Chapter 1:- Concrete Technology
Concrete is a construction material composed of cement, fine aggregates (sand) and coarse aggregates mixed with water which hardens with time. Portland cement is the commonly used type of cement for production of concrete. Concrete technology deals with study of properties of concrete and its practical applications.
In a building construction, concrete is used for the construction of foundations, columns, beams, slabs and other load bearing elements.
There are different types of binding material is used other than cement such as lime for lime concrete and bitumen for asphalt concrete which is used for road construction.
Various types of cements are used for concrete works which have different properties and applications. Some of the type of cement are Portland Pozzolana Cement (PPC), rapid hardening cement, Sulphate resistant cement etc.
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Materials are mixed in specific proportions to obtain the required strength. Strength of mix is specified as M5, M10, M15, M20, M25, M30 etc, where M signifies Mix and 5, 10, 15 etc. as their strength in kN/m2. In United States, concrete strength is specified in PSI which is Pounds per Square Inch.
Water cement ratio plays an important role which influences various properties such as workability, strength and durability. Adequate water cement ratio is required for production of workable concrete.
When water is mixed with materials, cement reacts with water and hydration reaction starts. This reaction helps ingredients to form a hard matrix that binds the materials together into a durable stone-like material.
Concrete can be casted in any shape. Since it is a plastic material in fresh state, various shapes and sizes of forms or formworks are used to provide different shapes such as rectangular, circular etc.
Various structural members such as beams, slabs, footings, columns, lintels etc. are constructed with concrete.
ACI 318 Building code requirements for structural concrete and ACI 301 Specifications for Structural Concrete are used in United States as standard code of practice for concrete construction.
There are different types of admixtures which are used to provide certain properties. Admixtures or additives such as pozzolans or superplasticizers are included in the mixture to improve the physical properties of the wet mix or the finished material.
Various types of concrete are manufactured these days for construction of buildings and structures. These have special properties and features which improve quality of construction as per requirement.
Table of Contents
Components of Concrete
Components of concrete are cement, sand, aggregates and water. Mixture of Portland cement and water is called as paste. So, concrete can be called as a mixture of paste, sand and aggregates. Sometimes rocks are used instead of aggregates.
The cement paste coats the surface of the fine and coarse aggregates when mixed thoroughly and binds them. Soon after mixing the components, hydration reaction starts which provides strength and a rock solid concrete is obtained.
What is Grade of Concrete?
Grade of concrete denotes its strength required for construction. For example, M30 grade signifies that compressive strength required for construction is 30MPa. The first letter in grade “M” is the mix and 30 is the required strength in MPa.
Based on various lab tests, grade of concrete is presented in Mix Proportions. For example, for M30 grade, the mix proportion can be 1:1:2, where 1 is the ratio of cement, 1 is the ratio of sand and 2 is the ratio of coarse aggregate based on volume or weight of materials.
The strength is measured with concrete cube or cylinders by civil engineers at construction site. Cube or cylinders are made during casting of structural member and after hardening it is cured for 28 days. Then compressive strength test is conducted to find the strength.
Regular grades of concrete are M15, M20, M25 etc. For plain cement concrete works, generally M15 is used. For reinforced concrete construction minimum M20 grade of concrete are used.
Concrete Grade Mix Ratio Compressive Strength
MPa (N/mm2) psi
Normal Grade of Concrete
M5 1 : 5 : 10 5 MPa 725 psi
M7.5 1 : 4 : 8 7.5 MPa 1087 psi
M10 1 : 3 : 6 10 MPa 1450 psi
M15 1 : 2 : 4 15 MPa 2175 psi
M20 1 : 1.5 : 3 20 MPa 2900 psi
Standard Grade of Concrete
M25 1 : 1 : 2 25 MPa 3625 psi
M30 Design Mix 30 MPa 4350 psi
M35 Design Mix 35 MPa 5075 psi
M40 Design Mix 40 MPa 5800 psi
M45 Design Mix 45 MPa 6525 psi
High Strength Concrete Grades
M50 Design Mix 50 MPa 7250 psi
M55 Design Mix 55 MPa 7975 psi
M60 Design Mix 60 MPa 8700 psi
M65 Design Mix 65 MPa 9425 psi
M70 Design Mix 70 MPa 10150 psi
How to Make Concrete?
Concrete is manufactured or mixed in proportions w.r.t. cement quantity. There are two types of concrete mixes, i.e. nominal mix and design mix. Nominal mix is used for normal construction works such as small residential buildings. Most popular nominal mix are in the proportion of 1:2:4.
Design mixed concrete are those for which mix proportions are finalized based on various lab tests on cylinder or cube for its compressive strength. This process is also called as mix design. These tests are conducted to find suitable mix based on locally available material to obtain strength required as per structural design. A design mixed offers economy on use of ingredients.
Once suitable mix proportions are known, then its ingredients are mixed in the ratio as selected. Two methods are used for mixing, i.e. Hand Mixing or Machine Mixing.
Based on quantity and quality required, the suitable method of mixing is selected. In the hand mixing, each ingredients are placed on a flat surface and water is added and mixed with hand tools. In machine mixing, different types of machines are used. In this case, the ingredients are added in required quantity to mix and produce fresh concrete.
Once the it is mixed adequately it is transported to casting location and poured in formworks. Various types of formworks are available which as selected based on usage.
Poured concrete is allowed to set in formworks for specified time based on type of structural member to gain sufficient strength.
After removal of formwork, curing is done by various methods to make up the moisture loss due to evaporation. Hydration reaction requires moisture which is responsible for setting and strength gain. So, curing is generally continued for minimum 7 days after removal of formwork.
Types of Concrete Construction
Concrete is generally used in two types of construction, i.e. plain concrete construction and reinforced concrete construction. In PCC, it is poured and casted without use of any reinforcement. This is used when the structural member is subjected only to the compressive forces and not bending.
When a structural member is subjected to bending, reinforcements are required to withstand tension forces structural member as it is very weak in tension compared to compression. Generally, strength of concrete in tension is only 10% of its strength in compression.
It is used as a construction material for almost all types of structures such as residential concrete buildings, industrial structures, dams, roads, tunnels, multi storey buildings, skyscrapers, bridges, sidewalks and superhighways etc.
Example of famous and large structures made with concrete are Hoover Dam, Panama Canal and Roman Pantheon. It is the largest human made building materials used for construction.
Steps of Concrete Construction
The construction steps are:
- Selecting quantities of materials for selected mix proportion
- Mixing
- Checking of workability
- Transportation
- Pouring in formwork for casting
- Vibrating for proper compaction
- Removal of formwork after suitable time
- Curing member with suitable methods and required time.
Source :theconstructor.orgConcrete | Advantages and Disadvantages of Concrete
Concrete
Concrete is an artificial stone-like material used for various structural purposes. It is made by mixing a binding material (as cement) and various aggregates (inert materials), such as sand, stone chips, brick chips, brick chips, pebbles, gravel, shale, etc with water and allowing the mixture to harden by hydration.
Advantages of Concrete
Some advantages of concrete are given below in brief.
- Concrete is economical when ingredients are readily available.
- Concrete’s long life and relatively low maintenance requirements increase its economic benefits.
- It is not as likely to rot, corrode, or decay as other building materials.
- Concrete has the ability to be molded or cast into almost any desired shape.
- Building of the molds and casting can occur on the work-site which reduces cost.
- Concrete is a non-combustible material which makes it fire-safe and able to withstand high temperatures.
- It is resistant to wind, water, rodents, and insects. Hence, concrete is often used for storm shelters.
Disadvantages of Concrete
Concrete has some disadvantages too along the advantages stated above.
- Concrete has a relatively low tensile strength (compared to other building materials),
- low ductility,
- low strength-to-weight ratio, and
- Concrete is susceptible to cracking.
Concrete remains the material of choice for many applications regardless of these limitations.
