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15ARC 8.

6
Module Title: PROJECT AND CONSTRUCTION
MANAGEMENT

MODULE -5

Delivered by: Er.Ashwini Patil

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Construction Equipment and
Management

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Intended Learning Outcomes
• At the end of the session, students will be able to:
– Describe the significance of taking safety measures during
equipment operation
– Calculate the total cost of operating an equipment and its
production rate
– Analyze the suitability of equipment plan based on project
requirements, equipment availability and total cost of operation
– Perform equipment replacement analysis based on depreciation
analysis and cost of employing an equipment

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Introduction
• Wide variety of relatively heavy machines which perform specific
construction (or demolition) functions under power
• Used to perform repetitive operations

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Advantages of Utilizing Construction Equipment

 Increase the rate of output


 Reduce the overall construction costs
 Carry out activities which cannot be done manually
 Eliminate the heavy manual work
 Maintain the planned rate of production
 Maintain the high quality standards

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Types of Construction Equipment and their
Selection Criteria

• Earthwork equipment

• Concreting equipment

• Hoisting equipment

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Types of Earthwork Equipment

 Backhoe
Roller compactor
 Front shovel
Scraper
 Dragline Dumper
 Clamshell Grader

 Dozers

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Backhoe

Used to:
• Clean up construction areas
• Dig holes in the ground
• Smoothen uneven ground
• Make trenches and ditches
• Remove deep roots from trees

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Front shovel

• Excavation purposes above its


own track or wheel level
• Heavy positive cutting in all types
of dry soils

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Dragline

• Bulk excavation below its track


level
• Suitable for
– loose soils
– marshy land
– areas containing water

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Clamshell

• Hydraulically controlled bucket


suspended from a lifting arm
• Deep confined cutting in pits
and trenches

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Dozers

• Moving earth up to a distance


of about 100m and
• Towing tractor and pusher to
scraper machine
• Track-mounted or wheel-
mounted

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Roller compactor
• Compaction of earth and other materials
• Large works of highways, canals and airports

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Scraper

• Site leveling, loading, hauling over distances varying between


150m-900m
• Towed, two-axle or three-axle type

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Dumper

• Horizontal transportation of
materials on and off sites
• Large capacity dumpers used
in mines and quarries

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Grader

• Grading and finishing upper


surface of earthen formations
and embankments
• Operates in the forward
direction

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Selection Criteria for Earthwork Equipment

Dependent on the following factors:


 Quantities of material to be moved
 Available time to complete the work
 Job conditions
 Prevailing soil types, swell and compaction factors, etc.

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Planning of number of Earthwork Equipment , depends on:

 Suitable class of equipment for earthwork


 Appropriate model of equipment
 Number of equipment needed
 Number of associated equipment required

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Types of Concreting Equipment

 Concrete batching and mixing plant

 Concrete mixers

 Concrete transit mixers

 Concrete pumps

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Concrete batching and mixing plant

• Weighing and mixing large


quantity of concrete
constituents
• Capacity:- 20cum/hr-250cum/hr

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Concrete mixers

• Mixing small quantities of


concrete constituents
• Capacity:-
– 200lt/batch (small mixers)
– 200-750lt/batch(large mixers)

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Concrete transit mixers

• Transporting concrete from


batching point
• Capacity:- 3cum-9cum

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Concrete pumps

• Horizontal and vertical


transportation of large volumes of
concrete in short duration
• Capacity:-
– 30cum/hr(ordinary
construction)
– 120cum/hr(specialized
construction)

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Selection Criteria for Concreting Equipment

 Site characteristics

 Equipment availability

 Continuity of operation

 Effect of permanent work

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Selection Criteria for Concreting Equipment (cont…)

 Weather conditions

 Temporary works

 Time restrictions

 Concrete specifications

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Concrete-mixing equipment selection will depend on
following factors:
 Maximum and the total output required in a given time frame

 Method of transporting the mixed concrete

 Requirement of discharge height of the mixer

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Concrete-placement equipment selection depends on
following factors:

• Capacity of the vehicle


• Output of the vehicle
• Site characteristics
• Weather conditions
• Rental costs, and the
• Temporary haul roads

