AGGREGATES

TECHNOLOGY
CONCRETE

content
ADMIXTURES

WATER
QUALITY
PARAMETERS

CONCRETE
AS A
MATERIAL
WATER QUALITY
PARAMETERS

AS PER
IS 456 : 2015
 IMPURITY TOLERABLE LIMIT
PH SHALL NOT BE LESS THAN 6
TURBIDITY ≤ 2000 PPM
CHLORIDES 1) RCC - ≤ 2000 PPM
2) PCC - ≤ 500 PPM
TOTAL / SUSPENDED SOLIDS ≤ 2000 PPM
DISSOLVED SOLIDS ≤ 1500 PPM
SULPHATES ≤ 400 PPM
CALCIUM CHLORIDES ≤ 2 % BY WEIGHT
INORGANIC MATTERS ≤ 3000 PPM
ORGANIC MATTERS ≤ 200 PPM
NAOH ≤ 0.5 % BY WEIGHT
NA2S ≤ 100 PPM
SUGAR ≤ 500 PPM
ACIDS ≤ 10000 PPM
IRON SALTS ≤ 40000 PPM
 Water is an important ingredient of concrete as it actively participates in

chemical process with cement.

 Since it helps to forming strength cement gel.

 Water also used for curing process through which hydration going on

continuously that’s why strength develop also continuously.

 Sea water not use for RCC and PCC but sometimes used for PCC but In

case of alkali aggregate it is restricted for PCC also.

 Water contain more than 0.8 ppm of iron is not recommended for curing

 If mineral oil concentration more than 2% by weight of cement may reduce

concrete strength by more than 20%

 If algae present in water than it entered large amount air in concrete by which

strength decreases

 Zinc chloride retard the set of concrete and the 3 day strength test can not be

performed.
 In alkali aggregate reaction a alkali sulphate gel form which have unlimited

swelling.

 The favorable temperature for this reaction is 10 to 38 0 c .

 The purpose of using water with cement is to cause hydration of cement . Water

in excess of that required for hydration act as a lubricant between coarse and

fine aggregate. and produce a workable concrete and economical concrete.

AGGREGATES

AS PER
IS 2386
 Aggregation of solid particles other than paste is called aggregate.

 Aggregate should be inert and inexpensive.

 Aggregates are important constituents as they are give body to concrete and reduce shrinkage
and effect economy.

 Aggregate occupies 70 to 80 % volume of concrete (55 % in mortar and 85 % in concrete ).

 Concrete can be classifies as a 2 phase material as :-

1) Paste phase

2) Aggregate phase

 Well graded aggregate mix preferable for concrete making.

 Generally max. size of aggregate for concrete making is 40 mm (20 mm for RCC works and 10
mm for flooring work are other size). Generally size as large as possible.
 But in case size of aggregate should not be more than 1 /4th of minimum

thickness of member.

 Presence of mica into fine aggregate will reduce compressive strength and

durability of concrete.

 Generally we use logeff size of aggregate.

 Nominal maximum size of aggregate (MSA) means majority of particles pass

through given size of sieve.

 It should be noted that surkhi and cinder are not chemically inert. Hence not use with
cement.
 Types of Gradations

• Uniformly graded
- Few points of contact
- Poor interlock (shape dependent)
- High permeability

• Well graded
- Good interlock
- Low permeability

• Gap graded

- Only limited sizes

- Good interlock

- Low permeability
 SHAPE OF AGGREGATE

FLAKY
ROUND OR
AGGREGATES ELONGATED
ANGULAR
AGGREGATES AGGREGATES
 ROUND AGGREGATE

Presence of round aggregate in concrete increase the workability but results

decrease in strength as far as the given volume of concrete.

Round aggregate have minimum surface area hence same volume of cement paste

would be able to lubricates more no. of round aggregates.

In round aggregates development of friction is also less due to smoothness and less

surface area.

Round aggregate have minimum voids in concrete ( 32 % ).

 ANGULAR AGGREGATE
 Its presence in concrete increase strength of concrete due to :-
1) Better interlocking

2) More surface area

3) More development of friction

4) More roughness than others

5) Due to all these reasons workability is low

 Angularity is represented in terms of a dimensionless no. known as angularity no. which signifies
total voids present in aggregates.

 If % voids in aggregate is 33 % than angularity no. is 0 means volume of solid is 67 %.

 if 5 % voids present in the aggregate is 44 % than angularity no. is 11 means
volume of solid 56 %.

