TECHNICAL ATTRIBUTES REQUIRED FOR LAUNCHING HYBRID CEMENT

A project report submitted to

STATE BOARD OF TECHNICAL EDUCATION, HYDEREBAD
Dissertation submitted in partial fulfillment of the requirement for the award of the
5

DIPLOMA IN
CIVIL ENGINEERING
Submitted by
G.VARSHA (16090-C-232)
10 UNDER THE GUIDENCE OF
Mr.ROSHAN REDNAM

15

DEPARTMENT OF
CIVIL ENGINEERING
20 VEMUGANTI MANOHAR RAO POLYTECHNIC COLLEGE

(AFFLIATED TO STATE BOARD OF TECHNICAL EDUCATION,HYDEREBAD)

Rampur(v),Dharmasagar(mdl),Warangal urban(dist),telangana,506151

2018-2019
 DEPARTMENT OF CIVIL ENGINEERING
VEMUGANTI MANOHAR RAO POLYTECHNIC
(Affiliated To State Board Of Technical Education,Hyderabad)
Rampur(vill),Dharmasagar(mdl),Warangal urban(Dist)
5

10

CERTIFICATE
This is to certify that the project entitled “construction and estimation of cement
concrete road “is submitted by bearing hall ticket number for the partial fulfillment
15 of the requirements for the award of the diploma in civil engineering during the
academic year 2018-2019.

G.VARSHA (16090-C-232)
20

GUIDE H.OD PRINCIPAL

25 MR.ROSHAN REDNAM Mr.RAGHU RAM Mr.PRADEEP KUMAR

30
EXTERNAL EXAMINER
 ACKNOWLEDGEMENT
I write this acknowledgement with the great honor,pride and pleasure to pay our
respects to all who enable directly or indirectly in reaching this stage .
5

I was indebted forever to our guide Mr.ROSHAN REDNAM department of civil

engineering(ASST.MANAGER-TECHNICAL SERVICES) for his valuable
suggestions,guidance and inspirations is carrying out this Major Project Work.
10 With the sense of privilege,I express our deep gratitude to the coordinates
department of civil engineering for their valuable suggestions ,sagacious
guidance ,scholarly advice and compressive critical remarks during the course of
major project .
15 I express our profound thanks for Mr.RAGHU RAM head of civil
department(H.O.D) for unflinching devotion , which lead us to complete this major
project .
I would like to pay respectable tanks for all the facilities required for completing
20 this dissertation work.
I wish to extend our sincere thanks to our parents and others understanding and co-
operation during the course of major project work.
25 I take this opportunity to convey our sincere thanks to our classmates who have
directly and indirectly contributed for the successfully completion of work.

G. VARSHA (16090-C-232)

30

DECLARATION

I am G.Varsha the student of diploma in civil engineer of Vmr

35 Polytechnic College, Rampur from StateBoard Of Technical
Education.Hyderabad,T.S. here by declares that the project entitled
“TECHNICAL ATTRIBUTES REQUIRED FOR LAUNCHING HYBRID CEMENT ” is the
 original work carried out by team.To the best of our knowledge

and belief we here by declare that this project bears no

resemblance to any other project submitted at Vmr Polytechnic

College,Rampur or any other college affiliated to form State

5 Board of Technical Education,Hyderabad for the award of

degree.
 ABSTRACT

Our project is to have a detail study on “TECHNICAL ATTRIBUTES

5 REQUIRED FOR LAUNCHING HYBRID CEMENT ”

This project was aimed to create amd focus on the following:

1. Construction practises.
10 2. Lead generation.
3. Brand promotion
4. Site supervision with consulting engineers
5. Customer relationship building
6. Cement plant visit.
15

20

Index :-

1. Company profile
25 2. Definition of cement
1. Types of cement
2. Types of process involved in cement manufacturers
3. The Cement manufacturing processes
4. Grades of cement
30 1.OPC of grades 43&53
2.PPC
 3.Strongcrete
4.Advantages of OPC & PPC
5.Properties of strongcrete
6.Difference between OPC &PPC
5 5. Concrete grades proportions
6. Clear cover of main reinforcement
7. Weight of steel/bars per m³ length
8. Design mix proportions
1.Aggregates
10 2.Water
3.Admixtures
4.Work-ability, strength & workability of concrete
9. Concrete materials & properties
10.Planning & site preparation
15 11.Compacting concrete
12.Finishing of concrete
13.Defects in concrete
14.Cube casting test
15.A Visit to cement plan
20 1.expreinces and photographs of cement plant
17.Conclusion
 Orient company profile :-
Industry :-Infrastructure / Manufacturing
Products / Service :- Cement
Orient cement was established in 1979amd is one of the India's most
5 efficient and high margine cement companies,with a production
capacity of five million tons per Annum.
With a focus on resilience and durability,the quality of the company
product has created bench marks in the industry.orient cement is one
of the only two Indian cement companies to be awarded the
10 prestigious TPM (total plant maintenance) excellence award by the
Japan Institute of plant maintenance.The company has also received
numerous award for green and safety practices.
Orient cement stands for strength and trust ,and has established a
reputation for the use of a high grade raw materials.Birla A1 premium
15 cement is the flagship brand ,and is suitable for all types of industrial,
residential and commercial constructions.

