1. Seminar by : Arivusudar NagarajanSeminar by : Arivusudar Nagarajan
2. 2
CEMENT REPLACEMENT
MATERIALS
FLY ASH
It is finely divided residue resulting from the combustion
of powdered coal and transported by the flue gases and
collected by electrostatic precipitator ( Thermal Power
plants)
Mostly used pozzolonic material
Reference IS-3812
Contd…
3. 3
Savings in cement
Reducing heat of hydration
Reducing water demand
Spherical shape and smooth surface of flyash helps to
reduce the inter-particle friction and thus facilitates
mobility.
Reduce Bleeding and drying shrinkage.
Fly ash particles plasticize cement paste and improves
flowability and rheology of the mix.
Contributes to strength
Contd…
ADVANTAGES OF FLY ASH
4. 4
CEMENT
+ C-S-H Gel + Ca(OH)2
WATER
FLYASH C-S-H Gel
SECONDARY HYDRATION OF FLY
ASH
10. 10
By-product from steel Industries.
Specific surface of about 400-600 m2
/kg
Higher cement replacement levels upto 70%
Glass content 85% (Min)
Blended with cement
Secondary hydration
Slag (GGBS)
11. 11
Reduces water demand
Water can be reduced based on slag content and fineness
of slag
Reduces bleeding
Water retention
Improves workability
Increases Pumpability
Effect of GGBS on Fresh Concrete
12. 12
Reduces heat of hydration
Improves the pore structure
Reduces permeability
Improves resistance to corrosion of reinforcement
Increased resistance to chemical attack
Higher ultimate strength
Saving cement in concrete mix
Effect of GGBS on Hardened
Concrete
13. 13
Condensed Silica Fume is a by product of ferro-Silicon
alloy industry and it is the dust which is collected from
furnace exhaust system
Fineness of silica fume is @ 15000 m2
/kg as against 280 to
290 m2
/kg of Cement
Contributes significantly to compressive strength due to
micro-filler effect and excellent pozzolanic properties
Leads to increase in density and reduction of permeability
in concrete
It’s use is must for manufacturing of concrete above M50
Contd…
SILICA FUME (Micro Silica)
15. 15
Admixtures are materials mostly chemicals that are added in small
quantities during the preparation of concrete to impart certain specific
properties to it.
The requirements may be
Improving the workability of concrete during placing
Retarding or accelerating setting
Improving the impermeability and water tightness of the cast
concrete.
Imparting corrosion inhibition etc
Entraining air in concrete
Chemical Admixtures
24. 1. Air entrainers :
TYPES OF ADMIXTURES
They entrain air in the form of micro air bubbles which
helps in improving the durability of concrete in freezing
environment, sulphate and alkali attack.
2. Water reducers
To reduce the water-cement ratio and yet retain
workability. It is possible to reduce water upto 12%.
The only precaution is that it should be mixed thoroughly
25. 3. Accelerating admixtures :
To accelerate setting of cement in
cold environment or where early setting is desired.
It assists in early removal of form work
4. Retarding admixtures :
To delay the setting time of concrete, for RMC supplied
to far off sites.
Prolongs setting time, giving higher strength at later
stages, also results in reduction in micro cracks.
26. 5. Super plasticisers :
To make flowing concrete for concreting in
heavily reinforced sections, tremie concrete, for
pumping concrete.
(when added to normal concrete with 75mm slump
upto 250mm can be achieved)
6. High range water reducers :
PC based admixtures
Water reduction capacity of about 25-40%
High performance
Early strength and early setting
27. 7. Bonding agents :
To increase bond strength,
old and new concrete(in repair and rehabilitation works),
they are usually modified latex or polymer compounds
8. Corrosion inhibitors :
To inhibit corrosion
28. Aggregate is the word used to describe any inert material .
Usually rock derivative generally between 50mm down to 75 micron
used to produce concrete .