PROCEDURE

 The cylinder is calibrated by determining the weight of water at 27oC

required to fill it
 Aggregate is sieved through 20, 16, 12.5, 10,6.3 and 4.75 mm IS sieves
 About 10 kg of the predominant size should be available

 An oven dried sample(100-1100 c @ 24 hr)filled/compacted in cylinder in 3

layers.
And each layer compacted by 100 times.

After compaction the cylinder weighted and 3 separate observation made for aggregate .

100W
Angularity no.  67 
C.GS

Where W= mean wt. of aggregate fill cylinder

C = wt. of water require to complete fill the cylinder(volume of cylinder)

GS = specific gravity of aggregate

3  AN
Angularity index   1.0
20
 FLAKY / ELONGATED AGGREGATES

 Flaky aggregate are those whose one dimension is much larger than other two.
 These are not used for concrete as they directly reduce workability.

 FLAKINESS INDEX:
 The flakiness index of aggregates is the percentage by particles whose least dimension
(Thickness) is less then 3/5th (0.6) of their mean dimension.

 Elongation index:
 The Elongation Index of an aggregate is the percentage by weight of particles whose greatest
dimension (length) is greater then 1 and 4/5th times (1.8 times) their mean dimension.
  TEST TYPES

a) Aggregate Crushing Value Test

b) Aggregate Impact Test.

c) Abrasion Test

d) Sieve test

e) Shape Tests
a) SIEVE TEST
 Through this test we determine fineness modulus which is an indicator of fineness and coarseness
of aggregate which calculated by dividing aggregate of cumlation % retain weight on different sieve
vary from 80 mm to 150 micron by a constant ( generally taken as 100 ).

 Higher the fineness modulus coarser the aggregates and make harsh concrete but lower fineness
modulus make uneconomical concrete.

 Fineness modulus of sand

 Fine sand – 2.2 to 2.6 – plaster work

 Medium sand – 2.6 to 2.9 – masonry work

 Coarse sand – 2.9 to 3.2 – concrete work

 fineness modulus for coarse aggregate is lie between 5.5 to 8 and 3.5 to 6.5 for all in aggregate.

 Grading of fine aggregate done as per IS 383 and it is recommend that sand is not used related to

zone ( iv ) and grading is done by help of sieve analysis

ZONE (I) > ZONE (II) > ZONE (III) > ZONE (IV)

FINENESS INCREASES

% PASSING 15 - 34 35 - 59 60 - 79 80 -100

ZONE OF I II III IV
SAND
 Serial Sieve size Weight retain % weight retain Cumulative % Fineness
no. (gm) weight retain modulus
1 80 10 6.67 6.67
2 40 25 16.67 23.34 639.8 / 100
3 20 20 13.3 36.64
4 10 15 10 46.64
5 4.75 30 20 66.64
6 2.36 10 6.67 73.75 6.39
7 1.18 20 13.3 86.6
8 600 20 13.3 100
9 300 - 0 100 Represent
coarser mix
10 150 - 0 100

150 gm 639.8
 Note – the aggregate size always denoted by size of sieve retain and size
of aggregate always represented by multiples of 2 (geometric mean).

 Like – 10 mm, 20 mm, 40 mm, 80 mm, 160 mm

Crushing strength test
 Purpose- to evaluate comp. strength of road aggregate.

 Size of aggregate – 10 to 12 mm

 No. of layers – 3

 Rate of loading – 4 ton/min @ 10 min

 Sieve size – 2.36 mm

 Result – aggregate crushing value(ACV)= w2 / w1

 Limits –
ACV for wearing surface should not be more than 30%.
ACV for general construction should not be more than 45%.
Note- W 2 = wt. of aggregate pass through 2.36 mm
W 1 = total wt. of aggregate
 Impact test  Limits –
 AIV for surface coarse should not be more than
 Purpose- to evaluate toughness.
30%.
 Size of aggregate- 10 to 12 mm
 AIV for base coarse should not be more than
 Wt. of plunger- 13.5 to 14.5 kg 40%.
NOTE- W 1 AND W 2 remain same
 Ht. of plunger fall- 38 cm

 No. of blows- 15

 Total energy- 7695 kg-cm

 Sieve size- 2.36 mm

 Result- Aggregate impact value(AIV)=W 2 / W 1

 Aggregate abrasion test
Purpose- loss angelus test machine

• Apparatus – loss angelus test machine

• Size of steel ball inside – 48 mm in dia. With total wt. 390 to 460 gm.

