CONCRETE PRACTICE’S

Kingsley.J.D.Ernest – CT Cell – HQ
L.S.Kannan - ZTC – Chennai
 COVERAGE
1. Material for concrete
2. Testing of material
3. Receiving and Storing material
4. Properties of concrete & concrete Testing
5. Mix proportioning concrete
6. Batching, Mixing and Transporting concrete
7. Placing, Leveling & Compacting concrete
8. Finishing and Surface preparation
9. Protection and Curing
10. Defects
11. Formwork and Reinforcement (rebar)
12. Durability of concrete - Repair
13. Newer technology - Some
14. Discussion
 Material for Concrete
→ Cement
→ Fine Aggregate
→ Coarse Aggregate
→ Water
→ Chemical Admixture
→ Mineral Admixture
→ Other additives
 CONCRETE & CEMENT HISTORY
• Oldest surviving concrete is found in Yugoslavia
which was thought to be laid in 5600 BC.
• The first major users were Egyptians around
2500 BC and Romans from 300 BC
Romans mixed materials from “Pozzuoli” a pink
sand with lime mortar and built their structures.
This is nothing but volcanic ash and they
produced the first “POZZOLANIC” Cement.
 CONCRETE & CEMENT HISTORY

• OPC – ORDINARY PORTLAND CEMENT

• Mr. JOSEPH ASPDIN
– 21ST OCT1824
– THE PRODUCT RESEMBLE NATURAL ROCK IN
PORTLAND- ENGLAND

• In India – 1902 (South India structural)

– India cement industries - 1904
How cement is made
Cement
 Cement
→ OPC - Ordinary Portland cement
→ PPC - Portland pozzolana cement
→ PSC - Portland slag cement
→ SRC - Sulphate resisting cement
Zuari
Ramco
 CEMENT TYPES
• OPC – 33 Grade IS 269
– 43 GRADE IS 8112
– 53 GRADE IS 12269
• PPC - IS 1489 Part I (fly ash based)
- IS 1489 Part II ( Calcined clay)
• PSC - IS 455
• SRC - IS 12330
 CHEMICAL ANALYSIS
1. LIME SATURATION FACTOR
CaO - 0.7SO3
0.90 0.80 - 1.02
2.8 SiO2 + 1.2 Al2O3 + 0.65 Fe2O3
2. Ratio of % Alumina to that of Iron Oxide
1.31 0.66 Min
Al2O3 / Fe2O3
3. Insoluble Residue (% by mass) 1.82 3.0 Max
4. Magnesia (% by mass) 1.21 6.0 Max
5. Sulphuric Anhydride (% by mass) 1.94 3.0 Max
6.Total Loss on Ignition (%) 1.50 5.0 Max
7. Chloride (%) 0.01 0.05 Max
PHYSICAL ANALYSIS
1. Fineness (m2 / Kg) 333 225 Min
2. Setting Time (Minutes)
a) Initial 180 30 Min
b) Final 270 600 Max
3. Soundness
a) Le-Chat Expansion (mm) 1.00 10 Max.
b) Auto Clave (%) 0.09 0.80 Max.
4. Compressive Strength (M Pa)
a) 72 +/- 1 Hr (3 Days) 40 23 Min.
b) 168 +/- 2 Hr (7 Days) 50 33 Min.
c) 672 +/- 4 Hr (28 Days) 62 43 Min.
 Cement - Comparison
Table 1 Physical requirements of cement
Type of cement OPC 33 OPC 43 OPC 53 SRC PPC PSC Sleeper
Grade Grade Grade (Flyash 53 S
Based)

IS Code No 1489
269 8112 12269 12330 part 1 455 12269

Fineness (Blaine)
(sq. cm / gm ) Min 2250 2250 2250 2250 3000 2250 3700

Setting Time (Minute)

Initial (Not less than) 30 30 30 30 30 30 60
Final ( Not more than) 600 600 600 600 600 600 600

Soundness
1)Le Chatelier (mm) 10 10 10 10 10 10 5

2) Autoclave (%) 0.8 0.8 0.8 0.8 0.8 0.8 0.8

Compressive strength
(Kg/ Sq.cm) Min

3 Days 160 230 270 100 160 160 -

7 Days 220 330 370 160 220 220 375

28 Days 330 430 530 330 330 330 -

Drying shrinkage (max %)
- - - - 0.15 - -
 Aggregate - types
examples of
class uses
aggregates used

vermiculite
ultra- lightweight concrete which can be sawed or
ceramic spheres
lightweight nailed, also for its insulating properties
perlite

expanded clay used primarily for making lightweight

lightweight shale or slate concrete for structures, also used for its
crushed brick insulating properties.

crushed limestone
sand
normal river gravel used for normal concrete projects
weight crushed recycled
concrete

heavyweig steel or iron shot

used for making high density
ht steel or iron pellets
 Fine Aggregate
→ Natural Sand
→ Crushed Sand
→ Combination
→ IS 383
 River Sand Crushed Sand

Contains harmful impurities like mud, Contains no organic Impurities, hence it

soil, silt, salt, alkalis, coal, mica, shoal, gives increased strength of Concrete with
sea shell, bone, organic matter etc. same cement content.

Gradation of sand is controlled in the

No consistency in particle sizing due to
manufacturing process, hence mix design
different sources, hence accuracy of
can be accurately used due to consistent
mix design becomes doubtful.
gradation.

Irregular sizing results in wastage in

No wastage since Sand is already sieved in
the form of singles to the tune of 10 -
the required size ( below 4.75 mm ).
15%

Erratic supply & fluctuating prices make Consistency in supply as well as stability in
it difffcult to control project cost. prices help in controlling the project cost.

