CONCRETE

CONSTRUCTION
By,
Engr. Usman Ilyas
Assistant Professor
Civil Engineering Department
University of Management and Technology, Lahore
 Introduction

Concrete and Steel are the two

most commonly used
structural materials in the
construction industry.
 Ingredients
Concrete consists of following ingredients
• Cementitious material (cement or lime)
• Coarse aggregate (Crush stone etc.)
• Fine aggregate (Sand )
• Water (which is fit for drinking)
• Admixtures (Chemical to enhance various
characteristics of Concrete)
 Portland Cement
Main compounds of portland cement are
• Tri calcium Silicate 3CaO. SiO2 C3S

• Dicalcium silicate 2CaO. SiO2 C 2S

• Tricalcium Aluminate 3CaO. Al2O3 C3A

• Tetracalcium Aluminoferrite 4CaO.Al2O3.Fe2O3 C4AF

 Hydration of Cement
When Portland cement is mixed with water, it
undergoes a chemical reaction which leads to the
hardening of the material. This process is called
hydration. The hydration process can be quantified
by two characteristics;
(1) the rate of reaction
(2) the heat of reaction.
 Heat of Hydration of Cement
Heat liberated when cement in contact with water as
a result of exothermic chemical reaction between
water and cement. It can result in thermal cracking
which can reduced the concrete durability.
PHASES OF HYDRATION
Ph
as
es
of
Hy
dr
ati
on
 TYPES OF CEMENT
ASTM Type I (Ordinary Portland Cement):
Used in general concrete construction where there is
no exposure to sulphates in soil or ground water.

ENV 197-1 :1992.

 TYPES OF CEMENT
ASTM Type II (Moderate Portland Cement):
This Type of cement has high resistance to the action
of sulphates than type I cement. This cement is used
where sulphates contents are higher than normal but
not severe. It is also used in massive concrete works
done such as heavy abutments and retaining walls.
Its use minimizes the temperature rise, which is
important, when concrete is been placed in hot
weather. Type II generates less heat than type I and
reaches its desired strength in 45 days.
 TYPES OF CEMENT
ASTM Type III (High Early Strength Portland
Cement):
It is used where high strengths are required at early
periods. Usually a week or less. It is particularly
useful where it is required to remove from work as
soon as possible or when the structure is brought
into service quickly. Where there are tight deadlines
High Early Strength Cement can
improve construction, minimize labor costs etc.
 TYPES OF CEMENT
ASTM Type IV (Low Heat of Hydration Cement):
It is special cement for use where amount and rate of
heat hydration generated must be minimized.
Strength is also developed at low rate. It is intended
for use in massive concrete structures such as large
dams. It generates less heat though sets slowly but
becomes much stronger after curing. Its design
strength is 90 days.
 TYPES OF CEMENT
ASTM Type V (Sulphate resisting Portland Cement):
It is intended for use in structures subjected to attack
by sulphate concentration in some waters, such as
may be found in certain manufacturing plant or in
ground water in some areas.
 TYPES OF CEMENT
The rate at which strength of the concrete increases
varies according to the type of cement used.
Approximate strength of various types of cement is
as under.
Type of After 1 day After 7 day After 28 day After 3 Months
day
cement
Type 1 100% 100% 100% 100%
Type 2 75% 85% 90% 100%
Type 3 190% 120% 110% 100%
Type 4 55% 55% 75% 100%
Type 5 65% 75% 85% 100%
 Special Cements
White Cement:
• White Cement is used for architectural Purposes
such as face plaster of wall, decorating concrete or
so on.
• It is very similar to Portland cement except in
colour and made from specially selected raw
material, containing negligible amount of iron,
Magnesium oxide and the manufacturing process is
controlled to produce pure white and non-staining
cement.
 Special Cements
White Cement:
• White Portland cement differs physically from gray
cement only in terms of its color. Its setting
behavior and strength development are essentially
the same as that expected in gray cement, and it
meets standard specifications such as ASTM C 150.
• The use of white cements require scareful attention
to cleanliness on the job site. Mixing and placing
equipment, trowels must be absolutely clean and
free from rust, dirt and other contaminants.
• It is much more costly than ordinary cement.
Special Cements
 Special Cements
Rapid Hardening Cement:
• This cement is very similar to OPC but develops
strength more readily.
• Its three day strength is equal to seven days
strength of OPC with same water cement ratio.
• The increased rate of strength is due to the Tri-
Calcium Silicate. Rapid gain of strength corresponds
to high rate of heat of hydration.
• The cost of rapid hardening cement is about 10%
more than the ordinary cement.
• It is used for the Structures which are Subjected to
loads early e.g. Rigid Pavement (Roads), Bridges.
Special Cements
 Special Cements
Ultra High Early Strength Cement:
• This cement contains no admixtures and is
therefore, suitable for reinforced concrete.
• The early strength development is due to very high
fineness of the cement and for this purpose
gypsum content are to be high. This cement is
manufactured by separating fines from the rapid
hardening cement.
• The three day strength of rapid hardening cement
is reduced to 16 hours and seven days strength to
24 hours.
 Special Cements
Hydrophobic Cement:
• This cement is used where long storage under
unfavorable condition is required.
• It is obtained by intergrinding Portland Cement
with 0.1-0.4% oleic acid, stearic acid or
pentachlorophenol can also be used.
• The hydrophobic are due to
formation
properties of water the film
particle
repellentof the cement. around each
• The film is broken during mixing of concrete and
normal hydration takes place but early strength is
low. It is similar to OPC in appearance.
Special Cements
 Special Cements
Colored Portland Cement:
• These are made by adding pigments to white or
sometime gray cement.
• Its strength is comparatively lower than normal
Portland Cement and 10-15% additional cement
has to be used to maintain the strength.
 Special Cements

