Quality Control for Construction

Works – Challenges & Solutions

Dr K. Balasubramanian

Managing Director,
Hitech Concrete Solutions Chennai Pvt Ltd
 Outline
• Fundamentals of Concrete Technology
• Cracking
• Batching & Pumping
• Superplasticisers
• General Site Related Issues
• Lessons learnt & NCs at Site
INTRODUCTION…

Quality issues are a very disturbing event for a civil engineer.

It was almost non-existent in the past. Structures were
known for their durability, soundness and stability. They
were expected to be permanent. In this context, owners and
engineers are now alarmed by quality issues which have
become more common than one can anticipate.

Modern materials are said to have better quality and of

substantially increased strength. There is also an improved
understanding of structural analysis backed by sophisticated
design technology. These advances in technology, should
have produced better and more durable structures.
Unfortunately it is not so.
How Durable should Concrete be?

Do we want our concrete to last

2000 years or 20 years?
Concrete Technology
• Entire concrete technology boils down to the
following four
➢ Curing
➢Compaction
➢Cover Block
➢ Water
Site Related Issues
Plastic Shrinkage Cracks
Plastic Shrinkage Cracks
Causes
• Temperature
• Humidity
• Wind Velocity

Rate of evaporation of water

˃
Rate at which bleed water comes to the surface
Remedy for Plastic Shrinkage
Cracks
• Floating
• Sprinkling with water after approximately
30 minutes
Plastic Settlement Cracks
Flooring Cracks
Batching and Pumping
• As per 4926 (RMC code) , concrete should be
placed within 2 hours from the time cement
comes in contact with water at the Batching
Plant
• General retention time for SNF based
admixtures – 1 and half to 2 hours
• General retention time for PCE based
admixtures – 3 hours
Admixtures

• Chemical

• Mineral
Chemical Admixtures

➢Superplasticiser (Water Reducing)

➢Retarder

➢Accelerator
Superplasticiser
Normal slump concrete with no Superplasticiser
Concrete with Superplasticiser
The Concept of Superplasticiser /Water Reducer
M25 Concrete Grade
Water / Water cement Slump at Plant
Cement ratio

200/ 400 0.50 160mm

190/ 380 0.50 140mm

180/ 360 0.50 120mm

170/ 340 0.50 80mm SP 160

How Superplasticiser works?

➢ Long molecules in the Superplasticiser wrap

themselves around the smaller cement particles

➢ Gives it a highly negative electrostatic charge

➢ Cement particles deflocculate / get separated from

each other

➢ Entrapped water is released

➢ Workability is improved
 Types of Admixtures
Type Water Reduction Free water
Content
Lignosulphate

Modified
Lignosulphate
Melamine (Cold
Countries)
SNF 15- 20 % 160 - 170

PCE 30 – 35 % 130 - 140

• The grade of concrete for the PSC girders
was 50 MPa and the target strength to be
achieved was 63 MPa as per the MORTH
specifications.
• The cement content used in the design mix
for the above characteristic strength of
50 MPa was 450 kg/m3 and the water
cement ratio was 0.31.
• The water content for the above mix was
140 kg/m3.
• It was informed by the site engineers that SNF
based admixture was used in the casting of
the PSC girders for the above design mix.
• Generally, SNF based admixtures have a water
reduction capacity of 15% to 20 %.
• In the casting of the PSC girders, an admixture
with a water reduction capacity of 30%, viz., a
Polycarboxilic Ether (PCE) should have been
used to cater to a water content of 140 kg/m3.
• However, a water reducing admixture of SNF
based with a water reduction capacity of 15%
to 20% had been used in the casting of the 5
PSC girders.
• This would have led to a reduced workability
leading to the addition of water during the
concreting to increase the workability/slump
for facilitating the pumping of the concrete.
• This in turn had resulted in a higher water
cement ratio and the consequent reduction in
the strength.
• Hence, in view of the reduced strengths, the
Post tensioning operation had resulted in the
cracking and spalling of concrete in the
anchorage/end zone
Moisture Correction
An illustration for an M30 Grade Concrete

Content Normal Season Rainy Season

(3 % Moisture) (5 – 8 % Moisture)

Cement 380 380

Sand 700 700 x 5/100 = 35 kgs
Aggregate 1100 1100
Water 170 170 + 35 = 205
W/C ratio 0.45 205/ 380 = 0.54

Total water = Free water + absorption in coarse aggregate +

absorption in sand – Moisture Content in sand
 Other site related issues

• Age of cement
• Cubes
• Vibration
• BOQ/Technical Specifications
• Site Drawings
Other Site Related Issues (Contd)

