Unit 5 (Pt2) Cement Concrete (Part B) (Also Including Parts of Unit 6)

Unit 5(Pt2)
CEMENT CONCRETE (Part B)

(Also including Parts of Unit 6)
Presentations
by
PV ESWAR
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Eswar/ BTech2yr/ BMCT/ Unit5
PRODUCTION
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Quality Concrete
A Good Quality Concrete is essentially
a Homogeneous Mixture of Cement, CA, FA, Water
which consolidates into a Hard Mass, due to
Hydration.
Specific Functions of these four constituents
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CA acts as a Filler.
FA fills up the voids between the Paste and the CA.
Cement in conjunction with Water acts as a Binder.
The Mobility of the Mixture is aided by the Cement
Paste, Fines and nowadays, increasingly by the use of
Admixtures.
Quality Concrete
QUALITY CONCRETE
Most of the properties of the hardened concrete
depend on the Care exercised at Every Stage of
Mfg.
A Rational Proportioning of the ingredients of
concrete is the essence of the Mix Design.
However, it may not guarantee of having achieved
the objective of the quality concrete work.
The AIM of QC is to ensure the production of
concrete of Uniform Strength from Batch to Batch.
This requires some Rules to be followed in various
stages of Concrete Production
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Stages of Concrete Production

1. Batching, or measurement of materials
2. Mixing
3. Transporting
4. Placing
5. Compacting
6. Curing
7. Finishing
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BATCHING
Ensuring Proper and Accurate Quantity of all
ingredients to achieve Good Quality Concrete
Accuracy of Batching.
Aggregates, Cement and Water. 3%
Admixtures. 5%
2 Methods of batching
Volume batching
Weigh batching.
Factors affecting the Choice of Batching Method

Size of job
Production Rate
Required Standards of Batching performance.
For most important works Weigh Batching is

recommended.
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VOLUME BATCHING
VOLUME BATCHING
for Small Jobs only.
Amount of each Solid Ingredient is measured by Loose
Volume; using standard box known as Gauge Box (Fig.
10.1). Gauge Box Vol = 0.035m3
Cement
is always measured by Weight, irrespective of the method of
batching.
Volume of a Bag of Cement (50 kg) = 0.035 m3.
The amount of Solid Granular material in a CuM will be an

indefinite quantity. e.g. Density of Sand in a Moist Loose
condition << Density of Dry Compacted Sand.
Correction to the effect of bulking of FA should be made, if
volume batching is adopted
Water is measured either in Kg or Litres.
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Wooden Box for Gauging Aggregates
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WEIGH BATCHING
MANUAL BATCHING.
For Smaller Wks

Weighing and Batching done Manually.
Weighing may also be done by Ordinary Platform Weighing
Machines.
WEIGH BUCKETS.
For Large size wks.
Weigh Buckets are fed from Hoppers and these discharge
the ingredients by Gravity, straight into the Mixer.
AUTOMATIC BATCHING PLANTS.

Automatic batching plants ranging from Small to Large
capacity
Manually or Electrically Op
OP.
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By Pressing a Button, Weighing of Materials is put into Motion

Flow of each is Cut-Off when the Correct Wt is reached.
Some Batchers Record Graphically the Wt of each material
delivered to each Batch.
WEIGH BATCHING
Adding Water
Water is NOT added by Graduated Buckets, as the
Water may spill over during its addition.
A Horizontal or Vertical Tank is fitted to the Mixer.
The Fitting is so designed to have a Control to
admit any desired Qty of Water
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MIXING
The Object of Mixing is
to make the Concrete Mass
Homogeneous and Uniform
in Colour and Consistency.
All the Aggregate Particles should have a Coat of

Cement Paste
All the Ingredients should Blend into a Uniform
Mass.
The Mixing is done by

Hand
Mixer.
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11
for Small Jobs.

PROCESS
HAND MIXING
Measured Qtys of CA and FA are spread over an

impervious floor, in Alternate Layers.
Cement is poured over it, and, the ingredients are
Mixed Dry with shovel, until Uniformity in Colour is
achieved.
This Mix is Spread out in th of 200 mm and Water is
sprinkled.
The Mix is kept on Turning Over till a Uniform Colour
is achieved.
Desirable to add 10% extra Cement to cater for

the possible inferior concrete produced by this
method (as the Hand Mixing cannot be thorough)
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MACHINE MIXING
For Quality Wks
Mixers can be broadly classified as
Batch Mixers
Continuous Mixers.
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13
BATCH MIXERS (Machine Mixing)

BATCH MIXERS
Produce concrete Batch by Batch, with time interval
Small and Medium size wks.
Batch mixer may be of
Pan type
Drum type (Fig. 10.3).
Based on Technique of Mixing..Drum type are Cl as

Tilting (T)
Non-Tilting (NT),
Reversing (R) type,.
Based on Drum Capacity..Standard Sizes of the