Orient cement began cement production in the year 1982,at Devapur

in Adilabad district ,Telangana.In 1997,a split grinding unit was added
20 at Nashirabad in Jalgon,Maharastra.In 2015, orient cement started
commercial production at its integrated cement plant located at
Chittapur,Gulbarga,Karnataka.With a total capacity of 8 MTPA,they
serve Maharashtra, Telangana,Andhra Pradesh, Karnataka and parts of
Madhya Pradesh, Tamil Nadu, Kerala, Gujarat and Chattisgarh.
25

Definition of cement :- A powder of alumina,silica,lime , oxide and

magnesium oxide burned together in a kiln and finely pulverised and
used as an ingredient of mortar and concrete.
Types of cements :-
30  OPC (Orient Portland Cement)
 PPC (Portland Pozzolona Cement)
  Rapid Hardening Cement
 Extra Rapid Hardening Cement
 Quick Setting Cement
 Low Heat Cement
5  Portland Slag Cement
 Sulphate Resisting Cement

Types of process in cement manufacturing :-

1. Dry process
10 2. Wet process
 The main difference between these two process of
manufacturing of cement is that in the dry process, calcareous
and argillaceous raw material are fed into the burning kiln in a
perfect dry state.
15  And,In wet process,how ever these materials are supplied into
the kiln in the form of an intimate mixture with water called
“SLURRY”.
The main processes involved in the manufacture of OPC are:
1. Mixing of raw materials.
20 2. Burning.
3. Grinding.
Properties :-
1. The colour of cement should be uniform and should be in grey
with a light greenish shade.
25 2. Cement should have a smooth feel When hand is put in a bag of
cement (when opened0 it should have a cool sensation.
3. A small quantity of cement thrown in bucket of water should
sink and there should not be any floating particles. If it floats,
there is adulteration, such as missing as ash etc.
30 4. Cement should not have any hard lumps.
5. Cement should not feel oily when touched all the above.
6. Properties are similar to any type of cement, only it may vary for
 which purpose it is produced.
7. When sieved on IS No. 9, its resides shall not exceed 10 percent.
8. Its initial setting time is not less than 30 minutes and final
setting time not more than 10 hours.
5 9. Its compressive strength, after 3 days test is not less than 11.5
KN/mm2 and after 7 days test not less than 17.5N/mm2.
10. For unaerated cement the expansion is not more than
10mm and for aerated cement should not be more than 5 mm,
when soundness test is performed.
10 Uses:
1. It is used for all important engineering structure where great
strength is required.
For example; Heavy bridges, dams massive structure culverts
etc.
15 2. It is used for plastering and pointing.
3. It is used for drainage and water supply works.
4. It is also used for thin masonry work, where strength is required.
5. In wet places such as rivers etc. This is used to in foundations.
Ex: Foundation under water reservoir, water tight floors, dock
20 yards, water storage tanks, etc.
6. It is used for making cement mortar, plain concrete reinforced
concrete etc.
7. It is used for the manufacture of precast pipes, piles etc.
8. It is used for making cement mortar for floors, roof, beams
25 lintels etc.
Manufacturing of Portland cement
 Calcium silicates are the primary constituents of Portland
cement.
 Raw material for P.C is calcium & silica
30 alcium: lime stone, chalk, etc (Cao+ CO2)
Silica: clays shale’s (SiO2+ Al2O3= Fe2O3+ H2O)
 2/3 Calcium Raw mix should be well
1/3 Clay homogeneous before the heat treatment

