Concrete PDF

Little Birds School, Sanjay Nagar, Front of Railway Station, Alwar
Unit - 1
CONCRETE
CONCRETE -
A Mixture is contain (water + Cement + Sand Agg. + ad mixture)
Water - Property mixing (Toimpouove the quality of concrete)

+
Cement - Binding material
+
Sand - Filler material
+
Agg. - Inert material
+
Admixture - Specially use for increasing workability & strength
CEMENT
Historical development of OPC -
colour match
Manfactur Process of Oridinary Portland Cement : -
(i) Dry Process

(ii) Wet Process
(i) Dry Process - Raw material weight
Mix et process of the weight of Raw-meterial Mix
(ii) Wet process: Wet process raw materials weight 35-

50% mix
Note: -
Wet Process method
raw material Slurry Form Convert
Stage Matrial Add
Manufacturing Of OPC by Wet Process
OPC Raw-matrials Calcureous matrial (lime stone chalk), Argillaceous

Study Material & Online Exams Facility available on web App.
Website:-WWW.civilianinstitutealwar.in 1 Contact No.: 9610446964
material (shale, Clay)
Raw matrial - (Calcureous + Agrillaceous)
Raw matrials Calcareous materials Jaw Crushers Size reduce (about
- 150 mm) size
Argillaceous Calcureous material Fine Grinding
Ball Mill Tube Mill
OPC Raw material Chemical Composition
S.NO. OXIDE PERCENTAGE FOR GOOD

CEMENT
1 Lime/calcium oxide 6067% 63%
2 Silica (SiO 2) 1725% 22%
3 Iron oxide (Fe 2O 3) 0.56%
4 Alumina(Al 2O3 ) 38%
5 Magnesia(MgO) 0.14%
6. Sulphur Trioxide (SO 3) 1.33%
7. Alkalies (K2O, Na2 O) 0.41.3%
According dessending Order Cao > Sio2 > Al2O3 > Fe2O3>SO3>Mgo > So3 > Alkalies
- For a good OPC Cement - the composition is lime - 63% + silica 22% + 15% other gradient
- Maximum Quantity in OPC - Lime (CaO)
- Minimum Percentage in OPC - Alkalies
Ball Mill Tube mill Raw material Mix Raw
Materials Slurry Form Convert
Cement rotary Kiln dia 2.5
length 90-120 mtr 1 in 300 Angle inclined
Slurry Form Convert Raw materials Rotary Kiln Higher ENP
Raw materials Gravity Temperature
1400 -15000c Slurry (Nodules)
clinkers
Finer grinding Ball mill Tube mill
Weight Gypsum (CaSo4.2H2O) Calcium
Sulphate (CaSo4) Cement Gypsum
Flash setting Cement Initial Setting time
Gypsum Retarder
Raw matrials Oxcide
Bogoues Bogoues Compound

Bogus Compound
S.No. Compund Approximate Qty

1. Tricalcium Aluminate C3 A 3CaOAl2 O3 10.80%
2. Tricalcium Silicates C3 S 3CaOSiO2 54.10%
3. Dicalcium Silicates C2 S 2CaOSiO2 16.60%
4. Tetra Calcium C4 AF 4CaOAl2 O3Fe 2O 3 9.10%
Aluminate Ferriate
Le - Chetelia or Thornebohm Clincker Observation properties

bogoues Compound Bogoues compound
C3S - Alite C3A - Celite

C2S - Belite C 4Af - Felite
C3A :- (Tricalcium Aluminate) :

(i) Add C3A Reaction
(ii) C3S Set
Flash setting
Setting time increase C3A Counter Attack
Gypsum (CaSo4.H2O) or Calcium Sulphate (CaSo4) mix
(iii) Cement initial or Final Setting time C3A
(iv) cement C3A Sulphate resistance capacity
Sulphate resistance C3A
(v) Stage Heat of Hydration C3A
S.No. Compound Heat of Hydration(Cal/gram)

3 days 28 days 13 years
1. C3A 212 311 324
2. C3S 58 104 122
3. C4AF 69 98 102
4. C2S 12 42 59
Heat of Hydration Stage C3A

Heat of Hydration C2S
(vi) Undesirable properties C3A responisble
Heat of Hydration :- (Heat
lebration) Heat of Hydration
C4AF (Tetra Calcium Alminate Ferrite) (4Cao.Fe2O3.Al2O3) :-

This is Also Known as 'Felite'
Rate of Hydration C4AF

Rate of Hydration C4AF Rate of Hydration C2S

Note: C3A, C4AF C3A strength C4AF
Strength contribution
C3S (Tricalcium Silicate) (3Cao.Sio2) :-
This is Also known as 'Alite'
OPC C3S
28 Days Strength Charecterstic Early Strength
C3S
C2S (Di-Calcium Silicate) :-

(i) This Also Known as 'Belite'
(ii) Ultimete Strength C2S C2S (Slowly)
Strength
(iii) Heat of Hydration Reduce C2S Comparetively
(iv) Cemical Attacks Against (More resistance against

Chemicals Attack) C2S
Strength C3S Strength C4AF

Bogus Compound composition In Cement

Compound Qty. in Percentage
C3S 54.10
C2S 16.60
C3A 10.9
C4AF 9.10
C3S
C4AF
2 Main Component C3S or C2S
Oxide Row Meterial Lime High Setting time or strength
Increse Oxide Silica Strength or
Setting Increase
Strength setting time of cement lime content

silica content
Cement oxide Unburnt lime (free lime) or Magnesia

Unsoundness (expansion in cement after initial setting time)
oxide Iron colour (greenish Gray) oxide
burning process Help
Factory production Dry process cement 1 tonne cement 100 kg Coal
Wet Process 1 Tonne cement 350 kg coal
10000c Temperature Heated Loss of Weight due to igniation

