Concrete Basics NWA

CENTRAL WATER & POWER RESEARCH STATION INDUCTION TRAINING PROGRAM
For
New Appointees of Central Water
Engineering Services
30 th
DECEMBER 2015
NWA, PUNE
CONCRETE TECHNOLOGY – BASICS, THERMAL
CONSIDERATIONS AND REHABILITATION OF
HYDRAULIC STRUCTURES
S. J. Pillai
Scientist, Concrete Technology Division,CWPRS,Pune-24
CENTRAL WATER & POWER RESEARCH STATION
Concrete
WHAT IS CONCRETE?
 Construction material
 Mixture of portland cement, water, aggregates, and in some
cases admixtures.
 The cement and water form a paste that hardens and bonds
the aggregates together.
 Often looked upon as “man made rock”.
 Versatile construction material, adaptable to a wide variety of
uses.
 Strong, durable, versatile, and economical.
Type of Cement
 33 Grade ordinary Portland cement (IS 269)
 43 Grade ordinary Portland cement (IS 8 112)
 53 Grade ordinary Portland cement (IS 12269)
 Rapid hardening Portland cement (IS 8041)
 Portland slag cement (IS 455)
 PPC (fly ash based) (IS 1489 (Part 1))
 PPC (calcined clay based) (IS 1489 (Part 2))
 Hydrophobic cement (IS 8043)
 Low heat Portland cement (IS 12600)
 Sulphate resisting Portland cement (IS 12330 )
 High alumina cement (IS 6452)
 Supersulphated Cement (IS 6909)
Mineral admixture
 Pozzolanas
 Fly ash
 Silica fume
 Rice husk ash
 Metakaoline
 Ground granulated blast furnace slag

Tests on Cement
 Consistency
 Soundness
 Compressive Strength
 Fineness
 Heat of Hydration
 Loss On Ignition
CENTRAL WATER & POWER RESEARCH STATION Consistency Test
 Consistency of cement as per IS:4031( Part 4).
 Apparatus required is Vicat apparatus conforming to IS:
5513 – 1976.
 Find out the water content required to produce a cement
paste of standard consistency.
Vicat Apparatus – Set up for Consistency & Initial

Setting Time
CENTRAL WATER & POWER RESEARCH STATION Initial and Final Setting Time
As per IS:4031 (Part 5). Vicat apparatus
conforming to IS: 5513 – 1976
 Initial Setting Time: The time period elapsing
between the time, water is added to the
cement and the time, the needle fails to pierce
the test block by 5.0 ± 0.5mm measured from
the bottom of the mould, is the initial setting
time. Cement paste is prepared by gauging
the cement with 0.85 times the water required
to give a paste of standard consistency.
 Final Setting Time: Replace the above
needle by the one with an annular
attachment. The cement should be
considered as finally set when, upon applying
the needle gently to the surface of the test
block, the needle makes an impression
therein, while the attachment fails to do so.
CENTRAL WATER & POWER RESEARCH STATION Soundness
 Soundness refers to the ability of a hardened cement

paste to retain its volume after setting. Lack of soundness
is observed in the cement samples containing excessive
amount of hard burnt free lime or magnesia.
 Soundness of cement is determined by Le-Chatelier
method as per IS: 4031 (Part 3) – 1988. Apparatus – The
apparatus for conducting the Le-Chatelier test should
conform to IS: 5514 – 1969.
CENTRAL WATER & POWER RESEARCH STATION Autoclave Test
 The Le Chatelier test detects unsoundness due to free

lime only. This method of testing does not indicate the
presence and after effect of the excess of magnesia.
 Indian Standard Specification stipulates that a cement
having a magnesia content of more than 3 per cent shall
be tested for soundness by Autoclave test which is
sensitive to both free magnesia and free lime.
 Cement specimen 25 × 25 mm is pressurized with gauge
pressure of the steam to 21 kg/ sq cm for about 1 hour
from the time the heat is turned on. This pressure is
maintained for 3 hours.
The autoclave is cooled and the length measured
again. The high steam pressure accelerates the hydration
of both magnesia and lime.
CENTRAL WATER & POWER RESEARCH STATION Compressive Strength
Test Method: IS: 4031
 The compressive strength of hardened cement is the
most important of all the properties. The standard sand is
used for finding the strength of cement (i.e., ratio of
cement to sand is 1:3) in a non-porous enamel tray and
mix them with a trowel for one minute, then add water of
quantity (P/4 ) + 3.0 per cent of combined weight of
cement and sand and mix the three ingredients
thoroughly.
 Fineness (IS: 4031)

Fineness affects rate of hydration / gain of strength / evolution of
heat. Greater fineness increases early strength and more rapid
generation of heat. Cement fineness play a major role in
controlling concrete properties.
 Heat of Hydration (per IS : 4031)
When cement is mixed with water, heat is liberated. This heat is
called the heat of hydration, the result of the exothermic chemical
reaction between cement and water. The heat generated by the
cement hydration raises the temperature of concrete.
 Loss On Ignition (per IS : 4032)
This test helps in determining the inorganic analytical chemistry,
particularly in the analysis of minerals. It consists of strongly
heating ("igniting") a sample of the material at a specified
temperature, allowing volatile substances to escape, until its
mass ceases to change.
Summary –equipment, acceptance criteria and purpose

Sr. Particulars Equipments Acceptance Purpose of
No. of Tests criteria testing
1. Consistency #Vicat apparatus with About 30 percent Determines mixing water