Process Flow Chart

5 Cement Manufacture Process

There are six main stages of cement manufacturing process.
1. Raw Material Extraction/Quarry
The raw cement ingredients needed for cement production are
limestone (calcium), sand and clay (silicon, aluminum, iron), shale, fly
10 ash, mill scale and bauxite. The ore rocks are quarried and crushed to
smaller pieces of about 6 inches. Secondary crushers or hammer mills
then reduce them to even smaller size of 3 inches. After that, the
ingredients are prepared for processing.
2. Grinding, Proportioning and Blending
15 The crushed raw ingredients are made ready for the cement making
process in the kiln by combining them with additives and grinding
 them to ensure a fine homogenous mixture. The composition of
cement is proportioned here depending on the desired properties of the
cement. Generally, limestone is 80% and remaining 20% is the clay.
In the cement plant, the raw mix is dried (moisture content reduced to
5 less than 1%); heavy wheel type rollers and rotating tables blend the
raw mix and then the roller crushes it to a fine powder to be stored in
silos and fed to the kiln.
3. Pre-Heating Raw Material
A pre-heating chamber consists of a series of cyclones that utilizes the
10 hot gases produced from the kiln in order to reduce energy
consumption and make the cement making process more environment-
friendly. The raw materials are passed through here and turned into
oxides to be burned in the kiln.
4. Kiln Phase
15 The kiln phase is the principal stage of the cement production process.
Here, clinker is produced from the raw mix through a series of
chemical reactions between calcium and silicon dioxide compounds.
Though the process is complex, the events of the clinker production
can be written in the following sequence:

20 1. Evaporation of free water.

2. Evolution of combined water in the argillaceous components.
3. Calcinations of the calcium carbonate (CaCO3) to calcium oxide
(Ca O).
4. Reaction of Ca O with silica to form dicalcium silicate.
25 5. Reaction of Ca O with the aluminum and iron-bearing
constituents to form the liquid phase.
6. Formation of the clinker nodules.
7. Evaporation of volatile constituents (e. g., sodium, potassium,
chlorides, and sulfates)
30 8. Reaction of excess Ca O with dicalcium silicate to form tri
calcium silicate.

The above events can be condensed into four major stages based on
the change of temperature inside the kiln:

1. 100°C (212°F): Evaporation of free water.

 2. 100°C (212°F)-430°C (800°F): Dehydration and formation of
oxides of silicon, aluminum, and iron.
3. 900°C (1650°F)-982°C (1800°F): CO2 is evolved and Ca O is
produced through calcinations.
5 4. 1510°C (2750°F): Cement clinker is formed.

The kiln is angled by 3 degrees to the horizontal to allow the material

to pass through it, over a period of 20 to 30 minutes. By the time the
raw-mix reaches the lower part of the kiln, clinker forms and comes
out of the kiln in marble-sized nodules.
10 5. Cooling and final grinding
After exiting the kiln, the clinker is rapidly cooled down from 2000°C
to 100°C-200°C by passing air over it. At this stage, different
additives are combined with the clinker to be ground in order to
produce the final product, cement. Gypsum, added to and ground with
15 clinker, regulates the setting time and gives the most
important property of cement, compressive strength. It also prevents
agglomeration and coating of the powder at the surface of balls and
mill wall. Some organic substances, such as Trithanolamine (used at
0.1 wt. %), are added as grinding aids to avoid powder agglomeration.
20 Other additives sometimes used are ethylene glycol, oleic acid and
dodecyl-benzene sulphonate.
The heat produced by the clinker is circulated back to the kiln to save
energy. The last stage of making cement is the final grinding process.
In the cement plant, there are rotating drums fitted with steel balls.
25 Clinker, after being cooled, is transferred to these rotating drums and
ground into such a fine powder that each pound of it contains 150
billion grains. This powder is the final product, cement.
Packing and Shipping
Cement is conveyed from grinding mills to silos (large storage tanks)
30 where it is packed in 20-40 kg bags. Most of the product is shipped in
bulk quantities by trucks, trains or ships, and only a small amount is
packed for customers who need small quantities.
Uses of cement
Now a days cement is very extensively used in construction of
 all various heavy and important engineering structures. The main
reason wide usage is due to its quickly (early) setting and produces
good strength, following are the various uses

1. It is used in mortar for plastering, masonry work, pointing, etc.

5 2. It is used for water tightness of structure.
3. It is used in concrete for laying floors, roofs and constructing
lintels, beams, stairs, pillars etc.
4. It is used where a hard surface is required for the protection of
exposed surfaces of structures against the destructive agents of the
10 weather and certain organic or inorganic chemicals.
5. It is used for precast pipes manufacturing, piles, fencing posts etc.
6. It is used in the construction of important engineering structures
such as bridges, culverts, dams, tunnels, lighthouses etc.
7. It is used in the preparation of foundations, watertight floors,
15 footpaths etc.