5% of the weight of cement Loss of weight, moisture
content, Co2, Free lime of magnesia (evaporation)
Insoluble or Residual Matter in cement :-

insolube matter weight of cement
Magnesia Weight of cement
Particals Original Volume Expand
Aggregrates or Sand Partical Thin Layer (Gel)
cement Heat Libration Heat of hydration
Note :- Lime Original Volume 2.3 time expand

Slagging of lime
Water Requirement for Hydration of cement compound :-

Water requirement for Hydration of C2S - 24% of the weight of cement
Water required for Hydration of C2S - 21% of the weight of cement
For combined requirement to start the intially heat of Hydration - 23% of the weight of cement.
This is also known as Bound water.
Water required for gel process - 15% of the weight of cement
Total water required for complete Heat of Hydration - 38% of the weight of cement
Types of Cement :-
1. 33 grade - IS-269
Ordinary Portland Cement (O.P.C.) 43 grade - IS-8112
53 grade - IS-12269
Types of OPC Compressive Strength at

different age of cement
2 days 7 days 28 days
33 Grade 16 mpa 22 mpa 33 mpa
Grade Fineness or 28 days Stength represent

fineness represent
Fineness :-
53 grade > 43 Grade > 33 Grade
1 beg weight 50 kg 1 beg volume 0.0347 m3 (34.7 liter)
Initial setting time of O.P.C. Cement should not less than 30 minute.
Finial setting time of O.P.C. cement shound not more than 10 hours. (600 minute)
Normal relation between initial & final setting time T=90+1.20 t,
Where T= Final Setting time, t=Initial setting time
2. Repid Harding & Rapid strength cement :-
Compare to OPC Higher portion of C3S and Lower portion of C2S and finer grinding cement.
Repid Harding cement OPC Compare C3S increase C2S
decrease OPC Compare Finer (Finer grinding)
Repid Harding cement (R.H.C.) Stage Strength OPC compare (Higher)
R.H.C Strength O.P.C. Strength

1 days = 3days
3 days = 7 days
Initial setting time of Rapid Hardning cement - Greater than 30 minutes

Final Setting time of Rapid Hardning cement - Less than 10 Hours
Repid Hardning cement Ultimate strength O.P.C. equal concrete
mass concrete work (Retaining wall, Dam, Bridge) R.H.C. cement OPC
compared initial strength slow
Use of R.H.C. - R.H.C.
1. Road Repair Work or New Road work
2. Use in cold Area's
3. If form Work removing early then rapid hardning cement is prefered.
4. Use in pre-stress (Pre fabricated concrete)
3. Quick setting cement :-

OPC Clinkers (at the time of grinding) Gypsum
(CaSo4.2H2O) Reduce Quick Setting cement
Initial setting time for quick setting cement - Not less than 5 minutes
Final setting time of Quick setting cement - Not More than 30 Minutes
Use of Quick setting cement :
1. Use under water construction (where pumping involve)
2. Use for grounting opration (Grouting)
4. Low Heat Cement :-

OPC Compare C3A or C3S
C2S (Increase)
[Compare to OPC Lower percentage of C3A & C3S or Higher Percentage of C2S]
Low Heat Cement (L.H.C.) Final ultimate Streangth OPC equal Ultimate
Strength OPC Compare Higher
L.H.C. Strength OPC Strength

3 days 1 days
7 days 3 days
Initial setting time of L.H. Cement - More than 60 Minutes

Final setting time of L.H. Cement - Less than 10 Hours (600 minutes)
Use of Low Heat Cement :
1. Use in Mass concrete work (Dam. Retaining wall, Bridge etc.)
5. Sulphate Resisting Cement :-

Slulphate resisting cement OPC C3A or C4AF Reduce
C3S or C2S OPC Compare Increase
Sulphate Resisting Cement C3A 2XC3A + C4AF
Sulphate resisting Cement Conditions

1. Use for marine condition

2. If Concrete use in Foundation, Basement and all Structure with contact soil.
3. If concrete use in construction of sevrage treatment units.
6. Super Suphate Resesting Cement :- Slage + 10-15%

Gypsum + OPC Mix
Coloured Cement :- Coloured Pigment
White Cement :- White Cement Pure lime Stone or Chalk

Iron oxide Reduce White Cement Iron
oxide Clinkers OPC Compare Finer
Ex - Birla white, J.K. white Putty.
Note :- To measeure the coloured of cemnt Hunter Scale is used (White ness measured)
Whiteness should not less 70% when measured ISI scals.
9. Hydrophobic Cement :-
Longer Storage
OPC Clinkers clinker Weight 0.1%

to 4%, Oleic, Streac, Boric acid mix Particals Water
replant thin film (layer) Particals water Contact
Hydrophobic cement cost ordinary portland cement
10. Portland Slag Cement :-

OPC Slag Mix
Properties
1. Low heat of Hydration
2. Better Resistance to Chloride
3. Better Resistance of Marine effects
4. Reduce the permability of cement concrete
5. Increase the chemical resistance capacity
11. Extra Rapid Hardening Cement -

Rapid hardening Compare Strength Condition Extra
Rapid Hardening Cement Preferred Rapid Hardening
cement 2% weight of cement Calieiuim chloride (CaCl2) content mix

Cold Area
Extra Rapid Hardening cement Strength rapid hardining Compare
Extra Rapid hardening cement 7 days Strength rapid Hardening compare

12. High Alumina Cement :-
Lime Stone (Chalk) and Bauxite Finer Gryinding
Mix High Alumina cement
High Alumina cement intial setting time 4 Hours Final setting time 5 hours
Note :- High Alumina cement Initial setting time OPC, RHC, LHC Final
setting time
High Alumina Cement is used in following conditious -

1. Better resistance capacity against chemical Attack.
2. Better resistance against marine effect.
13. Portland Pozzolona Cement (PPC) :-

OPC Pozzolanic matarial 15-35% (Now
days) or (10-25%) (earlier) mix
Pozzolanic material binding porperty
Mix binding porpaerty develop Pozzolanic material silica
or Alumina Main Content
A Pozzolonic material - High siliceous & High Alumineous
PPC Cement Strength 33 grade OPC equal
Example of Pozzolonic Material -
(i) SURKHI (ii) FLY-ASH
SURKHI - Pozzolonic Material (Pilla bricks)
FLY-ASH - Pozzolonic material, Thermal Power Stations Wastage
Propertics of PPC :-
1. Low Heat of Hydration
2. Use ful in Marine condition
3. Use for Hydraulic structure other than mass concrete construction.
4. Longer currying period required compare to OPC
5. It is Cheaper compare to OPC
6. Reduce the permability of concrete
7. More Volume Covered by 50 kg bag.
Note :- Rapid Hardening cement OPC compare 10% More costly.