Mixers :
Tilting: 85T, 100T, 140T, 200T
Non-tilting: 200NT, 280NT, 340NT, 400NT, 800NT
Reversing: 200R, 280R, 340R, 400R.
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Pan-type Drum Mixer
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Tilting Drum Type Batch Mixer
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Tilting Drum Type Bucket Mixer
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Non-Tilting Drum type Concrete Mixer
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Reversing Drum Mixer
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MACHINE MIXING
CONTINUOUS MIXERS
Produce Concrete Continuously, till plant is

working.
for Large Size Wks, e.g., Dams.
A typical Vertical Batching Mixing Plant for large size
work is shown in Fig. 10.2
Sometimes Mixers are specified by 2 Qtys:

Total Volume of Ingredients Added, and
the Volume of Concrete Produced.
e.g. 285/ 200-Litres Mixer takes 285 Litres of
Ingredients and yields 200 Liters of Concrete.
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Vertical Batching Mixing Plant
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TILTING MIXERS
The Tilting Mixers may be
Hand Fed or
Loader (Skip) Fed.
The Mixer is generally

Bowl shaped
Double Conical Frustum type.
It can be Tilted for discharging Concrete. Blades

are fixed inside the drum. The Revolving Drum
with the Mixing Blades gives Lifting and Free Fall
to the mix, Combs and Agitates it. The Mixed
Concrete is discharged from the open top of the
drum by tilting it downwards.
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TILTING MIXERS (Contd)

The Concrete tips out rapidly under gravity in an
Unsegregated mass as soon as the drum is tilted.
These Mixers may be used to their Advantage for
Mixes of
Low Workability and
containing Large Size Aggregate.
The Disadvantage of these mixers lies in the fact

that some Mortar adheres to the Drum and is left
out in the drum during discharging.
To check this some amount of Mortar is mixed in
the mixer before the first Batching called
Buttering.
A typical tilting mixer is shown in Plate 1.
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Drum Type Batch Mixer
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24
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NON-TILTING MIXER
It consists of a
Non-tilting Cylindrical Drum with Blades inside
2 Circular Openings at the 2 ends.
The Drum rotates about a Horizontal Axis (Fig.

10.4).
The Ingredients are fed from one opening and
the Mix discharged from the other opening at
the other end by at inclined chute.
Drawback. Segregation that occurs owing to
Slow Rate of Discharge.
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Non-Tilting Drum type Concrete Mixer
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REVERSING DRUM TYPE MIXEER

These are also known as Forced action type
mixers and are used for large size works.
It consists of a
Horizontal Non-Tilting type Drum (Fig 10.5).
2 sets of Blades.
First Set of Blades. Mixes the Mix, while the Drum is
rotated in one Direction.
Second Set of Blades. Discharges the Mix, when the
Drum is reversed.
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Reversing Drum Mixer
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PAN TYPE (or) STIRRING MIXER

These are Non-Mobile Mixers and are used either
as a Central Mixing Plant or at Precast Concrete
Factory.
Primarily these are used for making Mortar but
are also used efficiently for Stiff and Cohesive
Mixes.
Rollers and Blades rotate in a Rolling Pan.
Apart from Mixing the Ingredients, they also
produce Kneading and Crushing action.
A Pan type Mixer is shown in Fig. 10.6. These are
also known as Dual Drum Mixers and are used for
mixing Concrete for Roads or Pavements.
The Concrete produced by this type of mixers
show NO Segregation
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Pan-type Drum Mixer
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PAN TYPE (or) STIRRING MIXER

Mechanism
The Drum comprises of 2 Hemispherical Halves,
rotating on a Horizontal Shaft.
One Half of the Drum is attached to the end of the Shaft and
the Other Half is free to slide over the Shaft, allowing the
Drum to open at the Centre.
A Rubber Joint and Adjustable Closing Pressure

ensures a Perfect Sealing when the Drum is closed.
Due to difference in Circumferential Speeds because
of the design of blades Cross Flow is created which
forces the Concrete towards the Centre causing
turbulence and produces a perfect Homogeneous Mix.
The Rotating Sliding Drum-Half can be retracted for
discharge of Concrete in few seconds.
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TRANSIT MIXER
Truck mounted mixers also know as Transit Mixers
(Fig. 10.7(a)) are very popular and have replaced
the Dumpers and Agitator Cars used earlier to
transport fresh concrete from the batching plant
to the site.
Transit mixers of capacity 4 to 12 Cu M mounted
on Truck Chassis are available.
Initially, these Mixers were NOT very efficient
and needed long Mixing Duration depending on
the extent of Dryness in the Mix.
Their Main Function is to keep the mix in an
agitated condition.
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Transit Mixer driven by Truck Engine
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With the development of Twin Fin Process Mixer (Fig.

10.7(b)), the Transit Mixers have become more
Efficient.
These mixers in addition to the Outer Spirals have 2
Opposed Inner Spirals.
The Outer Spirals convey the mix materials towards the
bottom of the drum while the Opposed Mixing Spirals
push the mix towards the feed opening.
The repeated Counter Current Mixing Process is carried
out within the Mixer Drum.
A number of Special Nozzles provided on the lower side of
Inner Mixing Spirals, precisely and uniformly Spray Water
on the Mix under Pressure along the entire length of the
Drum.
This results in thorough Mixing of the entire drum contents
within a short time.
Hence, production of High Quality Structural Concrete in
the transit mixer is possible at a Faster Rate
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Interior of Twin Fin Transit Mixer with Spay Arng
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The Order of Feeding the ingredients into the mixer is as

follows:
About 25 % of Water required for mixing is first introduced
into the Mixer Drum to prevent any sticking of Cement on the
Blades and bottom of the Drum.
Then the Ingredients are discharged through the Skip.
In the skip, the sequence of loading should be to add
Half the CA, then

Half the FA, and Over this
total Cement, and then
the balance Aggregates.
After discharging the ingredients into the drum, balance

Water is introduced.
The Speed of the mixers is generally 15 to 20 rpm.

