SUMMER TRAINING REPORT

ON

CONSTRUCTION MATERIAL AND TESTS

Submitted in partial fulfillment of the award degree of Bachelor of

Technology in Civil Engineering

Uttaranchal Institute of Technology

Uttranchal University, Dehradun
Uttarakhand

Submitted by

HARSH KATARIA
Enrollment No.: UU1101070005

SUMMER TRAINING COMPLETED UNDER

‘MINOR IRRIGATION DEPARTMENT’

DEPARTMENT OF CIVIL ENGINEERING

UTTARANCHAL INSTITUTE OF TECHNOLOGY
UTTARANCHAL UNIVERSITY DEHARDUN
UTTARAKHAND - 248007

(2023-24)
 .

i
 UTTARANCHAL UNIVERSITY
(Established vide Uttranchal University Act, 2012)
(Uttarakhand Act No. 11 of 2013)
Arcadia Grant, P.O. Chandanwari, Premnagar, Dehradun, Uttarakhand)

DECLARATION

We here by declare that the summer Internship report entitled

“CONSTRUCTION MATERIALS AND TESTS” is bonafide work
carried out by us under guidance of project team at Minor Irrigation
Department. . Further we declare that this report has not previously
formed the basis of award of any associate ship or other similar degrees,
has not been submitted anywhere else.

Date: Signature of Student

This to certify that the statement made by the candidate is true to the best
of my knowledge and belief.

Date: Signature of College Guide

Guide Name:

Mr. Gaurav Thakur

Assistant Professor

Countersigned

HOD
ii
 UTTARANCHAL UNIVERSITY
(Established vide Uttranchal University Act, 2012)
(Uttarakhand Act No. 11 of 2013)
Arcadia Grant, P.O. Chandanwari, Premnagar, Dehradun, Uttarakhand)

ACKNOWLEDGEMENT

Any endeavor cannot lead to result unless and until a proper

platform is provided for the same. We express our thanks to MINOR
IRRIGATION DEPARTMENT for giving us the opportunity to
undertake this summer internship program.

We sincerely thank Management for their constant guidance,

valuable suggestions and encouragement throughout the progress of
summer internship program.

We would also like to take this opportunity to thank all projects

team for their precious guidance and administration stafff or their help.

And last but not the least we would like to thank our parents and
colleagues for their motivational support.

iii
 ABSTRACT

This study presents the compendia of the observation made during the one month of
ourstudy.Thisreportmainlyresolvesaroundthematerialsusedandthetestsoneachbuildingcom
ponents.Tounderstandtheprocessofapplication,sustainablemasonryproductdevelopment is
discussed in detail. In order to evaluate the feasibility of the material, thenecessary test
evaluation method is also learned. The developed end product
performanceevaluationisalsolearnedbydesiredtestsasrecommendedbystandards(IS).Inthisre
portweestimate the quantitiesrequiredfortheconstructionofbuilding.
CONTENTS
1. COMPANYPROFILE (1-3)
 History 1
 Projects 2
 Awards 3
2. MATERIALSANDTESTS (4-23)
 SAND 5
I. Bulkingofsand 6
II. Sieveanalysis 7
III. Finenessmodulus 8
 COARSEAGGREGATE 9
I. Specificgravity 10
II. Waterabsorption 11
 CEMENT 11
I. Fineness test 12
II. Strengthtest 12
III. Specificgravitytest 13
 BRICK 13
I. Compressivestrength 13
II. Waterabsorptiontest 13
III. Efflorescence 13
 STONE 14
 CONCRETE 16
I. Slumpconetest 20
II. Compressivestrength 21
III. Waterpermeability 21
IV. Rapidpenetrationtest 21
V. Waterabsorptiontest 21
VI. Modulusofelasticity&Settingtime 21
 EQUIPMENT USED 22
 CONCLUSION 23
 COMPANYPROFILE

 HISTORY

IVRCL infrastructure & projects limited was established in the year 1987.
Commercialoperations of the company were started in the year 1990. In the same year, IVRCL
establisheditself as a premierEPC & LSTK Service Providerwith front-end engineering
capabilities.Company is in leading EPC and Infrastructure public limited company listed on
NSE and
BSEStockExchangesinIndia.Companystronglyentrenchedwithprovendomainknowledge,experien
ce and credentials. It is the largest water company in India and we take pride in building&
owning India’s 1st and largest desalination plant at Minjur (near Chennai) with
100MLDcapacity. We are present across the length and breadth of India with our major offices
in metrocities such as New Delhi (NCR), Mumbai, Chennai, Kolkata, Hyderabad, Pune,
Bangalore,AhmadabadandGuwahati.WehavealsomadeourglobalfootprintswithoperationsinSriLa
nka,Africa andtheMiddleEast.

