Concrete Mix Design

(for the Practicing Engineer)

Otto J. Schwarz, P.E., S.E.

Ryan Biggs | Clark Davis Engineering and
Surveying D.P.C.

SE University, September 2020 www.LearnWithSEU.com

 Learning Objectives
Learning Objectives:
 Understand the composition and curing of structural
concrete. (qualitatively)
 Learn the function and roles of:
 Pozzolans / supplementary cementitious materials
 “Common” Admixtures.
 Learn what to look for in a Concrete Mix Design Review
 Qualitatively predict the relative behavior of a concrete
mix design.
2
 Basis of Information
(experience and primary sources)
 Construction Materials, CE302, Tennessee Technological
University, Dr. L.K. Crouch, PhD, P.E.
 Theory and Chemistry of Concrete, CE 551, North Carolina State
University, Dr. Mike Leming, PhD
 “Properties of Concrete, 4th Ed.” A. M. Neville
 John A. Carpenter, P.E.
 ACI 318 Building Code Requirements for Structural Concrete
 ACI 301 Specifications for Structural Concrete
 22 years of personal experience in Concrete Building Structural
Design, Construction Support, and Concrete Restoration Projects:
 Florida, Tennessee, North Carolina, Texas, Oregon, New York,
South Carolina, Maryland, Etc.
 Concrete producers who lent their time & expertise over the years.
3
 Qualitative not Quantitative
for Practical Daily Use
 Focus on:
 General behavior
 Relative effects
 Approximate (estimated) properties

WHY?
 Because…
 Complex collection of interacting chemical reactions
 Sensitive to external variables
 Environmental
 Procedural
No complex math or balancing of chemical equations!
4
 Concrete Mix Design
(for the Practicing Engineer)

I. What is and what isn’t in Concrete?

II. Portland Cement Hydration
i. Hydration and the Strength Gain Model
ii. Pozzolans & Supplementary Cementitious Materials
iii. How much water is enough? (or Too Much)
III. Aggregate (Coarse and Fine)
i. Workability and Consolidation
ii. Strength and Shrinkage
IV. Chemical Admixtures
i. Air Entrainment
ii. Set / Rate Modifiers (Accelerators and Retarders)
iii. Lubricants (Water Reducing Admixtures)
5
 Concrete Mix Design
(for the Practicing Engineer)

V. Performance Specification - ACI 318 / 301

i. Durability Requirements / Restrictions / Reasons
VI. Concrete Mix Design Review
i. Specification
ii. ACI 318 / 301
VII. “Rules of Thumb” and Performance Approximation
VIII. Field Items, Investigations
i. “Bad Breaks”
ii. Petrography

6
 Concrete Mix Design Review
(Specifications - 318, 301)

 Specification / Drawings Govern Requirements

 ACI 318 Ch 26 lists minimum requirements (ASTM Compliance)
 Can incorporate ACI 301 (and modify)
 Specify Structural Requirements
 Specify Durability Requirements

 ACI 301 Section 4, Submittals

 Mixture Proportions
 Mixture Strength Data
 Concrete Materials and Durability Compliance
 Cement

 Aggregate

 Admixture

 Water

 Field Test Records / Trial Mixture Records

7
 What is Concrete?
Chemically bound heterogeneous mixture of Cement,
Aggregate (rock and/or sand), and Water.
(… and various other chemical admixtures intended to enhance the
interaction of the basic constituent materials and/or modify the final
properties of the concrete.)

8
Start with:
 Portland Cement (anhydrous)
 Fly Ash, Ground Granulated Blast Furnace Slag, Silica Fume (all
optional)
 Coarse Aggregate
 Fine Aggregate
 Water (free)
… and then a miracle occurs…
(thank you Sidney Harris)

End with:
 Calcium Silicate / Aluminate Hydrate Crystals, Lime, Gypsum
 Coarse Aggregate
 Fine Aggregate
 Water (chemically bound, trapped, free)

*Concrete does not “dry”, it hydrates (cures).

9
 What is Portland Cement?
Limestone, shells, and chalk or marl combined with shale,
clay, slate, blast furnace slag, silica sand, and iron ore1 are
crushed, mixed, and heated in a kiln to about 2,700° F and
then ground fine with small additions of fine gypsum and
limestone. (Water and C02 are
driven off early in the kiln followed
by chemical reaction/transformation.)

1. PCA, “How Cement is Made”, www.cement.org.... and other sources. 10

 Portland Cement Hydration
(quick notation summary to keep it “simple”)

PC Clinker Hydrated PC

2C3S + 6H ===> C3S2H3 + 3CH

and
2C2S + 4H ===> C3S2H3 + CH
C-S-H and CH make up more than 50% of PC paste volume.