• Size of aggregate- 10 to 12 mm

• Sieve size - 1.7 mm

• No. of revolution – 500 @ 30 to 33 rpm

• Dimension of cylinder- 700 mm dia and 500 mm length

• Result – Aggregate abrasion value(AAV)= W 2 / W 1

Limits –
AAV for surface coarse should not be more than 30%.
AAV for base coarse should not be more than 50%.
NOTE- W 1 AND W 2 remain same.
ADMIXTURES

AS PER
IS 9103
  Admixtures
 The term admixture as “a material other than water, aggregates, hydraulic cement, and fiber

reinforcement, used as an ingredient of a cementations mixture to modify its freshly mixed,

setting, or hardened properties and that is added to the batch before or during its mixing.

 Producers use admixtures primarily to reduce the cost of concrete construction to modify

the properties of hardened concrete to ensure the quality of concrete during mixing,

transporting, placing, and curing and to overcome certain emergencies during concrete operations
 Functions

 Increase workability without increasing water content or decrease

the water content at the same workability

 Retard or accelerate time of initial setting

 Reduce or prevent shrinkage or create slight expansion

 Modify the rate or capacity for bleeding

 Reduce segregation

 Improve pumpability

 Retard or reduce heat evolution during early hardening

 Accelerate the rate of strength development at early ages

 Increase strength (compressive, tensile, or flexural)

 Decrease permeability of concrete

 Control expansion caused by the reaction of alkalis with potentially reactive

aggregate constituents

 Increase bond of concrete to steel reinforcement

 Improve impact and abrasion resistance

 TYPE OF
ADMIXTURES

Chemical Miscellaneous
Mineral
admixtures admixtures
admixtures
 CHEMICAL ADMIXTURES

 Plasticizers

 Super plasticizers
 Retarders

 Air entraining

 Air detraining

 Accelerators

 Pozzolanic
 MINERAL ADMIXTURES

 Fly ash
 Silica fume
 Ground granulated blast furnace slag
 Metakaoline
 Rice husk
 MISCELLANEOUS ADMIXTURES

 Grouting admixture
 Alkali aggregate admixtures
 Coloring admixtures
 Insecticides admixtures
 Workability admixtures
 Corrosion resist admixtures
 Bonding admixtures
 damp / waterproofing admixtures
PLASTICIZERS(WATER REDUCERS)

These are organic or combination of organic or inorganic substances

which allow a water reduction for a given workability or high workability at the
same water content.

Plasticizers are surface active material and they induce a negative charge
on individual cement particles.

They act as a diflocculating agents hence get absorb over cement particles

There by due to repulsion make the entrapped water free which modifies
properties of mix.
 Doses of plasticizers varies in the range of 0.1 to 0.4 % by weight of cement
at which they permits reduction in water content up to 5 to 15 % or increase
in slump 30 to 150 mm.

 A good plasticizers is one which does not cause air entrainment in concrete more
than 1 or 2 %.
 The chemicals used as plasticizer (water reducing admixtures) are as follows:

 Lignosulfonic acids(Anionic and salts of sulphonates hydro carbons)

 Polyglycol esters (nonionic acids of Hydroxylated carboxylic acids)
 carbohydrates
SUPER PLASTICIZERS(HIGH RANGE WATER REDUCERS)

 These are modification over plasticizers.

 Use of super plasticizers permits the reduction of water to the extent up to 30 %

without reducing workability in comparison to 15 % of plasticizers.

At a given water /cement ratio and water content in the mix, the dispersing
action of super plasticize increases the workability of concrete, typically by
raising the slump from 75 mm to 200 mm, the mix remaining cohesive.

 By use of super plasticizers we make flowing self compacting, self levelling,

tremie, no segregate , no bleeding concrete.
 The optimum dose of super plasticizers to the cement calculated by
1. Marsh cone test
2. Mini slump test
3. Flow table test
 out of these Marsh cone test gives best results.
 There exist four main categories of super-plasticizers based
on their chemical composition:
 Sulfonated melamine formaldehyde

 Sulfonated naphthalene formaldehyde

 Modified lingo - sulphates.

 They are not use for slab, the upper surface of which slopes > 30 or for extruded concrete
 RETARDERS

 This type of chemical admixtures decreases the initial rate of reaction between
cement and water and thereby retards the setting of concrete that’s why concrete
remain plastic and workable for longer time.

 Retarders are generally use for construction of oil wells where the temperature
exceeds up to 2000c (otherwise it can set vary rapidly due to high temperature).

 If retarders are added in the range of 0.1 to 0.2 % than which may delay the
hydration up to 72 hrs.

Examples :- caso4 , sugar, starch, cellulose, ammonium, fe, fecl2

 ACCELERATORS

 Normally they reduce the setting time of concrete.

 Accelerate rate of hydration.

 Accelerate rate of gain of strength.

 They used in cold countries(CaCl2 and NaCl), psc works, cc roads, where

form work remove early.

