Concrete Design Studio Portfolio

CT 2015
CONCRETE:
EXPLORING ITS VERSATILITY
Submitted by: Devarsh Shah | UG180151

Guided by: Prof. Bhargav Tewar | Mr. Nikunj Dave | Nipun Patel
Spring Semester 2020
CT 2015
CONCRETE:
EXPLORING ITS VERSATILITY
Submitted by-
Devarsh Shah
UG180151
CT 2015 CONCRETE: EXPLORING ITS VERSATILITY
Table of Content
Module 1: Exploring Raw Materials in Concrete……………………………………………………………………………..……………. 01-18

Cement Tests…………………………………………………………………………………………………………….…………………........ 02-07
Fine Aggregate Tests…………………………………………………………………………………………….……………………………… 08-12
Coarse Aggregate Tests………………………………………………………………………………………………….…………………..… 13-18
Module 2: Concrete Trials by Volumetric Batching……………………………………………………………..…………………….….. 19-33
Exercise Overview………………………………………………………………………………………………….…..………………….…… 20-20
Slump Test……………………………………………………………………………………………………………………………………..… 21-21
Flow Table Test……………………………………………………………………………………………………………………………......… 22-22
Compaction Factor Test………………………………………………………………………………………………………………………… 23-23
Compressive Strength Test…………………………………………………………………………………………………………..………… 24-27
Split Tensile Strength Test……………………………………………………………………………………………………………………… 28-28
Flexural Strength Test………………………………………………………………………………………………………………………...… 29-32
Module 3: Exploring Special Materials in Concrete……………………………………………………………………..………….......... 32-35
Module 4: Material Library….……………………………………………………………......................................................................... 36-41
Concept Development…………………………………………………………………………………………………………….……..……... 37-37
Trials and Prototype………………………………………………………………………………………………………………….…….….... 38-38
Formwork Development…………………………………………………………………………………………………….………………….. 39-39
Concrete Activity…………………………………………………………………………………………………........................................... 40-40
Process Chart…………………………………………………………………………………………………………………………..…..…… 41-41
Module 5: Project Work-Special Concrete……….……………………………………………………………………………..………...... 42-57
Special Concrete and its Applications……………………………………………………………………………..……………………….…. 43-55
Project Work Sulphurcrete.……….……………………………………………………………………………………………………….……..…. 56-57
Devarsh Shah (UG180151)

ACKNOWLEDGEMENT
Presentation, inspiration and motivation have always played a key role in the success of any project.
I pay my deep sense of gratitude to Prof. Bhargav Tewar & Mr. Nikunj Dave to encourage me to the highest peak & to provide me with suggestions regarding the
exercises. I feel to acknowledge my indebtedness & thank Nipun Patel, Teaching Assistant, for helping us & coordinate between faculty & students.
I express my sincere thanks to Jagdish bhai, Bikash bhai and Upendra bhai, CEPT material testing lab staff, for cooperating with the students and helping us with
different tests & also special thanks to CEPT workshop team for helping in Library module.

Overview
This course lead to better understanding of conventional concrete, its practices,
standards to check the quality of it. Also learning about special concretes helped to
change the perspective of how concrete can be engineered even further. These
exercises were part of different modules. The modules are listed below with a brief
introduction –
1. Exploring Raw Materials in Concrete

Concrete basically consists of binder(cement) and filler(sand, coarse aggregate). In
this module we tested these materials for various qualities as per their relevant IS
Codes and understood how each of this qualities affected the final quantity of the
concrete.
2. Concrete Trials by Volumetric Batching

The simplest and most prominent method of preparing concrete is by mixing the
constituent materials in a volumetric proportions. In this exercise we prepared
concrete using this method and tested the properties of fresh and hardened
concrete.
3. Exploring Special Materials in Concrete

Concrete is mainly seen as addition of four materials. But nowadays Admixtures,
different binders, purpose specific aggregates among other materials are being used
widely in construction today. We identified four materials other than those
previously identified by students in the previous semester, and justified why usage of
these materials was feasible.
Concrete Studio - Batch Spring 2020 4. Material Library

A task was given to make a material library for stacking of raw materials. All
students engaged in this activity right from designing to execution for this material
library. Involved understanding of working for special concrete.
5. Project Work-Special Concrete

In this module we selected a special concrete to work on and proposed various
applications for it and the special concrete selected by others. We also proposed
product of individually picked special concrete & gave data regarding it .
Scan for Video
Module 1
Exploring Raw Materials in Concrete
Scope of work
concrete is a composite material, ie multiple constituent materials, each with a specific
role, go into the making of concrete. The first step to innovating in a field is to
understand that which already exists and the dynamics of the same. Bases on it there is
specific criteria of materials which are to be meet. The most basic classification of
concrete is Binders (Cement) & Fillers (Fine Aggregates & Coarse Aggregates). Thus
testing of this raw materials becomes very necessary as it is responsible for overall
performance of the concrete.
Learning Outcome
From this module, we learnt to perform various test regarding raw materials &
understood the role of each & every material in the concrete. The hydraulic property of
cement was studied in cement test, Whereas Fineness (Size distribution), bulking, water
content & density of materials were studied for Fine aggregates (River sand) & Coarse
aggregate (crushed stone <10mm & <20mm) respectively. Thus, after performing this
test we compared the result obtained by test with standard reference & concluded the
results obtained in the test.
Includes
This module include in depth every test performed. First tests performed on cement are
discussed followed by river sand and by coarse aggregate.

1.1 Standard Consistency Of Cement
Aim: Apparatus:
To determine amount of water required to make a cement paste of standard consistency.

Temperature and Humidity:
The temperature shall be maintained at 27 ± 2°C. The relative humidity of the laboratory shall be
65 ± 5 percent.
Reference IS Code:
❑ IS-4031 (Part 4)-1988: Determination of consistency of standard cement paste.
❑ IS 269-2015: Ordinary Portland Cement-Specification
❑ IS 5513-1976: Specifications for vicat apparatus
Specifications:
❑ The water content taken should be between 26% to 33% .
Stop Measuring
❑ The penetration should be between 5 to 7 mm of the vicat plunger. Watch Trowel
Figure 1.1.1: Vicat Apparatus (all dimension in mm) Cylinder
Procedure: Image 1.1.2: Apparatus Required
(Reference : IS 5513:1996)
Observations:
30
Penetration of Plunger (MM)

25
25
20 19
15 14
1 2 3 10
6
The temperature & humidity Sampling of the cement Sampling of the water shall .
5
should be checked shall be done be done
0
26 27 28 29
Water(%)
Graph 1.1.1: Penetration of plunger v/s water %
Significance:
Less amount of water causes improper hydration of cement where as more amount of water
causes segregation, thus appropriate percentage of water is found which is used in other
test like initial & final setting time, Soundness & Compressive strength of cement.
4 5 6 Conclusion:
The standard consistency of cement comes out to be 29%. Hence it can be used in making
Fill the mould, resting on a Place the sample in vicat
Cement paste is prepared with of concrete. Thus it is crucial to control the proportion of water and mixing of the constituents
non-porous plate, with the apparatus & note penetration
gauging time of 3-5mins. cement paste of plunger is very important.
Image 1.1.1: Test Photographs . .
Devarsh Shah (UG180151) 2

1.2 Initial & Final Setting Time of Cement Apparatus:
Aim:
To determine the initial and final setting times of cement
65 ± 5 percent.
Reference IS Code:
❑ IS 4031 (Part 5)-1988: Determination of initial and final setting times
Specifications:
Grade of Cement Initial Setting time (Mins.) Final Setting time (Mins.)
OPC 53 Min. 30 Max. 600
Procedure: Figure 1.2.1: Vicat Apparatus (all dimension in mm)

(Reference : IS 5513:1996)
Observations:
110
100
Mins. After adding water

90
80
70
60
1 2 50
40
30
Cement paste is prepared with Fill the mould, resting on a non-
20
0.78 times the water required for porous plate, the mould is diff.
10
standard consistency. than standard consistency mould.
5
.
0 1 2
. 3 4 5 6
Penetration (MM)
Graph 1.2.1: Penetration of plunger v/s initial setting time
Significance:
For convenience, initial setting time is regarded as the time elapsed between the moments that the
water is added to the cement, to the time that the paste starts losing its plasticity. The final setting
4 time is the time elapsed between the moment the water is added to the cement, and the time when
3 3 4 the paste has completely lost its plasticity and has attained sufficient firmness to resist certain
definite pressure.
Initial Setting Time Final Setting Time
Note the reading when the Note the reading when F type Conclusion:
penetration of C type needle is needle only shows impression of
dot & not circle The initial and final setting time comes out to be 110 mins. & 215 mins. Respectively which is in the
5.0 + 0.5 mm from the bottom
permissible range. So, the cement can be used for making of concrete. Changes in Appearance of
Image 1.2.1: Test Photographs
the concrete surface as its sets were observed.
1.3 Soundness Of Cement
Apparatus:
Aim:
To determine the soundness of the cement sample by Le-Chatelier method
65 ± 5 percent.
Reference IS Code:
❑ IS 4031 (Part 3)-1988: Determination of soundness of cement
❑ IS 5514-1969: Specifications for apparatus used in Le-Chatelier test
Specifications:
Le-Chatlier’s Gauging Measuring
❑ The mean value of the width of Le-Chaltier’s mould should <= 10mm. mould Trowel Cylinder
Procedure:
Image 1.3.2: Apparatus Required
Figure 1.3.1: Le-Chatilier Apparatus)

Observations:
Particulars Unit 1 2 3
Indicator reading after 24 hours (L1) mm 23.5 18.5 21.5
1 2 3 Indicator reading after boiling (L2) mm 25 20 22.5

Cement paste is prepared Place the lightly oiled mould The edges of the mould Mean value (nearest 0.5mm) (L2-L1) mm 1.5 1.5 1
with 0.78 times the water on a lightly oiled glass sheet shall be gently together
required for standard and then fill it with cement while gauging & is being Table 1.3.1: Observation table
consistency. paste. compacted. .
Significance:
This experiment is done to determine that concrete once hardened do not undergo a large
amount of volumetric change which results in formation of cracks due to unreacted content of
lime in it. It is also likely that too high a proportion of magnesium content or calcium sulphate
content may cause unsoundness in cement.
Results
The mean of the difference of the indicator values is (1+1.5+1.5)/3 = 1.33 mm.
4 5 6
Mould is covered with They are submerge in Keep the mould in water Conclusion
another piece of greased water at 27±2˚C for 24 bath for 3 hours. After
glass sheet and place a The soundness of the cement sample falls in the specified range (less than 10 mm). Hence it
hours and than diff. in removing allow it to cool
small weight over it. indicator is measured and measure indicator diff. can be used in making of concrete. This test shows the effect of constituents of cement when
Image 1.3.1: Test Photographs they react with water.