11
 Portland Cement Hydration Initial Set
(very simple hydration time-line)

1. Water, PC Clinker, and Gypsum react to form Ettringite.

2. As Gypsum is used up, Ettringite begins to break down.
3. Slower (exothermic) Hydration Reaction of Water and PC Clinker
Begin forming C-S-H and Lime (CH).
4. Pozzolans (amorphous silica) react with by-products of C-S-H
Hydration (CH & Water) to form more C-S-H.

12
 Portland Cement Hydration
(Pozzolanic Reaction – a little closer look)

Pozzolan: A material which possesses no cementing property by

itself, but in the presence of lime (CH) and water (H) produces
compounds with cementing properties.

CH + Silica(amorphous/non-crystalline and reactive) ===> C-S-H + H

1. Reaction requires the products (CH) of PC hydration

2. Reaction rate is slower than PC hydration

13
 Portland Cement Hydration
(Pozzolans and Supplementary Cementitious Materials) ACI Calls
This “Strength
Activity Index”

Material Type or Source Pozzolan? Effectiveness Cost/Ton

Form (lb/lb subst.) (2018)*
Fly Ash Class F1 Hard Coal Yes 1.2 $30
Fly Ash Class C2 Soft Coal No 1.2 $30
Slag Grade: Pig Iron Slag No 1 $60 to $70
(GGBFS) 80,100, 1203 (depends)
Silica Densified or Silica and Yes! 0.7 $400 to
Fume Slurry4 Ferrosilica $800
Industries

* Portland Cement Cost / Ton is approximately

• 2018 - $80 to $100 (2018) Highly Dependent on
• 2020 - $110 to $125 (2020) Location, Availability,
Global Events, etc.
* Fly Ash (2020) - $85 to $90/ton
14
 Portland Cement Hydration
(Pozzolans and Supplementary Cementitious Materials, the footnotes)

1. Class F Fly Ash is mostly amorphous silica and therefore

needs CH and water – Pozzolan.
2. Class C Fly Ash has a high lime content and is somewhat
self reactive and cementitious.
3. GGBFS contains limestone, silica, alumina, and iron which
are the same components found in Portland cement clinker.
It is self reactive and cementitious.
4. Silica fume is pure amorphous reactive silica and is ground
much more finely than Portland cement. It requires CH and
water but is highly reactive – Pozzolan.

15
 Portland Cement Hydration
(summary)

Approximate Strength / Mechanism / Cause

Time / Age Stage
1 ½ to 2 Hours Initial Set Ettringite (AFt) Formation
≈ 8 Hours Final Set Beginning C-S-H and CH
1 Day 25% f’c Continued Reaction
3 Days 50% f’c Pozzolinic Reaction Begins (if present)
7 Days 75% f’c Continued Reaction and Densification
28 Days 100% f’c
90 days 125% f’c

16
 Portland Cement Hydration
(how much water is enough?)

 Theoretical Chemical H2O Demand

 w/c ≈ 0.32 to 0.34

 Empirical Chemical H2O Demand

 w/c ≈ 0.23 (@ t > 28 days to t < 1 year)
 Because approximately 19% of PC remains unhydrated
 Yes, this is different with water reducing admixtures, etc.

 “Non-Evaporable” H2O Demand

 w/c ≈ 0.42 (reacted, bound, and held in discontinuous pores)

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 Portland Cement Hydration
(Theoretical and Chemical Water Demand)

C-S-H layer surrounding C3S. Flaking layer exposes more C3S. C-S-H mass becomes less permeable.

1) C-S-H skin forms on water-accessible perimeter of C3S particles.

2) Breaks in C-S-H skin occur due to mixing or osmotic pressure.
3) Solution/Precipitation reaction slowly changes to diffusion driven reaction
as C-S-H density increases.

Unhydrated C3S/C2S remains in mature concrete.

18
 Portland Cement Hydration
(Non-Evaporable Water, Structure, and Strength)

Schematic of PC Paste (C-S-H, CH, voids). Feldman-Sereda Model of

C-S-H Structure (1970)
“Unlike other porous materials such as sandstone, brick, or porous glass, the interatomic bonding continuity of cement-based
materials like concrete is far from obvious. When scrutinized at the micro- or nanoscopic level, the continuity of the ionic–
covalent bonding in the solid phase is interrupted almost everywhere by water molecules or liquid water films. The same
situation is found in set plaster. Yet, plaster and cementitious materials are able to withstand stresses of the same order of
magnitude as rocks. Molecular simulation studies and direct-force measurements by atomic force microscopy provide strong
arguments for predicting that short- and medium-range surface forces mediated by partially or totally hydrated calcium ions are
the essential components of cement strength, with additional contributions from van der Waals and capillary forces. This
provides a clue for understanding the nano- and mesostructure of cement-based materials and new levers for improving their
properties.”

