CONCRETE MADE EASY

CONCRETE
Basic Definition:

Concrete is a composite material that essentially consists of a binding

medium embedded with Fine-Aggregate (typically sand) and Coarse
Aggregate (typically gravel) with or without chemical and mineral admixture.

Constituents:

•Mixture of aggregate and paste

→paste 30 to 40%
Portland cement + Mineral Admixture 7% to 15% by Vol.
Water + Chemical Admixture 14% to 21% by Vol.

→Aggregates 60% to 70%

coarse aggregates
Fine aggregates
CONCRETE – Typical Ingredients Proportion (By
Volume)
 CONCRETE – Universal Construction Material

• Concrete is neither as strong nor as tough as steel, so why is it the most widely u
sed engineering material?

There are at least three primary reasons.

• concrete possesses excellent resistance to water.
• The second reason for the widespread use of concrete is the ease with which str
uctural concrete elements can be formed into a variety of shapes and sizes.
• The third reason for the popularity of concrete with engineers is that it is usually
the cheapest and most readily available material on the job.

Quantity of concrete consumed by humankind is next only

to water .
 Basic Concrete Ingredients

Coarse Aggregat
CEMENT NATURAL SAND
e

WATER
CONCRETE – IN FRESH STATE
CONCRETE – IN FRESH STATE
 Cement – As Concrete Ingredient

Portland cement, the basic ingredient of concrete, is a closely controlled

chemical combination of calcium, silicon, aluminium, iron and small amounts of
other ingredients to which gypsum is added in the final grinding process to regu
late the setting time of the concrete.

Lime and silica make up about 85% of the mass. Common among the mater
ials used in its manufacture are limestone, Bauxite, laterite, shells, shale, clay,
slate or , silica sand, and iron ore.
 Cement – As Concrete Ingredient
Portland Cement

• Dry powder of very fine particles

• Forms a paste when mixed with water

• Chemical reaction-Hydration

• Gel

• Paste coats all the aggregates together

• Hardens and forms a solid mass

Primary role is to give binding property & strength to concrete.

 Cement – As Concrete Ingredient
Types of Portland Cement

• Ordinary Portland Cement (IS 12269)

Typically 95% Clinker & 5% Gypsum

- 43 Grade (IS 8112) [less grinding, low surface area, strength target 43MPa+)
- 53 Grade (IS 12269) [high grinding, high surface area, strength target 53MPa+)

• Portland Pozzolana Cement (IS 1489)

Typically 85 to 65% clinker, Fly Ash (by product of thermal power plant) 15 to 35% & 3 to 5% Gypsum)

• Portland Slag Cement (IS 455)

Typically 65 to 30% clinker, GGBF Slag (by product of iron industries) 35 to 70% & 3 to 5% Gypsum)

As all cement differ (chemically, physically & mineralogically) in their

formulation, they can’t be substitutes to each other in a given concrete mix.
 Cement – As Concrete Ingredient
With increase in Cement Content :
Concrete
• At a given w/c ratio, high workability (because of high paste content, ball bearing a
ffect)
.
 Cement – As Concrete Ingredient
With increase in Cement Content :

Concrete

• Strength increases (w/c ratio constant)

• Cost Increases

• Volume instability( chances of plastic and drying shrinkages increases),

being the most reactive ingredient.

Cement content has to be kept bear minimum( considering all design

requirements) to get a economical & good concrete.
 Water – As Concrete Ingredient
Water :

• Needed for two purposes:

• chemical reaction with cement
• Workability

• only 1/3 of the water is needed for chemical reaction

• extra water remains in pores and holes

• results in porosity

• Good for preventing plastic shrinkage cracking and workability

• Bad for permeability, strength, durability.

Primary role is cement hydration

Water is necessary evil in a concrete mix

 Aggregate – As Concrete Ingredient
Aggregate:

• Economical Inert fillers

• Hard material

• Provide volume stability

• Reduce volume changes

• Provide abrasion resistance

Basic role is to give volume stability ,higher the cement content concrete
is more prone to shrinkage.
 Aggregate – As Concrete Ingredient
Aggregates are generally classified according to particle size, bulk density, or source).