1.4 Density of Cement
Aim: Apparatus:
To determine the density of cement
65 ± 5 percent.
Reference IS Code:
❑ IS-4031 (Part 1)-1998: Methods of physical tests for hydraulic cement
Specifications:
specific gravity of cement is in between 3.1-3.16 g/cc
Procedure:
Figure 1.4.1: Le-Chatilier Flask)
Observations:
Sr.No. Particular Unit Observation
1 2 1 Wt. of Tested cement Sample(W) gm 64

2 Initial reading on the stem of the flask (R1) ml 1
kerosene in filled in the 64 Grams of cement is 3 Final reading on the stem of the flask (R2) ml 21.6
flask between 0 and 1 ml taken in such a way
mark on the stem of flask that it don’t have lump. 4 Volume of cement sample( V ) = R2-R1 ml 20.6
5 .
Density of cement =W/V gm/cc 3.11
Table 1.4.1: Observation table:
Significance:
The accurate measurement of the density of hydraulic cement has an essential role in the
determination of concrete mixture proportions. As more supplementary cementitious materials
(SCM), such as fly ash, and slag, or cement replacements materials such as limestone and
calcium carbonate are used in blended cements, knowledge of the density of each powder or of
5 the blended cement would allow a more accurate calculation of the proportions of a concrete
3 4 Note the reading on
mixture by volume instead of by mass.
Add cement in the flask Shake it slightly for air flask after keeping it for
30 mins in water bath Conclusion:
and care be taken that void rise at the top of
the cement does not the liquid, and immerse The density of cement 3.11 gm/cc which is in the permissible range. So, the cement can be used
adhere above the liquid. the flask in water bath for making of concrete. The density of cement is directly connected to the fineness of cement, i.e.
Image 1.4.1: Test Photographs more the density, more the material in a given volume & less the air voids

1.5 Fineness of cement by Blain Air Permeability Test
Aim: Procedure:
To determine the fineness of cement Calibration
Temperature and Humidity: 1. Apply a thin layer of oil to the cell. Place the perforated disc on the edge & place two filter paper.
The temperature shall be maintained at 27 ± 2°C. The relative humidity of the 2. Fill the cell with mercury, level it by a glass plate. Weigh the cell (W1). Remove the mercury and one filter
laboratory shall be 65 ± 5 percent. paper and form a compacted bed of the standard reference material ( 2.8 g) provided and place one filter
paper and mercury and level it again. Take weight (W2)
Reference IS Code:
For testing with cement
❑ IS 4031 (Part 2)-1988: Determination of fineness by Blaine air permeability method
1. Insert the conical surface of the cell into the socket.
2. Close the top cylinder with a suitable plug. Open the stopcock and with gentle aspiration raise the level of
Specifications: manometer liquid to the highest etched line, close the stopcock & remove the plunger from the top.
Fineness should be greater than 225 m²/Kg. 3. Start the timer as the liquid reaches the second etched line and stop when it comes to third etched line, record
Apparatus the time to nearest 0.2 s
Observations:
Sr.No Particulars Unit Value
1 Specific Surface of standard cement sample m2 / kg 276
2 Measured time interval in second for standard cement sample at Sec 19.1
the time of calibration of the instrument
3 Measured time interval in second for test sample Sec 16.2
4 Weight of cell + mercury + 1 perforated disc + 2 filter paper (W1) g 204.25
Weight of cell + mercury + 1 perforated disc + 2 filter papers +
5 g 181.32
standard cement sample (W2)
Volume of cement bed (V) = (W1-W2)/Density of mercury = 1.69 m³
Filter Paper Weight to be taken for cement bed =V x porosity of cement(e) x ρ of cement = 1.69 x 0.5 x 3.15 = 2.662 g
mean pore Figure 1.5.1: Blain Air Apparatus Specific surface of SRM S= K (t1)^0.5
dia.=7 x 10-6m Petri dish Mercury SRM
∴K=276/4.37 = 63.16 m²/Kg.
Specific surface of cement S=63.16 x (t2)^0.5
∴S = 253.9 m²/Kg.
Significance:
Fineness of cement affects hydration rate hence the rate of strength gain. The smaller the particle size, the
greater the surface area-to-volume ratio, and thus, the more area available for water-cement interaction per unit
volume. Therefore finer cement reacts faster with water and the rate of development of strength and
corresponding heat of hydration is high.
Conclusion:
The specific surface of cement is more than 225 m²/ kg, thus the cement can be used in preparation of concrete
This higher value of fineness can be due to the fact that cement sample taken was left exposed to air, which
could have led to its hydration, making it less permeable.
1.6 Compressive Strength of Cement
Aim: Apparatus:
To determine the compressive strength of cement.
Temperature and Humidity: Cube Mould
(70.6 x 70.6 x 70.6)
65 ± 5 percent.
Reference IS Code:
❑ IS 4031 (Part 6)-1988: Determination of compressive strength of hydraulic cement other than
masonry cement
Vibrating Table (Confirming to IS
Vernier Callipers 10080-1982)
Specifications:
Compression testing machine
The compressive strength for 28 days of OPC 53 should be >= 53 N/mm2 (loading rate 35N/sq.mm./min)
Procedure: Image 1.6.2: Apparatus Required
Observations:
1 2 3
Sampling of the cement & Mixing the material for 3 to 5 The mortar mix is poured in
sand (zone 1,2,3) shall be mins with water P/4 + 3 % of the cube mould which is
done standard consistency. properly fitted & oiled
.
Graph 1.6.1: Compressive Strength Vs No. of days
Significance:
The compressive strength of hardened cement is the most important properties. The strength of
the binder (cement) has a significant effect on the performance characteristics of the mixture and
ensures the overall quality of the finished product. Strength tests are not made on neat cement
paste because of difficulties of excessive shrinkage and subsequent cracking of neat cement.
Conclusion:
4 5 6 The average compressive strength for cement mortar cube at 28 days comes 46.12 N/mm2
The mould is kept on the Mortar cubes are kept in jute The specimen are then tested which is lower than the specified value. The reason for this result can be said that the mixing
vibrating table and the mix is bag for 24 hours, after in compression testing might not be proper, the temperature of water for curing might not be same for the given period
being vibrated for two minutes. demolding it is kept in water machine (LR:35N/sq.mm./min)
and there could have been less compaction while vibrating the mould.
. .

1.7 Buking of Fine Aggregates (Sand)
Aim: Procedure:
To determine the bulking of fine aggregates.
Reference IS Code:
IS 2386 (Part 3)-1986: Methods of Test for Aggregates for Concrete (Specific
gravity, density, voids, absorption and bulking)
Specifications:
1 3
Water is added in
Moisture (5%) is added the cylinder upto
to the sand sample 250 ml mark
2 4
Sand is filled upto The sand is allowed
200 ml marking in a to settle down & then
Image 1.7.1: Test Photographs measuring cylinder readings is taken
Observations: Calculations:
Graph 1.7.1: Moisture added v/s % increase in volume
Sr.No Particulars Unit Value Percentage of bulking:
Procedure: [(Initial level/ final level) -1] *100
1 Volume of damp sand V1 ml 200
[(200/154) – 1] *100
2 Volume of submerged sand V2 ml 154 29 %
.
Significance:
Free moisture forms a film around each particle. This film of moisture exerts what is known as surface
tension which keeps the neighboring particles away from it. Similarly, the force exerted by surface
tension keeps every particle away from each other. Therefore, no point contact is possible between the
particles. This causes bulking of the volume. It is interesting to note that the bulking increases with the
increase in moisture content upto a certain limit and beyond that the further increase in the moisture
content results in the decrease in the volume
Conclusion:
The bulking of the sand is 29% when we added 5% of moisture content in it & on seeing the
specification graph we can conclude that the sand is between medium & fine grading
Figure 1.7.1: Procedure Figure

1.8 Bulk Density of Fine Aggregates (Sand)
Aim: Procedure:
To determine bulk density of fine aggregate.
Reference IS Code:
IS 2386 (Part 3)-1986: Methods of Test for Aggregates for Concrete (Specific gravity, density,
voids, absorption and bulking)
1 3
The sand sample The sand is filled in
Specifications:
is washed & taken the container &
❑ The bulk density of the fine aggregate should be between 1200-1750 Kg/m³ in SSD condition weight(w1) is taken
2 4
❑ The ratio of loose to bulk density of sand should be between 0.87 to 0.96.
The sand sample Sand is filled in 3
is sieved with 4.75 layer as shown below
mm sieve & weight(w2) is taken
Apparatus:
Observations:
Sr. No. Particulars Unit Value
Cylindrical
1 Weight of Cylinder Kg 3.2
measure: 3 Litre
2 Volume of container m³ 0.003
Weight
3 Loose wt. of Aggregate (W1) kg 4.223
Tamping Balance
Rod:16mm dia 4 Compacted wt. of Aggregate (W2) kg 4.740
Image 1.8.1: Apparatus Required Table 1.8.1: Observation table:
Result:
❑ Loose density of sand: 1.408 kg/l
❑ Compacted density of sand: 1.58 kg/l
❑ Ratio of loose to compacted sand: 0.89
Significance:
It is mainly used for concrete batching for conversion of weight batching to volume batching or
vice versa. It also signifies the amount of voids in the aggregate, higher the bulk density lesser
is the voids. The bulk density depends on the size distribution and shape of the particles:
particles all of one size can be packed to a limited extent, but smaller particles can be added in
the voids between the larger ones.
Conclusion:
The density of fine aggregate & the loose to compacted soil ratio is as per the specifications,
hence this aggregate can be used in concrete.
Figure 1.8.1: Procedure Figure

1.9 Specific Gravity & Water Absorption of Fine Aggregates
Aim: Procedure:
To determine Specific gravity & water absorption of fine aggregate 1. Sample of 500g for particle size less than 4.75mm shall be taken after sieving.
2. Sample shall be placed in the tray and covered with distilled water at a temperature of 22 to
Reference IS Code:
32°C and shall be kept for 24 hours.
IS 2386 (Part 1)-1986: Methods of Test for Aggregates for Concrete(Specific gravity,
3. The water shall then be carefully drained from the sample. The sample should then be made
density, voids, absorption and bulking)
surface dry. The saturated and surface-dry sample shall be weighed (weight A).
Apparatus 4. The aggregate be placed in the pycnometer which shall be filled with distilled water. Any
trapped air shall be eliminated by rotating the pycnometer on its side, the hole in the apex of
the cone being covered with a finger. (weight B).
5. The contents of the pycnometer shall be emptied into the tray; care being taken to ensure that
all the aggregate is transferred. The pycnometer shall be refilled with distilled water to the
same level as before, dried on the outside and weighed (weight C).
6. The water shall then be carefully drained from the sample by decantation through a filter paper
and any material retained returned to the sample. The sample shall be placed in the oven in
the tray at a temperature of 100 to 110°C for 24 + 0.5 hours and weighed (weight D).
Observations:
Sr. no. Particulars Observation (gm)
1 Weight of sample taken in SSD condition (A) 500
2 Weight of (pycnometer + water + sand) (B) 1852
3 Weight of (pycnometer + water) (C) 1544
Water Measuring
Pycnometer 4 Weight of oven dried sample (D) 488
Bottle Cylinder
Image 1.9.1: Apparatus Required Table 1.9.1: Observation table:
Oven - A well ventilated oven, thermostatically controlled, Result:

to maintain a temperature of 100 to 110°C. Specific Gravity ρ = 2.54
Figure 1.9.1: Apparatus required
Weight Balance Apparent specific gravity = 2.71
Water Absorption = 2.45 %
Significance:
Specific Gravity is important for several reasons. Some deleterious particles are lighter than the
"good" aggregates. Tracking specific gravity can sometimes indicate a change of material or
possible contamination. Also specific gravity of the aggregate is used in calculating the
percentage of voids of aggregates. The water absorption is important in determining the net
water-cement ratio in the concrete mix.
Conclusion:
From the result the specific gravity of the aggregate comes 2.54 and water absorption comes
2.45 % which needs to be taken care while making mix design.

