CONCRETE TECHNOLOGY AND MASONRY

STRUCTURES
[BEG 351 CI]

-Pranav Acharya
CONCRETE?
concrete = filler +
binder
Concrete is a composite material composed
of coarse granular material (the aggregate
or filler) embedded in a hard matrix of
material (the cement or binder) that fills the
space among the aggregate particles and
glues them together.
Advantages of concrete
• Economy
• Energy efficiency
• Ability of casting
• Water resistance
• Temperature resistance
• Industrial waste consumption
• Compatibility with steel
• Lesser Maintenance
Limitations of Concrete
• Quasi-brittle nature of failure
• Low tensile strength
• Low ductility
• Formwork requirement (Costs?)
• Curing periods (Time?)
• Cracks
Components of Concrete:
• Cement
• Aggregate
• Water
Aggregates
• Forms the “body” of concrete.
• Includes gravel, crushed stone, sand, slag, recycled concrete, etc.
• Occupies approx. 3/4th of volume of concrete
• Inert component of concrete? [physical/thermal/chemical]
• Mostly occur in natural forms, thus the properties can vary in wide
ranges.
Role of aggregates in concrete
• Fresh concrete:
-Influences the fluidity, cohesiveness and flow(rheology) of concrete
- Surface texture, size, and gradation of aggregate influences these behaviors
in fresh concrete

• Hardened concrete
- Although less reaction among aggregate and cement paste,
- Presence of aggregate reduces cost, shrinkage and creep of cement paste.
- Also enhances weight, stiffness, thermal properties, and abrasion resistance
of concrete
Role of aggregates
• Aggregates provide required volumetric stability to concrete
• Aggregate helps in reducing moisture related deformation i.e shrinkage
of concrete
• Impart wear resistance to hardened concrete
• Water resistance to concrete
• Impart the overall strength and stiffness to concrete necessary for
engineering use
• Restrains the creep of pure cement paste, thus providing acceptable
levels of long term deformation.
• Help to reduce cost, by forming the bulk of concrete
Classification of Aggregates
• According to :

1. Size

2. Shape

3. Source

4. Unit weight

5. Origin
Acc. To SIZE
1. Coarse Aggregate:
-Commonly understood as “gravel”
-Retained on No.4 sieve (4.75mm)
-Maximum Size of Aggregate (MSA) for normal concrete = 20mm

2. Fine Aggregates
-Commonly understood as sand (river sand), fines of crushed rock
-Passing through No.4 sieve (4.75mm)
-IS383-1970 gives four further grading of fine sand: Zone I to IV

“All in aggregate” : Mixture of fraction of coarse and fine aggregates.

 3. Angular Aggregates
Acc. To SHAPE -Distinct edges present
- Around 40% voids
-Good interlocking among particles thus
1. Round Aggregate:
good bond
-More or less round- shaped by attrition -Requires more paste to make workable
-Around 33% voids high strength concrete
Minimum ratio of surface area to -Crushed rocks
volume ratio implies minimum cement
required for good concrete
-less interlocking among particles thus
poor bond 4. Flaky and elongated Aggregates
Eg: river gravel, desert sands. -Poorly crushed weak rocks
- flaky: least lateral dimension : mean
dimension <3/5
2. Irregular Aggregates
- Elongated: greatest lateral dimension:
-Partly shaped by attrition
mean dimension > 9/5
-35-38% voids
- Pit sands
Acc. To SOURCE
1. Natural Aggregate:
-Obtained from natural deposits of river

2. Synthetic Aggregates
-Obtained from industries in the form of slag
-Recycled concrete, blast furnace slag aggregates, foam plastic
aggregates.
Acc. To UNIT WEIGHT
1. Ultra light weight aggregate: 3. Normal weight aggregate

-Unit weight of less than 500 kg/m3 -Unit weight of 1520-1680 kg/m3
-Used for non structural members like -Sand, gravel, Crushed rocks
partition walls. -Most commonly used for structural
members
-Perilite and foam plastic