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Hoisting Equipment
Group of equipment employed mainly for lifting or lowering of unit
load and others
Hoisting
Equipment

Hoists Cranes

Boom Chain Derrick Mobile


Hoists Hoists Crane Crane

Electric Tractor Tower


Hoists Hoists Crane
ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Boom Hoist

• Lifting of weights on hooks - bear


maximum loads
• Industrial machine- loads weight on
containers

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Chain Hoist

• Used in most of the construction


and industrial operations
• Chain rope and pulley used to
move the load from up to down

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Electric Hoist

• Modernized form of chain and boom


hoist
• Used industries for fast working
• Popular in material handling
industries
• Saves labor costs by handling
maximum loads at a time with no
damage threats

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Tractor Hoist

• Consist of a boom that is attached


with base of tractor

• A hook with rope - driver controls

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Cranes

• One of the most important equipment


• Key role in performing lifting tasks
• Categorized into:
– Derrick Cranes
– Mobile Cranes
– Tower Cranes

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Selection of Cranes

Factors affecting the selection of cranes are:


• Building Design

– Building height

– Project duration

• Capability

– Power supply

– Load lifting frequency

– Operators visibility
ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
• Safety

– Initial planning and engineering


• Economy
– Cost of move in, setup, and move out

– Cost for rent

– Productivity

• Site Conditions

– Soil Stability and ground conditions

– Access road requirement and site accessibility

– Operating clearance
ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Mobile Cranes

• Adequate for all types of structures (up to 107 m)

• Used for shorter projects duration (less than 4 months)

• Not considered to be very safe due to

– lack of safety devices

– limited switches to prevent overloading

• Can operate in muddy terrain but requires good ground conditions

• Needs adequate operating clearance

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Mobile Cranes

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Tower Cranes

• Preferable for high-rise (over 107 m)

• Used for longer project duration

• Considered to be very safe due to the presence of limit switches

• Can operate where ground conditions are poor

• Does not need adequate operating clearance

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Tower Cranes

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Derrick Cranes
• Preferable for high-rise and apartment buildings

• Can be used for both long term and short term projects

• Cheaper than mobile and tower cranes

• Not considered to be safe

• Used when

– clearance is inadequate for the other units

– sufficient space is unavailable for the erection of a tower


foundation
ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Derrick Cranes

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Session Summary

• The three basic categories of equipment used in construction are


earthwork equipment, concreting equipment and hoisting equipment.
• Selection and planning of equipment depends on a number of factors
such as size of the job, cost, time constraint, equipment characteristics,
site conditions, etc.
• Equipment replacement decisions depend upon depreciation, interest
and operation costs and revenue of a project.
• Most of the accidents with respect to equipments can be avoided if
suitable safety measures are taken during equipment operation.

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Concrete and Asphalt Plants

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Ready mix concrete(RMC):

• Components proportioned away


from the construction site for
delivery to the site

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Need for Ready Mix concrete

• Requirement for higher grades of concrete


• Correct accountability ingredients
• Rapid development of infrastructure industry
• Increased demand of concrete
• Possibility of manufacture of desired grades
• Mega project demands higher output
• Timely supply of reliable concrete

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Production of RMC

• Transit mixed concrete


• Shrink mixed concrete
• Central mixed concrete

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Flowchart of Manufacturing Process

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Ready Mix Batching Plant

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Raw Materials

• Water
• Additives
• Cement
• Aggregate
• Air

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Aggregates

• Make up roughly 60% to 75%


of ready mix concrete’s volume
• Obtained from quarries and
aggregate banks

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Additives

• Solid or liquid chemical


substance added to ready mix
concrete before or during
preparation
• Improve a hardened concrete’s
durability, or
• Reduce a concrete’s water
content

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Water

• Vital fluid
• Sets off a chemical reaction when it
comes into contact with the cement

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Cement

• Strength contributing ingredient


• Gray Portland type 1 and Puzzolona Portland type 2 cements

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Concrete mixing

• Components come together to produce a uniform mass of concrete.


