What is Concrete:

Concrete & Cement Defined

Components of a Basic Concrete Mix
There are three basic ingredients in the concrete mix:
1. Portland Cement
2. Water
3. Aggregates (rock and sand)
Portland Cement - !e cement and "ater form a paste t!at coats t!e aggregate and sand in t!e mix.
!e paste !ardens and #inds t!e aggregates and sand toget!er.
Water- Water is needed to c!emicall$ react "it! t!e cement (!$dration) and too pro%ide "orka#ilit$
"it! t!e concrete. !e amo&nt of "ater in t!e mix in po&nds compared "it! t!e amo&nt of cement is
called t!e "ater'cement ratio. !e lo"er t!e "'c ratio( t!e stronger t!e concrete. (!ig!er strengt!( less
permea#ilit$)
Aggregates- )and is t!e fine aggregate. *ra%el or cr&s!ed stone is t!e coarse aggregate in most
mixes.
Desired Properties of Concrete
1. The concrete mix is workable. +t can #e placed and consolidated properl$ #$ $o&rself or $o&r
"orkmen.
2. Desired qualities of the hardened concrete are met: for example( resistance to free,ing and
t!a"ing and deicing c!emicals( "atertig!tness (lo" permea#ilit$) ( "ear resistance( and strengt!.
-no" "!at $o& are tr$ing to ac!ie%e "it! t!e concrete.
3. Economy. )ince t!e .&alit$ depends mainl$ on t!e "ater to cement ratio( t!e "ater re.&irement
s!o&ld #e minimi,ed to red&ce t!e cement re.&irement (and t!&s red&ce t!e cost).
ake t!ese steps to red&ce t!e "ater and cement re.&irements/
&se t!e stiffest mix possi#le
&se t!e largest si,e aggregate practical for t!e 0o#.
1se t!e optim&m ratio of fine to coarse aggregate.
2isc&ss !o" to ac!ie%e $o&r goals for t!e concrete "it! $o&r read$ mix s&pplier.
Concrete Admixt&res/ Most Common $pes and W!at !e$ 2o
Admixt&res are additions to t!e mix &sed to ac!ie%e certain goals.
3ere are t!e main admixt&res and "!at t!e$ aim to ac!ie%e.
Accelerating admixtureaccelerators are added to concrete to red&ce setting time of t!e concrete
and to accelerate earl$ strengt!. !e amo&nt of red&ction in setting time %aries depending on t!e
amo&nt of accelerator &sed (see $o&r read$ mix s&pplier and descri#e $o&r application). Calci&m
c!loride is a lo" cost accelerator( #&t specifications often call for a nonc!loride accelerator to pre%ent
corrosion of reinforcing steel.
!etarding admixtures-Are often &sed in !ot "eat!er conditions to dela$ setting time. !e$ are also
&sed to dela$ set of more diffic&lt 0o#s or for special finis!ing operations like exposing aggregate.
Man$ retarders also act as a "ater red&cer.
"ly Ash- +s a #$ prod&ct of coal #&rning plants. 4l$ as! can replace 156-376 of t!e cement in t!e
mix. Cement and fl$ as! toget!er in t!e same mix make &p t!e total cementious material.
4l$ as! impro%es "orka#ilit$
4l$ as! is easier to finis!
4l$ as! red&ces t!e !eat generated #$ t!e concrete
4l$ as! costs to t!e amo&nt of t!e cement it replaces
Air Entraining Admixtures- m&st #e &sed "!ene%er concrete is exposed to free,ing and t!a"ing(
and to deicing salts. Air entraining agents entrains microscopic air #&##les in t!e concrete/ "!en t!e
!ardened concrete free,es( t!e fro,en "ater inside t!e concrete expands into t!ese air #&##les
instead of damaging t!e concrete.
Air entrainment impro%es concrete "orka#ilit$
Air entrainment impro%es d&ra#ilit$
Air entrainment prod&ces a more "orka#le mix
Water reducing admixtures-red&ces t!e amo&nt of "ater needed in t!e concrete mix. !e "ater
cement ratio "ill #e lo"er and t!e strengt! "ill #e greater. Most lo" range "ater red&cers red&ce t!e
"ater needed in t!e mix #$ 56-176. 3ig! range "ater red&cers red&ce t!e mix "ater needed #$ 126
to 376 #&t are %er$ expensi%e and rarel$ &sed in residential "ork.
Concrete 8einforcement/ 4i#ers %s. Welded Wire Mes!
4i#ers can #e added to t!e concrete mix in lie& of "elded "ire mes!.
The #roblem with welded wire mesh is t!at it often ends &p on t!e gro&nd from #eing stepped on
as t!e concrete is #eing placed. (partic&larl$ if no s&pport #locks are &sed). Anot!er pro#lem is t!at
mes! does not pre%ent or minimi,e cracking-it simpl$ !olds cracks t!at !a%e alread$ occ&rred
toget!er.