1.10 Sieve Analysis of fine Aggregate
Aim: Procedure:
To determine particle size distribution of fine aggregate by dry sieving. 1. Sampling of the aggregate (200 g) is done.
2. The shaking shall be done with a varied motion, backwards and forwards, left to right,
Reference IS Code:
circular clockwise and anti-clockwise for at least two minutes. Material shall not be forced
IS 2386 (Part 1)-1986: Methods of Test for Aggregates for Concrete(Specific gravity,
through the sieve by hand pressure.
density, voids, absorption and bulking)
3. Lumps of fine material, if present, may be broken by gentle pressure
Specifications: 4. Light brushing with a brush may be used on the 150 and 75-micron IS Sieves
IS sieve Percentage passing for 5. On completion of sieving, the material retained on each sieve, shall be weighed.
Grading Grading Grading Grading
Designation Observations:
zone 1 zone 2 zone 3 zone 4
10 mm 100 100 100 100
4.75 mm 90-100 90-100 90-100 95-100 Fine sand : 2.2 - 2.6
2.36 mm 60-95 75-100 85-100 95-100 Medium sand : F.M. : 2.6 - 2.9
Coarse sand : F.M. : 2.9 - 3.2
1.18 mm 30-70 55-90 75-100 90-100
600 µ 15-34 35-59 60-79 80-100
300 µ 5-20 8-30 12-40 15-50
150 µ 0-10 0-10 0-10 0-15
Table 1.10.1: Specification table:
Apparatus:
4.75mm Graph 1.10.1: IS Sieve designation v/s % aggregate passing

Result:
2.36mm Fineness modulus (FM):
=Total cum. % (up to 150 µ) retaining/100
1.18mm =237/100 = 2.37
600micron Sieve Vibrating Machine Image 1.10.2: Test Photographs

Significance:
300micron The concrete mix design depends on the gradation of aggregates Hence the sieve analysis of
aggregates determines the % of sizes of aggregates which helps in deciding mix design ratios
150micron for a concrete. fine aggregates are designated as coarse sand, medium sand and fine sand.
These classifications do not give any precise meaning. What the supplier terms as fine sand
75micron
may be really medium or even coarse sand. To avoid this ambiguity fineness modulus could be
Pan used as a yard stick to indicate the fineness of sand.
Conclusion:
Sieve as per IS designation Weighing Scale We can conclude that the sand is of ZONE 3, & the value of FM is 2.37

1.11 Sieve Analysis of Coarse Aggregate
Aim: Procedure:
To determine particle size distribution of coarse aggregate by dry sieving. 1. Sampling of the aggregate is done.
2. The shaking shall be done with a varied motion, backwards and forwards, left to right,
Reference IS Code:
circular clockwise and anti-clockwise. Material shall not be forced through the sieve by hand
❑ IS : 2386 ( Part I )-1986 – Method of test of Aggregates for Concrete (Particle size and shape)
pressure.
❑ IS : 383-2016 – Specifications for coarse and fine aggregates. 3. On completion of sieving, weigh each fraction of sample retained on each sieve and note
Specifications: down it in front of corresponding sieve sizes
IS Sieve Particular IS Sieve Particular Observations:

Designation passing (%) Designation passing (%)
Kapchi
20mm 85-100 12.5mm 100 120 100
Cum. % Passing
100 90
16mm - 10mm 85-100
80 59.1
12.5mm - 6.3mm -
60
10mm 0-20 4.75mm 0-20 40 18.41
Table 1.11.1: Specification table: 20 4.61 0.71 0.31
Apparatus: 0
25mm 20mm 16mm 12.5 mm 10mm 6.3mm 4.75mm
IS Sieves Designation
Graph 1.11.1: IS Sieve designation v/s % aggregate passing
10mm
120
96.53
Grit
25 mm
Cum. % Passing
6.3mm 90
20 mm 60
4.75mm 20.04
30
16 mm 5.28 2.84 1.21
0
12.5 mm 3.35mm 10mm 6.3mm 4.75mm 3.35mm 2.36mm
IS Sieves Designation
10 mm Graph 1.12.1: IS Sieve designation v/s % aggregate passing Image 1.11.2: Test Photographs
2.36mm
6.3 mm Significance:
4.75 mm Grading limits and maximum aggregate size are specified because grading and size affect the
Pan
amount of aggregate used as well as cement and water requirements, workability, pumpability,
Pan
and durability of concrete
Sieve set as per IS Sieve set as per IS Conclusion:

designation for Kapchi designation for Grit
We can conclude that the range lies between specified range of IS, hence it can be used in
(<20mm) (<10mm)
concreting

1.12 Bulk Density of Coarse Aggregate
Aim: Apparatus:
To determine the bulk density of Coarse aggregates
Reference IS Code:
IS 2386 (Part 3) -1986 - Specific gravity, density, voids, absorption and bulking Cylindrical metal
Specifications: measure: 15 Litre
❑ The bulk density of the fine aggregate should be between 1200-1750 Kg/m³ capacity
❑ The ratio of loose to bulk density of sand should be between 0.87 to 0.96. Weight
Procedure: Balance
Tamping Rod
(16mm dia.)

Observations:
Sr. Particulars Unit >10 mm >20 mm
No
1 Volume of container m³ 0.015 0.015
2 Loose weight kg 19.63 21.71
1 2 3 Compacted weight kg 21.53 23.67
The empty weight of the The cylinder is filled with 4 Loose Bulk Density kg/m³ 1309 1447
cylindrical metal measure the aggregates & then
is taken levelled with tamping rod 5 Compacted Bulk Density kg/m³ 1435 1578
Table 1.12.1: Observation table
Result:
Loose bulk density of grit is 1309 kg/l
5 Loose bulk density of kapchi is 1447 kg/l
Compacted bulk density of grit is 1435 kg/l
The weight of compacted Compacted bulk density of kapchi is 1578 kg/l
aggregates is measured &
than deducted with the Significance:
weight of the cylinder The concrete mix design depends on the gradation of aggregates Hence the sieve analysis of
(Compacted Weight)
aggregates determines the % of sizes of aggregates which helps in deciding mix design ratios
for a concrete. The bulk density depends on the size distribution and shape of the particles:
3 4 particles all of one size can be packed to a limited extent, but smaller particles can be added in
the voids between the larger ones, thus increasing the bulk density of the packed material.
The weight is measured & The cylinder is filled in
than deducted with the three equal layers with 25
weight of the cylinder tamping each layers & Conclusion:
(Loose Weight) levelled with tamping rod The density of Coarse aggregate & the loose to compacted ratio is as per the specifications,
Image 1.12.1: Test Photographs hence this aggregate can be used in concrete.

1.13 Specific Gravity & Water Absorption of Coarse Aggregates (<10mm)
Aim: Apparatus:
To determine the specific gravity and water absorption in coarse aggregates.
Reference IS Code:
IS 2386 (Part 3) -1986 - Specific gravity, density, voids, absorption and bulking
Specifications:
Specific gravity of aggregates should be between 2.1 to 3.2 and water absorption maximum 5%
Procedure:
Water Bottle Pycnometer Measuring Cylinder

Image 1.13.2: Apparatus Required Figure 1.13.1: Apparatus required
Observations:
Sr. no. Particulars Observation (gm)
1 2 1 Weight of sample taken in SSD condition (A) 1000
The aggregate are kept in The aggregate are placed
water for 24 hours & then in the pycnometer in such 2 Weight of (pycnometer + water + grit) (B) 2126
sample is taken in SSD that not a single specimen 3 Weight of (pycnometer + water) (C) 1474
Condition (Weight A) is left out
4 Weight of oven dried sample (D) 984
Result:
5 Specific Gravity ρ = 2.84
Water Absorption = 1.62%
The sample is further
kept in oven for 24 hours Apparent Specific Gravity ρ ′ = 2.97
& the weighed (Weight D)
Significance:
4 possible contamination. Also specific gravity of the aggregate is used in calculating the
3 Then Pycnometer is dried percentage of voids of aggregates. The water absorption is important in determining the net
Distilled water is added & from outside & weighed water-cement ratio in the concrete mix.
any trapped air shall be (Weight B) & Aggregates
eliminated by rotating the are removed and water is
pycnometer on its side filled & weighed (Weight C) Conclusion:
Image 1.13.1: Test Photographs From the result the specific gravity of the aggregate comes 2.84 and water absorption comes

1.14 Specific Gravity & Water Absorption of Coarse Aggregates (<20mm)
Aim: Apparatus:
To determine the specific gravity and water absorption in coarse aggregates.
Reference IS Code:
Balance >3kg
IS 2386 (Part 3) -1986 - Method of test of Aggregates for Concrete (Water absorption and specific
gravity of Aggregate) Stout
watertight
container
Specifications:
Specific gravity of aggregates should be between 2.1 to 3.2 and water absorption maximum 5%
Wire Basket
<6.3 mm mesh
Procedure: Oven
1. Weight of the basket along with aggregates is taken as A1 in submerged condition.

2. The basket and the aggregate shall then be removed from the water and allowed to drain Image 1.14.2: Apparatus Required
for a few minutes, after which the, aggregate is taken from the basket to dry clothes, and Observations:
the empty basket shall be returned to the water, and weighed submerged in water Sr. no. Particulars Observation (gm)
(weight A2).
1 Weight of sample taken in SSD condition (A) 2000
3. The aggregate shall now be brought to SSD condition by using a dry cloth and placing in
2 Weight of (basket + water + kapchi) (B) 2073
open for required time. The aggregate shall then be weighed (weight B).
4. The aggregate shall then be placed in the oven in the shallow tray, at a temperature of 3 Weight of (basket+ water) (C) 752.5
100 to 110°C and maintained at this temperature for 24 + 0.5 hours. 4 Weight of oven dried sample (D) 1972
5. It shall then be removed from the oven and weighed (weight C). Table 1.14.1: Observation table
Result:
Specific Gravity ρ = 2.9
Water Absorption = 1.42%
Apparent Specific Gravity ρ ′ = 3.03
Significance:
possible contamination. Also specific gravity of the aggregate is used in calculating the
percentage of voids of aggregates. The water absorption is important in determining the net
water-cement ratio in the concrete mix.
Conclusion:
From the result the specific gravity of the aggregate comes 2.9 and water absorption comes

1.15 Crushing Value of Coarse Aggregate (<20mm)
Aim: Apparatus:
To determine the crushing value of coarse aggregate.. Plunger
Reference IS Code:
❑ IS : 2386 ( Part 4 ) – 1986 -Method of test of Aggregates for Concrete (Crushing of Aggregate)
❑ IS : 383-2016 – Specifications for coarse and fine aggregates. Steel cylinder
15 cm dia.
Specifications:
The aggregate crushing value should not be more than 45 per cent for aggregate used for concrete
other than for wearing surfaces, and 30 per cent for concrete used for wearing surfaces such a
runways, roads and air field pavements. Tamping
Procedure: Rod:16mm dia.
and 60 cm long
Observations:
Sr no. Particulars Value
1 Weight aggregate A (gms) 3135
2 Time taken to apply 40 Tonnes Load (mins.) 10
1 2 3 3 Weight of aggregate retained 2.36 mm IS sieve B (gms) 2248
The cylindrical measure 4
The sample should pass The weight of the Weight of aggregate passing 2.36 mm IS sieve C (gms) 574
filled in three layers & each
through 12.5 mm and sample is measured Table 1.15.1: Observation table
layer tamped 25 times such
retained by 10 mm sieve that depth becomes 10 cm (Weight A) Result:
Aggregate Crushing Value = Weight of the aggregate passing = 574
= 25.5%
Total weight of aggregate 2248
Significance:
The strength of concrete is dependent on the strength of the aggregate as the 70% of the
volume of the concrete is occupied by the aggregates. Aggregates used in the construction,
should be strong enough to resist crushing. The aggregate crushing value gives a relative
measure of the resistance of an aggregate to crushing under a gradually applied compressive
load. Lesser the aggregate crushing value stronger is the given sample of aggregates.
4 5 6
The aggregate are then The sample is sieved with Conclusion:
filled with another cylinder Loading of the plunger
2.36 mm passing & The crushing value of aggregates comes 25.5 % which is within the specified limit. Hence, they
with three layer with 25 is at uniform rate of 40
retaining weight is can be used for making concrete.
tamping each & insert the tones per 10 mins measured (Weight B & C)
plunger

1.16 Impact Value of Coarse Aggregate (<20mm)
Aim: Apparatus:
To determine the Impact value of coarse aggregate..
Reference IS Code: 12.5mm
❑ IS : 2386 (Part 4)-1986 – Method of test of Aggregates for Concrete (Impact of Aggregate)
❑ IS : 383-2016 – Specifications for coarse and fine aggregates. Aggregate
Impact testing
10mm
Specifications: machine
The aggregate impact value should not be more than 45 per cent for aggregate used for concrete Pan
other than for wearing surfaces, and 30 per cent for concrete used for wearing surfaces such a
runways, roads and air field pavements.
Tamping
Procedure:
Rod and
Mould 2.36mm
Pan
Observations:
Sr no. Particulars Value
1 2 1 Weight aggregate A (gms) 375

2 Applied hammer blows (nos.) 15
The sample should pass The apparatus is filled
through 12.5 mm and in three layers & each 3 Weight of aggregate retained 2.36 mm IS sieve B (gms) 311
retained by 10 mm sieve layer tamped 25 times
4 Weight of aggregate passing 2.36 mm IS sieve C (gms) 64
Result:
Aggregate Impact Value = Weight of the aggregate passing = 64
5 Total weight of aggregate 375
= 17.1%
The sample is sieved

with 2.36 mm passing & Significance:
retaining weight is
The strength of concrete is dependent on the strength of the aggregate as the 70% of the volume
measured (Weight B & C)
of the concrete is occupied by the aggregates. The aggregate impact value gives a relative
measure of the resistance of an aggregate to sudden shock or impact, which in some aggregates
3 4 differs from its resistance to a slow compressive load.
Place the sample on the
The weight of the
base & hammer is Conclusion:
sample is measured
allowed to free fall for 15
(Weight A) The impact value of aggregates comes 17.1 % which is within the specified limit. Hence, they can
times at height of 380mm
be used for making concrete.

