1. Write short notes on (i) Light Weight Aggregates.

(ii) Fibre-Reinforced Concrete.

(i) Light Weight Aggregates.

To reduce the density and dead load of the concrete we can use light Aggregates.
Types :
Advantages :

(ii) Fibre-Reinforced Concrete.

Types pf Fibre:
STEEL FIBER GLASS FIBER
 2. Explain the manufacturing process of Pre-stressed Concrete. Why Special
Materials are needed for PSC. Also explain any two pre stressing systems in
practice.

MATERIALS FOR MAKING PRESTRESSED BEAMS

 Concrete, steel, grout
Prestressed concrete beams production process uses high quality concrete which must have
high tensile strength, low value of shrinkage and creep and also the durability.
In addition to steel and concrete other important material is grout that is used for filling
the space between tendons and duct. The grouting is accomplished under pressure. In that way,
tendons are protected from corrosion and good connection between tendons and concrete is achieved.
Grouting may not be applied at the temperatures below +5°C, ideal temperature is around +15°C.
Grouting material, it is usually a colloidal cement grout, must have some requirements such as:
fluidity, compressive strength, reduction in volume, reduction in water segregation, frost resistance.
Because ventilation is needed, the grout is injected in lowest point of the duct

Prestressing Steel
1) Forms of Prestressing Steel. The development of prestressed concrete was influenced by the
invention of high strength steel. It is an alloy of iron, carbon(1.5%), manganese, silicon (0.3-
0.4%), and optional materials.
The following material describes the types and properties of prestressing steel:-
a) Wires - A prestressing wire is a single unit ready of steel. The nominal diameters of the wires
are 2.5, 3.0,4.0, 5.0, 7.0 and 8.0 mm.
b) Strands - A few wires are spun together in a helical form to form a prestressing strand. The
central wire is larger than the other wires.
c) Tendons - A group of strands or wires are placed together to form a prestressing tendon. The
tendons are useingin post-tensioned members.
d) Cables - A group of tendons form a prestressing cable. The cables are useingin bridges.
e) Bars - A tendon can be made up of a single steel bar. The diameter of a bar is much morethan
that of a wire. Bars are accessible in the following sizes: 10, 12, 16, 20, 22, 25, 28 and 32 mm

2) Types of Prestressing SteelThe steel is treated to achieve the desired properties.

The following are the healing processes

a. Cold working (cold drawing)

 The cold working is done by rolling the bars through a cycle of dyes. It re-aligns the crystals and
increases the strength

b. Stress relieving.

The stress relieving is done by heating the strand to on 350º C and cooling bit by bit. This reduces
the plastic deformation of the steel after the onset of yielding.

c. Strain

tempering for low relaxation. This process is done by heating the strand to on350º C while it is
under tension. This also improves the stress-strain behaviour of the steel by dipping the plastic
deformation following the onset of yielding. In addition, the relaxation is reduced.

3)Properties of Prestressing Steel

The steel in prestressed applications has to be of good quality.

It requires the following attributes.

High strength

Adequate ductility

Bendability,

which is required at the harping points and near the anchorage

High bond, required for pre-tensioned members

Low relaxation to reduce losses

Minimum corrosion.

PRESTRESSED CONCRETE BEAMS PRODUCTION PROCESS

Concrete prestressed elements are produced according to project documentation in the factory
with allequipment that is necessary for production and quality of production must be achieved.
Nowadays,production process is accomplished usingthe equipment of newest technology generation.In
production process there are two methods for prestressing:

 pre-tensioning,
 post-tensioning
Phases of production process are as follows:
1)preparing the mould,
2)placing of reinforcement,
3)prestressing,
4)casting of concrete,
5)removing the mould,
6)storage
Preparing the mould
Before any of the production process phase is
applied, the mould must first be prepared.
For production of one prestressed beam,
quantity of concrete can be above than 4m3.
Therefore, moulds that are used for purposes
like this must be very strong and that is the
reason why steel moulds shown at the picture
2-a/b are most commonly used today.

