UNIT 5- QUALITY AND CONTROL OF CONCRETE

BATCHING
1) What is meant by batching? Explain the two types of batching.
Ans.
Batching – It is the measurement of materials required as per grade of concrete, called as batching.
Types of batching –
Batching is done in following two ways;
i. Volume batching:
a. In volume batching the ingredients to produce the concrete mix are measured by volume.
b. It is not good method for proportioning the material because of the difficulty it offers to measure angular
materials in terms of volume.
c. This type of batching may be adopted for any small work.

ii. Weight batching

a. In weight batching the ingredients to produce concrete mix are measured by weight.
b. Weight batching of aggregate is generally preferred because it is the correct method of measuring the
materials.
c. This method of batching is much more accurate than volume batching.
d. This type of batching is adopted where high quality concrete is required

State advantages and disadvantages of Volume Batching.

Advantages of Volume Batching: Weight batching Volume batching
i. Simple method to execute on site as compared to weigh In this, measurement of materials In this, measurement of materials is
batching. is done by taking weight. done by taking volume.
ii. Weighing balance and other related tools are not required.
iii. Iron pan or gauge boxes are required for measuring Weight machine is used. Gauge boxes are used
ingredients which are easily available on site. It is more accurate. It is approximate or less accurate.
iv. It requires less time as compared to weigh batching. It is useful for more important It is useful for less important works
v. Even unskilled labours perform volume batching. constructions where mix-design is where ordinary mix is used.
adopted.
Disadvantages of Volume Batching:
i. If fine aggregate containing moisture, then more aggregate is Weigh batching is done for Volume batching is done for
required to add for bulking correction. cement generally aggregates and water.
ii. Volume batching is not preferred for big and quality work. It requires skilled labours It requires less time even with unskilled
iii. If volume of ingredients is not measured accurately, it gives and more time is required labours
different results for each batch.
iv. It is not good method for proportioning the material because of the difficulty it offers to measure angular
materials in terms of volume.
v. Less accurate than weigh batching.

Explain the significance of batching.

Significance of Batching:
1. If the batching of materials required for concrete is not done appropriately, then random quantity of
materials produce Non-homogeneous concrete, which further leads to various Difficulties in handling the
concrete operations in terms of bad workability and poor strength.
2. There are more chances of wastage of concrete to produce good quality of concrete.
3. Un-batched materials results in various defects in concrete in later stages.

MIXING
Mixing can be done by two methods
1) Manual Mixing
2) Machine Mixing: -
The machine used for mixing concrete is known as concrete mixer. There are two types of mixer
a) Continuous mixer

b) Batch Mixer – There are two types of mixer

i) Tilting Mixer ii)Non-tilting Mixer

Manual mixing Mechanical mixing Tilting Mixer Non-tilting Mixer

The mixing is done manually The mixing is done In this, the drum is conical In this, the drum is cylindrical
by using phawrah, gumboot mechanically by using various and revolves about an and revolves about horizontal
etc. types of mixers. inclined axis. axis.
Blades are provided inside Blades are provided inside the
It is suitable for low It is applicable for highly
the drum so that materials drum as the drum rotates,
important constructions i.e important works i.e RCC
are continuously moved as blades pickup the concrete and
P.C.C, compound wall etc. buildings, dams etc. the drum rotates. when they reach their highest
It is required less time but It is require slightly more time point concrete drops at the
quality of mixture is not but gives homogeneous quality bottom.
homogeneous. of concrete mix. The drum can be tilted to Concrete materials are charged
different positions for into the drum through one
The wastage of material is The wastage of material is less charging and discharging opening and discharged
more. comparatively. of material through the other opening.
It is tedious and It is quite simple and gives Capacity is less. 100 T, Capacity is more. 280 NT, 400
uneconomical. overall economy. 140T, 200 T NT, 800 NT

State the purpose of mixing of concrete and types of mixer used For mixing of concrete ingredients.
Purpose of mixing of concrete:
1. To achieve the designed/ desired workability in the plastic stage
2. To achieve the desired minimum strength in the hardened stage
3. To achieve the desired durability in the given environment
Conditions
4. To produce concrete as economically as possible.
Types of mixer:
1. Non-tilting mixer
2. Split drum mixer
3. Tilting drum mixer
4. Reversing drum mixer
5. Drum Truck Mixers

What are the precautions to be taken during mixing of concrete?