+f $o& co&ld look into a section of concrete po&red "it! fi#ers $o& "o&ld see millions of fi#ers
distri#&ted in all directions t!ro&g!o&t t!e concrete mix. As micro cracks #egin to appear d&e to
s!rinkage as "ater e%aporates form t!e concrete (plastic s!rinkage)( t!e cracks intersect "it! t!e
fi#ers "!ic! #lock t!eir gro"t! and pro%ide !ig!er tensile strengt! capacit$ at t!is cr&cial time.
Click !ere for !o" fi#ers are an important part of 9!o" to #&ild !ig! .&alit$ sla#s on grade.9
A2:1)+;* C<;C8== M+>=) < C<88=C P?AC+;* P8<B?=M)
W!en t!e concrete sticks to the trowel "!en it is lifted off t!e concrete( or concrete sticks to t!e
finis!ers knee#oards( too m&c! sand in t!e mix or !ig!er t!an necessar$ air entrainment are most
likel$ t!e ca&ses.
Excessi$e bleedwater "ill dela$ t!e finis!ing operation and can ca&se serio&s pro#lems "it! t!e
s&rface of t!e concrete. Adding more sand to t!e mix( adding more entrained air( &sing less mix
"ater( or adding cement or fl$ as! are possi#le c&res.
Make s&re $o&r read$ mix s&pplier kno"s if $o& "ill #e p&mping concrete. Pum#ing mixes require a
sufficient amount of fines and t!ere are limits to t!e si,e of t!e aggregate in order for t!e mix to #e
p&mpa#le. 4l$ as! and air entrainment impro%e "orka#ilit$ and p&mpa#ilit$.
%etting time of the mix can be slowed "it! retarders.
!e mix ma$ #e cooled in !ot "eat!er #$ replacing part of t!e mixing "ater "it! ice( sprinkling "ater
on t!e aggregate pile at t!e read$ mix plant( or in0ecting li.&id nitrogen into t!e #atc!.
%etting time of the mix can be s#ed u# "it! accelerators.
!e mix can #e !eated at t!e read$ mix plant #$ !eating t!e mix "ater and aggregates.
&nstalling Concrete
Placing Concrete
;ormal concrete "eig!s approximatel$ 157 po&nds per c&#ic foot and s!o&ld #e placed as near as
possi#le to its final position. =xcess !andling can ca&se segregation of t!e co&rse and fine
aggregates. Wetting &p t!e concrete so it can #e raked or p&s!ed into a location far from "!ere it is
disc!arged is not accepta#le.
Concrete is po&red directl$ from t!e c!&te of t!e read$ mix tr&ck( "!eeled into place "it! a #&gg$( or
p&mped into place "it! a concrete #oom p&mp (see concrete p&mping).
Concrete is normall$ specified at a @-59 sl&mp. +nd&strial( commercial( and some residential pro0ects
re.&ire an inspector on concrete po&rs "!o monitors t!e concrete sl&mp and takes sl&mp
meas&rements at t!e re.&ired inter%als.
Also see( 3o" o B&ild 3ig! A&alit$ )la#s on *rade
%#reading Concrete
!e p&rpose of spreading fres! concrete is to place concrete as close as possi#le to finis! le%el to
facilitate straig!tedging'screeding t!e concrete.
)!ort !andled( s.&are ended s!o%els are recommended for spreading concrete. A come-along (a tool
t!at looks like a !oe and !as a long straig!t edged #lade) can also #e &sed. 2o not &se a ro&nd edge
s!o%el for spreading concrete since it does not spread t!e concrete e%enl$.
An$ spreader &sed s!o&ld #e rigid eno&g! to p&s! and p&ll "et concrete "it!o&t #ending/ ;ormal
concrete "eig!s approximatel$ 157 po&nds per c&#ic foot.
Cold "eat!er concreting
3ot "eat!er concreting
C&ring concrete
'ack to To#Concrete (ix Ad)ustment to Correct Placing
Problems
W!en t!e concrete sticks to the trowel "!en it is lifted off t!e concrete( or concrete sticks to t!e
finis!ers knee#oards( too m&c! sand in t!e mix or !ig!er t!an necessar$ air entrainment are most
likel$ t!e ca&ses.
Excessi$e bleedwater "ill dela$ t!e finis!ing operation and can ca&se serio&s pro#lems "it! t!e
s&rface of t!e concrete. Adding more sand to t!e mix( adding more entrained air( &sing less mix
"ater( or adding cement or fl$ as! are possi#le c&res.
Make s&re $o&r read$ mix s&pplier kno"s if $o& "ill #e p&mping concrete. Pum#ing mixes require a
sufficient amount of fines and t!ere are limits to t!e si,e of t!e aggregate in order for t!e mix to #e
p&mpa#le. 4l$ as! and air entrainment impro%e "orka#ilit$ and p&mpa#ilit$.
%etting time of the mix can be slowed "it! retarders.
!e mix ma$ #e cooled in !ot "eat!er #$ replacing part of t!e mixing "ater "it! ice( sprinkling "ater
on t!e aggregate pile at t!e read$ mix plant( or in0ecting li.&id nitrogen into t!e #atc!.
%etting time of the mix can be s#ed u# "it! accelerators.
!e mix can #e !eated at t!e read$ mix plant #$ !eating t!e mix "ater and aggregates.