Theyareadiversified group andtheircore workofareasincludevarioussectorssuchas

o WaterandEnvironment

o Irrigation

o Transportation

o Building&IndustrialStructures

o PowerDistribution&Transmission

o Operations&Maintenance

o Mining
 PROJECTS

1. Water&environmentprojects

Project:Chambal-Dholpur-Bharatpur-watersupplyproject

2. Transportation

Project:Design,construction,development,finance,operation&maintenanc
eof Indore-Gujaratborder on NH-59,in thestate of MadhyaPradesh.

3. Building&IndustrialStructure

Project:InfrastructureDevelopmentfortheDahejPetrochemicalComplexo
nLumpsumTurkey(LSTK)basis atDahej,Gujarat.

4. PowerDistribution&Transmission

Project:765KVS/C(Quad)TransmissionLinefromSeonito NandanwadiinMadhya
Pradesh.

5. Mining

Project:MalanjkhandOpenCastProject,Balaghat,MadhyaPradesh
 AWARDS

1. 11thAnnualGreentechSafetyAward2012:RihandSuperThermalPowerPlant.

2. 12thGlobalGreentechEnvironmentExcellenceAwards2011:SecretarialComplexforNRD
A,Raipur.

3. 10thAnnualGreentechSafetyAward2011: Make-upWaterPumphouse Project,Tiroda.

4. CIDC3rdVishwakarma Awards2011forBestProject–Roads&Highways.

5. 11thGlobalGreentechEnvironmentExcellenceAwards2010:ConstructionSector(Silver)forCI
DCOExhibitionCentre.

6. EPCWorld Awards2010: Outstanding CompanyinRoads&HighwaysSector.

VARIOUSCONSTRUCTIONMATERIALSANDTESTS

Building construction methods and materials have an enormous impact on fire behavior
andfirefighter safety. In this course, you will learn about various types of building construction,
theimportance of the fire resistance for structural support elements, and the risks associated
withperformingfire-
suppressionactivitiesinsideandaroundbuildingsinvolvedinfire.Youwillalsolearnabout the
importanceofteamwork amongfireprotectionand designprofessionals.

Uponcompletionofthiscourse,youwillbe able to:

 Describethebenefitsofcross-
disciplinarycooperationamongfireprotectionanddesignprofessionals.
 Explainthe elements
ofbuildingconstructionastheyapplytoconstructioncodes.
 Describetheelementsofbuilding
constructionastheyapplytofirefightersafety.
 Anticipatefirebehavior
basedonstructuralelementsandthermaleffectsoneachofthefollowingtypes
ofconstruction:

 Protectednoncombustiblebuildingconstruction
 Unprotectednoncombustiblebuildingconstruction
 Masonryconstruction
 Heavytimber construction
 Woodframeconstruction
VARIOUSBUILDINGMATERIALSFORCONSTRUCTIONS:

1. INEAGGREGATE

2. COARSEAGGREGATE

3. FCEMENT

4. BRICK

5. STONE
1) SAND:

Sand is a naturally occurring granular material composed of finely divided rock and
mineralparticles. It is defined by size, being finer than gravel and coarser than silt. Sand can also
refer toatexturalclassofsoilorsoiltype; i.e.,asoilcontainingmorethan85 percent sand-sized
particlesbymass.

The composition of sand varies, depending on the local rock sources and conditions, but the
mostcommonconstituentofsandininlandcontinentalsettingsandnon-
tropicalcoastalsettingsissilica,usually in the form of quartz. The second most common type of
sand is calcium carbonate, forexample,aragonite,

Sand is a non-renewable resource over human timescales, and sand suitable for making
concreteisinhighdemand.
COMPOSITION

The exact definition of sand varies. The scientific Unified Soil Classification System used
inengineering and geology corresponds to US Standard Sieves and defines sand as particles with
adiameterofbetween0.074and
4.75 millimeters. By another definition, in terms of particle size as used by geologists,
sandparticles range in diameter from 0.0625 mm (or 1/16 mm) to 2 mm. An individual particle in
thisrange size is termed a sand grain. Sand grains are between gravel (with particles ranging from
2mm up to 64 mm by the latter system, and from 4.75 mm up to 75 mm in the former) and
silt(particlessmallerthan0.0625mmdownto0.004mm).