1. Fine materials i.e. sand and cement should be spread over coarse aggregates.
2. Water should be added in stages to get uniform cement slurry.
3. The mixture should be homogenous without any signs of segregation.
4. The mixing should be by mechanical means i.e. concrete mixers and manual mixing should be avoided.
5. The mixing procedure should be completed within gauge time of cement to avoid start of hardening of
concrete mix.

COMPACTION
Define compaction. State various types of vibrators used and
explain with neat sketch poker vibrator.
Compaction: - It is the process to remove air voids from concrete
mixture to produce dense and compacted concrete, called as
compaction.
Types of vibrators-
i) Needle or Poker vibrator ii) Screed board vibrator
iii) Form vibrator iv) Platform vibrator
v) Table vibrator vi) Vibratory roller

Poker vibrator-
The poker or needle vibrator has a vibrating needle operates on petrol or diesel engine as shown in fig.1 above.
It gives 12000 cycles of vibration per minutes, which is useful to compact column and deep beams. Poker
vibrator is used to compact concrete internally by immersing it in concrete.

State the different types of vibrators with their uses at different locations.
Types of Vibrator -
1) Internal Vibrator (Needle vibrator) – Internal vibrators are used for slabs, beams or any concrete structure
2) External Vibrator (Form vibrator) – External vibrators are used for column, thin walls, casting of precast units
and where concrete section is heavily reinforced.
3) Surface vibrators (Screed vibrator)- Surface vibrator are used for roof slab and road pavement of shallow
depth.
4) Table vibrators- Table vibrators are mainly used in laboratories.
5) Vibropressing- Vibropressing has been used for mass manufacturing of concrete curbs.
6) Centrifugation or Spinning- This method is used in production of elements which are in circular cross section.

State any four advantages of compaction by vibrators.

Ans.
1. Vibrators can compact very stiff concrete mixture very easily.
2. It gives economy in big projects which is not possible by hand compaction.
3. Vibrators can give more smooth finish to concrete surface by reducing chances of honeycombing.
4. Vibratory compaction is advantageous in cube compaction, slab compaction, pavement compaction where
ordinary compaction becomes ineffective.

Significance of Compaction:
1. If compaction is not done then the concrete mass shows voids in it, resulting porous concrete.
2. Insufficient compaction results in honeycombing of concrete, hence it is important to get dense concrete
3. Compaction is significant to achieve desired strength and to ensure enhanced durability of concrete
structure.

FORMWORK
It is the temporary structure constructed to place the concrete mass in it for attaining required shape of
concrete.
List two materials used for form work
The materials generally used for formwork are:
i. Timber
ii. Steel
iii. Plywood
iv. Aluminum
Requirement of good form work:
1. It should be strong enough to resist the weight
of concrete, workers and machinery.
2. It should be economical compared to total cost
of construction.
3. It should be possible to use the formwork for
more number of times.
4. It should give smooth finish and shape to
concrete faces.
5. It should be possible to erect and dismantle the
formwork very easily.
6. It should be easily and locally available.
7. It should be rigid enough to retain its shape
without any deflection.
State the stripping Time of form work as per IS 456-2000.
i) Slab ii) Beam iii) Column iv) L-shaped column. With labeling on sketch.
Stripping time of form work as per IS 456-2000

i) Slab: ii) Beam:

1. Soffit formwork – 3 days 1. Soffit formwork for beam – 7 days
2. Span up to 4.5m – 7 days 2. Beam and arch of span up to 6m – 14 days
3. Span more than 4.5m – 14 days 3. Beam and arch of span more than 6m – 21 days
iii) Column: Vertical formwork – 16 to 24 hours

FORMWORK FOR SLAB

FORMWORK FOR L SHAPED COLUMN

FORMWORK FOR BEAM

FORMWORK FOR COLUMN
Draw a neat sketch of Formwork for R.C.C column footing.
What are the precautions to be taken while placing the concrete in formwork?
Ans. Precautions to be taken while placing of concrete are;
1. While placing of concrete, the mixture should reach at all corners uniformly and not intensively at one place.
2. Placing thickness for mass concrete should be less than 30-45 cm and for RCC work should be less than 15-
30 cm.

3. Before placing of concrete the formwork joints should be checked to avoid bleeding.
4. Concrete mixture should not be dropped from the height more than 1 m.
5. Before placing of concrete, oiling to inner face of formwork should be done properly.
6. Flow of placing of concrete should be continuous and joints should be left at appropriate position.

