ITD CEMENTATION INDIA LIMITED

CHAPTER
Fresh concrete and hardened concrete

. .

Definition of concrete- Concrete is the four components of materials aggregate,

cement, water admixture. There is two types of aggregates being used in
concrete. Coarse aggregate and fine aggregate.

1
 GRADE OF ONCRETE AS PER TABLE 2 OF IS 456:2000

Ordinary Concrete
1- M10
2- M15
3- M20
Standard Concrete
1- M25
2- M30
3- M35
4- M40
5-M45
6-M60
High Strength Concrete
1- M65
2-M70
3-M75
4-M80
5-M85
6-M90
7-M95
8-M100
 General Classification of Aggregates.
a) According to Production Methods

a- Which Coarse aggregate we can use for concrete works?

b- The Coarse aggregate should comply with Size, shape, mechanical durable and should
not harmful. (hardness),
1- Aggregate size should be as per IS 383-2016 table no-7 clause No-6.1
2- Aggregate shape should not more than combined flakiness & elongation 40%.
3- Aggregate crushing value/ten percent fines value should not more than-30%
4- Aggregate Impact Value for concrete should not more than 45% and road,
5- runway tunnel 30%.
6- Aggregate crushing value/ 10% fines value for concrete and wearing should
7- not more than 30%.
Aggregate abrasion Value for concrete should not more than 50% and road,
8- runway tunnel 30%.
Soundness of coarse aggregate 5 cycles with Sodium sulphate (Na2So4)-
9- 12% and magnesium
sulphate (MgSO4)-18%.
Soundness of fine aggregate 5 cycles with Sodium sulphate (Na2So4)-10% and magnesium
sulphate (Mg,S02)-15%.
Aggregate Alkali
10-Aggregate reaction-
deleterious Expansion
material should and Alkali than
not more content of cement
as per Sodium
IS 383-2016 Oxide-
table Na2O limits
-2 specified
Eq,=0.1% Na2O+0.658X% Potassium Oxide= K2O.

2
b)According to Production Methods
• Natural Aggregates:
- Taken from native deposits without any change in their
natural
states during production except for crushing, grading or
-washing.
Example: sand, gravel, crushed stone, lime rock.

• By-Product Aggregates
- Comprise blast-furnace slags and cinders, fly etc.
ash, Cinders are residue of coal or wood after
burning.

3
Processed Aggregates:
- Heat treated expanded materials with
lightweight characteristics.
- Example: Perlite, burnt clays, shales,
processed fly ash.

Colored Aggregates:
- Glass, ceramics, manufactured marble for
decorative and architectural purposes.

4
c) According to petrographically test

Rocks

Sandstone

Muscovite and Biotite

 According to Particle Size.
1) Fine Aggregate (sand):
Fine aggregate includes the particles that all through
passes
4.75 mm sieve and retain on 0.075 mm sieve.

2) Coarse Aggregate (gravel):

Coarse aggregate includes particles
the that retain on 4.75 mm
sieve.
Silt: sizes 0.002-0.075 mm

Clay: sizes smaller than 0.002 mm

9
10
 4.4 Mechanical Properties of Aggregates

4.4.1Bond of Aggregate
• Bond is the interlocking of the aggregate and the
paste owing to the roughness of the surface of the
former.
• A rough surface, such as that of crushed particles,
results in a better bond; bond is also usually
obtained
better with softer, porous and mineralogically
heterogeneous particles.

• No accepted test exists.

• Generally, when bond is good, a crushed concrete

specimen should contain some aggregate particles
broken right through, in addition to the more
numerous 13
ones pulled out from their sockets.
 4.4.2 Strength of Aggregate
• NOTE:
Hardness of Aggregate Comp. strength (concrete)< Comp. strength
(aggregate)
•The crushing strength of aggregate cannot be tested with
any direct test. There are some indirect tests to inform us
about
-
the crushing strength of aggregate.
Test method: Crushing value test

Other Mechanical Properties of Aggregates:

a) Impact value: Impact value of aggregates measures

the toughness of particles by impact.

14
b)Abrasion: Abrasion of aggregates measures the
resistance of aggregates against wearing.
• It is an important property of concrete in roads and in
floor
surfaces subjected to heavy traffic. The most frequently
used test method is the Los Angeles Abrasion Test.
• Los Angeles Abrasion Test:

• The aggregate of specified grading is placed in a cylindrical

drum, mounted horizontally. A charge of steel balls is added
and the drum is rotated a specified number of revolutions.
The tumbling and dropping of the aggregate and the balls
result in abrasion and attrition of the aggregate. The
resulting
grading should be compared with the standard limitations.

15
 4.5 Physical Properties

4.5.1Specific Gravity
• The specific gravity of an aggregate is a
characteristic of the material, which needs
to be determined in making calculations of
mix design of concrete.