IS:4031-(Part- plunger 10 mm dia. (G requirements for subsequent
4)-1988 (2009) type), tests
#Triple beam - and minimum
Balance water requirement for
hydration of
cement.
2. Setting time
IS:4031-(Part- 5)-1988 #Vicat apparatus with Not less than Placement compaction is to
(2009) needle 1 mm diameter 30 minutes be completed within initial
(a) Initial setting time (C- Type) Not more than time.
(b) Final setting time #Vicat apparatus with 600 minutes Final setting time limit
annular attachment indicates hardening and gain
(F-type) in strength.
3. Fineness
(a)By sieving IS:4031-#90 micron IS sieve Residue less than More volume retained on
(Part-I)- and 10 percent sieve indicates cement
1996 (2009) # Balance Not less than having undergone moisture
Specific surface by Blain air #Blain air 225 m2/kg for attack or inadequate grinding.
permeability IS:4031-(Part- permeability apparatusOPC (33, 43&
2)-1999 (2008) with accessories 53 grade) & SRC.
Not less than 300
4. Soundness
CENTRAL WATER & POWER RESEARCH STATION IS:4031-(Part- #LeChatelier’s Expansion not more More expansion
3)-1988 (2009) (a) apparatus with than 10 mm indicates likely
Le Chatelier’s accessories Expansion not more excessive and
method #Autoclave, Length than 0.80 percent. harmful chemical
(b) Autoclave comparator, 25 x 25 reactions.
method x 250 mm mould and -do-
Other accessories.
5. Compressive #Cube mould Higher strength

strength (7.07 cm) 50 cm2 Table below indicates
IS:4031-(Part- face area, acceptability
6)-1988 (2009) #Baby Vibrator,
#Compression
Testing Machine,
#Curing Tank Etc.
6. Chemical #Muffle
Analysis IS:4032- Furnace,
1985 (2009) #Oven,
#Platinum
Crucible,
#Chemical
Balance.
I S Code Provision
Sr. Particular of Acceptance Criteria
No. tests
Grade
33-G 43-G 53-G PPC SRPC

IS 269 IS 8112 IS 12269 IS 1489 IS 12330
1. Compressive
strength (Min.)
N/mm2
3 days 16 23 27 16 10
7 days 22 33 37 22 16
28 days 33 43 53 33 33
CENTRAL WATER & POWER RESEARCH STATION Aggregates
 Concrete contains 60 to 80%Aggregate by volume (70 to
85% by weight
 Concrete is more workable when smooth and rounded
aggregate is used instead of rough angular or elongated
aggregate.
 Crushed stone produces much more angular and elongated
aggregate, which have a higher surface to volume ratio,
better bond characteristics but require more cement paste to
produce a workable mixture.
 A smooth surface can improve workability yet a rougher
surface generates a stronger bond between the paste
and the aggregate creating a higher strength.
 The grading or size distribution of aggregate is an
important characteristic because it determines the paste
requirement for workable concrete
Fine Aggregates – Properties, Test Methods
The general properties ( as per IS 383) of fine aggregates

required to be evaluated for use in the concrete are :
 Specific Gravity
 Water Absorption
 Gradation & Fineness Modulus
 Material finer than 75 micron IS sieve
 Bulking
 Soundness
 Mortar Making Properties
 Organic Impurities
Fine Aggregates – Test Methods
 Bulk Density: This method of test covers the procedures

for determining unit weight or bulk density of aggregate
 Both Lose & Rodded Density is determine as per IS:2386

(Part-3)
 Silt And Clay Contents: This is a method of

determination of percentage of various silt and clay
contents in sand by mass.
 This test is conducted as per IS: 2386 (Part -1)

Fine Aggregates – Test Methods

 Sieve Analysis: A suitable gradation of an aggregate in a portland
cement concrete mixture is desirable in order to secure workability
of the concrete mix and economy in the use of cement.
 This test is conducted as per IS: 2386 (Part-1) Sieve analysis

helps to determine the particle size distribution of the coarse and
fine aggregates.
A set of IS Sieves of sizes – 80mm, 63mm, 50mm,

40mm,31.5mm, 25mm, 20mm, 16mm, 12.5mm, 10mm,
6.3mm,4.75mm, 3.35mm, 2.36mm, 1.18mm, 600µm, 300µm,
150µm and 75µm.
Test Methods
• The fineness modulus (FM) is an index number which is

roughly proportional to the average size of the particles in a
given aggregate. It is computed by adding the cumulative
percentages coarser than each of the standard sieves
(cumulative percent retain) and dividing by 100.
• Specific Gravity and Absorption of Aggregate: Specific

gravity is generally defined as the ratio of the mass of a given
volume of material to the mass of an equal volume of water.
When considering aggregate for portland cement concrete, the
most common definition for specific gravity is based upon the
bulk volume of the individual aggregate in a saturated, surface-
dry (SSD) condition.
CENTRAL WATER & POWER RESEARCH STATION Fine Aggregates – Test Methods
 Absorption capacity, or absorption, represents the
maximum amount of water an aggregate can absorb. It can
be determined by finding the weight of an aggregate under
both SSD conditions and oven-dry conditions. The
difference in weights expressed as a percentage of the
oven-dry sample weight is the absorption capacity.
 Organic Impurities: This test helps in determining the
presence of organic compounds in fine aggregates to for
use in cement mortar or concrete. The test provides a
quick, relative measure to determine if further tests of the
fine aggregate are necessary before approval for use. Test
Method: IS: 2386 (P-2)1963
 Sand Equivalent Value: The sand equivalent test is a rapid
field test to show the relative proportions of fine dust or clay-
like materials in fine aggregate (or granular soils). Test
Method: IS: 2720 (Pt-37).
FINE AGGREGATE
Sr. Particulars of Equipments Acceptance Purpose of