S.NO. Name of the ingredient Approx proportion percentage

1. Lime (Ca O) 60 to 67
2. Silica (SiO2) 17 to 25
3. Alumina (Al2 O3) 3 to 8
4. Calcium sulphate (Ca 2 to 4
SO4)
5. Iron oxide (Fe2 O3) 0.5 to 6
6. Magnesium oxide (Mg 0.1 to
O)
7. Sulphur trioxide (SO3) 1 to 3
8. Insoluble residue ≥ 1.5 %
9. Loss on ignition ≥4%

8. It is employed for the construction of wells, water tanks, tennis

 Grades of cement
1.OPC of grades 43 and 53
2.PPC
3.Strongcrete
5 4.Advantages of OPC and PPC
5.Properties Of strongcrete
6.Difference between OPC and PPC
TYPES OF CEMENT
1.OPC-ordinary Portland cement
10 2.PPC -Portland pozzolona cement
1.OPC-53grade and 43grade
Strongcrete
OPC :-ordinary Portland cement is one of the most widely used
type of cement
15 THE CHEMICAL CONSTITUENTS OF OPC ARE :-
1.Lime(CaO) :-60 to 67%
2.silica(Sio2):-17-25%
3.Allumina(Al2O3):-3-8%
4.Iron oxide(Fe2O3):-0.5-6%
20 5.magnesia(Mgo):-0.1-4%
6.Sulphur dioxide(So3) :-1-3%
7.soda&potassium (Na2O+k2O) :-0.5-1.3%
ADVANTAGES OF OPC:
1.It has great resistance to cracking and shrinkage
25 2.Less resistance to chemical attack
 3.Initial setting Time of opc is faster
4.Curing period of OPC is less than PPC
5.Curing cost reduces
DISADVANTAGES OF OPC :
5 1.It cannot be used for high concrety as it has high heat of
hydration When compared to PPC
2.The durability of concrete made using OPC is less than that of
the concrete made using PPC
3.OPC has over tineness and hence has higher permeability and
10 result it has lower durability
4.OPC is costlier than PPC
PPC
PPC:-Portland pozzolona cement is integrated cement which is
formed by synthesising OPC cement with pozzolanic materials in a
15 certain proportion.
ADVANTAGES OF PPC
1.It is an eco-friendly cement as the material used in the
manufacture are made of natural re-cycled waste
2.It is very tine cement hence, very good when used for
20 plastering works
3.pozzolona consists of silica material which makes it cheap and
hence reduces the cost of the cement making it economical to use
4.PPC is used in pre-stressed and post-tensioned concrete
members
25 5.It reduces the carbon monoxide emission from the concrete
making it environmental friendly

DISADVANTAGES OF PPC:
 1.The initial strength obtained is less, which effect the de-
shuttering of supports earlier
2.As it contains more tine material handing of concrete is
difficult
5 3.when compared to the OPC setting time is less for PPC
STRONGCRETE
strongcrete is especially engineered for concrete applications
such as in foundation, beams, columns and slabs
ADVANTAGES OF STRONGCRETE
10 1.It is specially designed for foundation,Beams,columns and slabs
2.It is faster setting time
3.LPP bags are used to pack the cement
DISADVANTAGES OF STRONGCRETE
1.The cost of strongcrete is more than PPC
15 2.strongcrete is not used in walls etc....
PROPERTIES OF STRONGCRETE
1.Higher initial strength 💪
2.crack resistance
3.corrosion inhabiter
20 4.Denser concrete
5.Higher ultimate strength
6.optimum tineness
7.Optimum partical size distribution
8.Optimum quality of mineral admixtures
25 9.Faster setting time
10.Low heat of hydration
 11.LPP bags
12.concrete engineer
DIFFRENCE BETWEEN OPC AND PPC:

OPC PPC

01.96%lime stone and 4%gypsum 1.65%-70%limestone,25%-

2.ISI mark will be in black 30%flyash+4%gypsum
3.Higher initial setting time 2.ISI mark will be red
(28days) 3.Lower initial setting time
4.High heat of hydration 4.Low heat of hydration
5.chances of getting cracks will 5.No chances of getting cracks
be high 6.Low permeability
6.High permeability 7.It forms secondary jel
7.No Secondary Jel formation formation
8.steel gets rust 8.No rusting of steel
9.High price 9.Low price
10.concrete Will be high 10.denser and cohesive concrete

5
 Proportions of concrete grades for design mix :-
M10 ( 1 : 3.92 : 5.62)

Cement : 210 Kg/ M³

5 20 mm Jelly : 708 Kg/ M³
12.5 mm Jelly : 472 Kg/ M³
River sand : 823 Kg/ M³
Total water : 185 Kg/ M³
Fresh concrete density: 2398 Kg/M³
10

M20 ( 1 : 2.48 : 3.55)

Cement : 320 Kg/ M³

20 mm Jelly : 683 Kg/ M³
15 12.5 mm Jelly : 455 Kg/ M³
River sand : 794 Kg/ M³
Total water : 176 Kg/ M³
Admixture : 0.7%
Fresh concrete density: 2430 Kg/ M³
20