Source:- civilengineersforum.com
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Chapter 2: Cement
Types Of Cement and Their Uses
|Types of Cement:
Following are the different types of cement used in construction works.1. Rapid Hardening Cement:
Rapid hardening cement is very similar to ordinary portland cement (OPC). It contains higher c3s content and finer grinding. Therefore it gives greater strength development at an early stage than OPC. The strength of this cement at the age of 3 days is almost same as the 7 days strength of OPC with the same water-cement ratio.The main advantage of using rapid hardening cement is that the formwork can be removed earlier and reused in other areas which save the cost of formwork. This cement can be used in prefabricated concrete construction, road works, etc.
2. Low Heat Cement:
Low heat cement is manufactured by increasing the proportion of C2S and by decreasing the C3S and C3A content. This cement is less reactive and its initial setting time is greater than OPC. This cement is mostly used in mass concrete construction.3. Sulfate Resisting Cement:
Sulfate resisting cement is made by reducing C3A and C4AF content. Cement with such composition has excellent resistance to sulfate attack. This type of cement is used in the construction of foundation in soil where subsoil contains very high proportions of sulfate .4. White Cement:
White cement is a type of ordinary Portland Cement which is pure white in color and has practically the same composition and same strength as OPC. To obtain the white color the iron oxide content is considerably reduced. The raw materials used in this cement are limestone and china clay.This cement, due to its white color, is mainly used for interior and exterior decorative work like external renderings of buildings, facing slabs, floorings, ornamental concrete products, paths of gardens, swimming pools etc.
5. Portland Pozzolana Cement:
Portland pozzolana cement is produced either by grinding together, portland cement clinkers and pozzolana with the addition of gypsum or calcium sulfate or by intimately and uniformly blending portland cement and fine pozzolana.It produces lower heat of hydration and has greater resistance to attack of chemical agencies than OPC. Concrete made with PPC is thus considered particularly suitable for construction in sea water, hydraulic works and for mass concrete works.
6. Hydrophobic Cement:
Hydrophobic cement is manufactured by adding water repellant chemicals to ordinary portland cement in the process of grinding. Hence the cement stored does not spoiled even during monsoon. This cement is claimed to remain unaffected when transported during rains also. Hydrophobic cement is mainly used for the construction of water structures such dams, water tanks, spillways, water retaining structures etc.7. Colored Cement:
This Cement is produced by adding 5- 10% mineral pigments with portland cement during the time of grinding. Due to the various color combinations, this cement is mainly used for interior and exterior decorative works.8. Waterproof Portland Cement:
Waterproof cement is prepared by mixing with ordinary or rapid hardening cement, a small percentage of some metal stearates (Ca, Al, etc) at the time of grinding. This cement is used for the construction of water-retaining structure like tanks, reservoirs, retaining walls, swimming pools, dams, bridges, piers etc.9. Portland Blast Furnace Cement:
In this case, the normal cement clinkers are mixed with up to 65% of the blast furnace slag for the final grinding. This type of cement can be used with advantage in mass concrete work such as dams, foundations, and abutments of bridges, retaining walls , construction in sea water.10. Air Entraining Cement:
It is produced by air entraining agents such as resins, glues, sodium salts of sulfate with ordinary portland cement.11. High Alumina Cement:
High alumina cement (HAC) is a special cement, manufactured by mixing of bauxite ( aluminum ore) and lime at a certain temperature. This cement is also known as calcium aluminum cement (CAC). The compressive strength of this cement is very high and more workable than ordinary portland cement.12. Expansive Cement:
The cement which does not shrink during and after the time of hardening but expands slightly with time is called expansive cement. This type of cement is mainly used for grouting anchor bolts and prestressed concrete ducts.Difference Between 43 Grade And 53 Grade Cement
|Difference Between 43 Grade And 53 Grade Cement:
There are different types of cement used in construction works. Ordinary portland cement is most widely used cement among them. Portland cement is graded according to their strength where the grade denotes the compression strength of concrete that will achieve after setting of 28 days in MPa (Mega Pascals) or in N/mm2.Compression Strength:
The compression strength of 43 grade cement is 43 MPa after 28 days of setting and the compression strength of 53 grade cement is 53 MPa after 28 days of setting.Initial Strength:
53 graded cement is mostly used in fast forward construction where initial strength needs to be achieved quickly.53 grade cement has faster setting compared to 43 grade cement. Compression strength of 53 grade cement after 7 days is 27 MPa but 43 grade cement gets 23 MPa after 7 days.
Uses And Application:
As 53 grade cement has a faster setting, it is used where earlier strength development is required such as reinforced concrete structures, cement grouts, prestressed concrete structures of higher grades, instant plugging mortars etc.
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Chapter 3 :-Aggregates (coarse and fine)
Types of Aggregates, Its Uses and Applications
Definition:
Aggregate is a granular material, such as sand, gravel, crushed stone, crushed hydraulic-cement concrete, or iron blast-furnace slag, used with a hydraulic cementing medium to produce either concrete or mortar.
Coarse Aggregate
Those particles that are predominantly retained on the 4.75 mm (No. 4) sieve and will pass through 3-inch screen, are called coarse aggregate. The coarser the aggregate, the more economical the mix. Larger pieces offer less surface area of the particles than an equivalent volume of small pieces. Use of the largest permissible maximum size of coarse aggregate permits a reduction in cement and water requirements. Using aggregates larger than the maximum size of coarse aggregates permitted can result in interlock and form arches or obstructions within a concrete form. That allows the area below to become a void, or at best, to become filled with finer particles of sand and cement only and results in a weakened area.
Fine Aggregate
Those particles passing the 9.5 mm (3/8 in.) sieve, almost entirely passing the 4.75 mm (No. 4) sieve, and predominantly retained on the 75 µm (No. 200) sieve are called fine aggregate. For increased workability and for economy as reflected by use of less cement, the fine aggregate should have a rounded shape. The purpose of the fine aggregate is to fill the voids in the coarse aggregate and to act as a workability agent.
Also See: Measuring Workability
Purpose & Uses of Aggregates
In concrete, an aggregate is used for its economy factor, to reduce any cracks and most importantly to provide strength to the structure. In roads and railway ballast, it is used to help distribute the load and assist in ground water running off the road.
- Increases the volume of concrete, thus reduces the cost
- Provide dimensional stability
- Influence hardness, abrasion resistance, elastic modulus and other properties of concrete to make it more durable, strong and cheaper.
Source:-www.aboutcivil.org
WHAT ARE THE PROPERTIES OF AGGREGATES FOR CONCRETE?
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Engineering Properties of Aggregates
Aggregates are used in concrete to provide economy in the cost of concrete. Aggregates act as filler only. These do not react with cement and water.
But there are properties or characteristics of aggregate which influence the properties of resulting concrete mix. These are as follow.
- Composition
- Size & Shape
- Surface Texture
- Specific Gravity
- Bulk Density
- Voids
- Porosity & Absorption
- Bulking of Sand
- Fineness Modulus of Aggregate
- Surface Index of Aggregate
- Deleterious Material
- Crushing Value of Aggregate
- Impact Value of Aggregate
- Abrasion Value of Aggregate
1. Composition
Aggregates consisting of materials that can react with alkalies in cement and cause excessive expansion, cracking and deterioration of concrete mix should never be used. Therefore it is required to test aggregates to know whether there is presence of any such constituents in aggregate or not.
2. Size & Shape
The size and shape of the aggregate particles greatly influence the quantity of cement required in concrete mix and hence ultimately economy of concrete. For the preparation of economical concrete mix on should use largest coarse aggregates feasible for the structure. IS-456 suggests following recommendation to decide the maximum size of coarse aggregate to be used in P.C.C & R.C.C mix.
Maximum size of aggregate should be less than
- One-fourth of the minimum dimension of the concrete member.
- One-fifth of the minimum dimension of the reinforced concrete member.
- The minimum clear spacing between reinforced bars or 5 mm less than the minimum cover between the reinforced bars and form, whichever is smaller for heavily reinforced concrete members such as the ribs of the main bars.