Extraction of sand from River beds is Does not harm the enviroment in any way
an enviromental hazard.
 GRADING LIMITS FOR FINE AGGREGATES

IS SIEVE ZONE 1 ZONE 2 ZONE 3 ZONE 4

10mm 100 100 100 100
4.75mm 90-100 90-100 90-100 95-100
2.36mm 60-95 75-100 85-100 95-100

1.18mm 30-70 55-90 75-100 90-100

600 15-34 35-59 60-79 80-100

300 5-20 8-30 12-40 15-50

150 0-10 0-10 0-10 0-15

 Coarse Aggregate
→ Crushed Aggregate
→ Natural Deposit
 Maximum Size of Aggregate
(Canadian Standards)
• The nominal maximum size of aggregate particles generally should not
exceed:
1.One-fifth of the narrowest dimension between sides of forms;
2.Three-quarters of the minimum clear spacing between reinforcing bars and
between the reinforcing bars and forms;
3. One-third the depth of slabs;
4.The specified cover for concrete not exposed to earth or weather, refer CSA
Standard A23.1, (Clause 12.6.2);
5.Two-thirds of the specified cover for concrete exposed to earth or weather,
refer CSA Standard A23.1, (Clause 12.6.2.2 and Table 9);
6. One-half of the specified cover for concrete exposed to chlorides, refer CSA
Standard A23.1, (Clause 12.6.2.2 and Table 9); or
7.For concrete that is to be placed by pump, the nominal maximum size of
coarse aggregate shall be limited to one-third the smallest internal diameter of
the hose or pipe through which the concrete is to be pumped or 40 mm,
whichever is smaller.
Except for the limitations of Numbers 6 and 7, the above limitations may be
waived if, in the judgment of the owner, workability and methods of
consolidation are such that the concrete can be properly placed with a larger
nominal maximum size aggregate.
 Maximum Size of Aggregate
(Indian Standards)
• The nominal maximum size of aggregate particles generally should not
exceed:
One-fourth of the narrowest dimension between sides of forms;

5mm less than the minimum clear spacing between reinforcing bars and
between the reinforcing bars and forms;
 PROPERTIES OF COARSE AGGREGATE

• GRADATION (SIEVE ANALYSIS)

• SPECIFIC GRAVITY
• WATER ABSORPTION
• DENSITY
• FLAKINESS INDEX/ELONGATION INDEX
• CRUSHING VALUE
• IMPACT VALUE
• LOS ANGELES ABRASION VALUE
• SOUNDNESS
• ALKALI AGGREGATE REACTIVITY TEST
 Contamination of Aggregate
Possible sources of contamination include:
• Allowing adjacent aggregate stockpiles to overlap, causing
cross-contamination
• Scooping up underlying soil when using a front-end loader to move
aggregate from a stockpile
• Dumping the wrong size aggregate in a bin or pile
• Aggregate leakage through or around bulkheads in storage bins
• Allowing leaves and other contaminants to fall into the aggregate
stockpile
• Allowing vegetation to grow in the aggregate stockpile
• Failure to let the receiving hopper and conveyor belt or elevator run
until empty before adding a different size aggregate
• The supplier may have contaminated the aggregate or delivered the
wrong aggregate
Grading
Grading Limit of Graded Coarse Aggregate
(as per IS 383)
Cumulative percentage passing I S Sieves for coarse
I S Sieve aggregate of nominal size
40 mm 20 mm 16mm 12.5mm 25mm
80 mm 100 - - - -

40 mm 95 – 100 100 - - 100

25 mm - - - 90-100
20 mm 30 – 70 95 – 100 100 100 -
16 mm - - 90 – 100 - -
12.5 mm - - - 90 – 100 25-55
10 mm 10 – 35 25- 55 30 – 70 40 – 85 -

4.75 mm 0 –5 0 –10 0 - 10 0 – 10 0-10

 All – In – Aggregate Grading
Cumulative percentage passing IS sieve
IS Sieve
40 mm 25 mm 20 mm 12.5 mm

63 mm 100 - - -

40 mm 95 – 100 100 100 -

25 mm 95 – 100 - -

20 mm 45 – 75 95 – 100 100

12.5 mm - 95 – 100

4.75 mm 25 – 45 30 – 50 30 – 50 35 – 55

600 micron 8 – 30 10 – 35 10 – 35 12 – 40

150 micron 0–6 0 – 10 0 - 10 0 – 12

 A simple tip.
Table No 15 : Preferred fine content for concrete making for various grading
zone of sand

Cumulative percentage passing 4.75 mm in all-in-aggregate

(i.e. coarse + fine)
Slump of
concrete
Crushed Natural+
Zone I Zone II Zone III Zone IV
sand crushed

0 to 30
40 % 35 % 30 % 25 % 30 % 33 %
mm
30 to 80
45 % 40 % 35 % 30 % 35 % 38 %
mm
80 to 130
50 % 45 % 40 % 35 % 40 % 43 %
mm

130 to 180
55 % 50 % 45 % 40 % 45 % 48 %
mm
Is shape a worry?
 Water
→ Bore well
→ Open well
→ Municipality line
→ Stagnant pond
→ Flowing river
 Chemical Admixture
→ Retarder
→ Accelerator
→ Plasticiser
→ Super plasticiser
→ Hyper plasticiser
→ Air entraining
→ Others
 Admixture - types
TYPE FUNCTION

improves durability, workability, reduces bleeding, reduces

AIR ENTRAINING
freezing/thawing problems (e.g. special detergents)

increase strength by decreasing water needed for workable concrete

SUPERPLASTICIZERS
(e.g. special polymers)

delays setting time, more long term strength, offsets adverse high
RETARDING
temp. weather (e.g. sugar )

speeds setting time, more early strength, offsets adverse low temp.
ACCELERATING
weather (e.g. calcium chloride)

MINERAL ADMIXTURES improves workability, plasticity, strength (e.g. fly ash)

PIGMENT adds color (e.g. metal oxides)