 EXAMPLES:- CaCl2, fluro silicate, tri-ethanol-amine, AlCl2, alkali carbonates

aluminate (by adding 1-2% NaOH gives wearing resist surface)

 ACCELERATORS

 These are type of admixtures which are entrap millions of air bubbles in between the voids of

aggregate which act as flexible ball bearing that slip pass over each other, there by modifies the

properties of the concrete wrt workability, frost, segregation, bleeding.

 It increase the resistance against attack of chlorides and sulphates and freezing and thawing

action.

 It reduce density of concrete and increase water tightness by reducing permeability.

 EXAMPLE :- Natural wood resins, H2o2, AL powder, zinc powder, animal fat
Silica fume (IS 15388)

Also referred as micro silica or condensed silica fume and also a pozzolanic

admixtures.

Very fine in nature(avg. dia 0.10 to 0.15 mm) and amorphous glassy shape of

SiO2 produce by silicon or Ferro silicon through electric arc(at 20000c)

Silica fume has specific surface area 20000 to 22000 m2/kg.

GROUTING AGENTS

 Rust generating (expandite) → iron(fine) + NH4Cl

 Methocel → obtain from dow chemical

Hydrogen generating(nevander) →checks, bleeding not expand

Chemically expansive(sulphoaluminate)
 RICE HUSK ASH

 Rice husk essentially consist amorphous silica (90 % SiO2), 5% carbon, 2% k2o,

 Its specific surface area 40 to 100 m2 / kg

METAKAOLINE

 Thermally activated ordinary clay(kaoline clay)and unpurified

 Carry pozzolanic properties but not highly reactive.

 GROUND GRANULATED BLAST FURNACE SLAG

 Mineral admixture like fly ash

 Non metallic product consist silicates and aluminates of aluminates of calcium

 The molten slag rapidly chilled by quenching in water to form a glassy sand

called GGBFS

 Specific surface area should not be less than 600 m2 / kg

 Chemical composition similar to cement.

 CONCRETE

INTRODUCTION

WORKABILITY & ITS TESTING

PRODUCTION OF CONCRETE

STRENGTH TESTING OF CONCRETE

MISCELLANEOUS TOPICS
 INTRODUCTION
 Composite man made material.

 Most widely used.

 Consists of rationally chosen mixture of binding material such as lime or cement,well graded
fine & coarse aggregates, water.

 Mix of sand water & cement called as matrix in concrete.

 Freshly mixed concrete is called as green concrete.

 After setting is called as set or hardened concrete.

 Major factors responsible for using cement concrete are mouldability, early hardening,
high early compressive strength, pumpability & durability.

 Versatile in nature.
 CONCRETE

BINDING
FINE COARSE WATER
MATERIAL ADMIXTURE
AGGREGATE AGGREGATE

CEMENT SMF
LIME SAND SNF FRESH
GRAVEL POTABLE
GGBFS
META WATER
KAOLINE
etc
 Homogenous mixture.

 The coarse aggregate acts as filler.

 The fine aggregate fills up the voids between the paste & coarse aggregate.

 The cement in conjunction with water acts as a binder.

 The mobility of mixture is aided by the cement paste, fines & now a days by
use of admixtures.

 The aim of quality control is to ensure the production of concrete of uniform

 strength from batch to batch.

 CLASSIFICATION ON THE BASIS OF:-

Based upon Cementing material

 Lime concrete
 Gypsum concrete
 Cement concrete
 Based upon grade
Grade Mix Perspective
of proportio characteristics
concret n strength
e
M 10 1:3:6 10 MPA

M 15 1:2:4 15 MPA

M 20 1 : 1.5 : 3 20 MPA

M 25 1:1:2 25 MPA
Based upon bulk density

 Heavy concrete → ᵞ > 2500 kg / m3

 Dense concrete → ᵞ = 1800 - 2500 kg / m3

 Light concrete → ᵞ = 500 – 1800 kg / m3

 very Light concrete → ᵞ < 500 kg / m3

FRESH CONCRETE

 Fresh concrete be such that the concrete can be properly compacted.

 The long term properties of hardened concrete like strength, volume, stability, and

durability affected by degree of compaction.

 Workability has more significance than consistency which only a general term to indicate

the degree of fluidity or the degree of mobility.

 A concrete which has highly consistency and more mobility need not be at right

workability.
WORKABILITY (IS 6461)

 It may also be defined as amount of useful internal work require to be done by the concrete to
achieve by full compaction.

 This useful internal work is a physical property of concrete alone and is the work or energy
require to overcome the internal friction between individual particles.

OR

 it is the measure of internal resistance of concrete.