• Illogical results
• Reading a batch sheet
• Sudden drop in the slump
• Design mix from external
agencies
 Lessons Learnt
• Retention of workability – A parameter not given
due consideration
• Redosing of admixture on site
• Specific gravity of the constituent materials-
Likely to affect the yield of concrete
• Moisture correction to be carried out from the
bin and not from the heap - for low water content
mixes
• Sequence of mixing – Particularly when Silica
fume and PCE based admixture are involved
 Why
Temperature Controlled Concrete
• When the difference between core concrete
temperature and the ambient temperature is
greater than 20 D Celsius, micro cracks occur-
common examples being raft and thick
elements
• Use of chilled water, ice and fly ash/slag will
reduce the temperature of concrete
 Restrained Shrinkage Cracks
• Normally happens in retaining walls, when the
wall is cast for longer lengths
• Restrict the casting length to approximately 18
m and leave a shutter or 2 shutter gap
Mineral Admixture

➢ Fly Ash

➢GGBS/ Slag

➢Silica Fume
Why Mineral Admixtures

➢Reduces the heat of hydration

➢Improves the workability

➢Improves the Durability

Reduced heat of Hydration

➢ Fly ash does not hydrate for the first 5 – 7 Days

resulting in lower heat of hydration

➢ Marginal reduction in strength

Durability Improvement

CSH Strong (60%)

C + Water
Ca (OH)2 (20%)

pH 12.5 6 – 8% Ca(OH)
2

Fly ash + Ca(OH) = CSH

2
Cost Effectiveness
✓ Normal Concrete M25 170/340 = 0.5

✓ Fly ash Concrete M25 170/(175 + 175) = 0.48

✓ 340 kg Cement @ 7 Rs per kg= Rs 2380

✓ Cost of 175 kg cement and 175 kg of Slag @

3.50 Rs per kg = Rs 175 x 7 + 175 x 3.5 = 1840

✓ Overall savings in a m3 of Concrete = Rs 500

Cost Effectiveness

✓Normal Concrete M25 170/340 = 0.5

✓Fly ash Concrete M25 170/(300 +60) = 0.47
✓40 kg cement savings = Rs 280
✓Cost of 60 Kg fly ash = Rs 90
✓Overall savings in a m3 of Concrete = Rs 190
 Conclusions

The fundamental things to learn

are Principles on which
Concrete Technology is based
We must avoid errors of the past in
which students were taught already
outdated factual information and, so
equipped, went forth to inhibit
future development beyond the
narrow confines of the little they
knew
It is not possible for any individual
to know even 10% of the total
available knowledge about
concrete
But it is possible to learn how to
function as a forward-looking,
receptive, and contributing
member of the concrete
fraternity
Significance for Education in
Concrete Technology

Need for flexibility – cannot teach

ability to invent but must not stand in
way

New developments as likely to come

from chemists, geologists, IT analysts
etc, as from concrete technologists
 Significance for Education in
Concrete Technology
Practitioners as well as students must
learn how to keep up to date
Continued Professional Development certainly required

A qualification in structural
design is an inadequate basis for
specification and control
Significance for Education in
Concrete Technology

ill-informed specifiers have held back

progress for decades

There will be a legal requirement for

an appropriate qualification before
being allowed to specify or control
concrete
Thank You
Additional Slides
What is curing?
• Curing is the process of preventing the loss of
moisture from the concrete whilst maintaining
a satisfactory temperature regime.

• As per IS 456:2000, concrete shall be cured for

at least 7 days from the date of placing
concrete in case of ordinary Portland cement
and at least 10 days where mineral admixtures
or blended cements are used.
What is Consolidation / Compaction of concrete?

➢ Freshly placed unconsolidated concrete

contains excessive and detrimental entrapped
air
➢ The purpose of compaction of concrete is to
remove entrapped air and eliminate all types of
voids
➢ Elimination of entrapped air voids increases the
strength of concrete. The strength is increased
about 5% for every 1% of entrapped air removed
during compaction
Poor Concreting in a TG Deck in a Thermal
Power Station
Poor concrete Surface in a Chimney in a Thermal Power
Station
Concrete Core extracted from chimney
How Concrete Gains Strength?

CSH Strong (60%)

C + Water
Ca (OH)2 (20%)

pH 12.5 to 13.5 (Alkalinity)

Why cover is provided to the reinforcement?