It is divided into coarse aggregate and fine aggregate
Those which are 4.75mm to 50mm are classified as coarse aggregates
Those below 4.75mm to 75 micron as fine aggregates
Except for mass concrete in dams etc. which may contain upto 150mm
size aggregate, the maximum size of aggregate is normally 20mm in
most cases
But it may be 40mm for plain concrete or massive works.
28
AGGREGATES
29. 29
Specific gravity: it should have good crushing strength
and density
Surface texture: it should be smooth,slightly rough but
not honeycombed
Particle shape : it should not be flaky or elongated.
Porosity : it should have very low water absorption
Should not be Reactive
PROPERTIES OF COARSE
AGGREGATES
30. Water demand,
Workability
Cohesion of concrete in plastic state
Strength,
Density,
Durability
Porosity of hardened concrete
Stability : it should be chemically inert.
Impurities: it should be free from impurities (like silt,
clay)
Compactness: it should be graded, as then only the
voids can be less.
30
PROPERTIES OF AGGREGATE
EFFECT
31. Specific gravity implies the absolute weight per unit volume
of aggregates
A low specific gravity may indicate
high porosity
poor durability
low strength.
Specific gravity of aggregates is used in arriving at mix
design
Generally the specific gravity of good aggregates is greater
than 2.5 g/cm3
31
SPECIFIC GRAVITY
32. Surface texture reveals how grainy or smooth the surface
of the aggregate is.
It indicates bonding strength and porosity.
Higher the smoothness of the particle, lesser is the
bonding between aggregate and cement matrix.
rough textured aggregates develop higher bond strength
than smooth textured aggregates,
This property is especially considered while producing
high strength concretes.
32
SURFACE TEXTURE
33. Particle shapes are classified as
Irregular
Rounded
Flaky
Angular
Aggregates should be as much cubical as possible in
shape
33
PARTICLE SHAPE
34. Grading of aggregates means particle size
distribution of the aggregates.
Principle of grading is that smaller size particles
fill up the voids left in larger size particles.
34
GRADING
35. IS sieve
Designatio
n
Percentage passing for single size aggregate of nominal size by
weight
63 mm 40mm 20 mm 16 mm 12.5 mm 10 mm Remarks
80 mm 100 - - -
63 mm 85-100 100 - -
40 mm 0-30 85-100 100 -
20 mm 0-5 0-20 85-100 100
16 mm - - 85-100 100
12.5 mm - - - 85-100 100
10 mm 0-5 0-5 0-20 0-30 0-45 85-100
4.75 mm 0-5 0-5 0-10 0-20
2.26 mm - - - 0-5
35
GRADING OF COARSE
AGGREGATE
36. Indian standards divides the sand into four zones
zone-I to zone-IV based on the sieve analysis
Sand falling in zone-I is coarse and that falling in
zone-IV is fine.
Sand falling in zone IV shall not be used for
reinforced concrete work.
Fineness modulus for sand : ranges from 2.2 to 3.2,
higher value indicates coarser grading
36
SAND
37. 37
IS sieve
designation
Percentage passing
Zone-I Zone-II Zone-III Zone-IV
10 mm 100 100 100 100
4.75 mm 90-100 90-100 90-100 90-100
2.36 mm 60-95 75-100 85-100 95-100
1.18 mm 36-70 55-90 75-100 90-100
600 microns 15-34 35-59 60-79 80-100
300 microns 5-20 8-30 12-40 15-50
150 microns 0-10 0-10 0-10 0-15
Remarks Very coarse Coarse Medium Fine
REQUIREMENT OF FINE
AGGREGATES
38. Water helps in dispersing the cement evenly
Quality of water for making concrete and for
curing
Water should be free from salts, oils, acids,
alkalis, sugar and organic materials
pH value shall not be less than 6
Sea water is not suitable for making concrete
38
WATER
39. SL.
No.
Description Tested as per Permissible limit (max) mg/l
1 Organic IS-3025(part-18) 200
2 Inorganic IS-3025(part-18) 3000
3 Sulphates (as SO3)
Sulphates (as SO4)
IS-3025(part-24)
IS-3025(part-24)
400
500
4 Chlorides (as Cl) IS-3025(part-32) 2000 mg/l for concrete not
containing embedded steel
1000 mg/l for RCC work
5 Suspended matter IS-3025(part-17) 2000
39
PERMISSIBLE LIMITS FOR SOLIDS IN
WATER
40. FRESH CONCRETE
Fresh concrete is a freshly mixed material which can
be moulded into any shape.