OR

 it may also be defined as ease with which concrete can be mixed, transported, placed,
compacted, and finished.
FACTORS AFFECTING WORKABILITY

1. WATER CONTENT
 By adding more water in concrete increase interparticle lubrication means no effect on

workability. This normal practice at site lowers the strength of concrete.

 With increase in water content the quantity of cement should also increase in same
proportion to increase or maintain strength of concrete.

 NOTE
 Workability can not be measure because it is not absolute term it depends upon type
of work.
2. MIX PROPORTION
 Explained by aggregate cement ratio :- aggregate
 Which deals with durability.
cement

3. SIZE OF AGGREGATE

SIZE ↑ than surface area ↓ than friction↓ than workability ↑

4. SHAPE OF AGGREGATE
Round shape ↑ than surface area ↓ than friction↓ than workability↑

Angular shape ↑ than surface area ↓ than friction↓ than workability↑

5. SHAPE OF AGGREGATE

Smooth aggregate than friction↓ than workability↑

Rough aggregate than friction↓ than workability↑

6. SHAPE OF AGGREGATE

 Well graded aggregate leads to the formation of high workable concrete due to less voids.

7. USE OF ADMIXTURE
MEASUREMENT OF WORKABILITY(IS 1199)

 Mostly 5 test available for this

 Slump test

 Compaction factor test

 Flow table test

 Vee bee consistometer test

 Kelly ball apparatus

  SLUMP TEST
 Slump tests in one of the most extensively used test all over the world.

 Most common method used to determine consistency of concrete which relates workability.

 Dimensions of the mould are bottom diameter = 200 mm, top diameter = 100 mm and

height = 300 mm

 Mould is filled in with fresh concrete in four layers, each layer of approximately one quarter of

the height of the mould and tamped with 25 strokes of the rounded end of the tamping rod.

 Strokes are distributed in a uniform manner over the cross-section

 Mould is remove immediately by raising it slowly and carefully in a vertical direction. Then the
concrete is allowed to subsidized and the slump is measured immediately by determining the
difference between the height of the mould and the highest point of the specimen being tested.

 Slump measured is recorded in terms of mm of subsidence of the specimen.

 More is slump than it show more is workability.

 Field test but can be perform in lab also.

 Suitable for plastic concrete mix not for stiff concrete mix (0 slump)

 Not suitable for very low and very high workability mix.

 Note :- this test recommended for design mix only and also recommended for concrete
which have aggregate size < 38 mm
APPARATUS
  COMPACTION FACTOR TEST
 This test is more accurate and
sensitive than the slump test
especially for it is useful for
concrete mixes of medium and
low workability.
 Here the workability is measured
in terms of compaction factor (0.4
, 0.8, 0.9)
 Concrete of very low workability
(0.7 or below), this test is NOT
APPLICABLE.
 It is primarily designed for
laboratory work but can also be
used in the field.
 PROCEDURE

 Sample of concrete to be tested is placed gently in the upper hopper, and levelled.

 Trap-door is then opened to allow the concrete to fall into the lower hopper.

 Concrete which has stacked in the upper hopper at sides is gently pushed into lower one.

 The trap-door of the lower hopper is opened so that the concrete falls in the cylinder.

 The excess of concrete remaining above the level of the top of the cylinder should be cut and
removed.

 Weight of the concrete in the cylinder is then determined, which is known as weight of partially
compacted concrete.

 The entire concrete is filled in cylinder and tamped with tamping rod, and the weight of concrete in
the cylinder is then determined, which is known as weight of fully compacted concrete.
 The degree of compaction called compaction factor measures by the density
ratio.

Density of partially compacted concrete

compaction factor 
Density of fully compacted concrete

 Higher the compacting factor, Higher the workability of concrete.

  FLOW TABLE TEST
 Lab test which gives an indication of the quality of concrete with respect to consistency ,
cohesiveness and the proneness to segregation.

 Suitable for very high workable concrete for which slump test and compaction factor test can not
be possible.

 When the mould is completely filled it lifted up vertically in upward direction and table is raised
and dropped by 12.5 mm , 15 times in 15 sec. that cause the concrete to flow over the flow
table.

 The spread of the concrete over the table is measured is at least 6 direction nearer to 5 mm.

 Generally flow % lies in the range 0 to 150

 More flow % more the workability.

 The ratio of initial height to
final height is measure of
consistency which is
reciprocal to compaction
factor.

 If a mix is desired slump is

not obtain the adjustment for
each concrete slump
difference is made by
adjusting water content by
0.5 %
  VEE BEE CONSISTOMETER TEST
 The mould (vee bee consistometer) placed
in a cylindrical container and mould have
dimensions same as slump test

 This test suitable for very low workable

concrete but not suitable for concrete slump
greater than 50 mm.