 Mineral Admixture
→ Pfa – Flyash
→ GGBFS – Slag
→ MS – Micro Silica
→ Rha – Rice Husk Ash
 Performance Enhancers
Table 3 - List of permitted performance
improvers and their percentages.
Performance Percentage addition Requirement
improvers ( max)
Fly ash 5 As per IS 3812 (part I)
Granulated Slag 5 As per IS 12089
Silica fume 5 As per IS 15388
Lime stone 5 CaCO3 content calculated from CaO content shall not be less
than 75 percent when tested as per IS 1760 (Part3)
Rice husk ash 5 a)Reactive silica shall not be less than 85 percent when
tested as per IS 3812 (Part I)
b)Pozzolanic Activity index shall not be less than 90 percent
when tested as per 10 of IS 1727
c)Loss on ignition shall not be more than 8 percent when
tested as per IS 1727
Metakaoline 5 a)Silicon dioxide(SiO2) plus aluminium oxide ( Al2O3) plus
Iron oxide ( Fe2O3) in percentage by mass shall not be less
than 95 percent when tested as per IS 1727
b) Loss on ignition shall not be more than 1 percent
when tested as per IS 1727
c)Total alkalis as Sodium oxide(Na2O) in percent by mass
shall not be more than 0.6 percent when tested as per
IS4032
d)Particle retained on 45 micron IS sieve (wet sieving) shall
not be more than 1 percent when tested as per IS 1727
Insoluble residue , percent by mass
a) In case no fly ash , silica fume , rice husk ash and metakaoline is added – Not more than 3.0
b) In case of addition of fly ash and / or silica fume and / or rice husk ash and / or metakaoline – Not
more than 5.0
 Flyash
Table 5 : Physical requirements of fly ash IS 3812 (PartI)- 2003
(tested as per IS 1727-1967)

Requirement Grade of
Sl.No. Characteristic fly ash

Fineness- specific surface in m2 / kg by Blaine Air

1 320
permeability method (Min)

Particle retained on 45 micron IS Sieve (wet sieving)

2 34
percent (Max)

Lime reactivity – average compressive strength

3 N/mm2 (Min) 4.5

Not less than 80 %

of the strength of
4 Compressive strength at 28 days in N/mm2 (Min) corresponding
plain cement
mortar cubes

Soundness by autoclave test expansion of specimens, 0.8

5 Percent (Max)
 Other Additives
→ Fibers
o Polypropelene, Polyester
o Steel
o Carbon, glass fiber
 Testing of Material
→Cement
→Fine Aggregate
→Coarse Aggregate
→Water
→Chemical Admixture
→Mineral Admixture
→Other additives
Testing
cement
 Testing
fine aggregate
 Testing
coarse aggregate
Testing
water
 Testing
admixture
Testing
ultimate
 Receiving and Storing Material

→Cement
→Fine Aggregate
→Coarse Aggregate
→Water
→Chemical Admixture
→Mineral Admixture
→Other additives
 Cement

Transported in bags or bulker

Store carefully

Use First – In – First – Out

Cement Storage
 Fine Aggregate
• Transported in lorry / haul
trucks
• Bulks when moist
• Ensure actual quantity received
• Avoid double handling if
possible
• Stack separately on well drained
area
• No intermixing allowed
 Coarse Aggregate
•Transported in lorry / haul trucks
•Ensure actual quantity received
•Avoid double handling if possible
•Stack separately on well drained area
•No intermixing allowed
 Water
•Not to be stored for too long in open area.
 Chemical Admixture

•Received in barrel or bulker

•Stack separately.
•Avoid dilution.
 Mineral Admixture
•Received in powder form.
•Handled with care.
•Flyash received in bags, jumbo bags or
bulkers.
•Slag and Microsilica received in bags.
 Others

•Packets or bags.
•Kept safely.
Properties of Concrete
 Properties of Concrete
Plastic
→ Workability - Slump
→ Cohesiveness
→ Slump retention
→ Setting time
Hardened
→ Compressive strength
→ Cracking
 Workability – Slump Cone

→ Collect sample in wheel

barrow.
→ Mix well.
→ Using scoop, place concrete
in four layers.
→ Tamp each layer 25 times.
→ Lift cone steadily upwards.
→ Measure using stainless
steel scale or steel tape.
→ Report to nearest 5mm.
 Cohesiveness
(Ball test / Slump test)
Slump retention
Slump retention
admixture effect
 Admixture compatibility
• Setting
• Stiffening
• Bleeding
Aggregate Fractions
 Optimal Aggregate Content
A mix made to the required consistence, should be assessed for stone
content before being used on a large scale.
This can be done by compacting some of the concrete in a container, eg
a bucket, by the means (vibration or hand tamping) to be used on the
job.
If stones protrude from the surface, stone content is too high.
If not, scratch the surface of the compacted concrete (before it hardens)
with a nail or screwdriver. If the stone content is right, stones should be
found two or three millimetres below the surface. If they are deeper than
this, the stone content is too low.
If stone content is too high, reduce it by 10 % and increase sand content
by the same amount, ie volume or mass. Then reassess.
Testing of Concrete
sampling
Concrete Cube
Slump Test
Mix proportioning of Concrete
Mix proportioning of Concrete
 Data for Proportioning
• Cement ?
• Sand ?
• Coarse aggregate ?
• Water ?
• Maximum size of aggregate – MSA?
• Workability – Slump ?
• Chemical admixture ?
• Mineral admixture ?
Mix proportioning of Concrete
• ACI
• BS
• Road Note
• IS
• L&T – Absolute Volume Method
 Initial assumptions
• Cement = 400 kg
• Water = ??? Kg / litres
• Air = ?
Check MSA & Workability required to
decide on water.
Check MSA required to decide on air.

Refer these table.

 Initial assumptions
• Cement = 400 kg
• Water = 190 Kg / litres
• Air = 2%
 Workability Selector
Placing condition Workability Slump
(mm)
Concreting of mass pours,
shallow sections, lightly Stiff 0 to 30
reinforced section

Concreting of screeds , pre cast

sections, beams, columns, Stiff plastic 30 to 80
slabs, pre stressed section

Concreting of wall sections,

concrete for vacuum
Plastic 80 to 130
dewatering, slip forming and
pumping

Concreting of piles, diaphragm

Flowing 130 to 180
walls using tremie.
 Water Content per cu.m.
Slump Maximum size of aggregates in mm
Description of
mm
workability 10 12.5 20 25 40

Extremely dry - 180 170 160 150 140

Very stiff - 185 185 170 160 150

Stiff 0 – 30 200 195 180 170 155

Stiff plastic 30 – 80 205 200 185 180 160

Plastic 80 – 130 225 215 200 195 175

Flowing 130 -180 240 230 210 205 185

Approximate amount of
3.0 2.5 2.0 1.5 1.0
entrapped air in percent.
 Mix proportioning of Concrete
(Absolute Volume Method)
Weight (Kg)
Absolute Volume (m3) = --------------------------------
(Solid / Liquid) Specific Gravity x 1000