• Mixing time registered from the movement material and water is poured
into the cement mixer, and it begins rotating

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Ready to use for site

• While transporting concrete to a site, the cement mixer rotates


• Speed is of two to six rotations per minute

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Equipment Required in R. M. C.

1. Batching plant

2. Silos

3. Belt Conveyor

4. Transit mixer

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Batching

Batching plants are classified as


1. Manual
2. Semiautomatic
3. Fully automatic

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Manual Batching Plant

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Semi automatic Batching Plant

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Automatic Batching Plant

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Storage Silos

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Aggregate Feeding Belt Conveyors

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Ready-mix Concrete Portable Conveyors
• For handling Ready Mix Concrete output from batching plant to transit
mixer / outer area
• Stationary or portable special type belt conveyors

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Transit Mixer

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Sampling and Testing of RMC

• Point and time of sampling

• Workability
– Slump
– Compacting factor

• Strength

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Environmental Considerations

• External appearance
• Plant, office buildings and staff facilities
• Traffic control and cleanliness
• Site safety
• Air pollution
• Noise and vibration

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Advantages Of Ready Mix Concrete
• Quality assurance
• Elimination of manual errors
• Mass production of concrete possible
• Water cement ratio maintained
• Reduced material wastage
• Labour cost saved
• Design mix as per IS standards

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Disadvantages of Ready Mix Concrete

• Materials are batched at a central plant


• Generation of additional road traffic
• Weight of the truck and load at access to site
• Concrete's limited time span between mixing and going-off

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
ASPHALT PLANT

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Asphalt concrete

• Composite material

• Used for surface roads, parking lots, and airports

• Consists of mineral aggregate bound together with asphalt

• Laid in layers, and compacted

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Asphalt plant

• Production of quality hot asphalt


mixture

• Should contain desired


proportions of asphalt and
aggregate

• Should meet all specifications

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Asphalt plant

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Types of Plants

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Typical Batch Plant

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Components of a Drum type Plant

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Material Flow Diagram

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Batch plant operations

• Aggregate storage and cold feeding


• Aggregate drying and heating
• Screening and storage of hot aggregates
• Storage and heating of binder
• Measuring and mixing of binder, aggregate and recycled materials
• Loading of finished asphalt mixture

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Material Blending (bins)

• Keeps materials separated


• Allows operator to blend materials at
rates/percentages dictated by mix
design
• Weighs aggregate as it enters drum
dryer
• Screens Aggregate

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
The Aggregate Dryer

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Aggregate Dryer Performs Two Functions

ER.ASHWINI PATIL81
©M. S. Ramaiah University of Applied Sciences ©M. S. Ramaiah University of Applied Sciences
Mixing Tower

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©M. S. Ramaiah University of Applied Sciences
Typical Mixing Cycle

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Burner

• Fuel can be heated/


pressurized/ atomized/ mixed
with air/ ignited

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Baghouse

Large metal housing containing hundreds of synthetic, heat resistant fabric


bags for collecting fines

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Air flow through baghouse
• Some utilize cyclone or knock
down box
• Air flows below and up through
bags and into top of baghouse
• Bag pulse to release built up
dust material
• Dust augured back to drum and
blended with mix

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Silo System
• Allow plant to continue
production while waiting on
customers
• Allow production/sale of
multiple mixes

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©M. S. Ramaiah University of Applied Sciences
Drum Plant

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©M. S. Ramaiah University of Applied Sciences
Parallel flow drum plant

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©M. S. Ramaiah University of Applied Sciences
Counter Flow Drum Plant

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©M. S. Ramaiah University of Applied Sciences
Double-Drum Plant

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©M. S. Ramaiah University of Applied Sciences
Double-Drum Plant

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©M. S. Ramaiah University of Applied Sciences
Portable Drum Plant

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©M. S. Ramaiah University of Applied Sciences
Modern Fixed Drum Plant

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Plant Control

• Heart of plant (the brain)


• Sophisticated controls
• Controlled blending system
• Updates status & control
• Process management and
diagnostics
• Inventory control
• Loading and ticketing
• Time entry

