Department of Civil Engineering

Government Polytechnic College

Manjeri

Concrete Technology
Shamjith km
shamjithkeyem@gmail.c
om
6015 – Concrete
Technology
 History of Concrete
3000 BC 300 BC – 476 AD 1793
Egyptians used mud Roman baths, the John Smeaton used
mixed with straw to Colosseum and hydraulic lime to
bind bricks. They used pantheon used rebuild Eddystone
gypsum and lime Pozzalana cement. Light house in England.
mortars in the Animal fat, milk and
pyramids. blood were used as
admixtures.

1849 1826 1824

Reinforced concrete First systematic test of Joseph Aspidin of
was invented by tensile and England invented
Joseph Monier compressive strength Portland cement.
took place in Germany.

India  1904
 History of Concrete
1854 1889 1936
The first home First Reinforced First large concrete
constructed using concrete bridge was dams were built –
Reinforced concrete constructed. Hoover Dam

2016 1970
3D Printed building Fiber Reinforced
FUTURE ? was introduced – The
Office of the future,
Concrete was
introduced.
Dubai
 Concrete
Composite material
Heterogenous
Mortar
Ingredients are: Cement
Sand
Cement water
Sand (No coarse aggregate)
Coarse
Used in plastering, masonry, etc
aggregate
water
Admixtures
 Cement concrete
Concrete is a composite
(heterogenous) product obtained
by mixing binding material,
aggregates and water in required
proportions.
Importance of concrete
One of major construction material
Used in masonry, plastering,
flooring, pointing, ornamental
works, etc
Preparation of Plain and reinforced
cement concrete
Construction of footings, beams,
columns, slabs, etc
Importance of concrete
Provide sufficient strength and
stiffness
Increased durability to structures
Acts as a strong solid when
hardened
Can be moulded to any shape
Takes compressive stress well
Provide cleanness and neat to
building
gredients of cement concrete and their function
Relevant IS Standards
IS 456:2000
Plain And Reinforced
Concrete Code Of Practice

IS 10262:2009
Concrete Mix Proportioning
- Guidelines
 Cement
1824 – Joseph Aspdin invented
Binder material (adhesive and cohesive
property)
On adding water  Hydration (Exothermic
reaction)
Ingredients and Sources
Lime : limestone, chalk, shells, shale or
calcareous rock
Silica : from sand, old bottles, clay or
argillaceous rock bauxite, recycled Aluminum, clay
Alumina : from
Iron : from clay, iron ore, scrap iron and fly ash
Gypsum : found together with limestone
 Ingredients in cement
• Binding property and strength
1 Lime CaO 62 %
•
•
Excess makes cement unsound
Deficiency – Quick setting of cement
• Lime ↑ Slow setting
• C2S, C3S – Strength contribution
2 Silica SiO2 22 % • Excess – Strength ↑ , Prolong setting
time
• Imparts plasticity and quick setting
3 Alumina Al2O3 5%
• Act as a flux to reduce clinkering
temperature (2000oC  1500oC)
• Produce more heat at time of hydration
• Gypsum - increase the initial setting
Calcium time
4 CaSO4 4% Added to rotary kiln at time of final
Sulphate •
grinding

5 Iron oxide Fe2O3 3% • Imparts colour, Hardness and strength

• Yellowish tint, excess  unsound,
6 Magnesia MgO 2% Hardness
Chemical composition of cement
First formed – within 24
Tricalcium aluminate
1 C3A 10 % hours
(Celite)
No strength contribution
Tetracalcium 2nd formed – within 24 hours
2 C4AF 8%
aluminoferrite No strength contribution

3 Dicalcium silicate (Belite) C2S 20 % Progressive strength

4 Tricalcium silicate (Alite) C3S 55 % Early strength

5 Sodium oxide Na2O < 2 % Efflorescence

6 Potassium oxide K2O < 2 % Efflorescence

CaSO4.2H2 Control setting time of

7 Gypsum 5%
O cement
 Bogue’s compounds

1 Dicalcium silicate (Belite) C2 S 2CaO.SiO2

2 Tricalcium silicate (Alite) C3 S 3CaO.SiO2
3 Tricalcium aluminate (Celite) C3 A 3CaO.Al2O3
Tetracalcium aluminoferrite 4CaO.
4
(Felit) C4AF Al2O3.Fe2O3
Manufacturing of cement
Mixing of raw
1 materials

2 Burning

3 Grinding
 Calcareous Argillaceous material
material
1
(Lime stone) (Clay)

Crushing Crushing
Mixing of
raw materials Grinding
Ball mill Ball mill
Grinding
Tube mill Tube mill

Storage Storage
basin basin

Mixing in correct proportion

Pre-heating @ 800oC

Storage tank
 2 Burning
CO2 ev
olves Heated air

Raw
materials Nodul
e Burnin
2.5 – 3 g zo n e
m s 1400 –
(lump 1500 o
s) (Alum
ina re C
clinke
ring te duces Clinker
Dry zo mpera
ture) forming
ne temperature
Pre-he
ating
zone
1
25
(1 in 25 to 1 in 30)

Cooling zone

Clinker
3-20 mm
95oC
Rotary kiln
3 Grinding

Add 3-5 % gypsum

Ball mill (large balls)
Tube mill (Small balls)
Calcination Burning a mixture of calcareous and
- argillaceous material at very high
temperature in correct proportion.

Calcined product = CLINKER

CLINKER + Gypsum = cement
 Types of
cement
1.Ordinary Portland Cement
2.Rapid Hardening Cement
3.Extra Rapid Hardening Cement
4.Sulphate Resisting Cement
5.Portland Slag Cement
6.Quick Setting Cement
7.Super Sulphated Cement
8. Low Heat Cement
9. Portland Pozzolana Cement – fly ash based and calcined
clay based

10. Air Entraining Cement

11. Coloured Cement (White Cement/Snowcem)
12. Hydrophobic Cement
13. Masonry Cement
14. Expanding Cement
15. Rediset Cement
16. High Alumina cement
1 Ordinary Portland Cement
(OPC)
Grades
• 33 Grade  min 33 N/mm2 strength (M20)
• 43 Grade  min 43 N/mm2 strength (Normal RCC
works)
• 53 Grade  min 53 N/mm2 strength
 For > M30
 Can reduce cement by 10 – 15 %
 Can reduce steel by 5 – 8 %
 High rise buildings, chimney, etc
 2 Rapid Hardening
Cement
• Speedly (rapidly) attains strength (3
days)
• Initial and final setting time same as
(56 %)
OPC
Progressive strength

• Higher
early stageCstrength
3S and lower C2S content

• Where speed of construction is needed

• pre-fabricated concrete construction
• Road repair works
 3 Extra Rapid Hardening
Cement

• RHC + Calcium chloride

• Transported, placed, compacted & finished within about 20
minutes
• Accelerates the setting and hardening process
• Strength 25 % higher than RHC
Use
s
• Concreting in cold weather
 4 Sulphate Resisting
Cement

• Resistant to sulphate attack

• low C3A content (below 5 % only)
• Has high silicate content  High sulphate resisting
ability

Uses
• Sewage treatment works, marine structures
 5 Portland Slag Cement

• OPC + Granulated blast furnace slag

• Low heat of hydration
• Resistance to chemical attacks
• Resistance to corrosion of steel
reinforcement
Uses
• RCC
 6 Quick Setting Cement

• Sets fastly
• Alumnina ↑
• Gypsum ↓
• Initial setting time = 5 minutes
• Final setting time = 30 minutes

Uses
• Pumping Concrete works
7 Super Sulphated Cement

• Granulated slag + gypsum + 5 % Portland cement

clinker
• Low heat of hydration
• High sulphate resistance

Use
•s Marine works
 8 Low Heat Cement

• Opposite of high alumina cement

• Less heat is produced at time of hydration
• Low C3S , C3A reduced
• Slow rate of gain of strength
• Same ultimate strength of OPC
• Initial setting time = 1 hour
Uses
• Final setting time = 10 hour
• Dams, mass concrete
9 Portland Pozzolana Cement
(PPC)
• OPC clinker + 10 - 35 % pozzolanic material
• Clinker replaced by cheaper pozzolanic material (Fly ash or
Calcined clay)

• PPC gives more volume of mortar than OPC.

