CIVIL ENGINEERING (CE-122)

Unit -4 Building Material Part-2

CONCRETE

Concrete is a composite material composed mainly of water, aggregate, and cement. Often,
additives and reinforcements are included in the mixture to achieve the desired physical
properties of the finished material. When these ingredients are mixed together, they form a
fluid mass that is easily molded into shape. Over time, the cement forms a hard matrix which
binds the rest of the ingredients together into a durable stone-like material with many uses.
The aim is to mix these materials in measured amounts to make concrete that is easy to:
Transport, place, compact, finish and which will set, and harden, to give a strong and durable
product. The amount of each material (ie cement, water and aggregates) affects the properties
of hardened concrete.

Production of concrete

A good quality concrete is essentially a homogeneous mixture of cement, coarse and

fineaggregates and water which consolidates into a hard mass due to chemical action between
the cement and water. Each of the four constituents has a specific function. The coarser
aggregate acts as a filler. The fine aggregate fills up the voids between the paste and the
coarse aggregate. The cement in conjunction with water acts as a binder. The mobility of the
mixture is aided by the cement paste, fines and nowadays, increasingly by the use of
admixtures.The stages of concrete productionare:Batching or measurement of materials,
Mixing, Transporting, Placing, Compacting, Curing andFinishing.

Batching

It i s 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.The proportions of
various ingredients are determined by proper mix design.

A concrete mix is designed to produce concrete that can be easily placed at the lowest
cost. The concrete must be workable and cohesive when plastic, then set and harden to give
strong and durable concrete. The mix design must consider the environment that the concrete
will be in; ie exposure to sea water, trucks, cars, forklifts, foot traffic or extremes of hot and
cold. Proportioning concrete is a mixture of cement, water, coarse and fine aggregates and
admixtures. The proportions of each material in the mixture affects the properties of the final

Basic Civil Engineering By HARISH DEVGAN

hardened concrete. These proportions are best measured by weight. Measurement by volume
is not as accurate, but is suitable for minor projects.

Cement content as the cement content increases, so does strength and durability.
Therefore to increase the strength, increase the cement content of a mix. WaterContent
adding more water to a mix gives a weaker hardened concrete. Always use as little water as
possible, only enough to make the mix workable.Water to cement ratio as the water to cement
ratio increases, the strength and durability of hardened concrete decreases. To increase the
strength and durability of concrete, decrease the water-cement ratio.Aggregates too much fine
aggregate gives a sticky mix. Too much coarse aggregate gives a harsh or boney mix.Mixing
concrete must be mixed so the cement, water, aggregates and admixtures blend into an even
mix. Concrete is normally mixed by machine. Machine mixing can be done on-site or be a
pre-mixed concrete company. Pre-mixed concrete is batched (proportioned) at the plant to the
job requirements. Truck mixing the materials are normally added to the trucks at batching
plants and mixed for required time and speed at the plant. The trucks drum continues to rotate
to agitate the concrete as it is delivered to the site. Site mixing when site mixing begin by
loading a measured amount of coarse aggregate into the mixer drum. Add the sand before the
cement, both in measured amounts.

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. The mixing may done by manually or by mechanical means like, Batch mixer,
Tilting drum mixer, Non tilting drum mixer, Pan type mixer, Dual drum mixer or Continuous
mixers.

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.

Basic Civil Engineering By HARISH DEVGAN

Compaction

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.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.

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

Basic Civil Engineering By HARISH DEVGAN

not be as strong as it should be.Air voids produce blemishes on struck surfaces. For instance,
blowholes and honeycombing might occur. There are two methods for compaction which
includes: vibration by vibrators or by tamping using tamping rods.

Curing

Curing is the process of making the concrete surfaces wet for a certain time period after
placing the concrete so as to promote the hardening of cement. This process consists of
controlling the temperature and the movement of moisture from and into the concrete.

Curing of concrete is done for the following purposes. Curing is the process of controlling the
rate of moisture loss from concrete to ensure an uninterrupted hydration of Portland cement
after concrete has been placed and finished in its final position.Curing also helps maintain an
adequate temperature of concrete in its early stages, as this directly affects the rate of
hydration of cement and eventually the strength gain of concrete or mortars.