Pellenq, Roland & Van Damme, Henri. (2004). Why Does Concrete Set?: The Nature of Cohesion Forces in Hardened Cement-Based
Materials. MRS Bulletin. 29. 10.1557/mrs2004.97.

RELAX, THIS IS WHERE WE STOP ON THIS TOPIC. 19

 Question #1

Initial Concrete Set is primarily driven by:

a) Crystallization of Lime (CH)

b) Desiccation and drying of concrete surface
c) Formation of Ettringite
d) Formation of Calcium-Silicate-Hydrate Crystal sheets.

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 Portland Cement Hydration
(how much water is enough?)

 w/c ≈ 0.42 at chemical + Non-Evaporable H2O Demand

…and…
 Characteristic porosity of PC (hydrated) ≈ 28% at
chemical water demand.
…and…
 Hydrated PC is more dense than Anhydrous PC + Water
(autogenous shrinkage)
…therefore…
 More water means:
 Increased continuous porosity
 Reduced density
 Reduced strength.
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 Portland Cement Hydration
(how much water is enough?)

 Why do we get mix designs with w/c at 0.5, 0.55, or 0.6?

 Workability
 Cost savings to the producer over chemical lubricants (water reducers)

 But what are the actual costs?

 High water content can lead to mix segregation (separation of rock & paste)
 Unreacted & unbound/trapped water evaporates
 Increasing “drying” shrinkage, and

 Leaving larger/continuous pores

 Where large continuous pores exist, concrete is more permeable.

 Where concrete is more permeable, concrete is more vulnerable to:
 Freeze thaw damage,

 Carbonation (reduction in internal pH),

 Reinforcing steel corrosion due to ingress of chlorides.

 Less dense concrete is weaker (bond of PC to aggregate suffers too)

 Increased trapped water movement increases long term creep behavior.
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 Portland Cement Hydration
(Drying / Autogenous Shrinkage)
Drying Shrinkage ≈ 10x Autogenous Shrinkage

 Continual Wet Curing leads to expansion:

 +100 to +150 x 10-6 for Concrete (at 500pcy PC)

 Curing without Additional Moisture:

 Autogenous (self desiccation) shrinkage
 -40x10-6 (1 month) to -100x10-6 (5 years)

 Drying Shrinkage (Concrete)

 Function of PC, Aggregate, and Water Content / Evaporation
 Neat PC Paste ≈ -4000x10-6
 Concrete ≈ 400x10-6 (0.48” in 100’ at 6:1 Agg./Cmt))
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 Shrinkage
Water/Cement Ratio and Aggregate Content

Neville, Figure 9.11

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 Aggregate
(Coarse and Fine)

 Aggregate (total) is typically:

 ≈ 69% to 77% by Weight of Concrete
 ≈ 63% to 67% by Volume of Concrete
 Typical ratio of coarse to fine aggregate:
 60/40 (1.5)

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 Aggregate
(ASTM C33 Coarse Gradation)
 Typical range 2” to #4 Sieve (passing)
 Varies based on Usage
 Size of concrete element being placed
 Congestion of Reinforcing
 Freeze Thaw Exposure
 Shrinkage Control

Size \ Sieve 2” 1½” 1” ¾” ½” 3/8” No. 4 No. 8

4 100 90 to 100 20 to 55 0 to 15 0 to 5
467 100 95 to 100 35 to 70 10 to 30 0 to 5
5 100 90 to 100 20 to 55 0 to 10 0 to 5
56 100 90 to 100 40 to 85 10 to 40 0 to 15 0 to 5
57 100 95 to 100 25 to 60 0 to 10 0 to 5
6 100 90 to 100 20 to 55 0 to 15 0 to 5
67 100 90 to 100 40 to 70 0 to 15 0 to 5
7 100 90 to 100 40 to 70 0 to 15 0 to 5
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 Aggregate
(Maximum Aggregate Size)

Shall not exceed:

 3/4 of the minimum clear spacing between reinforcement

 1/5 of the narrowest dimension between sides of forms

 1/3 of the thickness of slabs or toppings

ACI 318-19 26.4.2.1(a)(5)