TESTSONFINEAGGREGATE

1. BULKINGOFSAND
When sand is damp, the water coating on the surface of each sand particle causes separation
ofparticles from one another due to surface tension. This causes sand to bulk. Bulked sand
occupiesmorevolumeandhenceifvolumetricmeasuringisdonewhileproportioningit,bulkingcorrecti
onisnecessary.

Thebulkingtestisdoneas follows:

1. Thesandisfilled,inlooseconditioninaboxofmeasuredheight(Hcm).
2. TheboxisthenfloodedwithwaterandRodingisdonetomakethesandsettleandconsolidate.Caresho
uldbetakenthatsand doesnotoverflowduring theflooding andcompaction.
3. Thesandisthenleveledintheboxandthedropinheightis measured(hcm).
4. Bulkingiscalculated as:Bulking%=h/Hx100%

Dry sand occupies the same volume as fully saturated sand. The bulking will vary from load
toloadanddaytodaydependingonthe finenessofsandanditssurfacemoisturecontent.Itisthere-fore,
very essential to make bulking corrections by checking the actual bulking of sand proposedtobe
usedbyvolumetricbatchingformortarorconcrete.
 Moisturecontents Bulking
%agebywt. %byvolume

2 15

3 20

4 25

5 30

2.SIEVEANALYSIS
Sieveanalysisisdoneto checkthegradationofaggregate.Thetestisdoneasfollow.

1. Takerequiredamount ofaggregatesample(for coarseaggregatetakeapprox.

2.5 kgandforfineaggregatetake0.5 kg)
2. Arrangetherequirednoofsievesasperthecontractor jobrequirementinadescendingmanner.
3. Shakevigorouslythesievesetforatleast2minute.
4. Thenmeasuretheweight ofaggregateoneachsieveandexpressitasthepercentageofpassing.

Gradinglimitofcoarseaggregateandfineaggregateisgivenbelowforreference.
3. FINENESSMODULUS

Fineness modulus is generally used to get an idea of how coarse or fine the aggregate is. More
finenessmodulus valueindicatesthattheaggregateiscoarserandsmallvalueoffineness modulus
indicatesthatthe aggregateisfiner.

1. Sievetheaggregateusingtheappropriatesieves(80mm,40mm,20 mm,10mm,4.75mm,
2.36mm,1.18mm, 600micron, 300micron&150micron)
2. Recordtheweight ofaggregateretained oneachsieve.
3. Calculatethecumulativeweight ofaggregateretained oneachsieve.
4. Calculatethecumulativepercentageofaggregateretained.
5. Addthecumulativeweightofaggregateretained
anddividethesumby100.Thisvalueistermedasfinenessmodulus

Comparethetestvaluewiththevaluesgiveninthefollowingtableandyoucangetanideaabouthowcoarseorfin
ethesandis.
OnlysandbetweenFM2.6to2.9isconsidered suitablefor nominalmixproportion

TypeofSand FinenessModulusValue
Veryfinesand Below2.2
Finesand 2.2to2.6
Mediumsand 2.6to2.9
Coarsesand 2.9to3.2
Verycoarse sand Above3.2
2) COARSEAGGREGATE:

AGGREGATECLASSIFICATION[BASEDONSHAPE]

Accordingtoshapetheaggregateisclassifiedas

 Roundedaggregate
 Irregularorpartlyroundedaggregate
 Angular aggregate
 Flakyaggregate
 Elongatedaggregate
 Flakyandelongated aggregate

1. ROUNDEDAGGREGATE
The aggregate with rounded shape has the minimum percentage of voids ranging from 32 to 33%.
Itgivesminimumratioofsurfaceareatogivenvolumeandhencerequiresminimumwaterforlubrication.It
gives good workability for the given amount of water and hence needs less cement for a given
watercement ratio. The only disadvantages is that the interlocking between its particles is less and
hence thedevelopment of bond is poor. This is why rounded aggregate is not suitable for high strength
concreteandforpavements subjectedtotension.