Workability: is the ease with which fresh concrete
can be mixed, transported, placed and compacted
in the moulds or forms
Apart from water-cement ratio the concrete has to
be compacted well to get the required strength
40
UNDERSTANDING CONCRETE
41. TESTS ON FRESH CONCRETE
WORKABILITY
1. Slump Test
2. Compaction Factor Test
3. Flow Test.
Yield Test
42. 42
It is the science of the deformation and flow of
materials and is concerned with relationships
between stress, strain, rate of strain and time.
The term Rheology deals with the materials
whose flow properties are more complicated
than those of fluids (liquids or gases)
RHEOLOGY OF CONCRETE
43. Factors affecting workability:
Water content
Mix proportions
Size of aggregates
Shape of aggregates
Surface texture of aggregate
Grading of aggregate
Use of admixture
43
44. Segregation:
Segregation can be defined as the separation of the
constituent materials of concrete.
Bleeding:
Sometimes referred as water gain
It’s a particular form of segregation due to
highly wet mix
If water cement ratio is more than 0.7
Badly proportioned and insufficiently mixed
concrete
44
45. BLEEDING
45
While traversing from bottom to top
Bleeding channels responsible for permeability
It may be interrupted by aggregates (flaky)
It may be interrupted by reinforcement
Reduces bond between reinforcement,
aggregate and paste
Remedy— re-vibration, delayed finishing
47. Compaction of concrete is the process
adopted for expelling the entrapped air from
the concrete.
The entrapped air in the form of voids reduces
the strength of concrete.
For every 1% of entrapped air, the strength of
concrete falls about 5% to 6%.
47
COMPACTION
48. Hand compaction
Tamping
Ramming : generally permitted for
unreinforced foundation concrete
RCC should never be rammed
Compaction by vibration: common needle
vibrator dia is 25mm to 40mm
External vibrators
Surface vibrators
48
METHODS OF COMPACTION
Contd…
49. When inserting a needle vibrator, allow it to
penetrate the bottom of the layer as quickly as
possible.
If it is done slowly, the upper part of the
concrete will get compacted and prevent the
air in the bottom layer from escaping.
The vibrator should be left in the concrete for
about 10 sec. and then withdrawn slowly. If it is
withdrawn fast, a hole will be left in the
concrete.
49
PRECAUTIONS
Contd…
50. The vibrator should be inserted again at a
distance of not more than 50 cm from its last
position.
The vibrator should not be allowed to touch
the face of the form work or the reinforcement
to prevent the reinforcement from losing bond
with concrete
Do not stop the vibrator when the needle is in
the concrete.
Do not over vibrate or under vibrate
50
51. 51
The rate of levelling should not be less than
the rate placing of concrete
FINISHING OF CONCRETE
52. 52
Effect ofWater-Cement ratio
Effect of maximum size of aggregate on
strength
Grades of concrete:
Concrete in construction is specified by grade
like M20,M25 etc. Usually increments of five.
M20 means the specified crushing strength is
20 N/mm2
STRENGTH OF CONCRETE
53. 53
CURING
Why Curing ?
To prevent loss of moisture from the Concrete due
to combined effect of hot sun and drying wind
Creation of conditions for promotion of
uninterrupted and progressive hydration of
cement during the period immediately after
placing
Curing does not mean only application of water
HARDENED CONCRETE
54. 54
1. WATER CURING
2. MEMBRANE CURING
3. APPLICATION OF HEAT (Steam Curing)
4. ACCELERATED CURING
CURING METHODS
55. 55
Sampling Criteria
CubeTesting
Acceptance Criteria
Non DestructiveTesting of Concrete
1. Rebound HammerTest
2. Ultra sonic pulse velocity testing
CoreTest
COMPRESSIVE STRENGTH
56. 56
OTHER CONCRETES :
High strength concrete
High performance concrete
Mass Concrete
Light-weight concrete
High-density concrete
No-fines concrete
Roller compacted concrete
Ferrocement
Self compacting concrete.