Remember that the size & shape of aggregate particles influence the properties of freshly mixed concrete more as compared to those of hardened concrete.
3. Surface Texture
The development of hard bond strength between aggregate particles and cement paste depends upon the surface texture, surface roughness and surface porosity of the aggregate particles.
If the surface is rough but porous, maximum bond strength develops. In porous surface aggregates, the bond strength increases due to setting of cement paste in the pores.
4. Specific Gravity
The ratio of weight of oven dried aggregates maintained for 24 hours at a temperature of 100 to 1100C, to the weight of equal volume of water displaced by saturated dry surface aggregate is known as specific gravity of aggregates.
Specific gravities are primarily of two types.
- Apparent specific gravity
- Bulk specific gravity
Specific gravity is a mean to decide the suitability of the aggregate. Low specific gravity generally indicates porous, weak and absorptive materials, whereas high specific gravity indicates materials of good quality. Specific gravity of major aggregates falls within the range of 2.6 to 2.9.
Specific gravity values are also used while designing concrete mix.
5. Bulk Density
It is defined as the weight of the aggregate required to fill a container of unit volume. It is generally expressed in kg/litre.
Bulk density of aggregates depends upon the following 3 factors.
- Degree of compaction
- Grading of aggregates
- Shape of aggregate particles
6. Voids
The empty spaces between the aggregate particles are known as voids. The volume of void equals the difference between the gross volume of the aggregate mass and the volume occupied by the particles alone.
7. Porosity & Absorption
The minute holes formed in rocks during solidification of the molten magma, due to air bubbles, are known as pores. Rocks containing pores are called porous rocks.
Water absorption may be defined as the difference between the weight of very dry aggregates and the weight of the saturated aggregates with surface dry conditions.
Depending upon the amount of moisture content in aggregates, it can exist in any of the 4 conditions.
- Very dry aggregate ( having no moisture)
- Dry aggregate (contain some moisture in its pores)
- Saturated surface dry aggregate (pores completely filled with moisture but no moisture on surface)
- Moist or wet aggregates (pores are filled with moisture and also having moisture on surface)
8. Bulking of Sand
It can be defined as in increase in the bulk volume of the quantity of sand (i.e. fine aggregate) in a moist condition over the volume of the same quantity of dry or completely saturated sand. The ratio of the volume of moist sand due to the volume of sand when dry, is called bulking factor.
Fine sands bulk more than coarse sand
When water is added to dry and loose sand, a thin film of water is formed around the sand particles. Interlocking of air in between the sand particles and the film of water tends to push the particles apart due to surface tension and thus increase the volume. But in case of fully saturated sand the water films are broken and the volume becomes equal to that of dry sand.
9. Fineness Modulus
Fineness modulus is an empirical factor obtained by adding the cumulative percentages of aggregate retained on each of the standard sieves ranging from 80 mm to 150 micron and dividing this sum by 100.
Fineness modulus is generally used to get an idea of how coarse or fine the aggregate is. More fineness modulus value indicates that the aggregate is coarser and small value of fineness modulus indicates that the aggregate is finer.
10. Specific Surface of Aggregate
The surface area per unit weight of the material is termed as specific surface. This is an indirect measure of the aggregate grading. Specific surface increases with the reduction in the size of aggregate particle. The specific surface area of the fine aggregate is very much more than that of coarse aggregate.
11. Deleterious Materials
Aggregates should not contain any harmful material in such a quantity so as to affect the strength and durability of the concrete. Such harmful materials are called deleterious materials. Deleterious materials may cause one of the following effects
- To interfere hydration of cement
- To prevent development of proper bond
- To reduce strength and durability
- To modify setting times
Deleterious materials generally found in aggregates, may be grouped as under
- Organic impurities
- Clay , silt & dust
- Salt contamination
12. Crushing Value
The aggregates crushing value gives a relative measure of resistance of an aggregate to crushing under gradually applied compressive load. The aggregate crushing strength value is a useful factor to know the behavior of aggregates when subjected to compressive loads.
13. Impact Value
The aggregate impact value gives a relative measure of the resistance of an aggregate to sudden shock or impact. The impact value of an aggregate is sometime used as an alternative to its crushing value.
14. Abrasion Value of Aggregates
The abrasion value gives a relative measure of resistance of an aggregate to wear when it is rotated in a cylinder along with some abrasive charge.
Source :-Civilblog.org
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Chapter 4: Mineral admixtures, chemical admixtures and water
CONCRETE CHEMICAL ADMIXTURES AND MINERALS
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Different types of the admixtures are used in concrete construction.
1: Accelerators:
Setting time was reduced by the use of the accelerator and generally produce an early setting of concrete repair and patch work. In the cold weathers accelerators was used to achieve the early strength.
The calcium chloride (CaCl2) is the most common accelerator which was used in the plain cement concrete work. The quantity of calcium chloride is limited in a concrete mix is about 1%-2% by weight of cement.
The Main properties of accelerator were
1: Shortening setting time
2: Increase early strength
3: Aids, cold weather concreting
2: Retarders:
The function of reader is opposite to the accelerator. The retarder increase the setting time of concrete. By the use of retarder the water cement ratio was reduced.
Usually by the use of this admixture the water was reduced at about 10%. Various types of water, reducing agents and set-retarding admixtures was used in Ready mix concrete.The chemical are,
1: Lignosulphonic Acid and their salts.
2: Hydroxylated carboxylic acid and their salts.
3: Sulphonated melamine.
4: naphthalene formaldehyde.
They also have a detergent like properties.
3: Plasticizers:
The plasticizer is the admixture which was added in fresh concrete to increase it’s workability. Three main types of the plasticizers were used such as
1: Finely divided minerals (Either cementitious or pozzolanic)
2: Air-entertaining agents (Produces discontinuous air bubbles)
3: Synthetic derivatives (Produce soapy action)
4: Superplasticizers:
Extreme work ability of concrete was achieved by the use of superplasticizer. The reduction, water cement ratio was done without loss of work ability. The use of superplasticizer leads to the reduction of overall cost.
For extreme work ability the electrochemical activities were responsible. The increase of the mobility of concrete the concrete starts to flow without segregation.
Superplasticizer enable the saving in the cement and make the concrete ideal for pumping, Casting heavily reinforced concrete members and precast elements of concrete.
5: Waterproofers:
This type of admixtures was added in concrete to make the structure water proof. These chemicals react with lime, which is present in cement to form inorganic salts which blocks the pores and capillaries, thereby reducing moisture penetration.
Waterproofers may obtained in liquid and in powder form and consist of pore filling or water- repellent materials.
The chief material for a pore – filling are
1: Alkali silicated.
2: Notably silicates.
3: Zinc sulfates..
4: Chlorides of aluminium and calcium.
6: Miscellaneous Admixtures:
Many other chemical admixtures were used in concrete to achieve results such as
1: Gas-Forming and Expansive chemicals
2: Corrosion-Inhibiting Chemicals
3: Pigments
4: Antifungal admixtures
5: Curing compounds
6: sealants
7: Flooring
8: Floor coating
9: Guniting Aids
7: Mineral Admixtures:
To modify the concrete properties, mineral admixtures was used under the permits of IS: 456-2000. Those are
1: Fly Ash
2: Silica Fume
3: Rice Husk Ash
4: Metakaoline
5: Ground Granulated Blast Furnace slag.
The following materials may added in concrete either as a admixture or as a part of cement.
Sources and Types of Pozzolanic Material
Definition
A simple everyday definition of 'pozzolan' could be 'a finely powdered material which can be added to lime mortar (or to Portland cement mortar) to increase durability. A more formal definition is given by ASTM C618-84 as 'a siliceous or siliceous and aluminous material which, in itself, possesses little or no cementitious value but which will, in finely divided form in the presence of moisture, react chemically with calcium hydroxide at ordinary temperature to form compounds possessing cementitious properties'
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Sources and Types of Pozzolanic Material
Pozzolanic materials can be divided into the categories listed below, according to their origin and properties.