4. Heavy weight aggregates

2. Lightweight aggregates
-Unit weight greater than 2100 kg/m3
-Unit weight of 500-1120kg/m3 -Iron ore, crushed steel, magnesite,etc
-Blast furnace slags, volcanic pumice, -Used in special cases like radiation shields
etc. in nuclear plants, hospitals, labs, sound
shielding
Acc. To ORIGIN
1. Igneous Rock aggregates 3. Metamorphic Rock aggregates
- Produce crystalline, glossy aggregates
-foliated structure in parent rocks
- Most chemically active concrete
aggregates reacting with cement alkalis - Individual aggregate layer may
be foliated thus resulting in
2. Sedimentary rock aggregates inferior aggregates
-In natural form , found cemented under - Quarzite, gneiss preferred.
pressure
-Limestones, sandstones, flaky aggregates
-Degree of consolidation, type of
cementation, thickness of layers
determines aggregate properties
Grading of aggregates
• Particle size distribution of aggregates is termed as grading.
• “Good grading” – The particular sample of aggregate contains all
standard fractions of aggregate in required proportions such that the
sample contains minimum voids.
• Aggregate fills the cement paste and thus the content of aggregate
determines the requirement of cement paste in a concrete mix.
• Importance of grading from three points:

1. Durability and economy

• [Good grading] implies [minimum voids] implies [minimum cement paste required to fill
these voids] implies [ less cement and water] implies [ economy, lowered shrinkage,
higher durability]

2. Chemical deterioration of concrete contents

• [Good grading] implies [minimum voids] implies [minimum cement paste required to fill
these voids] implies [ less matter available for chemical attack] implies [ greater
durability

3. Compressive strength
[Good grading] implies [proper transfer of forces from particle to particle] implies
[optimum resistance to compressive load]
Sieve analysis
• Used to determine the particle
size distribution in aggregate
• Commonly used size of
aggregates : 80 mm, 40 mm, 20
mm, 10 mm, 4.75 mm, 2.36 mm,
600 micron, 300 micron and 150
micron.
• Grading pattern of a sample of
C.A. or F.A. is assessed by sieving
a sample successively through all
the sieves mounted one over the
other in order of size, with larger
sieve on the top.
Fineness modulus
• The coarseness or fineness of aggregate is defined by the Fineness modulus.
• Object of finding fineness modulus is to grade the given aggregate for the most
economical mix for the required strength and workability with minimum
quantity of cement.
• It gives general idea of the mean size of particles present in given sample.
• Fineness modulus of:
• Fine aggregate (2.0 - 3.5)
• Coarse aggregate (5.5 - 8.0)
• All-in-aggregate (3.5 - 6.5)

• Fineness modulus = Summation of (Cumulative retained) % / 100

 Assume, sample size is taken as 5000gm
Sieve size Weight Cumulative Cumulative
Sieve no.
(mm) retained (gm) retained retained(%)
1 80 0 0 0
2 40 200 200 4
3 20 1550 1750 35
4 10 1360 3110 62.2
5 4.75 1580 4690 93.8
6 2.36 150 4840 96.8
7 1.18 160 5000 100
8 0.6 0 5000 100
9 0.3 0 5000 100
10 0.15 0 5000 100
Summation 691.8

