Concrete Manual

CONSTRUCTION MANUAL
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MANUAL FOR CONCRETE

BORAK REAL ESTATE (PVT.) LTD.
CONCRETE MANUAL
BORAK REAL ESTATE (PVT.) LTD

45, Unique Oval, Kemal Ataturk Avenue
Banani, Dhaka - 1213
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ENGR. A.H.K. MAMUN

GENERAL MANAGER (CONSTRUCTION)
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CONSTRUCTION MANUAL
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Concrete Manual
Concrete
Concrete is an artificial stone made of binding material (i.e. cement) and
chemically inert aggregates (coarse & fine).
There are many binding materials like cement, lime, bitumen etc.
Scope
Applies for all stages of structural work i.e. in footing, column, grade
beam, slab, lintel, sunshade, beam, stair, false slab etc.
Description
Concreting work covers raw material selecting, producing fresh concrete
with proper workability, placing and compaction where required.
Constituent Raw Materials Requirement
Cement (Ordinary Portland or Composite Cement)
Fine Aggregate (Coarse and medium coarse sand)
Coarse Aggregate (Stone chips, shingles or brick chips)
Water (Potable)
Some Specifications and Requirements of Concrete Constituent

Materials
Cement
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The raw materials of cement are limestone and mud (consisting of silica
and alumina). From these materials clinker is made which is grinded and
mixed with gypsum thus making Ordinary Portland cement.
Some Important Characters of Cement

Hydration reaction of cement with water to form calcium silicate
hydrate (C-S-H) gel.
SettingStiffening of the cement paste i.e. changing from fluid to
rigid state. Two types of setting- Initial and Final. Initial setting time
shall not be less than 45 minutes whereas final setting time shall
not be more than 10hours.
Soundness- Once set the cement paste should not undergo a large
change in volume. Cement exhibiting volumetric expansion is
classified as unsound.
Fineness- Cement particle should be very fine to develop its
strength rapidly.
Compressive Strength of Cement

This testing method conforms to the ASTM requirements of
specifications C-109. The standard requirement of minimum
compressive strength as per ASTM C -150 for ordinary Portland
cement (type-1) is as follows.
Age(days)
3
7
28
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Minimum compressive strength (psi)

1800
2800
4000
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Some Physical Tests of Cement
Except some special type cement, the color of good cement is blackish
gray.
If the cement is felt cools when ones hand is inserted in a bag full of
cement, then the cement is considered good.

It should be free from any hardened lump.
A handful of cement is taken and thrown into a bucket of water. If the

cement particles are
found floating, then the quality of cement is
good.
A small amount of cement is taken between two fingers and
rubbed. Good quality cement gives smooth feeling.
Fine Aggregates
These are chemically inert material passing through No.4 ASTM sieve
and generally termed as sand.
There are three types of sand coarse, medium coarse and fine.
Coarse Sand
These are naturally available non plastic granular material
having grain size from 4 mm to 0.15 mm in diameter

(approximately).
These are sharp angular grained silica, which are hard, dense
and durable.
It has a F.M. of 2.5 to 2.0.
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When one handful of sand is put in a clean glass of water and if
after 3 to 5 minutes the water on top of sand looks clear this

means the sand is clean.
It is used in structural concrete works.
Medium Coarse Sand
Naturally available non plastic granular material having particle
size from 2 mm to 0.1 mm in diameter (approximately).

These are sharp grained silica, which are hard, dense and
durable.
It is used in plastering and minor concreting work.
Fine Sand
Angular and sharp grained.
It is used in foundation backfilling.
Deleterious Substances in Fine Aggregates

The amount of deleterious substances in fine aggregates should not
exceed the limits prescribed below:
Sl.
No.
01.
02.
Item
Maximum percent by wt. of total

sample
Clay lumps
3.0
Materials finer than no. 5.0
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220 sieve
03.
Coal & lignite
1.0
04.
Chloride content
Nil
Fine Aggregates should be free of injurious amounts of organic
impurities.
Coarse Aggregate
These are stone chips, shingles and brick chips.
Stone Chips
Quality of stone chips should conform to its parent materials
(i.e. boulder or hard rock).

It should be hard, dense, durable, clean, free from adherent
coatings, non-reactive with cement and should not contain

harmful materials such as salt, coal residue, clay lumps,
organic matter etc.
It must be well graded starting from required maximum size to
acceptable minimum size proportionately and should not

contain elongated and flaky chips.
Unit weight should not be less than 1610kg/m3 (100 lbs/ cft).
The Aggregate impact value should not exceed 30% limit as per
BS 812; part 3, chapter-6.