• Longer setting times
• Sulphate resistant
• Less compressive strength at early stages
Uses

• Sewage works, under water works, normal

works
1
0 Hydrophobic Cement

• Afraid of water !!
• Reduces wetting ability of cement
• Helps to reduce w/c ratio
• Contains admixtures – Acidol
- Napthene soap
- Oxidized petrolatum
• frost and water resistance
1
1 Acid resistant cement

• Binding material : Soluble gas

• Do not resist water

To resist water add

0.5 % linseed oil or
2 % ceresit
1
2 Coloured cement
(Snowcem)
5 – 10 % pigment
Chromium oxide - Green
Cobalt - Blue
Manganese dioxide – Black/Brown

1
3 Expanding cement
Expanding agent: Sulpho Aluminate
14 High Alumina cement
Alumina ↑ – 32 % - Quick setting
Initial setting time = 3

Final setting time = 5 hours

By fusing Lime stone + Bauxite, Gypsum not added

Less time, more strength

In England  Cement Fondu
In America  Lumnite
 Properties of cement
• Binder material (adhesive and cohesive
property)
• On adding water Hydration (Exothermic reaction-Heat)
• Fineness < 10 % of its original weight
• Initial setting time of OPC = 30 min
• Final setting time of OPC = 600 min
• Specific gravity of OPC = 3.15
• Normal consistency for OPC ranges from 26 to
33%
 Storage of
1. Jute
Cement
or gunny bags
2. Storage period = 3 months
3. Stacked in 10 bag piles
4. Care to maintain quality – no moisture content
5. Remove cement bags in order
6. Label – date of receipt – to find age of cement
7. Use waterproof shed/polyethylene during monsoon
 Hydration
Chemical reaction between cement and
water
Stages of
hydration:
1. Loss of workability
2. Setting (Solid  Concrete)
3. Hardening (Strength gain)
 Chemistry of Hydration
Cement + Water  C-S-H gel +
Heat
Bougue’s compounds

Compoun
Compound Name Chemical formula
d
C3 S Tri-Calcium Silicate 3 CaO.SiO2
C2 S Di-Calcium Silicate 2 CaO.SiO2
C3 A Tri-Calcium Aluminate 3 CaO.Al2O3
C4AF Tetra-Calcium Alumino Ferrite 3 CaO.Al2O3.Fe2O3
Reaction of Bougue’s compounds
CSH Gel Strength contribution
Early Strength Breakdown of Portland cement

2 C3S + 6 H  C3S2H3 + 3 Ca(OH)2 +

Progressive strength

2 C2S + 4 H  C3S2H3 + Ca(OH)2 +

First formed

2 C3A + 21 H  C4AH13 + C3AH8 + 2C3AH6 + 9 H +

Second formed

C4AF + 7 H  C3AH6 + CFH + 9 H +

 Reaction with gypsum

( Ettringe )  15 – 20 %
C3A + 32 H + 3CaSO4  C6AS3H2

C3A + 18 H + CaSO4  C4ASH18

 Tests on cement
Field tests Laboratory tests

1. Fineness
2. Specific gravity
3. Consistency
4. Setting time
5. Soundness
6. Compressive strength
7. Tensile strength
Field testing of cement
1. Open the bag and take a good look at the
cement
- no visible lumps.
2. Colour = Greenish grey
3. Should get a cool feeling when thrusted
4. When we throw the cement on a bucket full
of water, before it sinks the particle should
flow
1 Fineness Test on Cement
Degree to which the cement is
grinded into smaller and smaller
particles
Using 90 micron IS
Sieve

Air permeability
method
Hydration of cement
During mixing of cement with water, chemical
reaction take place between them. Heat is
liberated.
Apparatus required:

IS Sieve 90 micron cement weighing balance

 Procedure
1.Break down any air-set lumps in the cement
sample with fingers.
2.Weigh 100 grams of cement in IS 90 micron
3.Continuously sieve the sample for 15
minutes
4.Weigh the residue left after 15 minutes of
sieving.
5.This completes the test.
 Fineness = x 100

A = Weight of cement retained on 90 micron IS

sieve (15 minutes)
B = Total weight of sample

Rule in this experiment

For ordinary Portland cement (OPC) fineness should not be
more than 10 % of original weight as per IS code.
2 Specific gravity of cement

weight of a given volume of the

Gc = cement
weight of equal volume of
water

Standard value:
3.15
Apparatus required:

Specific gravity bottle weighing balance

 w1 w2 w3 w4 w5

w1 = weight of empty bottle

w2 = weight of bottle + cement
w3 = weight of bottle + cement +
kerosene
w4 = weight of bottle + kerosene full
Specific gravity of the kerosene
Gk = = w 4 −𝑤 1
𝑤5 − 𝑤 1

Specific gravity of the cement

Gc =

Gc = x Gk
 Standard/Normal Consistency
Standard Plunger (10 mm dia, 50 mm long

Initial Setting time

Square needle (1 mm)

Final Setting time

Vicat Apparatus Needle with annular collar
3 Standard consistency of cement

 Relative mobility of a
freshly mixed cement paste
 Ability of cement to flow.
 Easiness of work with
cement
Apparatus required:

weighing balance

Vicat apparatus
Trowel
 + Cement paste
Gauging time
( 3-5 minutes)
400 g cement 25 % water by
weight of dry cement

Repeat the process till the standard

consistency
(Water % for 33-35 mm penetration from
Generally normal consistency for
top) is got
OPC ranges from 26 to 33%.
Procedure

1.Take 400 g cement

2.Add 25 % water by weight of dry cement
3.Prepare cement paste within 3-5 minutes (Gauging
time)
4.Fill in Vicat mould
5.Attach standard plunger above the test block
6.Release plunger and note depth of penetration
7.If penetration ranges from 33-35 mm from top, it is
standard consistency for given cement.
8.Else add 1 % more water and repeat the
experiment till we get standard consistency.
4 Initial and final setting time

Initial setting time:

The time elapsed between the moment water is

added to the cement to the time at which cement
paste starts losing its plasticity.

For OPC > 30 minutes

Final setting time:

The period elapsing between the time water is

added to the cement and the time the needle makes
an impression on the surface of the test block

For OPC < 10 hours or 600 minutes

Procedure
1.Take 300 g cement
2.Add 0.85 times water required for standard consistency
3.Start stop watch
4.Prepare cement paste within 3-5 minutes (Gauging time)
5.Fill in Vicat mould
6.Attach square needle above the test block
7.Release square needle. In beginning needle penetrates
completely.
8.Paste starts losing its plasticity.
9.Release after half an hour, the needle penetrates 33-35 mm
from top.
Stop watch and note the time (initial setting time).
10.Replace needle with annular collar needle. Check after 10
hours.
11.Note the no impression forming time (final setting time).
5 Soundness test

• Soundness = Ability of hardened cement

paste to retain its volume after setting
without expansion.
• Reason: insufficiency in grinding, burning, etc
• Ensures:
 Cement does not undergo any large
 expansion
To detect the presence of excess lime in
cement
• Le Chatelier test detects unsoundness due to free
lime only
• Expansion should be less than 10 mm
• OPC – Ordinary Portland Cement
• RHC – Rapid Hardening Cement
• Low Heat Portland Cement

• If expansion of cement > 10 mm

• Unsound
• Excess lime  Cracks
 Paste
Take a
0.78 x P
sample
of 100
Cover
grams
with
cement.
glass
sheet

Fill in Le chatelier apparatus

Expansion = d2 –
d1
Immerse in water, 24 hrs,
270C

Note the
distance b/w Boil 3 hrs – reach boiling Note the distance b/w
pointers after Cool point within 25-30 pointers before boiling – d1
boiling – d2 minutes
6Compressive strength of cement

• Cube size = 7.06 X 7.06 X

7.06
• Face area = 50 cm2
 Aggregates
Includes gravel, crushed stone, sand, slag,
recycled concrete and geosynthetic
aggregates
May be natural, manufactured or recycled.

