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of Concrete Mix by Volume

Air
1%

Aggregates
62%

Cement
16%

Admixtures
1%
Water
20%

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% of Concrete Cost
Water
3%
Admixtures
10%

Aggregates
20%
Air
0%

Cement
67%

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cement

is the binder / glue that holds it all together

is the most expensive concrete ingredient

greatly influence the properties of concrete

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Types of Portland Cement

Typical composition

ASTM Type

Characteristic

C3A

C4AF

C3S

C2S

Type I

Normal (OPC)

11

50

24

Type II

Moderate

13

42

33

Type III

High Early Strength 9

60

13

Type IV

Low Heat of Hydration5

12

26

50

Type V

Sulphate Resisting

40

40

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COMPOSITION OF CEMENT
Compound

Time of Reaction

Function

C3A - Tricalcium

Immediately

- Minor contribution to
strength and initial set
- Contribute to heat liberation

Aluminate
C4AF - Tetra Calcium
Aluminoferrite
C3S - Tricalcium
Silicate
C2S - Dicalcium
Silicate

2 - 3 hours
3 - 4 hours
14 - 18 days

- Same as above

- Major contribution to initial,

- Contribute to heat liberation

- Major contribution to strength > 90

days

- Contribute to strength after 14 18 days

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aggregates

Hardness

Shape - rounded / angular

Grading

reduces total volume of voids

Grading affects:

workability

water demand

shrinkage

durability

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Test of aggregates
Character

Significance

Particles shape & Surface

texture

Workability

Grading

Workability
Economy

BS 882

Chemical Stability

Strength Durability

ASTM C289

Organic Impurities

Strength & Durability

Resistance to Abrasion

Quality Control

Absorption & Surface MoistureQuality Control

Relative density (S.G)

Mix Design

Test Method
BS 812 Part 1

ASTM C40
ASTM
ASTM
ASTM
ASTM

C70
C566
C70
C566

ASTM C127
ASTM C128

Requirement
Max % flat & Elongated
pieces
Min & Max% Passing std
sieve
Max expansion of Mortar
bar
Max yellowish colour
Max % loss of mass
---

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Aggregate Shape & Texture

affect properties of fresh concrete

rough-textured, angular, elongated and flat particles have greater
surface area and require more cement paste than do smooth and
round aggregates
angular and poorly graded aggregates can be harder to place and
finish
Generally:
rounded gravel makes stronger more finishable lean mixes
angular crushed stone makes is better suited for high strength,
richer mixes

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Impurities in Aggregates

Organic impurities such as sugar

retards setting time of concrete and strength gain

Inorganic salts like chloride

accelerates setting of concrete and risks of corrosion of
reinforcing bar.

Clay/silt
induces low strength and high shrinkage in concrete

Reactive minerals and weak materials

affects durability and strength of concrete

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Potential Mix Problems

with Fine Aggregate

Coarse sand or undersanded mix:

hard to pump
hard to consolidate
excessive bleeding
hard to finish
segregation
hard to get accurate slump

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Potential Mix Problems

with Fine Aggregate

Fine Sand or oversanded mix:

increased water demand
sticky mix, hard to finish
reduced strength
blisters
bugholes
scaling

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water

Potable and free from chlorides and sulphates

Includes all water from:

batch water / water added at site

aggregates moisture content

admixtures (small amount)

Controls concrete strength

Controls concrete workability

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Mineral Additives
Pozzolan

source

fly ash

coal fired power plants

blast furnace slag

iron & steel industries

microsilica

silicon metal industries

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Pozzolanic Reaction
Cement + Water = Calcium Silicate Hydrate (Glue) +
Calcium Hydroxide (lime)

Calcium Hydroxide (lime) + Pozzolan + Water = Calcium

Silicate Hydrate (Glue)

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What is an Admixture?
materials other than water, aggregates and cement,
which are added to a batch of concrete during mixing to
modify some property of the concrete

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Admixtures give:

Economy

Durability

Constructability
All resulting in VALUE for the Engineer, Contractor and
Ready Mix Supplier