1.17 Flakiness & Elongation Index of Coarse Aggregate (<20mm)
Aim: Procedure:
To determine flakiness and elongation index of coarse aggregate. 1. Sieving - The sample shall be sieved in accordance with the method described in above test
2. Separation of Flaky Material- Each fraction shall be gauged in turn for thickness on a metal
Reference IS Code:
gauge
IS : 2386 (Part I)-1986 – Method of test of Aggregates for Concrete (Particle size and shape)
3. Weighing of Flaky Material - The total amount passing the gauge shall be weighed to an
Specifications: accuracy of at least 0.1 percent of the weight of the test sample
The total value of flakiness & Elongation index should not exceed more than 40% 4. Separation of Elongated Material- Each fraction shall be gauged individually for length on a
Apparatus: metal length gauge.(Flaky material are not included in the sample)
5. Weighing of Elongated Material - The total amount retained by the length gauge shall be
weighed to an accuracy of at least 0.1 percent of the weight of the test sample

Figure 1.17.1: Flakiness Apparatus
Result:
Image 1.17.2: Flaky & Elongated Particles
Flakiness Index – 14.05%
Elongation Index – 18.4%
Significance:
Flaky Aggregates: The aggregate whose least thickness is less than 0.6 of its mean diameter
is called as flaky aggregates.
Elongated Aggregates: The aggregate whose greater dimension is greater than 1.8 of its
mean diameter is called as elongated aggregates.
Particle shape and surface texture influence the properties of freshly mixed concrete more than
the properties of hardened concrete. Rough-textured,Flaky, and elongated particles require
more water to produce workable concrete than smooth, rounded compact aggregate.
Consequently, the cement content must also be increased to maintain the water-cement ratio
Conclusion:
The total of flakiness & elongation index is 32.45% which is less than 40% thus this aggregates
Figure 1.17.2: Elongation Apparatus can be used in concrete

Module 2
C o n c r e t e Tr i a l s b y Vo l u m e t r i c B a t c h i n g
Group Activity
Scope of work
After understanding the properties of the raw materials in the previous module, we then
prepared a concrete mix with tested raw materials by means of volumetric batching
having concrete grade M20 & M25 with different water cement ratio 0.43, 0.48 & 0.5.
This module include the process of mixing of the concrete & testing of property of fresh
concrete as well as hardened concrete & comparing the results obtained by IS
specifications & analyze the results.
Learning Outcome
This module helped us in understand the efforts required for batching & casting of the
concrete. We also learnt the correct sequence of mixing of raw materials & time required
for mixing them through different trials. More importantly we learnt what common
mistakes should be avoided and how to work as a team quickly and efficiently. We also
understood the relations between fresh & hardened concrete property & understood the
impact on strength of concrete due to different types of curing. We also leant how
excess water cement ratio result in reduction of mechanical properties of concrete. We
also leant that change in shape & side widely affect the strength parameter of concrete.
Includes
This module include in depth fresh concrete test (workability test) like slump test, Flow
Group Members:
table test & compaction factor test & also includes hardened concrete test (Strength test)
Devarsh Shah
Jayraj Boghani like compressive strength, Split tensile strength & flexural strength of concrete.
Atharva Dave
Khyati Chandpa
Rutvik Vekadiya
Bhavdeep Bodar Devarsh Shah (UG180151)
OVERVIEW
Volumetric Batching was a Group exercise where grade M20 and M25 concrete was casted using three W/C ration 0.43, 0.48, 0.50. The major aim was to understand the
volumetric batching method of casting and, understand & perform various test related to fresh and hardened concrete property.
Types of Curing
Total Volume of
Concrete Casted
1.08 m³
Grade of concrete : M20(1:1.5:3) ; M25 (1:1:2)

Water Cement Ratio: 0.5 Sprinkling Ponding
Type of Batching : Volumetric Batching
Measuring Box Volume: 0.037 m3 (390mm x 310mm x 310mm) Without
Total Cubes Total Cylinder Total Beam
Mixing Type: Drum Mixer (300 Lit.), Hand Mixing
Curing
Casted Casted Casted
180 54 18 Curing
Compaction Type: Vibrating table, Compaction through steel rod
Compound
Specimen tested type & Quantity in each batching:
Total Wet Volume

1.08 m³ Concrete Test
Conducted
Total Dry Volume

1.64 m³ Cube (150x150x150mm) - 21 Cube (100x100x100mm) - 9 Cylinder (150x300mm) - 9
Fresh concrete harden concrete
property test property test
Compressive Slump Test

Beam (150x150x700mm) - 3 strength Test
Cement
11 Bags
Kapchi Split Tensile Flow Table
915 Kg Strength Test Test
Sand
Grit
650 Kg
423 Kg
Flexural Compaction
The quantity of material is calculated with density found in previous test & 10% Strength Test Factor Test
wastage is considered in the quantity of raw materials used in preparation of concrete

2.1 Slump Test for Concrete
Reference IS Code: Apparatus:
❑ IS:1199-(1959): Methods of sampling and analysis of concrete.
❑ IS 456:2000 Plain and Reinforced Concrete
Significance:
The concrete slump test measures the consistency of fresh concrete before it sets. It is performed
to check the workability of freshly made concrete, and therefore the ease with which the concrete Image 1.6.1: Types of slump observed while performing the test
flows. It can also be used as an indicator of an improperly mixed batch. The slump test is used to
Tamping Rod
ensure uniformity of different loads of concrete under field conditions Diameter: 16mm
Procedure: Length: 600mm
Figure 2.1.1: Slump Cone Apparatus

Image 2.1.2: Test photographs
Slump Test
140 130
120
120 High
Slump (mm)
100
80 Medium
60
Low
40 30
23
20
Very Low
0
M 20 M 25
Grade of Concrete
Image 1.2.1: Procedure sketch of slump test
Batch 1 Batch 2
1. The mould shall be filled in three layers each approximately one-third of the height of Observation:
the mould. It is observed that as the grade of concrete increased the slump increases because the ratio of
cement is to coarse aggregate decreased as the grade is increased. Also higher slump concrete
2. Each layer should be tampered 25 times from the rounded end of the tamping rod
was easy in casting because of its higher workability.
distributed uniformly across the cross section of the mould.
3. After the slump has formed put the mould on side of the concrete on the same base Learning:
plate and tamping rod shall be placed vertically on the cone and the difference in From this exercise I learned to perform the workability test of concrete and even inculcated an
height of the mould and top most part of concrete shall be measured using ability to judge the slump of concrete by viewing the mix.
measuring scale in mm.

2.2 Flow Table Test for Concrete
IS:1199-(1959): Methods of sampling and analysis of concrete
Significance:
The flow table test or flow test is a method to determine consistency of fresh concrete. Flow table
test is also used to identify transportable moisture limit of concrete. It is mainly used for concrete
that is too fluid (workable) to be measured using the slump test as when the slump cone will be
removed the concrete will flow & slump can not be measured.
Procedure:
Tamping Rod
Diameter: 16mm
Length: 610mm
Figure
Image 2.1.1: 2.2.1: Flow Table Apparatus
Apparatus
1 2 3
Flow Table Test 145
150
Sloppy 124
6 120
Flow Table (%)

Wet
90
Plastic
60
39.5
29 Stiff
30
4 5 6 Dry
Image 2.2.1: Procedure sketch of flow table test 0
M 20 M 25
Grade of Concrete
Batch 1 Batch 2
1. Clean the upper surface of the table and the inner side of the mould.
Observation: Image 2.2.2: Test photographs
2. Place the mould in the centre of the table. And mark six lines on the table passing from the
It is observed that as the grade of concrete increased the flow % increases because the ratio of
centre of it.
cement is to coarse aggregate decreased as the grade is increased. Also higher flow % concrete
3. Fill the mould in two layers each layer tamped by 25 strokes..
was easy in casting because of its higher workability.
4. Lift the mould slowly and allow the concrete to collapse.
5. The table shall then be raised and dropped 12.5 mm, 15 times in about 15 seconds.
Learning:
6. The diameter of the spread concrete shall be the average of six symmetrically distributed
From this exercise I learned to perform the flow table test. Also found that as this test is useful
caliper measurements read to the nearest 5 mm.
when the workability of concrete is very high and cannot be measured accurately using slump test.

2.3 Compaction Factor Test for Concrete
IS:1199-(1959): Methods of sampling and analysis of concrete
Significance:
The compaction factor test is a method to determine consistency of fresh concrete. The Tamping Rod
compaction factor is the ratio of weights of partially compacted to fully compacted concrete. Diameter: 16mm
The compaction factor test is used for concrete which have low workability for which slump Length: 600mm
test is not suitable.
Procedure:
Weight
Balance
Image 2.3.2 Flow Table Apparatus
1 2 3 4 5 0.98 0.99
1
0.95
Compaction Factor
0.9 0.87
0.84
0.85 High
0.8 Medium
0.75 Low
0.7
0.65 Very Low
16 7 8 0.6
M 20 Grade of Concrete M 25
Image 2.3.1: Procedure sketch of compaction factor test
Batch 1 Batch 2
1. The upper hopper is filled up to it’s brim level. Now, the trap-door is opened so that the Observation:
concrete falls into the lower hopper. Similarly it is free fall from lower hopper to cylinder. It is observed that as the grade of concrete increased the compaction factor increases because
2. Cut-off the excess concrete remaining above the cylinder top and wipe off the outer the ratio of cement is to coarse aggregate decreased as the grade is increased. Also higher
surface of the cylinder & weight of the concrete filled cylinder is taken. (Partially compaction factor concrete was easy in casting and compacting because of its higher workability.
Compacted Weight)
3. The cylinder is then refilled with the same concrete sample in approximately 5 cm deep Learning:
layers, ramming them heavily to obtain full compaction. From this exercise I learned to perform the compaction factor test. Also found that as this test is
4. Now, weight of the concrete filled cylinder is taken. (Fully Compacted Weight) useful when the workability of concrete is very low and cannot be measured accurately using
slump test.