For proper mixing, the RPM of Drum 25 to 30.
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MIXING TIME
Counted from the instant Complete Water is fed into
the mixer.
Time of mixing also depends on Capacity of Mixer and
is given in Table 10.3
If the Mixing Time is Reduced A Poor Quality of
Concrete is obtained
On the other hand if the Mixing Time is Increased
it is Uneconomical.
may cause Segregation.
Water may get Absorbed by the Aggregates or Evaporate
resulting in LOSS of Workability and Str.
However, it is found that
if the Mixing Time is increased to 2 minutes the Compressive
Str of Concrete produced is enhanced.
BUT, beyond this time the improvement in Compressive Str is
insignificant
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Time of Mixing
Ser
No
Capacity of
Mixer
(Cu M)
1
2
3
>= 3
2
<=1
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Minimum Mixing Time (min)

Natural
Manufactured
Aggregates
Aggregates
2
2.5
1.5
2
1.25
1.5
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TRANSPORTING
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TRANSPORTING
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MORTAR PAN
WHELL BARROW
CHUTES
DUMPER
BUCKET AND ROPE WAY
CONVEYOR BELT
SKIP AND HOIST
PUMPING
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WHEEL BARROW
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PLACING
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Foundations for Walls and Columns

Provided below the GL.
Before placing the concrete in the foundation
all the loose earth, roots of trees etc., are
removed.
If the foundation bed is DRY it is made Wet
so that earth does not absorb water from
concrete.
if the foundation bed is WET Water and
Mud is removed and Cement is sprinkled
before placing Concrete.
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BEAMS, COLUMNS and SLABS

Before placing the concrete,
the Forms must be examined for correct Alignment.
They should be adequately Rigid to withstand the weight
of concrete and construction loads without undue
deformation.
Forms should be Tight enough to avoid any loss of mortar
resulting in honeycombed concrete.
The insides of the forms should be Cleaned and Oiled
before use to avoid any sticking of concrete with the forms
and making their stripping off difficult.
Concrete should not be dropped but PLACED in

position to prevent Segregation. It should be PLACED
vertically from as small height as possible. It should be
Placed at One Point in the Formwork and allowed to
flow side ways to take care of Honeycombing.
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BEAMS, COLUMNS and SLABS

Laitance fmn
should be avoided.
It can be Checked by restricting th of layer of Concrete to
150300 mm for R.C.C work.
Laitance, however, if formed must be removed before
placing the next layer of concrete.
The surface of the Previous Lift is kept Rough and all the
laitance removed before placing the next lift.
The Rft
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should be checked for Tightness and Clean Surface.

The loose Rust or Scales if any, are removed by Wire Brush.
Paint, Oil or Grease if found should be removed.
The Minimum Cover for Rft should be checked before
Concreting.
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MASS CONCRETING
When the concrete is to be laid in Mass as for
Raft Foundation
Dam
Bridge,
Pier etc.,
LIFTS
Concrete is placed in layers of 350450 mm th. Several such
layers placed in quick succession form a LIFT
Before placing the Concrete in the next LIFT, the Surface of
Previous Lift is Cleaned thoroughly with Water Jets and
Scrubbed with Wire Brush.
In case of Dams, Sand Blasting is done.
The Laitance and Loose Materials are removed and Cement

Slurry is applied.
When the Concrete is subjected to Lateral Thrust,
Bond Bars or Bond Stones are provided
to form a Key between different layers.
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Concreting HWs and RUNWAYS

Concrete is laid in Bays for HW, Runway, or Floor
Slabs.
First the ground on which concrete is to be laid is
Prepared and all the loose materials and grass etc.,
are removed.
The Earth is Wetted and Compacted.
The Sub-Grades over which Concrete is to be laid

should be properly Compacted and Damped to
avoid any Loss of Moisture from Concrete.
Concrete is then laid in Alternate Bays. This
allows the Concrete to undergo sufficient
Shrinkage and Cracks do not develop afterwards.
Concrete is not placed in heap at one place and
then dragged, instead it is Placed in Uniform th.
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Concreting in BAYS
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10
11
12
22
13
23
14
16
15
17
24
18
25
19
20
21
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Concreting UNDER WATER
Concrete may be placed Under Water with the

help of Bottom Dump Buckets.
Concrete is taken through the water in Water- Tight
Bucket.
On reaching the place of deposition the bottom of the
Bucket is made to Open and the Concrete is dumped.
In this process certain amount of Cement is washed
away causing a reduction in Str of Concrete.
Another way of Concreting underwater is