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Precast Flat Panel Systems
• Precast panels cast and cured in a controlled factory environment
• Helps ensure panel quality and uniformity
• Can be installed in a short span of time
• No requirement of curing
• Elimination of weather delays

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Precast Flat Panel Systems
• Cast as
– solid reinforced precast concrete (flat panels), or
– reinforced concrete ribbed panels with a thin exterior shell
• Stronger concrete panels than poured concrete walls
• Thinner and lighter weight
• Walls can be customized during the order process

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Installation Procedure
• Planning
• Code Acceptance
• Arrange crane access
• Prepare foundation base
• Place and assemble panels
• Pour slab and install floor system
• Backfill

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
SUMMARY

RMC production process involves measuring concrete mix


ingredients by either mass or volume and mixing them to produce
concrete of uniform quality

The production process in Asphalt plant involves drying and heating


the aggregates and blending it with asphalt

Precast flat panel systems ensure stronger, thinner and lighter


structural components with quick installation

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
CONSTRUCTION
EQUIPMENTS(MIXING,TRANSPORTATIO
N ,PLACING,COMPACTION AND
CONSTRUCTION MATERIALS

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Intended Learning Outcomes

• At the end of this session, student will be able to:


– Describe the different types of materials used for construction
and code standards for the same

– Enumerate the factors which influence the quality of concrete


and their significance

– Describe the properties of metals, and their applications in


construction

– Discuss the manufacturing processes of cement and concrete

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Modern Construction Materials
• Cement

• Concrete

• Steel

• Aluminium

• Plastic

• Reinforced Polymers ER.ASHWINI PATIL


©M. S. Ramaiah University of Applied Sciences
Modern Construction Materials

• Non-weathering Materials

• Flooring and Façade Materials

• Water proofing compounds

• Construction Chemicals

• Smart and Intelligent Materials


ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Cement

• It acts as a binder

• Can be hydraulic or
non-hydraulic

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Cement
• Types of modern cement
– Portland cement

– Energetically modified cement

– Portland cement blends


• Portland blast-furnace cement

• Portland fly ash cement

• Portland pozzolana cement

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Cement

– Portland cement blends (contd..)


• Masonry cement

• Expansive cement

• White blended cement

• Colored cement

• Very finely ground cement

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Cement

– Portland cement blends (contd..)


• Pozzolana lime cement

• Slag lime cement

• Super-sulfated cement

• Calcium sulfo-aluminate cement

• Portland silica fume cement

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Grade of Cement
• Classified into 3 grades
– Tested as per IS 4031-1988
• 33 grade
1 • 28 days strength not less than 33 N/mm2

• 43 grade
2 • 28 days strength not less than 43 N/mm2

• 53 grade
3 • 28 days strength not less than 53 N/mm2

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Manufacturing of Cement

• Raw materials required

– Calcareous materials – limestone or chalk

– Argillaceous materials – shale or clay

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Manufacturing of Cement

Wet Process

Dry Process

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©M. S. Ramaiah University of Applied Sciences
Wet Process

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©M. S. Ramaiah University of Applied Sciences
Dry Process

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Aggregates

• Important constituents in
concrete

• Occupy 70-80 % of the


volume of concrete

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
• Can be classified as
– Normal weight aggregates

– Light weight aggregates

– Heavy weight aggregates

• Normal weight aggregates


– Natural aggregates

– Artificial aggregates

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Source of Aggregates

• Aggregates from Igneous Rocks


– Hard, tough and dense.

– Massive structure, entirely crystalline


or wholly glassy or a combination

– May be acidic or basic

– Light colored or Dark colored


Granite

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Source of Aggregates

• Aggregates from Sedimentary


Rocks

– Weathering agencies

– Cementing materials
• Carbonaceous, siliceous or
argillaceous in nature

– Static pressure of water Shale

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Source of Aggregates – contd..

• Aggregates from Metamorphic


Rocks

– High temperature and pressure -


metamorphism

– Foliated structure

Marble

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Size of Aggregates

• Max size – 80 mm

• Largest possible max size


– Reduction of the cement
content

– Reduction in water
requirement

– Reduction of drying shrinkage

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Shape of Aggregates

• Affects workability of
concrete

• Type of crusher

• Reduction Ratio

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Shape of Aggregates – contd..