Fineness
modulus 691.8/100
Thus, FM= 6.91

Average size of aggregate is between 6th and 7th sieve i.e between 2.36 and 1.18mm
Characteristics of Aggregates:
Parameters that influence the concrete properties
• Size : Coarse aggregates and Fine aggregates
• Shape : Round, Irregular, Angular, Flaky, Elongated
• Texture : Glossy, Smooth, Granular, Crystalline, Porous
• Strength : Crushing, Abrasion, Impact Values
• Specific gravity
• Bulk density
• Void content
• Porosity and absorption
• Moisture content of aggregates
• Bulking phenomenon in fine aggregates
• Thermal characteristics
Texture
• Directly influences the bond of
aggregate with cement : Hardened Group Texture Example
concrete
• Influences the fluidity of concrete: 1 Glossy Black flint
Fresh concrete 2 Smooth Slate, Marble
• Hardness, Grain size, pore structure, 3 Granular Sandstone
structure of parent rock determines
the texture of aggregate. 4 Crystalline Granite, Basalt
• Rougher the texture, more the surface 5 Porous Pumice, scoria
area available for aggregate for
bonding with cement (contact area).
• Smoother the texture, lower the bond
because of decreased contact area but
higher workability.
Strength of Aggregates
• Aggregate, which forms the major volume of concrete, its strength
also defines the overall strength of concrete to high extent.
• Higher the strength requirement of concrete, higher strength
aggregates are to be chosen.
• Three forms of tests for determining strength of aggregate:
• Aggregate Crushing Value : Measures direct compressive strength
• Aggregate Impact Value : Measures toughness of aggregate
• Aggregate Abrasion Value : Measures the resistance of aggregate to wear. Eg.
Deval Attrition Test, Dorrys abrasion test, Los Angeles test
Aggregate Crushing Value: Test
• PROCEDURE
• The aggregates passing through 12.5mm and retained on 10mm IS
Sieve are oven-dried at a temperature of 100 to 110C for 3 to 4hrs.
• The cylinder of the apparatus is filled in 3 layers, each layer
tamped with 25 strokes of a tamping rod.
• The weight of aggregates is measured (Weight ‘A’).
• The surface of the aggregates is then levelled and the plunger
inserted. The apparatus is then placed in the compression testing
machine and loaded at a uniform rate so as to achieve 40t load in
10 minutes. After this, the load is released.
• The sample is then sieved through a 2.36mm IS Sieve and the
fraction passing through the sieve is weighed (Weight ‘B’).
• Aggregate Crushing Value = Weight B/ Weight A *100
• Two tests should be conducted and average value should be taken.
Aggregate Crushing test apparatus
 Aggregate Impact Value: Test
• PROCEDURE
• The test sample should be such that it passes through 12.5mm IS sieve and retains
on 10mm sieve.
• The sample should be oven-dried for 4hrs. at a temperature of 100 to 110 C and left
to cool.
• Aggregates should be filled in three layers with 25 strokes to each layer by tamping
rod.
• The net weight of the aggregates in the measure should be determined to the
nearest gram (Weight 'A’).
• The sample is suitably placed below the impact testing machine.
• The hammer should be raised to 380mm above the upper surface of the aggregates
in the cup and allowed to fall freely onto the aggregates. The test sample should be
subjected to a total of 15 such blows, each being delivered at an interval of not less
than one second.
Aggregate Impact Value: Test Contd..

• The obtained sample is sieved through a 2.36mm IS

Sieve. The fraction passing through should be weighed
(Weight 'B’).
• The fraction retained on the sieve should also be
weighed (Weight 'C’)
• If the total weight (B+C) is less than the initial weight
(A) by more than 1gm, the result should be discarded
and a fresh test done.
• The ratio of the weight of the fines formed to the total
sample weight should be expressed as a percentage.
• Aggregate impact value = Weight B/ Weight A x 100%
• Two such tests should be carried out and the mean of
the results should be reported
Aggregate Impact test apparatus
 Los Angeles Abrasion Value: Test
• PROCEDURE
• Los Angles abrasion testing machine (70cm dia. and
50cm inside length)
• Abrasive charge: 12 nos. cast iron or steel spheres
approx. 48mm dia. and each weighing b/w 390 and
445g so that the total weight of charge is 5000 +- 25g
• The test sample should consist of clean aggregates
which has been dried in an oven at 105 to 110 C
• The test sample and the abrasive charge should be
placed in the Los Angles abrasion testing machine and
the machine rotated at a speed of 20 to 33
revolutions/minute for 1000 revolutions.
LA Abrasion Value test apparatus
• Upon the completion of the test, the material should be discharged
and sieved through 1.70mm IS Sieve.
• The material coarser than 1.70mm IS Sieve should be washed, dried
in an oven at a temperature of 100 to 110 C to a constant weight
and weighed (Weight 'B’).
• The proportion of loss between weight 'A' and weight 'B’ of the test
sample should be expressed as a percentage of the original weight
of the test sample.
• Aggregate abrasion value = Weight (A – B)/ Weight A *100
 Specific Gravity
• Defined as the ratio of the weight of solid in a given volume of sample to the weight of
an equal volume of water at the same temperature.
• Absolute specific gravity: Ratio of weight solid material excluding the voids to
weight of equal volume of water at same temperature.
• Apparent/ Bulk specific gravity:
• Aggregate comprises : Impermeable and capillary voids(voids between particles)
• Apparent sp. gr. Includes impermeable voids only
• The ratio of the mass of the aggregate dried in an oven at 100 to 110°C for 24
hours to the mass of the water occupying a volume equal to that of solids including
impermeable voids.