Concrete (ix Design 'asics
!e standard for designing a concrete mix is ACI 211.1, Proportions for Normal, Heavyweight, and
ass Concrete. ?ike most AC+ committee reports( t!is doc&ment is excellent( al#eit !ig!l$ tec!nical. +f
$o& "ant more detail( "ritten in a more &ser-friendl$ "a$( get a cop$ of t!e Portland Cement
AssociationBs!esign and Control of Concrete i"tures. !atBs t!e #i#le for concrete mix design.
AC+ 211.1 notes t!at t!e 9selection of concrete proportions in%ol%es a #alance #et"een econom$ and
re.&irements for placea#ilit$( strengt!( d&ra#ilit$( densit$( and appearance.9 4inding t!e rig!t #alance
to ac!ie%e all t!ese re.&irements comes mainl$ from experience.
Placea#ility is an important attri#ute of a good mi" design.
Atlanta $ric% & Concrete, Atlanta, 'A.
Placea#ilit$ is simpl$ t!e traits t!at t!e "et or plastic concrete !as t!at allo" it to #e placed and
finis!ed. Placea#ilit$ incl&des a mix t!at doesnBt segregate #&t t!at can #e consolidated. !e a#ilit$ to
#e p&mped is anot!er consideration. !e classic "a$ to meas&re placea#ilit$ is sl&mp( alt!o&g! t"o
different mixes can !a%e t!e same sl&mp and #e!a%e %er$ differentl$ depending on t!e aggregates(
t!e air content( and t!e admixt&res.
)trengt! is nearl$ al"a$s specified for a concrete mix. !e +nternational 8esidential Code( for
example( specifies t!at interior sla#s !a%e a minim&m compressi%e strengt! of 2577 psi. +n str&ct&ral
concrete applications( strengt! is indeed critical( since t!atBs "!at t!e designer is co&nting on to !old
&p t!e #&ilding. 4or flat"ork( t!o&g!( strengt! is seldom t!e controlling factor and !ig!er strengt!
concrete mixes( t!at prod&ce %er$ stiff concrete( can res&lt in more s!rinkage( "!ic! s!o"s &p as
c&rling and cracking.
?ong term d&ra#ilit$ is at least as important as placea#ilit$ and strengt!( #&t it is sometimes sacrificed
if t!ere are compromises to #e made. 2&ra#ilit$ is ac!ie%ed #$ getting a lo"-permea#ilit$( lo"-
s!rinkage concrete t!at !as t!e proper amo&nt and distri#&tion of entrained air. 2&ra#le concrete
m&st resist free,e-t!a" action and pre%ent c!loride from penetrating to t!e reinforcing steel to
contri#&te to corrosion.
(o retain its appearance, e"terior concrete must #e designed to handle free)e*thaw action.
$ec%er Architectural Concrete, +outh +t. Paul, N.
Appearance iss&es are o#%io&sl$ more important for decorati%e concrete t!an ot!er applications.
;ot!ing so&rs a client more t!at a #ea&tif&l floor t!at is cracked or spalled or a decorati%e "all t!at is
!one$com#ed. Wit! sla#s( s!rinkage is t!e n&m#er one concern and lo"er strengt! concrete ("it!
less cement paste) "ill often s!rink and c&rl less. And since "it! decorati%e concrete( s&rface
!ardeners "ill pro%ide a !ig! strengt!( more "ear resistant( less permea#le( s&rface la$er( t!e o%erall
concrete strengt! can #e less.
;o" letBs talk a#o&t t!e c!oices $o& "ill (or s!o&ld) make in concrete materials.
Concrete (aterials
,hat 'oes into the i"
We all kno" t!at concrete is primaril$ portland cement( aggregate( and "ater. And in general itBs #est
to keep it simple( since more ingredients can make it more diffic&lt to control.
!e single most important t!ing to start "it! is t!e "ater-cement ratio ("'c). ;earl$ 177 $ears ago
2&ff A#rams disco%ered t!e direct relations!ip #et"een "'c and strengt!Ct!e less "ater &sed t!e
!ig!er t!e strengt! of t!e concrete since too m&c! "ater lea%es lots of pores in t!e paste portion of
t!e concrete. 4or most applications( "'c s!o&ld #e #et"een 7.@ and 7.5Clo"er for lo"er permea#ilit$
and !ig!er strengt!. !e trade off( of co&rse( is "it! placea#ilit$( since %er$ lo" "ater content res&lts
in %er$ stiff mixt&res t!at are diffic&lt to place.
Cool Climate Concrete.
B&t "it! sla#s and floors( looking #e$ond "'c is important. Pat 3arrison( t!e c&rrent c!airman of AC+
Committee 372( Constr&ction of Concrete 4loors( "rote an o&tstanding article in t!e Marc! 277@ iss&e
ofConcrete International on t!e ideal sla# mixt&re. +n t!at article !e noted t!at a lo" "'c ratio 9ma$
increase strengt! and impro%e d&ra#ilit$( #&t it is not likel$ to red&ce s!rinkage.9 3e recommends
lo"ering t!e total "ater content and e%en t!e cement content to red&ce s!rinkage( e%en if it means
t!at t!e "'c goes a#o%e 7.5. Alt!o&g! t!is article "as "ritten specificall$ for ind&strial floors( itBs
"isdom applies e.&all$ to decorati%e floors.
