Concrete is a versatile construction
material.
It is plastic and malleable when
newly mixed, yet strong and
durable when hardened.
These qualities explain why
concrete can be used to build
skyscrapers, bridges, sidewalks,
highways, houses and dams.
CONCRETE – Constituents
Water
7 - 15 %
Cement Coarse
14 - 21 % Aggregate
40 – 50 %
Fine
Aggregate
20 – 30 %
CONCRETE STRUCTURES
QUALITY QUALITY
MATERIALS + PRACTICES
MATERIALS PRACTICES
BATCHING
CEMENT
MIXING
AGGREGATES TRANSPORTING
PLACING
WATER
COMPACTING
ADMIXTURES PROTECTING
CURING
CONCRETE – Code of Practice
Bureau of Indian Standards
published the code of
practice for concrete (IS : 456)
in 1953
- Fourth Revision in 2000
- Fourth Amendment in 2013
CONCRETE – Specifications
Standard Specifications for Roads and Bridges
Published by
Ministry of Road Transport and Highways (MORTH)
- First publication in 1973
- Fifth Revision 2013
CONCRETE – Guidelines
Guidelines
Published by
Indian Roads Congress
CEMENT
• Factory made material
• Checking Grade, Type and Brand
• Checking manufacturing week &
Year
• Checking storage place
Types of Cement
[Link] Types / Grade Of Cement Code
1. Ordinary Portland Cement - 33 Grade
2. Ordinary Portland Cement - 43 Grade IS : 269 - 2015
3. Ordinary Portland Cement – 53 Grade
4. Portland Pozzolona Cement IS: 1489
5. Rapid hardening Portland Cement. IS: 8041
6. Portland Slag Cement IS: 455
7. Sulphate resistant Portland Cement IS: 12330
8. Low Heat Portland Cement IS : 12600
Chemical Composition
Composition Cement (%) Fly Ash(%) GGBS(%) Silica Fume(%)
Cao 60-67% 15-40 35-40 -
Sio2 17-25% 15-45 30-35 85-97
Al2o3 3-8% 20-25 10-20 -
Fe2o3 0.5-6% 4-15 1 -
Mgo 0.5-4% - - -
So3 2-3.5% - - -
Specific Surface 370 420 400 15000-30000
Specific Gravity 3.15 2.38 -2.65 2.94 2.22
Cement Cement Property
General Use Primary Binder Replacement Replacement Enhancer
Cement –Chemical Comp.
Compound Formula Shorthand form % by weight
Tricalcium aluminate Ca3Al2O6 C3 A 6-12
Tetracalcium Ca4Al2Fe2O10 C4AF 6-8
aluminoferrite
Ca2SiO5 C2S 15-30
Dicalcium silicate
Tricalcium silicate Ca3SiO4 C3S 45-50
Sodium oxide Na2O N
Up to 2
Potassium oxide K2O K
Gypsum CaSO4.2H2O CSH2 1-4
Cement – Chemical Comp.
Tricalcium aluminates, C3A:-
It liberates a lot of heat during the early stages of
hydration, but has little strength contribution.
Tricalcium silicate, C3S:-
It is largely responsible for portland cement’s initial
set and early strength gain.
Dicalcium silicate, C2S:
C2S hydrates and hardens slowly. It is largely
responsible for strength gain after one week.
Ferrite, C4AF:
This is a fluxing agent which reduces the melting
temperature of the raw materials in the kiln (from
3,000o F to 2,600o F
STANDARD SPECIFICATION FOR 43 GRADE
ORDINARY PORTLAND CEMENT
PHYSICAL REQUIREMENTS
1. Fineness
2. Consistency
3. Setting Time
4. Soundness
5. Compressive Strength
6. Heat of hydration test
7. Chemical Composition Test
Fineness of Cement IS 4031 I
• Finer cement offers greater surface area for hydration
and faster strength development.
• Fineness is a measure of particle size of Cement
• Particle size between 3 to 32 microns are optimum
for cement performance
• Fine Cement reacts quickly with water
• Faster setting & High early strength depends on
fineness
Fineness of Cement IS 4031
Test in two ways
By Sieving (90 mic)
% retained shall not more than 10% for Ordinary
Cement.