Quantity (%)
Absolute Volume (m3) = --------------------------------
(Air) 100
 Coarse Aggregate Blending
Fix Coarse aggregate ratio’s
For 40mm MSA
• 20mm passing – 50%
• 10mm passing – 25%
• Ratio = 50:25:25

For 20mm MSA

• 10mm passing – 40%
• Ratio = 60:40
 All – In – Aggregate
Coarse + Fine
% of fine aggregate depends on –
• MSA
• Fineness of fine aggregate
• Weather natural, crushed or
combination
• Workability
• Cement content
 All – In – Aggregate
Coarse + Fine
• MSA – 20mm
• Fineness of fine aggregate – Zone II
• Weather natural, crushed or
combination – Natural / Crushed
• Workability – 30 to 80mm slump
• Cement content – 400 kg
• Fine aggregate % = 40 / 35
 Calculation by Absolute Volume
0.127m3 Cem : 400/3150 = 0.127 m3
0.190m3 F.Wat :190/1000 = 0.190 m3
0.020m3 Air : 2/100 = 0.020 m3

How much of fine aggregate – Fag???

How much of coarse aggregate – CAg????
 Mix design –contd
= 1.000 – (0.127+0.190+0.020)
0.663
= 0.663 m3
m3
If FAg is 40% : ??? = 0.40x0.663x2700 = 716 Kg
Then CAg is 60% : ???? = 0.60x0.663x2700 = 1074 Kg
FAg : 716/2700 = 0.263 m3
CAg : 1074/2700 = 0.400 m3
Total = 0.127 + 0.190 + 0.020 + 0.263 + 0.400 = 1.000m3
 Final Values?
0.127 Cem : 400/3150 = 0.127 m3
0.190 Free Wat: 190/1000 = 0.190 m3
0.020 Air : 2/100 = 0.020 m3
0.263 Dry FAg : 716/2700 = 0.263 m3
0.400 Dry CAg : 1074/2700 = 0.400 m3

Total = 1.000 m3

Total water = Free water + Water for absorption by dry aggregates

 Mix proportioning of Concrete
Batch Correction
• If aggregates are dry (ie. Moisture Content =
0%), No correction is required.
• For weigh batching, if aggregates are wet,
reduce water & increase wet material
quantity as required to maintain the batch
weights.
• For volume batching, if aggregates are wet,
reduce water and increase fine aggregate
quantity to compensate for bulkage.
 Water Content – Dry Aggregates
Total water = Free water + Water for absorption by dry aggregates

Free water = 190 litres

Absorbed water by dry aggregates :
Sand = 716 x (1.00/100) = 7.160 kg or litres
20mm = 0.60 x 1074 x (0.50/100) = 3.222 kg or litres
10mm = 0.40 x 1074 x (0.50/100) = 2.148 kg or litres
Water for absorption by dry aggregates :
7.160 + 3.222 + 2.148 = 12.530 kg or litres

Total water = 190 + 12.530 = 202.530 kg or litres

 Water Content – Wet Aggregates
Net water = Total water – Moisture content of aggregates determined
by frying
Total water for dry aggregates = 202.530 litres
Moisture content in wet aggregates :
Sand = 716 x (4.00/100) = 28.640 kg or litres
20mm = 0.60 x 1074 x (1.00/100) = 6.440 kg or litres
10mm = 0.40 x 1074 x (2.00/100) = 8.590 kg or litres
Moisture in wet aggregates :
28.640 + 6.440 + 8.590 = 43.670 kg or litres

Net water = 202.530 – 43.670 = 158.860 kg or litres

 Wet Aggregate Content

Weight of wet aggregate:

Sand = 716 + {716 x (4.00/100)} = 750 kg

20mm = {0.60 x 1074) + { 0.60 x 1074 x (1.00/100)} = 650 kg

10mm = {0.40 x 1074) + (0.40 x 1074 x (2.00/100)} = 438 kg

Mix proportioning of Concrete
• Do trials with different cement contents with a
free water to give slump of 80 to 100mm.
• Cast cubes and check 28 days compressive
strength
• Plot cement to free water ratio vs 28 days
strength graph
• Find out cement to free water ratio which
gives required target strength
• This is the optimal mix on strength basis
 Target Strength
TS = f ck + 1.65 x σ
σ = 3.5 for M10/15, 4.0 for M20/25 & 5.0 for M30-50

Grade of concrete (f ck)

Target strength N/mm2
N/mm2
M 10 16
M 15 21
M 20 27
M 25 32
M 30 38
M 35 43
M 40 48
M 45 53
M 50 58
 Free water ratio to cement vs Strength graph

60

55

50
28 days strength N/sq.mm

45

40

35

30

25

20

15

10
0.30 0.40 0.50 0.60 0.70 0.80 0.90
c/fw
 Cement to Free water ratio vs Strength graph

60

55
For M 30 target strength = 42 N / sq.mm
50
28 days strength N/sq.mm

45

40

35 Fw/c ratio = 2.24

30 Free water = 190 litres
Cement = 190 x 2.24 = 425 Kg
25

20

15

10
1.00 1.20 1.40 1.60 1.80 2.00 2.20 2.40 2.60 2.80 3.00
fw/c
Mix proportioning of Concrete
Durability :
• Decide on the exposure condition.
• Satisfy minimum cement content.
• Satisfy maximum free w/c ratio.
• Finalise the mix for the grade.
 Durability
(condition of exposure?)
S.No Environment Exposure condition

Concrete surface protected against weather or aggressive

1 Mild
conditions, except those situated in coastal area

Concrete surface sheltered from severe rain or freezing

whilst wet, concrete exposed to condensation and rain ,
2 Moderate concrete continuously under water, concrete in contact or
buried under non aggressive soil/ground water, concrete
surfaces sheltered from saturated salt air in coastal area