• coarse aggregate is used to describe particles larger than 4.75 mm.

• fine aggregate is used for particles smaller than 4.75mm; typically,

Fine aggregates contain particles in the size range 75 µm to 4.75 mm, and coarse
aggregates from 4.75 to about 50 mm, except for mass concrete which may
contain particles up to 150 mm.

Fine Aggregate and Coarse Aggregate are proportioned in a concrete mix to give
maximum packing density (Grading of each aggregate would influence there
proportion among each other )

Generally, aggregate properties affect not only the concrete mixture proportions but
Also the behavior of fresh and hardened concrete.
 Aggregate – As Concrete Ingredient

A knowledge of certain aggregate characteristics (i.e., density, grading, and

moisture state) is required for proportioning concrete mixtures. Porosity or density,
grading, shape, and surface texture determine the properties of plastic concrete
mixtures.

Size and Grading :

• There are several reasons for specifying grading limits and maximum aggregate size,
the most important being their influence on workability and cost.

For example, very coarse sands produce harsh and unworkabl

e concrete mixtures, and very fine sands increase the water requirement (therefore,
the cement requirement for a given water-cement ratio are uneconomical).

• Aggregates that do not have a large deficiency or excess of any particular size produ
ce the most workable and economical concrete mixtures.
 Aggregate – As Concrete Ingredient
Size and Grading :

• Larger the particle size, the higher the slump for a given paste content.
(Larger particles, less surface area, thicker coating, easy sliding (ball b
earing affect) of particles.

• Smaller particles, more surface area, thinner coating, interlocking of particles.

Shape:
• Flakiness Index :Thickness being 0.6 times their mean dimension, contributes more surface are
a for a unit volume occupied.
• Elongation Index :Greatest dimension being 1.8 times their mean dimension, contributes more
surface area for a unit volume occupied.

High flaky and elongated aggregates (>25%) requires high cement content to
produce a required workable mix. Angular/spherical shape of aggregate are best for
concrete making
 Aggregate – As Concrete Ingredient
Fineness Modulus (F.M) :Empirical factor called the fineness modulus is
often used as an index of the fineness of aggregate.

The fineness modulus is computed from screen analysis data by adding the cumulati
ve percentages of aggregate retained on each of a specified series of sieves, and divi
ding the sum by 100. The sieves used for determining the fineness modulus are: No.
100 (150 µm), No. 50 (300 µm), No. 30 (600 µm), No. 16 (1.18 mm), No. 8 (2.36 mm)
, No. 4 (4.75 mm), 10 mm,20mm,40mm etc.

→ Sand with Fineness Modulus in the range of 2.4 – 3.0 are best for concrete
making

→Higher the F.M the greater proportion of fine aggregate in a given concrete mix
Example : F.M = 2.6 : Sand = 35% ,C.A = 65%
F.M = 3.0 : Sand = 40% ,C.A = 60%
 Aggregate – As Concrete Ingredient
Slit Content :Material finer than 75-µm (No. 200) sieve are generally
called slit. They affect the workability as water demand increases, strength
is also influenced along with bonding.

IS limit is 3% by weight.

→ 1% Silt can reduce concrete strength by 15%

GENERAL ACCEPTACE CRITERIA BY VOLUME:

After 10mins = 12%

After 2hrs. = 8%

For durable concrete washed sand is advisable, with zero silt in sand considerable
amount of cement content can be reduced.
 Aggregate – As Concrete Ingredient

• Aggregate primarily acts as a inert filler, but has secondary influences on various con
crete properties.

• Awareness about the role played by aggregate in concrete can be instrumental in ex

ploiting the use of the same in achieving concrete properties as per intended require
ments, which would be of high performance and economical.

It is inappropriate to treat the aggregate with any less respect than cement.
 Admixtures – As Concrete Ingredients

Admixtures are material other than cement, aggregates & water that are added to concrete
either before or during mixing to alter its properties & performance in fresh (workability, setting
time etc) and hardened state (strength, durability etc.)

CONCRETE ADMIXTURES ARE BROADLY DIVIDED INTO TWO TYPES i.e.