Natural, Very Finely Divided, Highly Reactive Materials of Volcanic Origin:
These materials are formed from a combination of minerals, (mainly consisting of silica and alumina with smaller and variable quantities of other minerals containing calcium, magnesium, iron, potassium, and sodium), ejected from volcanoes in the form of very finely divided vitreous material. Other vitreous volcanic material, such as basalt, may have mild pozzolanic properties if very finely ground.
These natural pozzolans were widely used in 19th century engineering works in conjunction with natural hydraulic limes. They were recognized as being particularly appropriate for marine engineering and other works in difficult wet conditions, and for civil engineering works generally. Well known sources include puozzolana from Puozzoli in Italy, volvic pozzolan from South-east France, trass from the Rhineland and tuff from the Aegean islands. Crushed pumice was also used.
Low Temperature Calcined Clay Products In Various Forms
Pozzolanic additives derived from lightly fired and finely crushed clay products, such as clay tile or brick, were used by the Romans and combinations of non-hydraulic lime and low temperature brick dusts have been used over a long period of time. Similar specifications are successfully employed in modern conservation practice where additional set and durability are required without seriously reducing the permeability and flexibility of the mortar.
Bodies such as English Heritage have promoted the use, particularly for conservation work, of low temperature clay pozzolans in non-hydraulic mortars. Current advice is that the material should be derived from clay fired at temperatures below 950 °C, and ground to a range of particle sizes between 38 and 600 microns.Modern sources of potentially suitable material include reject bricks and tiles from traditional producers, which can be crushed in a roller pan mill. Some manufacturers also produce low temperature purpose-made dusts for sale as pozzolans.
Clay or Kaolin Products Specifically Manufactured as Pozzolans
These are produced primarily for use with Portland cement and all currently available technical and performance data relates to their use in that context. These materials are highly reactive and combine readily with calcium hydroxide to form calcium silicate hydrates and calcium alumino-silicate hydrates. Their effect on the performance and characteristics of lime mortars is not currently known but, subject to adequate investigation and trials, it is possible that their use could be extended into this field.
Also falling into the category of fired clays is the material known as HTI (high temperature insulation) powder. This was widely specified in the 1980s but has now largely been superseded by lower temperature materials which are thought to be more consistent in their performance.
Mineral Slag:
Furnace slag is a vitrified material, produced as a by-product of processes such as smelting, and requires grinding to convert it to a reactive material. It contains silica, alumina, lime and other minerals in various proportions and, in modern practice, is more commonly used as an additive in Portland cement concretes. Historically, forge scale and iron-rich slag, known as minion, were also used.
Ashes of Organic Origin:
Coal cinders generally have an acceptable balance of silica and alumina, and have been used historically as a pozzolanic additive, but their physical structure tends to weaken the mortar and to absorb excessive water. Coal ash is widely used, in the form of PFA (pulverised fuel ash) as an additive to cementitious mortars and in lime-based grouts. The use of coal-based products carries a risk of sulphate contamination and the materials should always be selected from low sulphate coals. The residue of fuels from lime burning, whether from coal-, coke-, or wood-fired kilns, known as lime-ash, is well known historically as a pozzolan and is still available. Other vegetable ashes, such as rice husk ash, are used as pozzolans in other parts of the world. Bone ash is also known to have been used.
Certain Natural Sands and Crushed Rock Products:
Certain types of sand, such as argillaceous (clayey) sands containing high proportions of schist, basalt, feldspar and mica, can have mildly pozzolanic properties. Whilst these sands are not generally specified for modern lime-based mortars it may be useful to recognize that, historically, in certain localities, their use could have influenced the nature of local lime mortars. Finely crushed rock products from sources containing an appropriate balance of minerals may also produce a mild pozzolanic effect. Traditionally, mortars were often produced using techniques which brought the sand into contact with hot slaking lime, and it is possible that this heat would have encouraged any potential for a mild pozzolanic reaction between sand and lime.
Natural, Very Finely Divided, Highly Reactive Materials of Volcanic Origin:
Low Temperature Calcined Clay Products In Various Forms
Clay or Kaolin Products Specifically Manufactured as Pozzolans
Mineral Slag:
Ashes of Organic Origin:
Certain Natural Sands and Crushed Rock Products:
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Quality of Water for Concrete Construction and its Specification
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Water Cement Ratio and Abrams' law
Posted on : 14 Mar 2016
Duff Abrams published data that showed that for a given set of concreting materials, the strength of the concrete depends solely on the relative quantity of water compared with the cement. In other words, the strength is a function of the water to cement ratio (w/c) where w represents the mass of water and c represents the mass of cement. This became known as Abrams law and it remains valid today as it was in 1918. However, more often, w/cm is used and cm represents the mass of cementing materials, which includes the portland cement plus any supplementary cementing materials such as fly ash, slag cement, or silica fume.
Unnecessarily high water content dilutes the cement paste (the glue of concrete) and increases the volume of the concrete produced. Some advantages of reducing water content include:
- Increased compressive and flexural strength
- Lower permeability and increased watertightness
- Increased durability and resistance to weathering
- Better bond between concrete and reinforcement
- Reduced drying shrinkage and cracking
- Less volume change from wetting and drying
The less water used, the better the quality of the concrete provided themixture can still be consolidated properly.
Smaller amounts of mixing water result in stiffer mixtures; with vibration, stiffer mixtures can be easily placed. Thus, consolidation by vibration permits improvement in the quality of concrete.
Reducing the water content of concrete, and thereby reducing the w/cm, leads to increased strength and stiffness, and reduced creep. The drying shrinkage and associated risk of cracking will also be reduced. The concrete will have a lower permeability or increased water tightness that will render it more resistant to weathering and the action of aggressive chemicals. The lower water to cementitious materials ratio also improves the bond between the concrete and embedded steel reinforcement.
Posted on : 14 Mar 2016
Unnecessarily high water content dilutes the cement paste (the glue of concrete) and increases the volume of the concrete produced. Some advantages of reducing water content include:
- Increased compressive and flexural strength
- Lower permeability and increased watertightness
- Increased durability and resistance to weathering
- Better bond between concrete and reinforcement
- Reduced drying shrinkage and cracking
- Less volume change from wetting and drying
Smaller amounts of mixing water result in stiffer mixtures; with vibration, stiffer mixtures can be easily placed. Thus, consolidation by vibration permits improvement in the quality of concrete.
Reducing the water content of concrete, and thereby reducing the w/cm, leads to increased strength and stiffness, and reduced creep. The drying shrinkage and associated risk of cracking will also be reduced. The concrete will have a lower permeability or increased water tightness that will render it more resistant to weathering and the action of aggressive chemicals. The lower water to cementitious materials ratio also improves the bond between the concrete and embedded steel reinforcement.
Source:- esolution-pt.com
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Chapter :-5 Properties of Concrete
Properties of concrete are influenced by many factors mainly due to mix proportion of cement, sand, aggregates and water. Ratio of these materials control the various concrete properties which are discussed below.
Properties of Concrete
Different properties of concrete:
- Grades (M20, M25, M30 etc.)
- Compressive strength
- Characteristic Strength
- Tensile strength
- Durability
- Creep
- Shrinkage
- Unit weight
- Modular Ratio
- Poisson’s ratio
1. Grades of concrete
Concrete is known by its grade which is designated as M15, M20 etc. in which letter M refers to concrete mix and number 15, 20 denotes the specified compressive strength (fck) of 150mm cube at 28 days, expressed in N/mm2.
Thus, concrete is known by its compressive strength. M20 and M25 are the most common grades of concrete, and higher grades of concrete should be used for severe, very severe and extreme environments.
2. Compressive strength of concrete
Like load, the strength of the concrete is also a quality which varies considerably for the same concrete mix. Therefore, a single representative value, known as characteristic strength is used.