Concrete surfaces exposed to severe rain, alternate wetting

and drying or occasional freezing whilst wet or sever
3 Severe
condensation, Concrete completely immersed in sea water,
Concrete exposed to coastal environment
Concrete surface exposed to sea water spray, corrosive
fumes or severe freezing conditions whilst wet, Concrete in
4 Very Severe
contact with or buried under aggressive sub soil/ ground
water.
Surface of members in tidal zone, Members in direct contact
5 Extreme
with liquid / solid aggressive chemicals
 Minimum cement &
Maximum free water-cement ratio.
Plain concrete Reinforced concrete

S.No Exposure Minimum Minimum

Maximum Minimum Maximum Minimum
cement cement
free w/c grade of free w/c grade of
content content
ratio concrete ratio concrete
(kg/cum) (kg/cum)

1 Mild 220 0.60 - 300 0.55 M 20

2 Moderate 240 0.60 M 15 300 0.50 M 25

3 Severe 250 0.50 M 20 320 0.45 M 30

Very
4 260 0.45 M 20 340 0.45 M 35
Severe

5 Extreme 280 0.40 M 25 360 0.40 M 40

 Dense fully compacted
concrete made with 20mm
If Sulphate is pres ent
Concentration of sulphates,
Expressed as SO3 Nominal MSA complying IS
383

In soil
Class

SO3 in
(foundations)
In
Type of cement
Minimum
Maximum free
2:1 water Ground cement
Total SO3 water content w/c ratio
: soil
extract

Percent g/l g/l (Kg/cum)

Ordinary portland cement or Portland

Traces Less than Less
1 slag cement or portland pozzolana 280 0.55
(<0.2) 1.0 than 0.3
cement

Ordinary portland cement or Portland

slag cement or Portland pozzolana
0.3 to 330 0.50
2 0.2 to 0.5 1.0 to 1.9 cement
1.2 310 0.50
Supersulphated cement or Sulphate
resisting Portland cement

Supersulphated cement or Sulphate

0.50 to 1.2 to resisting Portland cement 330 0.50
3 1.9 to 3.1
1.0 2.5 Portland pozzolana cement or Portland 350 0.45
slag cement

2.5 to Supersulphated cement or Sulphate

4 1.0 to 2.0 3.1 to 5.0 370 0.45
5.0 resisting Portland cement

Sulphate resisting Portland cement or

More More More
5 supersulphated cement with protective 400 0.40
than 2.0 than 5.0 than 5.0
coating
 Mix proportioning of Concrete
Optimisation

• Substitute water with chemical

admixture – Causes cement reduction.

• Substitute cement with mineral

admixture – flyash & GGBS cause cost
reduction.
 Volume Batching
(Aggregate per bag of cement)

Height = ??? mm
Total weight
40 to 50 Kg
max.

Breadth = 300 or 400 mm

Length = 300 or 400 mm

 Volume Batching
Loose Density = 1500 Kg / m3

Height = 278 mm
Total weight
H = 50/(1500 x 0.300 x 0.400)
50 Kg

Breadth = 400 mm

Length = 300 mm
 Volume Batching
Loose Density = 1500 Kg / m3

Height = 296 mm
Total weight
H = 40/(1500 x 0.300 x 0.300)
40 Kg

Breadth = 300 mm

Length = 300 mm
End of Day-1
Batching, Mixing & Transporting
RMC
Batching, Mixing & Transporting
 Batching
different storage types
 Batching accuracy
• Calibration.
• Cement tolerance : ± 2%
• Aggregate, admixture & water : ± 3%
• No stock pile intermixing.
• No pilferage in to weigh batcher due
to gaps in gate / sheet.
 Mixing
• Rotary mixer
• Pan mixer
• Twin shaft mixer
Transporting
Transporting
conventional
Site Activity
Site Activity
Placing

Levelling

Compacting
Placing
 Placing
static pump
 Placing
pumping - placer boom
Pumping – S tube
Pumping – trunk system
 Placing
shotcrete / spray plaster
 Placing
tower crane
Placing
crane
Placing
Placing
 Placing
free fall height
Levelling
Levelling
Compacting
Compacting
Compacting
Compacting
CONCLUSION:

•HIGH CYCLE POKERS PROVIDE BETTER RESULTS DURING ZERO, LOW OR MEDIUM SLUMP CONCRETING.

•HIGH CYCLE POKERS ARE MAINTENANCE FREE AND WORKS OUT TO BE COST EFFECTIVE IN LONG RUN.

•HIGH CYCLE POKERS PROVIDE BETTER RELAIBILITY, OPERATIONAL EASE SAFETY.

•HIGH CYCLE POKER PROVIDE UPTO 100% MORE PRODUCTIVITY THAN LOCAL MEACHINCAL POKERS.

•HIGH CYCLE POKER PROVIDE VERSATILITY FOR ALL KIND OF CONCRETING APPLICATIONS LIKE DAMS,

WALLS COLUMNS ETC.

•NON POLLUTING, LESSER NOISE, LOW VIBRATION AT THE OPERATOR LEVEL.

MOST PREFFERED AND SOLD POKERS WORLDWIDE.

Compacting
never
Finishing & Surface preparation
Finishing and Surface
Preparation
Finishing and Surface
Preparation
Dry Shake
Protection & Curing
Curing
Curing
Hot weather concrete
Curing
Common Defects
plastic shrinkage
Common Defects
Plastic Settlement
Revibration
Common Defects
Cold Joint
Cold Joints
Cracks
Cracks
Honeycomb
HONEY COMB
 CAUSE
• SEVERE SLURRY LOSS AT THE FORM
JOINTS
• CONGESTED REINFORCEMENT
• IN SUFFICIENT FINES/PASTE VOLUME
• IMPROPER PLACEMENT TECHNIQUE
BUG HOLES (OR) AIR VOIDS
 CAUSES
• Form face impermeable
• Poor wetting characteristics
• Form work too flexible
• Use of improper form release agent
FORM STREAKING
 CAUSES
• SLURRY LEAK THROUGH FORM
JOINTS
• EXESSIVE VIBRATION
• FORM GETTING VIBRATED DURING
CONSOLIDATION
• MORTAR WASHING THOUGH TIE
ROD HOLES
• LOOSE FITTING FORMS
Aggregate Transparency
 CAUSES

• TOO FLEXIBLE FORM

• HIGH DENSITY OR GLOSSY FORM
SURFACE
• LOW SAND CONTENT
• POROUS AGGREGATES
• HIGH SLUMP
SUBSIDENCE CRACKING
 CAUSES
• Poor thermal insulation

• Irregular shape restraining settlement

• Excessive Absorbency
The cracks are caused because the upper

concrete bridges between the forms while

the lower concrete settles.