2. IRREGULARORPARTLYROUNDEDAGGREGATE
Theaggregatewithirregularshapehashigherpercentageofvoidsrangingfrom35to37%.Itgiveslesserwork
abilitythanroundedaggregateforthegivenwatercontent.Waterrequirementishigher
and hence more cement is needed for constant water cement ratio. The interlocking
betweenaggregate particles is better than rounded aggregate but not adequate to be used for high
strengthconcrete andpavements subjectedtotension.

3. ANGULARAGGREGATE
The aggregate with angular shape has the maximum percentage of void ranging from 38 to
45%.It requires more water for lubrication and hence it gives least workability for the given
watercementratio.Forconstantwatercementratioandworkabilitytherequirementofcementincrease.T
he interlockingbetweentheaggregateparticlesisthebestandhencethedevelopmentofbond isvery
good. This is why angular aggregate is very suitable for high strength concrete and
forpavementssubjectedtotension.

4. FLAKYAGGREGATE
The aggregate is said to be flaky when its least dimension is less than 3/5th (or 60%) of its
meandimension.Meandimensionistheaveragesizethroughwhichtheparticlespassandthesievesizeon
whichtheseareretained.For example,meansizeoftheparticlespassing through25 mmsieveand
retained on 20 mm sieve is (20+25)/2 = 22.5 mm. if the least dimension is less than 3/5 x(22.5) =
13.5mm, then the material is classified as flaky. Flaky aggregate tends to be oriented inone
planewhichaffects the durability.

TESTSONAGGREGATE
Aggregate plays an important role in pavement construction. Aggregates influence, to a
greatextent,theloadtransfercapability of pavements.Henceitis essential thatthey
shouldbethoroughly tested before using for construction. Not only that aggregates should be
strong anddurable,they

Should also possess proper shape and size to make the pavement act monolithically.
Aggregatesaretestedforstrength,toughness,hardness,shape,andwaterabsorption.

Inordertodecidethesuitabilityoftheaggregateforuseinpavement construction,followingtestsare
carriedout:

1. SPECIFICGRAVITYANDWATERABSORPTIONTEST
The specific gravity and water absorption of aggregates are important properties that are
requiredfor the design of concrete and bituminous mixes. The specific gravity of a solid is the
ratio of itsmasstothatofanequalvolumeofdistilledwaterataspecifiedtemperature.Becausethe
aggregatesmaycontainwater-permeablevoids,sotwomeasuresofspecificgravityofaggregatesare used:

1. Apparent specificgravity
2. Bulkspecificgravity.

ApparentSpecificGravity
Gapp, is computed on the basis of the net volume of aggregates i.e. the volume excluding water-
permeablevoids.Thus

Gapp=[(MD/VN)]/W
Where,
MDisthedrymassofthe aggregate,
VNisthenetvolumeoftheaggregatesexcludingthevolumeoftheabsorbedmatter,Wis
thedensityofwater.

BulkSpecificGravity

Gbulkiscomputed onthebasisofthetotalvolumeofaggregatesincludingwaterpermeablevoids.Thus
Gbulk=[(MD/VB)]/W
Where,
VBisthetotalvolume oftheaggregatesincludingthevolumeofabsorbedwater.

WaterAbsorption:
Thedifferencebetweentheapparentandbulkspecificgravitiesisnothingbutthewater
permeablevoidsoftheaggregates.Wecanmeasurethevolumeofsuchvoidsbyweighingtheaggregatesd
ryandinasaturatedsurfacedrycondition,withallpermeablevoidsfilledwithwater.Thedifferenceofthea
bovetwois MW.

MW is the weight of dry aggregates minus weight of aggregates saturated surface dry
condition.Thus,

WaterAbsorption=(MW/MD)x100
Thespecificgravityofaggregatesnormallyusedinroadconstructionrangesfromabout2.5to2.9.Watera
bsorptionvaluesrangesfrom0.1toabout2.0percentforaggregatesnormallyusedinroadsurfacing.
2) CEMENT
TypesofCement:

RapidHardeningCement:

Definition:
It is also known as High-Early-Strength cement. It is manufactured with such adjustments in
theproportion of raw materials so that the cement produced attains maximum strength with-in 24-
72hours.