Aggregates (fine and coarse) make up some

60 -80% of the concrete mix
 Function of aggregates
Contributes to overall strength of the
concrete
Provide for volume stability
Reduces volume changes
Provide abrasion resistance
Provide for volume stability / body to
concrete
Cheap and hard filler material
Classification of aggregates

Geological Size Shape Unit

origin weight

1.Natural 1.Coarse 1.Rounded 1.Normal weight

aggregates > 4.75 2.Irregular 2.Heavy weight
• Igneous mm 3.Flaky 3.Light weight
• Sedimentary 4.Angular
• Metamorphic 2.Fine
2.Artificial < 4.75
aggregates mm
• Blast furnace
slag
 Fine aggregate (Sand)
• Sand basically consists of Silica (SiO2)
• Formed by decomposition of sandstone due to weathering
• action.
Also called as adulterant

Types/sources of Sand

1. Pit sand - angular shape

2. River sand – round shape
3. Sea sand – from sea shore. Contain salts.
4. Sand dunes – desert sand
 Classification of sand

1. Fine sand < 1.5875 mm

2. Coarse sand < 3.175 mm
3. Gravelly sand < 7.62 mm
 Coarse aggregates
• Size > 4.75 mm
• Major contribution to strength in concrete
• Influences workability & degree of compaction of
concrete
• Materials generally used are :

1.Gravel
2.Crushed stone
3.Slag
4.Recycled concrete
5.Geo-synthetic aggregates
Requirements of good coarse
aggregates
• Hard, strong and durable
• Free from organic impurities
• Free from grass and roots
• Clay content < 4 %
• Resistance to change in volume
• Well graded
 Commonly used sizes for different
applications
Different based on type of work. Commonly used
are •
Retaining walls and abutments = 75 mm
• Concrete dams = 75 mm
• Roads = 40 mm
• Column and slab = 20 mm
• Self compacting concrete (SCC) = 10 mm
 Alternative materials
Coarse aggregate Fine aggregate alternatives
alternatives (Usually river sand)
(Usually gravel)
EPS: Expanded Polystyrene M-Sand (Manufactured)
Plastic Reservoir sand
Glasscrete Dune sand
Crushed rubber Beach/offshore sand
High Density Polyethene Recycled materials/wastes
(HDPE)
Quarry wastes (for both) P-Sand (Plastering Sand)
 Tests for aggregates
Aggregate crushing
1 strength
2 Impact test

3 Abrasion tests
Flakiness & Elongation
4 Index
1 Aggregate crushing strength
Gives a relative measure of the
resistance of an aggregate crushing
under gradually applied compressive
load
1 Aggregate crushing strength
☼ Weight empty cylinder (W1)
☼ Fill sample in 3 layers, 25 strokes (W2)
☼ Place cylinder with plunger on CTM
☼ Load rate: 40 TON in 10 minutes
☼ Weight crushed fraction passing through
IS sieve 2.36 mm (W3)
1 Aggregate crushing strength
A
Aggregate crushing strength = X
100 B
W3
Aggregate crushing strength = X
100 W2 – W 1
2 Impact test
To measure resistance to sudden impact/shock
☼ Aggregates passing 12.5 mm and
retained on
10 mm IS sieve is taken
☼ Fill cylinder: 3 layers, 25 strokes
☼ Place cylinder in impact testing
apparatus
☼ Raise and release hammer 15 times
☼ Weigh fraction passing 2.36 mm sieve
2 Impact test

A
Aggregate impact value= X 100
B
W3
Aggregate impact value =
X 100 W2 – W 1
3 Abrasion tests (Dowel & Los
Angeles)
Dowel's abrasion test

Los Angele’s abrasion test

4 Flakiness and Elongation Index
Flakiness Index
☼ Percentage by weight of particles
whose least dimension (thickness)
is less than 3/5 (0.6) of their mean
dimension
4 Flakiness and Elongation Index
Elongation Index
☼ Percentage by weight of particles whose
greatest dimension (length) is greater than
1.8 times their mean dimension
 Grading of coarse and fine
aggregate
• Particle size distribution of aggregates
• Measured by sieve analysis method
• Described using Grading curve

Gives ‘cumulative %
passing’ against standard
IS Sieves
• Influences workability & degree of
compaction
• Poorly graded  All particles of aggregate
have same size – more voids
• Well graded  Contains particles of all sizes (GOOD)

• Gap graded  Some big, some small

particles.
 Fineness modulus

It is an index number indicating mean

particle size of aggregates

∑Percentage retained
Fineness modulus
= 100
Specific gravity of aggregates
Ratio of Weight of Aggregate to the
Weight of equal Volume of water.

Weight of Aggregate
Specific gravity =
Weight of equal Volume of water
 Bulking of Sand

When water is added to dry sand, a film

forms around each sand particle. Thus
volume increases.
 Bulking of Sand
When more water is added, the water
films break and thus volume decreases.

BULKING
Increase in volume of fine
aggregates due to presence of
water
 Bulking of Sand
(4 - 8 %)
% bulking 

% bulking =

Moisture content 

1.Fine sand bulks more than coarse sand.

2.Coarse aggregate does not bulk
 Alkali-aggregate reaction
C-S-H GEL
Alkali-Silica rxn
Cement Aggregat Alkali-carbonate
(Highly
Paste
alkaline) e silica/carbonate)
(Reactive rxn
Alkali-Silicate rxn

• Known as ‘Concrete Cancer’

• Expansion of concrete  Volume increases 
Swelling/Bulging  cracks forms  Strength
reduces
Factors affecting Alkali-aggregate
reaction
☼ High alkali content in cement
☼ Reactive silica or carbonate in aggregates
☼ Availability of moisture
☼ Temperature = 350C
Alkali-aggregate reaction: Remedial
measures:

☼ By using low alkali content cement

☼ Selecting non reactive aggregates
☼ By controlling moisture and
temperature
☼ By using pozzolanas, slags, silica
fumes, etc
☼ By using air entraining agents
 Water
Potable water is used for concreting
i.e., water that is fit for drinking
 Quality of Water
Potable water (drinking water) is used in
concrete
Amount of water controls Workability of
concrete
Water lubricates aggregates and facilitates passage of cement through voids.

Amount of water controls Hydration

Amount of water controls Curing
Defines strength of concrete
Defines shrinkage of concrete
 Water-cement ratio
Amount of
w/c ratio =
water
Amount of cement by
weight

• Ratio of weight of ‘free water’ (excluding that

absorbed by aggregates) to cement in a mix.

• Strength and quality of cement concrete

primarily depends on w/c ratio
 Abrams Law
Water-cement ratio is inversely proportional to
compressive strength of concrete.