2.4 Compressive Strength Test
Specification IS: Procedure:
IS:516-(1959)- methods of test for strength of concrete Casting of moulds
Significance: 1. After the mixing of concrete is complete, concrete is poured into a non-porous, non-absorbent base.
This test is performed to check the basic criteria of concrete i.e. strength. The 2. The moulds are oiled beforehand
performance in terms of N/mm2 for the concrete after 3, 7, 28 days is checked in the test. 3. The concrete is then poured into the moulds with the help of hand scoop and filled in three layers each
Two sizes of cubes (150mm x 150mm x 150mm) and (100mm x 100mm x 100mm) and 5cm in depth of the mould.
cylinder (150mm x 300mm) were casted and tested to understand the significance of size 4. Each layer is rodded with tamping rod from the rounded with 35 strokes each,
and shape in strength. 5. After the top layer is rodded the mould is kept on the vibrating table for compaction until a hint of
Apparatus: bleeding is seen on the top, keeping in mind that the moulds are filled to the top of the surface of the
mould.
6. Then the moulds are removed from the vibrating table and the top surface is finished with trowel by
moving it horizontally on the surface.
Tamping Rod 7. These moulds are then kept in moist room or moist condition or covered under plastic sheet for 24
Diameter: 16mm hours.
Length: 600mm 8. The cubes are demoulded after 24 hours and kept in clean water for curing.
Testing on specimen
Weighing Machine: Vernier Callipers 1. Take specimen from the curing tank and clean the surfaces. The test has to be performed on the wet
Compression testing machine: Maximum capacity: 50kg (measure upto-300mm) specimen.
Rate of loading (kN/s) = Accuracy: 0.005kg 2. Measure all dimensions of the sample by Vernier calipers and weigh the samples.
(140*l*b)/6000 (in mm) 3. Samples are placed in the CTM such that axes of CTM and samples coincide.
4. Apply load gradually till the specimen fails. Loading pattern as 140 kg/cm2/min.
5. Observe the failure pattern at peak load.
For Cylinder Test-
1. After the cylinder is taken out from curing tank a layer of POP shall be applied in order to flatten the to
surface of loading.
Cube (100x100x100mm) Cube (150x150x150mm) Cylinder (150x300mm)
Image 2.4.1 Compressive Strength Apparatus
For comparing the results of strength in terms of curing type, 4 methods were done.
Acceptable Failure Patterns 1. Ponding- where the cubes after demolding were kept submerged in water for the required time period.
2. Curing compound- curing compound chemical was applied on the cubes with each surface applied
six timed and left untouched for 28 days.
3. Sprinkling- cubes were kept in a jute bag with water sprinkled over it at regular intervals and left
untouched for 28 days.
4. Without Curing- cubes after demolding were kept in a tray under open environment without letting any
type of curing method.
Image 2.4.2 Acceptable Failure Patterns -The results of strength were compared for the same

Weight Density Peak Load Comp. St. Average Comp. M20 cube(150x150x150)
Days Batch L (mm) B (mm) H (mm) 40 37.69
(kg) (kg/m3) (kN) (N/mm2) St. (N.mm2)
Compr. stremgth (N/mm2)

35
2 100.4 100.12 100.11 2.53 2514.13 171.186 17.03 29.08
30
3 Days 1 99.71 99.61 100.21 2.54 2552.00 240.158 24.18 22.67 25 22.67 20
1 100.1 100.42 99.87 2.51 2500.26 269.495 26.81 20 14
1 98.8 101.1 99.81 2.44 2447.42 339.016 33.94 15 10
7 Days 1 99.7 100.21 100.22 2.43 2426.87 305.723 30.6 29.08 10
2 100 100.6 99.8 2.39 2380.51 228.463 22.71 5
2 101.4 101 99.78 2.46 2407.31 382.107 37.31 0
28 Days 1 100.48 99.43 100.16 2.41 2408.38 410.519 41.09 37.69 3 7 28
1 100.11 98.8 100.78 2.41 2417.73 342.817 34.66 No. of days
Required strength as per IS code Average Compr. strength
Table 2.4.1: M20 grade observation table (100mm x 100mm x 100mm)
Graph 2.4.1: Compressive Strength M20 grade (100mm x 100mm x 100mm)
Density Peak Load Comp. St. Average Comp.

M20 cube(150x150x150)
Days Batch L (mm) B (mm) H (mm) Weight (kg) 30 27.24
(kg/m3) (kN) (N/mm2) St. (N.mm2) 26.13

1 150.31 149.7 152 8.33 2435.52 468.70 20.83 25
20.09 20
3 Days 1 150.7 151.1 151.09 8.41 2444.46 485.02 21.3 20.09 20
14
2 149.54 150.2 149.23 8.1 2416.58 407.44 18.14 15
10
1 150 150.8 150.32 8.41 2473.36 618.89 27.76 10
7 Days 1 148.4 150.23 149.01 8.19 2465.35 629.04 27.88 27.24 5
2 149.32 151.1 149.32 8.11 2407.25 589.62 26.1 0
1 151.2 149.41 148.4 8.28 2469.82 600.24 26.57 3 7 28
28 Days 1 151 149.05 148.98 8.31 2478.36 608.35 27.03 26.13 No. of days
2 150.31 150.24 150.1 8.19 2416.18 560.05 24.8 Required strength as per IS code Average Compr. strength
M20 cube(150x150x150)
Type of Density Peak Load Comp. St. Average Comp. 30
Batch L (mm) B (mm) H (mm) Weight (kg) 26.13

Curing (kg/m3) (kN) (N/mm2) St. (N.mm2) 24.72 24.51 20
25 22.7
1 150.7 151 149.68 8.65 2539.58 633.519 27.84 20
Curing
28 days
1 149.53 150.3 149.66 8.41 2500.36 578.265 25.73 24.72 15
Compund
2 149.5 150.5 150.64 8.4 2478.34 463.495 20.6
10
2 148.7 149.72 150.01 8.48 2539.13 517.623 23.25
Sprinkling 1 149.9 149.2 150.024 8.5 2533.31 441.263 19.73 22.7 5
1 151.01 149.7 149.88 8.57 2529.35 567.189 25.09 0
Curing Sprinkling Without curing ponding
1 150.78 150.1 149.64 8.31 2453.74 575.081 25.41 compound
Without
1 148.74 151 149.8 8.44 2508.57 611.354 27.22 24.51
Curing Curing methods
2 149.9 151.2 150.21 8.38 2461.45 473.696 20.9 Required strength as per IS code Average Compr. strength
Table 2.4.3: M20 grade observation table-Curing Types (150mm x 150mm x 150mm) (28 Days)

Weight Density Peak Load Comp. St. Average Comp. 50 M25 cube(150x150x150) 43.28

Days Batch L (mm) B (mm) H (mm) 45
(kg) (kg/m3) (kN) (N/mm2) St. (N.mm2)
40
1 98 100.8 99.55 2.43 2471.03 197.27 20.11 35 30.04 25
3 Days 1 99.07 102.1 97.6 2.33 2360.14 178.53 17.65 18.88 30 17.5
25 18.88
2 99.81 101.23 100.2 2.32 2291.59 M.F M.F. 12.5
20
1 100.11 100.7 99.86 2.46 2443.64 304.85 30.24 15
7 Days 1 99.72 99.07 99.3 2.39 2436.26 304.28 30.8 30.04 10
2 98.94 99.37 98.8 2.24 2306.02 287.18 29.21 5
1 100 101.3 100.12 2.51 2474.82 451.19 44.54 0
28 Days 1 101.32 99.09 99.8 2.49 2485.10 430.61 42.89 43.28 3 7 28
2 101.5 100.32 99.84 2.4 2360.77 423.29 41.57 No. of days
Density Peak Load Comp. St. Average Comp. 30 M25 cube(150x150x150) 27.46

Days Batch L (mm) B (mm) H (mm) Weight (kg)
(kg/m3) (kN) (N/mm2) St. (N.mm2) 25 25
21.94
1 150.3 150.1 150.01 8.35 2467.33 345.62 15.32 17.5
20
3 Days 1 149.7 151.3 150.03 8.5 2501.38 448.24 19.79 15.82 15.82
15 12.5
2 151.1 149.8 149.89 8.44 2487.67 267.32 12.35
1 148.9 148.48 149.21 8.41 2549.38 531.27 24.03 10
7 Days 1 151 149.1 150.22 8.29 2451.16 446.90 19.85 21.94
5
2 150.15 149.32 150.31 8.26 2451.03 M.F. M.F.
1 150 151 150.7 8.66 2537.09 705.77 31.16 0
3 7 28
28 Days 1 150.08 150.6 150.12 8.47 2496.30 648.45 28.69 27.46
No. of days
2 149.72 150.04 149.88 8.34 2477.05 506.11 22.53
M25 cube(150x150x150)
Type of Density Peak Load Comp. St. Average Comp. 32.09
Batch L (mm) B (mm) H (mm) Weight (kg) 35

Curing (kg/m3) (kN) (N/mm2) St. (N.mm2)
30 25.71 25 27.46
1 151.31 148.81 149.85 8.44 2501.42 730.88 32.46 25
Curing 19.3
1 150.76 149.72 150.11 8.36 2467.35 750.51 33.25 32.09 20
28 days
Compund
2 149.43 149.86 150.27 8.39 2493.25 684.57 30.57 15
2 149.39 152.1 151.8 8.31 2409.23 602.37 26.51 10
Sprinkling 1 148.71 151.26 150.8 8.45 2491.10 540.30 23.82 25.71 5
2 150.32 149.47 149.64 8.38 2492.44 602.15 26.8 0
1 150 148.8 150.4 8.34 2484.41 449.75 20.15 Curing compound Sprinkling Without curing ponding
Without Curing methods
1 151.03 151.98 150.12 8.38 2431.96 426.02 18.45 19.3
Curing
2 149.79 150.54 149.86 8.28 2450.25 M.F. M.F. Required strength as per IS code Average Compr. strength
Table 2.4.6: M25 grade observation table-Curing Types (150mm x 150mm x 150mm) (28 Days)

Observation Table:
Diameter Length Volume Weight Density Average Comp. St.
Grade Batch No. Comp. St. (N/mm2)
(mm) (mm) (m3) (kg) (kg/m3) (N.mm2)
B1 150.1 299.44 0.005298 13.14 2480 23.54
M20 B1 149.64 301.9 0.005309 13.1 2467 21.72 22.64
B2 148.3 300.4 0.005188 13.03 2511 22.66
B1 149.78 300.09 0.005287 13.2 2496 24.59
M25 B1 150.1 299.86 0.005306 13.02 2454 22.9 23.72
B2 149.85 298.95 0.005272 12.9 2447 23.67
Table 2.4.7: M20 and M25 grade observation table for cylinder specimen (150mm x 300mm) (28 Days test Result)
Conclusions:
❑ Its is observed that the compressive strength of concrete after 28 days for both the grades pass as per specified. For the results of types of curing are showing adequate result except
Without curing method as the M25 specimen failed in the compressive strength test.
❑ So the without curing method would not be appropriate because during the casting time the ambient temperature was low which led to less evaporation of the water inside the concrete,
giving its strength. Thus even at low temperature it failed so it is clear that curing is very necessary part .
❑ Also the for compressive strength of cylinder the average strength is roughly around 0.8 times the compressive strength of cubes.
❑ Also the strength of the cubes came much higher than specified for because in volume batching there may be an error while sampling the raw material, so extra safety factor is
considered in the ration for both grade which will give the desired strength even if raw material is slightly less.
Learning:
❑ From this exercise I learned to perform the compressive strength test of cubes and understood the types of curing methods which can be used as per requirements. Also, learned to
analyse the results and understood the reason for the any wrong results.
❑ Also the compressive strength of cylinder is done because while checking the strength of a building, core cutting is done and the core is cut in shape of cylinder. So if we know the
relation between the actual strength with respect to the shape of concrete specimen we could know the strength of the concrete in the building.
❑ Thus the major learning from this test were that mixing, compaction & curing all the three process are equally important as thus if any one process is not taken care of this will effect the
strength of the concrete. All the shape & size of the specimen plays an important role in strength.
Types of Failure Pattern seen during the compression test:
Image 2.4.3 Observed Failure Patterns

2.5 Split Tensile Strength Test
Specification IS: Apparatus:
IS:516-(1959)- methods of test for strength of concrete
Significance:
Tensile strength is an important property of concrete because concrete structures are highly Tamping Rod
vulnerable to tensile cracking due to various kinds of effects and applied loading itself. It has Diameter: 16mm
Length: 600mm
been estimated that tensile strength of concrete equals roughly about 10% of compressive
strength.
Procedure: Cylinder
Weighing Machine: (150x300mm) Vernier Callipers
Casting of moulds Maximum capacity: 50kg
(measure upto-300mm)
Accuracy: 0.005kg
1. After the mixing of concrete is complete, concrete is poured into a non-porous, non-
absorbent base. Compression testing machine:
2. The moulds are oiled beforehand
3. The concrete is then poured into the moulds with the help of hand scoop and filled in
three layers each 5cm in depth of the mould.
4. Each layer is rodded with tamping rod from the rounded with 35 strokes each,
5. After the top layer is rodded the mould is kept on the vibrating table for compaction until a
hint of bleeding is seen on the top, keeping in mind that the moulds are filled to the top of
the surface of the mould. Plunger & Jig
Image 2.5.1 Split Tensile Strength Apparatus
6. Then the moulds are removed from the vibrating table and the top surface is finished with
Observations: Image 2.5.2 Failure Patterns
trowel by moving it horizontally on the surface.
7. These moulds are then kept in moist room or moist condition or covered under plastic Batch Diameter Length Weight Density Peak load Fct. Ave. Fct.
Grade
No. (mm) (mm) (kg) (kg/m3) (kN) (N/mm2) (N/mm2)
sheet for 24 hours.
B1 149.7 298.8 13.21 2512 169 2.406
8. The cubes are demoulded after 24 hours and kept in clean water for curing.
M20 B1 149.45 299.62 13.16 2504 163 2.319 2.33
B2 150.2 299 13.07 2467 160 2.269
Testing on specimen
B1 150.21 299.7 13.1 2467 152.24 2.15
Take out the specimen from the curing tank and clean the surfaces. The test has to be
M25 B1 149.32 300.1 13.15 2502 154.01 2.19 2.17
performed on the wet specimen.
B2 149.7 299.18 13.07 2482 153.4 2.18
1. Measure all dimensions of the sample by Vernier calipers and weigh the samples.
Table 2.5.1: M20 and M25 grade Split tensile strength for cylinder specimen (150mm x 300mm)
2. Markings shall be made on the surface such that the jig falls parallel to the line drawn.
3. A thin strip of wood shall be placed between the plunger and cylinder and jig. Conclusions:
4. Samples are placed in the CTM such that axes of CTM and samples coincide. According to online sources, the splitting tensile strength of a cylinder should fall from minimum 3-10%
5. The load shall be applied without shock and increased continuously at a nominal rate of the compressive strength of the concrete. For M20 the result should fall between or above 0.6-2.0
within the range 1.2 N/(mm²/min) to 2.4 N/(mm²/min). N/mm^2 the average value comes out to be 2.33 N/mm² and for M25 the result should fall between or
6. Observe the failure pattern and take reading of peak load above 0.75-2.5 N/mm² the average value comes out to be 2.17 N/mm², which are acceptable.
7. Resultant Split tensile Strength = 2P/ πDL Learning:
P = Peak load; D = Diameter; L = Length From this exercise I learned to perform the slit tensile strength test and understand the result
comparison with the compressive strength of concrete.

