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Unit 06 - Concrete I

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0% found this document useful (0 votes)
20 views64 pages

Unit 06 - Concrete I

Uploaded by

Dhanusha Rukshan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Concrete as a construction material

Samantha Manawadu
Outline
• Introduction
• Reasons for popularity
• Ingredients of Concrete
• Mixing of Concrete
• Placing and compacting
• Curing
• Sampling and compliance criteria
Introduction
• Concrete is the universal material in
construction
• According to the world business council for
sustainable development concrete is, after
water, most widely used material on Earth
• Romans were the inventors of Concrete
• But the knowledge is lost with the fall of
empire and regained by English people in
latter of 18 th Century
Introduction Cont.
• Reinforced concrete, which the steel bars are
embedded to resist the tensile forces was
developed in 1850
Reasons for popularity
1. Raw ingredients for manufacture are readily
available in almost every part of the world
2. Concrete can be made in to buildings from
tools ranging from primitive shovel to
computerized plant
3. Does not rot or burn
4. Relatively cost is low
Reasons for popularity Cont.
5. Can be used for every building purpose from
lowly pavings to sturdy structural frames and
finishes also
6. Since no form it’s own possible to get any
form
7. Compressive strength is very high
8. Permeability is very low
Ingredients of Concrete
• Concrete is a mixture of cement + fine aggregate
+ coarse aggregate + water in control proportion
and of a suitable quality
• Cement – Types of cement and their standards
• Water – Quality of water
• Coarse Aggregate
These are crushed stone that is mainly retained
on a 5mm BS 410 test sieve. It shall be clean,
sharp, undecomposed gneiss or other approved
metamorphic or igneous rock having clean, hard,
dense and durable fragments
Ingredients of Concrete Cont.
• Shape, Surface texture and grading(Distribution of
particle size) are factors which influence the
workability and strength
• Fine Aggregate
That is mainly passing a 5mm BS 410 test sieve
Natural Sand – Obtained from the natural
disintegration of rock, from river or pit sand free of
earth
Crushed Stone Sand – Use of this is permitted only
for designed mixes and this is manufactured from
hard tough uncoated rock
Ingredients of Concrete Cont.
• Off shore sand
This can be used in construction work subjected to
1. Compliance with requirements of BS 882
2. The chloride iron content should less than .02%
3. Allowable shell size less than 5mm
4. Sand should be procured from a stock pile
maintained by a responsible organization which
has an acceptable quality assurance
5. Sand extract from the beach or from river
mouth should not be used
Ingredients of Concrete Cont.
Photograph of a cross
section of a polished
concrete, showing a
close packing of fine
and coarse aggregate
and complete coating of
every particle with
cement paste
Mix Design
• Combination of materials to provide the most
economical mixture to meet the performance
characteristics suitable for the application
• Developed in laboratory - produced in a batch plant
• Mix proportions will typically vary over a range for a
given job
– Required strength and exposure conditions
• Mix consistency must be ensured to guarantee
concrete performance
Mixing of Concrete

