CE 238 (PCC) CONCRETE TECHNOLOGY Cr. Hrs. 3 (244) tte Credit 2 0 1 Hours 2 0 2 Course Outcome: At the end of the course, the student will be able to: CO1 Acquire knowledge of composition & characteristics of cement, ‘aggregates and concrete. CO2 Understand various types of admixture used in concrete CO3 Design concrete mix based on IS 10262: 2019 CO4 Understand concrete handling methodology procedures as per field condition COS —_Understand properties of conerete and special type of concrete ‘and get knowledge of form work. CO6 Analyze and determine various concrete properties with the aid of experimental studies Unite Coment:Constituents of cement and their role, composition of cement (Bogue's equation) hydration of cement, structure of hydrated cement, heat of hydration. Tests of cement as per 1S code. Aggregates: Classification, properties and grading of aggregates. Tests ‘on aggregates as per IS code ‘Admixture in Concrete Chemvcal and mineral admixtures (their types and Use under different conditions). Use of fy ash and silica fume in concrete. = Unit Concrete:Grade of concrete, proportioning of ingredients, water content and its quality for concrete, water/cement ratio and its role. Concrete Mix Design: Controling factors and Design of mix by IS method Fresh Concrete: workability, flowability, factors affecting and methods to determine these properties. Standard tests on fresh concrete as per IS code Unit Hardened Concrete: Swength, permeability, creep and shrinkage, factors influencing these properties. Standard tests on fresh and hardened concrete as per IS code Acceptance Criteria. ‘Concrete Handling in Field ‘Introduction to mixing & batching methods, placing, transportation, compaction and curing methods, Ready mix concrete” Unity ip Form Work: Requirements, type & method to provide centering and ‘shuttering for beams, slabs and walls, slip and moving formwork ‘Special Concretesintroduction to: High Strength Concrete, High performance Conorete, Light weight concrete, Fibre reinforced concrete, Polymer concrete composites, Self Compacting Concrete Practicals 1. To determine the percentage of water required to prepare a cement paste of standard consistency, To determine the Initial Setting Time for a cement sample, To determine the specif gravity and void ratio for a cement sample. To determine the compressive strength for a cement sample. To determine the specific gravity and void ratio for a sample of (i) Fine aggregate (i) Coarse aggregate To determine the bulking of sand for varying water content To determine the Fine modulus and Grading for a sample of {) Fine aggregate (i) Coarse aggregate, To determine characteristics compressive strength of concrete with varying water cement ratio. 9. To determine Slump and Compaction factor of concrete 10. To determine the modulus of rupture of concrete and relation with its compressive strength. 11. To determine the effect of compaction and curing on compressive strength of concrete. 12, To determine the effect of quantity of fine aggregate on compressive strength of concrete, 13. To design a concrete mix using I'S. method Suggested Books & References 1. Shetty M.S, "Concrete Technology” eed 2. Mehta (LS Menten — Coe eta Bm Neville ai 2 Bemes or, eucrh Tete,[eeheet 7 ri Porkhend Cement + Colour Hecwibcied, Eoepruaas Fe Wesemrblel wah coluc yp Fvathurl Aer ee feeet CUM | ones Chemical Composition © Raw Mateos — eev Lw Stor The raw materials used for the mani oof cement const main of ime si, | alumina and iron oxide, These oxides interact with one another in the kin at high femperature E\e to form more complex compounds. The relative proportions of these oxide compositions are responsible for influencing the various properties of cement: in adaition to rate of cooling and fineness of