27
 Aggregate
(Fine Gradation)
 3/8” to No. 200 (0.0029”)
 Fills overall gradation gap between
coarse aggregate and cementitious
fines. (0.1 to 250 µm)
Sieve % Passing
3/8” 100
No. 4 95 to 100
No. 8 80 to 100
 Higher surface area to volume
No. 16 50 to 85 ratio than coarse aggregate.
No. 30 25 to 60  Creates greater water demand
No. 50 3 to 30 than comparable volume of
No. 100 0 to 10 coarse aggregate.
No. 200 0 to 3
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 Aggregate
(General)

 Dimensionally stable component of concrete

 Does not undergo drying shrinkage
Rock / PC / CTE (linear)
 Restrains shrinkage of Cement Paste Concrete 10-6 per °F
Granite 1.0 – 6.6
Sandstone 2.4 – 7.7
 Coefficient of thermal Limestone 0.5 – 6.8
expansion “similar” to PC Chert 4.1 – 7.3
Marble 0.6 – 8.9
Dolomite 3.7 – 4.8
Portland Cement 6.0 – 11.0
Concrete 5.5 – 6.5

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 Aggregate
(Alkali-Silica Reaction – Quick Note)

Reaction between siliceous minerals and alkaline

hydroxides forming a “water-swelling gel” at in bond zone
between aggregate and paste. Alkali-Silica reaction only
occurs in the presence of water and Ca++ ions.

 ASTM C33, section 11.2…

 “coarse aggregate for use in concrete that will be subject to
wetting, extended exposure to humid atmosphere…shall not
contain any materials that are deleteriously reactive with the
alkalies in the cement…”

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 Concrete, Aggregate, Strength
(General)
 Generally stronger than PC paste (and bond region) until
f’c = 5,000 or higher.
 Fracture path diverts around aggregate in low to moderate strength
concrete
 Fracture path passes through aggregate in high strength concrete

 Elastic Modulus roughly twice that of PC

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 Concrete, Aggregate, Strength
(Saying the Same Thing Several Ways)

 Concrete Strength increases with:

 Curing (Completion of Hydration)
 Reduction in water content (W/C ratio)
 Reduction in porosity
 Increase in density
 Compaction / Consolidation
Strength = f(void volume)
 Strength of aggregate
 Uniformity of gradation and distribution of constituents

“The strength of concrete results from: (1) the strength of the mortar; (2)
the bond between the mortar and the coarse aggregate; and (3) the
strength of the coarse aggregate.” (Walker and Bloem, Gilkey, J. Amer. Conc. Inst., Part 2, Dec.
1961)

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 Question #2

Final (and 28 day) concrete compressive strength is a function of:

a) Volume and distribution of pores/voids

b) Strength of aggregate
c) Degree of curing / PC hydration
d) All of the above

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 Chemical Admixtures

 Air Entrainment
 Freeze Thaw Durability
 Workability

 Set / Rate Modifiers

 Accelerators
 Retarders

Images courtesy of
“Atlantic Testing Laboratories”

 Lubricants
 Water Reducers

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 Air Entraining Admixtures
(ASTM C260)

 Predominant Chemical Compound:

 Neutralized Vinsol Resin – (Soaps and Detergents)

Mechanism Disadvantages Advantages

Polar Organic Molecule (+/-) - Prolonged mixing - Increases F/T* durability
- Attracted to C-S-H reduces air content - Increases workability
- Repels Water (creates - High air content reduces - Reduces water demand
air void) strength for same slump

* F/T = Freeze/Thaw

35
 Air Entraining Admixtures
(Entrained / Entrapped Air and Voids)

Pore Size Type of Pore / Void

Large Irregular Voids
[BIG] Honeycomb
(lack of proper vibration / consolidation)
< 1x106 nm Accidental / Entrapped Air ≈ 1% - 3%
(artifact of mixing, etc.)
50x103 – 200x103 nm Entrained Air
(intentional freeze-thaw resistance)
10 – 50 nm Capillary Porosity
3x103 – 5x103 nm f(w/c, % hydration)
1 – 3 nm Gel Pores
f(C-S-H)

36
 Set / Rate Modifiers
(Accelerators)

 Predominant Chemical Compound:

 Calcium Chloride, Calcium Nitrite/Nitrate

Mechanism Disadvantages Advantages

Increases solubility of Si - Chlorides increase - Accelerates Set
and Al compounds in corrosion potential for - Accelerates Early
Portland Cement reinforcing Strength Gain
- CaCl2 increases drying - Nitrite is a corrosion
(Increased Al solubility shrinkage inhibitor
increases rate of Ettringite - Reduces sulfate
formation) durability
- Reduces F/T durability

37
 Set / Rate Modifiers
(Retarders)

 Predominant Chemical Compound:

 Gluconates (sugars), Hydroxy carboxylic acids (polymers), Phosphates

Mechanisms Disadvantages Advantages

- Forms less permeable - Overdosing can - Retards set
calcium saccarate skin permanently forestall set. - Typically does not effect
around clinker particles early (1 day) strength
and extends induction
period
- Interferes with solubility
of PC compounds

38
 Lubricants
(Water Reducers)

 Predominant Chemical Compound:

 WRA (Plasticizers) – calcium-ligno-sulfates, hydroxylated-carboxylic acids
 HRWR (Superplasticizers) – Sulphonated-naphthalene-formaldehyde-
condensate, sulphonated-melamine-formaldehyde-condensate

Mechanisms Disadvantages Advantages

- Absorbs to surface of - Multiple additions may - Increases slump with same
cement particles and cause air bubbles to w/c (or) reduces water and
breaks up flocs coalesce (become more cement for same slump
allowing water to be coarse) - Reduces capillary porosity
more effective - Can retard set (presence - Increases cohesion of mix
of polymer can retard (does not cause segregation)
hydration and set - Increases f’c due to more
slightly) complete hydration.

39
 Question #3

Water Reducing Admixtures effect concrete by:

a) Facilitating more complete reaction of PC Clinker

b) Increasing slump and improving workability/consolidation
c) Increase strength gain potential of mix
d) a, b, and c
e) a and c

40
 Performance Specification
(ACI 318-19 CH 26 - Material / Durability Requirements)

 Cementitious Materials
Cementitious Material Specification
Portland Cement ASTM C150
Blended Hydraulic Cement ASTM C595
Expansive Hydraulic Cement ASTM C845
Hydraulic Cement ASTM C1157
Fly Ash and Natural Pozzolan ASTM C618
Slag Cement ASTM C989
Silica Fume ASTM C1240

41
 Performance Specification
(ACI 318-19 CH 26 - Material / Durability Requirements)

 Aggregate
 Normal Weight – ASTM C33
 Light Weight – ASTM C330

 Mineral Fillers – (optimized particle packing)

 ASTM C1797

 Water
 ASTM C1602 (Potable)

42
 Performance Specification
(ACI 318-19 CH 26 - Material / Durability Requirements)

 Admixtures
Use Specification
Water Reduction and ASTM C494
Setting Time Modification
Producing Flowing ASTM C1017
Concrete
Air Entrainment ASTM C260
Corrosion Inhibition ASTM C1582

43
 Performance Specification
(ACI 318-19 CH 26 - Material / Durability Requirements)

“The requirements for each concrete mixture used for the Work are to
be stated in the construction documents. These are determined from
applicable concrete design requirements in 19.2 and durability
requirements in 19.3. The most restrictive requirements that apply are
to be stated.”(ACI 318-19 R26.4.2.1)
 f’c (indicate test age if different than 28 day)
 Ec (optional)
 w/c
 Nominal maximum size of coarse aggregate
 Air content
 Limits and requirements for and on supplementary cementitious materials
based on exposure class (as applicable)
 Equilibrium density for lightweight concrete
 [Shrinkage (limitations and/or aggregate volume fraction)]

44
 Performance Specification
(Durability)

Exposure Categories and Classes*

 Freezing and Thawing (F)

 Sulfate (S)

 In Contact with Water (W)

 Corrosion Protection of Reinforcement (C)

* Introduced in ACI 318 in 2008 code…. but present since 1983.

45
 Exposure Categories and Classes
(Freezing and Thawing)

Concrete exposed to moisture and cycles of freezing and thawing, with or

without deicing chemicals. Saturation Matters
Category Class Condition
F0 Concrete not exposed to freezing and thawing cycles.
Concrete exposed to freezing and thawing cycles with
F1 limited exposure to water. (not subject to snow and
ice accumulation / vertical surfaces, etc.)
Freezing and
Thawing (F) Concrete exposed to freezing and thawing cycles with
F2
frequent exposure to water.
Concrete exposed to freezing and thawing cycles with
F3 frequent exposure to water and exposure to deicing
chemicals
ACI 318-19 table 19.3.1.1

46
 Exposure Categories and Classes
(Freezing and Thawing)

Limits on
Exposure Max. Min. Additional Requirements
cementitious
Class w/cm fc’, psi Air content
materials
F0 N/A 2500 N/A N/A
Table 19.3.3.1 for concrete or table
F1 0.55 3500 N/A
19.3.3.3 for shotcrete
Table 19.3.3.1 for concrete or table
F2 0.45 4500 N/A
19.3.3.3 for shotcrete
Table 19.3.3.1 for concrete or table
F3 0.40 5000 26.4.2.2 (b)
19.3.3.3 for shotcrete
ACI 318-19 table 19.3.2.1