 Low w/c ratio is

good
Additives and admixtures
Chemicals added to concrete before or
during mixing of concrete to modify some
specific property of fresh or hardened
concrete.
 Reduces cost of construction
 Ensure quality of concrete during mixing

Romans : Milk, Blood, etc used as

admixtures
 Function of admixtures

Increase workability without increasing water

content
Accelerate or retard initial setting time
Reduce shrinkage or create slight expansion
Reduce segregation – separation of aggregates
Improve pumpability
Improve Strength, durability, bond
 Chemical admixtures

1. Plasticizer
2. Superplasticizer
3. Accelerators
4. Retarders
5. Air entraining Add in very
admixtures small amounts
6. Water-reducers
 Mineral admixtures
1. Fly ash Added in very
2. Silica fume (SF) large amounts
3. Rice Husk Ash
4. Metakaolin
5. Ground granulated blast furnace slag
(GGBFS)
6. Slags
Plasticizers and super plasticizers
Plasticizers and super plasticizers
• A type of water reducing admixture
• Also called as High range water reducer
• Increase fluidity : flowing, self levelling,
• etc
Reduced water cement ratio: High early
strength
• Commonly used superplasticizers are
1. Sulphonated melamine formaldehyde condensates (SMF)
2. Sulphonated naphthalene formaldehyde condensates
(SNF)
3. Polycarboxylate ether superplasticizers (PCE)
 Accelerators

• A type of admixture
• Increase rate of hydration of cement
• Reduce setting time
• Increase rate of strength development
• Eg:- Na2SO4, NaCl, K2SO4, CaCl2
 Retarders

• To increase (retard/delay) the setting time

• Slow rate of hydration
• Helpful – concrete transporting to long
distance
• Eg:- Derivatives of sugar and carbohydrates,

gypsum, plaster of paris, etc

 Air entraining admixtures

Air-entraining agent introduces air in the form of

minute bubbles distributed uniformly throughout the
cement paste.
 Air entraining admixtures
Salts of wood resins
Animal or vegetable fats and oils
Sulphonated hydrocarbons
Eg:-
Alkyl-Aryl Sulphonate
Alkyl Sulphonates
Phenol ethoxylates
Water proofing agents
6015 – Concrete
Technology
 Fresh Concrete
Stage of concrete in which
concrete can be moulded and it is
in plastic state.
Properties of Concrete
Workability
Setting of Concrete
Bleeding
Segregation
Hydration
Air Entrainment
 Workability of concrete

Property of freshly mixed concrete (or mortar)

which determines the ease and homogeneity
with which it can be mixed, placed, compacted
and finished.
Ability to flow and work with concrete
Factors affecting workability
• Water content
• Size – finer particles  more water  large specific surface
• Shape – Angular aggregates require more water than rounded
aggrgates
• Texture and grading
• Mix proportions
• Grading of aggregates
• Use of admixtuers
 Tests for workability
1. Slump test
2. Compaction – factor test
3. Vee-bee test
4. Flow test
 1. Slump test
• Field and lab test to find workability of fresh
concrete
Slump
The difference in height between the concrete
before removing slump cone and height of the
concrete after removing of slump cone
Types of slump
1. Zero slump – no slump when slump cone is
removed
2. Collapse slump
3. Shear slump – some portion subsides largely
4. True slump
Procedure for slump test
1. Prepare mix and fill slump cone in 3 layers – 25
times tamping to each layer
2. Cut the excess concrete and level the top
3. Remove the slump cone slowly
4. Measure the slump : Max slump = 300 mm
2. Compaction factor test
• Field and lab test
A

Prepare mix. Eg:

M20
Procedure for compaction factor test
• Fill concrete in HOPPER A
• Open trap door  Concrete falls to HOPPER B
• Open trap door  Concrete falls to CYLINDER
• Note the weight of partially compacted
concrete
• Remove all concrete from cylinder – EMPTY IT
• Again fill the cylinder from same sample mix
• 3 LAYERS – 25 Tamping with tamping rod
• Weight the fully compacted concrete
• Compaction Factor is
C.F =
 3. Vee Bee test
To determine workability of concrete 
Indirectly
Lab test
 3. Vee Bee test
Procedure
O Slump cone placed inside cylinder
O Swivel glass is turned & placed on slump cone
O ON the vibrator + Start stop watch
O Conical shape of slump disappears  Flat
O OFF the stop watch
O The time taken is noted  Vee bee seconds
 Segregation
Separation of constituent materials of
concrete mix so that the mix is no longer
in homogenous condition.
Coarse aggregate separating
out / settling down from mix
Paste separating out away from
coarse aggregate
 Prevention methods
Concrete mix should be properly designed with
optimum quantity of water
Field quality control must be maintained while
handling, transporting, placing & compacting and
finishing concrete
If at any stage segregation is observed, then
remixing should be done to make the concrete again
homogeneous.
Admixtures, such as pozzolanic materials or air
entraining agent should be used to avoid
segregation
Concrete should not be allowed to fall from greater
heights. It should be placed as near its final position
as possible.
 Bleeding
Appearance of water along with cement
particles on the surface of freshly laid
concrete.
Tendency of water to rise to surface of
freshly laid concrete.
Particular form of segregation
 Bleeding
Reason : Water has low specific gravity
than
other contents
Source: Over limit of compacting

Quality and strength of concrete are

affected by bleeding.
 Manufacture of concrete
Batchin
g Transpo Compa Finishin
Mixing Placing Curing
/Proport rting cting g
ioning
Proportioning/Batching
concrete
Process of selection of relative
proportions of cement, sand, coarse
aggregate and water so as to obtain a
concrete of desired quality.

Process of measuring concrete mix

ingredients either by mass or volume
and introducing them into the mixer.
 Types of Proportioning
1. Volume batching
• Small jobs

2. Weight batching
• Accurate
• Uniform proportioning
 Mixing of concrete
Mixing of the ingredients to get
homogenous mixture with uniform colour
and consistency.
 Mixing : Hands (Using hand
shovels)
Hand shovels etc
Done for Less output of concrete.
 Stationary Mixers
Concrete is sometime mixed at jobsite in a
stationary mixer having a size of 9 cubic
meter .
 Tilting type mixer
It consist a conical drum which rotates on
an inclinable axis.

It has only one opening.

The drum charged directly and

discharged by tilting and
reversing the drum.
 Non tilting type mixer
The mixing drum is cylindrical in shape
and revolves two – horizontal axis.

It has opening on both sides.

The ingredients are charged

in from one opening.
For discharging concrete chute is
introducing to other opening by
operating a lever.
 Ready Mixed Concrete
Proportioned and mixed off at the project
site
Delivered to the construction area in a
freshly mixed and unhardened state.
Transported in a truck specially made for
this
Central-mixed
concrete
Truck-mixed concrete
 Central-mixed concrete
Mixed completely in a stationary mixer
Delivered in
Agitator Trucks
A non-agitating truck
 Truck-mixed concrete
Production of concrete
at jobsite
Combined materials
transporter and batching
and mixing system
One-man operation
 Transporting and placing

1. Mortar pan

2. Wheelbarrows and
Buggies
 Transporting and placing
3. Belt Conveyors

4. Cranes and Buckets

 Transporting and placing
5. Pumps

6. Transit Mixer
 Transporting and placing
5. Pumps

6. Transit Mixer
 Compaction of concrete
To expel entrapped air from the concrete
1% air in the concrete approximately
reduces the strength by 6%
If we don’t expel this air, it will result into
honeycombing and reduced strength
 Compaction of concrete

Hand
Compaction by
Compaction
1. Rodding Vibration
1. Internal vibrator
2. Ramming 2. Formwork
3. Tamping Vibrator
3. Table Vibrator
4. Platform vibrator
5. Surface vibrator
 Compaction of concrete

Rodding Ramming Tamping

 Compaction of concrete

Internal vibrator External vibrator Table vibrator

 Compaction of concrete

Platform vibrator Surface Vibrator

 Curing of concrete
Process of preventing the loss of
moisture from the concrete while
maintaining a satisfactory temperature

Concrete gain strength by hydration

To avoid loss of moisture, curing is
required
Prevents concrete from cracking
Reasons to cure concrete

Gain of strength in concrete

Improved durability of concrete
Improved serviceability
Improvement in
microstructure of concrete
Writing of date of
casting
 Methods of curing

Ponding Sprinkling Wet coverings

Membrane/Plastic sheet Steam Water based

Properties of concrete in hardened
state
1. Strength 8. Modular ratio
2. Stiffness 9. Creep
3. Poisson’s ratio 10.Shrinkage
4. Ductility - X 11.Bond strength
5. Fatigue 12.Durability
6. Impact 13.Malleability - X
7. Elasticity 14.Brittleness
1 Strength
Resistance offered by the concrete for
external loads against failure.
Primary design parameter
Maximum stress developed in the
material at failure
1 Strength