by filling Cement Bag with Dry or Semi-Dry Mix of
Cement and Aggregates and lowering them to the
place of deposition.
The DRAWBACK of this method is that the Concrete
will be full of Voids interspersed with pieces of Gunny
Bags.
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CONCRETING UNDER WATER
The BEST METHOD of placing Concrete underwater is by

the use of TREMIE PIPE.
The Concrete is poured into it through Funnel.
Bottom end of the pipe is closed with a thick Polythene Sheet,
with the bottom end of the pipe at the place of deposition.
The Concrete (Slump 150200 mm) is poured into Funnel till the
whole pipe is filled with concrete.
The pipe is slightly lifted and given a jerk, the Polythene Sheet
Cover falls and Concrete discharged.
It should be ensured that the End of Pipe remains inside the
Concrete so that water does not enter the pipe.
The pipe is again filled with concrete through funnel and the
process repeated till the concrete level comes above the water
level.
No compaction is required for Underwater Concrete as it gets
compacted by the Hydrostatic Pressure of water.
Concrete can also be placed underwater with the help of

Pipes and Pumps.
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Concreting Under Water using TREMIE PIPE

2. CONCRETE Pored
From Here The pipe is
slightly lifted and
given a jerk
1 INITIALLY Bottom end of the

TREMIE pipe is closed with a thick
Polythene Sheet, with the bottom
end of the pipe at the place of
deposition.
3. Tremie Pipe lifted up in

Stages
As Concreting progresses,
Water Level
Through out Concreting,
Bottom of Tremie Pipe
Has to be below Concrete
To achieve Tremie Seal
TREMIE PIPE
Concrete Under Water

River Bed
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COMPACTION
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COMPACTION
After concrete is placed at the desired location, the
next step in the process of concrete production is its
Compaction.
Compaction of the Concrete is the Process to
get rid of the Entrapped Air and Voids,
Elimination of Segregation occurred and
form a Homogeneous Dense Mass.
Compaction Consolidates Fresh Concrete

within the Moulds or Frameworks and
around Embedded Parts and Rft Steel.
Considerable qty of Air is Entrapped in Concrete during

its Production and there is possible Partial Segregation
also.
Voids and Segregations .Both of these affect the
Quality of Concrete ADVERSLY .
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COMPACTION
Voids, Permeability, Rusting, Str
Voids effect Str
5 % Voids in Hardened Concrete REDUCE the Str by 30%
10 % Voids REDUCE the Str by 50%.
Therefore, the Density and consequently the Str and
Durability of Concrete largely depend upon the Degree
of Compaction.
For Max Str Driest possible Concrete should be
Compacted 100%.
Voids increase Permeability of Concrete.

Permeability creates Easy Passage of Moisture, Oxygen,
Chlorides, and other Aggressive Chemicals into the
Concrete.
This causes Rusting of Steel and Spalling
(Disintegration) of Concrete i.e., loss of Durability.
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COMPACTION (Contd)
Easy entry of Sulphates from the environment causes
Expansive Reaction with the C3A present in Cement.
This causes Disintegration of Concrete and Loss of Durability.
Entry of CO2 causes

Carbonation of Concrete i.e., Loss of Alkalinity of Concrete or Loss of
the Protective Power that Concrete gives to the Rft or other Steel
embedded in it.
Once the Carbonation Depth > th of Concrete Cover to the embedded
Steel, Steel becomes Vulnerable to the attack of Moisture.
This expedites Rusting of Steel as the protective Concrete Cover
remains NO longer Alkaline in nature.
Voids also
REDUCE the Contact between embedded Steel and Concrete. This
results in Loss of Bond Strength of Reinforced Concrete Member and
thus the Member loses Str.
Voids such as Honeycombs and Blowholes on the exposed surface
produce Visual Blemish. Concrete surface is not good to look with all
such blemishes. Concrete with smooth and perfect surface finish not
only Looks good but is also Stronger and more Durable.
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COMPACTION (Contd)
Compaction is achieved by imparting external
Work over the Concrete to overcome the
Internal Friction
between the Particles forming the Concrete,
between Concrete and Rft and
between Concrete and Forms and
by reducing the Air Voids to a Minimum.
The Compaction of Concrete can be achieved

by the Methods given in succeeding Slides.
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HAND COMPACTION
Used for Small and Unimportant Jobs.
Extremely useful for Thin Elements such as Slabs, and for
members with Congested Rfts.
for Mixes with any Workability. EXCEPT for very fluid or
very plastic Mix.
Hand Compaction is achieved by Rodding, Ramming, or
Tamping.
Rodding is done with the help of 16 mm diameter, 2 m long
Steel Rod to pack the Concrete between the Rft, Sharp Corners
and Edges, continuously during Concreting.
Ramming is permitted only for Unreinforced Concrete
Constructions.
Tamping. Roof and Floor Slabs are usually tamped for achieving
Compaction. Tampers are 100 mm 100mm in section and
about 1 m long. Tamping Bars not only Compact the Concrete
but also Level the Top surface.
Limitation. large W-C ratio is required for full compaction.