1.Chemical Admixtures (Water Reducers, Super plasticizers, Retarders, Accelerators etc.)

2.Mineral Admixtures (Fly Ash, GGBFS, Metakaoline, Silica Fumes etc.)
 Admixtures – As Concrete Ingredients
Typically incorporated to improve the following concrete properties

• Protect Against Freeze Thaw Cycles –Improve Durability

• Water Reduction in the Mix
• Mid- Range water reducers
• High-Range water reducers – superplasticizers
• High Strength Concrete
• Corrosion Protection
• Set Acceleration
• Strength Enhancement
• Set Retardation
• Crack Control (shrinkage reduction)
• Flowability
• Self levelling
• Finish Enhancement
Chemical Admixtures – As Concrete Ingredi
ents
• Chemical admixtures are used to improve the quality of concrete during mixing, transporting,
placement and curing. They reduce the cost of construction, modify properties of hardened c
oncrete, ensure quality of concrete during mixing/transporting/placing/curing, and overcome
certain emergencies during concrete operations.

• They are basically chemical compounds. Dosage ranges from 0.2% to 2% by weight of cement
.

→ They fall into the following categories:

• air entrainers
• water reducers
• set retarders
• set accelerators
• superplasticizers
• specialty admixtures: which include corrosion inhibitors, shrinkage control, alkali-silica reactivi
ty inhibitors, and coloring.
Chemical Admixtures – As Concrete Ingredi
ents
• Air entraining Admixtures:
Air-entraining agents entrain small air bubbles in the concrete. The major benefit of this is
enhanced durability in freeze-thaw cycles, especially relevant in cold climates.

• Retarding Admixtures:
Retarding admixtures slow down the hydration of cement, lengthening set time. Retarders are
beneficially used in hot weather conditions in order to overcome accelerating effects of higher t
emperatures and large masses of concrete on concrete setting time

• Accelerating admixtures: :
Accelerators shorten the set time of concrete, allowing a cold-weather pour, early removal of for
ms, early surface finishing, and in some cases, early load application.
Chemical Admixtures – As Concrete Ingredi
ents
• Water Reducing Admixtures :

Water reducing admixtures require less water to make a concrete of equal slump, or increase the
slump of concrete at the same water content. Typical water reduction is the range of 10 – 15%.

• Superplasticizers :

High range water reducers are admixtures that allow large water reduction or greater flowability
(as defined by the manufacturers, concrete suppliers and industry standards) without substantia
lly slowing set time or increasing air entrainment.

• Specialty admixtures:

Include corrosion inhibitors, shrinkage control, alkali-silica reactivity inhibitors, and coloring.
Chemical Admixtures – As Concrete Ingredi
ents
Using a Water Reducer: Option 1

• To get a stronger and more durable concrete from a given amount of cement by allowing reduct
ion of water-cement ratio

• Most regular water reducers will permit 5-15% reduction water

Example
• Original mix:
330 kg cement, 181.5 kg water, w/c = 0.55
strength at 28 days = 30 MPa

• Mix with water reducer

330 kg cement, 165 kg water, w/c = 0.5
strength at 28 days = 36 MPa
Chemical Admixtures – As Concrete Ingredi
ents

Using a Water Reducer: Option 2

• For a given w/c a mix may turn out to be unworkable.

• Add water reducer to increase slump without making adjustment to mix proportions.

• Results in better workability of the mix and slight increase in strength.

Chemical Admixtures – As Concrete Ingredi
ents
Using a Water Reducers: Options 3

• Economy: a concrete with the same w/c and same strength can be produced with less cement.

• Normally the extra cost for the water reducer is more than offset by savings in cement.

Example
→Original Mix
330 kg cement, 165 kg water, w/c =0.5

→Mix with WR (10% water reduction)

150 kg water, For w/c = 0.5
cement required = 300 kg. ÎSave 30 kg cement/m 3 of concrete)
 Mineral Admixtures – As Concrete Ingredie
nts
• Mineral admixtures affect the nature of the hardened concrete through hydraulic or pozzola
nic activity. Pozzolans are cementitious materials and include natural pozzolans (such as the
volcanic ash used in Roman concrete), fly ash, Silica Fume, Metakaolin, Rice Husk Ash, GG
BFS.