• Rounded aggregates are


preferable

• Rounded aggregates are


smooth textured

• Angular aggregates are rough


textured.

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Shape of Aggregates – contd..

• Angular aggregates -
better interlocking

• Total surface area of


angular aggregates >
rounded aggregates

• Angular aggregates –
higher bond strength

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Texture of Aggregates

Group Surface Texture Examples


1 Glassy Black flint
2 Smooth Chert; Slate; Marble; some Rhyolite
3 Granular Sandstone; Oolites
4 Crystalline Fine: Basalt; Trachyte
Medium: Dolerite; Granophyte; Granulite;
Microgranite
Coarse: Gabbro; Gneiss; Granite; Granodiorite;
Syenite
5 Honeycombed Scoria; Pumice; Trass
and porous

Surface characteristics of aggregate ER.ASHWINI PATIL


©M. S. Ramaiah University of Applied Sciences
Grading of Aggregates

• Affects workability.

• Well graded aggregate - least


amount of voids

• Total voids are less - better


lubricating effect

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Grading of Aggregates

• Excess amount of paste -


prevents segregation

• Better grading – lesser


voids –higher workability

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Manufacturing of Concrete

• Process involves:
– Batching
– Mixing
– Transporting
– Placing
– Compacting
– Curing
– finishing

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Batching

• The measurement of materials for making concrete is


known as batching.

• There are two Methods of batching:


– Volume batching
– Weigh batching

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Volume Batching

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©M. S. Ramaiah University of Applied Sciences
Weigh Batching

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©M. S. Ramaiah University of Applied Sciences
Weigh Batching

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©M. S. Ramaiah University of Applied Sciences
Measurement of Water

• Weigh Batching

• Graduated Bucket – not accurate

• Horizontal tank or Vertical tank

• These tanks are filled up after every batch accurately.

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Mixing

• Thorough mixing is essential

• Homogeneous, uniform in
colour and consistency

• Two methods
– Hand Mixing
– Machine Mixing

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Hand Mixing

• Small scale unimportant


concrete works.

• Cannot be thorough and


efficient.

• Impervious concrete or
brick floor.

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences
Hand Mixing

• Coarse aggregate and


Fine aggregate –
alternate layers

• Pour the cement and


mix

• Uniformity of colour

ER.ASHWINI PATIL
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Hand Mixing

• Uniform mixture – 20 cm
thick

• Water is sprinkled

• Uniform, homogeneous
concrete

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Machine Mixing

• RCC work, medium and large


scale work

• Efficient and Economical

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Machine Mixing

• Concrete Mixers

• Batch Mixers and


Continuous Mixers

• Large scale work

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Machine Mixing

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Machine Mixing

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Mixing Time

• Concrete mixers -15 to 20 rpm

• Proper mixing - 25 to 30 rpm

• Optimum benefit

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Concrete high-speed mixer in a batching plant ER.ASHWINI PATIL140
©M. S. Ramaiah University of Applied Sciences ©M. S. Ramaiah University of Applied Sciences
Transporting

• Variety of methods and equipments

• Homogeneity should be maintained

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Transportation

• Methods adopted
– Mortar Pan

– Wheel Barrow, Hand Cart

– Crane, Bucket and Rope way

– Truck Mixer and Dumpers

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©M. S. Ramaiah University of Applied Sciences
Transportation

• Methods adopted
– Belt Conveyors

– Chute

– Skip and Hoist

– Transit Mixer

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Mortar Pan

• Disadvantage – exposes
greater surface area

• Wetted at start

• Kept clean during the entire


operation

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Wheel Barrow

• Concrete – placed at ground


level

• Hauling – comparatively
longer distance

• Rough ground – segregation

• Pneumatic wheel

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Crane, Bucket and Rope way

• Above ground level

• High-rise construction
projects

• Move concrete
horizontally as well as
vertically

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Crane, Bucket and Rope way

• Concrete work in a
valley or of a pier

• Concrete discharged
from the smallest
height

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Truck Mixer and Dumpers

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Belt Conveyors

• Limited applications

• Principal objection –
concrete tends to
segregate on steep
inclines

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Belt Conveyors

• Segregation - rubber
belt vibration

• Concrete should be
remixed

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Chute

• Ground level to a lower level.

