Computers and Concrate, Yo! 10. No, (2012) 19-38 rr An approach of using ideal grading curve and coating paste thickness to evaluate the performances of concrete-(1) Theory and formulation HAY. Wang*!, C.L. Hwang? and 8.1. Yeh! ‘Department of Cv! Engiwerng, National Kaobstng Univeraty of Applied Sciences, eahsung, Taran. ROC. “Department of Construction Engineonng and Technolgy, Notional Taiwan Univesty {of Science and Technology, Tapet, Taman. ROC. (Received September 3, 2008, Rwsea Cedar 23,201, Accepted October 24,2011) Abstract. The performance of a concrete is simificamly influmnced by its mixture proportion and the ‘outing thickness on aggregate surface. The conetete inthis study is designed by estimating the Mending ‘ato of aggregate using « densified mixture design algorithm (DMDA) bed on an ‘desl grading Curve and estimating the paste volume asthe sum of the amount of paste needed to prove an assizned coating paste thickness. So_as to obtain appropriate concrete amount, and this can accurately exinate the property of concrete. Deduction of this mix design formula is simple and easy unlersanding, and meanvile to obtain result i fst. This estimation model of mix design can effectively uprade concrete ‘quality and is expected to be beneficial t industry. Keywords: densitit miaure design slgoritim (OMDA): 4. Introduction Concrete is a composite material, but, duc to interface bonding defects among various materials and assoviated imperfections, the mechanical properties are difficult to estimate according. t0 mathematical formulae of composite material (Hsu and Hsw 2002). Inthe past, the mix proportion was obtained by laboratory tests and trial batching, each property ofthe concrete was estimated by empirical equations and test results, and the mix proportion was seldom designed by theory fiom @ igang curve, Literature reviews ffom past studies (Hsu and Hsu 2002, Chang ef ol. 2001, Zhan 1988, Kessler 1944, Kwan e” a. 1999, Mora et al. 1998, Mora et a. 2000), Present a theorticl spproach to arranging aggregate o fi in an ideal grading curve, establishing the optimum blended ‘atio of sggsegates and other solid particles in concrete, so as to reach the maximum packing ensity. The effect of fly ashislag on the property of reactive powder mortar designed by using Fuller grading curve and error function, that mainly focused on Fuller grading cuve to theoretically ‘esign blended ratio of all solid materials of a reactive powder mortar (RPM), also known a reactive powder concrete (RPC) (Chan and Chu 2004). By computing the total surface area of ‘agregates and particles in concrete and then assigning 8 coating paste thickness, based on nominal thickness of coating paste prescribed, one can determine the relationship between paste amount and * Comesponding autor. Profesor, E-mei: wangho@hussedi20 HY. Wag, Cl. Hoang end ST Yo content of coarse and fine aggregates. A complete and precise formula to estimate the optimum Coating thickness s0 a5 to limit the paste amount can ensure sufficient coating paste and dense fageregate structure. In future vasious properties of concrete can be obtained and expected based on the peste amount. This approach is expected to solve the problem that current concrete mix proportion can only be determined by elaborated experimental work and operator's experience, to build up 2 set of fast and efficent mixture design algorithm to secure long term perfermance of concrete as required. RPC is elso known as ulir-high-performance concrete (UHPC). That is Characterizing by excellent physical properties, particularly high compressive (200-800 MPa) and flexure strength (40-50 MPa) (Matte er al, 2000). “The aggregate occupies about 60-70% of concrete volume and was previously regarded as filler, but is now known to be the main component conferring strength. The particle properties, size and ‘pdation of aggregate will influence the packing density of a concrete mixture. A simple sieve “alysis is generally employed to describe particle