Testing of Cement :-
It is classify in two types-
1. Field Test
2. Laboratry Test
1. Field Test - Following test are conduction to determine the properties of cement-
(a) Cement should be free from lump.
(b) Colour of cement should be greenish grey.
(c) Thrust your hand into beg and it must give cool feeling.
(d) Take a pinch of cement and feel between the fingure. It should give a smooth feeling.
(e) Take a sample of cement and throw it on bucket of full with water, the particles of cement should be
float for sometime before they sink.
2. Laboratry Test -Following test are done in laboratry

(a) Constancy Test :-
Test Condition - Humidity maintain - 90%
Room Temprature - 27 20c
Test Appratus -Vicate Appratus are used
self weight - 300 gram
Plunger size - dia -10mm
height - 50 mm
Sample mould size -

vicats apparatus mm dia 50 mm hight plunger
apparatus weight mould penetrate
plunger mould top r mm penetrate bottom mm
consistancy of cement
Standard consistance obtained - 30% water of the weight of cement.
(b) Setting Time Test - Setting time Clasified

(i) Initial setting time (ii) Final setting Time
inital or final setting time vicket apparatus use

initial or Final setting time 0.85 P Mix
Test Condition - Temperature - 270c 2ºC
Test condition same as a consistency test
Initail setting time - Paste apparatus penetration 1 mm square size

Needle cement paste penetration Needle top 33-35
mm penetrate Bottom 5-7 mm Initial setting time of cement
Final setting time - vicate apparatus Final setting

time vicate appratus 5 mm dia colar
concrete Final setting time of cement

Intial & final setting time of different types of cement :-
S.No. Types of Cement Initial Setting Final Setting

1. Quick Setting Cement More than 5 minutes Not more than 30 min
2. Low heat cement More than 60 minutes Not more than 10 hrs.
3. High Alumina Cement More than 4 hrs. Not more than 5 hrs
4. OPC, PPC, Slag, More than 30 minutes Not more than 10 hrs
Sulphate, Hydrophobic (600 minuts)
RHC, Super Sulphate
(c) Soundness Test -

Soundness test cement initial setting time expansion
Soundness test 0.78 P mix P standard

consistancy soudness Test
(i) Le-chetelia Method (ii) Autoclave
Le chetelia Appartus Free lime soundness
AutoclaveAppartus Free lime or magnesia Soundness
Magnesia Soundness Condition
Le-Chetelia Appartus:-
The unsoundness or expansion of cement (edge distance of Le-Chetelia Appartus) should not more
than 10mm in case of OPC, R.H.C., L.H.C., P.P.C.
(d) Strength Test - Cement Tensile or compressive strength 1:3 (cement : Sand)
Mix
Test
(i) Tensile strength Test (ii) Compressive strength Test
(i) Tensile Strength Test - Test condition - Temprature - 27 20c

Humidity - 90% (moisture content in atomosphere)
P
Water Requirement - 2.5%
5
'P' Standard consitency
OPC Cement Tensile strength 3 days 2 N/mm2
OPC Cement 7 days Tensile strength 2.5 N/mm2
Cement Tensile strength, compressive strength 10-15%

1 Briqutte Crossectional Area 6.45 cm 2
Cement Tensile Strength 6 Nos. Briqutte Average

Strength Tensile Strength of cement
(ii) Compressive Strength Test -
Test condition : Temperature - 270C+2ºC

Humidity - 90%
P
Water Requirement - 3%
4
Cement Compressive Strength Cube (7.06 7.06 7.06 cm) or
70.6 mm Cube Crossection Area (7.06 7.06 = 49.84 cm2 50
cm or 5000 mm2)
2
PPC and OPC Cement 3 days or 7 days Compressive Strength 16 N/mm2 or 22 N/mm2
Cement Strength test 185 gram cement ( 200 gram) or 555 gram sand ( 600
gram)
Cement Strength test Cement, Sand or Water Minimum Mixing Period 3 Minute
(e) Fineness Test -Cement Fineness Area/Mass Ratio

Cement Fineness Method
(i) Sieve Analysis Method
(ii) Air Permeability Method (Nurse & Blain Permeability Method)
(iii) Sedimentaion Method or Wagner's turbidity meter Method
(i) Sieve Analysis Method - Cement Fineness test, sieve Analysis method
Sieve No. is 9 (90 ) (0.09 mm) sieve mechinal derive
(Shaking) Sieve
S.No. Types of Cement % of

Residue
1. OPC 10%
2. PPC 5%
3. RHC 5%
(ii) Air Permeability method - Method Fineness Blain Appratus

Different types of cement Specific surface area
S.NO. Types of Cement Specific Surface Area Should Not