 The time taken by the sample to assume

the shape of cylinder is known as vee bee
degree

 If vee bee degree is more than lesser the

workability.
  KELLY BALL TEST
 This test not covered by Indian standard.
 This test have greater precision than slump
test and much faster and can be perform at site
also

 The disadvantage of this test it required a large

sample of concrete and can not be used when
concrete place in thin section.

 The minimum depth of concrete must be at

least 20 cm and the minimum distance from
center of the ball to nearest edge of the
concrete 23 cm
 SEGREGATION

 Can be defined as separation of the constituents of a homogeneous mix so that their distribution

is no longer uniform.

 The different size particles present in concrete this is the primary cause of segregation.

 Segregation may have 3 types.

1. The coarse aggregate separate or setting down from the matrix

2. Paste(cement + water + fine aggregate) separate away from coarse aggregate.

3. Water separate out from the concrete (due o lower specific gravity) cause bleeding
 BLEEDING

It is referred as water gain and it is a particular form of segregation.

In bleeding water from concrete comes out to the surface of concrete due to lower

specific gravity among all ingredient and it is highly observed in high wet mix.

Sometimes along this water certain quantity of cement also comes to the surface when

the surface worked up with the trowel and floats the aggregate get down and cement

and water comes up to the surface this formation of cement paste is known as laitance

due to which poor wearing resist surface obtained.

 This laitance form on roads produce dust in summer and mud in rainy season and also develops

higher shrinkage cracks.

 This accumulated water reduces bond between aggregates and reinforcement bars and make

concrete porous.

 The bleeding is not completely harmful if the rate of evaporation of water from the surface is

equal to the rate of bleeding.

 Early bleeding not harmful but delayed bleeding harmful when concrete looses its plasticity
STAGES FOR PRODUCTION OF CONCRETE:-

 BATCHING
 MIXING
 TRANSPORTING
 PLACING
 COMPACTING
 CURING
 FINISHING
 1.Batching:-

 Batching is the process of measuring

concrete mix ingredients by either mass or

volume and introducing them into the mixer.

 To produce concrete of uniform quality, the

ingredients must be measured accurately for

each batch.

 Volume batching

 Weight batching
a) Volume batching:-

 This method is generally adopted for small jobs . (M 5 TO M 20 grade

concrete)
 Gauge boxes are used for measuring the fine and coarse
aggregate.
 The volume of gauge box is equal to the volume of one bag of
cement.
 In volume batching bulking correction required.
 In India generally volume batching adopted.
b) Weight Batching:-
 Batching by weight is more preferable than volume batching ,as it is more
accurate and leads to more uniform proportioning.
 Adopted for all important works specially used for design mix( > M 20
concrete mix).

 It does not have uncertainties associated with bulking.

 Note :- the aggregate & cement & water should be measured with
accuracy of ± 3% of he batch quantity and the admixture by ± 5% of
batch quantity.
 2. MIXING:-
 The mixing should be ensured that the mass becomes homogeneous , uniform in color and
consistency.
 mixing done either by HAND or MIXER
 Note:- in hand mixing there are 10 – 15 % extra cement is added and hand mixing use for
small works
 For all important works mixing is done by mixers.

BATCH MIXERS FOR SMALL AND MEDIUM

(IS 1791) WORKS

MIXERS
CONTINUOUS FOR MAJOR WORKS
MIXERS
 TILTING(T) 85T, 100T, 140T, 200T

BATCH MIXERS NON TILTING(NT) 200NT, 280NT, 340NT

REVERSING(R) 200R, 280R

 Optimum no. of revolution in mixers is 25 to 30 @ speed 15 to 20 r.p.m

 Some times mixers specified as 285 / 200 lit. which means mixers take 285 lit. of ingredient and
yield 200 lit of concrete.

 To prevention of adhesion of mortar in mixers drum there are some amount of mortar is mixed in
mixer before 1st batching called buttering.

 Generally mixing time is lie in between 1.5 to 2.5 min.

BATCH MIXERS
 TRANSIT MIXER

 Also known as continuous mixer

 Having capacity 4 to 12 m3 (generally in

India It is 6 m3)

 Their function is mainly to keep the mix is in

agitated condition.

 A concrete mixer specified by

• Volume of mixing

• Volume of mixed concrete discharged

• Speed of mixer drum

 3. TRANSPORTING

 Should be transported at the earliest without the loss of homogeneity obtained at the
time of mixing.

 Transporting time of concrete is max. 2 hr. truck with agitator and 1 hr. with truck
without agitator.