distibution, and the blended ratio of agaregate has a great impact on the workability and properties of conerete. To make a comprehensive description of the gradation of a blended aggregate, proper characteristic values are needed to “describe the composition of each single particle. Normally, fineness modulus (FM), specific surface farca (Sq) and nominal maximum particle diameter (Dag) are taken as eonerete characteristic values. ‘The pocking of individual aggregate can be expressed as an ideal gradation curve from many gailing curves oblained from experimental work and error test, may be expressed in a diagram, fuch as sieve analysis curve, or denoted in functions, such as a Fuller curve and Bolomey parabola Curve. Consequently, calling such composite material a “concrete” is somewhat of a misnomer and emote closely approximates a momar, However, RPM is unique in attempting to optimize the entire ‘grain size distribution of the composite matrix in order to reach maximum compaction (Chan and ‘Chu 2004, Lee et al. 2005), When aggregate packing reaches she maximum bik density, such & ‘mixture can be deemed as most closely packed mix (Chang ef a. 2001). And the total surface area Of aggregate ean be determined based on the obtained proportion of apasegate, which fciitates Calculation of concrete coating paste by assigning a thickness and assuming a round aggregate. In ‘Taiwan, the Hwang's research group tried to achieve the maximum dry loose density by simply pecking all solid particles including coarse aggregates, sand and fly ash, to reduce the quanity of Tutbrcating paste but Keep desired workability for HPC (Hoang 2003, Hwang and Chen 2002) as ‘Well ax RPM. As the category of materials less than tree, the blend ratio (a, ) (Hwang and Chen 12002, Lee and Hwvang 2002) of solid materials can be casily obtained by experimental work, ctherwise the packing seems cifficult especially as the material size finer than 1 gam. Therefore, itis hecessary to adopt numerical approach to oblain proper packing order of all granular materials Mixing water is done primarily to increase cement hydration and desired concrete workability Cement content affects the cost of concrete and CO; emission, and the quantity and quality of ‘cement hydration influences concrete stability and durability, so minimizing the paste amount is essential “The chemistry of the carbonation process of conerete is conceptually straightforward. It i a through-solution process, where usually CO; from the atmosphere diffuses into the concrete. This Cifusion results ina lowering of the pH, destabilizing all the cement hydration produets (C-S-H, ‘APL, AF, CH), These hydration products become unstable at diferent plt-vafues (Claus and Maia 2007), “The employment of eltemative fuels (Le, waste materials), which have exploitable energy. i in tse for many years in the cement industry and i€ presents one way of conserving natural energyAn approach of wing ideal grading eurve and coating pase thickness Pa sources. Through this, thanks to the characteristics of clinker baking, waste materials ae disposed of in a Way that is safer for the environment. With that kind of approach, CO, emission, which ‘would have been released by combustion at, eg. an incinerating plant, is being reduced (Popovic er fal, 2002, 2003), Three sources of CO: emission, which are the result of CaCO decarburzations fom raw material, the reaction of fuel combustion during the process of baking in rotary furnace and equivalent of electic energy consumption, are present in cement production (Popovié 2003), ‘Ove of the most significant activities today aims at a higher percentage of replacement of clinker in cement with secondary rw materials, with the possibilty of improvement of cement charaetisics and rabilty of concrete. With this kindof approach, the consurption of natural raw materia thermal and cleric energy, together withthe reduction of CO; emission, are decreasing (Popovié 2001, Vanderborght and Brodmann 2001, Horton 2001, Onuma 