Concrete’s ability to carry the weight or

load
Concrete is strong in
compression, and weak in
tension
Unit = N/mm2
Eg:- M20  fck = 20 N/mm2
Types of concrete strength

Compressive strength
Tensile strength
Shear strength
Bond strength
Impact strength
Fatigue strength
 Factors affecting strength of
concrete
Depending on testing Independent of
methods testing
1. Size of test specimen 1. Type and age of cement
2. Maximum size of aggregate 2. Type of aggregate used
used 3. Degree of compaction
3. Moisture condition of 4. W/c ratio
specimen 5. Aggregate-cement ratio
4. Rate of loading adopted 6. Presence of air voids
5. Type of testing machine used 7. Method of curing
8. Uni-Bi-Tri-axial stress
 Strength of concrete

Note:-
Tensile strength = 10 % X Compressive stress

Bending strength = 15 % X Compressive

strength
Shear strength = 20 % X Compressive
strength
Characteristic compressive strength

Imp property of hardened concrete

Compressive strength is given in
terms of characteristic compressive
strength of 150 mm size cubes tested
at 28 days
Defined as strength of concrete below
which not more than 5 % of test results
are expected to fall [IS 456:2000]
Characteristic compressive strength

Follows NORMAL DISTRIBUTION

Stress - Strain characteristics of
concrete

Max compressive stress =

0.67 x characteristic cube
Design stress-strain curve of
concrete
2 Stiffness

Resistance of concrete member against

deformation
Secondary design parameter
Rigidity of an object
Extent to which concrete resists
deformation
Stiffness =
3 Poisson’s ratio

When a material is stretched in one

direction, it tends to get thinner in
other two directions
Ratio of lateral strain to longitudinal
strain
= =

Normal concrete : 0.15 – 0.20

4 Ductility
Material which can be deformed to thin
wires
Large reduction in area before fracture
Large permanent strains before failure
Related to tension
Example for ductile materials –
mild steel, copper, lead, etc
Concrete should be non-ductile in nature
5 Fatigue

Weakening of materials due to

repeated cyclic loads

If total accumulated strain energy

exceeds toughness = FAILURE

Life of the material decreases

6 Impact

Sudden loading on a material

High force or shock applied

for a short time
7 Elasticity
When a force is applied, material
deforms.
The property of a material to regain
its original shape even after loading
is termed as elasticity.
Concrete is not a perfectly elastic
material
Modulus of elasticity of concrete is
determined by cube test
7 Elasticity

EC = 5000
 7 Elasticity
Modulus of elasticity
= Slope of straight line portion of stress-strain
diagram
Initial tangent modulus
= Slope of modulus drawn from the first tangent

Secant modulus
= Slope of line connecting a specified point to the
origin
Modulus of elasticity commonly used in practice is secant
modulus
 7 Elasticity
Secant modulus
= Slope of line connecting a specified point to the
origin
Modulus of elasticity commonly used in practice is secant
modulus

Chord modulus
= Slope of dotted line is the
chord modulus
8 Modular ratio (m)
Ratio of modulus of elasticity of
steel to that of concrete
= =

m=
9 Creep
Time dependent deformations of
concrete under permanent loads

Permanent deformation with

time at constant loading

Plastic deformation
(Permanent and non-recoverable)
Homologous temp – temperature at which creep is
uncontrollable.
10 Shrinkage
Shortening/contraction of concrete
due to drying (loss of moisture)
Evaporation of water
from concrete mixture
leads to loss of moisture.
11 Bond strength
Strength between rebar and
concrete
Ensures no slip of steel bar from
concrete
Develops primarily due to friction and
adhesion b/w rebar and concrete
In general, bond strength proportional
to compressive strength
12 Durability
Resistance to deterioration
Time for which the structure can
fulfil its desired objectives
Ability to withstand the damaging
effects over a long time
Factors affecting durability
Permeabilit
y
Frost action, Thermal effects on
concrete
Sulphate attack, Cracks
Mineral oils
Organic acids
Vegetables & animal oils and
fats
Sugar
Sewage
13 Malleability
Property by which material is made
into thin sheets or plates
Related to compression
Plastic deformations
All ductile materials are malleable
with same properties
Concrete is not malleable, but steel is
14 Brittleness
Materials which fails suddenly
Opposite of plasticity
Breaks before it deforms
High in compressive strength and
low in tensile strength
NOTE: Concrete is brittle
Testing of Hardened Concrete

Compression test (cube & cylinder)

Flexural strength test

Flexural strength test

1 Compression test
To determine compressive strength of
concrete
M20  20 N/mm2
Cube test
Cylinder test
1 Compression test - cube
3 cubes – 15 X 15 X 15 cm
Mould removal – after 1 day
Curing – 3, 7, 28 days
Tested using UTM/CTM
1 Compression test - cube

Compressive stress =

axa
2 Compression test - Cylinders
3 cylinders – dia= 30 cm, 60 cm
Mould removal – after 1 day
Curing – 3, 7, 28 days
Tested using UTM/CTM
2 Compression test - Cylinders

Compressive stress =

2
𝐴=𝜋𝑟
Comparison – cube and cylinder
test
3 Flexural strength test
Beam mould: 15 X 15 X 70 cm
Tamping bar
Flexural testing machine
Loading rate = 400 kg/min
 3 Flexural strength test
Flexural strength or modulus of rupture (fb)

fb =
when a > 20 cm

fb = when a < 20 cm and a > 17 cm

a = distance b/w line of fracture and the nearer

support
4 Split tensile strength test
To determine tensile strength of
concrete
Diameter = 15 cm
Height = 30 cm
Tested using UTM
4 Split tensile strength test
1. Draw diametrical lines on two ends
2. Note weight and dimension of specimen
3. UTM  Plywood strips on either sides
4. Align the specimen
5. Apply load (Rate = 14 - 21 kg/cm2/minute)
6. Note breaking load
4 Split tensile strength test

As per IS 456,
Split tensile strength of concrete = 0.7 fck

Split tensile strength =

6015 – Concrete
Technology
 Concrete Mix

Nominal Mix Design Mix

Mixes of fixed proportions Designed on the

basis of
IS 456:2000 permits
requirements of
M20 and lower
concrete in fresh
and hardened
states.
 Nominal Mix
Specifies the proportion of the
cement , sand and aggregates without
making special effort to know their
individual properties
Nominal mix has Volumetric batching.
Eg:- M15 1:2:4
M20 1:1.5:3
Is a random method, not a scientific
method
 Nominal Mix: an ART
RCC slab  M20 = 1:1.5:3
What is the source of the sand? Actually we don’t
What is its fineness modulus know about these
things
( FM )?
We are taking a value
how much is the silt content? based on our
what is the particle size? experience and tests
results taken at a later
Crushing value of aggregates? stage
Flakiness index ?
OPC or PPC? 33 / 43 / 53 grade?
Setting times? Consistency?
 Design Mix: a SCIENCE
Each and every ingredient of the
concrete is first tested in the
laboratory.
Design mix has Weigh batching.
For design mixes we specify standards:
1. Sources , quarries , brands and grades
for each and every constituent.
2. Conducts lab test before
mixing to
find out the attributes in detail.
 Concrete Mix Design
Definition

Mix Design is the art and science of

determining the relative proportions of
the ingredients of concrete to achieve
the desired properties in the most
economical way.
 Purpose of Mix Design
To find a good / optimized combination
of ingredients for concrete mix
Should satisfy the required
specifications
 Durability requirements to resist environmental
situations
 Workability – Mixing, placing, compacting and
It should
finishingbe economical
 Complies with specifications of structural strength
Not a pure science, is an ART too.
Purpose of Mix Design

(Page 1, IS 10262:2009)
References from various IS codes
 Principles of Mix Design (Design
requirements)
1. Grade of concrete
2. Type of cement
3. Type and Size of aggregates
4. Nominal maximum size aggregate (m.s.a)
5. Max/Min cement content (kg/m3)
6. Type of water mixing and curing
7. Max w/c ratio Selected
8. Degree of workability appropriately
9. Air content (Entrapped air content not taken in IS 10262:2009)
10.Type of admixtures used
11.Max/Min density of concrete
12.Max/Min temperature of fresh concrete
13.Environmental exposure conditions
Methods of proportioning
1. IS Method
2. ACI Method
3. Road Note-4 Method
4. IRC-44 method
5. Arbitrary method
6. Max density method
7. Fineness modulus method
8. Surface area method
9. Mix design for high strength
concrete
10.DOE mix design method
 Common Terminologies
(1) Mean
strength:
Mean strength () =

=
 Common Terminologies
(2) Variance
Difference between any single observed
data from the mean strength

Variance () =

Deviation from mean value.