No. Tests criteria testing
1 Gradation Fineness #Fine sieve set of As per relevant Poor gradation &
modulus 4.75, 2.36,1.18 mm & specification lower F.M. give
IS: 2386- (Part-1)1963 600, provision and low strength,
looking to the
(2007) 300, 150, 75 micron, demand more
purpose of the use
#Lid, For concrete water for mixing
#Pan and IS:383-1970
#Balance (Accuracy Masonry mortar
0.1 % weight of IS: 2116 –1980
sample) Plaster IS:1542-
1992
2 Specific #Pycnometer, As per relevant Lower specific
gravity & water #Oven, specifications & gravity & higher
absorption IS: 2386- #Two pan design water absorption
decrease durability &
(Part-3)1963 # Balance, 2 Kg
density & increase
( 2007) (0.5 % sensitive) shrinkage
3 Silt content #75 micron sieve, Not more than 3% Higher silt content
IS: 2386- (Part-1)1963 #Balance, or the relevant reduces strength,
(2007) #Oven specification’s increases water
requirement &
provision
inhibits bond
Continued…

4 Alkali reactivity #Reactivity As per Sc/Rc Amorphous silica,
IS: 2386- (Part- container, curves. glass, mica
1)1963 #Water bath, content lead to
(2007) #Balance chemical
disintegration
5 Petrographic #Microscope, Relevant Deleterious

examination IS: #Balance, 2 Kg specification’s material beyond
2386-(Part (Sens. 0.1 gm) provision or 5% affects
–8)1963 (2007) deleterious durability
constituents plus
silt content not
more than 5%
TESTS ON COARSE AGGREGATES
 Specific Gravity
 Gradation
 Soundness
 Crushing Strength
 Flakiness Index
 Elongation Index
 Alkali- Aggregate Reactivity
- Chemical Method
- Mortar Bar Method
- Accelerated Method
•Water Absorption
•Aggregate Impact Value
•Aggregate Abrasion Value
•Petrographic Examination
•Deleterious Material - (coal & lignite, clay lumps,

material finer than 75 micron IS sieve , soft
fragments & shale)
• Specific Gravity & Water Absorption: Test Method: IS:

2386 (P-3)1963, ASTM C 127, 128-2007.The electronic
balance is used to determine weight of sample in water.
The specific gravity of an aggregate is considered to be a
measure of strength or quality of the material. The
specific gravity test helps in the identification of stone.
 Elongation Index : This test is performed as per IS:

2386 (Part 1). This method of test is performed to
determine the elongation index of the coarse aggregate
 Water Absorption test procedure: This test helps to

determine the water absorption of coarse aggregates as
per IS: 2386 (Part III) – 1963.
Flakiness Index : As per IS: 2386(Part 1).

Flakiness is the term applied to aggregate or
chippings that are flat and thin with respect to their
length or width.
Aggregate particles are said to be flakey when
their thickness is less than 0.6 of their mean size.
The flakiness index is found by expressing the
weight of the flakey aggregate as a percentage of
the aggregate tested.
 Particle Size Distribution: This test helps in determining the

percentile quantity of particles of known diameter within a
sample. Test Method: IS: 2386 (P-1) & IS: 383
Grain Size Distribution
100
90
80
70
Percent Passing
60
50
40
30
20
10
0
0.01 0.1 1 10
Particle Size (mm)
 Aggregate Impact Value:

 This test is done to determine
the aggregate impact value of
coarse aggregates as per IS:
2386 (Part IV) – 1963.
 The apparatus used for
determining aggregate impact
value of coarse aggregates is
Impact testing machine
conforming as per above IS
specifications.
Aggregate Crushing Value
This test helps to determine the

aggregate crushing value of coarse
aggregates as per IS: 2386 (Part IV).
The Aggregate Crushing Value offers a
related measure of the resistance of an
average to crushing under a
compressive load that is gradually
applied. This test helps in determining
the value which indicates the ability of an
aggregate to resist crushing.
Aggregate Abrasion Value
This test helps to determine the abrasion
value of coarse aggregates as per IS:
2386 (Part IV). The apparatus used in
this test are Los Angles abrasion testing
machine, IS Sieve of size – 1.7mm,
CENTRAL WATER & POWER RESEARCH STATION  Alkali Aggregate Reactivity (AAR)
AAR reaction between the alkali in the cement and non-
crystalline silicon dioxide in aggregates. This reaction can
cause expansion of the altered aggregate, leading to
spalling and loss of strength of the concrete. Test Method:
IS: 2386 (P-7)
 Chloride Content
The total chloride content of aggregate is usually measured
to assess whether the aggregate's contribution to the total
chloride content of a concrete mix will be low enough to
prevent the early onset of corrosion of any embedded steel
reinforcement. Test Method: IS: 4032
 Organic Impurities Effect On Mortar Strength
This test helps in determining the rapid assessment of
organic impurities by indicates their presence. Comparison
is made between compressive strengths of mortar made
with washed and unwashed fine aggregate.
CENTRAL WATER & POWER RESEARCH STATION Coarse agregarte
1. Gradation: #Set of coarse As per relevant Gradation
IS: 2386 (Part-1)-1963 sieves 80mm to specifications' governs the bulk
(2007) 4.75mm, provision density and void
#Balance, content.
(Accuracy 0.1%
of test sample)
2. Sp. gravity & water #Wire basket, As per relevant Higher the specific
absorption #Balance (3 kg, specifications' gravity, higher the
IS: 2386(Part-3)-1963 accuracy provision Sp. density
(2007) 0.5gm) gravity generally and greater the
#Oven, 100 – 2.5 to 3.0 and durability.
110 0 C water absorption 1
to 1.5%
3 Flakiness & #Balance As per design Flaky material
elongation indices (Accuracy 0.1%) needs more sand,
IS:2386-(Part-1)-1963 #Length gauge, water & cement
(2007) #Thickness gauge, for same strength.
#Sieves
CENTRAL WATER & POWER RESEARCH STATION Continued…
Sr. Particulars of Acceptance Purpose of
No. Tests Equipments criteria testing
4 Impact value #Impact testing machine, As per IS: 383- Lower impact value
IS: 2386 (Part- #Tamping rod 1970 gives better
4)-1963 (2007) #Balance (500 gm, Accuracy Concrete-wearing- performance in facing
0.1 gm)
surface-30% max. successive
#Sieves 12.5,10 & 2.36 mm
#Hammer (13.5-14 Kg) Overlaid surface moving loads
Oven , 100 –110 0 C 45%max.
Abrasion value #Los Angeles abrasion As per IS: 383- Higher abrasion value
5 IS: 2386 (Part- machine, 1970 indicates more wear
4)1963 (2007) #Sieve 1.7 mm Concrete- Wearing &tear
surface-
&higher cost of repairs
30%max.
Over laid surface-
&
50 % max. maintenance
Soundness #Sieves (Sq. as per IS460- As per-IS:383- Higher loss indicates
6 IS: 2386 (Part- 1962) 1970 less ability of the
5)1963 (2007) #Oven 100 –110 0 C and Concrete with stones to withstand
#Balance (500 gm, coarse aggregates. effect of freezing &
Accuracy Loss with Na2SO4 thawing
0.1 gm) -12%max.
Loss with MgSo4
-18%max.
CENTRAL WATER & POWER RESEARCH STATION Continued…
Sr.No. Particulars of Equipments Acceptance Purpose of
Tests criteria testing
7 Alkali reactivity #Scales As per Sc/Rc curve Deleterious

