SEMINAR BY : RAGHUNATH.

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CONTENTS
1. Understanding concrete materials
Cement
Cement Replacement Materials
Sand
Aggregates
Water
Admixtures
2. Understanding concrete
Fresh concrete
Hardened concrete

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OTHER CONCRETES :
 High strength concrete
 High performance concrete
 Light-weight concrete
 High-density concrete
 Aerated concrete
 No-fines concrete
 Sulphur-infiltrated concrete
 Fibre-reinforced concrete
 Polymer concrete
 Roller compacted concrete
 Ferrocement
 Self compacting concrete.
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 CONCRETE

Expectations?

 Should acquire desired strength ( Design strength)

 Should be workable

 Should be durable

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 HOW TO ACHIEVE

 By careful selection of ingredients.

 By careful proportioning of all the
ingredients. (cement, water, sand and
coarse aggregates)
 By proper mixing.
 By proper placing, compacting and
protecting when it is green.
 By adequate curing.

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 CEMENT
 Cement was invented by Joseph Aspdin
of U.K. in 1824.
 What is cement ?
 Cement is a fine powder which sets and
hardens when mixed with water.
 It’s a binding material
 Can be produced in controlled conditions.
 Early strength.

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Raw materials
 Limestone
 Hematite
 Bauxite
 Clay … etc.

Oxides required in raw material

 Lime
 Silica
 Alumina
 Iron-oxide

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COMPOSITION OF PORTLAND CEMENT

C3S
Silica
C2S

Lime Allumina C3A

Iron Oxide C4AF

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EXTENT OF CHEMICAL COMPOUNDS IN CEMENT

Sl. Compounds Composition as

No. percent
1 C3S 45 -55 %
2 C2S 25-35 %
3 C3A 5-14 %
4 C4AF 9 -15 %
5 Free lime 0.5-1.5%

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EFFECT OF MAJOR COMPOUNDS ON
CEMENT PERFORMANCE
1. C3S :
 High early strength (1,3,7 days),
 Early removal of formwork,
 Reduces cement consumption in concrete

2. C2S :
 Low heat of hydration,
 Contributes to ultimate strength (28 days
strength)

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3. C3A
 Reduced permeability in concrete
 Enhanced durability
 Develops high ultimate strength.
 Generates low heat of hydration.
 Greater volumetric stability
 Moderate sulphate resistance properties.
 Less cracking tendency

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 HYDRATION OF CEMENT

 What is hydration of cement ?

 The reaction between water and cement
is called hydration of cement.
 This reaction is exothermic i.e. heat is
evolved during the course of hydration
 It is called heat of hydration

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 HEAT OF HYDRATION
 Hydration of cement (exothermic)
This heat is called heat of hydration
 It is desirable to know the heat
producing capacity of cement in order to
choose the most suitable cement for a
given purpose
 High degree of fineness of cement
increases the rate of heat of hydration
but not the total heat of hydration.

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 TESTING OF CEMENT

Main physical parameters are

 Fineness
 Consistency
 Setting time
 Compressive strength

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BLAINE AIR PERMEABILITY APPARATUS

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COMPRESSIVE TESTING MACHINE

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 FIELD TESTS

 Check that bags are fresh and machine stitched.

 Indian standards mark
 Check the manufacturing week on the bag.
 There should be no lumps .
 Colour of the cement is uniform.
 Feels cool when hand is inserted.

 Check that an handful of cement when thrown in a

bucket of water floats for some time and then settles
down.

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 TYPES OF CEMENT
There are many types of cement to suit every
need.
1. Ordinary Portland cement (OPC)
2. Portland Pozzolana cement (PPC)
3. Rapid Hardening Portland cement
4. Portland Slag cement (PSC)
5. Sulphate resisting Portland cement (SRC)
6. Low heat Portland cement
7. Hydrophobic cement.
8. Oil well cement
9. White cement

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 SELECTION OF CEMENT
 The type of cement selected should be
appropriate for the intended use
 Some of the major factors which effect the
selection of cement are
 Functional requirement of the structure,
design parameters
 Speed of construction
 Durability characteristics
 Environmental condition

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 OPC 33 GRADE
 Used for general civil construction works.

 Now-a-days this variety is generally not produced

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 OPC 43 GRADE
 Now-a-days 43 grade is being used widely for
general construction work.
 However, 43 grade OPC is gradually being
replaced by blended cements.

