11/2005

BATCHERS STUDY GUIDE

USES OF CONCRETE

AAA - Prestressed Concrete

AA-1 - Precast Concrete as called for on Plans or High Early Strength concrete if approved by the Engineer
AA - Bridge superstructure concrete or precast concrete as called for on Plans
A - General Purpose
B - Massive sections or lightly reinforced sections or miscellaneous non-structural concrete
CS - To be used as a subbase where required by Plan

Min. 1 Cement Max. Water/Cement Slump Acceptance Ent. Air Acceptance

Class of Coarse Aggr. Content, Ratio Limits (in) 5 Limits (%) Min. Comp. Str. @ 28
Concrete Size Nos. lbs/yd3 gals/yd3 lbs/lbs Lower Upper Lower Upper days (f’c), psi

AAA 67, 68 2 675 35.65 0.440 2 4 2.5 6.0 5000

AA-1 67, 7 675 35.65 0.440 2 4 2.5 6.0 4500

AA 56, 57, 67 635 33.9 0.445 2 4 3.5 7.0 3500

A 56, 57, 67 611 35.9 0.490 2 4 2.5 3 6.0 3000

B 56, 57, 67 470 37.2 0.660 2 4 0.0 6.0 2200

CS 56, 57, 67, 280 47.1 1.400 - 3 3.0 7.0 1000 4

Graded Aggr.

Notes: 1. Portland cement may be partially replaced with fly ash or slag as provided in 500.3.04.D.4 and 5.
2. Specific size of coarse aggregate may be specified for precast/prestressed concrete.
3. Lower limit is waived when air entrained concrete is not required.
4. The mixture will be capable of demonstrating a laboratory compressive strength at 28 days of 1000 psi + 0.18 R*. Compressive
strength will be determined based upon result of six cylinders prepared and tested in accordance with AASHTO T 126 and T 22.
* Where R = difference between the largest observed value and the smallest observed value for all compressive strength specimens
at 28 days for a given combination of materials and mix proportions prepared together.
5. Slump limits may be altered by the Laboratory only when Type “F” water reducers are used.

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I. Basic Calculations in Concrete and Aggregate Technology:

A. Moisture Content and Absorption of Aggregate

Aggregate used in concrete consists of materials as sand, gravel, crushed stone,
stone sand, and lighted aggregates. Usually these materials contain some
moisture when they are batched into the mixer. The water can be present in two
forms:

(1) Absorbed water in pores or cavities of individual aggregate particles. This

water is not visible on the surface of particles and it is not available to
contribute to plasticity of fresh concrete. Absorbed water is not included
as a portion of the mixing water.
(2) Free water on the surface of individual aggregate particles (see Figure 1).
This is the water that is visible on wet aggregates; it makes the particles
generally appear shinny. It is free surface moisture that contributes to the
mixing water in concrete because it is available to produce slump and to
help make the fresh concrete plastic.

Saturated, Damp
State: Dry surface dry (SSD) or wet

Total moisture: None Contains only Contains absorbed water

absorbed water and free surface
moisture

Figure 1

The general formula linking the two kinds of moisture in aggregate is as

follows:
Total Moisture = Free (Surface) Moisture + Absorbed Moisture

Our general way of expressing moisture content is as a percentage of SSD

aggregate weight. Then when the moisture quantities in kilograms are desired
for a known quantity of aggregate, they can be computed by taking a percentage
of the SSD weight. Aggregate moisture percentages --% total moisture, % free
moisture, and % absorption – are computed from test made on a sample of the
aggregate.
(3) Saturated Surface Dry (SSD)
Aggregate is SSD when the following two conditions are met:
(1) The interior pores of the particles are saturated with water and
(2) The particle surfaces are dry.

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II. Sampling Fine and Coarse Aggregates:

Procedures for sampling fine and coarse aggregates are given in the Sampling,
Testing, and Inspection Manual for sampling off belts, stockpiles, and railroad cars.
We feel that you should implore the method in which the most representative
sample can be obtained. In our opinion this would be sample taken from a
conveyor belt for gradation test and a sample taken near to the weigh hopper for
moisture test.

Samples from conveyor belts should be taken by stopping the belt and removing the
entire cross-section of material on the belt at three different locations and
combining these portions into a composite sample.