• Mineral admixtures make mixtures more economical (enables reduction in total cement co
ntent), reduce permeability, increase strength, and influence other concrete properties.

• They can be used with Portland cement, or blended cement either individually or in combin
ations.
 Mineral Admixtures – As Concrete Ingredie
nts
Fly Ash (By product of Thermal Power Plant) :

•Derived from burning coal, fly ash is a valuable additive that makes concrete stronger, more
durable and easier to work with.
•Fly ash aids the formation of cementitious compounds to enhance the strength, impermeabil
ity and durability of concrete.

→Two main classes of fly ash are used in concrete, Class F, and Class C.

Class F
Reduces bleeding and segregation in plastic concrete. In hardened concrete, increases ul
timate strength, reduces drying shrinkage and permeability, lowers heat of hydration and red
uces creep.

Class C
Provides unique self-hardening characteristics and improves permeability. Especially usef
ul in pre-stressed concrete and other applications where high early strengths are required. Al
so useful in soil stabilization.
 Mineral Admixtures – As Concrete Ingredie
nts
Fly Ash (By product of Thermal Power Plant) :

•In addition to economic and ecological benefits, the use of fly ash in concrete improves its w
orkability, reduces segregation, bleeding, heat evolution and permeability, inhibits alkali-aggr
egate reaction, and enhances sulfate resistance.

•Even though the use of fly ash in concrete has increased in the last 20 years, less than 20%
of the fly ash collected was used in the cement and concrete industries

•One of the most important fields of application for fly ash is PCC pavement, where a large q
uantity of concrete is used and economy is an important factor in concrete pavement constru
ction.
 Mineral Admixtures – As Concrete Ingredie
nts
Silica Fume (By product of Silicon and Ferro-Silicon Alloy) :

• When measured by nitrogen absorption techniques, its particles are approximately 100 tim
es smaller than the average cement particle. Because of its extreme fineness and high silica
content, Silica Fume is a highly effective pozzolanic material

•Silica fume can make a significant contribution to early-age strength of concrete. One kilogr
am of silica fume produces about the same amount of heat as a kilogram of Portland cement
, and yields about three to five times as much compressive strength.

•Silica fume improves concrete in two ways – the basic pozzolanic reaction, and a micro filler
effect. Addition of silica fume improves bonding within the concrete and helps reduce permea
bility, it also combines with the calcium hydroxide produced in the hydration of portland ceme
nt to improve concrete durability.
 Mineral Admixtures – As Concrete Ingredie
nts
Silica Fume (By product of Silicon and Ferro-Silicon Alloy) :

• As a microfiller, the extreme fineness of the silica fume allows it to fill the microscopic voids
between cement particles. This greatly reduces permeability and improves the paste-to-aggr
egate bond of the resulting concrete compared to conventional concrete.

•Silica Fume is used in concrete to improve its properties. It has been found that Silica Fume
improves compressive strength, bond strength, and abrasion resistance; reduces permeabilit
y; and therefore helps in protecting reinforcing steel from corrosion.

Caution:
The higher percentage of silica fume used, the higher the amount of super plasticizer neede
d - but mix can become "sticky".
 Mineral Admixtures – As Concrete Ingredie
nts
Ground Granulated Blast Furnace Slag (By product of Iron Industries)

•Ground granulated blast-furnace slag is the granular material formed when molten iron blast fur
nace slag is rapidly chilled (quenched) by immersion in water. It is a granular product with very li
mited crystal formation, is highly cementitious in nature and, ground to cement fineness, hydrate
s like Portland cement.
•Concrete containing GGBFS as a partial cement replacement has longer-lasting workability and
low slump loss during hot weather construction.
•Concrete containing GGBFS exhibits a lower heat of hydration than conventional Portland ceme
nt concrete.
•The use of GGBFS as a partial replacement for Portland cement can reduce available alkalies a
nd can reduce the reaction between certain siliceous components of concrete aggregates and th
e alkalies in the concrete
•Use of GGBFS as a partial cement replacement gives concrete moderate resistance to sulfate a
ttack
 Mineral Admixtures – As Concrete Ingredie
nts
Metakaolin:
• Calcination of Kaolin (a fine, white clay mineral), results a highly pozzolanic material called mat
akaolin.