Less than
1. High Alumina Cement 2250 cm2 /gram
OR OPC
2
2. PPC 3000 cm /gram
3. RHC and LHC 3250 cm2 /gram
4. Super Sulphate Cement 4000 cm2 /gram
(iii) Specific Gravity Test - Cement Specific Gravity test Le-Chetelia Flask
OPC cement Specific gravity 3.15
Uint -II
WORK ABILITY
Concrete mix easily transport easily place

easily compaction Finishing "Workable concrete" Concrete
"Workability"
Consistancy - It is the related mobility and also the one dimensional measurment of workability. It
is the property of concrete which provided penetration resistance in concrete paste.
Following test are use to find out the workability of concrete :-
(i) Slump test
(ii) Compaction Factory test
(iii) Vee-Bee test
(iv) Flow test
(v) Kelly ball test
(i) Slump Test -

- Slump test laboratry or fiels Method
very wet or very dry (very High workable or very low workable)
concerete suitable
- Slump test Cement concrete workability or consistancy
- Slump test Concrete maximum size of Aggregate 40 mm 38

mm
- Slump test Mould or tapering rod Size

Slump Mould
Concrete fill in mould for slump test - 4 layers

Thickness of each layer - 7.5 cm of each layer
No. of blows on each layer - 25 blows
SLUMP :- It is classified in three types -

(i) True slimp (ii) shear slump (iii) Collapse slump

(Non-Cohesive slump-represent segrightation of conc.)
If concrete slump evenly then it is called true slump.

If one half of the cone slide down than it is called shear slump and also known as cohessive concrete
concrete very high workable collapsable slump denote
- Concrete Slump value Classify
S.N. Slump Value Workab ility Degree of Plasticity

1 2575 mm Low workable conc. Stiff plastic conc.
2. 50100 mm Medium workable conc. Plastic Conc.
3. 100150 mm High workable conc. Flowing Conc.
Note :- Slump test are more useful plastic mix.
Recomanded value of slump for different types of work -
S.N. Types of work Slump

Value
1. Conc. in Road Construction 2040 mm
2. Mass Conc. Work (dam, bridge) 2550 mm
3. Conc. in Beam and Slab 50100 mm
4. Conc. in Column or thin walls 80150 mm
normal R.C.C. works
(ii) Compating Factor Test - test laboratry method Low workable concrete
Test concrete compaction factor
instrument Compaction factor
Wight of partially compaction Con.
Compacting Factor= Weight of Fully Compacted Con.
Hopper-A
Bottom Internal Dia=12.7 cm

Top internal dia=25.4 cm
Internal height of hopper =27.9 cm
Distance between hopper A and Hopper B 20.30 cm
Hopper-B
Bottom internal dia- 12.7 cm
Top internal dia -22.9 cm
Internal Hieght of Hopper =22.9 cm
Distance between hopper B and Mould =20.3 cm
Mould
Internal Dia=15.2 cm
Internal Height=30.5 cm
Compacting Factor Concrete Workablity Classify
S.No. Compacting Factor Workability Plasticity

1. 0.750.80(.78.80) Very Low Stiff
2. 0.800.85 Low workable Stiff
Plastic
3. 0.850.92 Medium work Plastic
4. G reater than 0.92 High workable Flowing
(>0.92)
(iii) Vee-Bee test - Test very low workable concrete Test Vibration
instrument concrete mould
mould Concrete Vibration Concrete
Flat Concrete Workability Vee-Bee
Value
Concrete Workability Vee-Bee value Classified
S.No. VeeBee Value W orkability P lasticity

1. Less than 2 sec High workable Flowing
2. 25 sec Medium Platic
3. 510 sec Low Stiff Plastic
4. 1020 sec Very low Stiff
(iv) Flow Test - Laboratry test Catagory Test cement concrete

consistancy, cohessiveness and seggrigation properites concrete
Test Flow Plate 700 700 mm table weight 16 kg 1kg
concrete mould size

Tempring Rod
Mould Plate up and down up

and down Height 12.5 mm up and down time 2 sec
5 sec Plate 15 time up and down
Spread Concrete 6 directions nearest 5 mm measure
Avg. spread diameter in cm 25
Flow percent = 100
25
Note :- Concrete Flow value 0 to 150% vary test very high workable
concrete
(v) Kelly-Ball Test - Method Field category Method Result, slump test
compare more accurate method slump test compare (Quicker result)
Test cement consistancy
concrete workability high concrete strength

concrete permeability & poronsness high

concrete workability low concrete strenght high con-
crete permeability & porousness low
Factor Affection The Workability of Concrete

Following Factor are affected workability of concrete -
Water content :- Workability of concrete Water content

Note : Concrete workability cement water ratio inversly proportional
1
workability
cement
water
Mix Proportion :- Mix of concrete broadly classified as 2 typed

a) Lean mix b) Rich Mix
a) Lean Mix : If aggregate to cement ratio is high is called lean mix.

lean mix workability is low as compared to rich mix. (Lean mix low workable)
b) Rich Mix : if the aggregate to cement ratio is low is called Rich mix
Workability of rich mix are more compare to lean mix.
Size of aggregate :- Courser partical Workability Finner courser compare

Courser agg. - Less surface area - More workable - Low stregnth
Finner agg. - More surface area - Less workable - High Strength
Shape of Aggregate : According to Shape of Aggregate it is classified in 4 types -
a) Rounded Aggregate
b) Angular Aggregate (Cubical Angular Agg.)
c) Flakiness aggregate
d) Elonginated Aggregate
Note :- In Concrete Best Workability Concrete High Workable Rounded

Shape Aggregate are used.
- Concrete High Strength Angular Shape (Cubical shape) Aggregte are used.
- In Concrete work Flakiness or eloginated shpaes aggregate are not used.
5. Surface Texture of Aggregate :- According to surface texture the aggregate is classified in two
types-
A) Rough Surface Texture B) Smooth surface Texture
- High workable conrete Smooth surface texture aggregate
Surface area rough agg. Compare
- High strength concrete Rough surface texture aggregate
surface Area Smooth Agg. compare
Smooth Surface : Higher workability - lower strength
Rough surface- Low workablility - Higher strength
SUMMARY
1
- Surface Area
Size of agg.
- Surface Area Surface Roughness
1
- Workability
SurfaceArea
- Strength of Concrete Surface Area
Grading of Aggregate :- Well graded aggregates Workability High poorly graded agg.
Workability
Workability of concrete Grading of Aggregate

