German University in Cairo

CIS 401: Material Properties and Testing II

CIS 401:
Material Properties and
Testing II

Agenda
➢ ACI Standard 211.1
➢ Empirical Method
➢ The Egyptian code of practice

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 ACI Standard 211.1
“Recommended Practice for Selecting Proportions for Concrete”
The procedure is as follows:
Step 1. Evaluate strength requirements.
Step 2. Determine the water-cement (water–cementitious materials) ratio required.
Step 3. Evaluate coarse aggregate requirements.
✓ maximum aggregate size of the coarse aggregate
✓ quantity of the coarse aggregate
Step 4. Determine air entrainment requirements
Step 5. Evaluate workability requirements of the plastic concrete.

Step 6. Estimation of mixing water and air content

Step 7. Determine cementing materials content and type needed.

Step 8. Evaluate the need and application rate of admixtures.
Step 9. Evaluate fine aggregate requirements
Step 10. Determine moisture corrections.
Step 11. Make and test trial mixes.

ACI Standard 211.1

Step 1. Strength requirement
In order to compute the strength requirements for concrete mix design, three
quantities must be known:
1) the specified compressive strength, f’c
2) the variability or standard deviation s of the concrete
3) the allowable risk of making concrete with an unacceptable strength
The allowable risk has been established by the American Concrete Institute
(ACI). One of the risk rules states that there should be less than 10% chance that
the strength of a concrete mix is less than the specified strength.
The standard deviation should be determined from at least 30 strength tests.
Case 2: 15≤tests≤30 Case 3: 15>tests
Case 1: 30 standard tests
The larger values

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 ACI Standard 211.1

ACI Standard 211.1

Step 2. Selection of water/cement ratio.

The required water/cement ratio is determined by strength,

durability and finish ability. The appropriate value is chosen from
prior testing of a given system of cement and aggregate or a value
is chosen from Table 10.3 and/or Table 10.4.
Table 10.3: Water-Cement Ratio and Compressive Table 10.4 Maximum Permissible
Strength Relationship Water/Cement Ratio for Concrete in
28-Day Water-cement ratio by Several Exposures
Compressive weight
Strength in MPa Non-Air- Air-
(psi) Entrained Entrained
41.4 (6000) 0.41 -
34.5 (5000) 0.48 0.40
27.6 (4000) 0.57 0.48
20.7 (3000) 0.68 0.59
13.8 (2000) 0.82 0.74

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 ACI Standard 211.1

ACI Standard 211.1

Step 3. Choice of maximum size of aggregate.

Large maximum sizes of aggregates produce less voids than smaller sizes.
Hence, concretes with the larger-sized aggregates require less mortar per unit
volume of concrete, and off-course; it is the mortar which contains the most
expensive ingredient, cement. Thus the ACI method is based on the principle
that the
MAXIMUM SIZE OF AGGREGATE SHOULD BE THE LARGEST AVAILABLE SO LONG IT IS
CONSISTENT WITH THE DIMENSIONS OF THE STRUCTURE.
In practice the dimensions of the forms or the spacing of the rebars controls
the maximum CA size. ACI 211.1 states that the maximum CA size should not
exceed:

Special Note: When high strength concrete is desired, best

results may be obtained with reduced maximum sizes of aggregate
since these produce higher strengths at a given w/c ratio.

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 ACI Standard 211.1

ACI Standard 211.1

Estimation of coarse aggregate content.
The most economical concrete will have as much as possible space
occupied by CA since it will require no cement in the space filled by
CA.
Nominal Maximum Aggregate Fine Aggregate
Fineness Modulus
Size 2.40 2.60 2.80 3.00

9.5 mm (0.375 inches) 0.50 0.48 0.46 0.44

12.5 mm (0.5 inches) 0.59 0.57 0.55 0.53
19 mm (0.75 inches) 0.66 0.64 0.62 0.60
25 mm (1 inches) 0.71 0.69 0.67 0.65
37.5 mm (1.5 inches) 0.75 0.73 0.71 0.69
50 mm (2 inches) 0.78 0.76 0.74 0.72
Notes:
1) These values can be increased by up to about 10 percent for pavement
applications.
2) Coarse aggregate volumes are based on oven-dry- rodded weights obtained
in accordance with ASTM C 29.