III. Determine Moisture Contents of Fine and Coarse Aggregates:

A. % Total Moisture

This must be determined frequently since the total moisture of aggregates can
vary a large amount from hour to hour or day to day. Differences may be large
within one stockpile or bin compartment. The most direct and accurate way of
measuring total moisture is to weigh a sample of the wet aggregate and then dry
it completely in an oven or over a burner. The calculations are as follows:

Total Wt. of Water = Wet Wt. of Agg. – Dry Wt. of Agg.

Total Wt. of Water

% Total Moisture = × 100
Dry Wt. of Agg.

therefore,
Example No. 1 (Sand):
Wet weight of sample = 847 grams
Dry weight of sample = 792 grams

847 - 792 55
% Total Moisture = × 100 = × 100
792 792

= 0.069 × 100 = 6.9 %

Total Wt. of Water = 847 – 792 = 55 grams

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 B. % Free Moisture.
Free surface moisture is computed by the following method:
% Free Moisture = % Total Moisture - % Absorption
Also,
Wt. of free water = Wt. of Total Water – Wt. of Absorbed Water

Example No. 2 (Stone): If an aggregate has an absorption of 1.5% and the total
moisture content of a sample is determined to be 2.5%, what is the % free
moisture:

% Free Moisture = 2.5% - 1.5% = 1.0%

For this aggregate how much free water will be batched with the aggregate if
the batch weight for an 8 cubic yard load is 14,000 lbs of SSD aggregate?

Wt. of free water = 1.0 % of 14,000 lbs

= 0.01 × 14,000 = 140 lbs

Free moisture content is necessary to compute the amount of water on the

aggregate which will contribute to mix water in the concrete. The weight of
separately added water will be equal to the total mixing water of the batch of
concrete minus the total weight of free water present on both fine and coarse
aggregate going into the concrete.

C. Determining Free Moisture by Chapman Flask.

1. Fill flask with water to 200 ml. mark. This mark will usually fall between
the two bubbles in the flask.

2. Weight 500 grams of wet sand and place in the flask with the 200 ml. of
water.

3. Agitate flask to remove entrapped air.

4. Read the water level on the stem.

5. Using the water level reading and the specific gravity of the material you
can determine the free moisture content from the Chapman flask chart.

IV. Adjusting Batch Weights for Aggregate Moisture

When batch weights are set up for a specific class of concrete, the aggregate
weights will be expressed as saturated-surface-dry weights and the amount of water
indicated is the total mixing water. However, since aggregates, as batched into the

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mixer, are very seldom saturated-surface-dry, adjustments must be made in both the
weights of the aggregates and the quantity of water to be added.

A. Example 1: What is the equivalent weights for 1200 lbs of saturated-surface-

dry sand if in a wet condition it has an absorption = 1.5% and total moisture =
7.0%. How many gallons would the total mixing water be reduced for the
conditions described above?

Solution: We are only interested in the amount of free water contained in the
sand because this is the water which contributes to consistency.

Free Moisture = Total Moisture – Absorption

Free Moisture = 7.0 – 1.5 = 5.5%

5.5
Express % moisture as decimal = = 0.055
100

Equivalent Wt. = 1200 lbs × 1.055 = 1266 lbs

Water Reduction = 1266 - 1200 = 66 lbs

66 lbs
= 7.9 gals.
8.33 lbs gal

B. Example 2: The following is a Class A mix which meets the Department of

Transportation Specifications. The batch weights are given in SSD condition
for a one cubic yard batch. What actual weights should be used if the sand and
stone are wet?

Cement 611 lbs

Sand 1150 lbs
Stone 1820 lbs
Total Mixing Water 34.2 gals
Air Content 4 %

Wet Sand (Total Moisture = 5.5%; Absorption = 1.5%)

Wet Stone (Free Moisture = 1.0%; Absorption = 0.5%)

Solution:
We now calculate the amount of free moisture in the aggregates since the batch
weights are expressed in SSD. The necessary aggregate weight and water
adjustments for this free moisture must be made.

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Sand: Free Moisture = Total Moisture – Absorption
Free Moisture = 5.5% - 1.5% = 4.0%

Water and Water Adjustment:

Convert % free moisture to its decimal equivalent

4.0
= 0.040
100

Adjusted Sand Wt. = 1150 lbs × 1.040 = 1196 lbs

1196 - 1150 46
Water Adjustment = = = 5.5 gals.
8.33 lbs gal 8.33

Stone: In this example the stone is already expressed as a percent free moisture
so no conversion is necessary.

Convert % Free Moisture to its decimal equivalent.