Curing of concrete must be done as soon as possible after placement and finishing and must
continue for a reasonable period of time, for the concrete to achieve its desired strength and
durability.Uniform temperature should be maintained throughout the concrete depth to avoid
thermal shrinkage cracks.

Material properties are directly related to micro-structure. Curing assists the cement
hydration reaction to progress steadily and develops calcium silicate hydrate gel, which binds
aggregates leading to a rock solid mass,makes concrete denser, decreases the porosity and
enhances the physical and mechanical properties of concrete.

Some other purposes of curing can be summed up as: curing protects the concrete surfaces
from sun and wind, the process of curing increase the strength of the structure, the presence
of water is essential to cause the chemical action which accompanies the setting of concrete.
Generally there is adequate quantity of water at the time of mixing to cause the hardening of
concrete,but it is necessary to retain water until the concrete is fully hardened.

If curing is efficient, the strength of concrete gradually increases with age. This
increase in strength is sudden and rapid in early stages and it continues slowly for an
indefinite period.By proper curing, the durability and impermeability of concrete are
increased and shrinkage is reduced.The resistance of concrete to abrasion is considerably
increased by proper curing.

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Curing period:

For ordinary Portland cement, the curing period is about 7 days to 14 days.If rapid hardening
cement is used the curing period can be considerably reduced.

Disadvantages of improper curing:

Following are the disadvantages of improper curing of concrete:

The chances of ingress of chlorides and atmospheric chemicals are very high.The
compressive and flexural strengths are lowered.The cracks are developed due to plastic
shrinkage, drying shrinkage and thermal effects.The durability decreases due to higher
permeability.The frost and weathering resistances are decreased.The rate of carbonation
increases.The surfaces are coated with sand and dust and it leads to lower the abrasion
resistance.The disadvantages are more prominent in those parts of surfaces which are directly
exposed or which have large surfaces compared to depth such as roads, canal, bridges,
cooling towers, chimneys etc.

Factors affecting evaporation of water from concrete:

The evaporation of water depends upon the following 4 factors: Air temperature, Fresh
concrete temperature, Relative humidity and Wind velocity.

From the above mentioned factors it can be concluded environment directly influences the
process of evaporation, hence only the fresh concrete temperature can be monitored or
supervised by the concrete technologists.The evaporation of water in the first few hours can
leave very low amount of water in the concrete hydration, this leads to various shrinkage
cracks.Under normal condition the average loss of water varies from 2.5 to 10 N per m2 per
hour.The major loss occurs in the top 50 mm layer over a period of 3 hours, the loss could be
about 5% of the total volume of that layer.

Methods of curing:

While selecting any mode of curing the following two factors are considered:

 The loss of water should be prevented.


 The temperature should be kept minimum for dissipation of heat of hydration.

Methods of curing can be categorised into the following categories:

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Water curing-preventing the moisture loss from the concrete surface by continuously wetting
the exposed surface of concrete.

Membrane curing-minimizing moisture loss from concrete surface by covering it with an

impermeable membrane.

Steam curing-keeping the surface moist and raising the temperature of concrete to accelerate
the rate of strength gain.

Water curing is of the following types:

Ponding: most inexpensive and common method of curing flat slabs, roofs, pavements etc. A
dike around the edge of the slab, is erected and water is filled to create a shallow pond. Care
must be taken to ensure that the water in the pond does not dry up, as it may lead to an
alternate drying and wetting condition.

Sprinkling: fogging and mist curing- using a fine spray or fog or moist of water to the
concrete can be efficient method of supplying water to concrete during hot weather, which
helps to reduce the temperature of concrete.

Wet coverings: water absorbent fabrics may be used to maintain water on concrete surfaces.
They must be continuously kept moist so as to prevent the fabrics from absorbing water from
the body of concrete,due to capillary action.

Impermeable membrane curing is of following types:-

Formwork: leaving the form work in place during the early age of concrete is an efficient
method of curing.

Plastic sheeting: plastic sheets form an effective barrier to control the moisture losses from
the surface of concrete, provided they are secured properly and protected from damage. The
efficiency of this system can be enhanced by flooding the concrete surface with water, under
the plastic sheet.