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 ACI Standard 211.1

ACI Standard 211.1

Step 4. Determine air entrainment requirements.

The need for air entrainment is evaluated. Air

entrainment is required whenever concrete is exposed to
freeze–thaw conditions and deicing salts. Air entrainment is also
used for workability in some situations. The amount of air
required varies based on exposure conditions and is affected by
the size of the aggregates. The exposure levels are defined as
follows:
a) Mild exposure:—Indoor or outdoor service in which concrete is not exposed to
freezing and deicing salts. Air entrainment may be used to improve workability.
b) Moderate exposure: —Some freezing exposure occurs, but concrete is not exposed to
moisture or free water for long periods prior to freezing. Concrete is not exposed to
deicing salts. Examples include exterior beams, columns, walls, etc., not exposed to
wet soil.
c) Severe exposure: —Concrete is exposed to deicing salts, saturation, or free water.
Examples include pavements, bridge decks, curbs, gutters, canal linings, etc.

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 ACI Standard 211.1
Mixing Water Quantity in kg/m 3 (lb/yd3) for the listed Nominal Maximum Aggregate Size
Exposure 9.5 mm 19 mm
Conditions 12.5 mm 25 mm 37.5 mm 50 mm 75 mm 100 mm
(0.375 (0.75
(0.5 in.) (1 in.) (1.5 in.) (2 in.) (3 in.) (4 in.)
in.) in.)

Recommended Air Content (percent)

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

ACI Standard 211.1

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 ACI Standard 211.1
Step 5. Choice of slump

If slump is not specified, a value appropriate for the work can be selected from
the below Table which is reproduced from the text book below*, (note that the
table numbers are given from the text book rather than the ACI standard).

Type of Construction Slump

(mm) (inches)
Reinforced foundation walls and footings 25 - 75 1-3

Plain footings, caissons and substructure 25 - 75 1-3

walls
Beams and reinforced walls 25 - 100 1-4
Building columns 25 - 100 1-4
Pavements and slabs 25 - 75 1-3
Mass concrete 25 - 50 1-2

ACI Standard 211.1

For batch adjustments, slump increases about 25 mm (1 in.) for each 6 kg
of water added per m3 (10 lb per cubic yard) of concrete.

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 ACI Standard 211.1
Step 6. Estimation of mixing water and air content.

The ACI Method uses past experience to give a first estimate for
the quantity of water per unit volume of concrete required to
produce a given slump.

In general the quantity of water per unit volume of concrete

required to produce a given slump is dependent on the maximum CA
size, the shape and grading of both CA and FA, as well as the
amount of entrained air.

The approximate amount of water required for average aggregates

is given in Table 10.2.

ACI Standard 211.1

Table 10.2: Approximate Mixing Water and Air Content Requirements for Different
Slumps and Maximum Aggregate Sizes.
Mixing Water Quantity in kg/m 3 (lb/yd3) for the listed Nominal Maximum Aggregate Size
9.5 mm 19 mm
Slump 12.5 mm 25 mm 37.5 mm 50 mm 75 mm 100 mm
(0.375 (0.75
(0.5 in.) (1 in.) (1.5 in.) (2 in.) (3 in.) (4 in.)
in.) in.)
Non-Air-Entrained
25 - 50 207 199 190 179 166 154 130 113
(1 - 2) (350) (335) (315) (300) (275) (260) (220) (190)
75 - 100 228 216 205 193 181 169 145 124
(3 - 4) (385) (365) (340) (325) (300) (285) (245) (210)
150 - 175 243 228 216 202 190 178 160
-
(6 - 7) (410) (385) (360) (340) (315) (300) (270)
Typical entrapped air
(percent) 3 2.5 2 1.5 1 0.5 0.3 0.2
Air-Entrained
25 - 50 181 175 168 160 148 142 122 107
(1 - 2) (305) (295) (280) (270) (250) (240) (205) (180)
75 - 100 202 193 184 175 165 157 133 119
(3 - 4) (340) (325) (305) (295) (275) (265) (225) (200)
150 - 175 216 205 197 184 174 166 154
-
(6 - 7) (365) (345) (325) (310) (290) (280) (260)
Recommended Air Content (percent)