grinding. Table 1.4 shows the approximate oxide compostion limits of ordinary Portland cement. Table 1.4. Approximate Oxide Composition Limits of Ordinary Portland Cement Onde Par cent content a0 60:67 Si0. “47-25. AOs 0,05 Meo Aalies (4,0, Na,0) $03 Su 1 Ge naing aaa wake} j wet Preces< s WES Lap Plo” “aeeage *Heabing Lisee cl (st iC Day Presse oa. es . dea L Se err —r Deda Gusunphe os Aare i ) a 4 Wee ae as Ss 4 Storage basins ———+ Wet grinding mills to make slury ~—— Storage basins Water Limestone Blending of stury to correct composition + Storage of corrected slurry Powdered oa cil or gue ——L-+ Comeced shy edo Rotary kin Slury is converted into clinker + Addition of 2 to 3% of gypsum? ————+ Clinker is ground in Ball mill + Cement silos Packing plant[ee fees ser , Timcnca bal om mace] MANUFACTURING OF CEMENT Cy eR FLOW CHART wr aura (Canker zation Seton Iron te Ec « - \ v Yee Fonte (Mayet 44 # ey — A” = a = = a} B Silo 3 uel sae comet en — a" on f - _| €_e a a __ dak ee |. Diagrammatic representation of the dry process of manufacure of cement. ri RogudsCompomd CaS, C25 C2, CuAe eh co0 Syor i sits )= 7606700) ~6.7 afal0,) — 48 R83) Lot Bop urbe > Caos 4.07 0) Q ¥ ) ee ere get eee) Name of Gompound Formula Abbreviated Fora Tsun seat 3620.50; os Dieslun sete 2620.50, os Been TWeaeum eliminate 3C20.A,0, oA Ae BECO) Tetracalcium aluminoferrite 4C20.Al,0 5Fe,05| CAF pea Oxide compostion Per cent Calculated compound composiion gues equation per cen| So Brey tad, )iy Commen > & @ sz goede ee (J Raped Havcen! iq 6 ee Cr) Lew Heal ener @>s2 9 ope sublets Rear (A) lattes) qamtnlaticend © = Tapert Au piuds when Begue's tompord ure dation clupende — ferceute fe Gora wanterf Hew, dor & yt pene B H Comporre| oe ed ao hed ed aceoraingh, Cale Ia tod Hydro | Cetnend= - ns c Cement t Wah > { foe | frevess Heat Libersted Cexctherme Crees 2 tarceyl fle 2. 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Ha2— Ps enn Puce (Ca A) Canoes Hlasl. seth Benes , ahh ts oe a, averd Flask seth (ca se 2th i Ehegite Cap Cobwebs to Sibben ly i Close g consrtees ’) : «Se 7 t ac ~ben) + Oe. wee ae ay ie There gee H xm Wros perks | ts e-$- ) cy eee pata 7 Siruckere gy Hh bed Come t— ronment) conenks Three plas erst — Cement fast Phase O| Aagesgole Chaat = C B eae ak srecthe caw ard CYAE weakest btuln Renee Felure Aeperd wher avebty b Avante Eee J [Comat taet Chase] Enc] Fees Comet pee AA a Kewe fo wel a S Ceme Fh walk i) Cement avhcler “Ae peed ae aqusens Archon WU Byatt Metnets ayy Bun Hydyete4 oeBie. 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Weder Bake ad cmelee, Ahern ar Remsen) Cisne bee ce lo Arfhret Ste Pushes \ ae imap J) k ca ee predic oate sa henge : pared Cemwew ae ciate. com vate ered, Micali becee ti = i “comes Ean eae) ao alt er 4 ot ater = BES ra Atis LS pene bh tate depo fen exe (lab Ae ed _———— chitin. . feeb welds 7)Wale Recut vent fax 4 Wo ba, @ woler4e Artuinement dar Ca ig Ne au}, mr fo-ce.s bert oF 2 Vy, Renee avermye efeweled tal Reputremat for cemscn] Yeacha ic ca be Amie cy 2 EWA : Tht bale Ciebaee aah Ges od Nenourn a, boc) Uschen | wake x tetd ‘a \V-peree | kenme & geluetea | Se Eshitkd aqyenhty i ¢\ wale as pee Litetve te \She . Tew es eS Ge — Gelwalr acd oon Awl e~ On i Ao cock oth. _ Resutbead etre! — wale = 88% Ts used 8 esl wll ge be )Y | ya bed (Poel asantn sg “Qa be aed Kev Focwe bet 4 capiary Camtnes ) > Spanley, 324 4 a Canin ete Ss oes — Ph walk < 287, _ @ Rll hydm ben 6 mol echived — Chanta\ acher 5 ck complel— — UM hycienb=a} Cemet wil brachl Ves“Tete oy Sear... ‘ eer OSE ead Cousrsteny © Test | Ferd Teer ) Faw te) 2 Hsetreg Ame = © i | § — @com eee 5 bruset ) + Howal recck - et SOs prbe omy et > @)Srundnees Teet ebent — da brelet SS Tefov Prubtl= OM Awa Chfe Pasks (Vicaks 2 Shape jr Cape bod Ap pavteo Pe a Gy [SFacdand