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Compaction by VIBRATION
This is the Most Common and Widely Used method of

compacting concrete for any Structural Element.
Vibrations imparted to the Fresh Concrete
REDUCE the Internal Friction between the particles of
Concrete by setting the Particles in Motion and
thus PRODUCES a Dense and Compact mass.
On vibration,
Concrete mix gets Fluidized and

Internal Friction between the Aggregate particles REDUCES
resulting in Entrapped Air to rise to the Surface.
On losing entrapped air the Concrete gets Denser.
Vibrations do not affect the Str of Concrete; but

Concrete of Higher Str and better Quality can be made
with Lesser Water and given Cement Content.
Therefore, with vibrations Stiff Concrete with low W-C
ratio can also be Well Compacted.
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Compaction by VIBRATION
For Full Compaction, Vibration can be considered to be Sufficient

when the Air Bubbles Cease to appear and
Sufficient Mortar appears to close the Surface Interstices and facilitate
easy Finishing Op.
Vibration
Helps Entrapped Air to escape first from between the CA particles and
later from the Mortar.
When Vibration continues some more Entrapped Air from the Mortar
is Driven out.
However, during this Second Phase, Concrete does not show any
movement but it is in this phase that Maximum Entrapped Air is
driven out and that is the time when Most of the Consolidation takes
place.
Plastic mixes need less time of Vibration than Harsh or Dry Mixes.
Types of Vibrators in use are
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Needle,
Formwork,
Table or Platform, and
Surface Vibrators.
60
NEEDLE VIBRATOR
can be used for any type of concrete work.
This consists of
a Steel Tube, called Poker, having an Eccentric
Vibrating Element inside
The Needle Diameter varies from 20 to 75 mm and its
Length from 250 to 900 mm.
In places where the Rft is Congested , Blades are used
instead of Needle.
Flexible Shaft
Power Unit. An average Frequency of Vibration is
3,500 to 5,000 CPM
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NEEDLE VIBRATOR (Contd)
A Needle Vibrator is shown in Plate 2. USE

Immersed into Concrete at a Spacing of < 600 mm (or)
8 to 10 times the Diameter of the poker.
The Vibrator is immersed at a place for about 30 Secs
to 2 Mins.
Location of the Poker Insertion should be STAGGERED
to ensure that every bit of concrete is compacted (Fig.
10.9).
The Vibrator should be allowed to Penetrate the
Concrete Vertically (inclination 10) under its Own Wt.
Poker Position should be changed gradually from the
Side of the Heap and moving away from the heap ALL
ROUND (Fig. 10.10(a).
Poker should NOT be introduced in the CENTER of the
Heap (Fig. 10.10(b)
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Method of Poker insertion near a heap
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64
FORMWK VIBRATOR
These are also known as External or Shutter
vibrators.
These are generally USED under the following
Circumstances:
1. Compaction in a Very Thin or Very Densely
Congested Reinforced Section.
2. In addition to Internal Vibration, Compaction is
required to be done specially in the Cover Area
where at times Needle or Poker Vibrator is
Unable to do satisfactory Compaction.
3. Compaction of Very Stiff Concrete is required
to be done because such Concrete cannot be
Compacted by Internal Vibrators.
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FORMWK VIBRATOR
Formwork Vibrators are used for Concreting
Columns
Thin Walls and
Precast Units.
These are Rigidly Clamped to the Formwork,

causing it to Vibrate and consequently Transfer
the Vibrations to Concrete. The performance of
these vibrators when directly attached to
Formwork is NOT generally satisfactory.
The Vibrator is mounted on a Steel Plate, which is
attached to a Channel or I-beam, which runs
along the Formwork touching the Form Stiffeners.
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FORMWK VIBRATOR (Contd)

Shuttering and Formwork have to be Rigid, Strong and
Watertight.
Vibrators operate at a Frequency of 3,000 - 9,000 CPM
Formwork to be properly Designed to tfr Vibrations to
Concrete without itself getting Displaced or Opening up.
Consume MORE Power and are LESS Efficient than Needle
Vibrators
Compaction Time. between 1 to 2 Mins.
Should NOT be used on Top of the Vertical Formwork.
Use of Form Vibrator at top locations will generally cause
Separation of Concrete from the Formwork. Due to Formwork
being inadequately stiffened at top, it results in In and Out
Movement causing Separation.
Gen, should be fixed 1000 mm below the Top Finished Level of
Concrete.
The Top Layer of Concrete must be vibrated by a Needle
Vibrator.
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Form vibrators if used in addition to Internal
Vibrators
help removing Entrapped Air along the Concrete
Surface
giving a much Superior Finish.
Generally, Tapping with a Wooden Mallet on

the external face of the Formwork also helps
REMOVE Entrapped Air which generally
blemishes the concrete surface inspite of
adequate internal vibration.
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VIBRATING TABLE.
A Special Case of a Formwork Vibrator used in Labs and Factories is
Vibrating Table.
The Vibrating Table consists of
a Rigidly Built Steel Platform
Mounted on Flexible Springs and
Driven by an Electric Motor.
The average Frequency of vibration is 4000 CPM. The Moulds are