 During transporting concrete bleeding and segregation is not take place.

 Transporting equipment are :- mortar, wheel barrow, dumper, chutes, belt conveyor,
pumping, bucket and ropeway , ship and hoist.
 4. PLACING

 Placing of concrete is done in

foundation , beams, columns,
slabs, mass concreting, highway.

 Concrete is placed on form works.

 The form works should be cleaned.

 If concrete is to be placed for

foundation, the soil bed should be
compacted well & is made free
from loose soil.
 Concrete should be dropped on its final position as closely as possible.

 If dropped from a height, the coarse aggregates fall early & then
mortar matrix.

 This results as segregation into weaker concrete.

 The concrete should be deposited in horizontal layers about 150

mm height and for mass concreting it may be up to 400 to 500 mm
height (it is for preventing accumulation of water in top layer
known as laitance)
 5. COMPACTION

 Compaction is done to achieve maximum strength due to reduction in voids by 100 % compaction.
 1 % void in concrete mix reduces its strength up to 5 % so removal of void through compaction
essential

 There are 2 type of compaction

1. Hand compaction :-

 used for small works and unimportant works

 hand compaction achieved by ramming tamping rodding

 rodding is done with help of 16 mm dia and 2 m long steel rod to pack the concrete between
reinforcement.
2. Compaction by vibrators

a) Needle vibrator
Known as immersion, poker,
internal vibrator

Needle vibrator can be used for

any type of concrete work

The needle diameter vary 20 to

75 mm and its length 250 to
900 mm
 The vibrator is immerse into concrete at a spacing of not more than 600 mm or

8 to 10 time the dia of poker (poker is steel rod means tube which find in

vibrator.) @ 30 sec to 2 min.

 Location of poker insertion should be staggered should be to insure that every bit

of concrete is compacted

 Vibrator allow in concrete vertically (inclination should not be more than 100)
b) Form work vibrator

 known as external or

shutter vibrator

Used for column and thin

walls and precast units

More powerful but least

efficient than needle

vibrator
c) Surface vibrators

 used for roofs slabs

and pavement
surfaces these are
effective up to 150
mm depth only but
can be used at 250
mm
 6. CURING

 Sufficient water should be made available to concrete to allow it to gain full strength the

process of keeping concrete damp for this is known as curing

 Strength is function of hydration process which is carry by presence of moisture so the object

of curing to prevent the loss of moisture from concrete during hardening process.

 Curing must be done for at least 3 weeks and in no case for less than 10 days.

 Approx. 14 litt. Water required to hydrate each bag of cement.

 Methods of curing

1. water curing :-
• Done by joot bags, covered on concrete surfaces and make wet continuously, ponding, spraying,
immersion, are example of this method.
2. steam curing :-
• Increase in strength of concrete due to increase in hydration reaction but due to pressure the
bond strength reduces up to 50 % and due to this shear strength reduces .

 Steam curing done with :-

a) Increase in temperature of cured water

b) Increase in pressure of cured water

• High temperature accelerates hydration process so gain in strength is vary fast

• When increase in temperature and pressure simultaneously it is called auto claving

• In high pressure steam curing concrete is subjected to max. temperature 1750 c and max
pressure to this temperature is 8.5 kg / cm2
• Steam curing is not done in case of rapid

hardening cement (already gain in

strength is high) and also in case of high

alumina cement due to bad effect of hot

and cold condition on strength of this

cement.

• The hydrating c2s and c3s react together

at high temperature to form sulphate

resist compound and initial shrinkage and

moisture movement also reduced.

 MATURITY OF CONCRETE
• Strength of concrete is a function of summation of product of
time and temperature this is called maturity of concrete.

MATURITY   time temperature

• The temperature reckoned from an origin lying between, -12 to

-100c
 STRENGTH TEST OF CONCRETE

Destructive
Non destructive
test test
 Destructive test
(IS 516)
1. COMPRESSIVE STRENGTH TEST
 Cement, fine aggregate and Coarse aggregate (up to 40 mm) to be used for making concrete are

weighed in the required ratio to be used in field and are thoroughly mixed, by adding requisite

amount of water until the concrete appears homogeneous.

 If the max. nominal size of aggregate greater than 20 mm than cube of 150 mm used but if

the max. nominal size of the aggregate is less than 20 mm (not less than 10 mm) than cube

of 100 mm used

 The test SPECIMENS are cast in the required sizes of cubes, 150 mm x 150 mm x 150 mm or

cylinders of 150 mm diameter and 300 mm height. [D/H = 1/2]

 Test specimens are stored
at room temperature for 24
hrs from the time of
addition of water to dry
ingredients.