• Cracks may occur when there is an
insufficient interval between placement of
concrete in columns and placement of
concrete for slabs or beams.

• They may also occur adjacent to

blockouts or over reinforcing bars with
shallow cover.
 PREVENTION
• To prevent subsidence cracking, the concrete
can be re-vibrated.

• Re-vibration is most effective when done at the

latest time at which the vibrator head will
penetrate the concrete under its own weight.

• Subsidence cracking over reinforcing bars can be

controlled by increasing concrete cover during
the design phase and by using well-consolidated,
low-slump concrete.
COLOUR VARIATION
 CAUSES

• Non uniform concrete

• Vibrator placed near to the form work

• Excessive vibration at closer interval

• External vibration used haphazardly

• Non uniform application of the release agent.

Sand Streaking
 CAUSES

• Low absorbency of the form

• Excessive bleeding along the forms.
• Very harsh mixes
• Too wet mix - High slump
LAYER LINES
 CAUSES
• Dark horizontal lines on formed surfaces
which indicate the boundary between
concrete placements.
• Layer lines are caused by stiffening or
insufficient consolidation of the lower level
due to lack of penetration of the vibrator into
the lower level.
FORM OFFSET
 CAUSES
• Inadequate stiffness or anchorage
of the forms and can be
aggravated by too high a rate of
placement and/or using too
powerful a vibrator.
COLD JOINT
 CAUSES
• TOO EARLY STIFFING OF CONCRETE

• CAN BE PREVENTED BY

– ADEQUATE PLANNING OF RESOURCES

– PLANNING LAYER THICKNESS
– PLACING SUCCESSIVE LAYER BEFORE INITIAL
SETTING OF CONCRETE
Minor defects in concrete
Bug hole
 Minor defects in concrete
-bug hole prevention-
• Prevention
(1)Proper consolidation. Vibration should be completed with each lift of concrete
placed. As successive lifts are placed, the vibrator should penetrate the previous
lift, working the entrapped air towards the form and then vertically up the sides.
(2)Permeable Forms. When impermeable forms are used, more vibration is
necessary to move the air voids to the free surface of the concrete. The use of
permeable forms has been shown through research to reduce bugholes
significantly by allowing escaping air to move through the form to the ambient
air. Choosing the proper form releasing agent in the proper amount can also
improve the surface quality.
(3)Mix design. Workable, flowing mixtures are easier to place and consolidate
and therefore reduce the risk of bughole formation. Concrete with an optimally
graded aggregate that avoids excessive quantities of fine aggregate, properly
proportioned cement content, and any admixture that provides increased flow,
workability, or ease of consolidation contributes to bughole reduction. Self-
Consolidating Concrete (SCC) is becoming increasing popular for industries
(precast especially) to improve surface quality.
Minor defects in concrete - OK
Minor defects in concrete
bird bath
Minor defects in concrete
trowel mark
Minor defects in concrete
designer
Minor defects in concrete
efflorescence
Minor defects in concrete
bird bath
Formwork
Formwork - Failures
Formwork - Stripping
Reinforcement (Rebar)
Reinforcement (Rebar)
Rebar
chair
Cover Block
Rebar
cover
Rebar - Beware
 Repair
Injection Grouting

Max. 160 PSI (11 Kg / sq.cm.)

 Repair
patching material
Two approaches are possible:
• The use of “semi-dry” mixtures of cement,
water and aggregate which are compacted by
being rammed into position. Useful for Cavity.
• The use of plastic mixtures of cement, water,
polymer emulsion (SBR or Acrylic) and
aggregate (polymer-modified mixtures) which
are applied by means of a trowel or spatula.
 Repair
patching
 Repair
patching
 Repair
patching
 SPECIAL CONCRETE
• SELF COMPACTING CONCRETE
• SLIPFORM CONCRETE
• MASS CONCRETE
• HOT WEATHER CONCRETE
• CONTROLLED LOW STRENGTH
MATERIAL - CLSM
 Introduction
• The term ‘self compacting concrete’ (SCC) was introduced
in 1989 by Professor Ozowa of Japan. The concept was to
revolutionize concrete technology and open up new
horizons in concrete applications that were before
unthinkable. SCC had been defined as the following:
• ‘A concrete that is able to flow and fill every part
and corner of the formwork, even in the presence
of dense reinforcement, purely by means of its
own weight and without the need for any
vibration or other type of compaction’
Osowa/Khurana
 Pioneering SCC in India
• Since 1989, SCC has been used extensively in
Europe and Japan, SCC has now become a new
technology in India. This is not because of a
shortage of labour as in Europe and Japan, but
because of the tangible advantages it brings in
terms of the quality, time and cost to a project in
addition to the new previously unimaginable
possibilities SCC brings to the Indian
Construction Industry. The amount of work L&T
has done on various projects, L&T will be
considered pioneer of launching SCC in India .
 SCC BENEFITS
IT HAS PROVED BENEFICIAL BECAUSE OF A NUMBER OF
FACTORS, INCLUDING :
• FASTER CONSTRUCTION
• REDUCTION IN SITE MANPOWER
• BETTER SURFACE FINISH
• EASIER PLACING
• IMPROVED DURABILITY
• GREATER FREEDOM IN DESIGN
• THINNER CONCRETE SECTIONS
• REDUCED NOISE LEVELS ABSENCE OF VIBRATION
• SAFER WORKING ENVIORMENT
 Advantages
Designer Contractor
 Innovative design –  Reduced constructiontime
Any shape  Less manpower
 Denser reinforcement  Reduced e q
u
ip m e ntcost
 Improved durability  More repetition
of shutter
 Safe and eniro
v
n
m e
n
tfriendly
 Reduced repair w o
rk
 Characteristics
• Requires no vibration
• Compaction under self weight
• Passes round obstructions
(Deformability)
• No segregation of Water / Slurry
• Excellent surface finish
APPROACH TO SCC MIX DESIGN
 Introduction