CLEAR COVER OF MAIN REINFORCEMENT :-

1.FOOTINGS : 50 mm
2.RAFT FOUNDATION.TOP : 50 mm
3.RAFT FOUNDATION.BOTTOM/SIDES : 75 mm
25 4.STRAP BEAM : 50 mm
 5.GRADE SLAB : 20 mm
6.COLUMN : 40 mm
7.SHEAR WALL : 25 mm
8.BEAMS : 25 mm
5 9.SLABS : 15 mm
10.FLAT SLAB : 20 mm
11.STAIRCASE : 15 mm
12.RET. WALL : 20/ 25 mm on earth
13.WATER RETAINING STRUCTURES : 20/30 mm
10

WEIGHT OF ROD PER METER LENGTH:

DIA WEIGHT PER METER
6mm = 0.222Kg
8mm = 0.395 Kg
15 10mm = 0.616 Kg
12mm = 0.888 Kg
16mm = 1.578 Kg
20mm = 2.466 Kg
25mm = 3.853 Kg
20 32mm = 6.313 Kg
40mm = 9.865 Kg
 CONCRETE
Concrete is a construction material composed of cement, fine
aggregates (sand) and coarse aggregates mixed with water which
hardens with time. Portland cement is the commonly used type of
5 cement for production of concrete. Concrete technology deals with
study of properties of concrete and its practical applications.
In a building construction, concrete is used for the construction of
foundations, columns, beams, slabs and other load bearing elements.
There are different types of binding material is used other than cement
10 such as lime for lime concrete and bitumen for asphalt concrete which
is used for road construction.
Various types of cements are used for concrete works which have
different properties and applications. Some of the types of cement are
Portland Pozzolana Cement (PPC), rapid hardening cement, Sulphate
15 resistant cement etc.
Materials are mixed in specific proportions to obtain the required
strength. Strength of mix is specified as M5, M10, M15, M20, M25,
M30 etc, where M signifies Mix and 5, 10, 15 etc. as their strength in
KN/m2. In United States, concrete strength is specified in PSI which is
20 Pounds per Square Inch.
Water cement ratio plays an important role which influences
various properties such as workability, strength and durability.
Adequate water cement ratio is required for production of workable
concrete.
25
 When water is mixed with materials, cement reacts with water and
hydration reaction starts. This reaction helps ingredients to form a
5 hard matrix that binds the materials together into a durable stone-like
material.
Concrete can be casted in any shape. Since it is a plastic material in
fresh state, various shapes and sizes of forms or formworks are used to
provide different shapes such as rectangular, circular etc.
10 Various structural members such as beams, slabs, footings, columns,
lintels etc. are constructed with concrete..
Various types of concrete are manufactured these days for
construction of buildings and structures. These have special properties
and features which improve quality of construction as per
15 requirement.

Concrete Grade Mix Compressive Str

 Ratio MP a (N/mm2)

Normal Grade of Concrete

M5 1 : 5 : 10 5 MP a

M7.5 1:4:8 7.5 MP a

M10 1:3:6 10 MP a

M15 1:2:4 15 MP a

M20 1 : 1.5 : 3 20 MP a

Standard Grade of Concrete

M25 1:1:2 25 MP a

Design
M30 30 MP a
Mix

Design
M35 35 MP a
Mix

Design
M40 40 MP a
Mix

CONCRETE GRADES :
M5 = 1:4:8
M10= 1:3:6
 M15= 1:2:4
M20= 1:1.5:3
M25= 1:1:2

5 Concrete Materials :-
CONCRETE is made by mixing :
Cement
Water
Coarse and fine aggregate
10 Admixture (if required)
Aim is to mix these materials in measured amount to make concrete
that is easy to
Transport
Place
15 Compact
Finish
And which will set ,and harden ,to give a strong and durable product.
The amount of each materials (i.e cement,water and aggregates)
affects the properties of hardened concrete.

20 Concrete properties :-
The Properties of
Concrete are its
characteristics or basic
qualities.
25 The four main properties
of concrete are:
WORKABILITY
COHESIVENESS
 STRENGTH and DURABILITY
Concrete has three different states:
PLASTIC
SETTING
5 HARDENING
In each state it has different properties.

CONCRETE STATES
Plastic State When the concrete is first mixed it is
like 'bread dough'. It is soft and can be worked or
10 moulded into different shapes. In this state concrete is
called PLASTIC. Concrete is plastic during placing
and compaction.
The most important properties of plastic concrete are
workability and cohesiveness.
15 A worker will sink into plastic concrete.