Strength of Concrete & Grading of Aggregate
Poprosity of Aggregate :- Concrete High Porosity Aggregates

concrete Workability Reduce Low Porosity Aggregates
Concerete Workability increase
Time :- Concrete Placing (Mixing) Time Concrete
Workability reduce
Temperature :- Concrete Workability Temperature increase
Decrease
Admixture :- Concrete Workability increase Concrete Admixtures Provide
Concrete High workability
water
1. Workablity Ratio
Cement
1
if Cement is more than Workablity
Cement/water
cement
2. Lean mix. Workablity
Agg.
1
if Agg. is more Workablity
Agg./Cement
3. Workability Size of Agg.
4. Workability Smoothness
5. Workability Gradeing of Agg.

1
6. workability
Porosity
1
7. workability
Time
1
8. workability
Temperature
workability Admixture
Note :- Conrete Workability or Strength Water, Cement Ratio, Cement Agg.
Ratio, Size of Agg., Smoothness, Gradeing Admixture
Degree of Plasticity Slump Value in Compacting VeeBee

Workability (mm) Factor Value Value (see)
Very low Stiff .75 0.80 1020 (sec)
Low Stiff 2575 mm 0.800.85 510 Sec
Plastic
Medium Plastic 50100 mm 0.850.92 25 sec
High Flow 100150 mm Greter than 0.92 Less than 2 sec
Very High Flow
Most suitable Most Suitable low Most suitable very
medium and high workable low workable
SEGGREGATION
Seggregation :- Concrete Mix Placing larger particals Smaller

particals Sepration Seggregation
Concrete Seggregation
1. Not Proper Perportion of concrete content.
2. Not proper handeling of concrete at the time of transportation, placing.
3. At the time of placing Free fall Height are exceed 1.5 m.
4. Not proper cohessive force between concrete contains.
Preventation of seggregation in concrete :-

1. Proper Perportion of concrete content.
2. Proper handeling of conrete at the time of transportation placing.
3. At the time of placing free fall height are not exceed 1.5 m
4. Proper adhesion force between concrete content
5. Use of Pozzolonic material.

6. Use of Air entering agent in concrete
BLEEDING :- Conceret Finish Water Concerete Sepretion

Concrete Top surface Conceret defect Bleeding
Preventation of Bleeding in concrete :-
1. Use of Pozzolonic Material
2. Use of Airentering Agent
3. Use of Richer mixer (because lean mix have more bleeding)
4. Uniform and compete mixing of concrete
5. Proper porportion of concrete content
Process of manufacturing of concrete :-

Following steps are follows to manufacture concrete
1. Batching
2. Mixing
3. Transportation
4. Placing
5. Compaction
6. Finishing
7. Curing
1. Batching - Concrete Step Baching Concrete
Materials Mode Measured Concrete batching
a) Volume Batching - Niminal Mix (M-5 to M-25)

b) Weight Batching - Design Mix
Weight Baching is more Accurate Compare to volume Bactching.
2. Mixing of Concrete - Concrete Mix
a) Hand Mixing
b) Machine Mixing
Concrete Mix hand mixing Machine mixing compare Proper mix
hand mix process machine mix compare 10% cement Extra mix
Transportion : Concrete Mix transportation

placing free fall hight 1.5 m
4. Compaction - Concrete Placing Higher Compaction efforts (proper compac-
tion) high Strength Concrete Compaction Concrete
Air Voids remove Concrete Stength concrete

Airvoids concrete Strength Reduce
% of voids in concrete Reduce of Strength of concrete
1% 5%
2% 10%
5% 30%
10% 50%
5. Curing of concrete - Concrete Finishing Wet Process
curing of concrete Concrete Wet Curing period
Method of curing - Concrete Curing

1. Water curing
2. Membrance Curing
3. Application of heat & steam curing
4. Miscellaneous Process
Note :- In Normal Condition OPC Minimum Curing Period 7 days RHS have smaller curing period.
Low heat cement have most longer curing period.
Unit - III
AGGEREGATES
Classification of Aggregates according to source - Aggregates

Artifical Aggregate Bricks
Source of Aggregates
1. Naturally - Obtained from Rocks
2. Artificially - Obtained From Brick slag
Natural Agregated
1. Igneous Rock
Ex.- Granite, Basalt, Trap, Dolerite
2. Sedimentary Rocks
Ex.- Lime Stone, Sand Stone, Chalk, Gypsum, Kankar
3. Metamorphick Rocks
ex- Quratzite, slate, marble
Note :- Conceret Aggregates Igneous Rock Best Quality

Classification of a aggregates According to size-
Acc. Size Aggregates are Classified in 2 types-
1. Courser Aggregates
2. Finer Aggregates
1. Coarser Aggregates - Aggregated 75mm sieve 4.75 mm Sieve

Coarser Aggregates
[A Aggregate which is passing from 75mm sieve and retend on 4.75mm sieve is called coarser
Aggregates]
2. Finer Aggregates - Aggregate 4.75mm Sieve 0.150mm sieve
Finer Aggregates
Classification of a Aggregates According to surface texture -

According to surface Texture Aggregates are Classified as follow -
1. Smooth surface
ex- Slate, marble, chert
2. Rough surface (Angular)
ex- sand stone, oilites
3. Glassy
Ex- Black flinsh
4. Honey Combed surface
Ex- Scoria, Pumile
5. Crystal Surface
Ex- Basalt, Dolerlite, Granite, Glassic
Note :- Stone Aggregate "Glassy Surface"
Influence The strength of concrete by the texture -
Percent of Partical Water cement
Smooth Rough Ratio
100% 0% 0.54
50% 50% 0.57
0% 100% 0.60
Strength of Aggregate
Flexural strength Compressive Strength

4.30 N/mm2 34.8 N/m2
4.60 N/mm2 32.1 N/m2
4.80 N/mm2 29.5 N/m2
Note :- Higher Compressive strength Smooth Aggregate are Used.
higher Flexural Strength (High bond strength under tension) in
that condition "Rough surface Agg." are used.

