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UNIT I
CONCRETE TECHNOLOGY
Content
CONCRETE : Definition
Quality of concrete
Application
Concrete Chemicals
Cement
In 1824, Joseph Aspdin, a bricklayer and mason in Leeds, England,
took out a patent on a hydrauliccementthat hecalled portland
cementbecause its color resembled the stone quarried on the
Isle ofPortlandoff the British coast.
Definition
PERCENT
Lime
62
Silica
22
Alumina
Calcium Sulphate
Iron Oxide
Magnesia
Sulphur
Alkalies
Usually cement attains about 70% of its final strength in 28 days and about
90% of its final strength in one year or so.
Calcareous
material
Dry
process
Argillaceous
material
crushing
crushing
Fine
grinding
Fine
grinding
storage
storage
Mixing in correct
proportion
Coal
dust
Formation of clinkers
cooler
Grinding of clinkers in
ball mills and tube
mills
Storage in silos
Weighing &packing in
bags
distribution
gypsu
m
Wet
process
Calcareous
material
limestone
Argillaceous
material
clay
crushing
crushing
storage
storage
channel
Grinding mill
Formation of slurry
Correcting basin
Storage tank
pumping
Coal dust
Rotary kiln
Formation of
clinkers
cooler
Grinding of clinkers in ball
mills
Storage in silos
Weighing and packing in
bags
distribution
gypsum
Burning
It is supported on rollers.
Slurry is injected at upper end and it descends to burning zone carbondioxide gets evaporated and forms nodules.
Rotary kiln
from storage tank
slurry dust nodules
rotary arrangement
coal
dust
burning
zone
refactoy
lining
air
Support
cooler
clinkers
Grinding
Properties of cement
It is an excellent binding material.
Gives strength to masonry.
Possesses a good plasticity.
Offers a good resistance to moisture.
Easily workable.
It hardens quickly after addition of water.
The colour of cement should be uniform.
Cement should be free from lumps.
Cement should feel smooth when touched or rubbed in
between fingers.
Uses of cement
It is used for constructing engineering structures such as
dams, bridges, storage reservoirs.
Used for making joints for pipes, drains.
Used for preparation of foundations, footpath.
Used for manufacture of precast pipes, fencing posts.
Used for masonry work, plastering, pointing.
Used for laying floors, roofs and constructing lintels.
Used for protecting the structures from weather.
Types of cement
Quick setting cement
Low heat cement
High alumina cement
Expanding cement
Rapid hardening cement
Acid resistant cement
Sulphate resisting cement
White cement
Coloured cement
Testing of cement
Testing of cement can be brought under two categories:
Field testing
Laboratory testing
Strength test:
Compressive strength is most important.
The standard sand is used for finding the strength of cement.
Fineness test
Fineness of cement is important bearing on the rate of
hydration and on rate of gain of strength.
Finer cement offers a greater surface area and hence faster
and greater the development of strength.
Fineness of cement is tested in two ways:
By sieving.
By determination of specific surface by air- permeability.
Concrete
Definition
Concrete may be defined as a building material obtained by mixing
cement, fine, coarse aggregates and water in suitable proportions.
It is plastic mixture after curing it becomes hard mass.
The coarse aggregates are broken stone, broken bricks or gravel, the fine
aggregate is sand or surki and the binding material is lime or cement.
Fresh concrete or plastic is a freshly mixed material which can be
moulded into any shape.
The relative quantities of cement, aggregates and water together control
the properties in the wet state as well as in the hardened state.
Constituents of Concrete
Cement
Fine aggregate and Coarse aggregate
Water
Advantages of Concrete
It is plastic when freshly prepared and can be moulded to any
shape.
Concrete does not lose its strength with age and does not
require maintenance.
The proportion of mix can be suitable designed to give concrete
of required strength.
It is durable and not affected by weather.
It affords quickness and ease of a construction.
It can be given various finishes.
Concrete is water repellent and can be made water proof.
Concrete can be made fire proof or light weight or chemical
resistant by using suitable admixtures.
Properties of Concrete
Concrete has high compressive strength depends on the
proportion of cement, sand, coarse aggregates and water used.
It hardens with age and process of hardening continuous for
long time even after it has attained sufficient strength, but the
rate of hardening decreases with age.
It is free from corrosion and atmospheric effects.
It is weak in tension. Steel reinforcement is placed in cement
concrete at suitable places to take up the tensile stresses called
as RCC.
It shrinks in the initial stage and during hardening. This can be
minimized by proper curing.
Workability
The property of freshly mixed concrete which determines the ease and
homogenous with which it can be mixed, placed, compacted and finished
Water content
Mix proportion
Aggregate/cement
ratio
is
an
important
factor
influences
workability.
Higher the aggregate/cement ratio, leaner is the concrete.
Size of aggregate
Bigger the size of the aggregate, less is the surface area and less is
the amount of water.
It will give better workability.
Shape of aggregate
The shape of aggregate influences workability.
Angular, elongated or flaky aggregate makes the concrete harsh
when compared with rounded aggregates.
Surface texture
The total surface area of rough textured aggregate is more than the
surface area of smooth rounded aggregate of same volume.