18
 4.5.2 Porosity and Absorption of Aggregates

• The porosity of aggregate, its permeability, and

absorption influence the bonding between aggregate
and cement paste, the resistance of concrete to
freezing and thawing and resistance to
abrasion.
• When all the pores in the aggregate are full it is said
to be saturated.
• If just the surface of aggregate is dry then it
is said_s aturated-surface-dry.

• If the aggregate in saturated surface dry

condition
allowed to stand free in dry air, some water from
pores will evaporate and it is said to be air dry
condition.
19
water absorption:

Determined by measuring the increase in weight

of an oven-dried sample when immersed in
water, for 24 hours. (The surface water
being removed).

The ratio of the increase in weight to the weight of

dry sample, expressed as a percentage is termed
absorption .
• Water absorption = W- Va ,

At the time of setting of concrete the

aggregate is in a saturated-surface-
dry 20

condition.
 Moisture Content of Aggregate

• Moisture content is the water in excess of

that saturated surface dry state.
• Total water content of a moist aggregate
is equal to the sum of absorption and
moisture content.

21
4.5.5 Deleterious Substances in Aggregates
a)Organic Impurities:
• Consists of products of decay of vegetable matter. The organic
imp urities may interfere with the process of hydration of cement.
This affects the rate of gaining strength.

b) Clay and Other Fine Materials:

• Found as surface coatings which interfere with the bond between
aggregate and the cement paste. Affects the strength and durability
of concrete.
Other types of fine material:
Silt and crusher dust.
Affect the bond between cement paste and aggregates.
- "BS EN 12620: Aggregates for Concrete" limits the content of all
three materials not more than the follows:
• 15% by weight in crushed sand
• 3% by weight in natural or crushed
• gravel
1% by weight in coarse aggregate.

23
c) Salt Contamination:

• Aggregates from the seashore contain salt and have to

be washed with fresh water. The aggregate washed even
with the sea water do not contain harmful quantities of
salts.

• If salt is not removed;

- It will absorb moisture from the air and cause efflorescence
unsightly white deposits on the surface of the concrete.
- A slight corrosion of reinforcement may also result, but this
is not believed to progress to a dangerous degree,
concrete
especiallyiswhen thequality and adequate cover to reinforcement is
of good
provided.

24
d) Alkalinity of Aggregates:

• Reactive forms of silica such as opal may occur in

some types of rocks, like siliceous limestone.

• The reaction takes place between the siliceous

minerals in the aggregate and the alkaline hydroxides
derived from the alkalis (Na2O, K2O) in the
cement.
• The resulting gel tends to increase in volume in
a humid medium and causes cracking of
concrete.
• In this case, it is recommended to control
the limit of alkalis in the cement.

25
 4.5.6 Soundness of Aggregate

This is the name given to the ability of

aggregate to resist excessive changes in
volume as a result of changes of physical
conditions.

• Aggregate is said to be unsound when

volume changes, induced by the freezing
and thawing result in deterioration of the
concrete.

26
 4.5.7 Sieve Analysis

• Sieve analysis is the name of the operation of

dividing a sample of aggregate into fractions,
consisting of particles of the same size.
each

• In practice each fraction contains particles

between specific limits, these being the
openings of standard test sieves.

27
 Grading curves & standard limits of aggregates

GRADING CURVES OF AGGREGATES

100
95
90
~
A --
85
80
.,,,, r

F
c
z
75
70
wf

5 w 4

.... ,,~ ~ , "

--
65

.-
0 60 L

-
<C
~

-
55

•
0... 4
50

-- -- - -~
z
I 45
.-
!
w
·· L s4el

-
40

-
-~ . - - -
0
-
35 f
0
w 30
25
.
0...

...
a
20

-
a

. ~'
15

--
10 a

5
0
0
- 10 100
.
1 SIEVE OPENING (mm)
-- BS 882:1973 limits

28
 4.5.10 Grading Requirements
• The purpose of sieve analysis is to determine whether or not
a particular grading is suitable. The related problem of
grading is the combining of fine and coarse aggregates so as
to produce desired grading (See Table 4 5 . 4.6).

The main factors governing the desired aggregate grading are:

1. the surface area of the aggregate, which determines the
amount of water necessary to wet all the solids
2. the relative volume occupied by the aggregate
3. the workability of the mix
4. the tendency to segregation.

43
 4.5.10 Grading Requirements
• The grading of aggregate is a major factor in
the workability of a concrete mix.

• Grading affetcs characteristics of fresh concrete and

hardened state: strength, shrinkage and durability.

• Ensure that the grading is kept constant during the

concreting work; otherwise variable workability
results and as this is usually corrected at the mixer by
a variation in the water content, concrete of variable
strength is obtained.

