Mix Management Theory and COMMANDqc

1. Mix Management Theory and COMMANDqc James M. Shilstone, Jr., FACI jshilstone@commandalkon.com Phone: 205-879-3282 x2320

2. Session Objective Review the basics of Mix Management Theory with Concrete Technologist Jay Shilstone and learn how to use COMMANDqc to implement theoretical best practices. Topics will include: • Concrete Products • Specifications, • Exposure Conditions • Classes • Mix Designs • Using water/cement curves, • Aggregate proportioning The session is designed for new or existing COMMANDqc users, QC and technical personnel, as well as management and senior operators responsible for mix design maintenance and cost control. Mix Management Theory and COMMANDqc

3. Mix Design Materials and quantities selected to achieve design objectives Example Rock – 1800 lbs Sand – 1300 lbs Cement – 525 lbs Water – 275 lbs Products vs. Mix Designs Products • Generic products for sale • Based on specifications • Example • 3000 psi f’c • Air entrained • 1” max. aggregate Mix Management Theory and COMMANDqc

4. Mix Management Mix Management Theory and COMMANDqc

5. Adding a Concrete Product Mix Management Theory and COMMANDqc

6. Entering a New Concrete Product Mix Management Theory and COMMANDqc

7. Entering a New Concrete Product Setup->Concrete Product Screen Layout Setup -> Concrete Requirement Classes Mix Management Theory and COMMANDqc

8. Exposure Classes ACI 318 Classes • F- Freeze Thaw • S- Sulfates • P- Permeability • C- Corrosion • (Nothing for ASR) EN-206 Classes • X0 – no severe exposure • XC – Corrosion by carbonation • XD – Corrosion from chlorides • XS – Corrosion from chlorides in sea water • XF – Freeze-thaw • XA – Aggressive chemical attack

9. ACI 318 Exposure Classes Mix Management Theory and COMMANDqc

10. Entering a New Concrete Product Mix Management Theory and COMMANDqc

11. Concrete Mix Design Mix Management Theory and COMMANDqc

12. Mix Proportions Mix Management Theory and COMMANDqc

13. Mix Proportions Mix Management Theory and COMMANDqc

14. Add Materials in COMMANDseries! • Materials added in COMMANDseries are automatically transferred to COMMANDqc • Transferred Materials must have a “Supplier” assigned • Materials added in COMMANDqc do NOT transfer to COMMANDseries • Only add Materials in COMMANDqc if they are for trial use in a lab Mix Management Theory and COMMANDqc

15. Mix Calculated Properties Mix Management Theory and COMMANDqc

16. Mix Other Properties Mix Management Theory and COMMANDqc

17. Mix Grading Mix Management Theory and COMMANDqc

18. Mix Strength Curves Files => Concrete Producer-Concrete = > Strength-Water/Cement Curve Mix Management Theory and COMMANDqc

19. Mix Aggregates % Passing, Indiv. % Retained, Coarseness Factor, 0.45 Power Mix Management Theory and COMMANDqc

20. Aggregate Yield Mix Management Theory and COMMANDqc

21. Aggregate Percentages Mix Management Theory and COMMANDqc

22. Aggregate Optimization Mix Management Theory and COMMANDqc

23. Determining cement-ACI 318 • Best – use historical test data and determine appropriate overdesign, then determine cement content • Alternate – produce lab batches to develop w/c vs strength curve and select appropriate cement content • If no data available, use “expertise”

24. Field experience - overdesign Concrete Producer => Concrete Performance Analysis => Strength Performance

25. w/cm Ratio Curve Files => Concrete Producer-Concrete => Strength-Water/Cement Curves

26. Trial mixtures - overdesign

27. Determining cement – EN 206 • Initial • Avg of 3 tests >= f’c + 4 MPa • Indiv >= f’c – 4 Mpa • Continuous • Avg of 15 tests >= f’c + 1.48 * sdpop • Indiv >= f’c – 4 MPa

28. k-values • Fly ash / cement <= 0.33 by mass • CEM I 32.5 k=0.2 • CEM I 42.5 k=0.4 • Silica fume / cement <= 0.11 by mass • For w/c <= 0.45 k = 2.0 • For w/c > 0.45 k = 2.0 except for XC and XF k=1.0 • Equivalent concrete performance

29. Combined grading

30. Combined grading - % Pass

31. Combined grading – Ind % Rtn

32. Combined grading – .45 Power

33. Combined grading - Bolomey

34. Athens Research

35. Coarseness Factor Chart

36. Coarseness Factor

37. W-Adjust • W= % passing #8 sieve • Wadj = W + ((WtC+P- 564) * (2.5/94))

38. Air Force Findings

39. Mortar Requirements

40. MORTAR NEEDS (Approximate) • 52.0 for a 5” diameter high pressure pump with a long stroke (gravel). • 54.0 to 55.5% for 5” diameter high pressure pump with long stroke (cubical crushed). • 55.5 to 57% for lighter, but good, pumps (crushed stone). • 60% for 1/2” sharp edged crushed stone with a 2” line. • 63.3 to 63.8% for topping mixes.

41. 1990’s Aggregate Distribution

42. WATER DEMAND

43. Objective of particle packing

44. HAYSTACK - “Optimum”

45. C33 - 1923 Graded Mix

46. Colorado Bridge Deck

47. Wisconsin Univ/DOT ResearchOptimized Aggregate Conclusion • Compressive strength - plus 10 to 20% • Air entraining agent - minus 20 to 30% • Potential water demand - minus 20 to 30% • Potential high spacing factor for air voids • Reduced segregation and higher density following extended vibration

48. Wisconsin DOT/UnivEffects of particle distribution on segregation

49. 8/18 Grading Spec

50. .45 Power Chart