PLACING OF CONCRETE
Precautions to be taken while placing of concrete:
1. While placing of concrete, the mixture should reach at all corners uniformly and not intensively at one
place.
2. Placing thickness for mass concrete should be less than 30-45 cm and for RCC work should be less than
15-30 cm.
3. Before placing of concrete the formwork joints should be checked to avoid bleeding.
4. Concrete mixture should not be dropped from the height more than 1 m.
5. Before placing of concrete, oiling to inner face of formwork should be done.
6. Flow of placing of concrete should be continuous and joints should be left at appropriate position

COMPACTION
Methods of compaction
The following methods are adopted for compacting the concrete:
i. Hand compaction
a. Hand compaction of concrete is adopted in case of unimportant work of small magnitude.
b. Hand compaction consists of rodding, ramming or tamping.
c. When hand compaction is adopted, the consistency of concrete is maintained at higher level.
ii. Compaction by vibration:
a. Where high strength is required, it is necessary that stiff concrete, with low water/cement ratio be used.
b. To compact such a concrete mechanically operated vibratory equipment must be used.
c. The modern high frequency vibrators make it possible to place economically concrete which is
impracticable to place by hand

TRANSPORTATION OF CONCRETE
Methods of transportation of concrete: There are three methods of transportation of concrete listed
below.
1. Manual method- Transportation through the hands of labour in the ghamela, wheel barrow.
2. Semi-manual method- Transpiration using belt conveyor, skip and hoist arrangement.
3. Mechanical Method- Transportation using truck, dumper, RMC vehicle.

List method of transportation

i. Mortar pan
ii. Crane, bucket, rope way
iii. Wheel barrow and hand cart
iv. Truck mixer and dumper
v. Belt conveyor
vi. Skip and hoist
vii. Transit mixer
viii. Pump and pipe
Suggest the relevant method of transportation of concrete used for construction in following
situation.
Method of transportation of concrete for:
1) Concreting in hilly areas: Ropeway and helicopter.
2) Concreting of high-rise building: Skip and hoist arrangement, concrete pump, slip form technique.
3) Concreting under water: Tremie pipe, grout pipe.
What are the precautions to be taken during transportation of concrete?
1. Establish mixing plant nearest possible to the construction site to reduce time of transportation.
2. Select higher w/c ratio, if distance between mixing plant and working site is more.

3. Maintain cold or humid condition around the concrete mixture during transportation.
4. Use retarding admixture, to avoid early setting and hardening of concrete.
5. Cover the concrete mixture, if it is transported in open trucks to avoid direct sunlight.
6. Due care should be taken to avoid leakage and wastage of concrete mix during transportation

FINISHING OF CONCRETE

Finishing of concrete surface is achieved by completing the following operations.

i) Screeding
ii) Floating operations on concrete.
iii) Trowelling

Screeding: - In this operation of concrete finishing, excess concrete,

hollow or cavities present on concrete surface are striker off using chisel
or hammer.
This is done by using a heavy beam or steel plate or plank having
handles on both sides known as screed.
When Screeding is done all over concrete surface, then the surface
becomes rough and approximately leveled.

Floating: - In this second operation of finishing, the cement mortar is applied Screeding
uniformly using wooden float of 60cm length and 20 cm width.
Sometimes a large metallic or aluminum float is used to level and finish
the target concrete surface.

Trowelling
It is the final operation of finishing. It provides a smoother finish
which is hard and abrasion resistant. Trowelling may be necessary
to finish points not finished in a satisfactory manner by floating. It
should be done after all excess water has evaporated. Trowelling
with a steel float when the concrete is almost dry gives a very
smooth finish. The trowel is 25 to 50 cm long and 8 to 12 cm
wide.
Requirement of good finish
Trowelling
1. To achieve proper finish of the slabs and pavements, concrete should be placed and spread in such a
manner that no segregation takes place
2 A properly designed mix is essential, the consistency of each batch should be the same otherwise the
finish will not be uniform
3. Trowelling for final finish cannot be done till the surface water evaporates. Therefore for greater slump
much time is wasted so slump of about 50 mm gives good results for finishing
Curing
Define curing and state necessity of curing.
Ans: Curing – Curing may be defined as the operation of maintaining humidity and temperature of freshly
placed concrete during some definite period following placing, or finishing to assure satisfactory hydration of
the cement and proper hardening of the concrete.
Or
Curing – It is the process or method of keeping humidity or temperature of freshly placed concrete to ensure
complete hydration of cement.

