BASICS OF CONCRETE TECHNOLOGY

by
Prakash Channappagoudar, VP (Structural Designs), SKA/TEBS
 Concrete Properties
 Versatile
 Cheapest
 Strong & Durable
 Does not Rust or Rot. In fact, strength
increases with time.
 Does Not Need a Coating
 Excellent Resistance to Fire
 Types of concrete
Based on unit weight:
1) Normal-weight concrete (2400kg/Cum)
2) Light-weight concrete (< 1800 kg/Cum)
3) Heavy-weight concrete (>3200 kg/Cum)

Based on Strength: (As per IS:456-2000)

1) Ordinary concrete: (10-20 MPa)
2) Standard concrete (25 to 55 MPa)
3) High Strength concrete (60-80 MPa)
 Constituents of Concrete

• CEMENT
• FINE AGGREGATES
• COARSE AGGREGATES
• WATER
• ADMIXTURES
– MINERAL
– CHEMICAL
CEMENT
Types of Cement recommended by IS 456

a. 33 Grade ordinary Portland cement conforming to IS 269

b. 43 Grade ordinary Portland cement conforming to IS 8112

c. 53 Grade ordinary Portland cement conforming to IS 12269

d. Rapid hardening Portland cement conforming to IS 8041

e. Portland slag cement conforming to IS 455

f. Portland pozzolana cement (fly ash based) conforming to IS 1489 (Part 1)

g. Portland pozzolana cement (calcined clay based) conforming to IS 1489 (Part 2)

h. Hydrophobic cement conforming to IS 8043

i. Low heat Portland cement conforming to IS 12600

j. Sulphate resisting Portland cement conforming to IS 12330

High Early Strength Cement Low Heat of Hydration Cement

OPC OPC
43 Grade Ordinary Portland Cement – Compressive strength – IS 8112

a. 72 ± 1 hour not less than 23 MPa

b. 168 ± 2 hour not less than 33 MPa
c. 672 ± 4 hour not less than 43 MPa

53 Grade Ordinary Portland Cement – Compressive strength - IS 12269

a. 72 ± 1 hour not less than 27 MPa

b. 168 ± 2 hour not less than 37 MPa
c. 672 ± 4 hour not less than 53 MPa
FINE AGGREGATE (SAND)
SIEVE ANALYSIS OF FINE AGGREGATES AS PER IS 383
BULKAGE OF SAND
 CRUSHED ROCK FINES
• A BYPRODUCT OF CA CRUSHING UNITS.
• NEEDS TO BE WASHED WITH WATER/AIR AS IT CONTAINS
EXCESSIVE FINES.
• AS IT CONTAINS FLAKY MATERIAL, SHOULD BE USED WITH
CAUTION.
• MUST SATISFY THE GRADATION REQUIREMENTS OF IS:383.
• BETTER TO GO FOR MANUFACTURED SAND, MADE BY
VERTICAL SHAFT IMPACTORS. (BARMAC ‘B’ SERIES VSI
CRUSHER).
• MANUFACTURED SAND CONTAINS CUBIC SHAPED PARTICLES
AND HENCE HAVE LESSER VOID CONTENT.
COARSE AGGREGATES
SIEVE ANALYSIS OF COARSE AGGREGATES AS PER IS 383
Effect of Aggregate Size
 Tests on aggregates and Acceptable limits – IS 383

Other than for wearing For wearing surfaces

surfaces

Aggregate Crushing Value Shall not exceed 45% Shall not exceed 30%

Aggregates Impact Value Shall not exceed 45% Shall not exceed 30%

Aggregate Abrasion Value Shall not exceed 50% Shall not exceed 30%
WATER
Permissible Limits of Deleterious materials in water as per IS
456
MINERAL ADMIXTURES

FLY ASH GGBS

Mineral Admixtures recommended by IS 456

1. Pozzolanas
a. Fly ash (pulverized fuel ash)
b. Calcined clay based

2. Silica fume

3. Ground Granulated Blast Furnace Slag

4. Rice husk ash

5. Metakaoline
Why Mineral Admixures are added to Concrete ?
EFFECT OF FLYASH ON REDUCTION OF Ca(OH)2
EFFECT OF FLYASH ON HEAT RELEASE
EFFECT OF FLYASH ON STRENGTH (IN 28 DAYS)
EFECT OF FLYASH ON STRENGTH (IN ONE YEAR)
EFECT OF GGBS ON STRENGTH
CHEMICAL ADMIXTURES
 CHEMICAL ADMIXTURES