• No separation or segregation

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Skip and Hoist

• Transporting
concrete vertically
up

• Taller structures

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Transit Mixer

• RMC Plant

• Truck mounted

• Capacity - 4 to 7 cubic
meter

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Transit Mixer

• 2 variations:

– Concrete is kept agitated -


2 to 6 revolutions per
minute

– Mixing is done in truck


mixer

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©M. S. Ramaiah University of Applied Sciences
Placing Concrete

• Optimum results

• Loose earth must be


removed

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Placing Concrete

• Water and slush must


be removed completely

• Great thickness -
placed in layers

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Placing Concrete

• Thickness of layers -
mode of compaction

• RCC – layers - 15 to
30 cm thick and in
mass concrete - 35
to 45 cm thick

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Placing Concrete

• Reinforcement and
joints are checked

• Formwork – mould
releasing agents

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Placing Concrete

• Reinforcement -
clean and free from
oil

• Small quantity at a
time

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Formwork

• Rigid

• Prevent loss
of slurry

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Summary

• The manufacturing of cement is done either by wet


process or dry process.

• The manufacturing of concrete consists of batching,


mixing, transporting, placing, compacting, curing and
finishing.

• Tests are carried out on fresh concrete as well as hard


concrete.

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Compaction of Concrete

– Expelling entrapped air


– Lower workability –
Higher air entrapment

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Compaction of Concrete

– High percentage of
entrapped air – higher
compacting efforts

– Insufficient compaction
increases permeability

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Compaction of Concrete

Methods
– Hand Compaction
– Roding

– Ramming

– Tamping

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Compaction of Concrete

Methods
– Compaction by Vibration
• Internal vibrator (Needle vibrator)
• Formwork vibrator (External vibrator)
• Table vibrator
• Platform vibrator
• Surface vibrator (Screed vibrator)
• Vibratory Roller

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Compaction of Concrete

Methods
• Compaction by Pressure and Jolting

• Compaction by Spinning

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Hand Compaction

• Unimportant concrete work

• Large quantity of
reinforcement

• Thickness -15 to 20 cm

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Rodding

• Rod - 2 metre long, 16 mm


dia

• Bamboos or canes are also


used

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Ramming

• Light ramming - unreinforced


foundation or in ground floor
construction.

• Not permitted - reinforced concrete


or in the upper floor construction

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Tamping

• Compacting roof or floor slab or road pavements – thickness


- comparatively less and surface - smooth and level

• Wooden cross beam -10 x 10 cm

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©M. S. Ramaiah University of Applied Sciences
Compaction by Vibration

• Satisfactory results

• Hand compacted concrete –


low strength – high water
cement ratio

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©M. S. Ramaiah University of Applied Sciences
Compaction by Vibration

• High frequency vibrators

• Congestion of
reinforcement

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©M. S. Ramaiah University of Applied Sciences
Internal Vibrator

• Also called “Needle Vibrator”,


“Immersion Vibrator” or “Poker
Vibrator’’

• A power unit, a flexible shaft and a


needle

• Eccentric weights

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©M. S. Ramaiah University of Applied Sciences
Internal Vibrator

• Needle diameter - 20 mm to 75
mm and length - 25 cm to 90 cm

• Bigger needle - mass concrete


dam

• Needle can be replaced by a


blade

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Formwork vibrator (External vibrator)

• Columns, thin walls or precast


units.

• Machine – clamped on
external wall surface

• Vibration given to formwork

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©M. S. Ramaiah University of Applied Sciences
Formwork vibrator (External vibrator)

• Reinforcement, lateral
ties and spacers

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Table Vibrator

• Vibrator - clamped to the table

Or

• Table - mounted on springs

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Table Vibrator

• Vibrating concrete cubes

• Mostly used in the laboratories

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Platform vibrator

• Table vibrator - larger in size.