47
 Exposure Categories and Classes
(Freezing and Thawing)

Nominal Max. Target air content, percent

Aggregate Size, in. F1 F2 and F3
3/8 6.0 7.5
1/2 5.5 7.0
3/4 5.0 6.0
1 4.5 6.0
1-1/2 4.5 5.5
2 4.0 5.0
3 3.5 4.5
*ACI 318-19 table 19.3.3.1

48
 Exposure Categories and Classes
(Freezing and Thawing)
F3 ONLY

Maximum percent of total

Cementitious material
cementitious material by mass
Fly ash or other pozzolans conforming to
25
ASTM C618
Slag cement conforming to
50
ASTM C989/C989M
Silica fume conforming to ASTM C1240 10
Total of fly ash or other pozzolans, slag
50
cement, and silica fume
Total of fly ash or other pozzolans and
35
silica fumes
ACI 301-16 table 4.2.1.1(b)

49
 Exposure Categories and Classes
(Sulfate)

Concrete in contact with soil or water containing deleterious amounts of water

soluble sulfate ions. (Secondary Ettringite!)

Category Class Condition

Water soluble sulfate (SO₄²⁻) Dissolved sulfate (SO₄²⁻) in
in soil, % by mass water, ppm
S0 SO₄²⁻ < 0.10 SO₄²⁻ < 150
Sulfate (S)
S1 0.10 ≤ SO₄²⁻ < 0.20 150 ≤ SO₄²⁻< 1500 or seawater
S2 0.20 ≤ SO₄²⁻ ≤ 2.00 1500 ≤ SO₄²⁻ ≤ 10,000
S3 SO₄²⁻ > 2.00 SO₄²⁻ > 10,000
ACI 318-19 table 19.3.1.1

50
 Exposure Categories and Classes
(Sulfate)

Cementitious Materials - Types Calcium

Exposure Max. Min.
Chloride
class w/cm fc’, psi ASTM C150 ASTM C595 ASTM C1157 Admixture
No type No type No type
S0 N/A 2500 No restriction
restriction restriction restriction
Types w/ (MS)
S1 0.50 4000 II MS No restriction
designation
Types w/ (HS)
S2 0.45 4500 V HS Not permitted
designation
V plus Types w/ (HS) HS plus
Opt 1 0.45 4500 pozzolan or plus pozzolan pozzolan or Not permitted
S3 slag cement or slag cement slag cement
Types w/ (HS)
Opt 2 0.40 5000 V HS Not permitted
designation
ACI 318-19 table 19.3.2.1

51
 Exposure Categories and Classes
(Water)

Concrete in contact with water. (permeability and ASR)

Category Class Condition

W0 Concrete dry in service
In contact Concrete in contact with water where low permeability is
W1
with water not required
(W) Concrete in contact with water where low permeability is
W2
required
ACI 318-19 table 19.3.1.1

52
 Exposure Categories and Classes
(Water)

Limits on
Exposure Max. Min.
Additional Requirements Cementitious
Class w/cm fc’, psi
Materials
W0 N/A 2500 None
W1 N/A 2500 26.4.2.2(d)
W2 0.50 4000 26.4.2.2(d)
ACI 318-19 table 19.3.2.1

26.4.2.2(d) – Comply with both:

(1) Aggregates are not alkali-silica reactive or measures to mitigate alkali-silica reactivity have
been established.
(2) Aggregates are not alkali-carbonate reactive.

53
 Exposure Categories and Classes
(Corrosion)

Nonprestressed and prestressed concrete exposed to conditions that require

additional protection against corrosion of reinforcement.

Category Class Condition

C0 Concrete dry or protected from moisture
Corrosion Concrete exposed to moisture but not to an external
C1
protection of source of chlorides
reinforcement Concrete exposed to moisture and an external source
(C) C2 of chlorides from deicing chemicals, salt, brackish
water, seawater, or spray from these sources
ACI 318-19 table 19.3.1.1

54
 Exposure Categories and Classes
(Corrosion and Chlorides)

Max. water-soluble chloride ion (CL-)

content in concrete, % by mass of
Exposure Max. Min. cementitious materials Additional
Class w/cm fc’, psi Provisions
Nonprestressed Prestressed
concrete Concrete
C0 N/A 2500 1.00 0.06 None
C1 N/A 2500 0.30 0.06
Concrete
C2 0.40 5000 0.15 0.06
Cover
ACI 318-19 table 19.3.2.1

Increase time before carbonation

reaches steel and reduces alkaline
passivation of steel. (pH)