Air Permeability method (represented as Specific
surface area -m2/kg)
Fineness of Cement : IS 4031 - Part 2
Aim : Determination of Specific Surface of Cement
Apparatus : Blaine Air Permeability apparatus
Specific Surface of Cement
shall not be less than
225 m2/kg
Consistency of Cement : IS 4031 – Part 4
Aim : Determination of Quantity of Water
required to produce standard cement
paste
Apparatus : Vicat apparatus with Plunger
(Plunger-10mm dia and 50mm length)
Percentage of water corresponds to a
consistency which will permit the
plunger to penetrate to 5 mm – 7 mm
from the bottom of mould
VICAT
APPARATUS
Initial Setting Time : IS 4031 – Part 5
Aim : Determination of Initial Setting Time
Apparatus : Vicat apparatus with Needle
•The time elapsed between the moment
that the water is added to the cement, to
the time that the paste starts losing its
plasticity.
• Initial Setting Time shall not less than
30 minutes
Final Setting Time : IS 4031 – Part 5
Aim : Determination of Final Setting Time
Apparatus : Vicat apparatus and needle with
Annular Attachment
Final Setting Time shall not more
than 600 minutes ( 10 hours )
FOR FINAL SETTING TIME
Soundness of Cement : IS 4031 - Part 3
Aim : Determination of Soundness
Apparatus : Le Chatelier apparatus
(30mm dia & 30mm High)
It Is very important that the cement
after setting shall not undergo any
appreciable change of volume.
The unsoundness in cement is due
to the presence of excess of lime
combined with acidic oxide at the
kiln. Expansion not more than
10 mm
Compressive Strength : IS 4031 – Part 6
Aim : Determination of Compressive Strength
Apparatus : Compression testing machine
• This is most important properties of hardened
cement.
• Due to excessive shrinkage and the cracking the
strength test are not made on heat cement paste.
Standard sand is used for finding the strength of the
cement.
Compressive Strength : IS 4031 – Part 6
Aim : Determination of Compressive Strength
Apparatus : Compression testing machine
43 GRADE CEMENT
COMPRESSIVE
DAYS STRENGTH
(N/mm2)
3 23
7 33
28 43
Compressive Strength : IS 4031 – Part 6
Aim : Determination of Compressive Strength
Apparatus : Compression testing machine
53 GRADE CEMENT
COMPRESSIVE
DAYS STRENGTH
(N/mm2)
3 27
7 37
28 53
Heat of Hydration Test
Cement with water –an exothermic reaction.
Heat of hydration will be found out using thermos flask.
About 120 calories of heat is generated in the hydration
of 1 gm of cement.
AGGREGATES
COARSE AGGREGATES : AGGREGATES RETAINED ON
4.75 MM SIEVE
FINE AGGREGATES : AGGREGATES PASSING THROUGH
4.75 MM SIEVE
AGGREGATE
Properties
• Specific Gravity
• Water absorption
• Bulk Density
• Gradation
COARSE AGGREGATE
SPECIFICATIONS (IS : 383)
• Particle size distribution
• Crushing value
• Impact value
• Abrasion value
• Soundness
• Flakiness index
• Elongation index
FINE AGGREGATE
GRADING REQIREMENT - IS : 383 TABLE 4
SIEVE SIZE ZONE - I ZONE - II ZONE - III ZONE - IV
10 mm 100 100 100 100
4.75 mm 90 – 100 90 – 100 90 – 100 95 – 100
2.36 mm 60 – 95 75 – 100 85 – 100 95 – 100
1.18 mm 30 – 70 55 – 90 75 – 100 90 – 100