2.6 Flexural Strength Test
Specification IS: Procedure:
IS:516-(1959)- methods of test for strength of concrete Casting of moulds
Significance: 1. After the mixing of concrete is complete, concrete is poured into a non-porous, non-absorbent
Flexural test evaluates the tensile strength of concrete indirectly. It tests the ability of base.
unreinforced concrete beam or slab to withstand failure in bending. The results of 2. The moulds are oiled beforehand
flexural test on concrete expressed as a modulus of rupture which denotes as (MR) in 3. The concrete is then poured into the moulds with the help of hand scoop and filled in three layers
MPa or psi. each 5cm in depth of the mould.
Specifications: 4. Each layer is rodded with tamping rod from the rounded with 35 strokes each,
The average flexural strength for the unreinforced concrete beam fall between 10-20% of 5. After the top layer is rodded the mould is kept on the vibrating table for compaction until a hint of
the compressive strength of the cubes. bleeding is seen on the top, keeping in mind that the moulds are filled to the top of the surface of
Apparatus: the mould.
6. Then the moulds are removed from the vibrating table and the top surface is finished with trowel
by moving it horizontally on the surface.
7. These moulds are then kept in moist room or moist condition or covered under plastic sheet for
24 hours.
8. The cubes are demoulded after 24 hours and kept in clean water for curing.
Testing on specimen
1. The specimen from the curing tank and clean the surfaces. The test has to be performed on the
wet specimen.
2. Measure all dimensions of the sample by Vernier callipers and weigh the samples.
3. Indicate position of beam placement in the UTM and position of loading by markings.
Weighing Machine: 4. Marking for placements: at 300 mm from centre on the bottom surface.
Maximum capacity: 50kg
5. Marking for loading: at 100 mm from the centre on the top surface.
Universal Testing Machine: Accuracy: 0.005kg
6. The bearing surface of the supporting and loading rollers are wiped clean of any loose sand or
Rate of loading (kN/s) = 140 kg/cm2/min
other material from the place of contact
7. The axis of specimen is aligned with the loading axis of device. The load is increased until the
specimen fails and maximum load applied to the specimen during the test is recorded.
Tamping Rod 8. The appearance of the fractured faces of concrete and any unusual features in the types of the
Diameter: 16mm failure in noted. Observe the failure pattern and note the peak load.
Length: 600mm
9. Precaution should be taken that load shall be divided equally between 2 loading rollers and all
rollers shall be mounted in such a manner that load is applied axially and not torsional or
restraints.
Beam (150x150x700mm) Vernier Callipers

(measure upto-300mm)
Image 2.6.1 Flexural Strength Apparatus

Observation Table:
Flexural Avg.
Weight of Volume Density
Grade Batch Length (mm) Width (mm) Height (mm) Peak load(N) a (mm) strength strength
sample (Kg) (m^3) (kg/m3)
(N/mm^2) (N/mm²)
B1 695 150.12 150 39.78 0.01565 2542 27570 219 4.90

M20 B2 697 150.14 151.03 38.85 0.01580 2458 21330 209 3.74 4.31
B3 697 150.04 150.11 39.7 0.01570 2529 24180 204 4.29
B1 699 150.64 149.89 38.4 0.01578 2433 20050 214 3.55
M25 B2 698 151.45 150.8 37.5 0.01594 2352 19680 240 3.43 3.5
B3 701 150.1 150.46 38.89 0.01583 2457 19850 213 3.51
Table 2.6.1: M20 and M25 grade flexural strength for beam specimen (150mm x 150mm x 700mm)
L
d
a
Diagram 2.6.1: Markings on the beams
𝑃𝑙 3𝑃𝑎
f = for a > 20cm f = for a < 20cm
𝑑2 b 𝑑2 b
where P = Peak Load (N)

L = Distance between two supports (mm)
d = Ave. depth (mm)
b = Ave. breadth (mm)
Image 2.6.2:Markings & Failure Pattern for beam

Conclusions:
From the result it is clear that the average flexural strength fall between 10-20% of the compressive strength. Hence this concrete is appropriate for construction purpose.

2.7 Comparison of strength results with different W/C ratio-

Cube (150x150x150) Compressive Strength Cylinder Compressive Strength
40 35
34.66
35 31.18 31.27 30 28.88 27.54 28.21
30 26.13 27.46 25 22.64 23.72
24.13 21.97
25
20
20
15 15
10 10
5 5
0
W/C Ratio 0.43 W/C Ratio 0.48 W/C Ratio 0.50 0
W/C Ratio 0.43 W/C Ratio 0.48 W/C Ratio 0.50
M20 ( N/mm²) 31.18 24.13 26.13 M20 ( N/mm²)) 28.88 21.97 22.64
M25 ( N/mm²) 34.66 31.27 27.46 M25 ( N/mm²) 27.54 28.21 23.72
M20 ( N/mm²) M25 ( N/mm²)
M20 ( N/mm²)) M25 ( N/mm²)
Cylinder Split Tensile Strength Beam Flexural Strength
3 5
2.61 2.5 2.59 4.5
4.38 4.31
2.5 2.33 3.84
2.13 2.17 4 3.5
3.5 3.22 3.135
2
3
1.5 2.5
2
1 1.5
0.5 1
0.5
0 0
W/C Ratio 0.43 W/C Ratio 0.48 W/C Ratio 0.50 W/C Ratio 0.43 W/C Ratio 0.48 W/C Ratio 0.50
M20 ( N/mm²) 2.13 2.5 2.33 M20 ( N/mm²) 3.22 3.5 3.135
M25 ( N/mm²) 2.61 2.59 2.17 M25 ( N/mm²) 4.38 4.31 3.84
M20 ( N/mm²) M25 ( N/mm²) M20 ( N/mm²) M25 ( N/mm²)
Graph 1.7.1: Comparison of the strength result with different w/c ratios.
Conclusions:
From the graphs it is clear that as the w/c ratio increased there was in decrease in strength in all the tests. So, it can be concluded that as lower w/c ratio higher the strength and out of the three w/c ratio
0.43 is optimum. We have also tried with w/c ratio 0.4 for M20 batch concrete which was not workable thus if we want to further reduce the w/c ratio super plasticizer are required to be added.

Module 3
Exploring Special Materials in Concrete
Scope of work
After the basic knowledge of the raw materials used in conventional concrete we were to
find four new materials which can be used in concrete which enhance the property of the
concrete. Thus by reading many literatures four material were suggested & after getting
it approved by the faculty in-depth study of that material was done.
Learning Outcome
We got chance to understand almost 60 different materials which bring something new
to the conventional concrete. This process involved reading of lot of literatures though
which we came across many new things related to concrete which change our the view
point towards concrete. We also learnt ways to communicate to vendors/suppliers. This
exercise helped us in selection of our final concrete product.
Includes
This include List of all raw materials explored and detailed information of four raw
material like advantages, disadvantages, applications, Dosage, cost etc is included.

Special Materials
Binders Fillers Fibers Coatings Admixtures

Chlorinated Sodium
Washed Propylene Rubber Based Foaming Agent Aniline
Volcanic Ash Bottom Ash Fiber Gluconate
Coating
Polyvinyl Boric Acid

Red Mud Cotton Fiber Corn Starch Calcium Nitrate
chloride Powder
Spent Coffee Poly Acrylic Polyvinyl

Calcined Kaolin PVC Fiber Paraffin Wax
Ground Ester Alcohol
Polycarboxylate
Bentonite Silicon Carbide Aramid Fibers Triethanolamine Tartaric Acid
Ether
Rapid Sodium
Hardening Diatomite Naphthalene Citric Acid Nano Silica
cement Formaldehyde
Low Heat Copper

Portland China Clay Soluble Zinc Oxalic Acid
Carbonate
Cement
Graphene Coconut Shell Titanium Tributyl

Sodium Nitrate
Oxide Aggregate Dioxide Phosphate
Here listed are some special raw materials
Polyethylene explored by my batch during the semester which Calcium Ploy Dimethyl
Sorel Cement Silver Nitrate
Terephthalate Chloride Siloxane
are unique and can be used in concrete to
enhance its properties. The highlighted ones were Calcium
Ammonium
Gypsum Quarry Dust Vinsol Resin
explored and studied by me and an overview is Lignosulphonate Formate
mentioned on the latter pages.
Blast Furness Activated Sodium Urea
Zeolite Carbon Benzoate Formaldehyde
Slag
Alccofine M-sand
Iron Ore
Tailings

Titanium Dioxide (TiO₂) Calcium Chloride (CaCl₂)
Under which category: Admixture Under which category: Admixture used as accelerator
Description: Titanium dioxide, also known as titanium(IV) oxide or titania, is the naturally Description: Calcium chloride is an inorganic compound, a salt with the chemical
occurring oxide of titanium. It is sourced from ilmenite, rutile, and anatase. It is available in formula CaCl2. It is a white colored crystalline solid at room temperature, highly soluble in water.
powder form & found from opaque to white in colour. The density ranges from 3780-4230 kg/m³. It can be created by neutralizing hydrochloric acid with calcium hydroxide. It is available in both
Powder form or pellets form
Availability: Titanium Dioxide is extensively used & it is easily available everywhere.
Make: T The major producer of Titanium Dioxide in india are Kerala Minerals and Metals Availability: Calcium chloride is easily available everywhere.
Limited (KMML) and Kolmak Chemicals Ltd
Make: The major producer of calcium chloride in India is Grasim-Aditya Birla Group. It is also
Positive impact over conventional concrete: Titanium Dioxide significant increase in tensile manufactured by many other small-medium enterprise..
strength, flexural strength & Compressive Strength. It can significantly refine the pores and
make them shift to harmless pores. It can significantly improve the toughness, structure Positive impact over conventional concrete: Concrete containing calcium chloride hardens
compactness, durability and effectively avoid the high brittleness of cement-based materials. It rapidly and develops early resistance to damage by freezing and thawing. It also Improves
also does proves to be effective as a pollution reducer and also exhibits a self-cleaning workability & reduces bleeding. Addition of chloride to pozzolanic cements reduces the volume
property, It also acts as a photocatalyst. of large pores & permeability
Negative impact over conventional concrete: These should be used in optimal amount to get Negative impact over conventional concrete: Due to use of calcium chloride in concrete, a
positive effects. Exposure of non reactive material in environment can leads to serious whitish deposit is formed on the cured concrete surface in some instances. Calcium chloride
environmental pollution. Due to its very small size and highly reactive in nature, it can harm slows down the setting of high alumina cement as well as reduced its strength thus it cannot be
human as well as other living creature, thus proper care should be taken before using it. used with it.
Application: It can be used in conventional concrete as well as it can be used in exposed Application: It can be used in conventional concrete as well as it can be used in winter
concrete work due to its self cleaning property concreting & used in road surfacing as it reduces the need of grading(earthwork)
Dosage: 2% to 5% of the total cement weight (Preferably 3%)

Dosage: Based on research it can be used upto 2% of the total cement weight
Shelf Life/Pot Life: Shelf Life: 3 Years (After that can be used after retesting)
Shelf Life/Pot Life: Shelf Life: 3 Years (After that can be used after retesting)
Minimum order quantity: It is Available in 25kg and 50 kg bags to tonne.