3. Characteristic strength of concrete
It is defined as the value of the strength below which not more then 5% of the test results are expected to fall (i.e. there is 95% probability of achieving this value only 5% of not achieving the same)
Characteristic strength of concrete in flexural member
The characteristic strength of concrete in flexural member is taken as 0.67 times the strength of concrete cube.
Design strength (fd) and partial safety factor for material strength
The strength to be taken for the purpose of design is known is known as design strength and is given by
Design strength (fd) = characteristic strength/ partial safety factor for material strength
The value of partial safety factor depends upon the type of material and upon the type of limit state. According to IS code, partial safety factor is taken as 1.5 for concrete and 1.15 for steel.
Design strength of concrete in member = 0.45fck
4. Tensile strength of concrete
The estimate of flexural tensile strength or the modulus of rupture or the cracking strength of concrete from cube compressive strength is obtained by the relations
fcr = 0.7 fck N/mm2. The tensile strength of concrete in direct tension is obtained experimentally by split cylinder. It varies between 1/8 to 1/12 of cube compressive strength.
5. Creep in concrete
Creep is defined as the plastic deformation under sustained load. Creep strain depends primarily on the duration of sustained loading. According to the code, the value of the ultimate creep coefficient is taken as 1.6 at 28 days of loading.
6. Shrinkage of Concrete
The property of diminishing in volume during the process of drying and hardening is termed Shrinkage. It depends mainly on the duration of exposure. If this strain is prevented, it produces tensile stress in the concrete and hence concrete develops cracks.
7. Modular ratio
Short term modular ratio is the modulus of elasticity of steel to the modulus of elasticity of concrete.
Short term modular ratio = Es / Ec
Es = modulus of elasticity of steel (2 x 10 5 N/mm2)
Ec = modulus of elasticity of concrete (5000 x SQRT(fck) N/mm2)
As the modulus of elasticity of concrete changes with time, age at loading etc the modular ratio also changes accordingly. Taking into account the effects of creep and shrinkage partially IS code gives the following expression for the long term modular ratio.
Long term modular ratio (m) = 280/ (3fcbc)
Where, fcbc = permissible compressive stress due to bending in concrete in N/mm2.
8. Poisson’s ratio
Poisson’s ratio varies between 0.1 for high strength concrete and 0.2 for weak mixes. It is normally taken as 0.15 for strength design and 0.2 for serviceability criteria.
9. Durability of concrete
Durability of concrete is its ability to resist its disintegration and decay. One of the chief characteristics influencing durability of concrete is its permeability to increase of water and other potentially deleterious materials.
The desired low permeability in concrete is achieved by having adequate cement, sufficient low water/cement ratio, by ensuring full compaction of concrete and by adequate curing.
10. Unit weight of concrete
The unit weight of concrete depends on percentage of reinforcement, type of aggregate, amount of voids and varies from 23 to 26 kN/m2. The unit weight of plain and reinforced concrete as specified by IS:456 are 24 and 25 KN/m3 respectively.
Tests Applied on Concrete for Strength and Workability
a) Concrete Slump Test
This test is performed to check the consistency of freshly made concrete. The slump test is done to make sure a concrete mix is workable. The measured slump must be within a set range, or tolerance, from the target slump.
Workability of concrete is mainly affected by consistency i.e. wetter mixes will be more workable than drier mixes, but concrete of the same consistency may vary in workability. It can also be defined as the relative plasticity of freshly mixed concrete as indicative of its workability.
Tools and apparatus used for slump test (equipment):
- Standard slump cone (100 mm top diameter x 200 mm bottom diameter x 300 mm high)
- Small scoop
- Bullet-nosed rod (600 mm long x 16 mm diameter)
- Rule
- Slump plate (500 mm x 500 mm)
Procedure of slump test for concrete:
-
Clean the cone. Dampen with water and place on the slump plate. The slump plate should be clean, firm, level and non-absorbent. Collect a sample of concrete to perform the slum test.
-
Stand firmly on the footpieces and fill 1/3 the volume of the cone with the sample. Compact the concrete by 'rodding' 25 times. Rodding means to push a steel rod in and out of the concrete to compact it into the cylinder, or slump cone. Always rod in a definite pattern, working from outside into the middle.
-
Now fill to 2/3 and again rod 25 times, just into the top of the first layer.
-
Fill to overflowing, rodding again this time just into the top of the second layer. Top up the cone till it overflows.
-
Level off the surface with the steel rod using a rolling action. Clean any concrete from around the base and top of the cone, push down on the handles and step off the footpieces.
-
Carefully lift the cone straight up making sure not to move the sample.
-
Turn the cone upside down and place the rod across the up-turned cone.
-
Take several measurements and report the average distance to the top of the sample.If the sample fails by being outside the tolerance (ie the slump is too high or too low), another must be taken. If this also fails the remainder of the batch should be rejected.
b) Concrete Compression Test
The compression test shows the compressive strength of hardened concrete. The compression test shows the best possible strength concrete can reach in perfect conditions. The compression test measures concrete strength in the hardened state. Testing should always be done carefully. Wrong test results can be costly. The testing is done in a laboratory off-site. The only work done on-site is to make a concrete cylinder for the compression test. The strength is measured in Megapascals (MPa) and is commonly specified as a characteristic strength of concrete measured at 28 days after mixing. The compressive strength of concrete is a measure of the concrete’s ability to resist loads which tend to crush it.
Apparatus for compression test
Cylinders (100 mm diameter x 200 mm high or 150 mm diameter x 300 mm high) (The small cylinders are normally used for most testing due to their lighter weight)
- Small scoop
- Bullet-nosed rod (600 mm x 16 mm)
- Steel float
- Steel plate
How to do Compression Test?
Procedure for compression test of concrete
-
Clean the cylinder mould and coat the inside lightly with form oil, then place on a clean, level and firm surface, ie the steel plate. Collect a sample.
-
Fill 1/2 the volume of the mould with concrete then compact by rodding 25 times. Cylinders may also be compacted by vibrating using a vibrating table.
-
Fill the cone to overflowing and rod 25 times into the top of the first layer, then top up the mould till overflowing.
-
Level off the top with the steel float and clean any concrete from around the mould.
-
Cap, clearly tag the cylinder and put it in a cool dry place to set for at least 24 hours.
-
After the mould is removed the cylinder is sent to the laboratory where it is cured and crushed to test compressive strength
Non-destructive tests of concrete is a method to obtain the compressive strength and other properties of concrete from the existing structures. This test provides immediate results and actual strength and properties of concrete structure.
The standard method of evaluating the quality of concrete in buildings or structures is to test specimens cast simultaneously for compressive, flexural and tensile strengths.
The main disadvantages are that results are not obtained immediately; that concrete in specimens may differ from that in the actual structure as a result of different curing and compaction conditions; and that strength properties of a concrete specimen depend on its size and shape.
Although there can be no direct measurement of the strength properties of structural concrete for the simple reason that strength determination involves destructive stresses, several non- destructive methods of assessment have been developed.
These depend on the fact that certain physical properties of concrete can be related to strength and can be measured by non-destructive methods. Such properties include hardness, resistance to penetration by projectiles, rebound capacity and ability to transmit ultrasonic pulses and X- and Y-rays.
These non-destructive methods may be categorized as penetration tests, rebound tests, pull-out techniques, dynamic tests, radioactive tests, maturity concept. It is the purpose of this Digest to describe these methods briefly, outlining their advantages and disadvantages.
Methods of Non-Destructive Testing of Concrete
Following are different methods of NDT on concrete:
- Penetration method
- Rebound hammer method
- Pull out test method
- Ultrasonic pulse velocity method
- Radioactive methods
1. Penetration Tests on Concrete
The Windsor probe is generally considered to be the best means of testing penetration. Equipment consists of a powder-actuated gun or driver, hardened alloy probes, loaded cartridges, a depth gauge for measuring penetration of probes and other related equipment.