The percentage of wear as determined by Los Angeles Abrasion
Test should not be more than 30%. (As per ASTM C 535).
Shingles
These are small sized (average diameter is 3/8 to 1) rounded

water worn stone and can be used directly as building materials.
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These must be hard, dense, durable, clean and free from adherent
coatings, and should not contain any elongated or flaky pebbles.

Any shingle should not show cracks, veins etc. which are sign of
non-durability.
The dimension of single rock should not differ notably. The ratio
between the smallest and largest dimension of single stone should

generally not less than 0.4.
The Aggregate impact value should not exceed 30%.
The percentage of wear as determined by Los Angeles Abrasion Test
should not be more than 30%. (As per ASTM C 535).

It must be well graded i.e. it must contain all sizes of stone starting
from required maximum
proportionately.
size
to
acceptable
minimum
size
Brick Chips
It must be made from 1st class picket bricks.
It must be well graded within the particle size distribution limits.
It must be free form organic and foreign materials
It should be completely non-plastic.
Unit weight should not be less than 1200kg/m3 (75 lbs/ cft).
Water absorption as a percentage of dry weight should not exceed
15%
The percentage of wear as determined by Los Angeles Abrasion Test
should not be more than 40%.

It should be well shaped i.e. not elongated or flaky.
The fine and coarse aggregates should be washed at least once in clean
water immediately before being used in concrete production.
Water
Concrete water should be same as potable water and free from salinity.
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Strength of Concrete Depends on Some Factors

The main influencing factors on strength are taken in practice are as
follows:
Water/Cement ratio.
Degree of compaction.
Aggregate/Cement ratio.
Quality
strength and stiffness)

The maximum size of aggregate.
of the aggregate (grading, surface texture, shape,
Workability
The definition of workability is the amount of useful internal work
necessary to produce full compaction.
The strength of concrete is adversely and significantly affected by the
presence of voids in the compacted mass, it is vital to achieve a
maximum possible density. This requires a sufficient workability for
virtually full compaction to be possible using a reasonable amount of
work under the given conditions. The presence of voids in concrete
reduces the density and greatly reduces the strength: 5 percent of voids
can lower the strength by as much as 30 percent.
Factors Affecting Workability
Workability depends on a number of interacting factors:
Water content.
Aggregate type and grading.
Aggregate/ Cement ratio.
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Fineness of cement.
Presence of admixtures.
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Water Cement Ratio (W/C)

Normally the water cement ratio is varied from 0.40 to 0.50 for RCC slab,
column etc. and above 0.60 for pile casting.
For all cases, water cement ratio should not be more than 0.45.
Example: The amount of water for 1 bag cement = (50kg*0.45) = 22.5
liter.
General Mix Proportion (cement: fine aggregate: coarse aggregate)
Location
Type
of Ratio
work
Footing,
pile
cap,
U.G.W.R,
footing
of
boundary wall
Pile work
Footing/Pile cap
Column & shear wall
Grade beam, column of
boundary wall, grade
beam of boundary wall,
U.G.W.R, septic tank
Slab, beam & stair
False slab, lintel, drop
wall & tie column
Mixing Time
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3
C.C 1:3:6
work
Strengt
Standard
Slump
(psi)
2000
in mm.
25-75
R.C.C
R.C.C
R.C.C
R.C.C
1:1.5:3
1:2:4
1:1.5:3
1:2:4
3500
3000
3500
3000
<150
25-75
50-75
25-75
R.C.C
R.C.C
1:2:4
1:2:4
3000
3000
25-75
25-75
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Concrete mixers are generally designed to run at a speed of 15 to 20

revolutions per minute. For proper mixing, it is seen that about 25 to 30
revolutions are required in a well designed mixer. In the site, the normal
tendency is to speed up the out turn of concrete by reducing the mixing
time. This results in poor quality of concrete. On the other hand, if the
concrete is mixed for a comparatively long time, it is uneconomical from
the point of view of rate of production of concrete and fuel consumption.
Therefore it is important to mix the concrete for such duration which will
accrue optimum benefit.
Capacity of Mixer
3 cum or larger
2 cum
1cum or smaller
Minimum Time of Mixing