1.0
= 0.01
100

Adjustment in stone weight for corresponding % moisture =

1820 lbs × 1.01 = 1838 lbs
Adjustment for water = 1838 - 1820 = 18 lbs
18 lbs
Convert pounds of water to gallons = = 2.2 gals.
8.33 lbs gals
Since these aggregates contain free moisture that will contribute to the
consistency of the concrete, the total mixing water will be reduced by the
amount of free moisture in the aggregates expressed in gallons.

Free water in the sand = 5.5 gals

Free water in the stone = 2.2 gals
Total Free Water = 7.7 gals

Actual Mixing Water = Total mixing water – total free water

Actual Mixing Water = 34.2 gals – 7.7 gals = 26.5 gals

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 Your actual batch weights for one cubic meter which would be as follows:
Cement 611 lbs
Sand 1196 lbs
Stone 1838 lbs
Water 26.5 gals

What would be the actual batch weights of a 5 cubic yard batch?

Cement = 611 lbs yd 3 × 5 yd 3 = 3055 lbs

Sand = 1196 lbs yd 3 × 5 yd 3 = 5980 lbs

Stone = 1838 lbs yd 3 × 5 yd 3 = 9190 lbs

Water = 26.5 gals yd 3 × 5 yd 3 = 132.5 gals

C. Example 3: If the 5 cubic yard weights in the previous example were actually
batched and produced a zero slump, how many gallons of water could be added
without exceeding the maximum gallons for its class?

Solution:
Go to “Uses of Concrete” chart and find the maximum water per cubic meter for
a Class “A” mix, which is 35.9 galsyd3.

Actual total mixing water in Example = 34.2 gals/yd3.

The water which could be added to a one cubic yard batch without exceeding
the maximum is equal to the maximum minus the actual.

Maximum = 35.9 gals/yd3

Actual = 34.2 gals/yd3
Addable water = 1.7 gals/yd3

V. Water Cement Ratio:

The water-cement ratio of a batch of concrete is the ratio of mix water (lbs) to
cement (lbs). This calculation is a simple one and can be accomplished by dividing
the pounds of water by the pounds of cement.

A. Example 1: What is the water/cement ratio of the following mix?

Cement 611 lbs
Sand 1150 lbs
Stone 1838 lbs
Total Mixing Water 34.2 gals
Air Content 4 %

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Convert 34.2 gallons of water to pounds:
34.2 gals × 8.33 lbs gal = 284.9 lbs
284.9
Water / cement ratio = = 0.47
611