Setting State
Concrete then
begins to
stiffen. The
20 stiffening of
concrete,
when it is no
longer soft, is
called
25 SETTING.
Setting takes place after compaction and
during finishing.
Concrete that is sloppy or wet may be easy to place but will be more
difficult to finish.A worker leaves footprints in setting concrete.
30 Hardening State After concrete has set it begins
 to gain strength and harden. The properties of hardened concrete are
strength and durability.Hardened concrete will have no footprints on it
if walked on.
AGGREGATES :-
5 Aggregates are of two basic types:
COARSE: crushed rock, gravel or screenings.
FINE: fine and coarse sands and crusher fines.
Sand should be concreting sand and not brickies sand or plasterers
sand.
10 Aggregates should be:
STRONG and HARD A stronger,
harder aggregate will give a stronger
final concrete. Never use a crumble or
flakey rock like sandstone.
15 DURABLE to stand
up to wear and tear
and weathering.

CHEMICALLYCHEMICALLY INACTIVE so the

aggregates don’t react with the cement.

20 CLEAN Dirt or clay sticking to the aggregates will

weaken the bond between paste and aggregates.

GRADED Aggregates should range in size so that they fit together

well.
This gives a stronger and denser
25 concrete.
Rounded aggregates give a more
workable mix. Angular aggregates
make concrete harder to place, work and
compact, but can make concrete stronger.
 STORAGE Aggregates should be stored where they will stay clean,
separated from other materials and dry. If the aggregates are very wet
use less water in the mix.
WATER :-Water is mixed with the cement powder to form a paste
5 which holds the aggregates together like glue.
Water must be clean, fresh and free from any dirt,
unwanted chemicals or rubbish that may affect concrete.
Many concrete plants now use recycled water.

10

Always check bore water before use.

Don’t use sea water as it may rust the
steel reinforcement in the concrete

15 ADMIXTURES:- Admixtures are mixed

into the concrete to change or alter its
properties, ie the time concrete takes to
set and harden, or its workability.
WORKABILITY AND DURABILITY :- Well made concrete is a
20 naturally strong and durable material. It is DENSE, reasonably
WATERTIGHT, able to resist changes in TEMPERATURE, as well
as wear and tear from WEATHERING.Strength and Durability are
affected by the density of the concrete. Denser concrete is
morewatertight (or less permeable).Concrete durability INCREASES
25 with strength.Well made concrete is very important to protect the steel
in reinforced concrete.Strength of the concrete in the hardened state is
usually measured by the COMPRESSIVE STRENGTH using the
 compression test.

PLANNING & SITE PREPARATION :-

 The most important step in placing concrete is planning.
5  Always plan every step before any concrete is delivered.
 Proper planning avoids delays, wastage, segregation and
problems which develop from these.
 To eliminate the problem of delay, segregation and wastage.
The following steps should be taken before any concrete is placed.
10  Measure and stake out the area to be
concreted and consider how thick the
slab must be.
 The thickness will depend on the
weight the concrete must carry (ie
15 driveway carries the weight of a car
and needs to be thicker than a
garden path).
 THE FINISHING LEVEL Once the thickness of concrete has
been established, work out where the concrete will finish.
20 Concrete cannot finish too high against steps or the external
house wall and should not cover any part of weepholes in the
wall. The finishing level shows how much digging or excavation
must be done. Pavements must grade away from buildings and
boundaries.
25

COMPACTION of Concrete :- Compaction is removing the air

from concrete. Proper compaction results in concrete with an
increased density which is stronger and more durable.
Compaction is done by shaking, or vibrating,
30 the concrete which liquefies it, allowing the
trapped air to rise out.
WHEN TO COMPACT Compaction must be done as concrete is
 placed, while it is still plastic. Never let concrete dry-out and stiffen
because it will be too hard to compact.
WHY COMPACT Properly compacted concrete is more dense,
strong and durable. Off-form finishes will also be better.
5 EXTERNAL VIBRATION
Screeding Screeding levels and compacts thin concrete slabs and
the top layers of thicker slabs. A screed board will not compact the
concrete very well. Mechanical vibration or hand rodding is required
to provide adequate
10 compaction.
The Mechanical Screed
Concrete is screeded TWICE.
The first screed levels the
concrete roughly and
15 compacts it.
The second screed levels and
compacts the concrete more.
The screed is pulled along the
top of the forms by two
20 workers.
Always keep a small amount,
or surcharge, of concrete, in
front of both beams of the
screed to avoid holes forming
25 in the surface. If a hollow develops, the
screed will not compact the concrete.
The mechanical screed compacts the concrete as it vibrates.
INTERNAL VIBRATION Internal
vibration is done with a mechanical
30 vibrator or poker vibrator. The POKER is
put into concrete and vibrates it from the
inside.
 Method
Make sure there are enough workers so some can compact while
others continue to place.
Put the poker into the concrete QUICKLY. Take the poker out very
5 SLOWLY otherwise a hole,
or weak spot, may be left in the concrete.