concreting

In-situ Ready mix


concrete concrete

Machine Hand
mixing mixing
In-situ Concrete
Proportioning by volume
• Generally fine and coarse aggregates are measured
by volume
• Special box is used here which has volume of
.035m3 and corresponds to the volume of 1 bag of
cement weighing 50 kg. the dimensions are 400 x
300 x 250mm or 12” x 12” x 15”. If cement is also
measured by gauge dimensions of it’s should be 400
x 350 x 290mm. This is account for bulking.
• While measuring the aggregate shaking, ramming or
heaping shall not be done
Mixing proportions by volume
In-situ concrete Cont.
Proportioning by weight
• Cement, fine aggregate, coarse aggregate and
water are measured by their weight
• Used in ready mix concrete plants
• Quality controlling is better compared to
proportioning by volume
Machine Mixing
• The mixer drum should
be free from hardened
mortar
• The drum should be
primed by washing with
rich cement grout
before mixing
commence
• First dry coarse
aggregate are placed in
hopper
Machine Mixing
• Then fine aggregate and cement are added
• Then skip is raised dry materials are slipped in
to drum
• The dry materials are mixed at least four turns
of drum
• Then the correct quantity of water is added
gradually while the drum is in motion to
ensure the even distribution
• The total quantity of water is added before
25% mixing time is elapsed and is regulated to
achieve specified water cement ratio
Machine Mixing Cont.
• Materials should be mixed for a period of not
less than 2 minutes until a uniform colour and
consistency are obtained. The time is count
once after all materials are put in to drum
• The complete contents of the mixer is emptied
before recharged
• When the mixer is closed down for a period of
more than 20 minutes it is flushed and clean
Hand Mixing
• This is done on a smooth, clean and water
tight plat form of suitable size
• First measured quantity of sand and cement
are mixed intimately with shovels until it
becomes even in colour throughout and
spread
• Then measured quantity of coarse aggregate
is spread out
Hand Mixing Cont.
This is mixed three times dry, by shoveling and
turning over from center to side then back to the
center and again to sides
•A depression is made middle pile to receive water
•This is mixed at least three times until get a
uniform colour and consistency
•The mixing platform is washed at the end of the
day
Ready Mix Concrete
Transported from trucks
Which have capacities of
2, 4, 5, 6 cubic meters
The grade of the concrete
and slump should be
informed to plant
Once receive the
concrete it is important
to check the dispatch
note thoroughly
Quality test in site
• Check Slump
• Cast test cubes as per
the specification