IS:2386-(Part- #Weights or relevant aggregate cause
7)1963 (Reaffirmed #Photometer specifications disintegration of
2007) #Analytical provisions Concrete
Balance
#Crushing equipment
#Grinding
equipment
#Sieves IS-
460: 1962
#Reaction container
#Temp. bath
8 Petrographic #Microscope, Relevant Deleterious

examination #Hammer, specifications provision material beyond
IS:2386(Part-8)- #Balance 2 Kg, or deleterious 5% leads to chemical
1963 (Reaffirmed Sensitive 0.1 constituents not more reactions,
2007) gm. than 5% including silt cracking of concrete
content etc.
Tests on Fresh Concrete
 Slump test useful on site, gives fairly good consistent

results for a plastic mix but not sensitive for a stiff-mix.
 In case of dry-mix, no variation can be detected between
mixes of different workability.
 In case of rich mixes, the value is often satisfactory, their
slump being sensitive to variations in workability
 An increase in slump may mean for instance, the moisture
content of the aggregates has suddenly increased or there
has been sudden change in the grading of aggregates.
 The slump gives the warning to correct the causes for
change of slump value.
 The simplicity of the test is another reason, why this test is
still popular in spite of the fact that many other workability
tests are in vogue.
Compacting Factor
 Compacting factor of fresh

concrete is done to determine the
workability of fresh concrete by
compacting factor test as per IS:
1199 – 1959. The apparatus used
is Compacting factor apparatus.
Compacting factor =
(Weight of partially compacted concrete)
(Weight of fully compacted concrete)

Laboratory Tests on Hardened Concrete

 There are several reasons why testing of hardened concrete
is important:
 Test can investigate the fundamental physical behavior of

concrete such as elastic properties and strength
characteristics
 When physical laws are not fully understood testing can

simulate expected conditions to evaluate performance
 Tests to determined physical material constants

 Modulus of elasticity
 Quality control.
Properties of concrete
o Compressive strength
o Split tensile strength
o Flexural strength
o Modulus of elasticity & Poisson’s ratio
o Shear parameters
o Ultimate strain capacity

Test for Compressive
Strength
 The most common test preformed on concrete is for

compressive strength. There several reasons for this:
 It is assumed that the most important properties of concrete as
directly related to compressive strength
 Concrete has little tensile strength and is used primarily in
compression
 Structural design codes are based on compressive strength
 The test is relatively simple and inexpensive to perform.
Determination of compressive strength
of concrete
c = Load applied / Cross sectional

area of specimen
Split tensile strength (Tsp )
Tsp = 2P/dl
P = maximum load (kg)
d = diameter of specimen (cm)
l = length of the specimen (cm)
CENTRAL WATER & POWER RESEARCH STATION Creep characteristics of concrete
CREEP : Creep of concrete is time dependant
deformation. Creep is an important parameter
required for predicting tensile strain capacity of
concrete required for estimating the suitable
placement temperature. Knowledge of creep is
also necessary in assessing post structural
behaviour of mass concrete dams.
ESTIMATION OF CREEP: Creep of concrete is

influenced by temperature and humidity and is
determined under controlled conditions of
temperature and humidity. A frame for
sustained load and a large size temperature and
humidity control chamber are essential facilities
for estimation of creep
CREEP OF CONCRETE
Creep is time dependant deformation

under sustained load
Mechanical dial gauges or resistance /

vibrating wire strain gauges are used for
measuring deformation .
The specific creep and creep coefficient

determined from studies are used for:
• Estimating Tensile strain
capacity of concrete
• Thermal analysis of dams
CREEP SET UP
PAST FACILITIES FOR CREEP DETERMINATION
 The 100% humidity was achieved by continuous spray of
water over the samples
The temperature of surroundings was controlled using Jumbo
contact thermometers.
Demerits:
• Possibility of variation in environmental conditions.
• Required continuous personal attention
• Limitation on number of test rigs
Humidity and temperature controlled chamber facilitated in
achieving any combination of temperature and humidity
automatically
 Size - 4 m (W) x 3 m (D) x 2.4 m (H).
 Fully automatic - Control of temperature (10 to 60 0 C)

and Humidity (40 to 95 %) – runs for 180 days continuously
 Can accommodate 4 to 5 test rigs at a time