Necessity of curing –
1. Curing is essential to maintain sufficient moisture in concrete for completing hydration.
2. It is necessary to maintain uniform temperature of concrete i.e. above freezing point.
3. It is useful to avoid chances of formation of shrinkage cracks and to attain uniform finishing.
4. It helps to increase impermeability and durability of concrete by achieving characteristic compressive
strength.

Classify the methods of curing of concrete with detail explanation of any one method.
Methods of curing:
A. Water curing
B. Membrane curing
C. Application of heat
D. Miscellaneous methods

1. Water curing:
i) This is the best method of curing, because it satisfies all the requirements of curing.
ii) The precast concrete items are normally immersed in curing tanks for certain duration. Pavement slab,
roof slab etc. are covered under water by making small pond.
iii) Water curing can be done in following ways: Immersion, Ponding method, Spraying or fogging, wet
covering.

2. Membrane curing:
i) Sometimes concrete works are carried out in places where there is acute shortage of water. Therefore
lavish application of water for water curing is not possible for the reason of economy.

ii) Water from concrete gets evaporated, which is covered with membrane which will effectively seal the
concrete.
iii) A membrane will prevent the evaporation of water from the concrete. The membrane can be either in
solid or liquid form, known as sealing compound. Other membrane curing sealing compounds are: Rubber
latex emulsion, emulsion of resins, varnishes etc.

3. Application of heat:
i) The development of strength is not only a function of time but also that of temperature.
ii) Concrete subjected to higher temperature accelerates the hydration resulting in faster development of
strength. Prefabricated members are normally steam cured.

iii) In this method the ingredients of concrete heated and the strength is gained at very fast rate. This can
be done in following manner: Steam curing, Curing by infra-red radiation, Electrical curing

4. Miscellaneous method:
i) Calcium chloride is used either as a surface coating or as an admixture. It has been satisfactorily used as
a curing medium.
ii) Both of these based on the fact that calcium chloride, being a salt shows affinity for moisture. The salt
not only absorbs moisture from atmosphere but also retains it at the surface.
iii) The moisture held at the surface prevents the mixed water from evaporation and thereby keeps the
concrete wet for a long time.

Explain in brief infrared radiation method of curing.

Infrared radiation method of curing-
1. This method of curing is useful to cure concrete very rapidly than steam curing.
2. In this, initial temperature in concrete does not reduce ultimate strength.
3. Infrared radiations are generated at a temperature of 900c to cure the target surface.
4. This method is adopted generally in cold regions , where curing by other methods does not found
effective
5. Infrared curing is adopted for curing of hollow concrete blocks.

WATER PROOFING
Explain the two different methods of water proofing.
1. Waterproofing by use of pore fillers – In this method, pore filler materials like silicate of soda, aluminum
and zinc sulphates and aluminum and calcium chloride are used. These chemically active pore fillers accelerate
setting time which results impermeability in concrete at early stage.
Some chemically inactive pore filler materials like chalk, fuller’s earth, talc reduces water without disturbing
workability to give imperviousness in concrete.
2. Waterproofing by use of water repellents – The water repellent materials like soda, potash soaps, resins,
vegetable oils, fats and coal tar residues are useful in this method. Some water proofing admixture, inorganic
salts of fatty acids, calcium or ammonium stearate repels water from concrete. Lime can be added in concrete
for waterproofing. Calcium chloride accelerates strength and helps in curing for making impervious concrete

Give importance and need of water proofing.

Importance of water proofing:
i. It reduces permeability as well as damage to structures.
ii. It increases durability and strength.
iii. It keeps good sanitation of building.
iv. It prevents paint and appearance of building from damage.

Need of waterproofing
i. Due to defective construction there is need of waterproofing.
ii. Poor drainage at building site causes leakages in structure, therefore, need arises for waterproofing.
iii. If ground water table is at shallow depth, then, in case of basement waterproofing is needed.
In case of retaining wall to prevent the seepage from wall, waterproofing is necessary.