– WATER REDUCERS (HRWRA) / SUPER PLASTICISERS

– RETARDERS
– VISCOSITY MODIFIERS (VMA)
– WATER PROOFING CHEMICALS
– ACCELERATORS
– AIR ENTRAINING AGENTS
– CORROSION INHIBITORS
– COLOURING PIGMENTS
CONCRETE
Grades of Concrete as per IS 456
WORKABILITY OF CONCRETE
DEGREE OF WORKABILITY OF CONCRETE AS PER IS 456
COMPACTING FACTOR APPARATUS – IS 1199
FLOW TABLE APPARATUS – IS 1199
MOULD FOR FLOW TEST – IS 1199
Minimum Cement Content, Maximum Water-Cement Ratio and Minimum Grade of
Concrete for Different Exposures with Normal Weight Aggregates of 20 mm Nominal
Maximum Size – IS 456
Environmental exposure conditions as per IS 456
Frequency of sampling as per IS 456
INITIAL & FINAL SETTING OF CONCRETE
 Concrete Curing
 Must be kept Moist

 Moisture Needed for:

Hydration
(Development of Strength)
READY MIXED CONCRETE
Materials testing requirements – Aggregates – IS 4926
Minimum test frequencies

-Continued-
Materials testing requirements – Aggregates – IS 4926 (Contd)
 Sampling of Ready Mixed Concrete – IS 4926

1) Allow the truck-mixer to remix the concrete at site.

2) Allow at least the first one-third of a CuM of
concrete to be discharged.
3) Take at least 4 incremental samples from the
remainder of the load.
4) Avoid sampling the last CuM of concrete.
5) Thoroughly re-mix this composite sample either on
a mixing tray or in the sampling bucket.
6) Proceed with the required testing.
 DELIVERY TICKET INFORMATION - IS 4926
G-1 The following information shall be included in the delivery ticket to
accompany the load to the purchaser:

a. Name or number of the ready-mixed concrete depot.

b. Serial number of the ticket.
c. Date.
d. Truck number.
e. Name of the Purchaser.
f. Name and location of site.
g. Grade or mix description of the concrete.
h. Specified target workability.
i. Minimum cement content (if specified).
j. Type of cement and grade (if specified).
k. Maximum free water-cement ratio (if specified).
l. Nominal maximum size of aggregate.
 DELIVERY TICKET INFORMATION - IS 4926 (Contd)

m. Generic type or name of any chemical and mineral admixtures included.

n. Quantity of concrete in M3
o. Time of loading.
p. Signature of the plant operator.
q. A statement warning the purchaser of the precautions needed to be taken
when working with cement and wet concrete.

G-2. On site, the following information will be added.

a. Time of arrival on site.
b. Time when discharge was completed.
c. Any water/admixture added by the supplier to meet the specified
workability.
d. Any extra water/admixture added at the request of the purchaser of the
concrete, or his representative, and his signature.
e. Pouring location.
f. Signature of the purchaser or his representative confirming discharge of
the load.
Sample collected Slump Cone Filled

Cone Removed and Concrete

Allowed to ‘Slump’ Slump Measured
REASONS FOR SLUMP LOSS
 CONCRETE MIX DESIGN
(Ref: IS: 10262)
Objective : To determine the proportion of ingredients that
would produce a workable concrete mix that is
durable, and of required strength,
and at a minimum cost.

Principles of Mix Design

- Workable mix
- Use as little cement as possible
- Use as little water as possible
- Gravel and sand to be proportioned to achieve a dense mix
- Maximum size of aggregates should be as large as possible, to
minimize surface area of aggregates
 CONCRETE MIX DESIGN (Cont’d)

Methods of Mix Design

- Volumetric method (arbitrary)
- Proportioning from field data method
- Proportioning by trial mixtures method
- Mass proportioning method
- Absolute volume method (BIS approved method)

BIS Design based on Absolute Volume

1. Calculate target concrete strength as per the degree of quality control at site.
2. Find the w/c ratio for the target strength as per the grade of cement used.
3. Check this w/c ratio w.r.t exposure condition.
4. Select the maximum size of coarse aggregates
Concrete Mix Design (cont.)
5. Find maximum water content in Kgs for the given size of CA.
6. Calculate Cement content from w/c ratio and step 5.
7. Check this cement with the minimum cement requirement for the given
exposure condition.
8. Find quantity of FA as % of total aggregates for the given size of CA.
9. Select the Compaction factor as per the task.
10. Find NMC and air content of the aggregates.
11. Apply corrections to water content for NMC of FA & CA.
12. Apply corrections to FA content for change in Compacting factor.
13. Calculate the weights of CA and FA.
14. Find the weights of field mix (containing moisture) per unit volume.
15. Compute the field mix proportions.
16. Cast Cubes and test them to confirm they give target strength.
 ACCEPTANCE CRITERIA
AS PER IS-456 :2000

Specified Average strength Individual test

Grade of 3 specimens results
(N/sq.mm) (N/sq.mm)
M20 or  fck + 4  fck - 4
more N/sq.mm N/sq.mm

Note:
If std. deviation is established at work site,
the av. str. should be  fck + 0.825 Sd

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