A probe, diameter 0.25 in. (6.5 mm) and length 3.125 in. (8.0 cm), is driven into the concrete by means of a precision powder charge. Depth of penetration provides an indication of the compressive strength of the concrete.
Although calibration charts are provided by the manufacturer, the instrument should be calibrated for type of concrete and type and size of aggregate used.
Read More on Penetration Tests on Concrete
Benefits and Limitations
The probe test produces quite variable results and should not be expected to give accurate values of concrete strength. It has, however, the potential for providing a quick means of checking quality and maturity of in situ concrete.
It also provides a means of assessing strength development with curing. The test is essentially non-destructive, since concrete and structural members can be tested in situ, with only minor patching of holes on exposed faces.
2. Rebound Hammer Method
The rebound hammer is a surface hardness tester for which an empirical correlation has been established between strength and rebound number.
The only known instrument to make use of the rebound principle for concrete testing is the Schmidt hammer, which weighs about 4 lb (1.8 kg) and is suitable for both laboratory and field work. It consists of a spring-controlled hammer mass that slides on a plunger within a tubular housing.
The hammer is forced against the surface of the concrete by the spring and the distance of rebound is measured on a scale. The test surface can be horizontal, vertical or at any angle but the instrument must be calibrated in this position.
Calibration can be done with cylinders (6 by 12 in., 15 by 30 cm) of the same cement and aggregate as will be used on the job. The cylinders are capped and firmly held in a compression machine.
Several readings are taken, well distributed and reproducible, the average representing the rebound number for the cylinder. This procedure is repeated with several cylinders, after which compressive strengths are obtained.
Read More on Rebound Hammer Method
Limitations and Advantages
The Schmidt hammer provides an inexpensive, simple and quick method of obtaining an indication of concrete strength, but accuracy of ±15 to ±20 per cent is possible only for specimens cast cured and tested under conditions for which calibration curves have been established.
The results are affected by factors such as smoothness of surface, size and shape of specimen, moisture condition of the concrete, type of cement and coarse aggregate, and extent of carbonation of surface.
3. Pull-Out Tests on Concrete
A pull-out test measures, with a special ram, the force required to pull from the concrete a specially shaped steel rod whose enlarged end has been cast into the concrete to a depth of 3 in. (7.6 cm).
The concrete is simultaneously in tension and in shear, but the force required to pull the concrete out can be related to its compressive strength.
The pull-out technique can thus measure quantitatively the in-situ strength of concrete when proper correlations have been made. It has been found, over a wide range of strengths, that pull-out strengths have a coefficient of variation comparable to that of compressive strength.
Read More on Pull-Out Tests on Concrete
Limitations and Advantages
Although pullout tests do not measure the interior strength of mass concrete, they do give information on the maturity and development of strength of a representative part of it. Such tests have the advantage of measuring quantitatively the strength of concrete in place.
Their main disadvantage is that they have to be planned in advance and pull-out assemblies set into the formwork before the concrete is placed. The pull-out, of course, creates some minor damage.
The test can be non-destructive, however, if a minimum pullout force is applied that stops short of failure but makes certain that a minimum strength has been reached. This is information of distinct value in determining when forms can be removed safely.
4. Dynamic Non Destructive Test
At present the ultrasonic pulse velocity method is the only one of this type that shows potential for testing concrete strength in situ. It measures the time of travel of an ultrasonic pulse passing through the concrete.
The fundamental design features of all commercially available units are very similar, consisting of a pulse generator and a pulse receiver.
Pulses are generated by shock-exciting piezoelectric crystals, with similar crystals used in the receiver. The time taken for the pulse to pass through the concrete is measured by electronic measuring circuits.
Pulse velocity tests can be carried out on both laboratory-sized specimens and completed concrete structures, but some factors affect measurement:
- There must be smooth contact with the surface under test; a coupling medium such as a thin film of oil is mandatory.
- It is desirable for path-lengths to be at least 12 in. (30 cm) in order to avoid any errors introduced by heterogeneity.
- It must be recognized that there is an increase in pulse velocity at below-freezing temperature owing to freezing of water; from 5 to 30°C (41 – 86°F) pulse velocities are not temperature dependent.
- The presence of reinforcing steel in concrete has an appreciable effect on pulse velocity. It is therefore desirable and often mandatory to choose pulse paths that avoid the influence of reinforcing steel or to make corrections if steel is in the pulse path.
Read More on Dynamic Non Destructive Tests on Concrete
Applications and Limitations
The pulse velocity method is an ideal tool for establishing whether concrete is uniform. It can be used on both existing structures and those under construction.
Usually, if large differences in pulse velocity are found within a structure for no apparent reason, there is strong reason to presume that defective or deteriorated concrete is present.
High pulse velocity readings are generally indicative of good quality concrete. A general relation between concrete quality and pulse velocity is given in Table.
Table: Quality of Concrete and Pulse Velocity
General Conditions Pulse Velocity ft/sec
Excellent Above 15,000
Good 12,000-15,000
Questionable 10,000-12,000
Poor 7,000-10,000
Very Poor below 7,000
Fairly good correlation can be obtained between cube compressive strength and pulse velocity. These relations enable the strength of structural concrete to be predicted within ±20 per cent, provided the types of aggregate and mix proportions are constant.
The pulse velocity method has been used to study the effects on concrete of freeze-thaw action, sulphate attack, and acidic waters. Generally, the degree of damage is related to a reduction in pulse velocity. Cracks can also be detected.
Great care should be exercised, however, in using pulse velocity measurements for these purposes since it is often difficult to interpret results. Sometimes the pulse does not travel through the damaged portion of the concrete.
The pulse velocity method can also be used to estimate the rate of hardening and strength development of concrete in the early stages to determine when to remove formwork. Holes have to be cut in the formwork so that transducers can be in direct contact with the concrete surface.
As concrete ages, the rate of increase of pulse velocity slows down much more rapidly than the rate of development of strength, so that beyond a strength of 2,000 to 3,000 psi (13.6 to 20.4 MPa) accuracy in determining strength is less than ±20%.
Accuracy depends on careful calibration and use of the same concrete mix proportions and aggregate in the test samples used for calibration as in the structure.
In summary, ultrasonic pulse velocity tests have a great potential for concrete control, particularly for establishing uniformity and detecting cracks or defects. Its use for predicting strength is much more limited, owing to the large number of variables affecting the relation between strength and pulse velocity.
5. Radioactive Methods of NDT
Radioactive methods of testing concrete can be used to detect the location of reinforcement, measure density and perhaps establish whether honeycombing has occurred in structural concrete units. Gamma radiography is increasingly accepted in England and Europe.
The equipment is quite simple and running costs are small, although the initial price can be high. Concrete up to 18 in. (45 cm) thick can be examined without difficulty.
Purpose of Non-Destructive Tests on Concrete
A variety of Non Destructive Testing (NDT) methods have been developed or are under development for investigating and evaluating concrete structures.
These methods are aimed at estimation of strength and other properties; monitoring and assessing corrosion; measuring crack size and cover; assessing grout quality; detecting defects and identifying relatively more vulnerable areas in concrete structures.
Many of NDT methods used for concrete testing have their origin to the testing of more homogeneous, metallic system. These methods have a sound scientific basis, but heterogeneity of concrete makes interpretation of results somewhat difficult.
There could be many parameters such as materials, mix, workmanship and environment, which influence the results of measurements.
Moreover, these tests measure some other property of concrete (e.g. hardness) and the results are interpreted to assess a different property of concrete e.g. strength, which is of primary interest.
Thus, interpretation of results is very important and difficult job where generalization is not possible. As such, operators can carry out tests but interpretation of results must be left to experts having experience and knowledge of application of such non-destructive tests.
