Professional Documents
Culture Documents
Quality
Definition : Conformance to requirements – expressed
& implied.
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Quality
System of causing Quality
DIRFT (DO IT RIGHT FIRST TIME)
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Quality
Measure : The measurement of quality is the “Price of
non-conformance”.
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Durability
Definition –
• A durable concrete is one that performs satisfactorily in the
working environment during its anticipated exposure
conditions during service (IS 456-2000)
• Durability of concrete is its ability to resist weathering action,
chemical attack, abrasion or any other process of
deterioration (American Concrete Institute).
• When exposed to environment durable concrete is
likely to retain its original form, quality and serviceability
during its lifetime.
• Durable Concrete envisage limits for maximum water
cement ratio, minimum cement content, cover thickness,
type of cement used and presence of amount of chloride
and sulphates in concrete. ( IS-SP-28)
• As Low permeability as possible under situation. (IS-SP-23)
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Consequences of Improper Quality and
Inadequate Durability
• Loss of strength of concrete
• Concrete liable to be easily affected by deterrents
• Corrosion of rebars
• Loss of serviceability
• Unpleasant appearance
• Danger to persons and property
• Expensive repair costs
• Poor perception of concrete as a material
• Poor perception of agencies involved
• Reduction of service life
• External agencies like weathering, attack by natural or Industrial
liquids, Gases, bacterial Growth etc.
• Alkali- aggregate reaction.
• Ingression of moisture/air facilitating corrosion of steel and cracking
concrete cover.
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Consequences of
Inadequate Durability
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Consequences of
Inadequate Durability
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Consequences of
Inadequate Durability
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Factors Influencing Durability of
Concrete (IS: 456-2000)
• The Environment
• Type and quality of constituent materials
• Cement content and W/C ratio of concrete
• Workmanship especially in compaction curing – it is
very important
• Cover to embedded steel
• Shape and size of the member
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Factors Affecting Durability
Durability depends on two main factors
a) The concrete system &
b) The service environment
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Selection of
Good Quality Materials
(Conforming to relevant IS codes)
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UNSOUND MATERIALS
• Cement or aggregate is considered unsound when
they cause unacceptable volume change, hardened
concrete or mortar which causes cracks and affects
durability.
• Aggregates containing certain materials such as
shale, clay lumps, coal, iron pyrites etc show
unsoundness later when concrete undergoes wetting
and drying or freezing and thawing.
• More moisture absorption in aggregate (CA1 or CA11)
is often used as a rough index for unsoundness
• Cement parameters that impact soundness are – free
lime, MgO & excess gypsum
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Water - Permissible Limits for Solids. IS 456:2000 Table-1
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PROCESSES
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Workmanship for
Durable Concrete
Batching
Mixing
Transportation
Placing
Compaction
Finishing
Protection
Curing
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Compaction of Concrete
• Ensuring suitable workability employing
appropriate placing and compaction
equipment
• Adequate compaction without segregation
• 1% voids reduces strength by 5%
Criticality of Curing
• Extremely important if the water-cement ratio
is low & cement content is high.
• If the cement has a high rate of strength
development
• Ambient temperature during placing is high
and day is windy
• If the concrete contains GGBFS or Pulverized
Fly ash (PFA)
Recommended Moist Curing
(IS 456: 2000)
• Normal Weather Conditions
* OPC Based Concretes - 7 Days
* Blended Cements based concretes - 10 Days
a) Physical –
Temperature, Moisture, alternate wetting and
drying, freezing and thawing
b) Chemical –
Acidic, gaseous, alkaline, corrosive
PHYSICAL ENVIRONMENTS
ATTACK AFFECTING DURABILITY
Physical Environment impacts
Temperature
Significantly affects rate of hydration of cement.
Leads to Plastic shrinkage cracks in fresh concrete
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2. Alkali - Aggregate Reaction
• Alkali from cement, reacts with reactive silica (of
aggregates) to form alkali-silica gel of unlimited
swelling type.
• The continuous growth of silica gel exerts osmotic
pressure within the concrete.
• This manifests into cracking and bulging of concrete
Occurrence is due to :
1. High alkali content in
cement (more than 0.6%)
2. Reactive silica in
aggregate
3. Availability of moisture
Alkali - Aggregate Reaction
• Alkali-aggregate reaction (AAR) is basically a chemical
reaction between the hydroxyl ions in the pore water
within concrete and certain types of rock minerals
• Since reactive silica in the aggregate is involved in this
chemical reaction it is often called alkali-silica-
reaction (ASR).
• It is recognized as one of the major causes of cracking
of concrete.
