PHILIP L. WORMELEY, JR.
Cement concrete is the product resulting from an intimate mixture of cement mortar with an aggregate of crushed stone, gravel or similar material. The aggregate is crushed or screened to the proper size as determined from the character of the work. In foundation work, stone or gravel 3 inches in size may be used to advantage, whereas in the case of molded articles of small sectional area, such as fence posts, hollow building blocks, etc., it is best to use only such material as will pass a one-half inch screen. An ideal concrete, from the standpoint of strength and economy, would be that in which all voids in the aggregate were completely filled with sand, and all voids in the sand completely filled with cement, without any excess. Under these conditions there would be a thoroughly compact mass and no waste of materials.
It is a simple matter to determine the voids in sand and also in the aggregate, but in mixing concrete the proportions vary a great deal, depending in each case upon the nature ot the work and the strength desired. For example, in the construction of beams and floor panels, where maximum strength with minimum weight is desired, a rich concrete is used, whereas in massive foundation work, in which bulk or weight is the controlling factor, economy would point to a lean mixture.
When good stone or gravel is used, the strength of the concrete depends upon the strength of the mortar employed in the mixing and upon the proportion of mortar to aggregate. For a given mortar the concrete will be strongest when only enough mortar is used to fill the voids in the aggregate, less strength being obtained by using either a greater or less proportion. In practice it is usual to add a slight excess of mortar over that required to fill the voids in the aggregate.
It is more accurate to measure cementby weight, unless the unit employed be the barrel or sack, because when taken from the original package and measured bulk there is a chance of error due to the amount of shaking the cement receives. As it is less convenient, however, to weigh the cement it is more common to measure it by volume, but for the reason stated this should be done with care.
For an accurate determination of the best and most economical proportions where maximum strength is required, it is well to proceed in the following way: First, proportion the cement and sand so that the cement paste will be 10 per cent in excess of the voids in sand; next determine the voids in the aggregate and allow sufficient mortar to fill all voids, with an excess of 10 per cent.
To determine roughly the voids in crushed stone or gravel, prepare a water-tight box of convenient size and fill with the material to be tested; shake well and smooth off even with the top. Into this pour water until it rises flush with the surface. This volume of water added, divided by the volume of the box, measured in the same units, represents the proportion of voids. The proportion of voids in sand may be more accurately determined by subtracting the weight of a cubic foot of quartz and dividing the difference by 165.
For general use the following mixtures are recommended:
1 cement, 2 sand, 4 aggregate for very strong and impervious work. 1 cement, 2 1/2 sand, 5 aggregate, for work requiring moderate strength. 1 cement, 3 sand, 6 aggregate, for work where strength is of minor importance.
In the case of gravel containing sand or crushed stone from which the small particles have not been removed by screening, the amount of such sand or fine stone should be determined and due allowance made for it in proportioning the mortar.
When mixing an aggregate containing small particles with mortar, the same conditions obtain as if these particles had been screened from the aggregate and added to the sand used in making the mortar, and in reality we have a mortar containing a larger proportion of sand than was present before the aggregate was incorporated. It is evident, then, that in such cases the quality or richness of the mortar should depend upon the proportion of fine material in the aggregate.
For example, suppose that 1 cubic foot of gravel contains O.r cubic foot of sand, and that the voids in gravel with sand screened out measure 40 per cent.
For general purposes this would suggest a 1-2-5 mixture, but since each cubic foot contains 0.1 cubic foot of sand, 5 cubic feet of gravel will contain 0.6 cubic foot sand, and the proportions should be changed to 1 part cement, 1 1/2 parts sand, 5 parts gravel.
It has been demonstrated that concrete can be mixed by machinery as well, if not better, than by hand. Moreover, if large quantities of concrete are required, a mechanical mixer introduces marked economy in the cost of construction. None of the various forms of mechanical mixers will be described here, since concrete in small quantities is more economically mixed by hand.