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 OPC 53 GRADE
 Used in RCC and pre-stressed concrete of
higher grades,
 Cement grouts,
 Instant plugging mortars etc,
 Where initial higher strength is the criteria.

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 PORTLAND POZZOLONA CEMENT
 Pozzolana: which will in finely divided form
and in the presence of moisture react with
calcium hydroxide to form compounds
possessing cementicious properties.
 PPC makes concrete more impermeable.
 Denser as compared to OPC.
 The long term strength of PPC is higher
compared to OPC,
Contd…

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 PPC produces less heat of hydration
 Offers greater resistance to the attack of
aggressive waters than normal OPC.

 PPC is ideally suited for

 Domestic construction like plastering,
brickwork,
 Mass concreting works like dams, large
foundations etc

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 PORTLAND SLAG CEMENT
 PSC provides better protection against
chloride and sulphate attack.
 PSC is preferred over OPC for usage in
constructions where the structures are
susceptible to sulphate and chloride attack,
 e.g. Marine structure- or structures near the
sea, sewage disposal treatment works, water
treatment plants

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SULPHATE RESISTING PORTLAND CEMENT
 SRC can be used wherever OPC/PPC/PSC is
used
 It is advantageous for foundations, piles,
basements, underground structures, sewage
and water treatment plants and coastal
works, where sulphate attack due to water or
soil is anticipated.

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 LOW HEAT PORTLAND CEMENT
 Low heat Portland cement is particularly
suitable for making concrete for dams
 Many other types of water retaining
structures
 Bridge abutments
 Massive retaining walls,
 Piers, Slabs etc

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 RAPID HARDENING CEMENT (RHC)

 The Rapid hardening cement is used for

repair and rehabilitation works and
 Where speed of construction and early
completion is required due to limitations
of time, space, or other reasons

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HYDROPHOBIC PORTLAND CEMENT
 Special requirement for high rainfall areas to
improve the shelf life of cement.
 The cement particles are given a chemical
coating during manufacturing,
 Provides water repelling property ,
 Cement is not affected due to high humidity
 Can be stored for a longer period,
 Due to abundant availability of cement in all
parts of the country, this Cement is rarely
produced these days.

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 WHITE CEMENT
 White Portland cement is made from raw materials
containing very little iron oxide and manganese
oxide.
 Burning in the kiln is done with furnace oil or gas
instead of coal.
 Limited quantities of certain chemicals , which
improve whiteness of cement, are added during
manufacturing.
 This type of cement is generally mean for non-
structural works.
 It is used for architectural purposes such as
mosaic tiles, wall paintings, and for special
effects.

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 OIL WELL CEMENT
 This is a special kind of cement for use in the
drilling of oil wells to fill the space between the
steel lining tubes and the wall of the well.
 It sets slowly in order to give the slurry made with
it sufficient time to reach the large depths of the
wells.
 However, once set, it develops strength rapidly
and remains stable at high temperatures.

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CEMENT LOSES STRENGTH AS IT AGES

Loss of
SL. No. Age in months
strength in %
1 3 Nil to 10

2 6 20-30
3 12 30-40

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CEMENT REPLACEMENT MATERIALS
FLY ASH
 It is finely divided residue resulting from the
combustion of powdered coal and transported by
the flue gases and collected by electrostatic
precipitator ( Thermal Power plants)
 Mostly used pozzolonic material
 Contributes to environmental Pollution control
 Reference IS-3812

Contd…
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 ADVANTAGES OF FLY ASH
 Savings in cement
 Reducing heat of hydration
 Reducing water demand
 Spherical shape and smooth surface of flyash
helps to reduce the inter-particle friction and thus
facilitates mobility.
 Reduce Bleeding and drying shrinkage.
 Fly ash particles plasticize cement paste and
improves flowability and rheology of the mix.
 Contributes to strength

Contd…
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SECONDARY HYDRATION OF FLY ASH

CEMENT
+
C-S-H Gel + Ca(OH)2
WATER
FLYASH C-S-H Gel

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PETROGRAPHIC VIEW OF FLY ASH

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FLYASH-PARTICLE PACKING EFFECT