Aggregate is t!e ot!er main ingredient in concrete( #&t it is often o%erlooked. Wit! o&r goal of
red&cing s!rinkage( t!o&g!( aggregate #ecomes critical. o red&ce s!rinkage( "e need to red&ce t!e
total amo&nt of cement paste in t!e mixCt!e aggregate doesnBt s!rink. o red&ce t!e cement paste(
"e need to minimi,e t!e spaces #et"een t!e aggregate particles. !at is accomplis!ed "it! a 9"ell-
graded9 aggregate mixt&re t!at starts "it! t!e largest aggregate si,e possi#leCideall$ 1 D inc!es(
alt!o&g! it s!o&ld #e less t!an 1'3 of t!e sla# t!ickness and fe" stamping contractors "ill "ant to
stamp a mix "it! aggregate t!at large. 9+ specif$ E inc!(9 sa$s Bo# 3arris of t!e 2ecorati%e Concrete
+nstit&te. 9Most of o&r stamp mixes are some"!ere aro&nd D inc! top si,e aggregate #&t if "eBre
po&ring t!ick concrete "e can s&ccessf&ll$ stamp E inc! or F5G stone.9
Aggregate gradation is important for o#taining high -uality concrete.
Portland Cement Association.
B&t regardless of t!e largest aggregate si,e( "e "ant to !a%e aggregate of all si,es. W!en aggregate
is e%al&ated( it is r&n t!ro&g! a series of sie%es to determine t!e si,e distri#&tion. !e classic
distri#&tion is to !a%e #et"een H6 and 1H6 of t!e total aggregate on eac! of t!e standard sie%es. A
"ell-graded mix( as opposed to a more traditional gap-graded mix( "ill !a%e less cement and less
s!rinkage.
Water is( of co&rse( essential to a placea#le mix. We 0&st donBt "ant to add too m&c! 9"ater of
con%enience(9 "!ic! is t!e "ater added to increase sl&mp. 3arrison( in !is article( s&ggests t!at t!e
minim&m "ater content for a finis!a#le mix ("it! a 3-inc! sl&mp &sing 1 D inc! maxim&m si,ed
aggregate) is a#o&t 2G5 po&nds per c&#ic $ard (since "ater "eig!s H.3@ po&nds per gallon( t!at
"o&ld #e a#o&t 33 gallons). <ften specifications "ill allo" some addition of "ater on site to ad0&st t!e
sl&mpCsl&mp is t$picall$ increased 1 inc! #$ adding 17 po&nds of "ater per c&#ic $ard (1.2 gallons).
.arious admi"tures are used in concrete to create specific effects.
Portland Cement Association.
Admixt&res are t!e ot!er primar$ ingredient of modern concrete and t!e most important is air-
entraining admixt&re. An$ concrete t!at "ill #e exposed to free,e-t!a" and deicing salts must !a%e
entrained air to pre%ent spalling of t!e s&rface and e%en complete #reakdo"n of t!e concrete. +n
se%ere expos&re areas( t!e air content s!o&ld %ar$ from G.56 for 3'H inc! maxim&m si,ed aggregate
to 5.56 for 1 D inc! aggregate (t$picall$ "it! a tolerance of pl&s or min&s 16). As noted #efore( some
air is #eneficial for all concrete since it impro%es "orka#ilit$ and red&ces or e%en eliminates #leeding
Calt!o&g! t!at ma$ not #e an ad%antage "it! color !ardeners. Be caref&l not to specif$ air( t!o&g!(
for !ard-tro"eled interior floors. 3ard tro"eling seals t!e s&rface and can ca&se air to acc&m&late
&nder a t!in s&rface la$er leading to #listering of t!e s&rface.
Anot!er %er$ &sef&l admixt&re is "ater red&cer. !ese come in %ario&s ranges( "it! !ig! range often
called s&perplastici,er. Water red&cers can #e &sed to maintain a specific sl&mp "it! less "aterC
red&cing "ater content &p to 376 or e%en t&rning concrete into self-consolidating concrete ()CC) t!at
!as a so&p$ consistenc$ t!at is %er$ &sef&l for detailed decorati%e "alls or "!en $o& "ant concrete to
flo" easil$ aro&nd em#edded o#0ects or congested reinforcing steel. )CC is also ideal for prod&cing
glass$ s&rfaces on sc&lpt&re( f&rnit&re( or co&ntertops.
8etarders and accelerators are also &sef&l admixt&res( especiall$ "!en dealing "it! t!e %ariations in
set time from cold or !ot temperat&res. <ne tec!ni.&e e%er$ decorati%e contractor s!o&ld &nderstand
is set retardation (see Concrete Construction( :&l$ 2772( p. @I). !is in%ol%es adding retarder on t!e
0o# site to keep t!e concrete from setting so .&ickl$ t!at it #ecomes too !ard to stamp.