Natural Aggregates
Manufactured Aggregates
2 minutes
2.5 minutes
1.5 minutes
2 minutes
1.25 minutes
1.5 minutes
Placing of Concrete
Fresh concrete should be placed within 30 minutes for better strength. To
avoid cold joint the interval of casting in a segment should not be more
than 30 minutes in any case. Vibrator should be used for casting
thickness more than 150mm. Proper vibration is needed for good
compaction.
After 24 hours of casting curing should started up to 28 days age of
concrete.
Curing of Concrete
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Curing can be described as keeping the concrete moist and warm enough
so that the hydration of cement can continue. More elaborately, it can be
described as the process of maintaining satisfactory moisture content
and a favorable temperature in concrete during the period immediately
following placement, so that hydration of cement may continue until the
desired properties are developed to a sufficient degree to meet the
requirement of service.
Curing Methods
Curing methods may be divided broadly into four categories:
i)
ii)
iii)
iv)
Water curing.
Membrane curing.
Application of heat.
Miscellaneous.
Here it has been discussed about water curing because water curing is
by far the best method of curing as it satisfies all the requirements of
curing, namely, promotion of hydration, elimination of shrinkage and
absorption of the heat of hydration. Water curing can be done in the
following ways:
a)
a)
b)
c)
Immersion
Ponding
Spraying
Wet covering.
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The precast concrete items are normally immersed in curing tanks for
certain duration.
Pavement slabs, roof slabs etc. are covered under
water by making small ponds. Vertical retaining wall or plastered
surfaces or concrete column etc. are cured by spraying water. In some
cases, wet coverings such as wet gunny bags, Hessian cloth, jute
matting, straw etc. are wrapped to vertical surface for keeping the
concrete wet. For horizontal surfaces saw dust, earth or sand are used as
wet covering to keep the concrete in wet condition for a longer time so
that the concrete is not unduly dried to prevent hydration.
When to Start Curing and How Long to Cure
The best practice is to keep the concrete under the wet gunny bag for 24
hours and then commence water curing by way of ponding or spraying.
For general guidance, it can be said that concrete must be cured at least
for 7 continuous days.
Form Work Removing Time

Formwork removing should be started after the following duration
For column
Minimum after 24 hours
For side formwork of Minimum after 24 hours
beam
For slab and beam
After
achieving
required
strength (but not less than 7
days)
Sequence of Removing Form work
For cantilever slab and beam removal of form work should be started
from the free end.
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For slab and beam after achieving required strength, formwork can be
removed at a time starting from centre of the span to ends.
Tests of construction materials:
1. Slump Test Slump Test is a test of concrete which determines the
water cement ratio in the field. The test is performed with slump cone.
The following figure is an illustration of the Slump Test
Original height of concrete

Dia 102 mm
Slump (25mm-50mm)
Height 305 mm
Height after subsidence

Dia 203 mm
(SLUMP CONE)
(SLUMP)
Procedure of Slump Test:

o
Take a slump cone having top dia of 102 mm, bottom dia of 203 mm
and height of 305 mm. The base of 203 mm dia is placed on a smooth
surface. Make the inner surface of the slump cone clean and smooth.
Pour freshly prepared concrete into the slump cone in three layers.
Give at least 25 blows for each layer with 4600 mm long and 16 mm
dia plain rod. During placing of concrete it should be noticed that the
cone is not disturbed.
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Remove the cone and measure the difference in heights between the
central tip of subsided concrete and top level of the cone which is the
slump.
If the slump value is less than minimum, then amount of water is to

be increased. On the other hand if the slump value is more than the
maximum, then the amount of water is to be reduced. Normally the
water cement ratio (i.e. w/c) is varied from 0.40 to 0.50 for RCC
slab, column etc. and above 0.60 for pile casting.
2. Cylinder Test - Cylinder test is a test of concrete which is done in the