• The reaction produces what is called alkali-silica gel
of unlimited swelling type under favorable conditions
of moisture and temperature.
• The crack width can range from 0.1mm to as much as
10mm.
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Alkali - Aggregate Reaction
• Alkali content (K2O and Na2O) or what is called soda
equivalent.
• This is calculated as the actual Na2O content plus
0.658 times the K2O content of the clinker.
• It should be less than 0.6 percent by mass of
cement.
• Alkalis from all these sources must be included in
finding the total alkalis.
• British standard 5328 : part 1 : 1091 specifies a
maximum of 3.0 kg of alkalis (expressed as soda
equivalent) in 1 m3 of concrete in case of alkali
reactive aggregates are used.
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Alkali - Aggregate Reaction
Remedial Measures:
1. Use non-reactive
aggregates from alternate
sources
2. Use low-alkali cement
3. Reduce cement content in
concrete
At the anode, steel releases electron and takes the ionic form
Fe → 2e- + Fe2+
Fe++ + 2(OH)- 2H
→ 2Fe(OH)
O+O24e 2→
-=4Iron
(OHHydroxide
-) (Rust)
Example of Delamination
of Concrete cover
Corrosion
Crack formed due to bursting pressure on
account of rusting of reinforcements
Methods of
Controlling Corrosion
• Limit the chlorides in water, cement, superplastizers,
etc to acceptable levels
• Provide proper cover as per IS norms
• Cover blocks also need to be of good quality
• Concrete should be properly compacted
• Make dense, impermeable / waterproof concrete
• Have protective coatings wherever suitable
• Ensure proper & timely maintenance of structures
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4. Carbonation of Concrete
• Mechanism : Carbon dioxide from the air reacts
with calcium hydroxide to form calcium carbonates
• In the presence of moisture, carbonic acid is
formed which reduces the alkalinity of concrete
• pH value of concrete reduces from 12.5 to 9, thus
destroying the protective layer and exposing the
steel to corrosion
• Rate of Carbonation depends upon relative
humidity, grade of concrete, permeability of
concrete, depth of cover and time
• Nearly 1 mm carbonation is reported per year in
normal M-20 grade of concrete
Measurement of
Depth of Carbonation
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Steel in Passivity condition
• Concrete is under continuous attack by aggressive
environmental agencies.
• Good concrete and sufficient cover is the answer
for durability
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Acid attack
• But the attack is severe only at a pH value below 5.5.
• At a pH value below 4.5, the attack is very severe.
• Cement compounds are eventually broken down and
leached away.
• If acids are able to reach the reinforcing steel
through cracks corrosion can occur leading to further
cracking
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COVER TO REINFORCEMENT
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Cover to Reinforcement
(IS 456 – 2000)
Exposure Min Nominal
Condition cover (mm)
Mild 20
Moderate 30
Severe 45
Very Severe 50
Extreme 75
Note :
1) For main reinforcement upto 12 mm dia bar for mild exposures,
the nominal cover may be reduced by 5 mm
2) Unless specified otherwise, actual concrete cover should not
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deviate from the required nominal cover by +10mm or 0mm
Effect of Other materials
• Mineral Oil – usually effects only fresh concrete in their
hardening process (petrol, petroleum distillates etc)
• Organic Acid – have corrosive effect
• Vegetable & Animal oils & Fats – causes deterioration of
concrete surfaces due to their corrosive action
• Action of Sugar – has retarding effect on fresh concrete;
has gradual corrosive effect on hardened concrete
• Action of Sewage – concrete sewers running full remain
unaffected; but in partially filled sewers where hydrogen
sulphide gas is evolved & sulphuric acid is formed, concrete
above sewage level gets affected due to corrosive action of
such acids
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Fire Resistance
• The fire resistance is not only dependent upon the
type of concrete but also on the thickness of cover to
reinforcement.
• Effect of temperature on the strength of concrete is
not much upto a temperature of about 250oC
• Above 300oC definite loss of strength takes place.
• Portland blast furnance slag cement is found to be
more resistant to the action of fire.
• Light weight concrete stand up better to fire than
ordinary concrete.
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Fire Resistance
• Best fire resistant aggregates amongst the igneous
rocks are, the basalts and dolerites less amount of
silica.
• Since then decomposition takes place only at a very
high temperature of 900oC , Limestone is considered
as a good fire resistant aggregate.
• Serious reduction in strength occurs at a
temperature of about 600oC.
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Constraints/Issues for Concrete in
Aggressive Environment
I am CSO I am COM
After
construction &
commissioning
Construction Process Analysis
What it should be
What we think it is