<ne last ingredient in man$ concrete mixt&res toda$ is s&pplementar$ cementitio&s materials ()CM)--
also called po,,olans. !ese materials incl&de fl$ as!( slag cement (sometimes called gro&nd
gran&lated #last f&rnace slagC**B4) or slag cement)( silica f&me( and metakaolin. )CMs are &sed
as replacement for cement and since t!e$ !a%e a %er$ small particle si,e t!e$ red&ce t!e permea#ilit$
of concrete( "!ic! is good.
+upplementary cementitious materials. /rom left to right, fly ash 0Class C1,
meta%aolin 0calcined clay1, silica fume, fly ash 0Class /1, slag, and calcined shale.
Portland Cement Association.
4l$ as! is t!e most common )CM and it impro%es finis!a#ilit$ alt!o&g! it tends to slo" t!e set time(
especiall$ in cold "eat!er. )CMs can #e &sed to replace as m&c! as @76 of t!e cement in a mix.
)lag and metakaolin lig!ten t!e color of concrete "!ic! can #e #eneficial "it! integrall$ colored
concrete. Metakaolin also !elps to red&ce t!e danger of efflorescence.
The &m#ortance of (ix Design
'etting the 2ight i" for Any Pro3ect
:&st "!at is mix designJ !e American Concrete +nstit&te doesnBt e%en &se t!e term( preferring mix
proportioning. B&t mix design is reall$ more t!an simpl$ coming &p "it! t!e proportions of eac! mix
constit&ent( it is e%er$t!ing t!at makes t!e concrete "ork "ell for $o&r application.
!ere are t!ree stages in concreteBs life t!at need to #e considered "!en de%eloping t!e mix/ t!e
fres! concrete( t!e ne"l$ completed concrete( and e%er$t!ing after t!at for t!e rest of its life. !e
re.&irements for good performance in eac! of t!ese t!ree stages can act&all$ conflict. As "e all
kno"( a "et eas$-to-place concrete is not likel$ to #e a d&ra#le concrete. B&t if $o& order t!e "orldBs
most d&ra#le concrete and find it impossi#le to place( t!en t!atBs no good eit!er.
Properly proportioned mi"es will remain #eautiful for many years.
$est +tamped Concrete Inc., Huntsville, A4.
<ne "a$ to get t!e rig!t mix for $o&r application is to !a%e a great relations!ip "it! $o&r read$ mix
s&pplier. Ko& can t!en tell !im "!at $o&r application is( "!en $o& plan to place( and "!at t!e
specification re.&ires and !e can de%elop t!e ideal mix. A program c&rrentl$ #eing promoted #$ t!e
;ational 8ead$-Mixed Concrete Association called P2P (Prescripti%e-to-Performance) takes t!at
concept to t!e &ltimate concl&sion--completel$ rel$ing on t!e prod&cer to pro%ide t!e rig!t mix.
!ereBs not!ing "rong "it! t!is if $o& !a%e a %er$ kno"ledgea#le prod&cer and tell t!em precisel$
"!at $o& need. B&t &nderstanding "!atBs going on in t!e mix is still $o&r responsi#ilit$.
)o letBs start #$ looking at !o" to design a good mixCone t!at "ill satisf$ all $o&r re.&irements. !en
"eBll look at "!at kind of mix $o& s!o&ld &se for stamping( staining( or o%erla$s.
Designing the !ight Concrete (ix
1sing t!e AC+ 211.1 met!od( !ere is an a##re%iated r&n-t!ro&g! on !o" to design a mix/
1. C!oose t!e target sl&mp
2. C!oose t!e maxim&m aggregate si,eCremem#er t!at t!e larger t!e #etter for red&cing
s!rinkage and c&rling.
3. =stimate t!e "ater and air content &sing AC+ 211.1 a#le I.3.3.
@. )elect t!e "ater-cement ratio.
5. Calc&late t!e cement content #$ di%iding t!e "ater content #$ t!e "ater-cement ratio.
I. =stimate t!e coarse aggregate content.
G. =stimate t!e fine aggregate content.
H. Ad0&st for aggregate moist&reC"et aggregate can significantl$ red&ce t!e amo&nt of "ater to
#e added.
L. Make trial #atc!es to see "!at $o&B%e got.
Concrete is tested for strength #y #rea%ing cylinders.
)o $o& see t!at after all t!ese fanc$ calc&lations( t!e #ottom line is t!at concrete is still designed #$
experience "it! pre%io&s mixes or #$ making trial #atc!es in t!e la# and testing t!e concrete. ;ot!ing
#eats experience "it! a mix. Man$ decorati%e contractors "ill !a%e @ or 5 mixes t!at t!e$ &se for
different applications or "eat!er conditions. +f $o& !a%e t!ese mixes alread$ in $o&r read$ mix
pro%iderBs office( !e can .&ickl$ p&ll o&t t!e design and $o& can tell !im to #ring $o&r mix F3 or F5.