Membrane curing compounds: Curing compounds are wax, acrylic and water based liquids
are spread over the freshly finished concrete to form an impermeable membrane that
minimises the loss of moisture from the concrete surfaces.These are cost effective methods of
curing where standard curing procedures are difficult to adopt.When applied to cure concrete
the time of the application is critical for maximum effectiveness.Too early application dilutes
the membrane, whereas too late application results in being absorbed into the concrete.They

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must be applied when the free water on the surface has evaporated.For concrete with low w/c
ratio, this is not a suitable process.

Steam curing: Steam curing is the process of accelerating the early hardening of concrete and
mortars by exposing it to steam and humidity. These types of curing systems are adopted for
railway sleepers, concrete blocks, pipes, manhole covers, poles etc.Precast iron is cured by
this method under pressure.Curing in hot and cold weather requires additional attention.

Hot weather: During hot weather, concrete must be protected from excessive drying and
from direct wind and sun. Curing materials which reflect sunlight to reduce concrete
temperature must be used.
0
Cold weather: Some problems associated with temperature below 40 C are:

 Freezing of concrete before strength is developed.


 Slow development of concrete strength.

 Thermal stresses induced by the cooling of warm concrete to cooler ambient
temperatures
Chemical curing: In this method water is sprinkled over the surface, after adding certain
amount of some hygroscopic material (e.g. sodium chloride or calcium chloride). The
hygroscopic materials absorb moisture from the atmosphere and thus keep the surface damp.

Alternating current curing: Concrete can be cured by passing alternating current through
freshly laid concrete.

Water cement ratio and compressive strength

A cement of average composition requires about 25% of water by mass for chemical reaction.
In addition, an amount of water is needed to fill the gel pores. Nearly 100 years ago, Duff
Abrams discovered the direct relationship between water-to-cement ratio and strength,
i.e.,lesser the water used higher the strength of the concrete,since too much water leaves lots
of poresin the cement past. According toAbram’s law, the strength of fully compacted
concrete at a given age and normal temperature is inversely proportional to the water –
cement ratio. Here the water-cement ratio is the relative weight of water to the cement in the
mixture. For most applications, water-to-cement ratio should be between 0.4 and 0.5 lower
for lower permeability and higher strength. In concrete, the trade off, of course,is with
workability, since very low water content result in very stiff mixtures that are difficult to
place. The water-to-cement ratio is a factor selected by the civil engineer.

Basic Civil Engineering By HARISH DEVGAN

Workability

Workability is one of the physical parameters of concrete which affects the strength and
durability as well as the cost of labor and appearance of the finished product. Concrete is said
to be workable when it is easily placed and compacted homogeneously i.e without bleeding
or Segregation. Unworkable concrete needs more work or effort to be compacted in place,
also honeycombs &/or pockets may also be visible in finished concrete.Definition of
Workability “The property of fresh concrete which is indicated by the amount of useful
internal work required to fully compact the concrete without bleeding or segregation in the
finished product.”

Factors affecting workability:

 Water content in the concrete mix


 Amount of cement & its Properties

 Aggregate Grading (Size Distribution)

 Nature of Aggregate Particles (Shape, Surface Texture, Porosity etc.)

 Temperature of the concrete mix

 Humidity of the environment

 Mode of compaction

 Method of placement of concrete

 Method of transmission of concrete

How to improve the workability of concrete

 Increase water/cement ratio


 Increase size of aggregate

 Use well-rounded and smooth aggregate instead of irregular shape

 Increase the mixing time

 Increase the mixing temperature

 Use non-porous and saturated aggregate

 With addition of air-entraining mixtures

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Workability tests:

There are 4 types of tests for workability.They are slump test, compacting factor test, flow
test, and vee bee test

Slump test

The slump test result is a slump of the behavior of a compacted inverted cone of concrete
under the action of gravity. It measures the consistency or the wetness of concrete.Metal
mould, in the shape of the frustum of a cone, open at both ends, and provided with the
handle, top internal diameter 4 in (102 mm), and bottom internal diameter 8 in (203 mm)
with a height of 1 ft (305 mm). A 2 ft (610 mm) long bullet nosed metal rod, (16 mm) in
diameter.Apparatus Required: Compacting Factor apparatus, Trowels, Graduated cylinder,
Balance and Tamping rod and iron bucket

The test is carried out using a mould known as a slump cone or Abrams cone. The
cone is placed on a hard non-absorbent surface. This cone is filled with fresh concrete in
three stages, each time it is tamped using a rod of standard dimensions. At the end of the third
stage, concrete is struck off flush to the top of the mould. The mouldis carefully lifted
vertically upwards, so as not to disturb the concrete cone. Concrete subsides. This subsidence
is termed as slump, and is measured in to the nearest 5 mm if the slump is <100 mm and
measured to the nearest 10 mm if the slump is >100 mm.