Nondestructive Quality Test

This tests are useful to:
 Quality control
 Determination of the time for form removal
 Help assess the soundness of existing concrete structures
Different non-destructive Tests:
 Surface Hardness Methods
 Rebound Hardness
 Penetration Resistance
 Pull-Out Test
 Ultrasonic Pulse Velocity
 Surface Hardness Methods: Basically, the surface is impacted
with a mass and the size of the resulting indention is measured.
The accuracy of these type of tests is only 20 to 30%.
 Rebound Hardness : The most common nondestructive test is
the rebound test. The test measures the rebound of a hardened
steel hammer impacted on the concrete by a spring. This method
has the same limitations as the surface hardness tests. The
results are affected by: surface finish; moisture content;
temperature; rigidity of the member being tested; carbonation of
the surface; and direction of impact. Most useful in checking the
uniformity of concrete.
 Penetration Resistance: Resistance of
concrete to penetration by a steel probe
driven by a given amount of energy is
measured. This test is not affected by
surface hardness or carbonation as the
above tests, however, the mix proportions
and material properties are still important.
 Pull-Out Test -- Pull-out test determine the
force required to pull a steel insert out of
concrete which it was embedded during
casting. This test is a measure of the shear
strength of the concrete which can be
correlated with compressive strength. This
test is better than those previously
discussed, however, the test may be
planned in advance and the assembly
embedded in the concrete during casting.
Durability of Concrete
What does durability mean?...
 Ability of concrete to
 resist weathering action
 resist chemical attack
 resist abrasion
 resist effects due to exposure to environment

CENTRAL WATER & POWER RESEARCH STATION Mix Design Procedure as per IS:10262.
1. Determine the mean target strength ft from the specified
characteristic compressive strength at 28-day fck and the level of
quality control.
ft = fck + 1.65 S ,
where S is the standard deviation
2. Obtain the water cement ratio for the desired mean target
using the empirical relationship between compressive strength
and water cement ratio so chosen is checked against the limiting
water cement ratio. The water cement ratio so chosen is
checked against the limiting water cement ratio for the
requirements of durability given in table and adopts the lower of
the two values.
3. Estimate the amount of entrapped air for maximum nominal
size of the aggregate from the table.
4. Select the water content, for the required workability and
maximum size of aggregates (for aggregates in saturated
surface dry condition) from table.
Mix Design Procedure as per IS:10262.
5. Determine the percentage of fine aggregate in total

aggregate by absolute volume from table for the
concrete using crushed coarse aggregate.
6. Adjust the values of water content and percentage of
sand as provided in the table for any difference in
workability, water cement ratio, grading of fine aggregate
and for rounded aggregate the values are given in table.
7. Calculate the cement content from the water-cement
ratio and the final water content as arrived after
adjustment. Check the cement against the minimum
cement content from the requirements of the
durability, and greater of the two values is adopted.
CENTRAL WATER & POWER RESEARCH STATION Mix Design Procedure as per IS:10262.
8. From the quantities of water and cement per unit volume of
concrete and the percentage of sand, calculate the content
of coarse and fine aggregates from the relations:
• V = absolute volume of concrete- volume of entrapped air

• Sc = specific gravity of cement
• W = Mass of water, C = mass of cement
• p = ratio of fine aggregate to total aggregate by absolute volume
• fa, Ca = total masses of fine and coarse aggregates, per cubic metre of
concrete, respectively, kg, and
• Sfa, Sca = specific gravities of saturated surface dry fine and coarse
aggregates, respectively
Mix Design Procedure as per IS:10262.
9. Determine the concrete mix proportions for the first trial
mix.
10. Prepare the concrete using the calculated proportions

and cast three cubes of 150 mm size and test them wet
after 28-days moist curing and check for the strength.
11. Prepare trial mixes with suitable adjustments till the

final mix proportions are arrived at.
ILLUSTRATIVE EXAMPLE
CONCRETE MIX DESIGN (Grade M 20)
28-days Characteristic compressive strength 20 N/mm2
Maximum size of aggregate (angular) 20 mm
Degree of workability (compacting factor) 0.90
Degree of quality control, Good
Type of exposure Mild

Materials Test Data
1) Cement Ordinary Portland cement (IS : 269)

2) Specific gravity of cement 3.15
3) Specific gravity of coarse/ fine aggregates 2.60
4) Water absorption
i) Coarse aggregate 0.5 %
ii) Fine aggregate 1.0 %
5) Free (surface) moisture
i) Coarse aggregate Nil
ii) Fine aggregate 2.0 %
CENTRAL WATER & POWER RESEARCH STATION Materials Test Data
6) Sieve analysis
i) Coarse aggregate ( confirms to table 2 of IS 383)
IS Sieve Size % passing
20mm 100
10 mm 71.2
4.75 mm 9.4
ii) Fine Aggregate (Conforms to grade Zone III of Table 4 of IS:
383)
IS Sieve Size % passing
4.75 mm 100
2.36 mm100
1.18 mm 93
600 micron 60
300 micron 12
150 micron 2
SUGGESTED VALUES OF STANDARD DEVIATION
Target Mean
Strength of GRADE OF
STANDARD DEVIATION FOR DIFFERENT
DEGREE OF CONTROL(N/mm2)
Concrete CONCRETE
Very Good Good Fair
For a tolerance factor

(1) (2) (3) (4)
of 1.65 and using side
M10 2.0 2.3 3.3
Table,
M15 2.5 3.5 4.5
M20 3.6 4.6 5.6