Purposes of Non-destructive Tests
- Estimating the in-situ compressive strength
- Estimating the uniformity and homogeneity
- Estimating the quality in relation to standard requirement
- Identifying areas of lower integrity in comparison to other parts
- Detection of presence of cracks, voids and other imperfections
- Monitoring changes in the structure of the concrete which may occur with time
- Identification of reinforcement profile and measurement of cover, bar diameter, etc.
- Condition of prestressing/reinforcement steel with respect to corrosion
- Chloride, sulphate, alkali contents or degree of carbonation
- Measurement of Elastic Modulus
- Condition of grouting in prestressing cable ducts
Equipments for Non Destructive Testing
According to their use, non-destructive equipment can be grouped as under:
- Strength estimation of concrete
- Corrosion assessment and monitoring
- Detecting defects in concrete structure
- Laboratory tests
===================================
Chapter 6:- Concrete operations:-
- Grades (M20, M25, M30 etc.)
- Compressive strength
- Characteristic Strength
- Tensile strength
- Durability
- Creep
- Shrinkage
- Unit weight
- Modular Ratio
- Poisson’s ratio
Thus, concrete is known by its compressive strength. M20 and M25 are the most common grades of concrete, and higher grades of concrete should be used for severe, very severe and extreme environments.
The value of partial safety factor depends upon the type of material and upon the type of limit state. According to IS code, partial safety factor is taken as 1.5 for concrete and 1.15 for steel.
Design strength of concrete in member = 0.45fck
fcr = 0.7 fck N/mm2. The tensile strength of concrete in direct tension is obtained experimentally by split cylinder. It varies between 1/8 to 1/12 of cube compressive strength.
Short term modular ratio = Es / Ec
Es = modulus of elasticity of steel (2 x 10 5 N/mm2)
Ec = modulus of elasticity of concrete (5000 x SQRT(fck) N/mm2)
As the modulus of elasticity of concrete changes with time, age at loading etc the modular ratio also changes accordingly. Taking into account the effects of creep and shrinkage partially IS code gives the following expression for the long term modular ratio.
Long term modular ratio (m) = 280/ (3fcbc)
Where, fcbc = permissible compressive stress due to bending in concrete in N/mm2.
The desired low permeability in concrete is achieved by having adequate cement, sufficient low water/cement ratio, by ensuring full compaction of concrete and by adequate curing.
Tests Applied on Concrete for Strength and Workability
This test is performed to check the consistency of freshly made concrete. The slump test is done to make sure a concrete mix is workable. The measured slump must be within a set range, or tolerance, from the target slump.
Workability of concrete is mainly affected by consistency i.e. wetter mixes will be more workable than drier mixes, but concrete of the same consistency may vary in workability. It can also be defined as the relative plasticity of freshly mixed concrete as indicative of its workability.
- Standard slump cone (100 mm top diameter x 200 mm bottom diameter x 300 mm high)
- Small scoop
- Bullet-nosed rod (600 mm long x 16 mm diameter)
- Rule
- Slump plate (500 mm x 500 mm)
- Clean the cone. Dampen with water and place on the slump plate. The slump plate should be clean, firm, level and non-absorbent. Collect a sample of concrete to perform the slum test.
- Stand firmly on the footpieces and fill 1/3 the volume of the cone with the sample. Compact the concrete by 'rodding' 25 times. Rodding means to push a steel rod in and out of the concrete to compact it into the cylinder, or slump cone. Always rod in a definite pattern, working from outside into the middle.
- Now fill to 2/3 and again rod 25 times, just into the top of the first layer.
- Fill to overflowing, rodding again this time just into the top of the second layer. Top up the cone till it overflows.
- Level off the surface with the steel rod using a rolling action. Clean any concrete from around the base and top of the cone, push down on the handles and step off the footpieces.
- Carefully lift the cone straight up making sure not to move the sample.
- Turn the cone upside down and place the rod across the up-turned cone.
- Take several measurements and report the average distance to the top of the sample.If the sample fails by being outside the tolerance (ie the slump is too high or too low), another must be taken. If this also fails the remainder of the batch should be rejected.
The compression test shows the compressive strength of hardened concrete. The compression test shows the best possible strength concrete can reach in perfect conditions. The compression test measures concrete strength in the hardened state. Testing should always be done carefully. Wrong test results can be costly. The testing is done in a laboratory off-site. The only work done on-site is to make a concrete cylinder for the compression test. The strength is measured in Megapascals (MPa) and is commonly specified as a characteristic strength of concrete measured at 28 days after mixing. The compressive strength of concrete is a measure of the concrete’s ability to resist loads which tend to crush it.
Cylinders (100 mm diameter x 200 mm high or 150 mm diameter x 300 mm high) (The small cylinders are normally used for most testing due to their lighter weight)
- Small scoop
- Bullet-nosed rod (600 mm x 16 mm)
- Steel float
- Steel plate
- Clean the cylinder mould and coat the inside lightly with form oil, then place on a clean, level and firm surface, ie the steel plate. Collect a sample.
- Fill 1/2 the volume of the mould with concrete then compact by rodding 25 times. Cylinders may also be compacted by vibrating using a vibrating table.
- Fill the cone to overflowing and rod 25 times into the top of the first layer, then top up the mould till overflowing.
- Level off the top with the steel float and clean any concrete from around the mould.
- Cap, clearly tag the cylinder and put it in a cool dry place to set for at least 24 hours.
- After the mould is removed the cylinder is sent to the laboratory where it is cured and crushed to test compressive strength
Chapter 6:- Concrete operations:-
Batching, Mixing, Placing and Compaction of Concrete
Batching
Batching is the process of measuring concrete mix ingredients either by volume or by mass and introducing them into the mixture. Traditionally batching is done by volume but most specifications require that batching be done by mass rather than volume. Percentage of accuracy for measurement of concrete materials as follows.
Cement:
When the quantity of cement to be batched exceeds 30% of scale capacity, the measuring accuracy should be within 1% of required mass. If measuring quantity is less than 30% i.e. for smaller batches then the measuring accuracy should be within 4% of the required quantity.
Aggregates:
If the measurement is more than 30% of the scale capacity then the measuring accuracy should be within 1%. If measurement is less than 30% then the measuring accuracy should be within less than 3%.
Water:
Water is measured in volumetric quantity as 1 litre = 1kg. In case of water, the measuring accuracy should be within 1%.
Admixtures:
For mineral admixtures same accuracy as that required for cement.For chemical admixtures same accuracy as that required for water. Mineral admixtures accuracy is same as that of cement because it is used as partial replacement of cement. As chemical admixtures are liquid or added to water therefore its accuracy is same as that of water.
Mixing
The mixing operation consists of rotation or stirring, the objective being to coat the surface the all aggregate particles with cement paste, and to blind all the ingredients of the concrete into a uniform mass; this uniformity must not be disturbed by the process of discharging from the mixer.
Batch mixer
The usual type of mixer is a batch mixer, which means that one batch of concrete is mixed and discharged before any more materials are put into the mixer. There are four types of batch mixer.
Tilting drum mixer:
A tilting drum mixer is one whose drum in which mixing take place is tilted for discharging. The drum is conical or bowl shaped with internal vanes, and the discharge is rapid and unsegregated so that these mixers are suitable for mixes of low workability and for those containing large size aggregate.
Non tilting drum mixer:
A non tilting drum is one in which the axis of the mixer is always horizontal, and discharge take place by inserting a chute into the drum or by reversing the direction or rotation of drum. Because of slow rate of discharge, some segregation may occur.
Pan type mixer:
A pan type mixer is a forced–action mixer, as distinct from drum mixer which relies on the free fall of the concrete inside the drum. The pan mixer consist of a circular pan rotating about its axis with one or two stars paddles rotating about vertical axis of pan.
Dual drum mixer:
A dual drum is sometimes used in highway construction. Here there are two drums in series, concrete being mixed part of the time in one and then transferred to the other for the remainder of the mixing time before discharging.
Continuous mixers:
These are fed automatically by a continuous weigh-batching system.
