Concrete Mix Design, Quality Control and Specification

380 Pages·2006·6.841 MB·English

by  Ken Day, Ken W. Day

Concrete Mix Design, Quality
Control and Specification
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Concrete Mix Design,
Quality Control and
Specification
Third Edition
Ken W. Day
First published 1995
by E & FN Spon
Second edition published 1999
by E & FN Spon
This edition published 2006
by Taylor & Francis
2 Park Square,Milton Park,Abingdon,Oxon OX14 4RN
Simultaneously published in the USA and Canada
by Taylor & Francis
270 Madison Ave,New York,NY 10016
Taylor & Francis is an imprint of the Taylor & Francis Group,aninforma business
© 1995,1999,2006 Ken W.Day
This edition published in the Taylor & Francis e-Library, 2006.
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All rights reserved.No part of this book may be reprinted or
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invented,including photocopying and recording,or in any
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The publisher makes no representation,express or implied,with regard
to the accuracy of the information contained in this book and cannot
accept any legal responsibility or liability for any efforts or omissions
that may be made.
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library
Library of Congress Cataloging in Publication Data
Day,Ken W.
Concrete mix design,quality control,and specification/
Ken W.Day.– 3rd ed.
p.cm.
1.Concrete – Mixing – Quality control. 2.Concrete –
Specifications. I.Title.
TA439.D39 2006
620.1'36–dc22 2006003160
ISBN10:0–415–39313–2 (hbk)
ISBN10:0–203–96787–9 (ebk)
ISBN13:978–0–415–39313–3 (hbk)
ISBN13:978–0–203–96787–4 (ebk)
Contents
List of figures ix
List of tables xiii
Acknowledgements xv
Introduction xix
1 Advice to specifiers 1
1.1 Mix selection 1
1.2 Quality control 2
1.3 ISO 9001 3
1.4 Testing 4
1.5 Cash penalty specifications 5
1.6 Originality 5
1.7 Conclusion 6
1.8 P2P 6
2 Properties of concrete 8
2.1 Durability 8
2.2 Rusting 10
2.3 Strength 11
2.4 Impermeability 13
2.5 Workability 16
2.6 Pumpability 18
2.7 Slump 18
2.8 Self-compacting concrete 19
2.9 Dimensional stability 19
2.10 Good appearance 19
2.11 Heat generation 20
2.12 Economy 20
vi Contents
3 Mix design 21
3.1 Simple mix design 21
3.2 Origins and limitations of specific surface mix design 31
3.3 Cost-competitive mix design 37
3.4 The ConAd system 58
3.5 Alternative methods of mix design 58
3.6 Mix design competitions 73
4 Quality control 75
4.1 The nature of concrete variability 76
4.2 The objectives of quality control and quality assurance 80
4.3 Cusum charts 82
4.4 The significance of control action requirements 86
4.5 Who should control? 87
4.6 Quality assurance 89
4.7 Pareto’s principle 89
4.8 Related variables 91
4.9 Practical use of a cusum analysis 92
4.10 Direct plots 96
4.11 Rejection, penalization or bonus? 98
4.12 Data retrieval and analysis/ConAd system 99
4.13 EN206 – can we do better? 118
4.14 Use of ConAd test result entry and data analysis
systems for early age 121
4.15 Batching control (by Don Bain) 122
4.16 Truck-mounted mixing and workability control system 126
5 Concrete in the 22nd century 132
5.1 Integrated mix design and QC 133
5.2 Relational mix maintenance (by Mark Mackenzie) 144
5.3 High performance (SCC) concrete 152
5.4 TecEco concretes (by John Harrison) 157
5.5 Advances in inorganic polymer concrete technology 163
6 Specification of concrete quality 165
6.1 The philosophy behind specifying concrete 165
6.2 Development of standard mixes 170
6.3 Batch plant equipment 171
6.4 Proposal – approval specifications 171
Contents vii
7 Aggregates for concrete 173
7.1 Fine aggregate (sand) 173
7.2 Coarse aggregate 193
8 Cementitious and pozzolanic materials 201
8.1 Portland cement 201
8.2 Fly-ash (pfa) 206
8.3 Blast-furnace slag 211
8.4 Silica fume 213
8.5 Rice hull ash (RHA) 215
8.6 Superfine fly-ash 216
8.7 Colloidal silica 216
8.8 Metakaolin 216
8.9 Superfine calcium carbonate (pure limestone) 217
9 Chemical admixtures 218
9.1 Specifying admixture usage 220
9.2 Possible reasons for using an admixture 220
9.3 Types of admixtures available 221
10 Statistical analysis 229
10.1 The normal distribution 230
10.2 Variability of means of groups 237
10.3 Variability of standard deviation assessment 238
10.4 Components of variability 239
10.5 Testing error 240
10.6 Coefficient of variation 241
10.7 Practical significance of the foregoing 242
11 Testing 245
11.1 Philosophy of testing 245
11.2 Range of tests 245
11.3 Compression testing 248
11.4 The maturity/equivalent age concept 257
11.5 Permeability testing 269
11.6 Non-destructive testing 270
11.7 Fresh concrete tests/workability 272
viii Contents
12 Unchanging concepts! 282
12.1 Cash penalty specification 282
12.2 What is economical concrete? 290
12.3 How soon is soon enough? 293
13 Troubleshooting 300
13.1 Strength, pumpability, appearance 301
13.2 Causes of cracking in concrete slabs 305
Summary and conclusion 307
Appendix: advances in inorganic polymer concrete technology 308
Glossary 338
References 340
Index 349
Figures
2.1 Relation between w/c ratio and permeability 14
2.2 Reduction of permeability with curing 15
3.1 Simple mix design screen 23
3.2 Specific surface calculation 23
3.3 Material combiner 24
3.4 Water content estimation 25
3.5 Table of mixes 28
3.6 Variation of selected parameters over entire range of mixes 38
3.7A The Shallard spreadsheet 41
3.7B Entry and output section of spreadsheet in Fig. 3.7A 42
3.8 Solver set-up for spreadsheet 43
3.9 Material gradings 45
3.10 Material gradings listing 46
3.11 Sand grading variation over time 46
3.12 Automix constituents screen 51
3.13 Automix mix properties screen 52
3.14 Class A and B grading zones (B.S. 882/1944 concreting sands) 60
3.15 British sand grading zones (mean values) 60
3.16 Road Note 4 reference gradings for 0.75 in (20 mm) maximum
size aggregate 62
3.17 Selection of fine aggregate per cent 64
3.18 Strength – w/c curves 65
3.19 Examples of relationships between free water demand and
cement content for six sets of materials 70
3.20 Functions of water in filling voids in concrete 72
4.1 The normal distribution 76
4.2 Change points and basic variability 80
4.3 Simple cusum control chart 83
4.4 Use of V-mask on cusum chart 83
4.5 Cusum graph exhibiting both real and non-significant
changes 84
4.6 QC program (free download from author’s website) 93