• Large prefabricated concrete


elements

• Also coupled with jerking or


shock - good compaction

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©M. S. Ramaiah University of Applied Sciences
Surface vibrators

• Also known as “Screed


Board Vibrators”

• Thin concrete members

• Floor slabs and roof slabs

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©M. S. Ramaiah University of Applied Sciences
Vibratory Roller
• Very dry and lean concrete

• Such concrete is known as


Roller Compacted
Concrete

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©M. S. Ramaiah University of Applied Sciences
Compaction by Pressure and Jolting

• Very dry concrete

• Hollow blocks, cavity blocks and


solid concrete blocks

• Combined action of the jolts,


vibrations and pressure

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©M. S. Ramaiah University of Applied Sciences
Compaction by Spinning

• Fabrication of concrete pipes

• Plastic concrete – compacted


by centrifugal force

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Compaction by Spinning

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Curing of Concrete

• Hydration

• In the field - water evaporates

• Impervious covering or application of


curing compounds

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Curing of Concrete

• Creation of a favourable environment

• High quality concrete

• Irreparable loss

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Curing of Concrete

Methods

• Water curing

• Membrane curing

• Application of heat

• Miscellaneous

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Water curing

Methods

• Immersion

• Ponding

• Spraying or
Fogging

• Wet covering

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Membrane curing

• Acute shortage of water

• Effectively seal off the


evaporation of water

• Bituminous compounds,
polyethylene or polyester film,
rubber compounds

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Application of heat

• Development of strength -
function of time and
temperature

• higher temperature - accelerates


the hydration process - faster
development of strength.

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Application of heat

• Concrete cannot be
subjected to dry heat

• Steam curing

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Finishing

• Exhibit pleasant surface


finishes

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Finishing

• Surface finishes
– Formwork Finishes

– Surface Treatment

– Applied Finishes

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Finishing

• Formwork Finishes

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Finishing
• Surface Treatment

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©M. S. Ramaiah University of Applied Sciences
Finishing
• Surface Treatment

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©M. S. Ramaiah University of Applied Sciences
Finishing
• Surface Treatment

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Finishing

• Surface Treatment

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©M. S. Ramaiah University of Applied Sciences
Finishing

• Applied Finishes

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©M. S. Ramaiah University of Applied Sciences
Testing of Fresh Concrete

• Workability

• The following tests are commonly employed to measure workability


– Slump Test
– Compacting Factor Test
– Flow Test
– Kelly Ball Test
– Vee Bee Consistometer Test

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©M. S. Ramaiah University of Applied Sciences
Slump Test

• Laboratory or site

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©M. S. Ramaiah University of Applied Sciences
Slump Test

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©M. S. Ramaiah University of Applied Sciences
Compacting Factor Test

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©M. S. Ramaiah University of Applied Sciences
Compacting Factor Test

• Degree of compaction  Compaction Factor

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©M. S. Ramaiah University of Applied Sciences
Compacting Factor Test
Compaction Factor Apparatus for use with Aggregate not
exceeding 40 mm Nominal Max. Size

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©M. S. Ramaiah University of Applied Sciences
Workability, Slump and Compacting Factor of Concretes with 20 mm or 40 mm
Max. Size of Aggregate

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Flow Test

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Flow Test

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Kelly Ball Test

• Field test

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Vee Bee Consistometer Test

• Laboratory test

• Measures indirectly the workability of concrete

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©M. S. Ramaiah University of Applied Sciences
Vee Bee Consistometer Test

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©M. S. Ramaiah University of Applied Sciences
Testing of Fresh Concrete

• Bleeding

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Testing of Fresh Concrete

• Bleeding

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Testing of Fresh Concrete

• Setting Time of Concrete – Penetrometer Test

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Penetrometer Test

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©M. S. Ramaiah University of Applied Sciences
Testing of Hardened Concrete

• The various tests carried on a hardened concrete are:

– Compression Test

– Flexural Strength

– Non Destructive Tests


• Rebound Hammer Test
• Pull Out Test
• Dynamic or Vibration Tests
• Magnetic and Electrical Methods

ER.ASHWINI PATIL
©M. S. Ramaiah University of Applied Sciences

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