Couns dep OL 4 Q a po Ey eS BL wrote ee sy Cor Clg iow de penehealeey, Aceh Repl Che Zw ahve ee Ye bette ENiCe ay Take 400 gm of cement and prepares a paste of cement with a weighted quantity of water (Starting from 25%), Time of gauging should be kept between 3-5 minutes. ow fil he Vieat mould resting upon non-porous pate withthe prepared pase. After completely filing the mould, smooth off the surface of paste by single movernent of palm making it level with the top of the mold va peta Weald mild winapi eo ede ther ached wisps. (Spe Bring the plunger down up tothe specimen surface, release it gently and allow i to peneate. Note the penetration from the dial Lanpensdy mapon Conver Prepare trial pastes with varying percentage of water fifty ‘at an interval of 4% and test unl the amount of water necessary for standard consistency as defined is obtained then ‘animarva oft) (Se . % Seating Tree 4 Dated / erwe| ee sintil setting time” is defined as the period elapsing between the time when the water is added to the cement and the time at which the needle of 1mm square section falls to plerce the test block to @ depth of about 5 mm from the bottom of mould. Initial setting time testis important for transportation, time duration is required to delay the process of hydration of hardening: vrialeetng times defined a the period elaping between theime when the Wale 5 added to the cement and placing and compaction of cement concrete initial seit the time at which the needle of 1.mm square with s mm diameter attachment fails to make an impression on the f ed ——- tet block Final setting time isthe time when the paste completely loses its plasticityIre ce sting tin ot, ote conte ts tea he water requed oie paste normal consistency (P). nd oepr aescenet se nth gs} wterby wah fee secu teot tye 30 mes Sa the op Wa tear whe ewer beso ‘coment. Record this tim scree vet mou resting on ss lat wih the cement paste gauged a above Filthe mul amletey ‘and smooth off the surface of the paste making it level with the top of the mould. The cement block thus prepared iscalled est block (0) DETERMINATION OF INTIALSETTING TIME PT ncn Bek conned in th mk! and esing on he nonporous ae, nde he od being he nese © (im square wth lower end beng at Figure 2 a nue gently unit comes in contact wth he rice fet blk nd quick ease, allowing 10 peneat it the test back 4am pening te ele completely ples he test ot, Repeat his rose i: quel rlnsng ie oe ear cery miei ened ato its he lock or eout im messed fom he bem of the mould, Note this tine(T)) tah) seiny = TL (C) DETERMINATION OF FINAL SETTING TIME: “ee 1 ordetermiing the al setting time, replace the needle ofthe Vea apparats by the needle with an annular aacmee game a nedl Cut wth metal atachent alowed out soasio leave cer cting edge smn diameter Figure 2). ane caidered aly st when pon apg he ral setingneeaagnt oe sures fhe Favs sock; the neale makes an Impression thereon, wht the attachment fl to. 0082, Record this tim baa Upertahen (eee Phan pine) —— © Seo ht Cosannty, 21-7; ead i int on stem between the zero and the one ‘ml mark. 1. Day the Mas carefully and fill t with Kerosene © point on ste A eros lak ‘Note the initial reading i, weight of flask plu Kerosene and the level of kerosene (Wa}8) ell 2. ry inside ofthe ask above the level of lau 3, Immerse the fas ina constant emperatre Walet bath maintained at room temperature (10 avoid variation es w in readings taken). WE Hak : (w) wr jet 1d in smaft amount. This Vote 44 Record the level of Tigud inthe flask as inital readin 5, A.weighted quantity of cement (about 64g of Portland cement) shall be introduce , oi sli he ‘wll nerease the level of Kerosene in the pote. Care shal be taken to vod spa BST yee Ng ‘ement doesnot adhere tothe sides ofthe flask above the liquid, ee en, e air