57. 57
HIGH STRENGTH CONCRETE
CONCRETE GRADE FROM M60 ONWARDS
REGARDED AS HIGH STRENGTH CONCRETE
FOR HIGH STRENGTH CONCRETE DESIGN
STANDARDS GIVEN INTHE CODE IS-456-2000
MAY NOT BE APPLICABLE
THEY HAVETO BE OBTAINED FROM SPECIFIED
LITERATURES OR BY EXPERIMENTAL RESULTS
SPECIAL CONCRETES
58. 58
POSSESSING
1. HIGHWORKABILITY
2. HIGH STRENGTH
3. HIGH DENSITY
4. HIGH DIMENSIONAL STABILITY
5. LOW PERMEABILITY
6. RESISTANCETO CHEMICAL ATTACK
HIGH PERFORMANCE CONCRETE
59. 59
NORMAL CONCRETE
HEAVY SELFWEIGHT
(DENSITY 2200 to 2600 KG/M3
)
LIGHT WEIGHT CONCRETE
DENSITY (300 to 1850 KG/M3
)
LOWTHERMAL CONDUCTIVITY
LIGHT WEIGHT CONCRETE
60. 60
DENSITY 3360TO 3840 KG/M3
EVEN 5280
KG/M3
USING IRON AS BOTH F.A. AND C.A
DENSITY 50% HIGHERTHANTHE
CONVENTIONAL CONCRETE
USED AS A SHIELDING MATERIAL FOR
PROTECTION FROM RADIATION
HIGH DENSITY CONCRETE
61. 61
It is made by introducing air or gas into the
slurry composed of cement and finely
crushed sand by alluminium powder.
Uniformly cellular structure is formed.
Also called as gas concrete, foam concrete,
cellular concrete
AERATED CONCRETE
62. 62
By Omitting fine aggregate fraction
Made by cement, water and single sized coarse
aggregates
Having large voids and hence light in weight
Applications
Temporary structures
In external walls forThermal insulation
Rough texture gives good base for plastering
Free from dampness because of low capillary action
on account of large voids
NO-FINES CONCRETE
63. ROLLER COMPACTING CONCRETE
Recent development particularly in the
field of Dam construction.
Lean mix
No slump concrete
High volume fly ash to the extent of 60 to
65%
Compacted by Rollers.
Compressive strength of about 7 Mpa to
30 Mpa
64. FERRO CEMENT
It is a relatively new material consisting of wire
meshes and cement morar.
Thickness of elements is 2 to 3 cm
Water –cement ratio 0.4 to 0.45
Cement -sand ratio 1:2
External cover to reinforcement is 2 to 3mm
65. APPLICATIONS OF FERROCEMNT
FOR CASTING DOMESTIC OVER-HEAD
WATER TANKS
FOR TANKS USED AS GRAIN SILOS IN
VILLAGES
FOR CONTAINER USED AS GAS HOLDER
UNIT IN “GOBBAR GAS” PLANTS.
IDEAL MATERIAL FOR BOAT BUILDING
FOR MANHOLE COVER
66. SELF COMPACTING CONCRETE
Self levelling concrete
With Super plasticizer (Glenium )
Fines
Should not be vibrated
Applications
Precast units.
67. MASS CONCRETE
It’s is a concrete having considerable dimensions
that may get affected by thermal behavior of
Concrete. Ex-Concrete Dam
Members with minimum cross sectional
dimension of a solid concrete member
approaches or exceeds 2 to 3 ft
Cement contents above 364 kg/m3
68. It is a latest development in the construction
industry
Concrete is batched and mixed in a centralised
Plant and transported to the sites far-away
from the plant through Transit-Mixers and
placed through pumps to the required height
and distances.
68
RMC (READY MIX CONCRETE)