Key properties of fresh SCC

Flowability Passing ability Filling ability

Segregation resistance
FLOW BY SLUMP CONE
FLOW BY SLUMP CONE
FLOW BY SLUMP CONE
 . Form system

• All common material for form surfaces can be

used but it has been observed that plywood
is slightly better than steel regarding surface
pores.
• For forms in excess of 3 meters in depth ,the
full hydrostatic head should be taken in to
consideration. This may require modification
of the formwork design.
• If crucial, then do a trial.
• It is difficult to obtain a slope of a surface
greater than 2% with SCC and without using
an upper form
 Transport
• It is not recommended to add water into the truck
drum as this method is rather uncertain and
segregation can easily occur.
• Our recommendation is that the truck-driver
normally does not add any admixtures to the batch.
However, if the concrete is too stiff, the filling ability
can be adjusted by adding superplasticiser directly
into the truck drum.
• If the truck-driver has to add this at the site, he shall
have appropriate written instructions on how to do
this, which tests shall be performed and how to
complete the delivery note.
• If admixtures are introduced in the truck-mixer at a
site the same testing that normally is carried out at
the concrete plant has to be done at the site.
 Transport
.

• As the SCC can segregate if it is not agitated

properly during transport and waiting-time
• During the transport to the site and the waiting
time the drum should rotate at low speed (not
less than 2 Rotation per minute). However, just
before delivery the drum has to be rotated on full
speed (10 - 20 rotations per minute) for at least 3
minutes at the construction site. Extra care
should be taken for long deliveries.
 Placing of scc

• Placing of concrete done by pump, skip or chute.

There is no problem with pumpability if the
concrete mix is well designed .Boom placer also
used for placing
• SCC limits the vertical free fall distance to 5
meters and limits the permissible distance of
horizontal flow from point of discharge to 10
meters.
• If longer distance flow will be used then this
should be taken care of at the mix design stage.
Development of SCC in L&T

Mock-up trial at L&T

•Mock up in 2001
•2.0x 1.0x 0.25 meter
•M20 grade SCC
SCC - Mockup
Small scale application

Smooth finish
Sharp edges

Construction of Shiva temple in L&T

SCC in Siva temple - salient features
 SCC in rainy season
 Maximum aggregate size 25mm
 Height of pour – 4.5m (column)
 Deshuttering at 18 hrs. (6 pm – 12
noon)
 Flow = 70cm, excellent surface finish
 Manual placing - spread : 2.500m
- slope : 1 in 48
DMRC STATION BUILDING
 TN01 project

Crash barrier - 1 6 meter with SCC

 TN01 project

1 6 running meter - finished in 40 min.

 Taj wild fire

Foundation - 4m 3 /6 min .
Taj wild fire
Thickness -
100mm
One layer
reinforcement
Electrical
conduits
Clear
spacing -
30mm
Shear wall – L&T Infotech
 LTIT – CHENNAI - 2005

Length of pour 25 m height 3.8 m –SCC

 LTIT – CHENNAI - 2005

Wall constructed with SCC

L&T Infotech
L&T Infotech
 Roof Elements- Bottom Side

SCC at Bangalore International Airport Project

 Why SCC ?
• The finished element has a unique shape
• The sectional thickness is 250 mm
• Length 24 M & Width 7 M
• Congested reinforcement
• Uniform colour with smooth finish ??
• Vibration – very difficult due to shape

• Weight of each element – 110 MT

Reinforcement
Reinforcement
Roof Element

Top side of element

Roof Element

Top side of element

Kuttiyadi – HEPP

Power House Wall SCC – 200 mm Thk

 Kuttiyadi
• Core
samples
extracted
to know
the
characteris
tic of
concrete –
free from
segregatio
n
 SCC in L&T Projects
• Taj Wild Fire Hotel- Bangalore
• Khopoli Water Inductor System
• Oberai Flight Kitchen – Chennai
• Technology Centre II – L&T Infotech (All building elements)
• MIOT Hospital Slab concrete
• DMRC – Delhi Metro
• Bangalore International Airport
• Hyundai Car Factory- Chennai
• Hyderabad International Airport
• CTS – Siruseri & MEPZ
• TCS Siruseri
• Kuttiyadi Hudro Electric Project
• Second Vivekananda Bridege - Kolkata
 Conclusions

• So far, the use of SCC on these

project has been seen to be very
beneficial in terms of time savings,
quality and ease of placement and
is gaining great acceptability
amongst clients.
Special Concrete

Slip form concrete

 Slipform concrete
• Concrete requirements
– Cohesive
– Slightly over sanded
– Slump of 80 to 120 mm
– Has no bleeding
– Has required retarding (initial setting)
WORKABILITY REQUIRED

A. Easy compaction
B.To cover and protect the reinforcement.
C.To have less friction on formwork shutters.
• A film of mortar is created by compaction at
the contact with the form panel.
• This mortar film avoids micro - cracks
during
slipform lifting.
D.Provide smooth surface to wall.
.
 Concrete mix
• Cement content – just adequate to give
strength. Excessive cement content not to be
used
• W/c ratios – For Chimney, cooling tower etc
0.45, others- as per IS 456
• Sand – 40 to 45 %
• Slump – 80 to 120 mm
• Setting – Depend on Structure/Pouring
planned
• Free from segregation & bleeding
 SLUMP

TEMPERATURE SLUMP TEST (ON FRUSTUM OF A CONE) CM

TC
MANUAL COMPACTION VIBRATION

T>+25  C 10 -12 8 -10

T<+25  C 6-8 4-6

If the concrete is too dry, it cannot be well compacted, thus

leading to inadequate quality of work, and repairs being
necessary. If the temperature is more than 40ºc adequate
precautions are to be taken.
CONCRETE PLACEMENT

Normally concrete to be placed in 250 to

300mm layers.

The layer thickness should be decided based

on:

1. Size of the structure

2. Concrete production rate

3. Initial setting time of concrete

COMPACTION OF CONCRETE

(I) Compaction only by concrete vibrators having atleast

5000-6000 vibration /min.