Classification of Aggregates According to Shape :-
According to shape Aggregates are classified as below -
1. Rounded particals
2. Angular or cubical particals
3. Elonginated particals
4. Flakiner particals
1. Rounded Particals - Concrete Better Workability concrete Rounded

Particals
2. Anfular or cubical particals - Concrete higher strength Condition
Angular or cubical Aggregate preffered
Note :-
1. Concrete elonginated Flakiness Agg. Rounded or Angular
agg. mix flakiness elonginated index 15%
elonginated or flakiness index 6.3mm Particals Valied
2. Rounded particals Void ratio 33% Angular particals void ratio 44%
Rounded particals compare Angular partical higher strength concretes
Angular partical bond Strength rounded particals Compare High
9
3. Elonginated Aggregate - Aggregate length Mean Dimension of Aggregate
5
elonginated Aggregate
Lenght are exceed : 1.8 x mean dimension of Agg.

Min. Dimension - Avg. of passing and retand sieve
Q. What is the lenght of elonginated agg. If passing on 45 mm sieve and retend on 20 mm

sieve.
45 20
1.8 58.50mm
2
9
Elonginated Agg= mean dim ension
5
45 20
Mean Dimension = 32.5
2
9
= 32.5 58.50mm
5
4. Flakiness Aggregate : Aggregate thickness 3/5 x mean dimension
Flakines Agg.
[If thickness of agg are less than 0.60x mean dimesion]

Q. Agg. sieve sieve retend
Agg. flakiness thickness
20 10 20 10
0.60 9.0mm 9mm Flakiness Agg. = 15
2 2
3
Flakiness Agg.= mean dim ension
5
3
15 9mm
5
Classification accroding to zone:
According to zone aggregate are classified in 4 zone:
Agg. Zone ZoneI ZoneII ZoneIII ZoneIV
Type of Aggregate Coarse Agg Medium Agg. Find Agg. Very Fine Agg
Aggregate zone Agg. finness Agg. Size
Reduce
Fineness Modules:
Fineness Modules Sand Aggregate Classfied
Types of Sand Finess Modules
Fine Sand 2.2-2.6
Medium Sand 2.6-2.9
Coarser Sand 2.9-3.2
Types of Aggregates Fineness Modules

Find Sand 2.0-3.5
Medium Sand 5.0-7.0
Coarser Sand 6.5-8.5
Note: Sand Fineness modules 3.2
Fineness modules : Sand or Agg. fineness modules sand Agg. particals size
Idea Fineness calculate standard sieve
sieve percentage 100 divide fineness modules calculate
Calculate the fintness modules of a given sample if passing quantity is of sample are given at differ-
ent -different sieve.

Stan dard Passing R eta ine d % o f R eta nie d

Sie ve Q ty Q ty Agg/ Sa nd
40m m 50 Ni l 0%
kg=100%
20m m 45kg=9 0% 5Kg 5/50x100=1 0%
10m m 38 Kg=76% 7Kg 10% +7/5x100=24% 12/ 50= 24%
4.75mm 32Kg=64% 6 Kg 24% +6/50x100= 36% 18/ 50= 36%
2.36 mm 24Kg=48% 8Kg 36% +8/50x100= 52 % 26/ 50= 52%
1.18 mm 17Kg=34% 7Kg 52% +7/50x100= 66% 33/ 50= 66%
600? 10Kg=20% 7Kg 66% +7/50x100= 80 % 40/ 50= 80%
350? ? 8Kg=1 6% 2Kg 80% +2/50x100= 84% 42/ 50= 84%
150? ? 0Kg=0 % 8Kg 84% +8/50x100= 100 5 0/ 50=100%
452
Fineness moudles = 4.52
100
Bulking of sand or Aggregates:
dry sand or Agg. Moisture content sand
or Agg. partical surface tension create particals
sand or Agg. volume 5% moisture content sand or
Agg. or bulking maximum continuesly moisture maximum
continuesly Moisture content sand or Agg
20% moisture content sand or Agg
Note :
1. Bulking of Sand of Agg. 5% moisture Maximum
2. Buling of sand Finner Particles Coarser Particales
3. Dry sand or Agg. Moisture content Agg.

Amount 5% maximum moisture
reduce
4. moisture content directly proportional
TEST On Aggregate's:
Calculate the prporties of Aggergatics following test are conducted:
Properties of Aggregate Test
Crushing Strength Crushing Test
Hardness Derry Abrasioin testing
Rate of Wear Attriation test
Toughness Impect test
Durability Soundness test
Shape factor Shape test
Abraison value Loss Angleste
Aggregate crusing value (A.C.V.):

Sample -Agg. crushing value sample 12.5 mm sieve
mm sieve retained
Aggregate crushing value Agg. mould Size
normally 25 mm dia or 25 mm height
Aggregate mould pluner total 40 ton load (4 ton per minutes)
Aggregate mm sieve pass
W2
A.C.V.= 100
W1
Where,
W1=Total weight of sample
W2=Weight of sample passing through 2.36 mm sieve
Result: Agg Road Pavement or Bitumen povement top surface(Bearing surface)

A.C.V. Value 30%
Agg. bearing surface other then bearing surface Road Base
coarse or concrete ACV Value 45%
Aggregate Impact Value Test:

Test Aggregate Impact Resistanmce Compacity Impact resistance
Mould Size 10.2 cm Mould Aggregate
14 Hammer 38 cm height Sample
2.36 mm Sieve pass hammer

Nos of blow = 15
W2
AIV Value = 100
W1
Where W1=Total weight of sample
W2=Weight of sample passing through 2.36 mm sieve.
1. Agg Road Pavement Bearing surface (Top surface of pavement)

Agg. Impact value 30%
Agg. bearing surface Base coarser or road, concerete
Agg. Impact Value 45%
Aggregates Abraisa Value (A.A.V.)