3= 8<?= <4 A**8=*A= +; C<;C8==
Aggregates are generall$ t!o&g!t of as inert filler "it!in a concrete mix. B&t a closer look re%eals t!e ma0or role
and infl&ence aggregate pla$s in t!e properties of #ot! fres! and !ardened concrete. C!anges in gradation(
maxim&m si,e( &nit "eig!t( and moist&re content can all alter t!e c!aracter and performance of $o&r concrete
mix.
=conom$ is anot!er reason for t!o&g!tf&l aggregate selection. Ko& can often sa%e mone$ #$ selecting t!e
maxim&m allo"a#le aggregate si,e. 1sing larger coarse aggregate t$picall$ lo"ers t!e cost of a concrete mix #$
red&cing cement re.&irements( t!e most costl$ ingredient. ?ess cement ("it!in reasona#le limits for d&ra#ilit$)
"ill mean less "ater if t!e "ater-cement ("'c) ratio is kept constant. A lo"er "ater content "ill red&ce t!e
potential for s!rinkage and for cracking associated "it! restrained %ol&me c!ange.
3ereBs an o%er%ie" of t!e most important factors to consider "!en selecting and proportioning concrete
aggregate.
KP+CA? A**8=*A= P8<P<8+<;)
Aggregates comprise as m&c! as I76 to H76 of a t$pical concrete mix( so t!e$ m&st #e properl$ selected to #e
d&ra#le( #lended for optim&m efficienc$( and properl$ controlled to prod&ce consistent concrete strengt!(
"orka#ilit$( finis!a#ilit$( and d&ra#ilit$ (P!oto 1). !e ingredients in con%entional concrete mixes &s&all$ fall
"it!in t!ese proportional ranges/
?earn more a#o&t t!e materials t!at go into a good concrete mix.
Ingredien
t
Cement
Range
7% - 15%
60% - 80%
Aggregate
Water
Air
14% - 18%
2% - 8%
A1A?+K C<1;)
Make s&re t!at $o&r concrete prod&cer p&rc!ases good-.&alit$ aggregate as %erified #$ reg&lar aggregate test
res&lts in compliance "it! A)M C 33( 9)tandard )pecifications for Concrete Aggregates.9 A !istor$ of good
performance of a local aggregate also pro%ides an indication of !o" "ell t!e material performs in ser%ice.
*ood-.&alit$ aggregate m&st #e clean( !ard( strong( !a%e d&ra#le particles( and #e free of a#sor#ed !armf&l
c!emicals( coatings of cla$( or ot!er contaminates t!at can affect !$dration of cement or red&ce t!e paste-
aggregate #ond. Aggregates to a%oid incl&de/
!ose t!at are fria#le or s&scepti#le to #eing split.
!ose "it! significant .&antities of soft and poro&s materials.
Certain kinds of 9c!ert(9 since t!e$ ma$ !a%e %er$ lo" resistance to "eat!ering and can lead to s&rface
defects( called popo&ts (P!otos 2 and 3).
)&rface of concrete flat"ork "!ere a popo&t occ&rred o%er a c!ert particle. !o&g! not a str&ct&ral concern( popo&ts are a
nagging s&rface defect t!at can #e a so&rce of aest!etic complaints( and if excessi%e( ma$ compromise co%er .&alit$ in
reinforced sla#s. (P!oto co&rtes$ of t!e Portland Cement Association)

Cross section of a core sliced longit&dinall$ ex!i#its t!e mec!anism of a popo&t. )ome c!ert particles are more a#sorpti%e t!an
!ig!er-.&alit$ aggregates. W!en located near a sat&rated s&rface( t!e$ can a#sor# "ater and &pon free,ing( expand and spall
t!e concrete immediatel$ a#o%e it( along "it! a portion of t!e aggregate. (P!oto co&rtes$ of PCA)
As a nat&rall$ occ&rring material( aggregate "ill sometimes incl&de "eat!ered or &nsta#le particles in t!e
deli%ered prod&ct. !e allo"a#le percentage of deleterio&s s&#stances for #ot! fine and coarse aggregate are
listed in A)M C 33 a#les 1 and 3( respecti%el$. )ome pro0ects mig!t re.&ire e%en more-stringent limits. o
a%oid post-placement pro#lems in concrete t!at are diffic&lt to rectif$( %erif$ t!at t!ese limits are not exceeded at
t!e time of material s&#mittals.
*8A2A+<;)
An optimi,ed gradation #ased on aggregate a%aila#ilit$ and pro0ect re.&irements "ill res&lt in an economical
concrete "it! good "orka#ilit$ and finis!a#ilit$. !e proportions #et"een coarse and fine aggregates "ill c!ange
#ased on t!e &ni.&e c!aracteristics of eac! aggregate( t!e placement met!od( and t!e finis! desired.
!e di%iding line #et"een fine and coarse aggregate is t!e 3'H-inc! sie%e. !e fineness mod&l&s (4M) is an index
of t!e fineness of an aggregate. !e 4M is calc&lated #$ adding t!e c&m&lati%e percentages #$ mass retained on
eac! of a specified series of sie%es and di%iding t!e s&m #$ 177 (see a#le 1). !e 4M for fine aggregate s!o&ld
fall "it!in t!e range of 2.3 to 3.1. !e 4M s!o&ld not c!ange more t!an 7.2M ot!er"ise( mix ad0&stments ma$ #e
necessar$. =xcessi%el$ fine materials "ill !a%e a !ig!er "ater demand and t$picall$ res&lt in a stick$ mix.