Properties:
TwoessentialpropertiesofRapidHardeningCementarefollowing.

(i) Itcontainsrelativelymoretri-calciumsilicate. This

isdonebyaddingagreaterproportionoflimestoneinthe raw materialscomparedtothat
requiredforordinarycement.

(ii) It is more fine-grained (Air permeability 3250 cm2/gm) than the ordinary cement.
Thisfactorhelpsinquickerandcompletehydrationofcementparticlesduringsettingandhelpsin
gainingearlystrength.

However,thesettingtimeandultimatestrengthofRapidHardeningCementissameasofOrdinaryCemen
t.

TESTSONCEMENT

Thephysicaltestswhicharegenerallyperformed
todeterminetheacceptabilityofcements are:

1. FinenessTest
2. StrengthTest
3. SpecificGravityTest
4. Settingtest

1. FinenessTest

Finenessisthemeansizeofcementgrain. Finenesstestisdonetomeasurethemeansizeofcementgrain.
The finer the cement the surface area for hydration will be large and it increases the strength
ofcement.Butthe finenessvariesindifferenttypes ofcement.
Followingthreemethodsareappliedtotestthefinenessofcement

 Sievemethod
 AirPermeabilitymethod
 Sedimentationmethod

2. StrengthTest

Cementhastwo typesofstrength– compressivestrengthandtensilestrength.

Toknowthecompressivestrengthandtensilestrengthofcementfollowingtestsareperformed–

Cementmortarcubetest(forcompressive strength)

 Briquettetest(fortensilestrength)
 Splittensiletest(fortensilestrength)

3. SpecificGravityTest

Specificgravityofcementisacomparisonofweightofacementvolumetotheweightofsamevolumeofwate
r.

4. SettingTest

Athickpaste ofcementwithwaterismade ona piece ofglassplate

anditiskeptunderwaterfor24hours.Itshouldsetandnotcrack.
 3) BRICK

ClassificationandCharacteristicsofBricksasperIS1077-1973
Testsfortheacceptanceofbricksfor buildingconstructionare:

1. Compressivestrengthtest
2. Water absorptiontest
3. Efflorescencetest

1. CompressiveStrengthTestonBricks
Thecompressivestrengthofacommonbrick should be 50 kg/sq.cm

2 .WaterAbsorptionTestonBricks
Ifthewaterabsorptioncapacityofabrickismore,itsstrengthwillbecomparativelylow. Forfirstclassbricks,the
waterabsorptioncapacityshouldnotbe morethan20%byweight.

3 .EfflorescenceTestonBricks
Thistest isperformedto knowthepresenceofany alkalinematterinthebricks.
4) STONE
Stone is a ‘naturally available building material’ which has been used from the early age
ofcivilization. It is available in the form of rocks, which is cut to required size and shape and
usedasbuildingblock.

PropertiesofStones

Thefollowingpropertiesofthestonesshouldbelookedintobeforeselectingthemforengineeringworks:

a. Structure:Thestructureofthestonemaybestratified(layered)oruncertified.Structuredstones
should be easily dressed and suitable for super structure. Uncertified stones arehard
anddifficulttodress.Theyare preferredforthefoundationworks.

b. Texture: Fine grained stones with homogeneous distribution look attractive and
hencetheyare usedforcarving.Suchstonesare usuallystronganddurable.

c. Density: Denser stones are stronger. Light weight stones are weak. Hence stones
withspecificgravitylessthan2.4are consideredunsuitableforbuildings.

d. Strength: Strength is an important property to be looked into before selecting stone

asbuilding block. Indian standard code recommends, a minimum crushing strength of
3.5N/mm2 for any building block. Table shows the crushing strength of various
stones.Duetonon-uniformityofthematerial,usuallyafactorofsafetyof10isusedto
findthepermissible stress in a stone. Hence even laterite can be used safely for a single
storeybuilding, because in such structures expected load can hardly give a stress of
0.15N/mm2. However in stone masonry buildings care should be taken to check the
stresseswhenthe beams (ConcentratedLoads)are placedonlateralwall.