Rice Husk Ash :

•Rice milling generates a by product know as husk . This surrounds the paddy grain. During milli
ng of paddy about 78 % of weight is received as rice , broken rice and bran .Rest 22 % of the we
ight of paddy is received as husk . This husk is used as fuel in the rice mills to generate steam fo
r the parboiling process .

•This husk contains about 75 % organic volatile matter and the balance 25 % of the weight of thi
s husk is converted into ash during the firing process , is known as rice husk ash ( RHA ). This
RHA in turn contains around 85 % - 90 % amorphous silica.
 Mineral Admixtures – As Concrete Ingredie
nts

•Mineral and Chemical Admixture play a very important role in concrete, its judicious selection im
proves its fresh and hardened concrete properties & enhances its long terms performance.

•New age concrete like Self Compacting Concrete, High Volume Fly Ash Concrete, High Perform
ance Concrete etc, would not have been realized without the availability / incorporation of mineral
and chemical admixture.

•Mandatory use of mineral and chemical admixture should be encouraged in order to attain true s
ustainable development.
 Placing, Compaction & Curing of Concrete

Planning

• Spaces to receive concrete are clear free from debris and free from water.

• Foundations to be concreted in layers of thickness not exceeding 300mm.

• Columns to be cast in one or maximum 2 lifts between the floors(window to restrict concrete
free fall to 1.5m), lift height not exceeding 3.0m for individual lifts.

• Slabs to be cast in strips and not in alternate bays.

• Construction joint locations should be approved or as shown in drawings

• Items like insert, pipe sleeves, water stop, pipe, bolt & other fixtures should be provided as gi
ven in the good for construction drawing.

• All works should be true to level, plumb and square and all corners and edges in all cases sho
uld be unbroken & neat.

37
 Placing, Compaction & Curing of Concrete
Transportation & Placing
• All concrete should be transported with the help of transit mixers to the place of la
ying as rapidly as possible.

• When a truck mixer of agitator is used for transporting concrete, the concrete sho
uld be delivered to the site of work and discharge should be complete within 3 hrs
from plant exit.

• Acceptable temperature of concrete, air temperature & shade temperature etc. sh

ould be as per specifications and verified by supplier before delivery.

• Placing of concrete should generally be done using pumps to achieve necessary he

ights wherever required.

• In case of deep trenches/footings, it may be done with the help of chutes or direct
ly from transit mixers from the reasonable height.
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 Placing, Compaction & Curing of Concrete
Transportation & Placing

• In columns it can be placed manually with the help of staging. Concrete from wheel barrows
should be dumped into the face of concrete already in place.

• Suitable platform should be provided for working wherever required.

39
 Placing, Compaction & Curing of Concrete
Transportation & Placing

• The concrete should be deposited as nearly as practicable in its final position to avoid re-han
dling.

• The concrete should be placed and compacted before initial setting of concrete commences
and should not be subsequently disturbed.

• Concrete should be placed in layers. Bottom layer should not finally set before the top layers
are placed.

• Methods of placing should be such as to avoid segregation. Care should be taken to avoid dis
placement of reinforcement or movement of formwork.

• Formwork should be continuously watched during and after the concreting. In case of leakag
es, bulging or sagging immediate action should be taken before initial setting of the concrete.

40
 Placing, Compaction & Curing of Concrete
Compaction
• Concrete should be thoroughly compacted and fully worked around the reinforce
ment, around embedded fixtures and into corners of the formwork.

Note : If no care is taken during vibration, it may result in honey combing. Remember
5 % Voids in Concrete , reduces strength of concrete by 30% 41
 Placing, Compaction & Curing of Concrete

Precautions

• Don’t use a vibrator to move concrete horizontally.

• Don’t start a job without a spare vibrator.

• Concrete should not be over vibrated

• Stop vibrating concrete when the concrete surface takes on a shining appearance

• Stop vibrating concrete when larger air bubbles no longer escape

• Stop vibrating concrete when there is a change in the pitch or tone of the vibrator.