55
 Performance Specification
(ACI 318-19 CH 26 - Material / Durability Requirements)

56
 Concrete Mix Design Review
(Specifications - 318, 301)

 Specification / Drawings Govern Requirements

 ACI 318 Ch 26 lists minimum requirements (ASTM Compliance)
 Can incorporate ACI 301 (and modify)
 Verify Compliance

 ACI 301 Section 4, Submittals

 Mixture Proportions
 Mixture Strength Data
 Concrete Materials and Durability Compliance
 Cement

 Aggregate

 Admixture

 Water

 Field Test Records / Trial Mixture Records

57
 Field Test Records / Trial Mixture Records
Concrete Production facility has field strength test records
Yes No

≥ 30 consecutive tests Two groups of consecutive 15 to 29 consecutive test

No test (total ≥ 30) No (No data for ss)
Yes No Yes
Yes
Calculate ss Calculate ss & increase
Calculate Avg. ss
Determine f’cr or
Determine f’cr
or
Field record of at least 10 consecutive test results using
similar materials and under similar conditions is available Make trial mixtures using at least 3
No different water-cementitious materials
Yes ratios or cementitious materials contents

Results represent 1 mixture Results represent 2 or

Plot avg strength vs. proportions
more mixtures
No & interpolate for req. avg. strength
Yes
Plot avg strength vs. proportions
Avg. ≥ Required Avg. & interpolate for req. avg. strength Obtain “Special Permission”
No
Yes
Submit for Approval 58
 Concrete Mix Design Review
(Trial Mixtures)

 Trial Mixture Required Average Strength, f’cr

fc’, psi fcr’, psi

Less than 3000 fc’ + 1000
3000 to 5000 fc’ + 1200
Over 5000 1.1fc’ + 700
ACI 301-16 table 4.2.3.1

59
 Concrete Mix Design Review
(Trial Mixtures)
Trial Mixture Required Average Strength, f’cr

f’c = 5,000 psi

then
f’cr = 6,200 psi

60
 Concrete Mix Design Review
(Field Test Records)
 Field Test Record Required Average Strength, f’cr
fc’, psi fcr’, psi
Use the larger of:
fcr’ = fc’ + 1.34kss
5000 or less
fcr’ = fc’ + 2.33kss - 500

Over 5000 fcr’ = fc’ +1.34kss

fcr’ = 0.90fc’ + 2.33kss
ACI 301-16 table 4.2.3.3(a)1

Total number of tests k-factor for increasing sample

considered standard deviation
15 1.16
20 1.08
25 1.03
30 or more 1.00
ACI 301-16 table 4.2.3.3(a)2
61
 Concrete Mix Design Review
(Field Test Records) Avg. of 3

Increase Factor
when < 30 tests

Greater Value
Governs Req’d
Avg. Strength

62
 Concrete Mix Design Review
(f’cr)

 Trial Mix
 5000 psi design must have f’cr = 6,200 psi or better

 Field Test / Standard Deviation Analysis

 5000 psi design (example) required f’cr = 5,620 psi or better

 This equates to about 94 lbs of cement more per yard

and affects:
 Price
 Shrinkage
 Heat of Hydration
63
 Rules of Thumb
(Comparative Performance Approximation)

For Similar Mix Design per cubic yard of concrete

(similar agg. content, cementitious material composition, etc.)
Variable Component Approximate Effect
+/- 100 lb/cy Cement +/- 1000 psi f’c
+ 100 lb/cy Cement + 100 µε drying shrinkage
+/- 10 lb/cy Water (1.2 gal) -/+ 200 to 250 psi f’c
+/- 10 lb/cy Water (1.2 gal) +/- 1” slump
+ 30 lb/cy Water + 100 µε drying shrinkage
+/- 0.1 floz/100wt AEA +/- 1% entrained air
+ 1% Air + ½” slump
+ 1 can Coke or Beer*/cy + 15-30 Min. workability
+/- 100 lb Cement +/- 10° to 15° peak hydration Temp.

* Must be added to concrete mixer, not worker. 64

 Rules of Thumb
(Performance approximation)

# Sacks/CY Lbs Cement/CY f’c f’c w/ WRA

5 470 2,500 3,000
5.5 517 3,000 3,500
6 564 3,500 4,000
6.5 611 4,000 4,500
7 658 4,500 5,000
7.5 705 5,000 5,500

65
 Rules of Thumb
(Performance approximation)

- Lowest / Highest Expected Shrinkage?

- Lowest / Highest (peak) Heat of Hydration?

- Freeze Thaw Durability?

- Approximate f’c?