Water Proof Cement:

• Adding small amount calcium or aluminium to the
cement clinkers during the final grinding normally
produces it.
• It has both white and gray color.
• The manufacturers of these cements claim that
concrete made with these cements is more
resistant to penetration of liquid, water and some
oils than OPC.
 Special Cements
Extra Rapid Hardening Cement:
• This cement is obtained by intergrinding
calcium chloride with rapid hardening cement.
• The quantity of Calcium Chloride should not exceed
2%. This cement is particularly suitable for
cold
weather concreting or when very high
strength is required. However early use
reinforcement is not allowed.
its with
• The strength of extra hardening cement is about
25% higher than that of rapid hardening cement at
1 or 2 days and 10-20% higher at 7 days. The
setting time of cement is from 10-30 minutes and
early placing s essential.
 Special Cements
High Alumina Cement:
• It is manufactured by the burning of bauxite ore
and lime stone in correct proportions and at high
temperature.
• The resulting product is then ground finely. It
develops Strength Rapidly. It is of black colour and
resists well the attack of chemicals especially of
sulphates and sea water.
• Its ultimate strength is much higher than OPC. Its
initial setting takes more than 2 hours and the final
set takes place immediately thereafter. Most of the
heat it gives in the first 10 hrs as a result it can be
conveniently used in freezing temperatures.
 Special Cements
Quick Setting Cement:
• It sets faster than the Ordinary Portland Cement. Its
Initial Setting Time is 5 minutes and the Final
Setting Time is not more 30 minutes.
• It is required for making concrete that is required to
set early as for lying under water or in running
water.
• Initial setting being very little there is always the
danger of concrete having undergone its initial
setting. Thus this type of cement is used in more
special cases.
 Special Cements
Low Heat Cement:
• The Heat Generated by cement while setting may
cause the structure to crack in case of concrete.
• This Heat generation is controlled by keeping the
percentage of Tri-Calcium Silicate and that of Tri-
Calcium Aluminate low.
• Its initial setting and Final setting times are nearly
the same as those of OPC.
• It is not very suitable for Ordinary structures
because the use of cement will delayed time of
drying. It will also need more curing.
 Aggregates