 Common Terminologies
(3) Standard
deviation
 Common Terminologies
(4) Coefficient of variation

Coefficient of variation () =

= 𝐱 𝟏𝟎𝟎
 Mix Design – IS METHOD

First : IS 10262:82
Previous : IS 10262:2000
Latest : IS 10262:2009
a) Grade designation

M20
M  Mix

20  fck = 20 MPa

Based on type of structure

(IS 10262:2009, P-3)

(IS 456:2000, P-23)
 b) Type of cement
OPC 33, 43, 53 grades
OPC – Ordinary Portland Cement
33, 43, 53 – Compressive strengths in MPa or N/mm2
at 28 days

53 grades – most commonly used for structural concrete

b) Type of cement

(Page 13, IS 456:2000)

c) Max nominal size of
aggregate

(Cl 5.3.3, IS 456:2000, P-14)

c) Max nominal size of
aggregate
20 mm for residential buildings

If exceeds 20 mm, the volume of CA to FA will be

increased. Thereby leading to poor strength and
durability

Lot of voids  Water enters

d) Minimum cement content

(Table 5, IS 456:2000)
e) Maximum water cement
ratio

(Table 5, IS 456:2000)
f) Workability
g) Exposure condition
h) Method of concrete placing

• CARE
• Setting time
• Grade of concrete increases  cement
content increases setting time
reduces
• Reinforcement
• Segregation
• Can be pumpable
i) Degree of supervision
Good

[Cl 13.6, IS 456:2000, P-27]

j) Type of aggregate

[IS 383:1970, P-5]

k) Minimum cement content

[Table 5, IS 456:2000]
 DATA FOR MIX
A-
1
PROPORTIONING
STIPULATIONS FOR PROPORTIONING
a) Grade designation M 40
OPC 43 Grade conforming to IS
b) Type of cement 8112
Max nominal size of
20 mm
c) aggregates
d) Minimum cement content 320 kg/m3
e) Maximum water cement ratio 0.45
(Slum
100 mm
f) Workability p)
g) Exposure condition Severe
h) Method of concrete placing Pumping
i) Degree of supervision Good
j) Type of aggregate Crushed angular aggregate
k) Maximum cement content 450
Superplasticiz
 DATA FOR MIX
A-
2
PROPORTIONING
TEST DATA FOR MATERIALS
a) Cement used OPC 43 Grade
b) Specific gravity of cement 3.15
Superplasticiz
Chemical admixture er
c) 7 kg/m3
d) Specific gravity of :
1) Coarse aggregates 2.74
2) Fine aggregate 2.74
e) Water absorption
1) Coarse aggregates 0.5%
2) Fine aggregate 1%
f) Free (Surface) moisture
1) Coarse aggregates Nil
2) Fine aggregate Nil
 DATA FOR MIX
g)
PROPORTIONING
Sieve analysis:
1) Coarse aggregates

Analysis of coarse
Percentage of different
aggregate fraction (Percent
IS sieve fractions
passing) Combined
sizes mm
I II I II
20 mm 10 mm 50% 50%
40 100 100 50 50 100
20 97.8 100 48.9 50 98.9
10 1.6 79.3 0.8 39.65 40.45
4.75 9.8 0 4.9 4.9
 DATA FOR MIX
PROPORTIONING
2) Fine aggregate

IS sieve Percent passing by

size mm weight, W

10 100
4.75 97.3
2.36 86.8
1.18 65.7
0.6 23.3
0.3 11.9
0.15 3.1

Fineness Modulus 3.88

a) Cement used
Cl 5.1, IS 456:2000, P-13

Check on cement bag

b) Specific gravity of cement

3.15

Specific gravity bottle

c) Chemical admixture
Superplasticizer
Note down amount used: 7 kg/m3
d) Specific gravity of
aggregates
Ranges from 2.5 to 3.0
Higher specific gravity Higher strength
e) Water absorption

IS : 2386 ( Part III ) - 1963

Ranges from 0.1 – 0.2 %
f) Free surface moisture
Fine and coarse aggregates should
Nil be free from surface moisture
content
Saturated Surface Dry (SSD) Condition:
Means water internally absorbed is there, but the surface is
dry.

Total water = Water absorbed by aggregate + free water available

for mixing
g) Sieve analysis
Coarse aggregates: Conforming to Table 2 of IS 383
g) Sieve analysis
Fine aggregates:
(Zone I preferred)
Conforming to Table 4 of IS 383
g) Sieve analysis
Fine aggregates:
Conforming to grading zone I of Table 4, IS 456:2000
2) Fine aggregate

IS sieve Percent passing by

size mm weight

10
4.75
100
97.3 𝐹𝑀 =
∑ 𝑊
2.36 86.8 100
1.18 65.7
0.6 23.3
0.3 11.9
0.15 3.1

Fineness Modulus 3.88

CALCULATIONS FOR MIX
DESIGN
A-3 TARGET MEAN STRENGTH ()

= fck + 1.65 S
S – standard deviation

(For accurate values, from site data, 30

cubes are tested and their standard
deviation is found. In India values in
Table 1 can be used.)

(Table 1, IS 10262:2009, page – 2)

CALCULATIONS FOR MIX
DESIGN
A-4 SELECTION OF WATER-CEMENT
RATIO
Selected based on
Test graph
ABCDEF curve
IS 456, Table 5

(Cl 4.1, IS 10262:2009, page – 2)

CALCULATIONS FOR MIX
DESIGN
A-4 SELECTION OF WATER-CEMENT
RATIO
ABCDEF curve

Deleted this method from IS 10262:2000

onwards
CALCULATIONS FOR MIX
DESIGN
A-4 SELECTION OF WATER-CEMENT
RATIO

(Table 5, IS 456:2000)
CALCULATIONS FOR MIX
DESIGN
A-5 SELECTION OF WATER CONTENT

For 20 mm sized
aggregates, maximum
water content is taken as
186 kg

(Table 2, IS 10262:2009, P-3)

CALCULATIONS FOR MIX
DESIGN
A-5 SELECTION OF WATER CONTENT

(Cl 4.2, IS 10262:2009, page – 2)

CALCULATIONS FOR MIX
DESIGN
A-5 SELECTION OF WATER CONTENT

If using admixtures,

(Cl 4.2, IS 10262:2009, page – 2,3)

CALCULATIONS FOR MIX
DESIGN
A-6 CALCULATION OF CEMENT
CONTENT
𝐖𝐚𝐭𝐞𝐫
= 𝐰 / 𝐜𝐫𝐚𝐭𝐢𝐨
𝐂𝐞𝐦𝐞𝐭
Water
Cement=
𝑤 /𝑐𝑎ratio

Calculated value should be b/w minimum

cement content specified in Table 5 of IS
456:2000
CALCULATIONS FOR MIX
DESIGN
A-6 CALCULATION OF CEMENT
CONTENT

(Table 2, IS 10262:2009, P-3)