2000) Concrete misture design algorithm evoives according to diferent control conditions, mainy including ACT mixture algocithm (ACT Commitee 318) and densified mixture design algorihan (DMDA). This study used the DMDA as the basic deduction formula, since an ideal grating curve is hard to achieve ‘heoreial grading curve deducted in this study was ased on H-G Kessler e als “sphere model theory of analyzing amangerent structure of varied size spheres densely packed” (Kessler 1994) 2, Theoretical deduction and verification (Hsu et al. 2002, Chang et al. 2001, Zhan 1998, Kessler 1994, Kwan et al, 1999) 2.1 Symbol indexes Percent retsned on the /* sieve of the * aggregate Nominal maximux size of agaregate, mm Weight ofd size aggregate, 2 Particle quantity of d size agpregate Percent rettined on j>j-+1 sieve of the /* aggregate Density of the /* aggregate retained on j-»j+I sieve (base of logx) Surface area constant ofa sieve grade, im Surface area constant of j sieve grade, 1m Ksst ‘Surface area per ke of blended gate mixture, m*/kg, & Theoretical percent retained on the j sieve by theoretical grading curve aM Diserete amount Pp Content of aggregate smaller than sized particle P, Volume perent of the / aggregate in blended aggregate mixture zB, Agaregite weight ratio of the 1” aggregate, ” ‘Aggregate volume ratio ofthe £ agaree v ‘Maximum unit weieht, kom? Allewable deviation limit Unit weight of the # agerepate, kgm? 8 Total surface area of unit volume concrete Coating paste thickness, gn “Total volume of cement paste, mn! i Total volume of voids and pores, mm?ALY Wang, CL. Hoang and ST. Yeh va Estimated volume of entrapped air, é Slag ratio, slagl(cement + sag) 2.2 Theoretical estimation of aggregate blended ratio to reality, as there are many types of aggregate, application of DMDA is time-consuming, 90 an effet wo splfy mix design process i emphasized in this study by applying the simples and mos onvenient Fuller’ curve (as shown in Eq. (1) and Fig. 3) 10 make theoretical deduction. (a jolt (Qn-i5 o [As agarepate consttion close fits with Fulle’s theoretical cure, its conttation wil render rae wetfectory compactness, 10 simplify the design process this study adopts the feast square rood to directly compute blended ratio of aggregate constitution. At first one need detailed wed, ig. 1 Particle denrbance sas (su eta. 2002) = Fig. 2 Type porosity“An approach of using ideal grading curve and coating paste richest a Pert Oimension tO) Fig. 3 Fuller's curve aggregate information, suppose the concrete uses type’s aggregates, m grade particle sieve, use the least square method and discrete amount from theoretical curve (M) is expressed as Eq. (2) 3{Era-4)) 3[Srarrans) ® ‘From Eqs. (3) and (4) can be derived, substitute Fg, (4) to Eq, (2), and obtain Eg (5) Me SPs = 100% o PenteSR “ 6 wifrarl-Sehoes) Next paral diferente Ba, (5) by P,reationship of M increment (a and P; canbe obtained as Ea (6) Som, a= SMap, 6 Lor ° ‘Then obtain conten of cach aggregate P; under minimum discrete ste (Minin) when M has cattemiam dataset df= 0 to satisfy Eq. (6) under each condition of dP, dPs-. dP asin Ea. (7) ‘hove ate totaly 9-1 condition! equations.u HY. Wang, C1. Hwang and Ste La, a2 Amd [qs Maz al] aa ee fou tua Bal os) (loa, aa MaadLa San au a4 wl ae 92 a4 ) los ayer Lemy Meno Meld ay M31 fans aur =~ anil] a] fom} [a {|| aa 20 Lars ona ~~ ual P2[elaJOll=0 re aie am lactam -~ @yal|Pe-d [o Merge all conditional equstons and simplify matrix Bas. 8) to (9), wsing Ea. (10) to obtain optimum amount of each aggregate (dP, dP... dPn.) a8 shown in formula Ea (11). ayy yy ove nl ni Py a fi {ayn} te 2 G19, (Alay [3h (Phe }Ueral=|] © Oy eo ln IP i i (AN Caen AE MAL LAC rel Ps AY Ulan A EL Ald (Phas Ua rl AI MEA Adler (ANU taal LATa MOH) a0) Substitute Pi~P, computed ftom Eqs. (10) and (4) to (2), and obiain M, divided by particle size ‘rade m,s0 as to evaluate ifthe seleted theoretical curve is applicable o nt, as shown in Ea. 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