e. Hardness: It is an important property to be considered when stone is used for

flooringand pavement. Coefficient of hardness is to be found by conducting test on
standardspecimeninDory’stestingmachine.
Forroadworkscoefficientofhardnessshouldbe
 atleast17.Forbuildingworksstoneswithcoefficientofhardnesslessthan14shouldnotbeuse
d.

f. PorosityandAbsorption:Allstoneshaveporesandhenceabsorbwater.Thereactionofwater
with material of stone causes disintegration. Absorption test is specified aspercentage
of water absorbed by the stone when it is immersed under water for
24hours.Foragoodstoneitshouldbeassmallaspossibleandinnocasemorethan5.

g. Toughness:Theresistancetoimpactiscalledtoughness.Itisdeterminedbyimpacttest.Stones
with toughness index more than 19 are preferred for road works. Toughnessindexes 13
to 19 are considered as medium tough and stones with toughness index
lessthan13arepoorstones.

h. ResistancetoFire:Sandstonesresistfirebetter.Argillaceousmaterials,thoughpoorinstrengt
h,aregoodinresistingfire.

CONCRETE:

Concrete is a construction material composed of cement, fine aggregates (sand) and

coarseaggregatesmixedwithwaterwhichhardenswithtime.
Portlandcementisthemostlyusedtypeofcementforproductionofconcrete.

Therearedifferenttypesofbindingmaterialisusedotherthancementsuchaslimeforlimeconcreteand
bitumenforasphaltconcretewhichisusedforroadconstruction.

Various types of cements are used for concrete works which have different properties
andapplications. Some of the type of cement is Portland Pozzolana Cement (PPC), rapid
hardeningcement,Sulphateresistantcementetc.
Table ofContents:

Materialsaremixedinspecificproportionstoobtaintherequiredstrength.

Strength of mix is specified as M5, M10, M15, M20, M25, M30 etc., where M signifies Mix
and5, 10, 15 etc. as their strength in kN/m2. In United States, concrete strength is specified in
PSIwhichis Pounds perSquareInch.
Watercementratioplaysanimportantrolewhichinfluencesvariouspropertiessuchasworkability,
strength and durability. Adequate water cement ratio is required for production ofworkable
concrete.
When water is mixed with materials, cement reacts with water and hydration reaction starts.
Thisreaction helps ingredients to form a hard matrix that binds the materials together into a
durablestone-
likematerial.Concretecanbecastedinanyshape.Sinceitisaplasticmaterialinfreshstate,various shapes
and sizes of forms or formworks are used to provide different shapes such
asrectangular,circularetc.
Various structural members such as beams, slabs, footings, columns, lintels etc. are
constructedwithconcrete.

ACI 318 Building code requirements for structural concrete and ACI 301 Specifications
forStructuralConcreteareusedinUnitedStatesasstandardcodeofpracticeforconcreteconstruction.

There are different types of admixtures which are used to provide certain properties.
Admixturesor additives such as pozzolans or super plasticizers are included in the mixture to
improve thephysicalproperties ofthewetmixorthefinishedmaterial.

Varioustypesofconcretearemanufacturedthesedaysforconstructionofbuildingsandstructures.These
havespecialpropertiesandfeatureswhichimprovequalityofconstructionasperrequirement.

ComponentsofConcrete:

Components of concrete are cement, sand, aggregates and water. Mixture of Portland
cementandwater
iscalledaspaste.So,concretecanbecalledasamixtureofpaste,sandandaggregates.Sometimesrocks
areusedinsteadofaggregates.
The cement paste coat the surface of the fine and coarse aggregates when mixed thoroughly
andbinds them. Soon after mixing the Components, hydration reaction start which provides
strengthandarocksolidconcreteis obtained.

WhatisGradeofConcrete?

Grade of concrete denotes its strength required for construction. For example, M30
gradesignifies that compressive strength required for construction is 30MPa. The first letter in
grade“M”isthemixand30isthe requiredstrengthinMPa..

Based on various lab tests, grade of concrete is presented in Mix Proportions. For example,
forM30 grade, the mix proportion can be 1:1:2, where 1 is the ratio of cement, 1 is the ratio of
sandand 2istheratioofcoarse aggregatebasedonvolume orweightofmaterials.