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 CHAPMAN FLASK MOISTURE CHART
Per Cent Moisture in Sand
Volume Bulk Specific Gravity, SSD basis
2.55 2.56 2.57 2.58 2.59 2.60 2.61 2.62 2.63 2.64 2.65 2.66 2.67 2.68 2.69 2.70 2.71 2.72 2.73 2.74 2.75
382 0.1
383 0.2 0.4
384 0.1 0.3 0.5 0.7
385 0.2 0.4 0.6 0.8 1.0
386 0 0.3 0.5 0.7 0.9 1.1 1.3
387 0.1 0.4 0.6 0.8 1.0 1.3 1.5 1.7
388 0 0.2 0.4 0.7 0.9 1.1 1.4 1.6 1.8 2.0
389 0.1 0.3 0.5 0.8 1.0 1.2 1.5 1.7 1.9 2.1 2.3
390 0 0.2 0.4 0.6 0.9 1.1 1.3 1.6 1.8 2.0 2.2 2.4 2.6
391 0 0 0.3 0.5 0.7 1.0 1.2 1.4 1.7 1.9 2.1 2.3 2.5 2.7 3.0
392 0 0.1 0.4 0.6 0.8 1.1 1.3 1.5 1.8 2.0 2.2 2.5 2.6 2.8 3.1 3.3
393 0 0 0.2 0.5 0.7 0.9 1.2 1.4 1.6 1.9 2.1 2.3 2.6 2.8 3.0 3.2 3.4 3.7
394 0 0.1 0.3 0.6 0.8 1.0 1.3 1.5 1.7 2.0 2.2 2.4 2.7 2.9 3.1 3.3 3.5 3.8 4.0
395 0 0.1 0.4 0.6 0.8 1.1 1.4 1.6 1.8 2.1 2.3 2.5 2.8 3.0 3.3 3.4 3.7 3.9 4.1 4.3
396 0 0.2 0.5 0.7 1.0 1.2 1.5 1.7 1.9 2.2 2.4 2.6 2.9 3.1 3.4 3.6 3.8 4.0 4.2 4.4 4.7
397 0.3 0.6 0.8 1.1 1.3 1.5 1.8 2.0 2.3 2.5 2.7 3.0 3.2 3.5 3.7 4.0 4.1 4.3 4.6 4.8 5.0
398 0.7 0.8 1.1 1.4 1.6 1.9 2.1 2.4 2.6 2.8 3.1 3.3 3.6 3.8 4.1 4.3 4.5 4.7 4.9 5.1 5.4
399 1.0 1.2 1.5 1.7 2.0 2.2 2.5 2.7 2.9 3.2 3.4 3.7 3.9 4.2 4.4 4.6 4.8 5.0 5.3 5.5 5.7
400 1.3 1.6 1.8 2.1 2.3 2.6 2.8 3.0 3.3 3.6 3.8 4.0 4.3 4.5 4.7 4.9 5.2 5.4 5.6 5.8 6.1
401 1.7 1.9 2.2 2.4 2.6 2.9 3.1 3.4 3.7 3.9 4.2 4.4 4.6 4.8 5.1 5.3 5.5 5.8 6.0 6.2 6.4
402 2.0 2.2 2.5 2.7 3.0 3.2 3.5 3.8 4.0 4.3 4.5 4.7 5.0 5.2 5.5 5.7 5.9 6.1 6.3 6.5 6.8
403 2.4 2.6 2.8 3.1 3.3 3.6 3.9 4.1 4.4 4.6 4.8 5.1 5.3 5.6 5.8 6.0 6.2 6.5 6.7 6.9 7.1
404 2.7 2.8 3.2 3.4 3.7 4.0 4.2 4.5 4.7 4.9 5.2 5.4 5.7 5.9 6.2 6.4 6.6 6.8 7.0 7.3 7.5
405 3.0 3.3 3.5 3.8 4.0 4.3 4.6 4.8 5.1 5.3 5.5 5.8 6.0 6.3 6.5 6.7 7.0 7.2 7.4 7.7 7.9
406 3.4 3.6 3.9 4.2 4.4 4.7 4.9 5.2 5.4 5.7 5.9 6.1 6.4 6.6 6.9 7.1 7.3 7.5 7.8 8.0 8.2
407 3.8 4.0 4.2 4.5 4.8 5.0 5.3 5.5 5.8 6.0 6.3 6.6 6.7 7.0 7.2 7.5 7.7 7.9 8.1 8.4 8.6
408 4.1 4.3 4.6 4.9 5.1 5.4 5.6 5.9 6.1 6.4 6.7 6.9 7.1 7.3 7.6 7.8 8.1 8.3 8.5 8.7 9.0
409 4.4 4.7 5.0 5.2 5.5 5.7 6.0 6.3 6.5 6.8 7.0 7.3 7.5 7.7 8.0 8.2 8.4 8.6 8.9 9.1
410 4.8 5.1 5.3 5.6 5.8 6.1 6.4 6.6 6.9 7.1 7.4 7.7 7.8 8.1 8.3 8.6 8.8 9.0 9.3
411 5.2 5.4 5.7 6.0 6.2 6.5 6.7 7.0 7.2 7.5 7.8 8.0 8.2 8.5 8.7 9.0 9.2
412 5.6 5.8 6.1 6.3 6.6 6.8 7.1 7.4 7.6 7.9 8.1 8.3 8.6 8.8 9.1 9.3
413 5.9 6.2 6.4 6.7 7.0 7.2 7.5 7.7 8.0 8.3 8.5 8.7 9.0 9.2
414 6.3 6.5 6.8 7.1 7.3 7.6 7.8 8.1 8.4 8.7 8.8 9.1
415 6.7 6.9 7.2 7.4 7.7 8.0 8.2 8.5 8.8 9.0 9.2 9.5
416 7.0 7.3 7.6 7.8 8.1 8.4 8.6 8.9 9.1 9.4 9.6
417 7.4 7.7 7.9 8.2 8.5 8.7 9.0 9.2
418 7.8 8.0 8.3 8.6 8.8 9.1 9.4 V - (500 / specific gravity) - 200
419 8.2 8.4 8.7 9.0 9.2 9.5 Per Cent moisture =
200 + 500 - V
420 8.6 8.8 9.1 9.4
421 8.9 9.2 where V = flask reading
specific gravity = bulk specific gravity, SSD basis
422 9.3

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