Mild Exposure 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0

Mode rate 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

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 ACI Standard 211.1

The recommendations in Table 7.8 are reduced for other aggregate shape as shown in this
table.

ACI Standard 211.1

Step 7. Calculation of cement content.

The amount of cement is fixed by the determinations made in Steps

3 to 5 above

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 ACI Standard 211.1
Step 8. Evaluate the need and application rate of admixtures.

Admixture Requirements If one or more

admixtures are used to add a specific quality in the
concrete (as discussed in admixture lecture), their
quantities should be considered in the mix
proportioning.
Admixture manufacturers provide specific
information on the quantity of admixture required to
achieve the desired results.

ACI Standard 211.1

Step 9. Estimation of Fine Aggregate Content.

At the completion of Step 8, all ingredients of the concrete have

been estimated except the fine aggregate. Its quantity can be
determined by difference if the “absolute volume” displaced by the
known ingredients-, (i.e., water, air, cement, and coarse
aggregate), is subtracted from the unit volume of concrete to
obtain the required volume of fine aggregate. Then once the
volumes are know the weights of each ingredient can be calculated
from the specific gravities.
W: water by volume
C: Cement weight

W = water by weight / Sw (=1) Sc: specific gravity of cement

C: Cement weight
Sfa: specific gravity of fine aggregate
C: Cement weight
Sca: specific gravity of coarse aggregate
P: total percentage of the fines aggregate / coarse aggregate

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 ACI Standard 211.1
The only remaining factor is the amount of dry fine aggregates
needed. The weight mix design method uses Table 7.10 to estimate
the total weight of a “typical” freshly mixed concrete for different
nominal maximum aggregate sizes.

ACI Standard 211.1

Step 10. Adjustments for Aggregate Moisture.

Aggregate weights: Aggregate volumes are calculated based on oven

dry unit weights, but aggregate is typically batched based on

actual weight. Therefore, any moisture in the aggregate will
increase its weight and stockpiled aggregates almost always
contain some moisture. Without correcting for this, the batched
aggregate volumes will be incorrect.
Amount of mixing water: If the batched aggregate is anything but

saturated surface dry it will absorb water (if oven dry or air dry) or
give up water (if wet) to the cement paste. This causes a net
change in the amount of water available in the mix and must be
compensated for by adjusting the amount of mixing water added.

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 ACI Standard 211.1

Step 11. Trial Batch Adjustments.

The ACI method is written on the basis that a trial batch of concrete

will be prepared in the laboratory, and adjusted to give the desired

slump, freedom from segregation, finish ability, unit weight, air

content and strength.

Empirical Method

This method proportions the ingredients of concrete based on

experiences. It is considered appropriate for small scale jobs; and the
most popular in Egypt.

Coarse Fine
Water Cement
Aggregate Aggregate
250 – 350 kg
0.4 – 0.7 of
0.8 m3 0.4 m3 5 to 7 cement
Cement Weight
bags

Disadvantages:
1) The W/C ratio is not determined
2) The summation of the given proportions do not give 1m3.
3) The percentage of course aggregate to fine aggregate is constant.