Minimum order quantity: It is Available in 250g, 25kg, and 50 kg bags to tonnes.
Cost: It is available at Rs.2500 to Rs.4000/Tonne Cost: It is available at Rs.6 to Rs.20/Kg.

Diatomite Silicon Carbide
Under which category: Fine aggregate (Filler) Under which category: aggregate (Filler)
Description: Diatomite also known as Diatomaceous earth or kieselgur. It is a naturally Description: Silicon carbide (SiC), also known as carborundum. It occurs in nature as the
occurring, soft, siliceous sedimentary rock that is easily crumbled into a fine powder. It has a extremely rare mineral moissanite. It is obtained in Greenish black to black in color & in both
particle size ranging 10 to 200 μm. It is available in white to light yellow in color. powder & solid form. The density of this material ranges from 2900-3100 kg/m³.
Availability: It is mainly available in Rajasthan where Diatomite rock are in abundance. Availability: Moissanite is available in some parts of Madhya Pradesh & Chhattisgarh.
Whereas Silicon carbide is available in many states including Gujarat.
Make: The major mining & manufacturing of Diatomite powder from Diatomaceous earth is
done Jaipur Magmatics Pvt. Ltd located in Rajasthan.
Make: The mining of moissanite mineral is mainly done by National Mineral Development
Corporation.
Positive impact over conventional concrete: Diatomite provide almost 55% decreases in
heat conductance, It has low density as a result it is highly pores thus can be used as a
Positive impact over conventional concrete: Tensile, Bending and Impact strength increases
lightweight aggregate. Diatomite when added to asphalt, viscosity increased rapidly at high
with addition of silicon carbide also Impact toughness value for this composite is more than
temperature and value of abrasion loss also decreases. It improve resistance to deformation at
many other filled composites It provides resistance to deformation at high temperature, and
high temperatures and the resistance to thermal cracking at low temperature
abrasiveness over a wide temperature range.
Negative impact over conventional concrete: It shows high reduction in compressive
strength thus it cannot be used in load bearing members. Also the amount of water absorption Negative impact over conventional concrete: The slump of the concrete paste is reduced
is very high, thus water reducing admixtures are needed considerably due to addition silicon carbide which affect the workability thus more amount of
water or super plastizer is required. The cost of the material is also very high.
Application: It is mainly used in the concrete which do not require high strength (i.e. non
structural members), Also due to decrease in heat conductance it is extensively used in
Application: It can be used for the concrete where impact resistance is a major concern. It can
agricultural buildings.
also be used in conventional concrete to enhance its mechanical properties.
Dosage: Based on research 15% to 30% of the total cement weight (It can completely replace
Dosage: Based on research silicon carbide desirable dosage is 2-6% of the total cement weight
fine aggregates)
Shelf Life/Pot Life: There is no certain shelf life or pot life for this material if it is kept in such a
Shelf Life/Pot Life: It is self stable material.
way that it does not pick moisture.
Minimum order quantity: It is Available in 25kg and 50 kg bags to tonne. Minimum order quantity: It is available in 50 kg bags & can be ordered in tonnes.
Cost: It is available at Rs.2500 to Rs.4000/Tonne Cost: It is available at Rs.2500 to Rs.4000/Tonne

Module 4
Material Library
Group Activity
Scope of work
This module included the preparation of library with any type of special concrete which
can include the materials which were to be procured. We have to submit the design of the
module & along with it BOQ was to be prepared. After getting approval from the faculty
we started working on the mix design, prototypes & after doing required changes in mix
design, we prepared a final formwork & we casted & demolded this library for four times.
Learning Outcome
In this module we got hands on experience about the entire process of creating
something with concrete. From design, to costing & to ascertaining the proper mix design
& creating was done in this module. Also we learnt to work in group effectively. We got a
chance to study Fibre Reinforced concrete in this activity. We used different admixtures &
role of admixtures in concrete was also learnt. Also, how to complete a time bound work
by coordination was learnt. We also had experience of formwork preparation & we came
across many different tools in the workshops.
Includes
This include the initial design & final design proposed, Trials, Formwork, concreting &
demolding process. It includes failures & learning in preparation of this library module.

Challenges Given Design Proposal 1 Design Proposal 2
A raw material display furniture was to be made up of non conventional furniture
material, i.e. Concrete with following challenges-
1. Budget based task
2. Weight should be less than 50 kg per module, i.e. 1 kg per unit.
3. Finish shall be neat, crisp, and elegant.
BOQ for Material Library

Sr. Item Description Unit Qty. Rate (Rs) Amt. (Rs)
A Materials Consumed
A1 Concrete Work
1 OPC 53 Grade Cement (50%) Kg 120.00 6.00 720.00
3 Silica Sand (50%) Kg 120.00 4.00 480.00
4 AR Glass Fiber (3% of dry mix) Kg 7.50 250.00 1875.00
5 HRWR admixture (1% of cement) Lt. 1.20 210.00 252.00 Last year output
Total for Raw Materials 3,327.00
B Formwork Required
1 PVC Sheets (16mm) Sq.ft. 64.00 104.00 6,656.00
2 Shuttering Oil Lt. 1.00 200.00 200.00
3 Screw Nos. 600.00 0.75 450.00
4 Adhesives (20 gram bottle) Nos. 10.00 50.00 500.00
5 POP Kg 5.00 20.00 100.00 Image 4.1: Design Proposal 1 & 2
6 Sand Paper Nos. 10.00 5.00 50.00
Total for Formwork 7,956.00 ❑ Design 1 was having a storage of 36 material per module, the design was
Total 11,283.00 such that is could be seen from either side. It was rejected as it was
Table 4.1: Cost evaluation for the library module structurally stable & also there was possibility of materials to fall down
❑ Design 2 consist of 4 pyramidical shape module each having capacity of 42
moulds. The main feature was it can be kept at eye level & material can be
viewed from both sides.
Execution sequence
Discussing the design

Discussion on
Selection of design of Selection of concrete Preparing BOQ for and working on the
Finalizing the design casting and formwork
module mix design the library changes given by the
sequence
client
Preparation of formwork Changes in mix

Casting & Preparation of
Finishing the module of final module as per design based on
Demoulding of mould prototype
design prototype
Finish of the module was not done because of lockdown so it is shown in different colour.

Trial 1 Prototype 1 was prepared after three Prototype 2 was prepared

Trial 4
• Cement: 33% (A) trials (1,2 & 3). Trial three was finalize after three trials (4,5 & 6).
• Cement: 50% (A)
• Fly ash: 40% (B) for casting of first prototype. Trial six was finalize for
casting of second prototype. • Silica Sand: 50% (B)
• Silica Sand: 27% (coarse)
• Glass Fiber: 2.5% of A+B
• Glass Fiber: 5% of A+B
• W/C: 0.29
• W/C: 0.35
• Admixture: 0.8% of A
• Admixture : 0.6% of A+B
Resulted in low workable concrete.
High Water cement ratio resulted in segregation. And less
bonding between materials was observed. Trial 5
• Cement: 50% (A)
Trial 2
• Silica Sand: 50% (B)
• Cement: 35% (A)
• Fly ash: 35% (B)
• W/C: 0.29
• Silica Sand: 30%
• Admixture: 1% of A
• Glass Fiber: 5% of A+B
Resulted in increase in workability, but the flow was not
• W/C: 0.3
sufficient. Less induction time.
• Admixture: 0.8% of A+B
• SBR: 5% of A+B
Trial 6
• Black Color Pigment: 1%
• Cement: 50% (A)
Resulted in good bonding property due to addition of
• Silica Sand: 50% (B)
SBR. Needed more flow. Image 4.2: Prototype 1
• The prototype was a failure as • W/C: 0.3
Trial 3
the concrete had not set even
• Admixture: 1% of A
• Cement: 35% (A) after 2 days.
• Fly ash: 35% (B) • The reason was SBR, excess This mix was appropriate as per the requirement and was
• Silica Sand: 30% w/c ratio and improper induction used for prototype casting.
Image 4.3: Prototype 2
• Glass Fiber: 5% of A+B time for mixing of material.
• The amount of binder material According to the final mix Mixing Process
• W/C: 0.3
was also very high. design we casted a prototype. 1) Dry mix – 1 min
• Admixture: 1% of A+B
• Fly ash did not shown good After the demolding the 2) Add water. Mix for 1.5 min (high speed)
• SBR: 5% of A+B prototype was as per the 3) Add plasticizer. Mix for 3 min.
results. Thus only cement can be
• Black Color Pigment: 3% used. challenge and the mix design 4) Add fiber and remaining plasticizer with water. Mix
This mix was appropriate as per the requirement and was • Thus we Did further trials for new was selected for the final 1 min (slow speed)
used for prototype casting. mix ratio. module. 5) Ready for placing.

Formwork Details
1. Formwork was made with 16 mm Thich PVC sheet

2. The formwork consisted of 2 parts-
1. The unit Mould
2. The outer Mould
3. The unit mould consists of 5 parts-1 bottom plate, 2 side
plates, and 2 front plates
4. The side plates have 45 degree cut outs at one of its smaller
edges, while base plate has 45 degree cut out on all 4 of its
bottom edges which were made using machine cutter.
5. The sides and base for the complete module were screwed
together.
6. The outer mould were cut according to the dimensions of the
mould with bottom and sides fixed with it.
7. The bottom part of it had fixed unit moulds with spacings in
between be spacers of 10 mm thickness.
8. This Spacers were stuck on the base of the formwork & after
trying different combinations the position of each unit mould
was finalized & marked
9. For the upper boxes, spacers were kept and both were
attached to a wooden stick, using screws in such a way that
the upper & lower mound remain in straight line.
10. Once all the components were in place, all the joints were
sealed using POP.
11. During casting first the bottom part was completely casted
the lying a bed of 10mm the top formwork was placed.
Image 4.3: Exploded View of Formwork Image 4.4: Bottom Formwork
Changes due to Failure

▪ Initially the molds were hand sanded resulting bad quality of inner surface of prototype. Thus we did machine sanding to
have a uniform inner finish of the module.
▪ During concreting the upper formwork resulted in bending giving uneven thickness. So we added spacers for equal
distancing in between the unit moulds.
▪ Also during our first casting, the side started to bulge. So, to overcome it we added additional support to it by fixing a
wooden rectangular cross section to the side.
Image 4.6: Unit Mould Image 4.6: Top Formwork

Casting & Demolding Details
Casting: Module 1
• Low workability concrete
1. The casting of the full mould was done at once. The concrete was mixed in one batch, in the • Fibers coming out of surface
pan mixer. • Not so good finishes
• Compaction was not proper
2. All the joint were sealed with POP & after drying of POP, releasing agent was applied in
• Demold was not proper
proportion of 1:3 with water.
• More voids
3. As soon as the mix was ready it was poured in the mould and the concrete was compacted • Variation in dimension
using trowel and was vibrated by slight tamping on the sides and the bottom. Steel scales
were also used for compaction.
4. After the lower part is completely compacted, 10 mm thich bed of concrete was laid & after
that upper formwork was placed & screwed on both the sides & after that concreting was
done.
5. The main problem in concreting was the alignment of the moulds as due to pressure of
concrete it seems to misplace which results in change in thickness of the mould
6. This was done by providing 10 mm spacers & also it was constantly checked during Module 2
concreting too. • Good workability concrete
• Mixing was not proper
7. The addition fibers reduced the workability of concrete greatly, and also formed knots at • Good surface finishes
certain places, which caused void formation. • Surface expanding during
compaction of concrete.
8. Other major problem faced was bulging of longer sides. This problem was solved by adding • Demold was bit difficult
counter weight in form of two Thich wooden horizontal runners. • Lesser voids
9. The major learning from this process was the behavior of fiber reinforced concrete, and how to
work with this type of material to produce thin sections effectively.
Demoulding:
1. The wooden sticks were unscrewed, followed by unscrewing of the sides of the unit mould
2. The front and back sides of unit mould were first removed, followed by the other sides, and at
last the base plate using screw and pliers. Following by the external sides. Module 3
• Good workability concrete Module 4
3. The same process is followed on the bottom, after which the whole module was cleaned of • Homogeneous mix • Good workability
pieces, and dust.
• Good surface finishes concrete
4. The biggest challenge while demoulding was to remove the based plate. This challenge was • Good compaction • Homogeneous mix
tackled by screwing the base plates and then pulling them out with the help of pliers. • Demould was easily done • Good compaction
• No voids
5. The learning during this exercise was to be patient, or else the mould could be broken while • As per dimensions
demoulding.
The demolding of module 4 was not done completely due to lockdown so there is no image of module 4