The target mean M25 4.3 5.3 6.3
strength for the M30 5.0 6.0 7.0
specified characteristic M35 5.3 6.3 7.3
Cube strength is M40 5.6 6.6 7.6
M45 6.0 7.0 8.0

20 + 4.6 x 1.65
M50 6.4 7.4 8.4
= 27.6 N/mm2.
M55 6.7 7.7 8.7
M60 6.8 7.8 8.8
Selection of
Water-Cement Ratio
From side Figure ,

the water cement ratio
required for the target
mean strength of
27.6 N/mm2 is 0.50.
This is lower than the

maximum value of Generalizes relationship between free
0.65 prescribed for water- Cement Ratio and
‘Mild’ exposure compressive strength of concrete
Selection of Water & Sand
Approximate sand and water content per m3
Content
W/C=.60
From side Table,
for 20 mm nominal MSA Workability
=0.80 CF
and sand conforming to
(Applicable for concrete up to grade M35)
grading Zone II, water
content per cubic meter of MAXIMUM SIZE WATER SAND PERCENT
concrete is equal to 186 kg OF AGGREGATE CONTENT PER OF TOTAL
(mm) CUBIC METRE AGGREGATE BY
and sand content as OF CONCRETE ABSOLUTE
percentage of total (kg) VOLUME
aggregate by absolute
volume is equal to 35
percent.
(1) (2) (3)
 For change in values in
water-cement ratio, 10 208 40
compacting factor and sand 20 186 35

belonging to Zone III, the
40 165 30
following
 Adjustment is required: *Water content corresponding to saturated surface
dry aggregate.
Selection /Adjustment of Water

Adjustment of values in water content and sand
& Sand Content %
Change in Adjustment Required in water
Required in Percentage Conditions
Stipulated for
Water sand tables
W/C ratio 0 - 2.0 Water

Content
Percentage sand in
Total aggregate.
(0.60 - 0.50=0.1)
(1) (2) (3)
compacting factor +3 0
For sand 0 +1.5 Percent for Zone I
(0.9 - 0.8= 0.10) confirming to - 1.5 Percent for Zone
grading Zone I, III
Sand as per Zone III 0 - 1.5 Zone III or Zone IV -3.0 Percent for Zone
of 4, IS 383-1970 IV
Total +3 - 3.5 Increase or ±3 0

decrease in the Percent
Therefore required sand content as value of
compacting
percentage of total aggregate by factory by 0.1
absolute volume= 35 - 3.5=31.5 %. Each 0.05 0 ±1 Percent
increase or
Required water content = decrease in water
cement ratio
186 + 5.58# = 191.6 litres/m3.
For rounded -15 -7 Percent
#186*31.5 /100=5.58
aggregate kg/cm3
Determination of Cement Content

W/C ratio = 0.50, Water = 191.6 litres

Therefore cement = 191.6/0.50
= 383 kg/m3
Cement content is adequate

for ‘mild’ exposure condition
as per Table

CENTRAL WATER & POWER RESEARCH STATION Determination of Cement Content

MINIMUM CEMENT CONTENT REQUIRED IN CEMENT CONCRETE TO ENSURE DURABILITY UNDER SPECIFIED
CONDITION OF EXPOSURE
Plain Concrete Reinforced Concrete
Exposure Minimum Maximum Minimum Maximum water
cement water Cement cement Cement Ratio
content Ratio content
(1) (2) (3) (4) (5)

Kg/m3 Kg/m3
Mild—For example completely protected against 220 0.7 250 0.65
weather, or aggressive conditions, except for a
brief period of exposure to normal weather
conditions during construction
Moderate-for example, sheltered from heavy and 250 0.6 290 0.55
wind driven rain and against freezing, whilst
saturated with water : buried concrete in soil and
concrete continuously under water
Severe-for example, exposed to sea water, 310 0.5 360 0.45

alternative wetting and drying and freezing to
whilst wet, subject to heavy condensation of
water and corrosive fumes
Note-1 —when the maximum water cement ratio can be strictly controlled, the cement content may
be reduced by 10 percent.
Note-2—The Minimum cement content is based on 20mm aggregate. For 40 mm aggregate, it
should be reduced by about 10 percent, for 12.5 mm aggregate, it should be increased by about 10
percent.
Determination of Coarse and Fine Aggregate Content

for the MSA of 20 mm, the amount of entrapped air in the wet
concrete is 2 percent.
Taking into account & applying above equation,

fa = 546 kg/m3, and Ca = 1187 kg/m3
The mix proportion then becomes:
 Water 191.6 litres

 Cement 383 kg
 Fine Aggregate 546 kg
 Coarse Aggregate 1187 kg
 Extra water to be added for absorption in case of Ca at 0.5 % by
mass = ( + ) 0.5 x 1187 x 0.01= 5.935 litres
 Water to be deducted for free moisture present in sand, at 2
percent by mass = ( -) 2.0 x 546 x 0.01= 10.92 litres
 Actual quantity of water to be added = 191.6 + 5.935 – 10.92
= 186.615 litres
 Actual quantity of sand required after allowing for mass of free
moisture = 546 + 10.92 = 556.92 kg
 Actual quantity of coarse aggregate required:
i) Fraction I (60%) = 712 – 6.55 = 705 45 kg
ii) Fraction II (40%) = 475 - 4.37 = 470.63 kg
Therefore, the actual quantities of different

constituents required for the mix are:
 water = 24.35 kg
 cement = 50.00 kg
 sand = 72.42 kg
 Coarse aggregate:
 Fraction 1 = 92.24 kg
 Fraction II = 61.49 kg
 Admixtures for concrete- Material that added during

the mixing process (not more than 5 % by mass of the
cement), to modify the properties of fresh and /or
hardened state
 Admixtures confer several beneficial effects such as
reduction in water requirements, increased workability,
controlled setting, accelerated hardening, improved
strength, better durability, desired coloration and volume
changes.
 The admixtures may remain in a free state as a solid or
solution, may interact at the surface or chemically
combine with the constituents of cement or cement
paste.
 The practical consequences include: compatibility;
predictability of properties of concrete.
Classification of admixtures
Different types of admixtures