FLYASH

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BALL BEARING EFFECT

Cement Flyash

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DISPERSION OF CEMENT PARTICLES
WITH FLY ASH

Trapped Water
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 SILICA FUME (Micro Silica)
 Condensed Silica Fume is a by product of ferro-
Silicon alloy industry and it is the dust which is
collected from furnace exhaust system
 Fineness of silica fume is @ 15000 m2/kg as against
280 to 290 m2/kg of Cement
 Contributes significantly to compressive strength due
to micro-filler effect and excellent pozzolanic
properties
 Leads to increase in density and reduction of
permeability in concrete
 It’s use is must for manufacturing of concrete above
M50
Contd…

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SILICA FUME

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 AGGREGATES
 Aggregate is the word used to describe any inert material .
 Usually rock derivative generally between 50mm down to 75
micron used to produce concrete .
 It is divided into coarse aggregate and fine aggregate
 Those which are 4.75mm to 50mm are classified as coarse
aggregates
 Those below 4.75mm to 75 micron as fine aggregates
 Except for mass concrete in dams etc. which may contain
upto 150mm size aggregate, the maximum size of aggregate
is normally 20mm inmost cases
 But it may be 40mm for plain concrete or massive works.

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PROPERTIES OF COARSE AGGREGATES
 Specific gravity: it should have good crushing
strength and density
 Surface texture: it should be slightly rough but
not honeycombed
 Particle shape : it should be angular, should not
be flaky or elongated.
 Porosity : it should have very low water
absorption

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PROPERTIES OF AGGREGATE EFFECT
 Water demand,
 Workability
 Cohesion of concrete in plastic state
 Strength,
 Density,
 Durability
 Porosity of hardened concrete
 Stability : it should be chemically inert.
 Impurities: it should be free from impurities
(like mica, silt, clay)
 Compactness: it should be graded, then only
the voids can be less.

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 SPECIFIC GRAVITY
 Specific gravity implies the absolute weight per
unit volume of aggregates
 A low specific gravity may indicate
 high porosity
 poor durability
 low strength.
 Specific gravity of aggregates is used in arriving at
mix design
 Generally the specific gravity of good aggregates is
greater than 2.5

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 SURFACE TEXTURE
 Surface texture reveals how grainy or smooth
the surface of the aggregate is.
 It indicates bonding strength and porosity.
 Higher the smoothness of the particle, lesser is
the bonding between aggregate and cement
matrix.
 Experiments have shown that rough textured
aggregates develop higher bond strength than
smooth textured aggregates,
 This property is especially considered while
producing high strength concretes.

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 PARTICLE SHAPE

Particle shapes are classified as

 Irregular
 Rounded
 Flaky
 Angular
 Aggregates should be as much cubical as
possible in shape

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 GRADING
 Grading of aggregates means particle size
distribution of the aggregates.
 Principle of grading is that smaller size
particles fill up the voids left in larger size
particles.

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 GRADING OF COARSE AGGREGATE
IS sieve Percentage passing for single size aggregate of nominal size by weight
Designation
63 mm 40mm 20 mm 16 mm 12.5 mm 10 mm Remarks

80 mm 100 - - -

63 mm 85-100 100 - -

40 mm 0-30 85-100 100 -

20 mm 0-5 0-20 85-100 100

16 mm - - 85-100 100

12.5 mm - - - 85-100 100

10 mm 0-5 0-5 0-20 0-30 0-45 85-100

4.75 mm 0-5 0-5 0-10 0-20

2.26 mm - - - 0-5

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SAND
 Indian standards divides the sand into four
zones
 zone-I to zone-IV based on the sieve analysis
 Sand falling in zone-I is coarse and that falling
in zone-IV is fine.
 Sand falling in zone IV shall not be used for
reinforced concrete work.
 Fineness modulus for sand : ranges from 2.2 to
3.2, higher value indicates coarser grading

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REQUIREMENT OF FINE AGGREGATES
IS sieve Percentage passing
designation Zone-I Zone-II Zone-III Zone-IV

10 mm 100 100 100 100

4.75 mm 90-100 90-100 90-100 90-100
2.36 mm 60-95 75-100 85-100 95-100
1.18 mm 36-70 55-90 75-100 90-100
600 microns 15-34 35-59 60-79 80-100
300 microns 5-20 8-30 12-40 15-50
150 microns 0-10 0-10 0-10 0-15
Remarks Very coarse Coarse Medium Fine