Placing of reinforcement
In addition to wires which will be used for prestressing, every concrete element has
traditional reinforcement (in the top and bottom of element, vertical shear reinforcement) that always
must be present, no matter which method of prestressing is applied. In pre-tensioned concrete, wires
for prestressing are places to the mould together with traditional reinforcement

Prestressing
This type of productionuses long linemethodof prestressing withparts shown at the picture
3.Picture shows that oneend ofwires is strongly connected to theabutment by an anchor. Other end
ofwires via anchor and spindle is connected with hydraulic jack. Wires are tensioned by hydraulic
jacktothe sufficient prestressing force. So wires remain tensioned and casting of concrete can begin

Casting of concrete
Quantity of concrete needed to make an element depends on element dimensions and it’s
specified according to project documentation. Casting of concrete must be performed with no
interruption. Ideal temperature is 14-20 °C. After concrete has been placed into the mould,
compacting of fresh concrete mast be performed. When concrete achieve compressive strength
around 30 MPa, connection between wires and anchors is released and prestressed element was
made.

Removing the mould

Mould can be removed from an element when concrete has achieved sufficient strength.
Removal must be taken with a care in order not to damage the edges of element. In prestressed
concrete beams production where prestressed force is applied, it is recommended to remove the
mould after concrete has achieved maximum compressive strength and that is for 28days after
casting the concrete
 Storage
By removing the mould production process is finished so the next phase is storage Storage must
be taken with a care. The most important is transportation of an element to the place of storage.
During the process of storage elements may not be damaged and must be perfectly placed without
providing the freedom of movement. In addition, elements must be on the straight surface without
possibility for bending moment to be occurred.

TWO PRE STRESSING SYSTEMS IN PRACTICE.

3. Summarize on Light Weight Concrete and its Application.

By replacing the normal Aggregate into Light Weight Aggregate we can get the Light
Weight concrete.
Advantages :
Types :
 Application :

1. Screeds and thickening for general purposes especially when such screeds or thickening
and weight to floors roofs and other structural members.
2. Screeds and walls where timber has to be attached by nailing.
3. Casting structural steel to protect its against fire and corrosion or as a covering for
architectural purposes.
4. Heat insulation on roofs.
5. Insulating water pipes.
6. Construction of partition walls and panel walls in frame structures.
7. Fixing bricks to receive nails from joinery, principally in domestic or domestic type
construction.
8. General insulation of walls.
9. Surface rendered for external walls of small houses.
10. It is also being used for reinforced concrete.

4. What is Pre-stressed Concrete. Compare Pre tensioned and Post tensioned

concrete.
Prestressed concrete is construction material in which external pre-stressing force is applied
on the concrete to reduce the tensile stresses which results in the prevention of cracking. It also makes
the prestressed concrete section stiffer than reinforced concrete section. The downward moment of
prestressed section is eliminated due to upward force which is imposed on the concrete in curved
tendons.
Prestressed concrete structures have become extremely useful in the construction of leakage
free structures. It is also being used for many years for structures under gravitational loading. The
applications of the material like high strength concrete and high strength steel are increasing rapidly,
encouraged as the suitability of prestressed concrete to modern prefabricatedconstruction.One of the
major problems with prestressed
 Pre-tensioning and Post-tensioning both methods are used under pre-stressing process which
has few edges over the orthodox non-stressed structures like greater span to depth ratio, higher moment
and shear capacity. These methods are generally adopted in the making of PSC girders, sleepers etc.

Pre-tensioning : Post-tensioning:

In this method, the concrete is prestressed with In this method prestressing is done after the concrete
 tendons before it is placing in position. attains sufficient strength.

This method is developed due to bonding
between the concrete and steel tendons.
Pre tensioning is preferred when the structural
element is small and easy to transport.
In this method, similar prestressed members are
prepared.
Pre-tensioning members are produced in
mould.
This method is developed due to bearing.
Post tensioning is preferred when the structural
element is heavy.
In this method, products are changed according to
structure.
Cables are used in place of wires and jacks are used
for stretching.

5. Illustrate the innovations of using pre-stressed concrete as building material

with appropriate case example.

Prestressed concrete is a method for overcoming concrete's natural weakness in

tension. Prestressing tendons (generally of high tensile steel cable or rods) are used which produces a
compressive stress that offsets the tensile stress that the concrete compression member would
otherwise experience due to self–weight and gravity loads. Traditional reinforced concrete is based
on the use of steel reinforcement bars, rebar, and inside poured concrete.
 In the prestressed concrete structures, high strength concrete and high strength steelare
used to improve the load bearing capacity and crack control.