Clamped on the Platform.
Vibrations are Stopped as soon as the Concrete in the moulds
develops a Level Smooth Surface.
Medium Workable Mixes generally require HIGHER Frequency of
Vibration than Stiff Mixes.
INCREASING Frequency and DECREASING Amplitude improves
Consolidation
Very Efficient in Compacting Stiff and Harsh Mixes required for
Precast Elements.
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SURFACE VIBRATOR
These are also known as Screed Board
Vibrators.
Surface vibrators are used for Floor and Roof
Slabs and Pavement Surfaces.
These are effective only up to a th of 150 mm
of Concrete but can be used up to 250 mm.
Surface vibrators cause movement of fine
particles to the top and hence aid the
Finishing Op.
The operating Frequency is 4,000 CPM.
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Compaction by SPINNING
This method is also known as Centrifugation
and is used for producing Circular Elements
such as Pipes.
The Plastic Concrete is SPUN into the
horizontal mould at a Very High Speed.
Water forced out of the mix during spinning
flows out of the Mould.
The initial W-C ratio required for effective
Compaction is 0.35 to 0.4 which after spinning
reduces to 0.3.
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COMPACTION BY JOLTING
In this method of Compaction, the mould
containing Dry Concrete is subjected to Jolt at a
frequency of 100 to 150 JPM.
Jolting
is a Vibrating action of Low Frequency and High
Amplitude.
The mould filled with Concrete is raised by about 12
mm and then allowed to Fall under gravity.
This method is used for Precast Units such as
Hollow Blocks
Cavity Blocks etc.
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COMPACTION BY ROLLING
Method of Compaction
the Soft and Plastic Concrete is fed continuously
between Rubber Rollers under Pressure up to 50
atm
This forces out the excess water in Concrete.
Rolling is used to manufacture Precast

Concrete Products such as Tiles.
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CURING
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75
CURING
The Process of keeping Concrete Damp is known as Curing.

The Object is
to PREVENT the loss of Moisture from Concrete due to Evaporation or
any other reason
SUPPLY Additional Moisture or Heat and Moisture to ACCELERATE the
Gain of Str.
Cement gains Str and Hardness because of the Chemical Action

between Cement and Water. This Chemical reaction requires
Moisture
favourable Temperature and
Time referred to as the Curing Period.
The variation of Compressive strength with Curing Period is shown

in Fig. 10.11 (a, b).
Curing of freshly placed concrete is very important for optimum Str
and Durability.
The Major part of the Str in the Initial period is contributed by the
Clinker compound C3S and partly by C2S, and is completed in about 3
weeks.
The Later Str contributed by C2S is gradual and takes long time.
As such sufficient Water should be made available to Concrete to
9/29/2014 allow it to gain Full Str.Eswar/ BTech2yr/ BMCT/ Unit5
76
Strength vs Age
9/29/2014
77
CURING (Contd)
for at least 3 weeks; in no case < 10 days.

14 litres of Water required to Hydrate 1 Bag
Cement.
For Initial 3 - 7 days increase in Str is VERY RAPID
& continues SLOWLY thereafter for an indefinite
period.
Concrete Moist Cured for 7 days is about 50%
Stronger than that which is exposed to Dry Air for
the entire period.
If the concrete is kept Damp for 1 Month, the Str
is about DOUBLE than that of Concrete exposed
only to Dry Air.
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Devp of Str with Curing
9/29/2014
79
METHODS OF CURING
Concrete may be kept moist by a number of

ways. The Methods consist in either supplying
additional moisture to concrete during early
Hardening Period by
Ponding
Spraying
sprinkling, etc. or
by preventing loss of moisture from concrete by
Sealing the Surface of Concrete by Membrane
formed by Curing Compounds.
Some of the Prevelent Methods of Curing are

discussed in succeeding slides.
9/29/2014
80
WATER CURING
is done by covering the concrete surface with Gunny Bags and then
Sprinkling Water over them Regularly
In Membrane Curing the surface is coated with a Bitumen layer to prevent
loss of moisture by Evaporation.
Sealing compounds may also be used as an alternative to Bitumen layer.
e.g.
Rubber Latex Emulsion

Resins
Varnish and
Wax
However, the Concrete here may not achieve Full Hydration as in moist
curing.
The Horizontal Surfaces are kept Wet by
storing Water over them (Ponding) or by
Damp Gunny Bags, Straw, etc.
Ponding, may, affect the strength if the Concrete is flooded TOO SOON.
When Sprinkling of Water is done at intervals, CARE must be taken that
the Concrete does not DRY OUT BETWEEN applications to prevent the
possibility of Crazingthe Fine Cracks that may occur in the surface of
New Concrete as it Hardens.
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81
STEAM CURING
Curing can be also accomplished by Artificial Heat while the
Concrete is maintained in Moist Condition. Both of these
conditions can be fulfilled by the use of Steam Curing.
This method of curing is also known as Accelerated Curing
since an increased rate of Strength Development can be
achieved. The accelerated process of curing has many
Advantages in the manufacture of Precast Concrete
Products;
(a) the Moulds can be removed within a Shorter Time;
(b) due to Shorter Period of curing, Production is
INCREASED Cost is REDUCED
(c) Requirement of Storage Space in the Factory REDUCED.
The Temperature can be raised by
Placing the Concrete in Steam or Hot Water or
by Passing an Electric Current through the Concrete.
9/29/2014
82
STEAM CURING (Contd)