until no further air 6, After patting all the cement into flask, roll the flask gently toffee the cement from sir untly 3 cat @& ‘bubbles rises to the surface of fluid. Keep the flask back in constant termperature WaleS bath and note down the new liquid level as final reading a. =V-\ sree Cranty * 3k 5 dabmad ar A hap y btn the “i »? ee ; vray, mad ad wast were Vow) Conte =e welt) G2 tir UN [pecctakets Plate@ co wane S : = D7) ~S terre Stee cg - Eonar Sood FH) a 1. The material For each cube shall be mixed separately [Quantity of cement= 200 gm, standard sand=600_. smi. The quantity of water is taken as (P/4+3.0) percent of combined weight of cement and sand (P is standard consistency). 2. Place the weighed mixture of cement and standard sand on a non-porous plate Mix it dry a trowel for one minute and then with measured quantity of water until the mix is of uniform colour. 4. Gauging (mixing) time should not be less than 3 minutes and should not exceed 4 minutes. If it exceeds, mix should be rejected and operation should be in above steps should be repeated with fresh cement, sand and water. Put oil the interior faces of the mould. 6. Place the assembled mould on the table of the vibration machine and firmly hold it in position by means of suitable clamps. 7. Securely attach a hopper of suitable size and shape at the top of the mould to facilitate filling and this hopper shall not be removed until completion ofthe vibration period. 8, Immediately after mixing the mortar as specified step 3, place the entire quantity of the mortar in the ites ata speed of hopper of the cube mould and compact the mortar by vibration for a period of about 2 1200+ 400 rpm, 9. After completion of vibration, keep the cubes at a temperature of 27+ 2°C in an atmosphere of at least 90% clave hui for 24 hous (rev [99 dey ) 10. Atte ed of tov per emove them from the mould nd immediely submerge ncn es aera ‘272°C. The cubes should be kept in water and should be taken out prior to testing. The water in which cubes are submerged should be changed after every 7 days. The cubes should not be allowed to dry up before testing. 11. Place the test cube on the platform of the compression testing machine without any packing between the cube and the stel plates ofthe testing machine. Apply the load steadily and uniformly starting from zero at arate of 35 Nimm’minute til the cube fails. Calculate the compressive strength from the observed failure load. © Sovuduess Test 1. Gauge 100 gm of cement Goorin water required to make apse of standard consist. 2. Place the by LE- CHATELIER apparatus on a glass plate and fill it with the paste. Level the top surface: 3. Cover the mould with another piece of glass sheet, place a small weight on this covering glass sheet anid immediately submerge the whole assembly in water at a temperature of 29 + 2° C and keep there for 24 hours 4, Measure the distange D, yeen the indicator points after 24 hours and again submerge the mould in water FF at the temperature preScfibed above Cewet Reparmy = D2 Dy a ages = oe er Diet CZoms dated | = TRS wnaered)shapes ani ze, ‘cement paste g i 8. M 200% eee ae @ube \ os me, 7 —_—_—_ _— = Avatrar Roane Pears ik)> as 5-1 a Be cpe tage 5.000 X Figure 2-2 Microstructure ofa hydrated cement pase Microstructures the subtle structure of a material sha is resolved with the help of a microscope. A tow SRO TCAISE 200 % ) elecrron micrograph of a hydraed cement paste shows tha the structure is not TRomogencous; while some arcs are dense, the others are highly porous. Ins the porous areas, iis possible lo eset the individual hydrated phases by using higher magnifications. For example, massive erysals fag aie fog adler ees of sng, dagen of smal oes sof Cra org eee of ae tealetum silicate hydrate con be seen at 2000 % and