Prestressed concrete is used in a wide range of building and civil structures where its improved
performance can allow for longer spans, reduced structural thicknesses, and material savings
compared with simple reinforced concrete. Typical applications include high-rise buildings,
residential slabs, foundation systems, bridge and dam structures, silos and tanks, industrial
pavements and nuclear containment structures.

First used in the late-nineteenth century, prestressed concrete has developed beyond pre-tensioning
to include post-tensioning, which occurs after the concrete is cast. Tensioning systems may be
classed as either monostrand, where each tendon's strand or wire is stressed individually, or multi-
strand, where all strands or wires in a tendon are stressed simultaneously.[5] Tendons may be located
either within the concrete volume (internal prestressing) or wholly outside of it (external
prestressing). While pre-tensioned concrete uses tendons directly bonded to the concrete, post-
tensioned concrete can use either bonded or unbonded tendons.

Pre – tensioned Concrete

It requires stout anchoring points between which the tendon is to be stretched and the
tendons are usually in a straight line. Thus, most pretensioned concrete elements are prefabricated in
a factory and must be transported to the construction site, which limits their size. Pre-tensioned
elements may be balcony elements, lintels, floor slabs, beams or foundation piles. An innovative
bridge construction method using pre-stressing is described in stressed ribbon bridge.

Post-Tensioning in Building Structures

Followings are the market factors, which favor implementing Post-Tensioning system in Building
structures:

 Longer spans
  Unique designs: irregular shapes
 Shorter construction cycles
 Cost reduction
 Shorter floor-to-floor heights
 Superior structural performance

Post-tensioning offers direct cost reduction over conventionally reinforced slabs primarily
by reducing concrete and rebar material quantities as well as rebar installation labor. Typically, savings
between 10%–20% in direct cost are achieved.

Followings are the factors which contribute to direct cost reduction:

 Less concrete material

 Reduction in slab thickness reduces total building height and cost
 Less rebar
 Less labor cost for installation of material
 Reduced material handling
 Simplified formwork leads to less labor cost
 Rapid reuse of formwork leads to less formwork on jobsite

Improved Construction Efficiency

Since post-tensioned slabs are designed to carry their own weight at time of stressing, they can
significantly improve construction efficiency and deliver an additional 5%-10% of indirect
savings.

Following factors contribute to improved construction efficiency:

 Shorter construction cycles

 Less material handling and impact on other trades
 Simpler slab soffit–less beams and drop caps/panels
 Quicker removal of shoring gives more access to lower slabs

Typical 5-Day Construction Cycle schedule for 800-1,000 m2 of slab is shown below. 3-day
cycle is also achievable with early strength concrete and industrial formwork.

Superior Structural Performance

The prestressing in post-tensioned slabs takes optimal advantage of tendon, rebar and concrete
properties to deliver an economical structural system.

Factors contributing to superior structural performance are listed here:

 Use of high-strength materials

 Deflection control
 Longer spans are achieved
 Crack control and water-tightness
 Reduced floor-to-floor height
 Lighter structure requires lighter lateral load resisting system
 Economy in column and footing design
 Reduced noise transmission compared to RC
  Lower total cost of ownership (maintenance) compared to RC alternatives

Building Examples :

Construction began August 2002 and

took 4 years and 2 months.
The tower was built using reinforced
concrete. using a slip form method. Eureka
Tower's lift core superseded the height of
Rialto Towers on 9 November 2004.
On 23 May 2006, the crane on top of
the tower was dismantled by a smaller
crane, which was dismantled by a smaller
crane that could be taken down the service
elevator.
Eureka Tower has 24 carat (99.9%)
gold plated glass windows on the top 10
floors of the building. Installation of the
gold glass was completed in March 2006.
Apartment owners and tenants had taken up
residence in the building between Ground
Level and Level 80 as of July 2006.
On 11 October 2006, the tower was
officially opened by then Premier of
Victoria, Steve Bracks.
 The Capital Gate project was able to
achieve its inclination through an
engineering technique, known as pre-
cambering, that allows floor plates to be
stacked vertically up to the 12th story and
staggered, one over another, between 300 to
1,400 millimeters (12 to 55 in).