44
 Grading Curves of Aggregates (grading requirement)

GRADING CURVES OF AGGREGATES

100
95
90
~
A --
85
80
.,,,, r

F
c
z
75
70
wf

5 w 4

.... ,,~ ~ , "

--
65

.-
0 60 L

-
<C
~

-
55

•
0... 4
50

-- -- - -~
z
I 45
.-
!
w
·· L s4el

-
40

-
-~ . - - -
0
-
35 f
0
w 30
25
.
0...

...
a
20

-
a

. ~'
15

--
10 a

5
0
0
- 10 100
.
1 SIEVE OPENING (mm)
-- BS 882:1973 limits

47
• Gap grading is a grading in which one or more
intermediate size fractions are omitted. (see
Figure4.2).

• Well Graded means sizes within the entire

range are in approximately equal amounts
(friction at many points, excellent interlocking,
very few voids) (see Figure4.2).

48
• Uniform gradation means a large
percentage of the particles are of
approximately the same size (poor
interlocking, high percentage of voids,
friction at few points of contact) (see Figure
4.2).

• Combined gradation means fine and coarse

aggregates are combined (friction at many
points, good interlocking, few
voids, economical).

49
 100

90

00

70

F...
~
00

£
. 6o
Un/torr

5
m
a
40

30

20

10

0
10 0.1 0.01 0.001
Grain
diarntor,
f i vmnmn
e Ty p o s o f G r a d a t io n

Figure 4.2 Grading of aggregates

50
 Grading of aggregates

(a ) J n if o r m siz e aggre g at e :
1, Friction at few points
of contact
2. Poor interlocking
.Hign percentage of vois

tb) Meil -3raec aggreg ate:

1, Friction at m a n y
points
of contact
2. Exceiient interlock ing
• Ve ry few v o id s

ic} M i x t u r e o f c o a r s e a n d f i r e
aggregate:
1, Friction at many points
of contact
2.Good intertocking
r
. F e w vois
d. c o n o m icat p r e p a r a t io n

• - ~ - - - - - - - - - - ✓-Lal 54 53
 Coarse
aggregate

F i n e aggregate

Due to filling the interstice with fine motar there will be a higher comprezzive strength
but alo a higher dry density
 Cement
First Portland cement Patent was invented by Joseph Spedin in 1824. The
fancy name of Portland was given owing to the resemblance of this hardened
cement to the natural stone occurring at Portland in England. Later in 1845 Isaac
Charles Johnson burnt a mixture of clay and chalk till the clinkering stage to make better
cement and established factories in 1851.

Type of cement

1- Ordinary Portland cement (OPC)-269-2015

- 33 Grade
- 43 Grade
- 53 Grade
2-Sulphate Resistant Cement (SRC)-12330-1988
3-Portland Slag Cement (PSC)- 455-1989
4-Portland Pozzolana Cement (PPC)-1489-2015 Part-1 (Fly ash based)
- 1489-2015 Part-2 (Calcined Clay based)
Cement is manufactured through a closely controlled chemical combination of
calcium, silicon, aluminum, iron and other ingredients. Common materials used to
manufacture cement include limestone, shells, and chalk or marl combined with
shale, clay, slate, blast furnace slag, silica sand and iron etc.
Harmful Cement in formation of C-H-S Gel ( Calcium Silicate Hydrate)
 Admixture
a- Accelerating admixture
b-Retarding Admixture
c-Water reducing admixture
d- Air entertaining admixture
e-Super Plasticizing admixture
f-Retarding super plasticizing admixture

Admixture base
1- Naphthalene base
2- Poly Carboxylate Either (PCE) base
a-Low PCE base admixture ( 10% to 20% water reducing)
b- Mid PCE base admixture (20% to 30% water reducing)
c- High range PCE base admixture (30% to 40% water reducing)

Advantage of usage of admixture

 Reducing water, increase strength, increase workability, reduce porosity,
increase durability.
 Water
Water should comply with IS 456-2000

1- Chloride as Cl
2- Sulphate as SO3
3- Inorganic Solids
4- Suspended Mater
5- Organic Solid
6- pH Value
 FRESH CONCRETE
REQUIREMENTS-
1-Slump•
2- Cohesiveness
3- Flow
4- Homogeneity
5- Retention
If complying requirements then accepted otherwise rejected/ modification
REJECTION-
1- Bleeding
2- Segregation
3- Proper mixing
4- Collapse slump

•
Slump Test-
. - - - -; ; 4 L
slump
; 'r -
: 'slump
l
' slump i $
.
,
'1
·«H· i
Collapse Shear
.
I
I '

True sl ump
Ty p e s o f
slump
 If accepted send to site for pour

Readiness of pour:
A-Checks
Reinforcement - Approved drawing, No of bar, dia of bar, placing of bar, cover blocks,
tying, fixing, extra bars etc .
Shutter- Hole, gaps sealed properly, oil, grease, debris, loose particles, binding wires
cleaned properly, verticality, line, level, openings, adequate supports,tightness, cover,
shuttering oil applied, checked found acceptable allowed for pour etc.