Agg. Abraisa Value lose angles machine
Agg. RPM Sample 1.70
mm Sieve pass
W2
A.A.V.= 100
W1
Where W1=Total weight of sample
W2=Weight of sample passing through 1.70 mm sieve.
Result:
Agg. beaing surface top surface of road pavement
Agg. Abraisa Value 30%
Agg. Wearing surface Base
coarser or concrete Agg. Abraisa value 50%
ACV AIV AAV

Agg. Are use for Notmore Not more Not more
wearing surface than 30% than 30% than 30
Agg. Are used for other Not more Not more Not more
than wearing surface than 45% than 45% than 50%
like as Base coarser &
concrete work
Deval Attriation testing Machine:

testing machine cylinder 20 cm dia or 34 cm long horizontal 30º 30º
inclination test Agg. rate of wear
Dorry Abrasion Testing Machine:

Testing machine Hardness of Agg.
Loss of Wt. in Gram
Hardness= 20-
3
Note: Road or concrete Agg Hardness cofficent 17
Angularity No.67%-% of value of solid particals in a Agg. Sample
Q. If all particle are rounded:

% of solid particals = 67%
% of voids =33%
Angularity No. =67-67=0
Note: Aggregate's angularity No. lies between 0-11
Specific Gravity : Concrete Agg specific gravity 2.6-2.8
Water absorption or Mositure content:

Agg. concrete water absorption capacity Agg. 10%
Agg. Bitumen Pavement water absorption capacity 0.5-1%
Akalies Aggregate Reaction :

Agg. Silica content late reaction
concrete damage posibility concrete
reaction cement alkalies 0.6%
Strength of Concrete
The strength concrete are classified in two types:
1. Compressive strength of concrete
2. Tensile strength of concrete
1. Compressive strength of concrete: To calculate the compressive strength of concrete cubetesting

or coretesting are used.
Compressive strenght of concrete
Cube test Core test
Standard size of cube Standrad size of cylinder

(15cm x 15cm x 15 cm) (15 cm x 30 cm)
Note : Cement concrete compressive strenght core result, cube resutl 85%
Cube strength cube strength

Age factor's for permissible compressive strength in case of OPC are use
Age of 3 days 7 days 28 2 3 6 1 year

Concrete days month month month
Compressive 0.50 0.600.70 1.0 1.10 1.16 1.20 1.24
Strength
Wise Com. 50% 6670% 100% 110% 116% 120% 124%
Str. Factor
Note : Concrete 28 days strength characterstic strength of concrere
Tensile strenght of Concrete: Concrete tensile strength compressive strength

approximate 10%
Two methods are used to calculate tensile strength of concrete
1. Direct method 2. Indirect Method
1. Direct Tensile Method: Tensile Strength effective

method result accurate
Indirect tensile method : Indirect method tensile strength test
1. Flexural strenght of concrete or Modulas of Rupture
2. Spliting strength of concrete
1. Flexural strength of concrete : modulus of rupture of concrete

standard size of mould 70 cm x 15 cm x 15 cm
cube size 50cm x 10 cm x 10 cm
Concrete flexural tensile strength 3rd Point loading
IS concrete flexural strength
Flexural Strength of Concrete Fcr= 0.70 ck or 0.70 fck
Note: Direct tensile strength flexural tensile
Ratio:
Direct Tensile
0.50
Flexural Tensile Strength
Flexural Tensile Strength
2.0
Direct Tensile
Spilit Strength of concrete test esa concrete speciman CTM Machine
method large scale concrere tensile stregnth
result accurate spilit tensile strength test
direct tensile strength compare 5-12% High result
Flexural tensile strength > Spilit tensile strength > Direct Tensile Strength

Fcr> Fcs>Fct
Note: Resultant tensile strength direction force perpendicular
Bond Strength :Concrere bond strenght steel or concrete friction or adhession

or
concrete hight flexural tensile strength or high impact stregnth smaller size
crush aggregate
Unit
Admixtures
Concretre properties improve admixtures
classify
1. Plasticizers 2. Super Plasticizers 3. Retarder
4. Accleators 4. Air Entering Admixtures
1. Plasticizwers -Concrete concrete work ability improve

concrete use 5-15% reduce
concrete strength increase
Concrete plasticizer cement weight to 0.4% mix
example-Modifed ligno sulpohate (MLS), Sul;phonated nepthaline Formal dehyded (SNF)
2. Supper plasticizer : Advance plasticizer
concrete working improve concrete Use
15-30% reduce

Eg:- Modified lignosulphonate, sulphonated nepthalene, formaldehydrade (SNF)
3. Retarder:- Concrete setting time extend Prolonging of setting time
admixtures retarder concrete admixtures retarder
(i) Calicum sulphate (CaSO4) (ii) Gypsum (CaSO4.2H2O)

(iii) Starches (iv) Cellulose
(v) Acid and Salts (vi) Sugar
- sugar effective retarder concrete
concrete ultimate strength setting
time extend sugar
concrete ultimate strength setting time extend
Accleators : Concrete setting time decrease admixture
accleators concrete calcium chloride (CaCl2) Admixture
cement concrete weight of cement
Air entering Agnets: Concrete arientering agents concrete workability increasing

concrete air entering agents concrete freezing and thawing
against safe concrete concrete strength redue
Function of Air Entering Agent:

1. Better Workability
2. Better resistance against freesing and thawing
3. Reduce the strength of concrete at all stages
4. Reduce segrigation of concrete
5. Reduce Bleeding of concrete
6. Reduce the unit weight of concrete
7. Reduce the permability of concrete
8. Reduce the Alkalies Aggregate recation
Unit
Pre-Stress Concrete
- concrete stress develop pre-stress concrete

Pre-stress concrete heavy load or larger span
Tendon : Pre-stress concrete carry steel bar or wire group
system tendon
Cable:Pre-stress concrete tendon cable

- Pre-stress concrete High grade of steel or high grade of concrete
- Pre-stress concrete High grade of steel use shrinkage or creep reduce
Pre-stress concrete steel ultimate stress 1500 N/mm2 (Yield stress =0.6x1500=900-
1000 N/mm2) steel
Method or system of Pre-stress

Concrete pre-stress develop system
1. Pre-tension Method
2. Post-Tension Method
1. Pre-Tension Method: Pre stressing method concreting steel bars

tension develop pre tension method
method pre stressing min grade of concrete M-40
Minimum Nominal concrete cover 20 mm
Pre-tension method concrete Pre-stress develop
1. Unit Mould Method 2. Long line Method
1. Unit mould method member pre-stress develop

Long line method member pre-stress develop
factory production Long line method preffered
2. Post-tension Method: Pre-stressing method concreting
reinforcement stress develop post tension method
Post-tension method pre-stressing Min.Grade of concrete M-30
minimum nominal concrete cover 30mm
Post Tension method: Pre-stress develop
(i) Fressinet Method
(ii) Megnal Balton Method
(iii) Lee-McCall Method
pre-tension method pre-stressing member strength or durability
larger span Method uneconomical larger span case post-
tension method
Losses In Pre-Stress Concrete:
Concrete Pre-stress loss in pre-stress concrete
Pre-stress concrete Losses mainly Classify

Losses In Pre-Stress Concrete
Immidiate Losses Time depended losses
Elastic shorting Friction Ancharge Loss due Loss due to Loss due to
of concrete losses slip losses to creep shrinkage steel relaxation
- Loss due to elastic shorting of conc. pre tension method develop

- Loss due to friction post-tension method develop
- Pre tension method total losses 20%
- Post tension method total losses 15%
- Pre-tension method post-tension method compare 5% Loss
- Pre-stress concrete steel relexation 2-8% losses
- Shrinkage strain in Pre-tension method =0.0003

2 10 4
- Shrinkage strain in Post-tension method =
log10 t 2
- Where t=represent age of concrete


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Little Birds School, Sanjay Nagar, Front of Railway Station, Alwar

Water - Property mixing (Toimpouove the quality of concrete)

Historical development of OPC -

Manfactur Process of Oridinary Portland Cement : -

(i) Dry Process

(ii) Wet process: Wet process raw materials weight 35-

Manufacturing Of OPC by Wet Process

OPC Raw-matrials Calcureous matrial (lime stone chalk), Argillaceous

S.NO. OXIDE PERCENTAGE FOR GOOD

Study Material & Online Exams Facility available on web App.

S.No. Compund Approximate Qty

Le - Chetelia or Thornebohm Clincker Observation properties

C3S - Alite C3A - Celite

C3A :- (Tricalcium Aluminate) :

S.No. Compound Heat of Hydration(Cal/gram)

Heat of Hydration Stage C3A

C4AF (Tetra Calcium Alminate Ferrite) (4Cao.Fe2O3.Al2O3) :-

Study Material & Online Exams Facility available on web App.

Rate of Hydration C4AF Rate of Hydration C2S

C2S (Di-Calcium Silicate) :-

(iv) Cemical Attacks Against (More resistance against

Strength C3S Strength C4AF

Study Material & Online Exams Facility available on web App.

Strength setting time of cement lime content

Cement oxide Unburnt lime (free lime) or Magnesia

10000c Temperature Heated Loss of Weight due to igniation

Insoluble or Residual Matter in cement :-

Note :- Lime Original Volume 2.3 time expand

Water Requirement for Hydration of cement compound :-

Ordinary Portland Cement (O.P.C.) 43 grade - IS-8112

Types of OPC Compressive Strength at

Grade Fineness or 28 days Stength represent

Repid Harding cement (R.H.C.) Stage Strength OPC compare (Higher)

R.H.C Strength O.P.C. Strength

Initial setting time of Rapid Hardning cement - Greater than 30 minutes

Study Material & Online Exams Facility available on web App.

3. Quick setting cement :-

4. Low Heat Cement :-

L.H.C. Strength OPC Strength

Initial setting time of L.H. Cement - More than 60 Minutes

5. Sulphate Resisting Cement :-

Sulphate resisting Cement Conditions

Study Material & Online Exams Facility available on web App.

6. Super Suphate Resesting Cement :- Slage + 10-15%

Coloured Cement :- Coloured Pigment

White Cement :- White Cement Pure lime Stone or Chalk

Ex - Birla white, J.K. white Putty.

OPC Clinkers clinker Weight 0.1%

10. Portland Slag Cement :-

11. Extra Rapid Hardening Cement -

Study Material & Online Exams Facility available on web App.

Extra Rapid hardening cement 7 days Strength rapid Hardening compare

High Alumina Cement is used in following conditious -

13. Portland Pozzolona Cement (PPC) :-

Note :- Rapid Hardening cement OPC compare 10% More costly.

Study Material & Online Exams Facility available on web App.

2. Laboratry Test -Following test are done in laboratry

Sample mould size -

Study Material & Online Exams Facility available on web App.

Standard consistance obtained - 30% water of the weight of cement.

(b) Setting Time Test - Setting time Clasified

inital or final setting time vicket apparatus use

Initail setting time - Paste apparatus penetration 1 mm square size

S.No. VeeBee Value W orkability P lasticity

Degree of Plasticity Slump Value in Compacting VeeBee