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WATER
 Water helps in dispersing the cement evenly
 Quality of water for making concrete and
for curing
 Water should be free from salts, oils, acids,
alkalis, sugar and organic materials
 pH value shall not be less than 6
 Sea water is not suitable for making concrete

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 PERMISSIBLE LIMITS FOR SOLIDS IN WATER

SL. Description Tested as per Permissible limit (max) mg/l

No.
1 Organic IS-3025(part-18) 200
2 Inorganic IS-3025(part-18) 3000
3 Sulphates (as SO3) IS-3025(part-24) 400
Sulphates (as SO4) IS-3025(part-24) 500
4 Chlorides (as Cl) IS-3025(part-32) 2000 for concrete not
containing embedded steel
1000 mg/l for RCC work
5 Suspended matter IS-3025(part-17) 2000

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 ADMIXTURES
Admixtures are materials mostly chemicals that are added in
small quantities during the preparation of concrete to impart
certain specific properties to it.
The requirements may be
 Improving the workability of concrete during placing
 Retarding or accelerating setting
 Improving the impermeability and water tightness of the
cast concrete.
 Imparting corrosion inhibition etc
 Entraining air in concrete
 There is much difference between the terms ‘additive’ and
‘admixture’

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Compatibility test by
Marsh Cone Apparatus

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DEFLOCULATION OF CEMENT PARTICLES

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DISPERSION OF MECHANISM

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EFFECT OF SUPER PLASTICISER
ON WORKABILITY

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SLUMP : Collapse

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EFFECT OF SUPER PLASTICISER
ON WORKABILITY

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PUMPABLE CONCRETE

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 UNDERSTANDING CONCRETE
FRESH CONCRETE
 Fresh concrete is a freshly mixed material
which can be moulded into any shape.
 Workability: Workability is the ease with which
fresh concrete can be mixed, transported,
placed and compacted in the moulds or forms
 Apart from water-cement ratio the concrete
has to be compacted well to get the required
strength

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 RHEOLOGY OF CONCRETE
 It is the science of the deformation and flow
of materials and is concerned with
relationships between stress, strain, rate of
strain and time.
 The term Rheology deals with the materials

whose flow properties are more complicated

than those of fluids ( liquids or gases)

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Factors affecting workability:
 Water content
 Mix proportions
 Size of aggregates
 Shape of aggregates
 Surface texture of aggregate
 Grading of aggregate
 Use of admixture

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Segregation:
 Segregation can be defined as the separation of
the constituent materials of concrete.
Bleeding:
 Sometimes referred as water gain
 It’s a particular form of segregation due to
highly wet mix
 If water cement ratio is more than 0.7
 Badly proportioned and insufficiently mixed
concrete

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 While traversing from bottom to top
 Bleeding channels responsible for
permeability
 It may be interrupted by aggregates (flaky)
 It may be interrupted by reinforcement
 Reduces bond between reinforcement,
aggregate and paste
 Remedy— re-vibration, delayed finishing

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 SPECIFIC GRAVITY
Cement – 3.15
Coarse aggregate – 2.70
Sand – 2.60
Water – 1.00
Fly ash – 2.15
Silica Fume - 2.20

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 COMPACTION
 Compaction of concrete is the process
adopted for expelling the entrapped air
from the concrete.
 The entrapped air in the form of voids
reduces the strength of concrete.
 For every 1% of entrapped air, the strength
of concrete falls about 5% to 6%.

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 METHODS OF COMPACTION
 Hand compaction
 Tamping
 Ramming : generally permitted for
unreinforced foundation concrete
 RCC should never be rammed
 Compaction by vibration: common needle
vibrator dia is 25mm to 40mm
 External vibrators
 Surface vibrators
Contd…

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 PRECAUTIONS
 When inserting a needle vibrator, allow it to
penetrate the bottom of the layer as quickly
as possible.
 If it is done slowly, the upper part of the
concrete will get compacted and prevent the
air in the bottom layer from escaping.
 The vibrator should be left in the concrete
for about 10 sec. and then withdrawn
slowly. If it is withdrawn fast, a hole will be
left in the concrete.