Suggest one type of materials for water proofing for the following situations.
i. Rising dampness in building
ii. Leakages in dam
iii. Concrete continuously in wet or damp condition Methods of waterproofing:
iv. Leakages in lavatory ,bathroom and kitchen floor i. Brick bat coba system.
v. Cracks on plastered surface ii. Bituminous treatment.
vi. Cracks on roof surface iii. Box-type waterproofing system.
iv. Sheet membranes.
Flexible materials like butyl rubber, hot bitumen (asphalt), plastic v. Surface coating/liquid membrane.
sheets, bituminous felts, sheets of lead. vi. Integral method.
ii. Liquid applied cementitious membranes vii. Hydrophilic system /crystalline.
iii. Liquid applied cementitious membranes viii. Hydrophobic admixtures.
iv. Liquid applied cementitious membranes, liquid applied latex ix. By use of pore fillers.
membranes, brick bat coba, liquid applied bituminous membrane. x. By use of water repellent
v. Liquid applied cementitious membranes.
vi. Brick bat coba, liquid applied bituminous membrane.
Suggest the relevant method of water-proofing used for following construction.
1) Basement of buildings.
2) Swimming pool.
3) Water tank.

Method of water-proofing for:

1) Basement of buildings: Waterproofing by using waterproof sealants.
2) Swimming pool: Waterproofing by spraying or grouting in cracks.
3) Water tank: Waterproofing by water proof coat

JOINTS IN CONCRETE CONSTRUCTION

What are the different joints in concrete? Explain with neat sketch.

Construction joint- The temporary joint left between Subsequent

concreting operations is known as construction Joint. It is
preplanned joint before concreting located away From maximum
bending moment. The construction joint is provided such that there
will be Strong bond between hard end and fresh concrete. It can be
Ensured by providing dowels or tongue and groove at a joint
Shown in figure below.

2. Expansion joint- The joint which is provided to present the

expansion in concrete caused due to thermal stresses. These
stresses produces due to extreme temperature conditions.
The typical expansion joint is provided with dowel bars
at a depth equal to half of slab thickness.
This dowel of 20 mm diameter and 550 mm long is covered
with metal cap filled with cotton and finally such joint is

sealed using sealants like wood, thermocol or bitumen.

3. Contraction joint-
The joint which is provided to prevent contraction of concrete
takes place due to plastic and drying shrinkage is called as
contraction joint.
These joints are provided at 5- 10 cm interval along the width
of road slab. Contraction joints of 3-4 mm width are cut at a ¼th
depth of slab thickness. Sometimes a smooth dowel bar is
also provided in it shown in figure below

4. Isolation joint- It is provided to isolate the structural part from

the surrounding is known as isolation joint.
It is provided where the concrete floor meets the permanent
structural elements like walls, columns, foundation blocks,
machine foundations. The width of these joints is about 10-12
mm which is filled by resilient materials and locked with joint
filling compounds shown in fig below
Suggest the type of joints in concrete when it is likely to increase in volume due to temperature
change. Explain it and draw its neat sketch.
When it is likely to increase in volume due to temperature change expansion joint is constructed.
i. Expansion joints are provided by keeping a gap between panels of concrete and later sealing it

ii. The joint which is provided to present the expansion in concrete caused due to thermal stresses.

iii. These stresses produce due to extreme temperature conditions.

The typical expansion joint is provided with dowel bars at a depth equal to half of slab thickness.
iv. This dowel of 20 mm diameter and 550 mm long is covered with metal cap filled with cotton and
finally such joint is sealed using sealants like wood, thermocol or bitumen.

METHOD OF JOINING OLD AND NEW CONCRETE

Explain the procedure for joining old and new concrete work, also state any two material used for
filling joints.
Procedure of joining old and new concrete:
When new concreting is done in continuation with old concrete after a gap of some days, months or even
years, then the new and old concrete must have a strong bond with each other. Hence some points
Should be kept in mind for joining old and new concrete.

Procedure:
1. Cleaning: The old concrete surface is first thoroughly cleaned with wire brush. Loose material if any,
should be clean first.

2. Chiseling: The old concrete surface is made rough by denting it with a chisel for a strong bond with
new concrete.

3. Application of cement slurry or paste with some admixtures:

The surface is then wetted with rich cement slurry. Sometimes an admixture has to be added to give
additional strength to the joints. Then fresh concrete is placed over the old concrete.

4. Providing overlap: To give homogeneity to the reinforcing bars, overlap is provided and the overlap
portion is bound tightly with high tensile wire.

Enlist any 6 materials used for filling joints.

Materials used for filling joints;
1. Asphalt, tar, bituminous materials 5. Polymer
2. Fibre and fibre products 6. Thermoplastic
3. Sponge rubber
4. Cork 7. Glass