Aggregate is an inert material used in

concrete to gain volume stability, durability
and economy.
Theoretically aggregate is not 100% inert, its
physical and chemical properties effects the
concrete properties.
 Types of Aggregates
• As per BS 882 : 1992 basic division between
corse aggregate and fine aggregate (sand)
is 5 mm or 3/16 “ sieve
• As per ASTM No.4 ASTM (4.75 mm) is the
dividing line for coarse and fine
aggregates.
• BS 812 : Part I : 1975 explains two types of
classification for aggregate.
• Classification of natural aggregate
• Particle shape classification
Shape of Aggregates
that must be avoided

Rounded Flaky

Elongated Sharp Pointed

 Parts Per Million
This is a way of expressing very dilute
concentrations of substances. Just as per cent
means out of a hundred, so parts per million or ppm
means out of a million. Usually describes the
concentration of something in water or soil. One
ppm is equivalent to 1 milligram of something per
liter of water (mg/l) or 1 milligram of something per
kilogram soil (mg/kg).
 Water
• Water containing less than 2000 ppm dissolved solids can
generally be used satisfactorily for making concrete.
• Sodium carbonate in water causes rapid setting.
• Bicarbonates may either accelerate or retard the setting time.
• Large concentration of above two salts reduces the strength.
• 20,000 ppm of sodium chloride are generally tolerable.
• 10,000 ppm of sodium sulfate is tolerable.
• Magnesium sulfate & magnesium chloride up to 40,000 ppm is
tolerable.
• Iron salts up to 40,000 ppm is tolerable.
• Inorganic salts like (salts of manganese, tin, zinc, copper & lead)
up to 500 ppm are tolerable.
• Sea water containing salts up to 35,000 ppm are tolerable.
• Acidic water containing hydrochloric acid, sulfuric acid up to
10,000 ppm have no effect.
 Water
• Potassium hydroxide up to 1.2% by wt. is tolerable.
• Industrial waste having less than 4000 ppm total solids cause up
to 10% reduction in compressive strength.
• Raw Sewage contain up to 400 ppm of organic matter. Diluted
sewage contain up to 20 ppm, which has little effect on the
strength of concrete.
• Sugar in water up to 0.03%-0.15% by wt. retard the setting time
of cement.
• Sugar 0.15% - 0.2% accelerate the setting time.
• Sugar greater than 0.25% accelerate the setting time but reduce
28 days strength.
• Sugar in water, less than 500 ppm has no effect at all.
• Suspended clay or fine rock particles up to 2000 ppm can be
tolerated.
• Mineral (petroleum) oils greater than 2% by wt. reduces the
strength more than 20%.
 Batching & mixing of concrete

Batching
– Batching means measuring of the ingredients of concrete.
It is of two types
• Batching by volume
• Batching by weight

Mixing
– Mixing is of two type
• Hand mixing
• Machine mixing

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 Batching by volume (ASTM C 685-94)
• In volumetric batching, ingredients of concrete are mixed by
volume.
• Buckets are used to measure volume of each ingredient.
• Normally volume of one cement bag is considered as standard
(its volume is 1.25 ft3)
• Sand quantities are computed by using volume.
• Quantity of water is affected by the
moisture of fine and coarse
aggregate so minimum desirable
computed net quantity of water
must be added.
 Batching by weight
• It is more accurate method of batching.
• Each ingredient of concrete is weighed and mixed.
• Weighting coarse aggregate is a laborious work.
• Batching plants are available now a days. They are expansive
and can be recommended for large projects, where the
quantity of concrete is considerable.
• Batching plants are of three types.
1. Swinging hopper type.
2. Horizontal hopper type.
3. Simple weight batcher.
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THANKS