=xcessi%el$ coarse material "ill prod&ce !ars! mixes t!at are more diffic&lt to place( consolidate( and finis!.
%ie$e si*e
Percentage of indi$idual fraction retained by
mass
Percentage #assing by mass
Cumulati$e #ercentage retained+ by
mass
,-. /m 0123
in-4
7 177 7
%ie$e si*e
Percentage of indi$idual fraction retained by
mass
Percentage #assing by mass
Cumulati$e #ercentage retained+ by
mass
5-6. /m 07o-
54
2 LH 7
8-19 /m 07o-
34
13 H5 15
:-:3 /m 07o-
:94
27 I5 35
9;; /m 07o-
1;4
27 @5 55
1;; /m 07o-
.;4
2@ 21 GL
:.; /m 07o-
:;;4
1H 3 LG
Pan 3 7 -
Total 177 2H3
4ineness mod&l&s N 2H3 O 177 N 2.H3
a#le 1 - 4ineness mod&l&s (4M) is calc&lated #$ totaling t!e percent
retained #et"een t!e ;o. 177 and ;o. @ sie%e di%ided #$ 177.
4ine aggregate s!o&ld fall "it!in gradation limits pro%ided in A)M C 33( )ection I. +f t!ere is a deficienc$ in a
locall$ a%aila#le fine aggregate( concrete ma$ #enefit from t!e addition of air entrainment( additional cement( or a
s&pplemental cementitio&s material ()CM) to address t!ese s!ortcomings.
Broad coarse-aggregate gradation ranges are listed in a#le 2 of A)M C 33. !ese #road gradation #ands are
for &se all across t!e co&ntr$. <nce a gradation is selected for a pro0ect( maintaining t!e gradation "it!in tig!t
ranges "ill ac!ie%e greater #atc!-to-#atc! consistenc$. !is is t$picall$ accomplis!ed #$ properl$ stockpiling
aggregates and re"orking stockpiles to co&nter excessi%e segregation (P!oto @).
!e maxim&m si,e of coarse aggregate t!at can #e &sed in a mix depends on t!e si,e( s!ape( and reinforcing of
a mem#er( #ased on t!ese 9not-to-exceed9 g&idelines (see P!otos 5 and I)/
3'@ of t!e clear spacing #et"een re#ar or #et"een re#ar and forms (co%er distance)
1'3 t!e dept! of t!e sla#
1'5 t!e narro"est dimension of a mem#er
<ften aggregates are anal$,ed &sing com#ined grading of fine and coarse materials proportioned as anticipated
in t!e proposed concrete mix (P!oto G). !is pro%ides an estimate of !o" t!e #lend "ill perform in concrete.
=%er$ region !as its o"n deficiencies in aggregates( #&t once a com#ined aggregate gradation is plotted
(percentage retained %s. sie%e si,e)( t!ese deficiencies can more easil$ #e identified and remedied. Alternati%e
aggregate so&rces or additional aggregate #lending can t!en #e considered to approac! t!e el&si%e 9ideal9
gradation t!at pro%ides t!e #est "orka#ilit$( p&mpa#ilit$( red&ced s!rinkage( and econom$ (4ig&re 1).
;ote t!at eliminating t!e sand from a mix transforms con%entional concrete to a 9no-fines9 mix( also kno"n as
9per%io&s9 concrete9 (see Per%io&s Concrete Pa%ements). Per%io&s concrete .&alifies for ?==2 points( a green
#&ilding rating s$stem de%eloped #$ t!e 1.). *reen B&ilding Co&ncil (1)*BC)( #eca&se it permits r&noff to
percolate directl$ into t!e s&#grade( rec!arging t!e gro&nd "ater ta#le.
P!oto @ - o address excessi%e segregation of particle si,es( #atc!ing is &s&all$ preceded #$ re"orking piles aro&nd t!e
circ&mference to re#lend si,es( rat!er t!an "orking straig!t into t!e pile. (P!oto co&rtes$ of PCA)

P!oto 5 - 8ecommended maxim&m aggregate si,e to pass t!ro&g! t!e clear distance #et"een reinforcing steel and co%er
dimension. (P!oto co&rtes$ of PCA)
P!oto I - Maxim&m aggregate si,e #ased on placement met!od and sla# t!ickness. (P!oto co&rtes$ of PCA)

P!oto G - )i,e distri#&tion from fine to coarse aggregate pla$s a significant role in concrete "orka#ilit$ and performance. (P!oto
co&rtes$ of PCA)
4ig&re 1 - <ptim&m com#ined aggregate grading for con%entional concrete. (Co&rtes$ of PCA)
)P=C+A? C<;)+2=8A+<;) 4<8 =>P<)=2-
A**8=*A= C<;C8==
Contractors placing decorati%e exposed-aggregate concrete( "!ere appearance is a prime concern( s!o&ld pa$
special attention to t!e aggregate s!ape( text&re( color( and o%erall appearance to $ield t!e #est looking final
prod&ct (P!oto H). W!en placing arc!itect&ral concrete( $o& s!o&ld test trial mixes and place mock-&ps to ens&re
t!at all parties are satisfied "it! t!e materials selected.