600 micron 15 – 34 35 – 59 60 – 79 80 – 100
300 micron 5 – 20 8 – 30 12 – 40 15 – 50
150 micron 0 – 10 0 – 10 0 – 10 0 – 15
Types of Fine aggregate
Types of Coarse PCC (%) RCC (%) Lean Concrete Less
Aggregate than M15 (%)
Iron Slag Aggregate 50 25 100
Steel Slag 25 Nil 100
Aggregate
Copper Slag 40 35 50
Aggregate
Recycled Concrete 25 20 100
Aggregate
GRADED COARSE AGGREGATE
IS : 383 TABLE 2
FOR 20 mm NOMINAL SIZE
IS SIEVE PERCENTAGE
DESIGNATION PASSING
40 mm 100
20 mm 90 – 100
10 mm 25 – 55
4.75 mm 0 – 10
GRADED COARSE AGGREGATE
IS : 383 TABLE 2
FOR 12.5 mm NOMINAL SIZE
IS SIEVE PERCENTAGE
DESIGNATION PASSING
20 mm 100
12.5 mm 90 – 100
10 mm 40 – 85
4.75 mm 0 – 10
GRADED COARSE AGGREGATE
IS : 383 TABLE 2
FOR 40 mm NOMINAL SIZE
IS SIEVE DESIGNATION PERCENTAGE PASSING
80 mm 100
40 mm 95 – 100
20 mm 30 – 70
10 mm 10 – 35
4.75 mm 0–5
AGGREGATE CRUSHING VALUE
IS : 2386 PART - IV
AGGREGATE CRUSHING VALUE SHALL
NOT EXCEED :
30 % FOR WEARING SURFACES SUCH
AS ROADS & PAVEMENTS
30 % FOR OTHER THAN WEARING
SURFACES
AGGREGATE IMPACT VALUE
IS : 2386 PART - IV
AGGREGATE IMPACT VALUE SHALL
NOT EXCEED :
30 % FOR WEARING SURFACES SUCH
AS ROADS & PAVEMENTS
45 % FOR OTHER THAN WEARING
SURFACES
AGGREGATE ABRASION VALUE
IS : 2386 PART - IV
AGGREGATE ABRASION VALUE SHALL
NOT EXCEED :
30 % FOR WEARING SURFACES SUCH
AS ROADS AND PAVEMENTS
50 % FOR OTHER THAN WEARING
SURFACES
Types of Coarse aggregate
Types of Coarse PCC RCC Lean Concrete Less
Aggregate than M15
Iron Slag Aggregate 50 25 100
Steel Slag 25 Nil 100
aggregate
Recycled Concrete 25 20 100
Aggregate
Recycled Aggregate Nil Nil 100
Bottom ash from Nil Nil 25
Thermal Power
plants
Water
• Clean and free from injurious amount of Oil,
Acid, Alkali, Sugar, Salt, and Organic materials
• Potable water is good for concrete
• Water having pH value less than 6 is not
permitted
• Sea water is not permitted
Steel Reinforcement for Structures
Properties of Steel bars
Properties Fe 415 Fe 415 D Fe 500 Fe 500 D Fe 550
Proof Stress 415 415 500 500 550
Minimum
(Mpa)
Ultimate 485 500 545 565 585
Strength
Minimum
(Mpa)
Elongation 14.5 18 12 16 10
Percentage
Minimum
(%)
Seismic Zone Map for Tamil Nadu
Steel Reinforcement for Structures
• As per IRC 112 for Zone III &Zone IV area it is
necessary to use HYSD bars having minimum
elongation of 14.5%
CONCRETE – Strength development
Fresh Stage
Concrete is Plastic, workable
capable of being moulded
Transition Stage
Workability reduces,
process of setting begins
Hardened Stage
Concrete becomes stiff and
gains enough strength to
support load
Concrete workability – Slump Test
Standard slump cone size
Top dia = l0 cm
Bottom dia = 20 cm.
Height = 30 cm
Standard tamping rod
Length = 0.6 m
Dia = 16 mm.
Test Procedure
Concrete shall be poured in four layers - each layer 25
blows. On removing the cone slowly, the slumped concrete
height has to be measured. The difference between this reading
and the original height of 30 cm is the slump of concrete.
Recommended slump Values
Concrete Workability
• The concrete mix shall have the consistency
which will allow proper placement and
compaction in the required position.