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 The Egyptian code of practice
1)Determine the ambient
environment for concrete
2)Determine the durability
requirements

Input:
Conditions of exposure = Totally
protected (indoors) concrete
Nominal maximum Size = 20 mm Type
of Concrete = reinforced

Output:
✓ Min. Cement content = 350 kg/m3
✓ Max. W/C ratio = 0.5
✓ Min Grade = 25 N/mm2

The Egyptian code of practice

1) Determine the ambient
environment for
concrete
2) Determine the
durability
requirements
Input:
Concentration of
Sulphites in the form of
Sulphur trioxide SO3 =
900 ppm (part per
million)
Nominal max. size =
20mm

Output: From Table (2-13)

Type of Cement = Sulphate resisting cement
Min Cement Content = 400 kg/m3 Max. W/C ratio = 0.45
Min Grade = 30 N/mm2

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 The Egyptian code of practice
Determine the target compressive strength fm in ECP

The Egyptian Code of Practice: Clause (2-6-2-1)

The Egyptian code of practice

➢ In case of having 40 test results or more determining the compressive concrete
strength on batch design mix (the constituents of the concrete mix should be the
same used in 40 samples)
➢ Case A: fcu (characteristic concrete strength) ≥ 20 N/mm2
σ = 4 N/mm2
In other words, if fck ≥ 20 MPa
σ = 4 MPa
➢ Case B: fcu (characteristic concrete strength) < 20 N/mm2
σ = 20 % from fck (N/mm2)
In other words, if fck < 20 MPa
σ = 0.2* fck MPa
➢ In case of not having 40 test results
➢ Case A: fcu (characteristic concrete strength) ≥ 20 N/mm2
σ = 8 N/mm2
In other words, if fck ≥ 20 MPa
σ = 8 MPa
➢ Case B: fcu (characteristic concrete strength) < 20 N/mm2
σ = 40 % from fck (N/mm2)
In other words, if fck < 20 MPa
σ = 0.4* fck MPa
➢ The fm should be changed if the 40 tests results or more have been provided during
the work, thus, σ should be the values of 40 test or more providing that the value
resulted should not be less than 3.5 N/mm2 (MPa)
➢ The practitioner should provide w/c ratio which results in required fm reached
during the initial design mix or after modification. This should be the basis of
determining the other concrete mix constituents.

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 The Egyptian code of practice
Trial and Confirmatory Concrete Mixes (ECP – Clause 2-6-3)
1) Trial Mixes

✓ Are the mixes conducted by the concrete mix designer – using the same materials as
those in site – to verify the properties of the fresh and hardened concrete. Based on
such verifications, modifications could be made to satisfy the requirements of the
project.
✓ It is mandatory that the concrete mix satisfies the target compressive strength fm in work
conditions.
✓ To approve the mix, the following information has to be reported by the designer:
1) The target strength; the mean target strength; the safety margin.
2) The properties of the constituents of the concrete mix
3) Weight of each component.
4) Slump.
5) Values of compressive strength.
6) Quantity/percentage of salts, chlorides and sulphates in the concrete.

The Egyptian code of practice

Trial and Confirmatory Concrete Mixes (ECP – Clause 2-6-3)
2) Confirmatory (Verifying) Mixes (Compulsory)

✓ Are the mixes conducted by the concrete mix manufacturer – using the same
materials as those used in site.
✓ Three “3” separate batches should be made under the same conditions of the
➢ actual work environment.
✓ The workability of the mix should be measured; “9” concrete cubes should be
➢ cast from each batch and tested after 28 days (it is optional to test 3 cubes after 3
days and 3 after 7 days, if necessary).
✓ The results of the three batches should satisfy the following:
(i) The mean compressive strength – for all cubes - after 28 days ≥ 95% fm (i.e. should
not less than 95% fm )
(ii) The mean compressive strength – for all cubes - after 28 days ≥ fcu + 6.5 N/mm2
(iii) The compressive strength – each individual cube - after 28 days ≥ fcu.
(iv) The difference between the greatest compressive strength value and the least – in
each set of tests – should be ≤ 15% of the mean value for this particular set.

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Summary:

✓British (DOE) Method

✓ACI Method
✓Empirical Method
✓ECP (Trail and confirmatory)

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