Contd…

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 The vibrator should be inserted again at a
distance of not more than 50 cm from its
last position.
 The vibrator should not be allowed to touch
the face of the form work or the
reinforcement to prevent the reinforcement
from losing bond with concrete
 Do not stop the vibrator when the needle is
in the concrete.
 Do not over vibrate or under vibrate

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 FINISHING OF CONCRETE
 The rate of levelling should not be less than
the rate placing of concrete

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 STRENGTH OF CONCRETE
 Effect of Water-Cement ratio
 Effect of maximum size of aggregate on

strength
 Grades of concrete:
 Concrete in construction is specified by grade

like M20,M25 etc. Usually increments of five.

 M20 means the specified crushing strength is

20 N/mm2

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 HARDENED CONCRETE
CURING
 Why Curing ?
 To prevent loss of moisture from the
Concrete due to combined effect of hot sun
and drying wind
 Creation of conditions for promotion of
uninterrupted and progressive hydration of
cement during the period immediately after
placing
 Curing does not mean only application of
water

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 CURING METHODS

1. WATER CURING
2. MEMBRANE CURING
3. APPLICATION OF HEAT (Steam Curing)
4. ACCELERATED CURING
 WARM WATER METHOD (1h+1.5 h +20 h+1h)
 BOILING WATER METHOD ( 23h+3.5h+2h)

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 COMPRESSIVE STRENGTH
 Sampling Criteria
 Cube Testing
 Acceptance Criteria
 Non Destructive Testing of Concrete
1. Rebound Hammer Test

 Core Test

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OTHER CONCRETES :
 High strength concrete
 High performance concrete
 Light-weight concrete
 High-density concrete
 Aerated concrete
 No-fines concrete
 Sulphur-infiltrated concrete
 Fibre-reinforced concrete
 Polymer concrete
 Roller compacted concrete
 Ferrocement
 Self compacting concrete.
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 SPECIAL CONCRETES
HIGH STRENGTH CONCRETE

 CONCRETE GRADE FROM M60 ONWARDS

REGARDED AS HIGH STRENGTH CONCRETE
 FOR HIGH STRENGTH CONCRETE DESIGN
STANDARDS GIVEN IN THE CODE IS-456-
2000 MAY NOT BE APPLICABLE
 THEY HAVE TO BE OBTAINED FROM SPECIFIED
LITERATURES OR BY EXPERIMENTAL RESULTS

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 HIGH PERFORMANCE CONCRETE

POSSESSING
1. HIGH WORKABILITY
2. HIGH STRENGTH
3. HIGH DENSITY
4. HIGH DIMENSIONAL STABILITY
5. LOW PERMEABILITY
6. RESISTANCE TO CHEMICAL ATTACK

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 LIGHT WEIGHT CONCRETE
NORMAL CONCRETE
 HEAVY SELF WEIGHT
(DENSITY 2200 to 2600 KG/M3)
 UN-ECONOMICAL
LIGHT WEIGHT CONCRETE
 DENSITY (300 to 1850 KG/M3)
 LOW THERMAL CONDUCTIVITY

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 HIGH DENSITY CONCRETE
 DENSITY 3360 TO 3840 KG/M3 EVEN 5280
KG/M3 USING IRON AS BOTH F.A. AND C.A
 DENSITY 50% HIGHER THAN THE
CONVENTIONAL CONCRETE
 USED AS A SHIELDING MATERIAL FOR
PROTECTION FROM RADIATION

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 AERATED CONCRETE

 It is made by introducing air or gas into

the slurry composed of cement and finely
crushed sand by alluminium powder.
 Uniformly cellular structure is formed.
 Also called as gas concrete, foam
concrete, cellular concrete

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 NO-FINES CONCRETE
 By Omitting fine aggregate fraction
 Made by cement, water and single sized
coarse aggregates
 Having large voids and hence light in weight
 Applications
 Temporary structures
 In external walls for Thermal insulation
 Rough texture gives good base for plastering
 Free from dampness because of low capillary
action on account of large voids

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 RMC PLANT

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CONVEYOR BELT

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DOUBLE SHAFT MIXER

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RMC PLACEMENT THROUGH BOOM PUMPS

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 Properties of Concrete by Naville
 Concrete Technology by M.S. Shetty
 Concrete Technology by Gambhir
 Literature from ACC Cement and RMC
 Literature from Birla Cement and RMC
 Literature from RMC India

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