laboratory to determine the compressive or crushing strength of
concrete. The cylinder is made with cylinder mold.
Procedure for Making Cylinder Test Sample :
o
Take a metallic cylinder mold having dia of 150 mm and height of 300
mm. Make the inner surface of the mold clean and smooth.
Fix tightly the nut and bolt with base plate so that there is no visible
gap in the bottom part of cylinder.
Place concrete into the mold in three layers. Give at least 25 blows for
each layer with 4600 mm long and 16 mm dia plain rod.
Remove the specimen carefully (as concrete is weak in this stage) from
the mold after 24 hours.
Cure the specimen in fully submerged condition for 28 days.
Take the specimen from water at least 24 hours before test.
Dia 150mm (6)
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Height 300mm (12)
(CYLINDER MOLD)
(CYLINDER)
The cylinder test shows 0.75 times the strength of the same
concrete crushed in the cube test.
3. Test of Reinforcement- Reinforcement cannot be tested at the field.
The tensile strength and other important physical properties of
reinforcement are to be determined in the laboratory before use. But
in the field it is very important to use rust free reinforcement. The
rust in the reinforcement reduces its diameter and the strength as
well as durability of it after a certain period. So, by any means, rust is
to be protected and removed, if any, from the reinforcement before
placing.
Some Important Behaviors of Concrete
Segregation
Segregation can be defined as the separation of the constituent materials
of concrete. A good concrete is one in which all the ingredients are
properly distributed to make a homogenous mixture. If a sample of
concrete exhibits a tendency for separation of say, coarse aggregate from
the rest of the in gradients, then, that sample is said to be showing the
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tendency for segregation. Such concrete is not only going to be weak; lack
of homogeneity is also going to induce all undesirable properties in the
hardened concrete.
Bleeding
Bleeding is sometimes referred as water gain in concrete. It is particular
form of segregation, in which some of the water from the concrete comes
out to the surface of the concrete, being of the lowest specific gravity
among all
the ingredients of concrete. Bleeding is predominantly observed in a
highly wet mix, badly proportioned and insufficiently mixed concrete.
Laitance
Due to bleeding, water comes up and accumulates at the surface.
Sometimes, along with this water, certain quantity of cement also comes
to the surface. When the surface is worked up with trowel and floats, the
aggregate matter goes down and the cement and water come up to the
top surface. This formation of cement paste at the concrete surface is
known as Laitance.
Self-Compacting Concrete (S.C.C)
Concrete having slumped higher than 6 is usually termed as self
compacting concrete.
In self compacted concrete no vibrator is used for compaction. SCC is
compacted by its self weight. SCC is used where reinforcement is highly
congested.
Designing of Concrete Mix
There are two recognized methods:
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ACI Method or American Method.
British Method.
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CONSTRUCTION MANUAL

MANUAL FOR CONCRETE

BORAK REAL ESTATE (PVT.) LTD

ENGR. A.H.K. MAMUN

MANUAL FOR CONCRETE

Cement (Ordinary Portland or Composite Cement)

Fine Aggregate (Coarse and medium coarse sand)

Coarse Aggregate (Stone chips, shingles or brick chips)

Some Specifications and Requirements of Concrete Constituent

ENGR. A.H.K. MAMUN

MANUAL FOR CONCRETE

Some Important Characters of Cement

Compressive Strength of Cement

ENGR. A.H.K. MAMUN

Minimum compressive strength (psi)

MANUAL FOR CONCRETE

Some Physical Tests of Cement

cement, then the cement is considered good.

A handful of cement is taken and thrown into a bucket of water. If the

These are naturally available non plastic granular material

having grain size from 4 mm to 0.15 mm in diameter

ENGR. A.H.K. MAMUN

MANUAL FOR CONCRETE

When one handful of sand is put in a clean glass of water and if

after 3 to 5 minutes the water on top of sand looks clear this

Medium Coarse Sand

Naturally available non plastic granular material having particle

size from 2 mm to 0.1 mm in diameter (approximately).

It is used in plastering and minor concreting work.

Angular and sharp grained.

It has a F.M. of 1.0 to 0.8.

It is used in foundation backfilling.

Deleterious Substances in Fine Aggregates

Maximum percent by wt. of total

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MANUAL FOR CONCRETE

Quality of stone chips should conform to its parent materials

(i.e. boulder or hard rock).

coatings, non-reactive with cement and should not contain

acceptable minimum size proportionately and should not

BS 812; part 3, chapter-6.

These are small sized (average diameter is 3/8 to 1) rounded

ENGR. A.H.K. MAMUN

MANUAL FOR CONCRETE

coatings, and should not contain any elongated or flaky pebbles.

between the smallest and largest dimension of single stone should

The percentage of wear as determined by Los Angeles Abrasion Test

should not be more than 30%. (As per ASTM C 535).

It must be made from 1st class picket bricks.

It must be well graded within the particle size distribution limits.

It must be free form organic and foreign materials

It should be completely non-plastic.

Water absorption as a percentage of dry weight should not exceed

should not be more than 40%.

ENGR. A.H.K. MAMUN

MANUAL FOR CONCRETE

Strength of Concrete Depends on Some Factors

strength and stiffness)

of the aggregate (grading, surface texture, shape,

Aggregate type and grading.

Aggregate/ Cement ratio.

ENGR. A.H.K. MAMUN

MANUAL FOR CONCRETE

Water Cement Ratio (W/C)