 Water reducing/plasticizing admixtures
Admixture, without affecting the water content increases
the slump/flow or produces both effects simultaneously.
 Water retaining admixtures
Admixture which reduces the loss of water by a
reduction of bleeding.
 Air entraining admixture
Admixture which allows a controlled quantity of small,
uniformly distributed air bubbles to be incorporated
during mixing which remain after hardening
 Set accelerating admixtures
Admixture which decreases the time to commencement

of transition of the mix from the plastic to the rigid state
 Hardening accelerating admixtures
Admixture which increases the rate of development of

early strength in the concrete, with or without affecting
the setting time

 Set retarding admixtures
Admixture which extends the time to commencement of

transition of the mix from the plastic to the rigid state
 Set accelerating/water reducing/plasticizing
admixtures
Admixture which produces the combined effects of a

water reducing/plasticizing admixture (primary function)
and a set accelerating admixture (secondary function)

 Water resisting admixtures
Admixture which reduces the capillary absorption of

hardened concrete.
 Set retarding/water reducing/plasticizing admixtures
Admixture which produces the combined effects of a

water reducing/plasticizing admixture (primary
function)and a set retarding admixture (secondary
function)
Mineral Admixtures
 The effect of mineral admixtures such as fly ash, silica

fume, and rice husk ash is explained by their chemical
reaction with the Ca(OH), formed during the hydration of
portland cement.
 This reaction results in increased strengths, lower
permeability, better resistance to chemical attack and
alkali-aggregate expansion.
Types of Mineral Admixtures

1. Cementitious -
 Ground granulated blast furnace slag (GGBFS) is the
granular material formed when molten iron blast
furnace slag is rapidly chilled (quenched) by
immersion in water. (It consists mainly of the silicates
and aluminosilicates of calcium, a by-product of iron
and steel making).
GGBFS with OPC and/or other pozzolanic materials
make durable concrete. Concrete sets slowly but
continues to gain strength. Lower heat of
hydration/temperature rises.
1. Cementitious - Ground granulated blast

furnace slag (GGBFS) when used sets slowly but
continues to gain strength, Lowers heat of
hydration/ temperature rise, reduces the risk of
damages caused by alkali-silica reaction (ASR),
provides higher resistance to chloride ingress,
reducing the risk of reinforcement corrosion, and
provides higher resistance to attacks by sulfate
and other chemicals.
2. Pozzolanic-
A pozzolan is a material which, when combined

with calcium hydroxide (lime), exhibits
cementitious properties and results in increased
strengths, lower permeability, better resistance
to chemical attack and alkali-aggregate
expansion. Fly ash, Silica Fume, Rice Husk
Ash, Metakaolin.
Types of Mineral Admixtures - Pozzolanic-
Fly Ash: burning coal in power plants leaves behind glassy

spherical particles rich in silica, alumina, and calcium.
Class F - ideal cementitious material in making mass

concrete and high strength, Low lime content and a higher
concentration of silica, aluminum, and iron.
Fly Ash:Class C type
Contains more than 20% lime (CaO) , unique self

hardening characteristics, Generally used in soil
stabilization.
FIBRE REINFORCED CONCRETE
•Fiber reinforced concrete (FRC) is Portland cement concrete (or

mortar) reinforced with randomly distributed fibers.
•FRC used in hydraulic structures, spillways, sluiceways, and
stilling basins—to enhance the resistance to cavitation and erosion
damage caused by high-velocity water flow.
•Shotcrete / concrete pneumatically projected at high velocity onto
a surface has made good use of steel fibers.
•Sprayed SFRC particularly well suited to thin-layer applications.
MAIN CHARACTERISTICS OF FIBERS

 Nature (organic, inorganic)
 Mechanical properties
 Geometry (length, diameter, aspect ratio)
 Surface characteristics (finishing)
 Durability in the matrix
 Good dispersion
F IB E R S
O R G A N IC IN O R G A N IC
S IN T E T IC
SYNTHETIC N A TU R A L M IN E R A L M E T A L L IC
P P , PE , PA N ,P VA , C E L L U L O S E (W O O D ) A R -G L A S S S TE E L
P A , C A R B O N , V E G E TA B LE A S B E S T O S , M IC A ,
A R A M ID W O L L A S T O N IT E
Cement Water Aggregates Plasticizer
Fibers
Admixtures
Fibre Reinforced Concrete (FRC)

Length = 60 mm
Steel fibres are made from
prime quality hard drawn Diameter = 0.75 mm
steel wire to ensure high L/d = 80
tensile strength and close
tolerances. TS = min. 1050 Mpa
The gluing of the fibres into A hooked end which slowly

bundles guarantees quick deforms during pull-out is
and easy mixing for a generally considered as the best
homogeneous distribution form of anchorage.
A system of glued fibre bundles

High length-diameter ratio (L/D ratio) enables fibres with a high L/D ratio
to be mixed easily and uniformly
Hooked ends
throughout the concrete
Controlled pull-out (due to deformation of

the hook)
High tensile strength steel

Fiber length
1. Bridge the crack
2. Overlap 2 aggregates
3. Workabilty : pumping, and hose
diameter ( 2/3)
Hose inner Diameter
( 100mm)
Fiber length should be < 66 mm