CALCULATIONS FOR MIX
DESIGN
A-7 PROPORTION OF VOLUME OF CA AND FA CONTENT

If water cement ratio is

not 0.5, adjust as
0.01 for every ± 0.05
change in water-cement
ratio
CALCULATIONS FOR MIX
DESIGN
A-7 PROPORTION OF VOLUME OF CA AND FA CONTENT

(Table 3, IS 10262:2009, P-3)

 Mix Design – Problem - 1
Problem - 1
MIX PROPORTIONING
M 25

moderate
MIX PROPORTIONING
MIX PROPORTIONING
 MIX PROPORTIONING

= fck + 1.65 S
= 25 + 1.65 x 4
= 31.6 N/mm2
MIX PROPORTIONING

0.5

If question provides water

cement ratio, use it. Else
assume suitably.
MIX PROPORTIONING
 CAUTION:
If slump given is 75 mm, use 3
100 mm  6
125 mm  9
150 mm  12
MIX PROPORTIONING
MIX PROPORTIONING

300
moderate
MIX PROPORTIONING
MIX PROPORTIONING

w/c ratio Vol of CA

0.50 0.60
0.45 0.61
0.40 0.62
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING

1103
MIX PROPORTIONING

849
1103

350 849 1103

350 350 350

1 : 2.42 : 3.15
Mix Design : Problem - 2
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING
 MIX PROPORTIONING

= fck + 1.65 S
= 30 + 1.65 x 5
= 38.25 N/mm2
MIX PROPORTIONING

If question provides water

cement ratio, use it. Else
assume suitably.
MIX PROPORTIONING
 CAUTION:
If slump given is 75 mm, use 3
If slump given is 100 mm, use 6
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING

FA : Zone II
w/c ratio Vol of CA
0.50 0.62
0.45 0.63
0.40 0.64
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING

852
1158

350 852 1158

350 350 350

1 : 2.4 : 3.3
 Mix Design : Problem - 3
Grade of concrete: M 25
Type of exposure: Moderate
Slump: 150 – 175 mm
Max size of CA : 20 mm
Fine aggregate: Zone III
Sp.gravity of cement: 2.93
Sp.gravity of water: 1
Sp.gravity of admixture: 1.21
Sp.gravity of CA: 2.82
Sp.gravity of FA: 2.65
Water absorption of CA: 0.86 %
Water absorption of FA: 1.25 %
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING
 MIX PROPORTIONING

Note: 1.65 is tolerance factor

= fck + 1.65 S (IS 10262:2009, P-3)

= 25 + 1.65 x 4 (IS 456:2000, P-23)

= 31.6 N/mm2
 MIX PROPORTIONING
Water cement ratio depends on exposure condition (Moderate)

w/c ratio = 0.45

MIX PROPORTIONING
 CAUTION:
As per IS 10262:2009, Clause 4.2, we can
increase 3 % for every additional 25 mm
slump
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING
MIX PROPORTIONING

758.82 kg/m3
1138.29 kg/m3

380 758 1138

380 380 380

1 : 1.99 : 2.99
Mix Design: Problem - 4
= fck + 1.65 S
= 35 + 1.65 x 5
= 43.25 N/mm2
849
1113

385 849 1113

385 385 385

1 : 2.2 : 2.9
6015 – Concrete
Technology
 Special Concrete
Concrete prepared for
specific/special purpose

Eg:-
► Light weight concrete
► High density concrete
► Fire protection
► Radiation shielding
 Comparison – Ordinary and special
concrete
Characteristics Ordinary concrete Special Concrete (LW)
2200 – 2600 kg/m3
Density 300 - 1850 kg/m3 Low
High
Self weight High Less
Haulage and
High Less
handling cost
Thermal
High Low
conductivity
Building, bridges, Nuclear reactor, acoustic
Uses
etc buildings
CA+FA+C+W+ LW
Ingredients CA+FA+C+W
aggregates
Cost Economical Costly
Classifications/ types of special
concrete
1. Light weight concrete
2. Air entrained concrete
3. High Strength concrete
4. High performance concrete
5. Polymer concrete
6. Geo Polymer concrete
7. Steel fibre reinforced Concrete
8. Sulphur concrete
9. Self compacting concrete
10. No-fines concrete
11. Pre-packed concrete
12. Guniting or shotcreting
1 Light weight concrete
Making concrete light weight by
inclusion of air in concrete
Three ways:
1. Replace aggregate with cellular porous/LWA
Light weight aggregate concrete
2. Introduce gas/air bubbles in concrete
Aerated concrete
3. By omitting sand fraction from aggregates
No fines concrete
1 Light weight concrete

Natural LWA Artificial

Pumice
LWA
Brick bats
Diatomite Cinder
Volcanic cinders Clinker
Saw dust Artificial cinders
Rice husk Themocole beads
Sintered flyash
Foamed clay
Advantages of light weight concrete

Reduction of self weight (Dead Load)

Less haulage and handling costs
Low thermal conductivity – Comfort – A/C
Smaller section of structural members can
taken
Increase in the progress of work
Good fire resistance
Overall economy
2 Air entrained concrete
• Also called as Aerated concrete, gas concrete
• By introducing gas/air bubbles into a slurry
• Density 300-800 kg/m3.
• Self weight is reduced

Applications:

1. Insulation purposes
2. Building blocks for load bearing walls
3. Pre fabricated structures
3 High Strength concrete
• Have higher compressive strength
• High cement content, less w/c ratio

• Methods:
1. Seeding
2. Revibration
3. Using admixtures
4. Sulphur impregnation

• Applications
 Used mainly in pre-stressed concrete
 High rise buildings, long span bridges
4 High performance concrete
• Engineered concrete
• Careful selection and proportioning of constituents
• Same ingredients, but different MICROSTRUCTURE
• Low w/c ratio  High density  Dense
microstructure  Makes migration of aggressive
ions more difficult  Durability increases
• Good dimensional stability
• Self desiccation (Capillary drying)
 HPC HSC
High Performance Concrete High Strength Concrete
high abrasion resistance Strength 70 MPa or more
Good compaction without A high-strength concrete is always
segregation a high-performance concrete, but
a high-performance concrete is not
always a high-strength concrete.
Sensitive to changes in constituent Where architectural considerations
material are required.
High cementitious content and a Early high strength
water-cementitious material ratio
of 0.40 or less
Ease of placement and Toughness is good
consolidation without affecting
strength 320
 5 Polymer concrete
• Concrete containing polymers

Concrete + Polymer Polymer concrete

Why Polymer concrete?

• Different drawbacks of concrete are
eliminated
• Reducing the drawbacks of ordinary concrete
• Alternative to conventional concrete
• Reduce green house effect
• Reduce energy consumption
• COMPRESSIVE STRENGTH
• Tensile strength
• Impermeability
• Chemical resistance Favorable
• Initial strength
• Good adhesion

• THERMAL CHARACTERISTICS
• Creep
• Continuous loading Unfavorable
• Cost
Precast works Floor and pavements

Channel sections
 Types of
Polymer
concrete

Polymer
Polymer Portland
Impregnated Geo polymer
Cement Concrete
Concrete concrete
(PPCC)
(PIC)
6 Polymer Impregnated Concrete
(PIC)
Impregnating a hardened Portland
cement concrete with a monomer
1. Methyl
Methacrylate
2. Styrene
3. T-Butyl styrene
4. Epoxy
Polymerize the monomer in site.
Improves durability
Improves surface resistance
7 Polymer Portland Cement Concrete
(PPCC)
Replacing a part of mixing water with
LATEX
Latex means polymer emulsion

Precast water tanks

8 Geo Polymer concrete
Made from flyash and alkaline solution
Converts waste products to useful
product
Curing temperature is b/w 600-900 C
Reduce CO2 emissions  Less green house
gas
High fire resistance
High compressive strength
Greater corrosion resistance
13 Pre-packed concrete
Concrete produced by placing coarse
aggregate in a form and later injecting a
portland cement-sand grout, usually with
admixtures, to fill the voids.
13 Pre-packed concrete