The gravitational pressure caused by

the 18° incline is countered by the pre-
cambering, using a core of concrete
reinforced with steel, with the core
deliberately built slightly off-center. It is
also anchored to the ground by 490 piles
which are drilled 20 to 30 meters (66 to
98 ft) underground

6. Explain About the Pre-cast Structural Product and construction procedures with
necessary sketches.
Precast structural Products

Precast Beams
Precast Columns
Precast floor slabs
Precast walls
Precast staircases
Precast Columns:
For structures of five storeys or less, each column will normally be continuous to
the full height of the building. For structures greater than five storeys two or more columns are
spliced together.The main types of precast columns are:

Edge columns – Internal columns –

Corner columns – symmetrical in one symmetrical in all directions.
not symmetrical at all. direction.

Precast floor slabs:

The main types of slabs are used in the precast frames are:

Hollow Cored slab :

Double tee slab :

Precast walls:

Precast concrete walls serve two functions:

• Stability
• As walls or boxes surrounding staircases and lift shafts.

Walls may be classified as infill or cantilever:

• Infill walls rely on contiguous composite action with the beam and column frame.
• Cantilever walls or boxes act as deep beams to which the frame is attached.

Precast staircases: Three options are available for precast staircases:

• A single precast unit containing all the flights and landings.

• Separate precast flights and landings.
• Parts of the flights and landings are made in one piece.
Connection Procedure :
Column to Foundation :

Wall to Foundation :
Beam to Column :
Column to Column :
Wall to Slab :
Slab to Beam :

Wall to Wall :
 Staircase to Slab :

7. Differentiate the Pre-Cast Concrete and Cast In-Situ Concrete.

8. Sketch different kinds of Pre cast blocks, tiles for wall , roof and floor, jali.
And mention its applications.

Blocks
Application

The use of concrete blocks as a masonry unit can be observed on many construction sites
because of the following advantages:

1. It increases the carpet area of the building because of small width of concrete block as
compared to the brick masonry wall.
2. It provides better thermal insulation, enhanced fire resistance and sound absorption.
3. It results in the saving of precious agricultural land which is used for manufacturing
bricks.
4. The blocks can be prepared in such a manner that the vertical joints can be staggered
automatically and thus the skilled supervision is reduced.
5. The construction of concrete block masonry is easier, faster and stronger than the
brick masonry.
6. The perfect shape and size of the concrete block makes the work of a mason much
simpler.
7. There is saving in construction of mortar because the numbers of joints are reduced.
8. The utility can be further increased by producing reinforced concrete block (RCB)
masonry units. The blocks are provided two holes for placing suitable reinforcing bars
and the structure with RCB units could safely resist wind and earthquakes, if so
designed. The traditional beams and columns can be completely eliminated and the
structure with RCB units can be given a better appearance.

Tile- Floor
Tiles - Wall
Tile - Roof

Application :

 Tiles are often used to form wall and floor coverings, and can range from simple square
tiles to complex
 Tile is one of the cheapest flooring options, especially compared to popular materials such
as hardwood and marble. Most tiles can withstand heavy use in living rooms and the heat
and moisture of bathrooms. Best of all, its easy to install.
 Small decorative tiles make great accents for walls, counters, and flooring. They usually
come in stronger, deeper colours and feature interesting patterns, often to complement the
colour of biggr tiles. Using tile , we can dress up large walls or can design.
  Roof tiles are designed mainly to keep out rain and heat. A large number of shapes (or
"profiles") of roof tiles have evolved.

Jali

Application

 A jali (meaning "net") is the term for a perforated stone or latticed screen, usually with an
ornamental pattern constructed through the use of calligraphy and geometry.
 The jali helps in lowering the temperature by compressing the air through the holes. Also
when the air passes through these openings, its velocity increases giving profound
diffusion.

9. Explain about the manufacturing and laying Process of Non-Structural Pre-

cast products.
Precast Pipe

Furniture
Compound Wall
Manhole Cap

10, Explain about the construction and finishing process of structural Pre-cast
Products.

Connection Procedure :
Column to Foundation :
Wall to Foundation :

Beam to Column :
Column to Column :
Architectural Finishes and Colors

Precast concrete products are known for their strength, durability, cost savings etc.
SlenderWall has all of those benefits wrapped up in a product that also enhances the aesthetics of
your project. We offer an extensive variety of standard and custom precast concrete cladding
finishes and detail options that can be produced within our 2-inch thick exterior cladding surface.