Small fiber section
1. More fibers per kilo
2. Shorter distance between the
fibers – networking effect
3. More contact surface steel/
concrete per unit weight
COMPRESSION TEST
200
154,6
147,1
160
Compressive strength (MPa)

120
80
40
0
0% 1%
Fiber content
Fibers 0% Fibers 1%
CENTRAL WATER & POWER RESEARCH STATION TENSILE STRENGTH
Addition of 1.5% fibers by volume will increase direct tensile

strength of mortar by about 40%. The increase in splitting
tensile strength is somewhat higher, with reported increases of
as much as 100%.
ABRASION RESISTANCE
Erosion due to cavitation and abrasion from high-velocity water

flow or impact from large debris, SFRC can provide
considerable improvement.
FATIGUE STRENGTH
Flexural fatigue strength increases with increasing percentage of

steel fibers.
Addition of fibers to a conventionally reinforced concrete
structure will increase the fatigue life and decrease crack widths.
Resulting deflection caused by fatigue decreases with the
addition of steel fibers.
The performance of steel fibre concrete can be

assessed using :
• ASTM C1018-89 and JSCE-SF4

• Beam tests
• Equivalent flexural strength and toughness (ductility)
TOUGHNESS
Advantages of SFRC is its increased toughness.
Toughness is defined as the total energy absorbed in
breaking a specimen.
Quantified by measuring the area under the load- deflection
curve obtained from a flexural test.
Impact resistance is related to toughness.
Load Deflection Curve of determination of

toughness index for FRC
SFRC MIX
•Steel fibers used were Dramix steel fiber RC-80/60-

BN (BEKAERT Make).
•Observed average density and slump was 2600 Kg/
m3 and 35-40 mm respectively.
53 Coarse
Grade Sand Dramix Aggregates Water
OPC fiber 20-10 10-05
mm mm
1 1.8 0.045 1.7 1.0 0.43

50 90 2.25 85 50 21.5
RESULTS OF SFRC & FINDINGS
Fiber dosage (kg/m3)

Properties 0 10 20 30 40
Compressive 450 - 500 480 - 510 500 - 530 520 - 530 530 - 570
Strength (kg/cm 2)
Flexural Strength 38 - 40 41 - 43 43 - 46 45 - 47 49 - 57
(kg/cm 2)
Toughness I5 -- 2.3-3.9 4.8 – 5.9 5.2 – 7.9 6.1 -8.4
Indices as
I10 -- 6.4 9.3 – 12.3 9.6 – 12.5 10.5 –
per ASTM
C-1018 - 97 12.9
I20 -- 12.7 22.7 23.7 27.4
Considerable improvement in properties of SFRC for

dosage of 20 kg/m3 of steel fibres in particular the flexural
strength and the toughness index recommending use of
SFRC for repairs to spillway structure and EDA.

Concrete Basics NWA

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CENTRAL WATER & POWER RESEARCH STATION INDUCTION TRAINING PROGRAM

 Rice husk ash

 Ground granulated blast furnace slag

Vicat Apparatus – Set up for Consistency & Initial

 Soundness refers to the ability of a hardened cement

 The Le Chatelier test detects unsoundness due to free

 Fineness (IS: 4031)

1. Consistency #Vicat apparatus with About 30 percent Determines mixing water

5. Compressive #Cube mould Higher strength

33-G 43-G 53-G PPC SRPC

The general properties ( as per IS 383) of fine aggregates

 Gradation & Fineness Modulus

 Material finer than 75 micron IS sieve

 Mortar Making Properties

 Bulk Density: This method of test covers the procedures

 Both Lose & Rodded Density is determine as per IS:2386

 Silt And Clay Contents: This is a method of

 This test is conducted as per IS: 2386 (Part -1)

 This test is conducted as per IS: 2386 (Part-1) Sieve analysis

A set of IS Sieves of sizes – 80mm, 63mm, 50mm,

• The fineness modulus (FM) is an index number which is

• Specific Gravity and Absorption of Aggregate: Specific

Sr. Particulars of Equipments Acceptance Purpose of

Sr. Particulars of Equipments Acceptance Purpose of

5 Petrographic #Microscope, Relevant Deleterious

TESTS ON COARSE AGGREGATES

•Aggregate Impact Value

•Aggregate Abrasion Value

•Deleterious Material - (coal & lignite, clay lumps,

• Specific Gravity & Water Absorption: Test Method: IS:

 Elongation Index : This test is performed as per IS:

 Water Absorption test procedure: This test helps to

Flakiness Index : As per IS: 2386(Part 1).

 Particle Size Distribution: This test helps in determining the

Grain Size Distribution

 Aggregate Impact Value:

This test helps to determine the

7 Alkali reactivity #Scales As per Sc/Rc curve Deleterious

8 Petrographic #Microscope, Relevant Deleterious

 Slump test useful on site, gives fairly good consistent

 Compacting factor of fresh

(Weight of partially compacted concrete)

(Weight of fully compacted concrete)

Laboratory Tests on Hardened Concrete

 Test can investigate the fundamental physical behavior of

 When physical laws are not fully understood testing can

 Tests to determined physical material constants

o Split tensile strength

o Modulus of elasticity & Poisson’s ratio

o Ultimate strain capacity

 The most common test preformed on concrete is for

c = Load applied / Cross sectional

Split tensile strength (Tsp )

ESTIMATION OF CREEP: Creep of concrete is

Creep is time dependant deformation

Mechanical dial gauges or resistance /

The specific creep and creep coefficient

 Size - 4 m (W) x 3 m (D) x 2.4 m (H).

 Fully automatic - Control of temperature (10 to 60 0 C)

 Can accommodate 4 to 5 test rigs at a time

Nondestructive Quality Test

What does durability mean?...

 resist weathering action