• Cover blocks are provided to protect the

reinforcement from corrosion and fire.

• Corrosion of reinforcement takes place due to

diffusion of carbon di oxide and chlorides into
concrete, which break the passive layer in the
reinforcement steel.

• Quality of concrete in the cover region ultimately

decides the durability and the service life of the
structure.
Causes for Depassivation

➢ Carbon dioxide

➢ Chlorides
CORROSION OF STEEL IN CONCRETE - CARBONATION

• Carbon dioxide diffuses into concrete through pore

system & forms mild acids.
• Reduction of pH
•Alkalinity reduced to less than pH 10
•Passive layer on steel lost when pH drops below 10
•Steel gets exposed to corrosion
 CORROSION OF STEEL IN CONCRETE CARBONATION

Step 1 Carbon dioxide Step 2 Carbon dioxide

passive oxide
layer
steel steel
concrete concrete

Step 3 Step 4 Carbon dioxide

Carbon dioxide

Passive
layer Lost corrosion
steel
steel
concrete
concrete
CARBONATION TIME (YEARS) FOR VARIOUS DEPTHS OF
COVER AND W/C RATIOS

Ordinary Portland Cement (no additives), aggregate

type, sand and gravel
Cover (mm)
w/c 5 10 15 20 25 30
ratio
0.45 19 75 100+ 100+ 100+ 100+

0.50 6 25 56 99 100+ 100+

0.55 3 12 27 49 76 100+

0.60 1.8 7 16 29 45 65

0.65 1.5 6 13 23 36 52

0.70 1.2 3 11 19 30 43
 CORROSION OF STEEL IN CONCRETE - CHLORIDE ATTACK

▪ Chlorides break down passive film when they reach steel

▪ Sets up alternate anodes and cathodes forming Corrosion

Cells

▪ Concrete acts as an electrolyte

▪ Causes pitting corrosion

STEEL IN CONCRETE- CHLORIDE ATTACK
C Cl- Cl-
Cl- Cl -
l - Cl-
Cl-
- Cl-
Cl- CHLORIDE ATTACK

Cl- - Cl-
Cl - Cl Cl-
Cl- Cl -
LOSS OF PASSIVE LAYER Cl- Cl-
-
Cl- Cl Cl-
 CORROSION OF STEEL IN CONCRETE
Cl- Cl- Cl- Cl-
Cl-
Cl- Cl- Cl-
Cl-
Cl- Cl- Cl-

anode cathode

Corrosion of steel

Fe Fe++ + 2e- (Anodic Reaction)

cracking/spalling
4e- + O2 + 2 H2O 4 (OH)- (Cathodic Reaction) Cl- Cl- Cl- Cl-
Cl-
Cl- Cl- Cl-
Cl-
Fe++ + 2(OH)- Fe(OH)2 (Ferrous hydroxide) Cl- Cl- Cl-

4Fe(OH)2 + 2H2O+O2 4Fe(OH)3 (ferric

hydroxide)
 Table 5 Minimum Cement Content, Maximum W/C Ratio and Minimum Grade
of Concrete for Different Exposures with Normal Weight aggregates of 20 mm
Nominal Max. Size (Clauses 6.1.2, 8.2.4.1 and 9.1.2)

Sl. Exposure Plain Concrete Reinforced Concrete

No

Min. Max. Min. Max. Min.

Cement Free Min. Cement Free Grade of
Content W/C Grade of Content W/C Concrete
kg/m3 Ratio Concrete kg/m3 Ratio

(1) (2) (3) (4) (5) (6) (7) (8)

i Mild 200 0.60 - 300 0.55 M 20

ii Moderate 240 0.60 M 15 300 0.50 M 25

iii Severe 250 0.50 M 20 320 0.45 M 30

iv Very 260 0.45 M 20 340 0.45 M 35

severe

v Extreme 280 0.40 M 25 360 0.40 M 40

Table 16 Nominal Cover to Meet Durability requirements
(Clause 26.4.2)

Exposure Nominal concrete Cover in mm not Less than

Mild 20

Moderate 30

Severe 45

Very 50
severe
Extreme 75
NOTES: For main reinforcement up to 12 mm diameter bar for mild exposure the
nominal cover may be reduced by 5 mm, Unless specified otherwise, actual concrete
cover should not deviate from the required nominal cover by +100 mm, For exposure
condition `severe' and `very severe' reduction of 5 mm may be made, where
concrete grade is M35 and above
Water
➢W/C - Strength

➢W- Water Content – Workability & Hydration

➢C – Cement content - Cost