(Ii) The vibrator must be slowly introduced in to the concrete,

allow its protruding into the previously compacted layer,
the vibration time is 10- 20 sec.

(Iii) it is absolutely forbidden to touch the form or

reinforcement with the vibrator in operation.
COMPACTING
 COMPACTING

Wrong way of compaction

Proper
X illuminati
on
Right way of compaction

√
Method of
vibration
 SETTING TIME OF CONCRETE:

If the concrete can be placed satisfactory into the forms and

adequately compacted setting time would appear to be the
important physical feature of the concrete, provide friction is not
excessive.

As setting time decreases with increasing strength of the mix or

more specifically setting time decreases with lower water cement
ratios and is affected by the type of cement and decreases with
increasing temperature.

The setting time of the concrete in the slipform context is equal to

the time for a given section of concrete to separate from the
forms. Considering the allowance setting time of the concrete is
that time after the end of any significant degree of vibration and
ADMIXTURES

•Type of admixture required is decided by,

1.Initial setting time required.
2.Climatic condition
•Normally we use retarder to increase the setting time
(or)
•Super plasticizer cum retarder to
increase workability and retardation.
 PRECAUTION FOR HOT WEATHER CONCRETING

When ambient temperature is >40ºC,

• Minimum time between mixing &
pouring.

 Add retarder to slow down

setting time.

 Wetting or cooling of coarse aggregates.

 Providing cover for aggregates.

 Covering the water tank.

 Continuous curing of exposed

surface.
PRECAUTION FOR COLD WEATHER CONCRETING

When ambient temperature is <5ºC,

 Insulation of the form

panels.

 Heating the “ mixing

water”

 Heating the
aggregates

 Slow down the lifting

 Heating the shutter.

 Mass concrete
• Large pours with higher volumes
• Depth of pours more than 2M
• Pours need monolithic casting
• Pours where thermal stress to be taken
care
 Blast Furnace Foundation
• The Furnace foundation
consists of following:
Base Raft
Bottom Pedestal
Top Pedestal
Tower Columns
 FOUNDATION DETAILS
• Raft (-) 6.5m to (-) 3.0m
Size : 43m x 28m x3.5m
Concrete volume: 4214m3
• Bottom Pedestal (-) 3.0m to (-) 0.719m
Size : 22.6m dia. X 2.281 m
Concrete volume : 914.5m3
• Top Pedestal (-) 0.719m to (+) 4.531m
Size : 17.2m dia. X 5.25m
Concrete volumn: 1219m3
Schematic Model of
Furnace Foundation
+4.531

Top Tower Column

Pedestal
-0.719

Bottom
-3.50
Pedestal

Base Raft -6.50

 RESOURCES

BATCHING PLANT : 04 + 02 Nos.

CONCRETE PUMP : 04 + 02 Nos.
TRANSIT MIXERS : 16 + 08 Nos.
Planned Productivity

BATCHING PLANT : @ 17 Cum per Hr. per No.

CONCRETE PUMP : @ 17 Cum per Hr. per No.
 Mass Concrete

29 31 38 45 52 59 65 68 70

20 28 30 37 44 51 58 64 67 69

14 19 22 27 36 43 50 57 61 63 66

3.5
M 10 13 18 21 26 35 42 49 56 62

6 9 12 17 25 34 41 48 55 60

3 5 8 11 16 24 33 40 47 54

1 2 4 7 15 23 32 39 46 53
43 M

4214 cum
 Quantity calculation
Quantity
per layer 14 cum
production 17 cum
No of plants 4
concrete produced 68 cum
Layer Length 5 M
No of hours required to
complete 4214/68 62 Hours
 PLAN SHOWING CONCRETE PUMP
ALLOCAATION N

R 8600
Concrete Pump(Stand By)

R 11300

FURNACE FOUNDATION
 CLSM
Controlled Low Strength Material
CLSM
 NEWER TECHNOLOGY

• SPRAY PLASTER
• MAGNETISED WATER
• COLOUR CONCRETE
 Spray plaster

• Spray plaster
– handles leaner mix
– Is faster
– Pumps to greater heights.

• In use at
– Purvapanorama
– BIAL
 Spray Plaster machine

View of Spraying Equipment

Front View – Hose Mixing blades

 TURBOSOL UNI 30
Cost of machine – INR 28 Lac
– Electric version fixed with mixer Max delivery distance – 200 m
Motor – 5.5 kW + 1.5 kW Granulometry – Sprayable – 6/7 mm
Output – 30 to 50 l/m Hopper capacity – 190 L
Mixer capacity – 180 L
Max pressure - 50 bar Size – 200 x 150 x 160 cm
Max delivery height pressure – 60 Weight – 840 kg
bar
• Spraying of mortars to injection of special mixes
at controlled pressure.
• Fitted with automatic safety device against over
pressure.
• Operates on pneumatic on/off remote control.
• Higher capacity enhancing pumpability of leaner
mortar.
 Mix used for spray plaster
• Mix used is in-house developed mortar
(to eliminate ready mix plaster)
• CM 1:6 for external plaster
• Sand – 2.36 mm down
• Water – 38 Lit / Bag
• Air Entraining admixture – 0.1 % v/w
• Consistency - Pumpable
 Application process
• Mixing
– Sand, cement, water and admixture added
in the mixer and mixed for 5 min
– Mix unloaded in pumping hopper at bottom
– Pumped through rubber hose connected to
the required height
– Sprayed in position uniformly to the
required thickness
– Finished using straight edge
 Productivity
• Labours
– Mason 2
– Helpers
• At bottom for feeding 5
• At top for hose adjustment 1
• At top with mason 1
• 1 st coat application – 200 sqm / day
• Average productivity for plain area –
12 sqm/ MD
Advantages & Disadvantages
• Advantages
– Faster application possible
– More productivity in plain walls
– Less wastage of material
• Disadvantages
– For building with architectural features not
suitable as application is faster, mortar sets
before finishing
– Needs more skilled masons
 Observations
Needs access over large areas to speed up
application process
• Continuous feeding of equipment
• Delay causes chocking at nozzle
Spray plaster application
Jump Form
Jump Form
Tilt Up Construction
Wastage