The slumped concrete takes various shapes, and according to the profile of slumped
concrete, the slump is termed as true slump, shear slump or collapse slump. If a shear or
collapse slump is achieved, a fresh sample should be taken and the test repeated. A collapse
slump is an indication of too wet a mix. Only a true slump is of any use in the test. A collapse
slump will generally mean that the mix is too wet or that it is a high workability mix, for
which slump test is not appropriate. Very dry mixes; having slump 0 – 25 mm are used in
road making, low workability mixes; having slump 10 – 40 mm are used for foundations with
light reinforcement, medium workability mixes; 50 - 90 for normal reinforced concrete
placed with vibration, high workability concrete; > 100 mm.

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This test is usually used in laboratory and determines the workability of fresh concrete when
size is about 40 mm maximum. The test is carried out as per specification of IS: 1199-1959.
1199

Compacting factor test:

Steps for performing the experiment:

 keep the apparatus on the ground and apply grease on the inner surface of the
cylinders.

 Measure the mass as w1 kg by weighing the cylinder accurately and fix the cylinder
on the base in such a way that the central points of hoppers and cylinder lie on one
vertical line and cover the cylinder with a plate.
plate.

 For each 5 kg of aggregate mixes are to be prepared with water
water-cement ratio by
weight with 2.5 kg sand and 1.25 kg of cement and then add required amount of water
thoroughly until and unless concrete appears to be homogeneous.
homogeneous.

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 With the help of hand scoop without compacting fill the freshly mixed concrete in
upper hopper part gently and carefully and within two minutes release the trap door so
that the concrete may fall into the lower hopper such that it bring the concrete into
standard compaction.

 Fall the concrete to into the cylinder by bringing the concrete into standard
Compaction immediately after the concrete has come to rest and open the trap door of
lower hopper and then remove the excess concrete above the top of the cylinder by a
pair of trowels, one in each hand will blades horizontal slide them from the opposite
edges of the mould inward to the center with a sawing motion.

 Clean the cylinder from all sides properly. Find the mass of partially compacted
concrete thus filled in the cylinder and say it W2 kg. After this refill the cylinder with
the same sample of concrete in approximately 50 mm layers, by vibrating each layer
heavily so as to expel all the air and obtain full compaction of the Concrete.

 Struck off level the concrete and weigh and cylinder filled with fully compacted
concrete. Let the mass be W3 kg.

 Calculate compaction factor by using the formula: C.F = W2 – W1 / W3 – W1

Flow Table Test:

The flow table test or flow test is a method to determine the consistence of fresh concrete.

Flow table with a grip and a hinge, 70 centimetres (28 in) square.Abrams cone, open at the
top and at the bottom - 30 centimetres (12 in) high, 17 centimetres (6.7 in) top diameter, 25
centimetres (9.8 in) base diameter.Water bucket and broom for wetting the flow
table.Tamping rod, 60 centimetres (24 in) longConducting the testTheflowtable is wetted.The
cone is placed in the center of the flowtable and filled with fresh concrete in two equal layers
layers. Each layer is tamped 10 times with tamping rod.Wait 30 seconds before lifting the
coneThe cone is lifted, allowing the concrete to flow.The flowtable is then lifted up 40mm
and then dropped 15 times, causing the concrete to flowAfter this the diameter of the
concrete is measured.

Vee-Bee Test:

This test is useful for concrete having low and very low workability. In this test the concrete
is moulded into a cone in a cylinder container and the entire set up is mounted on a vibrating
table. When vibrator starts, concrete placed on the cone starts to occupy the cylindrical

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container by the way of getting remoulded. Remoulding is complete when the concrete
surface becomes horizontal. The time required for completion of remoulding since start of
vibrator is measured and denoted as vee-bee seconds. This provides a measure for
workability. Lesser is the vee-bee seconds more is the workability.

Basic Civil Engineering By HARISH DEVGAN