• For pumpable concrete ranging from
75-150mm
CONCRETE – Strength
Eg : M 30
M refers to Mix
Grades of Concrete
As per IS : 456
M 10, M 15, M20 : ORDINARY CONCRETE
M 25, M 30, M35, : STANDARD CONCRETE
M 40, M 45, M 50,
M 40, M 45, M 50,
M 55, M60, M 65, M 7O, : HIGH STRENGTH
M 75 ,M 80, M 85, M 90, CONCRETE
M 95, M 100
Ordinary Concrete
Cement + Fine Aggregate
+
Coarse Aggregate
+
Water
Ordinary Concrete
Applications of Ordinary Concrete (M 10,M 15,M 20)
• Plain concrete works
• Lean concrete works
• Simple foundations
• Foundation for masonry walls
• Temporary RCC constructions
• Non load bearing structures
Standard Concrete
Ordinary Concrete
+
Chemical Admixture
(High range water reducers)
Standard Concrete
Applications of Standard Concrete (M 25 to M 60)
• Reinforced concrete works
• Pre stressed concrete works
• Prefabricated concrete
elements
• Load bearing structures
Achieving High Strength Concrete
Conventional
Concrete
+
Chemical
Admixture
+
Mineral
Admixture
High Strength Concrete
Applications of High Strength Concrete (M 65 – M 100 )
• High Rise Buildings
• Offshore Structures
• Nuclear Power Plants
• Spill ways of Dams
• Long span Bridges
• Ultra-thin whitetopping
MINERAL ADMIXTURES
RECOMMENDED BY IS : 456
• Fly Ash
• Silica Fume
• Ground Granulated Blast Furnace Slag
• Rice Husk Ash
• Metakaolin
Chemical Admixtures (IS 9103)
• Accelerator– Increase the rate of hydration and
shortens the setting time.
• Retarder- delays the setting time of cement paste
• Water reducing admixture -increase the
workability of concrete without increasing water
content
• Air entraining admixture –air to be incorporated
in the concrete in the form of minute bubbles.
• Super plasticizing admixture – large decrease in
water content and allow high workability.
• Retarding super plasticizer - Super plasticizing
admixture that imparts prolonged workability
retention and retards setting
Chemical Admixtures
• Compatibility of the admixtures with the cement
and any other pozzolans or hydraulic addition
shall be ensured by avoiding the following
problems.
Requirements of large dosage of super plasticizer
for achieving the desired workability.
Excessive retardation of setting
Excessive entrainment of large air bubbles
Unusually rapid stiffening of concrete
Rapid loss of slump
Excessive segregation and bleeding
Mineral Admixtures
• Fly Ash (IS 3812) – 20-35% of the total by mass
of OPC.
• GGBS (IS 12089) – 50-70%
• Silica Fume (IS 15388) - 5 -10%
Requirement of concrete for Different
Exposure Conditions
CONCRETE MIX DESIGN
• Mix Design can be defined as the process of
selection suitable ingredients of concrete and
determining their relative proportions with
the objective of producing concrete of
certain minimum strength and durability as
economically as possible
CONCRETE MIX DESIGN
• First Objective – Strength and Durability
• Second Objective – Economical production
and cost
CONCRETE MIX DESIGN
• Cement Content
• Water Cement Ratio
• Specific Gravity
1. Cement
2. Fine Aggregate
3. Coarse Aggregate
• Water Absorption
1. Fine Aggregate
2. Coarse Aggregate
• Fine Aggregate -as per Zone Classification
• Chemical Admixture -Dosage & Specific Gravity
CONCRETE MIX DESIGN
CONCRETE MIX DESIGN
General Guidelines
• Aggregates of size over 20mm shall not be used for RCC
works
• Shuttering shall be held tight and be free from gaps. Poor
shuttering leads to loss of water and cement slurry from
the concrete which leads to reduction in strength of
concrete.
• Concrete should be placed from a reasonable height to
avoid segregation and bleeding.
• Concrete should be placed immediately in the formwork
since the hydration process starts once water is added to
cement. Loss of water could lead to reduction in
workability.
• Concrete shall be cured well to ensure that the water
required for hydration process does not leave to the
atmosphere. Incomplete hydration leads to reduction in
strength of concrete.