In the Hydration Process of Cement at Higher
Temperatures,
The released Ca(OH)2
reacts with Finely divided Silica, present in CA and FA and
forms a Strong and fairly insoluble Compound which results in
Higher Str
Since free Ca(OH)2 content is reduced, the Leaching and

Efflorescence are MINIMISED.
The Hydrating C2S and C3A react together at High
Temperatures to form Sulphate Resisting Compounds.
Consequently Autoclaved Products show

HIGHER Resistance to Sulphate Attack.
The Initial Drying Shrinkage and Moisture Movements are
also considerably REDUCED.
However, High-Pressure Steam-Curing REDUCES the Bond
Str by about 50%
9/29/2014
83
The Concrete Members are Heated by Steam at

93 C either at Low Pressure or High Pressure.
Low Pressure Steam Curing gives 70 % of the 28
day Str (Compressive) in 16-24 hrs.
High Pressure Steam Curing
Applied to Precast Concrete members
Gives 28 day Str (Compressive) in 24 hrs.
The effect of Curing Temperature on Compressive Str

is shown in Fig. 10.12.
It also results in INCREASED Resistance to
Sulphate Action and to
Freezing and Thawing.
The Mixes with Low W-C ratio respond more

favourably to Steam Curing than those with higher
water/cement ratio.
9/29/2014
84
Curing Temp vs Str
9/29/2014
85

EFFECT OF TEMPERATURE
An early rise in Temperature at the time of Setting of
Concrete may be DETRIMENTAL because the Green
Concrete may be too weak to RESIST the air pressure set
up in the pores by the increased Temp
The Rate of Increase or Decrease of Temperature < 10 20 C per hr, to avoid Thermal Shocks.
The Higher the W/C ratio of Concrete the MORE
ADVERSE is the effect of an early rise in temperature.
Therefore, to meet the requirement of Compressive Str of
Concrete, the Temp and/or Time required for Curing can
be REDUCED by having a LOWER W/C ratio.
HIGHER the Max Temp GREATER is the Compressive Str.
The advantages of Curing at >70C are NEGATED BY
Dilational Tendencies due to the Expansion of Concrete.
9/29/2014
86

Steam Curing should be followed by Water
Curing for a period of at least 7 days.
This Supplementary Wet Curing is found to
Increase the Str of Steam-Cured Concrete by
20 - 35 %
In most cases, Steam Curing is employed only
for achieving 50 - 70 % of Specified Str in a
Short Period; instead of full treatment for 2 to
3 days required to obtain Specified Str.
9/29/2014
87

Low pressure Steam Curing at Atm Pressure
can be
Continuous or
Intermittent.
Max Curing Temp is limited to 85 - 90C.
In the Normal Steam Curing procedure,

it is advisable to start the Steam a few hrs after Casting.
A DELAY of 2 - 6 hrs, called the Presteam or Presetting
Period, is usual, depending upon the Temp of Curing
The Presetting Period helps to achieve a 15 - 30 % HIGHER
24 hr Str THAN that obtained when Steam Curing is
resorted to immediately.
The Rate of Initial Temperature Rise after Presetting

Period is of the order of 10 - 20C per hr.
9/29/2014
88
High-Pressure Steam-Curing
In the case of Normal Steam-curing at Atmospheric

pressure, the Ultimate Str of Concrete may be adversely
affected if the Temperature is raised rapidly.
This difficulty can be overcome by employing the steam at
a pressure of 8 Atm. The process is termed High-Pressure
Steam-Curing.
The increase in temperature allowed is
up to 50C in the first hour,
up to 100C in second hour and
up to 185C in the third hour.
The Period of Treatment under Full Pressure depends upon

the Str requirements. This period of treatment is
7 to 10 hours for hollow block products and
8 to 10 hours for slab or beam elements.
The period may be increased with the thickness of concrete.
9/29/2014
89
CURING BY IR RADN
A much more Rapid Gain of Str can be
obtained with the help of IR radiation than
even with Steam Curing.
The Rapid Initial Rise of Temperature does not
affect the Ultimate Str. It is particularly
suitable for the manufacture of Hollow
Concrete Products in which case the Heaters
are placed in the Hollow Spaces of the
product.
The Normal Op Temp is 90C.
9/29/2014
90
Electrical Curing
Concrete products can be Cured by passing AC
of Low Voltage (30 and 60 V) & High
Amperage through Electrodes in the form of
Plates covering the entire area of 2 Opposite
faces of Concrete.
Evaporation is prevented by using an
impermeable rubber membrane on the top
surface of the concrete. By electrical curing,
Concrete can attain the normal 28-day
strength in a period of 3 days.
The technique is Expensive.
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91
Chemical Curing
Chemical Membranes can be Sprayed on to Cure Concrete.
Liquid Membrane forming Curing compounds such as
Sodium Silicate (Water Glass) Solution
RETARD or PREVENT EVAPORATION of Moisture from Concrete.
They form a Film, Fill the Pores, Seal the Surface Voids and
Prevent Evaporation.
Adequate and Uniform Coverage of Curing Compounds is