The SIZE of the poker determines how much concrete is vibrated at

one time
 Defects in concrete :-

Some defects are obvious only to a

trained eye, others, such as
cracking, are obvious to anyone.
5 Some common defects, their causes
and how to prevent and repair them
are explained below.
If in doubt please consult an expert.

COLOUR VARIATION
10 Difference in colour across the surface of concrete. May appear as patches of
light and dark.

Defects in concrete :-Some defects are obvious only to a trained eye, others,
such as cracking, are obvious to anyone. Some common defects, their causes
and how to prevent and repair them are explained below.

15 If in doubt please consult an expert.

COLOUR VARIATION
Difference in colour across the surface of concrete. May appear as patches of
light and dark.

RAIN DAMAGE
20 The surface has bits washed away or
many small dents.

Causes Heavy rain while concrete

issetting or rainwater being allowed to
run across the concrete surface.
25

30
 Test conducted on concrete :-

1.CUBE TEST METHOD:

5 For cube test two types of specimens either cubes of 15cm X 15cm X 15cm
or 10cm X 10cm x 10cm depending upon the size of aggregate are used. For
most of the works cubical moulds of size 15cm x 15cm x 15cm are
commonly used.

10 This concrete is poured in the mould and tempered properly so as not to have
any voids. After 24 hours these moulds are removed and test specimens are
put in water for curing. The top surface of these specimen should be made
even and smooth. This is done by putting cement paste and spreading
smoothly on whole area of specimen.

15 These specimens are tested by compression testing machine after 7 days

curing or 28 days curing. Load should be applied gradually at the rate of 140
kg/cm2 per minute till the Specimens fails. Load at the failure divided by
area of specimen gives the compressive

strength of concrete.

31
 Following are the procedure for testing Compressive strength  of Concrete
Cubes

Apparatus for Concrete Cube Test

5 Compression testing machine

Preparation of Concrete Cube Specimen

The proportion and material for making these test specimens are from the
same concrete used in the field.

10

Specimen

6 cubes of 15 cm size Mix. M15 or above

Mixing of Concrete for Cube Test

Mix the concrete either by hand or in a laboratory batch mixer

15 Hand Mixing

1. Mix the cement and fine aggregate on a water tight none-absorbent

platform until the mixture is thoroughly blended and is of uniform
color
2. Add the coarse aggregate and mix with cement and fine aggregate

32
 until the coarse aggregate is uniformly distributed throughout the
batch
3. Add water and mix it until the concrete appears to be homogeneous
and of the desired consistency

5 Sampling of Cubes for Test

1. Clean the mounds and apply oil

2. Fill the concrete in the molds in layers approximately 5 cm thick
3. Compact each layer with not less than 35 strokes per layer using a
tamping rod (steel bar 16mm diameter and 60cm long, bullet pointed
10 at lower end)
4. Level the top surface and smoothen it with a trowel

Curing of Cubes

The test specimens are stored in moist air for 24 hours and after this period
the specimens are marked and removed from the molds and kept submerged
15 in clear fresh water until taken out prior to test.

Precautions for Tests

The water for curing should be tested every 7 days and the temperature of
water must be at 27+-2oC.

Procedure for Concrete Cube Test

20 1. Remove the specimen from water after specified curing time and
wipe out excess water from the surface.
2. Take the dimension of the specimen to the nearest 0.2m
3. Clean the bearing surface of the testing machine
4. Place the specimen in the machine in such a manner that the load
25 shall be applied to the opposite sides of the cube cast.
5. Align the specimen centrally on the base plate of the machine.
6. Rotate the movable portion gently by hand so that it touches the top
surface of the specimen.
7. Apply the load gradually without shock and continuously at the rate
30 of 140 kg/cm2/minute till the specimen fails

33
 8. Record the maximum load and note any unusual features in the type
of failure.

Note:

Minimum three specimens should be tested at each selected age. If strength

5 of any specimen varies by more than 15 percent of average strength, results
of such specimen should be rejected. Average of three specimens gives the
crushing strength of concrete. The strength requirements of concrete.

Calculations of Compressive Strength :

Size of the cube =15cmx15cmx15cm

10 Area of the specimen (calculated from the mean size of the specimen )=225
cm2

Characteristic compressive strength(f ck)at 7 days =

Expected maximum load =fck x area x f.s

Range to be selected is …………………..