Acceptance Criteria for Strength of Concrete
Strength of Concrete in
Structure
Strength of Concrete Sample 1 Sample = 3 Cubes
Minimum Frequency of Sampling
Quantity of Concrete (m3) Number of Samples
1-5 1
6 – 15 2
16 – 30 3
31 – 50 4
4 + 1 for each additional
51 and above
50 m3 or part
Sampling of Fresh Concrete
• Collect Samples from not less than 5 well-distributed
positions immediately after discharge
• Quantity of sample shall not be less than 0.02 m3
• Avoid edge of the concrete mass to avoid segregation
Making and Curing Test Specimen
• Mould shall be thinly coated with oil
• Concrete shall be filled in 3 layers
Each layer 5 cm deep
• Compaction with tamping bar
Number of strokes per layer : 35
Making and Curing Test Specimen
• Specimen shall be stored at safe place at 220 c to
320c for 24 hours
• After 24 hours, specimen shall be stored in clean
water at 270 c ± 20 c until the date of testing
Testing of Concrete specimen
• Specimens stored in water shall be
removed from the water
• Surface water shall be wiped off
• Specimens shall be tested while they
are in the Saturated Surface Dry
condition
Testing of Concrete specimen
• Load shall be applied perpendicular to Cast direction
Top
Top
•Rate of loading : 5.25 kN/sec
• Load shall be applied until the specimen breaks down
Load at Failure
•Compressive Strength =
Cross sectional area
Acceptance Criteria
Fc1 = Strength of
cube 1 The values of Fc1 , Fc2 and
Fc3 should be
Fc2 = Strength of within ± 15 % of Fc mean
cube 2
Fc3 = Strength of
cube 3 Fc mean > (Fck + 3)
Fc1 + Fc2 + Fc3
Fc mean = -------------------
3
Acceptance Criteria for M 30
15 % of 32.33 = 4.85 MPa
Fc1 = 33 MPa
32.33 – 4.85 = 27.48 MPa
32.33 + 4.85 = 37.18 MPa
Fc2 = 36 MPa
Fc1, Fc2 and Fc3 are between
27.48 Mpa and 37.18 Mpa
Test Result is valid
Fc3 = 28 MPa
Fck = 30 Mpa
Fck + 3 = 33 MPa
Fc mean = 32.33 Mpa
Fc mean is less than (Fck + 3)
Not Accepted
For 50 m3 of Concrete 4 Samples are required
Sample 1
Sample 2
Group - I
Sample 3
Sample 4
Factors affecting Strength of Concrete
•Water/Cement Ratio
•Cement Content
•Aggregate/Cement Ratio
•Type of Aggregate
•Placing & Compaction
•Curing condition
•Age of Concrete
•Environmental Condition
If cube strength fails ?
Non Destructive Tests
• Penetration method
• Rebound hammer method
• Pull out test method
• Ultrasonic pulse velocity method
• Radioactive methods
Penetration Method
• The probe test
produces quite variable
results and should not
be expected to give
accurate values of
concrete strength.
• It has, however, the
potential for providing
a quick means of
checking quality and
maturity of in situ
concrete.
Non Destructive Tests
Rebound Hammer Test
POSITION OF REBOUND
HAMMER - VERTICALLY
UPWARDS
Non Destructive Tests
Rebound Hammer Test
Pull out Test Method
• A pull-out test measures, with
a special ram, the force
required to pull from the
concrete a specially shaped
steel rod whose enlarged end
has been cast into the
concrete to a depth of 3 in.
(7.6 cm).
• Although pullout tests do not
measure the interior strength
of mass concrete, they do give
information on the maturity
and development of strength
of a representative part of it.
Such tests have the advantage of
measuring quantitatively the
strength of concrete in place.
Ultrasonic Pulse Velocity Test
Ultrasonic Pulse Velocity
Concrete Quality Grading
Pulse Velocity (km/s) Quality
Above 4.5 Excellent
3.5 to 4.5 Good
3.0 to 3.5 Medium
Below 3.0 Doubtful
Radioactive method
• Radioactive methods of
testing concrete can be used
to detect the location of
reinforcement, measure
density and perhaps establish
whether honeycombing has
occurred in structural
concrete units. Gamma
radiography is increasingly
accepted in England and
Europe.
• The equipment is quite simple
and running costs are small,
although the initial price can
be high. Concrete up to 18 in.
(45 cm) thick can be examined
without difficulty.
Fixing the core Drilling the
cutting machine concrete
Drilling in process Drilling completed
Concrete core Levelling
Curing
Fixing in machine Testing
ACCEPTANCE CRITERIA
COMPRESSIVE STRENGTH OF CORES
I ) AVERAGE EQUIVALENT 85 % of CUBE STRENGTH
CUBE STRENGTH OF CORE = of SPECIFIED GRADE
II ) STRENGTH OF ANY 75 % of CUBE STRENGTH
INDIVIDUAL CORE = of SPECIFIED GRADE
ACCEPTANCE CRITERIA
If the Concrete is not able to meet
any of the STANDARDS OF
ACCEPTANCE, the Structure is to be
Investigated
• Strength and durability of concrete
depends on many factors
• To achieve a strong and durable
concrete structure,
High Intention
Sincere Effort
Intelligent Direction and
Skillful Execution
are needed