essential.
In most cases 2 Applications are required.
Chemical membranes can be used for Curing at various stgs
Fresh Concrete
Further Curing of Concrete, after removal of forms
after initial moist curing.
9/29/2014
92
Chemical Curing
APPLICATION TIMING
The application should be made Immediately after
Concreting. If there is any delay, the Concrete should
be kept Moist until the membrane is applied.
Membrane Curing Compound should NOT be applied
when there is free water on the surface, because this
Water will be absorbed by the Concrete and the
Membranes BROKEN.
NOR should the Compound be applied after the
Concrete has Dried out: since it will be absorbed into
the surface of the Concrete and a Continuous
Membrane will NOT be formed.
The Correct Time to apply the membrane is when the
Water Sheet Disappears from the surface of the
finished concrete.
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FINISHING
9/29/2014
94
FINISHING
Concrete is basically used because of its High
Compressive Str. However, the Finish of the ultimate
product is not that pleasant. In past couple of decades
efforts have been made to develop surface finishes to
give a better appearance to concrete surfaces and are
as follows.
FORM WK FINISHES
Concrete takes up the Shape of the Form. Smooth
surfaces can be achieved by
careful Preparation of Formwork,
proper Mix Design and
good Workmanship.
Prefabrication Units can be produced to a Fine Finish.

9/29/2014
95
SURFACE TREATMENTS
The type of surface treatment depends upon the
purpose for which the concrete surface is to be used.
For example a pavement surface should be plane but
with sufficient roughness to exhibit skid resistance. To
make the surface ROUGH, Concrete (after levelling) is
rocked
broomed or
scratched
APPLIED FINISHES
The exterior surfaces of concrete elements can be
modified to give a pleasant look. The concrete surface
is roughened, cleaned and wetted. Over this a cement
mortar of ratio 1:3 is applied. This mortar rendering
can be given a number of surface finishes such as sand
facing, rough cast finish, Peeble Dash etc.
9/29/2014
96

Unit 5 (Pt2) Cement Concrete (Part B) (Also Including Parts of Unit 6)

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Unit 5 (Pt2) Cement Concrete (Part B) (Also Including Parts of Unit 6)

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Unit 5(Pt2)

CEMENT CONCRETE (Part B)

Eswar/ BTech2yr/ BMCT/ Unit5

Eswar/ BTech2yr/ BMCT/ Unit5

Specific Functions of these four constituents

Eswar/ BTech2yr/ BMCT/ Unit5

Stages of Concrete Production

Eswar/ BTech2yr/ BMCT/ Unit5

Factors affecting the Choice of Batching Method

For most important works Weigh Batching is

Eswar/ BTech2yr/ BMCT/ Unit5

The amount of Solid Granular material in a CuM will be an

Eswar/ BTech2yr/ BMCT/ Unit5

Wooden Box for Gauging Aggregates

Eswar/ BTech2yr/ BMCT/ Unit5

For Smaller Wks

AUTOMATIC BATCHING PLANTS.

By Pressing a Button, Weighing of Materials is put into Motion

Eswar/ BTech2yr/ BMCT/ Unit5

All the Aggregate Particles should have a Coat of

The Mixing is done by

Eswar/ BTech2yr/ BMCT/ Unit5

for Small Jobs.

Measured Qtys of CA and FA are spread over an

Desirable to add 10% extra Cement to cater for

Eswar/ BTech2yr/ BMCT/ Unit5

Eswar/ BTech2yr/ BMCT/ Unit5

BATCH MIXERS (Machine Mixing)

Based on Technique of Mixing..Drum type are Cl as

Based on Drum Capacity..Standard Sizes of the

Eswar/ BTech2yr/ BMCT/ Unit5

Pan-type Drum Mixer

Eswar/ BTech2yr/ BMCT/ Unit5

Tilting Drum Type Batch Mixer

Eswar/ BTech2yr/ BMCT/ Unit5

Tilting Drum Type Bucket Mixer

Eswar/ BTech2yr/ BMCT/ Unit5

Non-Tilting Drum type Concrete Mixer

Eswar/ BTech2yr/ BMCT/ Unit5

Reversing Drum Mixer

Eswar/ BTech2yr/ BMCT/ Unit5

Produce Concrete Continuously, till plant is

Sometimes Mixers are specified by 2 Qtys:

Eswar/ BTech2yr/ BMCT/ Unit5

Vertical Batching Mixing Plant

Eswar/ BTech2yr/ BMCT/ Unit5

The Mixer is generally

It can be Tilted for discharging Concrete. Blades

Eswar/ BTech2yr/ BMCT/ Unit5

TILTING MIXERS (Contd)

The Disadvantage of these mixers lies in the fact

Eswar/ BTech2yr/ BMCT/ Unit5

Drum Type Batch Mixer

Eswar/ BTech2yr/ BMCT/ Unit5

Eswar/ BTech2yr/ BMCT/ Unit5

The Drum rotates about a Horizontal Axis (Fig.

Eswar/ BTech2yr/ BMCT/ Unit5

Non-Tilting Drum type Concrete Mixer

Eswar/ BTech2yr/ BMCT/ Unit5

REVERSING DRUM TYPE MIXEER

Eswar/ BTech2yr/ BMCT/ Unit5

Reversing Drum Mixer