Charging the mixer:
There are no general rules on the order of feeding the ingredients into the mixer as this depend on the properties of the mixer and mix. Usually a small quantity of water is fed first, followed by all the solids materials. If possible greater part of the water should also be fed during the same time, the remainder being added after the solids. However, when using very dry mixes in drum mixers it is necessary to feed the coarse aggregate just after the small initial water feed in order to ensure that the aggregate surface is sufficiently wetted.
Uniformity of Mixing
In any mixer, it is essential that a sufficient interchange of materials occurs between parts of the chamber, so that a uniform concrete is produced. The efficiency of the mixer can be measured by the variability of the samples from the mix. ASTM prescribes samples to be taken from about points 1/6 and 5/6 of the discharge of the batch and the difference in the properties of the two samples should not exceed any of the following:
- Density of concrete 1 lb/ft³
- Air content 1%
- Slump 1" when average is less than 4"
- 1.5" when average is less than 4 to 6"
- % of aggregate retained on 4 No. sieve 6%
- Compressive strength 7 day, 3 cylinders 7.5%
Mixing time:
It is important to know the minimum mixing time necessary to produce a concrete of uniform composition, and of reliable strength.
The mixing time or period should be measured from time all the cementing materials and aggregates are in mixer drum till taking out the concrete.
Mixing time depends on the type and size of mixer, on the speed of rotation, and on the quality of blending of ingredients during charging of the mixer. Generally, a mixing time of less than 1 to 1.25 minutes produces appreciable non-uniformity in composition and a significant lower strength; mixing beyond 2 minutes causes no significant improvement in these properties.
Table: Recommended minimum mixing times
Cement:
Aggregates:
Water:
Admixtures:
Batch mixer
Tilting drum mixer:
Non tilting drum mixer:
Pan type mixer:
Dual drum mixer:
Continuous mixers:
Charging the mixer:
Mixing time:
Capacity of mixer (yd³)
|
Mixing time (Minutes)
|
Up to 1
|
1
|
2
|
1.25
|
3
|
1.5
|
4
|
1.75
|
5
|
2
|
6
|
2.25
|
10
|
3.25
|
Prolong mixing:
If mixing take place over a long period, evaporation of water from the mix can occur, with a consequent decrease in workability and an increase in strength. A secondary effect is that of grinding of the aggregate, particularly if soft; the grading thus becomes finer and the workability lower. In case of air entrained concrete, prolong mixing reduces the air content.
Ready mixed concrete:
If instead of being batched and mixed on site, concrete is delivered for placing from a central plant. It is referred to as ready-mixed or pre-mixed concrete. This type of concrete is used extensively abroad as it offers numerous advantages in comparison with other methods of manufacture:
- Close quality control of batching which reduces the variability of the desired properties of hardened concrete.
- Use on congested sites or in highway construction where there is little space for a mixing plant and aggregate stockpiles;
- Use of agitator trucks to ensure care in transportation, thus prevention segregation and maintaining workability
- Convenience when small quantities of concrete or intermittent placing is required.
There are two categories of ready-mixed concrete: central-mixed and transit mixed or truck mixed. In the first category, mixing is done in a central plant and then concrete is transported in an agitator truck. In the second category, the materials are batched at a central plant but are mixed in a truck.
Concrete Placing and Compaction of Concrete
The operation of placing and compaction are interdependent and are carried out simultaneously. They are most important for the purpose of ensuring the requirements of strength, impermeability and durability of hardened concrete in the actual structure. As for as placing is concerned, the main objective is to deposit the concrete as close as possible to its final position so that segregation is avoided and the concrete can be fully compacted. The aim of good concrete placing can be stated quite simply.
It is to get the concrete into position at a speed, and in a condition, that allow it to be compacted properly.
To achieve proper placing following rules should be kept in mind:
- The concrete should be placed in uniform layers, not in large heaps or sloping layers.
- The thickness of the layer should be compatible with the method of vibration so that entrapped air can be removed from the bottom of each layer.
- The rate of placing and of compaction should be equal. If you proceed too slowly, the mix could stiffen so that it is no longer sufficiently workable. On no account should water ever be added to concrete that is setting. On the other hand, if you go too quickly, you might race ahead of the compacting gang, making it impossible for them to do their job properly.
- Each layer should be fully compacted before placing the next one, and each subsequent layer should be placed whilst the underlying layer is still plastic so that monolithic construction is achieved
- Collision between concrete and formwork or reinforcement should be avoided.
- For deep sections, a long down pipe ensures accuracy of location of concrete and minimum segregation.
- You must be able to see that the placing is proceeding correctly, so lighting should be available for large, deep sections, and thin walls and columns.
Compaction
Once the concrete has been placed, it is ready to be compacted. The purpose of compaction is to get rid of the air voids that are trapped in loose concrete.
Why is compaction of concrete necessary?
It is important to compact the concrete fully because:- Air voids reduce the strength of the concrete. For every 1% of entrapped air, the strength falls by somewhere between 5 and 7%. This means that concrete containing a mere 5% air voids due to incomplete compaction can lose as much as one third of its strength.
- Air voids increase concrete's permeability. That in turn reduces its durability. If the concrete is not dense and impermeable, it will not be watertight. It will be less able to withstand aggressive iquids and its exposed surfaces will weather badly.
- Moisture and air are more likely to penetrate to the reinforcement causing it to rust.
- Air voids impair contact between the mix and reinforcement (and, indeed, any other embedded metals). The required bond will not be achieved and the reinforced member will not be as strong as it should be.
- Air voids produce blemishes on struck surfaces. For instance, blowholes and honeycombing might occur.
Summing up, fully compacted concrete is dense, strong and durable; badly compacted concrete will be porous, weak and prone to rapid deterioration. Sooner or later it will have to be repaired or replaced. It pays, therefore, to do the job properly in the first place.
Stiff mixes contain far more air than workable ones. That is one of the reasons why a low-slump concrete requires more compactive effort than one with a higher slump - the compaction needs to continue for a longer time, or more equipment has to be used.
Even air-entrained concrete needs to be compacted to get rid of entrapped air voids. The difference between air voids and entrained air bubbles should be noted at this stage. The air bubbles that are entrained are relatively small and spherical in shape, increase the workability of the mix, reduce bleeding, and increase frost resistance. Entrapped air on the other hand tends to be irregular in shape and is detrimental to the strength of the mix. It is to remove this air that the concrete must be properly compacted. There is little danger that compaction will remove the minute air bubbles that have been deliberately entrained, since they are so stable.
Methods of Compaction of concrete
Vibration:
To compact concrete you apply energy to it so that the mix becomes more fluid. Air trapped in it can then rise to the top and escape. As a result, the concrete becomes consolidated, and you are left with a good dense material that will, after proper curing, develop its full strength and durability.
Vibration is the next and quickest method of supplying the energy. Manual techniques such as rodding are only suitable for smaller projects. Various types of vibrator are available for use on site.
Poker Vibrators
The poker, or immersion, vibrator is the most popular of the appliances used for compacting concrete. This is because it works directly in the concrete and can be moved around easily.
Sizes:
Pokers with diameters ranging from 25 to 75mm are readily available, and these are suitable for most reinforced concrete work. Larger pokers are available - with diameters up to 150mm - but these are for mass concrete in heavy civil engineering.
Radius of action:
When a poker vibrator is operating, it will be effective over a circle centred on the poker. The distance from the poker to the edge of the circle is known as the radius of action.
However, the actual effectiveness of any poker depends on the workability of the concrete and the characteristics of the vibrator itself. As a general rule, the bigger the poker and the higher its amplitude, the greater will be the radius of action. It is better to judge from your own observations, as work proceeds on site, the effective radius of the poker you are operating on the concrete you are compacting.
The length of time it takes for a poker vibrator to compact concrete fully depends on:
- The workability of the concrete: the less workable the mix, the longer it must be vibrated.
- The energy put in by the vibrator: bigger vibrators do the job faster.
- The depth of the concrete: thick sections take longer.
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