Bot! gra%el and cr&s!ed stone are generall$ accepta#le for making .&alit$ concrete (P!oto L)( alt!o&g! gra%el is
&s&all$ preferred for exposed aggregate. !e &se of rec$cled concrete( cr&s!ed to proper-si,e concrete
aggregate( !as also demonstrated s&ccessf&l performance. 8ec$cled concrete "ill !a%e a !ig!er a#sorption and
lo"er specific gra%it$ t!an con%entional aggregates. o prod&ce good .&alit$( d&ra#le concrete containing a
portion of rec$cled concrete aggregate often re.&ires trial concrete mixes and close monitoring of t!e properties
of t!e old rec$cled concrete( "it! mix ad0&stments made( as needed.
=xposed-aggregate concrete pa%ement.

Bot! gra%el and cr&s!ed stone prod&ce .&alit$ concrete. *ra%el "ill !a%e a lo"er "ater demand compared to cr&s!ed stone.
*ra%el is preferred for exposed-aggregate concrete in "alk"a$s and decorati%e applications. Cr&s!ed stone "ill &s&all$ ex!i#it
a !ig!er paste-aggregate #ond. Cr&s!ed stone is preferred in pa%ement mixes since t!e !ig!er paste-aggregate #ond $ields
!ig!er flex&ral strengt!s (P!oto co&rtes$ of t!e PCA)
M<+)18= C<;8<?
4ig&re 2 - Aggregate moist&re content pla$s a part in concrete "orka#ilit$. +f aggregates are too dr$( t!e$ "ill a#sor# (steal)
"ater from t!e mix. +f aggregates are too "et( t!e excess moist&re m&st #e s&#tracted from t!e intended mix "ater .&antit$.
(P!oto co&rtes$ of PCA)
!e a#sorption and s&rface moist&re of aggregates are simple $et criticall$ important aspects of prod&cing
concrete t!at consistentl$ ac!ie%es t!e specified or targeted strengt!. !e f&ndamental relations!ip #et"een
"ater-to-cement ratio and strengt! starts "it! correcting for t!e moist&re contri#&tion or a#sorption #$ t!e
aggregates.
Aggregates are some"!at like small( !ard sponges. Mix design calc&lations are cond&cted ass&ming aggregates
are in a sat&rated s&rface dr$ ())2) condition( meaning t!eir a#sorption is satisfied and no "ater is taken from or
added to t!e mix. +f t!eir a#sorption is not satisfied( t!ese 9sponges9 steal "ater from t!e designated .&antit$ of
mix "ater( red&cing t!e sl&mp of t!e concrete. +f t!e 9sponges9 are excessi%el$ "et (#e$ond t!at amo&nt to
satisf$ t!e a#sorption)( t!e extra "ater m&st #e s&#tracted from t!e .&antit$ of #atc!ed mix "ater. <t!er"ise( t!e
target "'c ratio is exceeded and strengt!s "ill decrease (4ig&re 2).
+MP<8A; A**8=*A= 2<) A;2 2<;B)
D< &se aggregate t!atBs in compliance "it! A)M C 33( 9)tandard )pecifications for Concrete
Aggregates.9 Aggregates m&st #e so&nd( clean( !ard( d&ra#le( and free of excessi%e fines or contaminates t!at
can affect cement !$dration or disr&pt t!e paste-aggregate #ond.
D<7=T exceed limits for deleterio&s material content in fine and coarse aggregates. !ese limits are presented in
A)M C 33 a#les 1 and 3( respecti%el$. )ome specifications ma$ re.&ire more stringent limitations.
D< monitor moist&re contents of coarse and fine aggregates on a reg&lar #asis to promote #atc!-to-#atc!
consistenc$ and &niformit$. Moist&re pro#es in aggregate #ins s!o&ld #e cali#rated according to man&fact&rersB
recommendations. Moist&re pro#es s!o&ld also #e c!ecked periodicall$ "it! standard #&rn-off moist&re
determinations (A)M C 5II).
D< make s&re stockpiles are properl$ managed. !e$ s!o&ld #e #&ilt in !ori,ontal or gentl$ sloping la$ers to
red&ce segregation and #e ade.&atel$ spaced to allo" "orking t!e piles properl$. +n areas "!ere $ard space is
limited and stockpiles are diffic&lt to keep separate( #arriers s!o&ld #e &sed to a%oid intermingling and cross-
contamination of different-si,ed materials.
4or additional information a#o&t aggregates and concrete mix design( read/
2esign and Control of Concrete Mixt&res( Portland Cement Association (see C!apter 5( Aggregates for
Concrete).
American Concrete +nstit&te (AC+) Committee 8eport 2218-LI( *&ide for 1se of ;ormal Weig!t and
3ea%$"eig!t Aggregates in Concrete( )ection @.5.