The strength is measured with concrete cube or cylinders by civil engineers at construction
site.Cubeorcylindersaremadeduringcastingofstructuralmemberandafterhardeningitiscured
for28days.Thencompressive strengthtestisconductedtofindthe strength.
RegulargradesofconcreteareM15,M20,M25etc.Forplaincementconcreteworks,generallyM15isused.
Forreinforced concreteconstruction minimumM20 gradeofconcreteare used.

CompressiveStrength
ConcreteGrade MixRatio

MPa(N/mm2) Psi

NormalGradeofConcrete

M5 1:5:10 5 MPa 725psi

M7.5 1:4:8 7.5MPa 1087psi

M10 1:3:6 10 MPa 1450psi

M15 1:2:4 15 MPa 2175psi

M20 1:1.5:3 20 MPa 2900psi

StandardGradeofConcrete

M25 1:1:2 25 MPa 3625psi

M30 DesignMix 30 MPa 4350psi

M35 DesignMix 35 MPa 5075psi

M40 DesignMix 40 MPa 5800psi

M45 DesignMix 45 MPa 6525psi

M50 DesignMix 50 MPa 7250psi

 M55 DesignMix 55 MPa 7975psi

M60 DesignMix 60 MPa 8700psi

M65 DesignMix 65 MPa 9425psi

M70 DesignMix 70 MPa 10150psi

HowtoMakeConcrete

Concrete is manufactured or mixed in proportions w.r.t. cement quantity. There are

twotypes of concrete mixes, i.e. nominal mix and design mix. Nominal mix is used for
normalconstruction works such as small residential buildings. Most popular nominal mix are in
theproportionof1:2:4.
Design mixed concrete are those for which mix proportions are finalized based on
variouslabtestsoncylinder orcubeforitscompressivestrength.
Thisprocessisalsocalledasmixdesign.Thesetestsareconductedtofindsuitablemixbasedonlocallyavail
ablematerialtoobtainstrengthrequiredasperstructuraldesign.Adesignmixedofferseconomyonuse
ofingredients.
Once suitable mix proportions are known, then its ingredients are mixed in the ratio as
selected.Twomethodsare usedformixing,i.e.HandmixingorMachine Mixing.
Based on quantity and quality required, the suitable method of mixing is selected. In
thehandmixing,eachingredientsareplacedonaflatsurfaceandwaterisaddedandmixedwithhandtools.
In machine mixing, different types of machines are used. In this case, the ingredients areadded in
required quantity to mix and produce fresh concrete. Once it is mixed adequately it
istransportedtocastinglocationandpouredinformworks.Varioustypesofformworksareavailablewhic
h as selected based on usage. Poured concrete is allowed to set in formworks for specifiedtime
based on type of structural member to gain sufficient strength. After removal of formwork,curing
is done by various methods to make up the moisture loss due to evaporation.
Hydrationreactionrequiresmoisturewhichisresponsibleforsettingandstrengthgain.So,curingisgener
allycontinuedforminimum7days afterremovalofformwork.
 TypesofConcreteConstruction:

Concreteisgenerallyusedintwotypesofconstruction, i.e.
plainconcreteconstructionandreinforcedconcreteconstruction.InPCC,itispouredandcastedwithoutu
seofanyreinforcement.This is used when the structural member is subjected only to the
compressive forces and notbending. When a structural memberis subjected to bending,
reinforcements are required
towithstandtensionforcesstructuralmemberasitisveryweakintensioncomparedtocompression.Gener
ally, strength of concrete in tension is only 10% of its strength in compression. It is used asa
construction material for almost all types of structures such as residential concrete
buildings,industrial structures, dams, roads, tunnels, multi storey buildings, skyscrapers, bridges,
sidewalksandsuperhighways etc.
Example of famous and large structures made with concrete are Hoover Dam, Panama Canal
andRomanPantheon. Itisthelargesthumanmadebuildingmaterialsusedforconstruction.

StepsofConcreteConstruction

Theconstructionstepsare:

1. Selectingquantitiesofmaterialsforselectedmixproportion
2. Mixing

3. Checkingofworkability
4. Transportation

5. Pouringinformworkforcasting

6. Vibratingforpropercompaction
7. Removalofformworkaftersuitabletime
8. Curing memberwithsuitablemethodsandrequiredtime.