SlenderWall producers can make panels in any color or texture that is found within
the PCI Color and Texture Guide. Over 24 colors and 500 texture options are at your disposal for
limitless finish possibilities. However, colors and textures may vary by region due to the variance
of natural materials.

When it comes to the precast concrete cladding color, it’s important to keep in mind
that its surface texture will influence the appearance of color. The building's appearance is a
function of the architect's use of light, shadow, texture, and color.

Concrete offers opportunity for innovation and individual character in surface

textures, patterns, and shapes, all of which can be achieved by casting with various types of
formliners. A large pattern offers ever-changing details due to the play of light and shadow. A fine
texture offers a muted appearance that is subtle. Smooth surfaces bring out the elegance and
richness of simplicity. Textures created by modeling or sculpturing with liners may be used for
visual effect to enliven large concrete surfaces with low relief patterns. The options for
combination finishes, involving one or more basic finishing methods together with formliners, are
almost infinite. Innovative patterns and designs can now be achieved by utilizing a combination of
CAD and Computer Numerical Control (CNC) machining to produce custom formliners. CNC
integrates computers into component manufacture, allowing for intricate pattern and form
creation. An important consideration lies in selecting the texture and/or type of formliner best
suited to the project. If there are large wall expanses, a texture-like fractured fin with greater depth
may give a more noticeable appearance with deeper shadowing. Shallow flutes, bushhammered,
or subtle textures are often better for relatively small areas. Precast concrete patterns can be
produced in a range of sizes and patterns to suit a particular structure and the distance from which
it will most often be seen.
11. Explain Deeply the Pre-Fabricated Architecture.

PREFABRICATED ARCHITECTURE

• Increasing population, international economic problems, energy crisis and worldwide

environmental problems are considerable issues that are forcing the world to conceive
innovative solutions that are fast, feasible, and sustainable.

• Prefabricated architecture is an architectural approach based on an offsite manufacturing

process of building materials, components, or systems which are then installed together to form a
larger assembly on-site.

Prefabricated architecture is not a new trend; however, it has recently become a popular
trend worldwide due to several ADVANTAGES which promote sustainability such as:
 The quick construction process and assembly,
 High quality control,
 Construction waste reduction,
 Modular flexibility,
 Cost reduction,
 Affordability,
 Consistency
 Improving energy efficiency
 Environmental control.

 Although the various advantages of prefabricated architecture, its practices is still limited.
This can be referred to the lack of knowledge about its characteristics and properties.

• We have to determine the main characteristics of prefabricated architecture as an alternative

construction approach that promotes sustainability.

• This is achieved through a comprehensive critical analysis of existing relevant literature to

define these characteristics which include:

the different terminologies, scales of

prefabrication,
sustainability aspects,
and structural aspects.
•Defining these characteristics could facilitate design decision-making for optimum prefabricated
buildings practices and push stakeholders to promote this trend and encourage its application.

Prefabrication is used in a myriad of different industries but is especially prevalent in the

construction sector.

Some of the main uses of prefabrication are listed below:

 Prefabricated houses
 Prefabricated stores
 Prefabricated apartment blocks
 Modular units and rooms
 Prefabricated shelters
 Prefabricated military barracks/facilities

In a similar method to precast, prefabrication allows for a smoother and more efficient
construction process for building projects.

If a construction company has a project with limited space and time constraints, prefabricated
structures could allow the company a greater level of flexibility. All that is required is a team of
fitters to install the prefab unit, and ground workers to lay foundations if necessary.

Modular Construction can be considered a form of Prefabricated Construction.

 Difference between Precast Structure and Prefabrication Structure :

Precast structure and prefabricated structure both are prefabrication process but the differences are
following as:

 Limited building design flexibility in precast structure as compared to prefabricated

structure.
 All building products are connected well with nut and bolts in prefabricated structure but
connections may be difficult in precast structure due to heavy structure.
 Panel size is limited in precast structure, so it cannot be used for two-way structural
systems but in prefabricated structures any size of panel can be used by jointing them.
 Joints between panels are often expensive and complicated in precast construction but in
prefabricated structure it is not like that.
 Less construction time required in prefabricated structure but more construction time
required in precast structure.
 Prefabricated structure is a light steel structure while precast construction is comes in very
heavy members.
 Installation is easy in prefabricated construction but installation in precast structure is very
difficult, required cranes to lift the panels.