15 Similar calculation should be done for 28 day compressive strength

Maximum load applied =……….tones = ………….N

Compressive strength = (Load in N/ Area in mm2)=……………N/mm2

=……………………….N/mm2

Reports of Cube Test: They are..,

20 1. Identification mark
2. Date of test
3. Age of specimen
4. Curing conditions, including date of manufacture of specimen
5. Appearance of fractured faces of concrete and the type of fracture if

34
 they are unusual

Results of Concrete Cube Test

Average compressive strength of the concrete cube = ………….N/ mm2 (at 7

days)

5 Average compressive strength of the concrete cube =………. N/mm2 (at 28

days)

Compressive Strength of Concrete at Various Ages

The strength of concrete increases with age. Table shows the strength of
concrete at different ages in comparison with the strength at 28 days after
10 casting.

Age Strength percent

1 day 16%
3 days 40%
7 days 65%
14 days 90%
28 days 99%

15

CEMENT PLANT VISIT EXPERIENCES

35
 On 25th December,2018 we have taken to a cement plant visit which is situated at
Devalue, Manchiryal,Telangana by our internship program sir Mr.Roshan Rednam
and the plant visit is a part of our internship program.
Firstly we have a safety class on plant visit and next moved to the mining area
5 (200hectares)

SAFETY PRECAUTIONS CLASS QUARRY SITE

Cement manufacturing processes is of three processes

1) Wet process
10 2) Dry process
3) Semi dry process
After balsting the lime is collected into vehicles and transferred the the crushers
here the lime is crushed into small particles and mixed with purified clay in proper
properties to get raw slurry. Next the raw materials are mixed in proper
15 proportions.The mixture is dried pulverized (crushed into fine particles) and made
uniform. The resulting powder called "raw material".The raw slurry or raw meal ,

36
 obtained by one of wet and dry process called charge.Charge is introduced into a
rotary kiln.The rotary kiln consists of a steal cylinder about 150m long and 4m Dia
rotates 30 to 60 tones per hourIn Bob mill lime is crushed by bobs.After that
limestone is moved to secondary crushers through belts moved to grinding mill
5 sand and clay is dispatched.Next moved to the pre heaters and heated in kiln
burning i.e 1200°C to1700°C. Clinkers is formed it's size is 20mm to 30mm and
then clinkers is cooled and 4%gypsum is added to the OPC and PPC and and
separation of hybrid cement PPC stongctere, Ordinary Portland Cement ( OPC )
and Portland Pozzolana Cement (PPC) is stored in different silos and packing is
10 done by LPP and HDPE bags.The product mix incldes Ordinary Portland
Cement(OPC) and Portland Pozzolana Cement(PPC)sold under the brand of Birla
A1.Good quality and suitability for critical structures gives Birla A1.
With this very resolution Orient Cement rains to be one of the leading place in
Cement manufacturing and strides towards environment suitability.Orient Cement
15 belongs to the Orient people and industry limited part of the prestigious CK Birla
group.
We visited quality controlled labs in this each and every process is checked by
watching in computers.There they explained us how they check. Physical and
chemical labs are also there to test the cement properties.

20
OUR BATCH AT GARDEN ON QUARRY SITE
CHEMICAL LABORARTOTY
WHICH THEY BIULD FOR REHABILITATION

Nearly 2,000 workers work in the whole cement plant. At each and every stage
Every one explaned us us with clear data. They believe in team spirit and mutual
25 trust. They understand the needs of the costumers to and take continuous measures
to provide good quality cement.They produce 3.5mMillion tonnes capacity per

37
 annum.They use different names in the plant for the materials.The product range of
Orient Cement are destrimanative to high Compressive strength excellent
durability and economic feasibility quality procedures are followed to optimise the
product Orient Cement has on the prestigious NABL certificate and TPM (Total
5 Productive Maintanence)certificate and many other certificates.
At last we gave feedback on the Cement plant and gained few knowledge of
cement from HR sir,civil engineer and from other workers

38
 Conclusion

I conclude that in this internship program practical knowledge

in the site is the main aim for this program. The communication
5 skills are also improved by consulting engineers & by
approaching LHB’S, contractors & masons.In this training visited
most of the site works like slabs casting, reinforcement
place,brick work, placing foundation, plastering work,
earthworks excavation, flooring, finishing,mixing of
10 aggregates.And also we have learn about the total station with
equipment.And also visited to orient cement company
manufacturing of cement & stages of manufacturing of cement
explained by compo officials.It's great experience taking
internship program with orient cement company,we had also
15 discussed many other topics related to jobs, development skills,
behaviour of person while working & also our sir concluded
that “Diploma is a degree not a dignity”.