“Saturated Surface Dry (SSD)

aggregates”
-Preferred for sp. gr. computations.
-Water absorbed in the pores of the
aggregate does not take part in the
chemical reaction of the cement and
Specific Gravity : Aggregate
size>10mm
• PROCEDURE
• Sample of aggregate (around 2kgs) is washed to remove dust and then taken in wire
basket and immersed in water container.
• The entrapped air is removed from sample by lifting the basket above the base of tank
and dropping it 25 times @ 1drop per second.
• After keeping the basket and aggregate immersed in water for 24hrs, the weight of basket
+ aggregate (W1) is measured while it is still immersed in water.
• The aggregate is removed and weight of basket in water is measured. (W2)
• The aggregate is then dried with cloth to make them saturated surface dry and then
weighed. (W3)
• The aggregate sample is then oven dried for 24hrs @100 C then weighed. (W4)

• Apparent Specific Gravity =

• Specific Gravity =
Weighing apparatus for water absorption and sp. gr. test
• Specific gravity = Where,
• a = mass of saturated surface dry aggregate in
air, = W3
• Apparent specific gravity =
• b = mass of saturated surface dry aggregate in
water = W1-W2
• Water absorption = • c = mass of oven dried aggregate in air = W4
Specific Gravity : Aggregate size
<10mm
• PROCEDURE
• First, an empty pycnometer is taken, cleaned, dried and empty weight is
measured. (W1)
• About a kg of sample aggregate is taken in pycnometer and then weighed.(W2)
• Water is filled in the pycnometer containing the aggregates, just to fill the
pycnometer.
• To remove the entrapped air, pycnometer is shaken by covering the hole at top of
lid, and then again refilled with water, and finally weighed.(W3)
• Then, contents of pycnometer are discharged and clean pycnometer is refilled
fully with water and weighed.(W4)

• Apparent Specific Gravity =

Figure of pycnometer
Implications from specific gravity
• This specific gravity is required for calculations of the yield of
concrete or of the quantity of aggregate required for a given
volume of concrete.
• The specific gravity of an aggregate gives valuable information
on its quality and properties. It is seen that the higher the
specific gravity of an aggregate, the harder and stronger it will
be.
• If the specific gravity is above or below that which is normally
assigned to a particular type of aggregate, it may indicate that
the shape and grading of the aggregate has changed.
Characteristics of Aggregates:
Parameters that influence the concrete properties
• Size : Coarse aggregates and Fine aggregates
• Shape : Round, Irregular, Angular, Flaky, Elongated
• Texture : Glossy, Smooth, Granular, Crystalline, Porous
• Strength : Crushing, Abrasion, Impact Values
• Specific gravity
• Bulk density
• Void content
• Porosity and absorption
• Moisture content of aggregates
• Bulking phenomenon in fine aggregates
• Thermal characteristics
Bulk Density
• Defined as the mass of the material in a given volume and is expressed in kgs/liter.
• Depends on how densely the aggregate is packed, the moisture content of aggregate,
particle size distribution and shape of particles.