42
 Placing, Compaction & Curing of Concrete
Precautions

• Take extra precautions in locations of abrupt section change

• Set concrete not to be disturbed by successive vibration.

Remember
• Cube test cannot check degree of compaction achieved in-situ.

• Poor vibration may take all the difference between good and poor quality concrete.

• Vibration is a skilled job. Insist on a qualified operator. It will be good for the concrete and
make the operator take pride in his work.

43
 Placing, Compaction & Curing of Concrete

After Pouring Precautions

Finishing

• Roof should be troweled even & smooth with wooden float before concrete begins to set.

• Surface that will receive plaster should be roughened immediately.

• Surface in contact with masonry should be roughened immediately.

• Surface that will receive floor finishes, tiling etc. should be roughened while it is still green.

• Freshly laid concrete should not be disturbed

• For ramps and basement concrete should be broom finished.

44
 Placing, Compaction & Curing of Concrete

After Pouring Precautions.

• After removal of formwork from vertical members the surface is checked for defec
ts if any. All minor defects if appeared, to be rectified immediately.

• Hessian cloth should be wrapped on the surface of columns for curing.

• After 24 hrs of laying of concrete, the surfaces should be cured by either ponding
or covering with moist Hessian cloth for period of 7 days.

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Placing, Compaction & Curing of Concrete

46
GOOD PRACTICE BAD PRACTICE
 New Generation Concrete
High Performance Concrete (HPC):
The American Concrete Institute defines HPC as concrete that meets special
performance and uniformity requirements that cannot always be obtained using
conventional ingredients, normal mixing procedures, and typical curing
practices.

High Performance concrete is a specialized series of concrete

designed to provide several benefits in the construction of concrete
Structures.

Performance Benefits Cost & Other Benefits

•Ease of placement and consolidation with •Less material

out affecting strength. •Fewer beams
•Long term mechanical properties •Extended life cycle
•Early high strength •Aesthetics
•Toughness
•Volume stability
•Longer life in severe environmentss
 New Generation Concrete

Self Compacting Concrete (SCC):

• Self-compacting concrete (SCC) is an innovative concrete that does not require vibration for placing a
nd compaction. It is able to flow under its own weight, completely filling formwork and achieving full
compaction, even in the presence of congested reinforcement.

• The hardened concrete is dense, homogeneous and has the same engineering properties and durabili
ty as traditional vibrated concrete.

MIX DESIGN
• High Cementitious Content
• Low Coarse Aggregate Content & Increase Fine Aggregate Content
• Smaller Maximum Aggregate Size.
• High Range Water Reducing Agent
• Viscosity Modifying Agent
 New Generation Concrete

Self Compacting Concrete (SCC):

Benefits.
• Faster construction (Rapid speed of concrete placement)
• Reduce noise pollution (no vibrators used)
• Superior level of finish
• Less energy required
• Less labor required.
• SCC often designed with low water cement ratio has potential of high strength and durable concrete
etc.

Application:
• Elements with thin wall.
• Area of dense reinforcement
• Drill Shaft etc.
 New Generation Concrete
HIGH VOLUME FLY ASH CONCRETE (HVFA):

• Incorporates high volumes of fly ash (~50% by weight of total cementitious content)
• Low water and OPC content.
• Superplasticizer being mandatory to achieve high slump.

ADVANTAGES:
• Use of a byproduct otherwise wasted-disposal problem.
• Economical
• Better Concrete
• Conservation of resources
• Reduction in CO2 emission.

APPLICATIONS:
• Mass Concrete
• Structural and non-structural purposes.
• Severe to very severe environments.
 New Generation Concrete
OTHERS

Fiber-Reinforced Concrete. A new approach to reinforcing concrete is the use of steel fi

bers, about 0.014 inch in diameter and 1.5 inches long, uniformly distributed and randoml
y directed throughout the concrete mix. Such fibers can be utilized either in ordinary reinf
orced concrete or pre-stressed concrete to increase the tensile strength and resistanc
e to cracking.
THANK YOU