66
 Rules of Thumb
(Performance approximation)

- Total cementitious material approximately equivalent

- Water cementitious material ratio approximately equivalent
- Aggregate content approximately equivalent

- Fly Ash Pozzolanic effect and smaller particle size provides relative strength increase.

67
 Rules of Thumb
(Performance approximation)

- Total cementitious material approximately equivalent

- Water cementitious material ratio approximately equivalent
- Aggregate content approximately equivalent

- GGBFS is more effective and more reactive (finer ground)

- Higher air content increases porosity and reduces strength.

68
 Question #4

For two similar concrete mix designs, the one with 100 pcy higher
cementitious material content will:

a) likely have lower ultimate shrinkage

b) exhibit a lower peak heat of hydration
c) exhibit approximately 500psi higher average f’c
d) exhibit approximately 1000psi higher average f’c

69
 Field Items, Investigations
(for the Practicing Engineer)

 Bad Breaks
 Quick Checklist for What Went Wrong
and what to do now.

 Petrography
 What can you learn.

70
 Field Items, Investigations
(When Good Cylinders Go Bad)

 Bad Breaks and Non-Compliance

 What is not in compliance?
 Air content? Slump? f’c?
 How critical is the non-compliance?
 Are the test results erratic or typical?
 One bad cylinder, two bad cylinders, every third cylinder, group of three cylinders?
 How long was the truck waiting?
 Was the correct concrete shipped to site?
 Was water added at the jobsite?
 Where was the sample taken, and who made the cylinders?
 What was the temperature during placement?
 Where was the cylinder stored prior to pick-up?
 Were the cylinders moved prior to pick-up?
 Field Cured or Laboratory Cured?
 Talk to the contractor, the testing agency, the special inspector.
71
 Field Items, Investigations
(When Good Cylinders Go Bad)
ASTM C31 / C39 Cylinder Test Results…

 Reflect the potential of the concrete mix:

 Controlled consolidation (3 layers, 25 rods per layer)
 Controlled temperature (48h @ 60° - 80°, protected from direct sun)
 Continual wet cure for 28 days (73.5° +/- 3.5°)

NOT

 The actual strength of the concrete in the field – Subject to:

 effects of atmospheric temperature swing
 typical 7 day wet/protected cure period (per specifications)
 potential for rapid surface drying
 etc.

72
 Field Items, Investigations
(When Good Cylinders Go Bad)
 Let’s Say….
 Cylinders from multiple trucks are bad, Strength falls 500psi below f’c
 Air Content is too low/high
 Slump was out of specified range
 Concrete truck ticket missing mix design number and water added at site is not
provided…
 Contractor says testing agency is miss-handling cylinders
 Testing agency says contractor made cylinders and damaged them
 And…
 F’c needed for strength capacity
 Air content needed for freeze thaw
 Slump indicates difficulty with consolidation or possible segregation.

“Contractor shall show reason why material not conforming to project

specifications shall not be removed from project and replaced with
conforming materials.” (or be helpful…)
73
 Field Items, Investigations
(When Good Cylinders Go Bad)

 Field Core Test Cylinders

 Windsor Probe
 Schmidt Hammer

 Field Sample Density Verification

 Field Sample Water Soluble Chloride Ion Testing

 Petrography

74
 Field Items, Investigations
(When Good Cylinders Go Bad)
Concrete Petrography
 Air Content and Distribution
(Freeze / Thaw Durability)
 Aggregate Information
(type, max size, gradation, ASR)
 Water / Cement Ratio (approximate)
 Binder Type and Paste Content, Pozzolans
 Degree of Cementitious Material Hydration
(curing, surface bleed water, etc.)
 Crack distribution / micro-cracking
 Depth of Carbonation (Lowered pH)
Images courtesy of “Atlantic Testing Laboratories”

Likelihood that specified

mix design was provided…
75
 Learning Objectives
Learning Objectives:
 Understand the composition and curing of structural
concrete. (qualitatively)
 Learn the function and roles of:
 Pozzolans / supplementary cementitious materials
 “Common” Admixtures.
 Learn what to look for in a Concrete Mix Design Review
 Qualitatively predict the relative behavior of a concrete
mix design.
76
 Concrete Mix Design
(for the Practicing Engineer)

Otto J. Schwarz, P.E., S.E.

Ryan Biggs | Clark Davis Engineering and
Surveying, D.P.C.

SE University, September 2020 www.LearnWithSEU.com

 CHALLENGE QUESTION:
Which of the following components of concrete is
the answer to this session’s challenge question?

• Portland Cement
• Coarse Aggregate
• Fine Aggregate
• Water

Please circle the answer that is announced so that you can use the
information to complete your quiz for PDH.