Collapse Slump
True Slump Shear Slump
Placing of concrete
• All concrete conveyors, barrows and chutes
even pump car lines are primed by washing
with rich cement grout
• These should be cleaned immediately after
stopping concrete
• Records shall be kept of the time and date of
all concrete pours
• Check Lists
Placing of concrete Cont.
• Concrete should be poured in such a manner
to avoid the segregation
• Maximum falling height 1.5m
• Chutes are also used in deep trenches and
footings
• Cold joints should not be formed
• In concreting of slab and beams, it is
necessary to prepare a plan of layout to pour
concrete
Compaction of concrete
• Concrete is compacted in to a dense mass
immediately after placing
• Compaction should be completed before the
initial setting starts
• Manual Compaction is done by wooden bars
or rods. But it is suitable for small scale jobs
• Otherwise mechanical vibrators are used
Compaction Equipments
Not ….this
this….
Construction Joints
Columns
• Joints should be horizontal and located 100 to
150mm below the bottom of beam running in to
column.
• Portion above the joint is concreted with beam
• If kicker is used it should be at least 70mm high
• Better to prepare the joint to provide maximum
bond with new concrete
Construction Joints Cont.
Slabs and beams
The concreting should be carried out continuously
up to construction joints which is decided by in
advance by the Design Engineer
These are kept to minimum and located taking in to
account bending moment, shear forces and other
stresses
The surface of joint should be free from laitance and
roughened to the extent that the largest aggregate
exposed but not disturbed
Construction Joints Cont.
• A coat of neat cement slurry or suitable
chemical is applied on the roughened joint
prior to pour the fresh concrete
• If the concrete has to stopped due to
unavoidable reasons following methods
should be followed
• It should stop in a distance of 1/3 of span from
the support
Curing
• Curing is the process in which the concrete is
protected from loss of moisture and kept within a
reasonable temperature range.
• The result of this process is increased strength
and decreased permeability.
• Curing is also a key player in mitigating cracks in
the concrete, which severely impacts durability
• Curing should be done a minimum period of 7
days
Curing methods
Slabs and beams
• Under side of the slab and beams are
protected by the form work. How ever top
surface should be protected
• After concrete has begun to harden about 1-2
hours after it’s laying, better to protect from
quick drying with moist gunny bags
• After 24 hours of laying surface shall be cured
by flooding with water minimum 25mm depth
Curing Cont.
Curing Cont.
• Spraying of a curing compound good method
that seals the concrete surface against loss of
moisture
• Concreting in hot and windy weather should be
avoided as much as possible
• Temporary wind breaks and shades may have to
provide where necessary
• Frequent spray of water with a water jet may be
needed until the slab is hard enough to be
covered
Curing Cont.
Columns
The form work should be kept as long as
possible
Then cover with gunny bags. It should be
wetted frequently
Test cubes are generally cured in a tank with
fully immersed in water
Curing Cont.
Curing Cont.
Sampling and compliance criteria
• Sampling and testing shall be as per BS 1881
• The characteristic strength of the concrete on the
structural design is based is that 28 day cube
strength below which not more than 5 % of the
test results may be expected to fall
• Compliance is judged by tests made on cubes at
an age of 28 days. In order to get an idea of the
quality of concrete soon perhaps to before
removing of form work 7 days and 14 days
strength also used
Sampling and Compliance Cont.
• 7 days strength should be more than 75% of te
28 days strength
Sampling procedure
One sample shall be taken from average
volume of not more than 20 cubic meters, 20
batches or ¼ of the total quantity of concrete
under consideration for testing which ever is
the lesser
Sampling and Compliance Cont.
Testing plan and compliance criteria
Test specimens are cured for testing period
Two test specimens from a sample shall form a
single result
The first result alone can not be used. It is based
on groups of four consecutive test results
Compliance with the specified characteristic
strength may be assumed if the average strength
determined by any group of four consecutive test
results and if each individual test results complies
with the appropriate limits in columns A and B
Sampling and Compliance Cont.
• When there are less than four results i.e on
small jobs, the average of the first 2 or first 3
results , and the individual results should
comply with limits in column A and B
• For a result to be valid, the difference
between the strengths of two specimens
prepared from same sample shall not exceed
the 15% of mean strength
Sampling and Compliance Cont.
Sampling and Compliance Cont.
If the work is in minor nature or when the total
volume is small this alternative scheme can be
used
(a) The average value of 3 cubes made from
same sample shall equal or exceed the
Characteristic strength
(b) The lowest strength of any cube shall not
lower than .85 of characteristic strength
(c) The allowable range (maximum minus
minimum value) of the strength of 3 cubes
made from the same sample shall not exceed
20% of the average value of 3 cubes
Properties:
• Concrete has relatively high compressive strength, but
significantly lower tensile strength, and as such is usually
reinforced with materials that are strong in tension (often
steel).
• The elasticity of concrete is relatively constant at low stress
levels but starts decreasing at higher stress levels as matrix
cracking develops.
• Concrete has a very low coefficient of thermal expansion, and
as it matures concrete shrinks.
• All concrete structures will crack to some extent, due to
shrinkage and tension.
• Concrete can be damaged by fire, aggregate expansion, sea
water effects, bacterial corrosion, leaching, physical damage
and chemical damage (from carbonation, chlorides, sulfates
and distillate water).
Properties of Quality Concrete
• Workability
• Durability
• Strength
• Chloride Penetration Resistance
• Abrasion Resistance
Workability
 The function of water is also to lubricate the concrete so that the
concrete can be compacted with specified effort forthcoming at the
site of work.

 The lubrication required for handling concrete without segregation,


for placing without loss of homogeneity, for compacting with the
amount of efforts forth-coming and to finish it sufficiently easily, the
presence of a certain quantity of water is of vital importance.