 After this time specimens

are removed from the
moulds and placed in water
and kept there until taken
out just before the test.
 Usually specimens are tested for 7 days or 28 days strength, but IS: 456 suggests

only 28 days strength.

 Specimen is placed between the plates of compression testing machine, gradually load

is applied at the rate of 14 N/mm2/minute, until the specimen is crushed.

 Average of 3 specimen values is taken as the compressive strength of concrete,

provided individual variation is not more than +/- 15% of the average.

 Generally the Cube specimen strength is approximately equal to 1.25 times the

Cylindrical specimen strength. [This is due to the influence of size of the specimen]
 2. FLEXURAL STRENGTH TEST

 Flexural tensile strength test is done to determine the tensile load at which concrete
may crack.

 It is an indirect test for assessing the tensile strength of concrete.

 The size of concrete is 150 mm x 150 mm x 700 mm (if aggregate size > 20 mm)
and 100 mm x 100 mm x 500 mm (if aggregate size < 20 mm)

 The specimen is placed in the testing machine on two 38 mm diameter rollers

with a c/c distance of 600 mm. The load is applied through two similar rollers
mounted at the third points, spaced at 200 mm c/c.

 The maximum load at which the specimen fails is noted and from basics of strength of
material, the flexural strength is estimated.
 3. TENSILE STRENGTH TEST

 The tensile strength may be determined by by split tensile strength test ( BRAZILIAN
TEST AS PER IS 5816 ).

 As it is practically very difficult to apply uniaxial tensile load, therefore few indirect methods
are developed to determine tensile strength of concrete. Example is the split tensile strength
test.

 In split tensile strength test a compressive force is applied to the specimen( rate of loading 2
MPA / min up to failure) such that specimen fails due to induced tensile stresses.

 Specimen is made of cylindrical shape with diameter not less than 150 mm. Length is
generally twice the diameter.

 The maximum load at which the specimen fails is recorded and from it indirectly the tensile
strength of specimen is calculated.
 Non Destructive
test (IS 13311)

 Non destructive testing (NDT) can be done on both fresh concrete

and hardened concrete.

 On fresh concrete Ultrasonic pulse wave test [PUNDIT] can be done.

 On hardened concrete Pull Out test, Ultrasonic pulse wave test

[PUNDIT], Schmidt rebound hammer test, Radioactive Methods.
 1. REBOUND HAMMER TEST
• It is a surface hardness test for which an empirical correlation has been established between
strength and rebound number.

• It is based on the principle that the rebound of an elastic mass depends on the hardness of
the surface against which the mass impinges.

• Procedure:

• For this test, a rebound hammer [easily carried] also called SCHMIDT HAMMER, which
weighs about 1.8 kg is required and the test is suitable for both laboratory and field work.

• The Schmidt hammer has a spring-controlled hammer mass that

• slides on plunger with a tubular casing.

• The hammer is forced against the surface of the concrete by the spring and the distance of

rebound is measured on a scale of the instrument which gives indication of concrete strength.

• This test is suitable for the concrete having strength in the range of 20 – 26 Mpa.

 Limitations:

• Results are mostly affected by factors such as smoothness of surface, size and shape of

specimen, moisture condition of the concrete, type of cement & coarse aggregate and

extent of carbonation of surface.

 WATER CEMENT RATIO (W/C RATIO)

• The water-cement ratio (w/c) is one of the major factors influencing the strength of concrete.

• It is responsible mainly for the porosity of the hardened cement paste.

• Thus theoretically lower the w/c ratio means higher compressive strength as less voids are
created.

 Definition:

• Water-cement ratio is the water used to the quantum of cement in the mixture by weight.

• For proper workability the w/c ratio varies from 0.4 – 0.6
• However, theoretical maximum

strength is derived at w/c = 0.4

at which minimum capillary

cavities are expected to form.

• It may be noted that for complete hydration of cement

• under controlled conditions the water requirement is about 38 per cent. (i.e. w/c = 0.38)

• When it is decreased to less than 0.4 there is improper consistency and workability of cement
and honeycombed structure may result.

• Also, at w/c ratio more than 0.6, porosity increases and strength decreases.

Are there any Exceptions:

• However, concrete compacted by vibrator displays higher strength even up to w/c = 0.3.
 ABHRAM LAW

• Duff Abrahm gave the following equation to estimate the strength of concrete for a given w/c
ratio.

• where,

S = Strength of cement at 28 days and A, B are constants

x = Water to cement ratio (w/c)

• According to Abrahm’s law it is evident that strength of concrete depends only upon w/c ratio
provided the mix is workable.