TESTS
1. Slumptest beforeleavingthebatchingplantandonarrivalonsite
Thisistodeterminetheworkabilityofconcreteintermsofslumptest.Afterbatchingtheconcrete,asa
mpleoffreshconcreteshallbetakentotestforslumptestsandthesamplesfor
compressivestrengthtestbetakentoo.Thisistomakesurethatthebatchedconcreteiscomplyingwiththemi
xdesignbeforeit’sreleasedfromthe batchingplan
Upon arrival on site, a sample of fresh concrete shall be tested with slump testagain,
buttemperatureshallbecheckedwiththecalibratedthermometerbeforehand.Threecubesorcylinders
of samples shall be taken for compressive strength tests, these will be the samples fromthe site.

The plus or minus sign is the symbol of tolerance of slump. Let say for example the slump
ofapprovedconcretedesignmixforyoursuspendedslabis150mm+/-25.

2. Compressivestrengthtest
Three samples of cubes or cylinders shall be taken for compressive strength test, but it is
notcommonly three samples, sometimes it is two depend on the specification. You might ask
whysometimesthereisextraofonesample?Goodthatyouasked.Thisonesampleextrashallbetested“if!”
the two cubes or cylinders samples are tested from the three and if it is failed and theremaining
sample is passed. If the consultant is not satisfied with the result (definitely not!) andhe wishes
totestthe extraone.Itshallbetestedin60days.

3. WaterPermeability test
Awaterpermeabilitytestisoneoftheteststodeterminethedurabilityofconcrete.Threecubesshall be
taken from fresh concrete and tested in accordance to the German Standard DIN 1048
at28daysage.Thiskindoftestshallbetakenfromsubstructuresconcreteelementslikefoundations,concr
ete water tank, retaining wall etc. The frequency of the water permeability test can be foundinthis
articleTheFrequencyofVarious Tests.

4. RapidChlorideIonPenetrationTest
Likewaterpermeabilitytest,thisisalsooneofthe
teststodeterminethedurabilityofconcrete.Threecubesshallbetakenfromfreshconcretedeliveredonsit
eandtestedat28daysage.ThetestshallbedoneinaccordancetoASTM C1202-97

5. WaterAbsorption Test
Here is the other test that would determine the durability of concrete. The three cube
sampleshall be taken from the delivered fresh concrete and kept it in the curing tank for 28 days
or after24hourstheconcretesamplewouldberemolded anditwill besentdirectlyto theapprovedthird
 party laboratory to ensure its curing. The size of cube sample is 150 mm and tested in
accordancetoBS1881-122.

6. Modulusofelasticity
Modulus of elasticity of concrete is defined as the ratio of stress applied on the concrete to
therespective strain caused. The accurate value of modulus of elasticity of concrete can be determined
byconducting a laboratory test called compression test on a cylindrical concrete specimen. In the test,
thedeformation of the specimen with respect to different load variation is analyzed. These
observationsproduceStress-Straingraph(load-
deflectiongraph)fromwhichthemodulusofelasticityofconcreteisdetermined.

7. Settingtime
Theactionofchangingmixedcementfromafluid stateto asolidstateiscalled“SettingofCement”.

InitialSettingTime isdefinedastheperiod elapsingbetweenthetimewhenwater isaddedtothecementand the

time at which the needle of 1 mm square section fails to pierce the test block to a depth of about
5mmfromthebottomofthemold.
FinalSettingTime isdefinedastheperiodelapsingbetweenthetimewhenwater
isaddedtocementandthetimeatwhichtheneedleof1 mmsquaresectionwith5mmdiameter
attachmentmakesanimpressiononthetestblock.
 EQUIPMENTSUSED

ViCatapparatus CompressionTestingMachine

SlumpCone Finenessmodulus
 CONCLUSION

As an undergraduate of the AITAM College, we would like to say this training program is
anExcellent opportunity for us to get to ground level and experience the things that we would have
nevergainedthroughgoingstraightintoajobwearegrateful
totheAITAMandIVRCLLIMITED(Hyderabad)forgivingus thiswonderfulopportunity.

Themainobjectiveoftheinternshipistoprovideanopportunitytoundergraduatetoidentify,observe
and practice how civil engineering is applicable and the real site it is not only to get experienceon
technical practices but also to observe management practices and to interact with the field
workers.Theonlychancethatanundergraduatehastohavethisexperienceintheindustrialtraining period.