 Workability is the ability of a fresh (plastic) concrete mix to fill the


form/mold properly with the desired work (vibration) and without
reducing the concrete's quality.
Workability depends on
water content, aggregate
(shape and size distribution),
cementitious content and
age (level of hydration) and
can be modified by adding
chemical admixtures, like
superplasticizer
Factors Affecting for Workability

a) Water Content
b) Mix Proportions
c) Size of Aggregates
d) Shape of Aggregates
e) Surface Texture of Aggregate
f) Grading of Aggregate
g) Use of Admixtures.
Water-to-Cement Ratio
 More the water cement ratio more will be workability of concrete.
Since by simply adding water the inter particle lubrication is
increased.
 High water content results in a higher fluidity and greater
workability. Increased water content also results in bleeding.
another effect of increased water content can also be that cement
slurry will escape through joints of formwork.
 More water can be added, provided a correspondingly higher
quantity of cement is also added to keep the water/cement ratio
constant, so that the strength remains the same.
Mix Proportions
 The higher the aggregate/cement ratio, less quantity of paste is
available for providing lubrication, per unit surface area of
aggregate and hence the mobility of aggregate is restrained.
 On the other hand, in case of rich concrete with lower
aggregate/cement ratio, more paste is available to make the mix
cohesive and fatty to give better workability
Size of Aggregate & Surface Texture
 The bigger the size of the aggregate, the less is the
surface area and hence less amount of water is
required for wetting the surface and less matrix or
paste is required for lubricating the surface to reduce
internal friction.

 Greater size of Aggregate- less water is required to


lubricate it, the extra water is available for workability

 Porous aggregates require more water compared to


non absorbent aggregates for achieving same degree
of workability
Grading of Aggregates
 A well graded aggregate is the one which has least amount of voids in a
given volume and higher the workability.
 Other factors being constant, when the total voids are less, excess paste is
available to give better lubricating effect.
 With excess amount of paste, the mixture becomes cohesive and fatty
which prevents segregation of particles.
Weather Conditions

 If temperature is high, evaporation increases, thus


workability decreases.

 If wind is moving with greater velocity, the rate of


evaporation also increase reduces the amount of
water and ultimately reducing workability
Specifying concrete

Details of the concrete mix needed to meet the end-user


requirements are specified in the form of one of the
following types of mix.

 Designed mix
 Prescribed mix
 Standard mix
 Designated mix
Designed mix – Concrete is specified to an expected performance. The
criteria can include characteristic strength, durability and workability
to which a concrete manufacturer will design and supply an
appropriate mix. All grades are permitted.

Prescribed mix – This is a recipe of constituents with their properties


and quantities used to manufacture the concrete. The specifier must
state,
 type of cement
 type of aggregate and their maximum size
 mix proportions by weight
 degree of workability (slump and/or water/cement ratio)

Prescribed mixes are based on established data indicating conformity


to strength, durability and other characteristics.
ex: 1:3:6/40mm aggregate and 1:2:4/20 mm aggregate
Standard mix – BS guidelines provide this for minor works or
situations limited by available materials and manufacturing
data. Limited to strength characteristics of 7.5 to 25 N/mm2.
Mix proportions and details are specified by;

 cement to aggregate by weight


 type of cement
 aggregate type & maximum size
 workability
 use or omission of reinforcement

These mixes are most suited to site production, where the


scale of operations is relatively small. They may be used
where mix design procedures would be too time consuming,
inappropriate or uneconomical.
Designated mix - These mixes are selected for specific applications and
site conditions. Grading and strength characteristics are extensive, and
vary with application as indicated.

 General – ranging from 7.5 to 25 N/mm2 characteristic strength. for


foundations, floors and external works
 Foundations – with characteristic strength of 35N/mm2. Appropriate
for resisting the effects of sulphate in the ground.
 Paving - with characteristic strength of 35 or 45N/mm2. A strong
concrete for use in driveways & heavy-duty paving
 Reinforced concrete & pre-stressed concrete graded 30, 35, 40, 45
and 50N/mm2 characteristic strength and exposures ranging from
mild to most severe
Home Work

Find out factors and features related to following


concrete properties

• Durability
• Strength
• Chloride Penetration Resistance
• Abrasion Resistance

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