12. Explain the following

(i) Aerated Concrete
(ii) No-Fine Concrete
(iii) Polymer Concrete
(iv) Ferro-cement Concrete
(i) Aerated Concrete :

Aerated concrete (AC) is a lightweight, precast, foam concrete building material

suitable for producing concrete masonry unit (CMU) like blocks.

Aerated Concrete = quartz sand + calcined gypsum + cement + water and aluminum
powder,
AC products are cured under heat and pressure in an autoclave.
Invented in the mid-1920s, AAC simultaneously provides structure, insulation, and fire-
and mold-resistance. Forms include blocks, wall panels, floor and roof panels, cladding (façade)
panels and lintels
AC is strong enough to use for structural parts of a building, but isn't as strong as
conventional concrete. According to the Portland Cement Association, autoclaved aerated
concrete has an allowable shear stress of 8 to 22 psi, and a compressive strength of 300 to 900
psi.

AC is well suited for high-rise buildings and those with high temperature variations. Due to
its lower density, high-rise buildings constructed using AC require less steel and concrete for
structural members. The mortar needed for laying of AC blocks is reduced due to the lower
number of joints. Similarly, the material required for rendering is also lower due to the
dimensional accuracy of AC. The increased thermal efficiency of AC makes it suitable for use in
areas with extreme temperatures, as it eliminates the need for separate materials for construction
and insulation, leading to faster construction and cost savings.

(ii) No Fines Concrete

No Fine Concrete = Course Aggregate + cement + water

No-fines concrete is generally made with the aggregate/cement ratio from 6 : 1 to 10 :1.
Aggregates used are normally of size passing through 20 mm and retained on 10 mm.
Advantages of No-Fines Concrete :

1. No fines concrete is a lightweight concrete i.e. density is about 25 to 30% less than the
normal concrete due to no fine aggregates, thus self-weight of structure is less.
2. As it does not have sands or fine aggregates, it has less drying shrinkage compared to
normal concrete
3. It has better thermal insulating characteristic than normal concrete and thus it is useful for
construction of external wall.
4. As it has no fine aggregates, the surface area required for cement coating is reduced
considerably. So, quantity of cement required gets reduced per cubic meter compared with
normal concrete. So, it is economical.
5. Lightweight concrete has no effect on quality due to segregation of coarse aggregates as it
has no fine aggregates. Thus, it can be dropped from heights.
6. No fines concrete can be compacted without the need of any types of concrete vibrators
and can be easily done by tamping with rods.

(iii) Polymer Concrete :

Polymer Concrete = Course Aggregate + Fine Aggregate + Polymer + water

(iv) Ferro-cement Concrete
Steel Mesh Wire Mesh
13. Explain about the building material and components developed by CBRI.
14. Explain about the basic principle of Seismic design in concrete.
15. Explain about the renovation and retrofitting techniques for concrete.
Renovation :

Renovation is the process of improving a broken, damaged, or outdated

structure.
• Renovations are typically either commercial or residential.
• Additionally , renovation can refer to making something new, or bringing something
back to life and can apply in social contents.
Retrofitting :
Retrofitting refers to the addition of new technology or features to older
systems.
• Power plant retrofit , improving power plant efficiency / increasing output / reducing
emissions.
• Home energy retrofit, the improving of existing building with energy efficiency
equipment.

Retrofitting helps to reduce earthquake damages, hence it is worth much more than its cost.

• Homeowners want to ensure the safety of their family.

• Landlords want to avoid future loss of income from a vacant and damaged building.
Often retrofit involves modifications to existing commercial buildings that
may improve energy efficiency or decrease energy demand. In addition, retrofits are often
used as opportune time to install distributed generation to a building.

Other benefits of retrofit existing buildings includes;

• cost saving in long run by reducing the usage of energy and water by incorporating new
technology , services or equipment;
• increasing the comfort level in a building by redesign the façade and interior to improve
end users productivity and satisfaction through…

Techniques

Common seismic retrofitting techniques fall into several categories:

Adding steel beams on each side of an existing concrete beam
Enlarging a section an existing concrete beam

Retrofitting Concrete Column