Grading of aggregate
It influences maximum workability.
Better the grading, less the void content and higher the workability.
Use of aggregate
Use of air-entraining and pozzolanic material gives better
workability.
Measurement of workability
The following tests are commonly employed to measure workability:
Slump test K Slumper
Compacting factor test - Compacting factor apparatus
Flow test Flow table
Kelly ball test Kelly ball
Vee bee consistometer test- VBR
Segregation : Separation of the constituent materials of concrete
Bleeding : Water from the concrete comes out of the surface of the
concrete
Water Cement ratio : Ratio of weight of water used to that of cement.
It depends upon strength, workability and method of compaction
Process of manufacture of
concrete
The various stages of manufacture of
concrete are:
Batching
Mixing
Transporting
Placing
Compacting
Curing
Finishing
Batching
Mixing
Mixing of materials is essential for the production of
uniform concrete.
There are two methods for mixing concrete:
Hand mixing
Machine mixing.
Transporting concrete
Concrete can be transporting by a variety of methods and
equipments.
Mortar pan
Wheel barrow, Hand cart
Bucket and Rope way
Truck mixer and Dumpers
Belt conveyors
Chute
Skip and Hoist
Pumps and Pipeline
Placing concrete
Placing concrete within earth mould.
e.g.: foundation concrete for a wall or column.
Placing concrete within large earth mould or timber plank
formwork.
e.g.: road slab and airfield slab.
Placing concrete in layers within timber or steel shutters.
e.g.: mass concrete in dam construction or construction of
concrete abutment or pier.
Placing concrete within usual from work.
e.g.: columns, beams and floors.
Placing concrete under water.
Compaction of concrete
Compaction of concrete is the process adopted for expelling the
entrapped air from the concrete.
Hand compaction:
Rodding
Ramming
Tamping.
Compaction by vibration
Internal vibrator (needle vibrator)
Formwork vibrator (external vibrator)
Table vibrator
Platform vibrator
Surface vibrator (screed vibrator).
Compaction by pressure and jolting
Compaction by spinning.
Curing of concrete
Curing is the process of maintaining a satisfactorily moisture
Water curing
Water curing can be done in the following:
Immersion
Ponding
Spraying
Wet covering
Membrane curing
Bituminous compounds
Polyethylene
Waterproof paper
Rubber.
Application of heat
The exposure of concrete to higher temperature can be
done in the following manner:
Steam curing at ordinary pressure
Steam curing at high pressure
Curing by infra-red radiation
Electrical curing.
Cement Silo
Mixer Tanker
Batch Plant
Batch Plant
Uses:
It is used for estimating the compressive strength.
Establishing the uniformity of concrete.
Assessing the quality of one element of concrete in relation to
another.
Limitations:
Results are affected by the angle of test, surface smoothness, and
mix proportion.
It is only suitable for close-textured concrete.
Rebound hammer
concrete impact spring
compression spring
plunger
housing
surface
hammer
mass
Types of concrete
Normal
density
Air-entraining
Polymer concrete composites
Ferro cement
Light weight
Recycled
Heavy weight
No slump
Super plasticized
No fine
Coloured
Vacuum
Pumped
Spinned
Hot
FRC
Composite material consisting of mixture of cement mortar
and discontinuous discrete, uniformly dispersed suitable fibres.
Types:
a)
b)
c)
d)
Quality of concrete
Good workability
No segregation
No bleeding
High strength
Durability
Impermeability
Elasticity
Shrinkage
Least thermal expansion.
Advantages of concrete
Availability of concrete is easy.
Easy handling.
Easy transportation.
More economical.
Monolithic character gives better appearance.
Disadvantages of concrete
Expansion joints are required.
Construction joints are provided to avoid cracks.
Sustain loads develops creep in structure.
Due to low tensile strength, concrete is required to be
reinforced to avoid cracks.
Soluble salts in concrete cause efflorescence of moisture reacts
Concrete chemicals
They are used in cement as an additive, in mortar and
concrete as admixtures.
Such additives and admixtures is called as concrete
chemicals or construction chemicals.
It includes the following materials:
Plasticizers and super plasticizers.
Retarding plasticizers and retarders.
Accelerating plasticizers and accelerators.
Air-entraining agent.
Water proofing material.
Polymer bonding agents.
Queries:
Two marks:
What is cement and list out its chemical composition?
What are the process of cement manufacturing?
What are the methods of testing in cement?
What is meant by workability?
What is concrete and explain mix proportion of concrete?
What are the testing methods involved in fresh concrete and
hardened concrete?
What are the qualities of concrete?
Describe the advantage of concrete?
Describe the disadvantages of concrete?
What Is meant by concrete chemicals?
16 marks:
Describe the manufacturing of cement(dry and wet process)?
What are the different types of cement? explain their
properties and uses?
Describe the field testing and laboratory testing method in
cement?
Explain in detail the process of concrete manufacturing?
Explain the method of non-destructive testing in detail?
What tests are used to determine the workability of fresh
concrete? explain in detail:
What are the different types of concrete? explain their
properties and uses?
Explain the various types of concrete chemicals in detail?
THANK YOU