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Hot Weather Concreting

Hot weather effects the concretes:

setting time
quality of finished surface
durability
ultimate strength

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Special attention to:

concrete mix design

retardation

workability

site control

delivery timing

no water addition

curing

prevent cracking

ultimate strength

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Common problems with

concrete

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FRESH CONCRETE

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BLEEDING

CAUSES

PREVENTION/CORRECTION

COARSE SAND

FINER SAND

POORLY GRADED SAND

INCREASE % OF SAND
INTRODUCE AIR
ENTRAINMENT / FLY ASH
TO SUPPLEMENT SAND
FINES

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SEGREGATION

CAUSES

PREVENTION/CORRECTION

EXCESSIVELY WET MIX

LOWER SLUMP

OVER VIBRATION

MINIMIZE VIBRATION

EXCESSIVE DROP IN
PLACING

REDUCE FREE DROP

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LOW YIELD

CAUSES
INCORRECT BATCH
WEIGHTS
LOW AIR CONTENT

CORRECTION/PREVENTION
SCALE ACCURACY
ACCURACY OF S.G. OF
AGGREGATES
INCREASE AIR CONTENT

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HARSHNESS

CAUSES

PREVENTION/CORRECTION

INSUFFICIENT FINES

FINER SAND

POOR SAND GRADATION

HIGHER % OF SAND

COARSE AGGREGATE
GRADATION

CHANGE CEMENT/FLY ASH

PROPORTION
INTRODUCE AIR
ENTRAINMENT

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HARDENED CONCRETE

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LOW CYLINDER STRENGTH

CAUSES

PREVENTION/CORRECTION

POOR MOLDING OR
HANDLING OF CYLINDERS

MOLD CYLINDERS ACCORDING

TO ASTM STANDARD

EXPOSURE OF CYLINDERS
TO HIGH OR LOW
TEMPERATURE IN FIELD

STORE AT 60-80 DEGREE C ON

JOB SITE FOR 1 DAY, THEN 27
DAYS (OR UNTIL TEST) IN
LABORATORY

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DUSTING

CAUSES
WET MIX
OVER TROWELLING
RAPID DRYING

PREVENTION
CORRECTION
REDUCE WATER CONTENT

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SURFACE CRAZING

CAUSES

PREVENTION OR
CORRECTION

WET MIX

REDUCE WATER CONTENT

OVER TROWELING

LATER AND LESS

TROWELING

RAPID DRYING

MOIST CURING

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Concrete Cracks

Plastic Shrinkage Cracks

Before Set

Drying Shrinkage Cracks

After Set

Cracks occur when water evaporates from the surface

faster than it can appear at the surface during the
bleeding process.

Short, irregular cracks develop from this rapid drying

shrinkage and tensile stresses in the surface.

Generally plastic cracks appear when water sheen

disappears from surface.

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SHRINKAGE CRACKS

CAUSES

PREVENTION OR
CORRECTION

ABSENCE OF JOINTS

JOINTS AT 20 - 25 SPACING

RAPID DRYING

JOINT AT CHANGES IN
DIMENSION OF SLAB

WET MIX
LACK OF CURING

JOINTS AROUND EDGE OF

SLAB,COLUMNS,ETC.
REINFORCING MESH (HOLDS
CRACKS TOGETHER)
5 - 7 DAYS MOIST CURING

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Concrete Shrinkage
Concrete
Original Length

Unrestrained Shrinkage

Restrained shrinkage
Develops tensile stress
(Differential shrinkage between
surface and underlying layer)

If tensile stress >tensile strength

concrete cracks

All concrete undergoes a

volume change (shrinkage)
after placement. The volume
change is primarily caused by
moisture loss.

Reference: Engineering Bulletin No. 1

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Factors That Affect Early Cracking

Higher Water Content Mixes

Fine Dust/Clay-like Materials in Mix

Overheating in Cold Weather

Weather Conditions Influence Rate of Evaporation and

May Cause Cracks

Low Humidity

High Air/Concrete Temperature

High Wind Velocity

Temperature Changes

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Minimize Plastic Shrinkage Cracking

Saturate Forms and Sub-grade

Lower Concrete Temperature in Hot Weather

Minimize Time Between Placing & Finishing

Erect Wind Breaks

In Hot Weather, Protect the Concrete

Use Grace Fibers and MicroFiber

Covered in next module

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SETTLEMENT

CAUSES
POOR COMPACTION OF
SUBGRADE
HIGH EXPENSIVE
SUBGRADE

PREVENTION OR
CORRECTION
COMPACT SUBGRADE
COMPACTED 4 - 6
GRANULAR SUB-BASE
PREVENT BOND BETWEEN
FLOOR SLAB AND WALLS,
COLUMNS,FOOTINGS,ETC.

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HONEYCOMB

CAUSES
INADEQUATE SPADING
INADEQUATE VIBRATION
SEGREGATION
POORLY PROPORTIONED
MIX

PREVENTION OR
CORRECTION
INCREASE SPADING OR
VIBRATION
INCREASE MORTAR CONTENT
DEPOSIT CONCRETE AT MORE
FREQUENT INTERVALS
EXCESSIVE WATER LOSS
THROUGH FORM OPENING
USE AIR-ENTRAINED
CONCRETE

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