PROCEDURE
• A cylindrical measure shall be of 3, 15 or 30 litres capacity, according to the maximum
nominal size of the coarsest particles of aggregate.
• A straight metal tamping rod of cylindrical cross-section 16 mm in diameter and 60 cm
long, rounded at one end is taken.
• The cylindrical measure is filled in three parts with each part tamped 25 strokes by
tamping rod.
• The measure is made level by striking off the excess by tamping rod.
• The net weight of the aggregate in the measure is determined.
• Bulk density = Net weight of aggregate in kgs/ capacity of the measure in
litres
• Percentage of voids = (Gs – γ)/Gs *100

Where, Gs= Sp. Gr. Of aggregate, γ = Bulk density in kg/litres

 Cylindrical measure

Tamping Rod

Bulk density test apparatus

Implications from bulk density:
• For a coarse aggregate of given specific gravity, a higher bulk
density indicates that there are fewer voids to be filled by sand
and cement.
• The bulk density of an aggregate can be used for judging the
quality of aggregate by comparing it with normal density for that
type of aggregate.
• It determines the type of concrete for which it may be used.
• The bulk density is required for converting proportions by weight
into the proportions by volume.
Void Content
• The spaces available between individual aggregate particles is called
void.
• The total volume of aggregates minus the volume occupied the
particles alone is void content.
• Void ratio =
 Porosity and absorption of
aggregates
• Minute “pores” are formed within aggregate during the formation
process of parent rocks wherein small air bubbles are trapped.
• Overall porosity of concrete is significantly affected by the porosity of
aggregates, since the aggregates form major portion of concrete.
• Porosity affects bond between aggregate and cement paste, freezing and
thawing resistance, chemical stability, abrasion resistance and sp. gr of
aggregate.
• Water absorption: The water absorption of aggregate is determined by
measuring the increase in weight of an oven dry sample when immersed
in water for 24 hours.
Moisture content
• Moisture content: Surface moisture expressed as a percentage of the
weight of the saturated surface dry aggregate
• Absorption represents the water contained in the aggregate in SSD
condition;
• The “moisture content” is the water in excess of the absorbed value.
• Thus, the total water content of a moist aggregate is equal to the sum of
absorption and moisture content.
• Moisture content of aggregate gives the net water cement ratio for
concrete batching.
• A highly moist aggregate affects the overall value of water cement ratio
making weak concrete.
• Methods adopted for determining moisture content:
• Displacement method
• Drying method
Bulking in fine aggregates
• The increase in volume of fine aggregates due to presence of moisture is defined as
bulking of aggregates.
• Bulking occurs because of the thin film of water pushing the particles of fine
aggregate farther due to surface tension forces.
• Bulking increases to a certain percent of moisture added, after which it decreases
due to loss of such forces upon saturation.
• Finer sands bulk more than coarser sands because the thickness of film of water is
comparable to size of fine aggregate.

• Bulking and its extent depends upon :

1. Percent of moisture present in fine aggregate (maximum bulking upto 40%
moisture)
2. Fineness of fine aggregate
• Maximum bulking in fine sand is 40% with moisture content of around
10%.
• In coarse aggregate, bulking is negligible because the thickness of film is
very small compared to particle size.
• Bulking affects a lot during volume batching as compared to weight
batching.
• For given mass, moist sand occupies larger volume than dry sand, which
results in a sand-deficient mix causing segregation, honey combing and
lowered yield of concrete.
• Thus, nominal mix requires a certain allowance to be made to account for
the bulking phenomenon.
Note:
* Segregation = separation of concrete ingredients from the concrete mix during fresh state
* Honey combing = formation of honey comb like structure in hardened concrete due to
improper vibration, poor mixing, lacking of fine aggregates
* Nominal mix = already established mixing ratios of concrete ingredients, e.g. 1:2:4, 1:1:2 etc.
(cement : fine aggregate : coarse aggregate)
Fig: Effect of variation of moisture content on bulking of sand
Thermal properties of aggregate
• The overall coefficient of thermal expansion of concrete increases
with the increase in same for aggregate.
• If the coefficient of expansion of coarse aggregate and of cement
paste differs too much, a large change in temperature may introduce
differential movement which may break the bond between the
aggregate and the paste.
• Further, the thermal conductivity ( ability to pass heat through itself )
of aggregate also determines the overall conductivity of concrete.