Place coarse aggregate only in the form and

thoroughly compacting it to form a prepacked
mass

This prepacked mass is grouted with

cement mortar of required proportions.
13 Pre-packed concrete
Also called as GROUTED CONCRETE
Special technique of placing concrete under
water
when the tremie method or bottom dump method are not
feasible
This prepacked mass is grouted with
cement mortar of required proportions.
Used where reinforcement is complicated
☼ Mass concreting
☼ Piers
☼ Pipes and conduits
14 Guniting or shotcreting

Gunite – mortar conveyed through a hose and

pumped with a high velocity to the surface

Force of the jet impacting on the surface

compact the material

Eg: Rediset cement

 Concrete under special conditions

1.Underground and underwater

concreting
2.Concreting in cold weather
3.Concreting in hot weather
4.Mass concreting
5.Concreting in marine environment
1 Underground and underwater
concreting
• Placing concrete under water
• Special precautions should be selected
• Slump = 15 – 18 cm

Methods:
1. Tremie method
2. Bucket placing
3. Placing in bags
4. Pre-packed concrete
5. Placing in dewatered caissons
Requirements

• Workability and self compaction

• Cohesion about washout and segregation
• Low heat of hydration
• Controlled set time
• Sufficient compressive strength
• Adequate bond strength
 1. Tremie Method
• Tremie is a water tight pipe – 250 mm dia
• One end of formwork(or pipe) below water and
other end above water
• Funnel shape at top and loose plug at bottom
• Supported on a working platform above water
level.
• Concrete is poured from top to bottom through
this pipe with help of gravity
335
• Before concreting air and water must be excluded
336
337
 2. Bucket Placing

• Large quantity of STIFF/HARD concrete filled in

bucket
• Bucket is lowered to required depth using crane
• Top of bucket is suitably covered to avoid
disturbances
• The bucket is opened by divers or suitable
arrangement from the top
• Early discharge of concrete should be prevented,
338
so as to avoid entry of water into it.
339
 3. Placing in bags
• Concrete is filled in gunny/cotton bags
• Lowered into water and placed carefully in a
header and stretcher fashion by divers.
• Slow and laborious
• Accurate placing is difficult
• Expensive
• For shallow waters only

340
 4. Pre-packed concrete

• Aggregate is wetted before placing in position

• Consist of placing the coarse aggregate only in the
forms and thoroughly compacting it to form a pre-
packed mass.
• Grouted with cement mortar with required
proportions
• Max size of aggregate = 80 mm

341
2 Concreting in cold weather

• Small cracks  water enters  become ice  volume

increases  concrete cracks
• Temperature to be maintained = 50C
• Effects
1. Delayed setting
2. Freezing of concrete at early age
3. Freezing and thawing
4. Temperature stresses

342
Recommended practices and precautions

1. Selection of suitable type of cement

2. Temperature control of ingredients
3. Electrical heating of concrete mass
4. Use of insulating formwork
5. Admixtures of anti-freezing materials
6. Use of air entraining agents
7. Delayed removal of form work
8. Placing and curing of concrete
343
3 Concreting in Hot weather

• Temperature >400C
• Desert, tropical countries
• Effects:
1. Rapid rate of hydration
2. Rapid evaporation of mixing
water
3. Rapid evaporation during curing
4. Air-entrainment
5. Increased tendency of cracking
Recommended practices and precautions

1. Cooling of aggregates
2. Mixing water
3. Production of delivery

345
4 Mass concreting
Mass concrete
Associated with large structures
like dams, piers, etc
American Concrete Institute definition:
“Any volume of concrete in which a combination of
dimensions of the member being cast, the boundary
conditions, the characteristics of the concrete
mixture, and the ambient conditions can lead to
undesirable thermal stresses, cracking, deleterious
chemical reactions, or reduction in the long-term
strength as a result of elevated concrete
temperature due to heat from hydration.” (ACI
207.1R).
Idukki Dam
Temperature control is necessary
Concrete is thermally very poor
conductor
Unequal thermal expansion occurs
Tensile stresses are induced
Cracks develops at the surface
Loss of structural intergrity
Loss in monolithic action
Excessive shrinkage
Aesthetically objectionable
Methods to control temperature

1. Use of low heat materials

2. Pre-cooling of concrete
3. Post-cooling of concrete
4. Surface insulation

348
5 Concreting in marine environment
Offshore structures
- Sea (Petroleum related)
- Coastal area
Sea walls
Jetties
Groins
Breakwaters
Bulkheads
High risk of rapid deterioration
Subjected to physical & chemical deteriorations
processes.
Risk of corrosion of steel bars

Around 10 km from coastal areas need

to consider the marine effect – wind.
Recommended practices and precautions

Proper mix proportions

Selection of proper cement
Optimum concrete and proper
compaction
Galvanising steel bars
Selection of water-cement ratio
Use of non-reactive aggregates
Air entraining agents can reduce
deterioration
Different Zones:
Concrete continuously exposed to tides, water
and chemical environments

Marine environment

Submerge Splash Abdove

Tidal Zone
d Zone Zone Ground Zone
 Common defects in concrete

1. Permeability
2. Freezing and Thawing
3. Sulphate attack
4. Carbonation
5. Creep & Shrinkage
6. Leaching
7. Corrosion of
reinforcement
1. Permeability

Penetration of water into concrete

(Capillary)
Volume increases  cracks  Disintegrates
To prevent permeability, use low w/c ratio
Pozzolanic materials  fill capillarities
 reduce permeability
2. Freezing and thawing

Occurs if concrete is critically saturated (about 91

%)
When water freezes to ice, it occupies 9 % more
volume than that of water
As the season passes, concrete goes through
repeated process of freezing and melting.
Due to this repeated action of ice and water,
concrete deteriorates

This can be prevented by using suitable air

entrainments and admixtures.
3. Sulphate attack

Common in industrial situations

Sulphates
Ca, Na, K, Mg,
Ammonia
Less soluble
Agricultural soil (fertilizer – NPK)
Max damage

MgSO4  Serious damage to concrete

Whitish appearance is an indication of sulphate
attack
Sulphate attack can be external or internal

External – high sulphate soils, ground waters, etc

Internal – presence of gypsum, admixtures contain

sulphates
 Organic soil in decay Bacterial
marshy land H2S action H2SO4

Sulphates reacts with hydrated cement products

 Volume increases (227 %)
 Cracks  deterioration

Ca(OH)2 + Na2SO4.10 H2O  CaSO4.2H2O + 2NaOH + 8 H20

As sulphate dries, new compound named ETTRINGITE is

formed
ETTRINGITE – Calcium Sulphoaluminate hydrate
4. Carbonation

Main reason for corrosion of reinforcement

CO2 Ca(OH)2 CaCO3

CO2 Ca(OH)2
+ Moisture Carbonic acid

Shrinkage occurs
Rate of carbonation
Depends on

Level of pore water / moisture

Grade of concrete
Permeability of concrete
Whether concrete is protected or not
Depth of cover
Time
5. Creep and Shrinkage: Creep

Time dependent deformations of

concrete under permanent loads

Permanent deformation with

time at constant loading

Plastic deformation
(Permanent and non-recoverable)
Homologous temp – temperature at which creep is
uncontrollable.
5. Creep and Shrinkage: Shrinkage

Shortening/contraction of concrete
due to drying (loss of moisture)
Evaporation of water
from concrete mixture
leads to loss of moisture.
6. Leaching (Acid attack)

Strong acids damages stone. Eg:- H2SO4,

Acids
HNO3 reacts with Ca(OH)2 and C-S-H
Weathering of (Leaching)
edges
gel

H2SO4 Ca(OH)2 CaSO4

Salt  Crystallisation
Deteriorates
C-S-H gel

If pH < 4.5  Severe acid attack

7. Corrosion of reinforcements

Dampness  corrosion  Cracks

Encase the reinforcement bars with

dense cement mortar
Provide sufficient clear cover
Thank You
- Shamjith Km