Process Images & Learnings
Demoulding and understanding the problems in prototype

Preparation of prototype and mix ratio trials
▪ Demoulding sequence plays an important role as one of the reason of failure
▪ Learned to perform trials and asses changes required to be done in the mix design based on trials.
was unproper demoulding sequence.
▪ Performed fresh concrete property test (flow table test) to judge the workability of the mix.
▪ Observed demoulding problems and learnt that mixing time is important.
▪ Executed formwork for the prototype
▪ Changed the mix design for second prototype from the results obtained
during demoulding of prototype one.
Demoulding the module Casting of Mould

▪ It should be done with proper care because if small ▪ Importance of casting sequence was leant also Preparation of formwork for module
amount of pressure is applied there was a chance of compaction was a big problem faced during casting ▪ Prepared formwork for the final module and learnt hands-on work with tool
module to get damage due to its thin section. ▪ Addition spacers were added to keep the upper ▪ Studied about the concrete pressure & how to overcome it by providing
formwork in position extra supports in formwork

Module 5
Project Work -Special Concrete
Scope of work
We were given the task to find out a special type of concrete. A total of 16 special concrete
were selected where each student did research on them. Then all the students were to give
their different ideas regarding different applications & reason behind it. Then after that one of
the best suitable application is selected & proposal was prepared with following information:
▪ Requirements of the product.
▪ Reason for selecting this concrete application.
▪ 3-D representation of the product.
▪ List of materials to be used with proportion as per application.
▪ Advantages of using this over conventional concrete.
▪ Quantity and Rate analysis of materials.
▪ Manufacturing Process
▪ Types of joinery to be provided.
Learning Outcome
From this module , many new dimensions to product design and production. we leant to
analyze the problem faced in conventional concrete & how to overcome it. We also studied
& researched on different application of each & every concrete which made us understand
16 new concrete in depth.
conventional Industrial Flooring
Includes
This includes the applications of 16 different concrete found by me as well as by my
classmates & it includes in depth analysis of concrete & its application selected by me.

Pots Concrete pipes Paver Blocks Tiles
Lime Concrete
Limecrete is a combination of natural hydraulic lime and lightweight

aggregates such as sharp sand or glass fibers & it is a breathable material.
Mangalore Tiles
Compared to conventional Mangalore tiles
limecrete having fibers will result in higher
strength resulting in less breakage as well as it a
breathable material which allows transmission of Blocks
Sanitary ware
water vapor.
Low cost housing Floor Slabs Lime Mortar Garden benches

The application in centre is application selected by me whereas all other are application selected by my classmates

Curbing Foundation Paver Block Acid resistant tile
Alkali Activated Concrete
Alkali-Activated Concrete (AAC) is a concrete for which Portland cement is

completely substituted by an alternative binder. Instead of using OPC
cement, materials like Blast Furnace Slag (BFS) or Fly Ash (FA)
are activated with an alkaline activator solution
Acid Resistant Industrial Flooring

A large amount of concrete is used in
manufacturing of industrial floorings (slabs) which
results into high consumption of cement leading to
Water tank Blocks
high environmental impact. It is also more resilient
to attack from fire and acid than conventional
concrete. Thus it can be used in chemical
industries which are prone to acid attacks.
Concrete pipes Marine Structures Sewage treatment plant

Parking in snowy regions Walls in snowy regions Paver Blocks Drive-ways
Conductive Concrete
Conductive concrete can be defined as a cementitious composite which

contains a certain amount of electronically conductive components to attain
stable and relatively high electrical conductivity.
Grounding in Electric Transmission Tower

The main purpose of electrical grounding is to
protect the equipment in the event of an electrical
systems failure. The protection is achieved
through a proper electrical connection systems.
Sauna rooms Roof Slab
With its excellent structural engineering properties,
conductive concrete is good candidate for
grounding. This method is known as Ufer ground.
Roods in snowy region Bridge Deck Pipelines

Statues Bridges piers Façade panels Foundations
Self Healing Concrete
Self healing concrete also known as Bio-Concrete or bacterial concrete can

be produced by adding bacteria which produces calcite (limestone) to fill
cracks when this concrete comes in contact with water & air.
Dams
Water seepage/leakage is a major problem in
dams which result into cracking & further
reduction in strength. Thus by using self healing
concrete the cracks formed will be filled by
Underground Structure reaction of concrete with water which seeps inside Roof slabs
Diaphram Walls the crack & produces calcite which will seal the
crack.
Railway sleepers Tunnel linings Exposed concrete works Water Tanks

Military protection walls Major building component (core wall) Underground Structure
Airport runways
Reactive Powder Concrete
Reactive Powder Concrete (RPC) also know ultra-high performance concrete

which is prepared by replacing conventional concrete with Quartz powder,
Silica fume, steel fibres etc. It can be used where high strength greater than
80 N/mm² is required. It also posses high ductility.
Precast Concrete Piles

A large amount of concrete is used in foundation
which results into high consumption of cement
leading to high environmental impact. Thus by
Bridges using this, the volume of concrete required can be Deck Panels
reduced due to its property of high strength. It
posses lower permeability which results in less
seepage thus it do not allow steel to get corrode.
Arch Dams
Tunnel linings Wind Turbine Tower Water tank

Hume pipes Railway sleeper Septic tank Precast walls
Sulphur Concrete
Sulphur concrete is a composite construction material, contains Sulphur &

aggregates. Cement & water, important compounds in conventional concrete
are not used in it. Sulphur which acts as major binder exhibits great
mechanical properties & high resistance towards chemical & sulphate attacks
Industrial Flooring
A large amount of concrete is used in
manufacturing of industrial floorings (slabs) which
results into high consumption of cement leading to
high environmental impact. Due to its chemical
Cold storage structure Fountains
resistance property & ability to achieve 80% of its
strength in one day it can be used in industrial
floorings so that there is not need to apply addition
coating which saves both time & money.
Tunnel linings Diaphragm/Retaining Walls Decorative Moulding Precast Piles

Bioswales Sound Absorbing walls Artificial ground base Driveways
Pervious Concrete
Pervious concrete also called porous concrete, permeable concrete, no fines
concrete and porous pavement is a special type of concrete with a
high porosity used for concrete flatwork applications that
allows water from precipitation and other sources to pass directly through,
thereby reducing the runoff from a site and allowing groundwater recharge.
Swimming Pool Deck

Pervious concrete allows water to penetrate
through it, thus if we used it in form of tiles or slab
Tree Grate at swimming pools decks which are mainly wet Paver Block
due to water which causes accident like slipping
thus to avoid this & reduce the wastage of water
this concrete can be used.
Rainwater harvest tank Tennis court Parking Swimming pool deck

Dams Sewage Pipes Curbing Paver Block
Ecocrete
Ecocrete is a cement less & CO₂ absorbing concrete, uses iron powder as
major binder. It is a blend of various materials like Iron powder, Fly ash,
Limestone, Metakaolin & oxalic acid which is chemically stable in marine
atmosphere. It also reduces green house gases by using CO₂ for curing.
Break Water (Armored units)

Break water armor units are plain concrete
structures which consume large amount of
Marine Bridge Supports concrete & cement using ecocrete which is stable
Roadways
in marine environment can be used to replace
cement & overcome the CO₂ emission rate in the
environment
Sea water intake Blocks Precast Walls Facade

Canal Linings River Diaphragm Walls Swimming Pool tiles Façade Panels
Hydrophobic Concrete
Hydrophobic concrete repels water form its surfaces, rather than absorbing it.
This concrete reduced the polarity, they tend to form droplets, which do not
stick on the surface, and get absorbed into the capillaries of concrete. This
property can be achieved filling cracks with polymer or crystalline formations.
Tunnel Linings
Tunnels are mainly constructed in area where the
probability of water seepage is very high which
results into development of cracks in the
Dam Base structure. To overcome this problem Hydrophobic Roof Slabs
concrete is used as it fills the crack with polymer
which do not allow water to penetrate inside the
tunnel
Water Tank Bathroom slabs Structures built near water bodies Water Supply pipe lines

Façade Panels Walk ways/Drive ways Exposed Structural Members Industrial Chimney
Self Cleaning Concrete
Self cleaning concrete is produced by adding photocatalytic material like

titanium dioxide (TiO₂). It is activated by the energy from the sun light or UV
lamps and it decompose the external pollutants on the surface of the
concrete, which is removed by wind and rain action.
RE Wall panels for Flyovers

Re wall Panels are called as reinforced earth
retaining panels. This panels are exposed to more
carbon & dust & also visible thus if this panels are
Statues made up of self cleaning concrete there will be no Highway Barriers
or very less accumulation of dust. Also addition of
titanium dioxide increases mechanical properties
& life span of structure is also increased.
Precast Walls Tunnel Linings Paver Block Exposed Diaphragm Walls

Milestone Street lamps Reflective Facades Sewage treatment tank Swimming pool flooring Feed Bunks
Light Refractive Concrete Lightweight Concrete

Anti Bacterial Concrete
This concrete follows retroreflective mechanism, in which the concrete This type ofconcrete
Lightweight concretecanpossesses an effect
be defined as theoftype
controlling Sulphur
of concrete reducing
which includes &
features embedded glass spheres that reflect light directly back at its source. Sulphur
an oxidizing
expanding bacteria
agent The
which objectivethe
increases of this type of
volume of concrete
mixture is to improve
while giving
Thus this concrete surfaces send incoming rays of light (sunlight or artificial) the hygiene
additional and conservation
qualities conditions
like insulation of installations
& reduction in dead load.by Itreducing the risk
can be achived
back in the direction of source. of contamination
by expanded claythrough bacteria
aggregates and
or aie fungi andadmixtures
entraining the emission of foul odours.
Roofing Applications
Tunnel Linings Tiles in Food Processing unit &
The property of this concrete like thermal &
Reflectors at roads are major need at night time & Hospital
sound insulation can be used in roofing. Also by
applying radium can be costly affair & there is Hospital
using thisfloorings & walls
concrete are most
the dead loadprone to
on the
need to change them regularly. Thus by using this bacteria
structure &is cleaning
reduced.ofThus
floors
byiscreating
a majorprecast
task.
in tunnels during night time will be a great option Thus by panels
concrete using the
Antitime
Bacterial concreteis this
for installation also
as it reduces the chance of accident that can be reduce. can be overcome.
problems
causes as well as it is a permanent option
Curbing Signages Swimming pool deck Sewage Pipelines Railway Platform Laboratory Platform

Industrial Flooring Airport Runways Underground Bunkers Pots Concrete Canoe Garden Benches
Sifcon Concrete Lightweight Concrete
Slurry-infiltrated fibrous concrete (SIFCON) is a special type of fiber concrete Lightweight concrete can be defined as the type of concrete which includes
with high fiber content. The matrix usually consists of cement slurry. It has an expanding agent which increases the volume of mixture while giving
excellent potential for application where High ductility and resistance to additional qualities like insulation & reduction in dead load. It can be achieved
impact are needed. The fiber content of FRC generally varies from 1 to 3 by expanded clay aggregates or air entraining admixtures
percent by volume, but for SIFCON it varies between 5 and 20 percent.
Garden Benches Roofing Applications

Thin section of garden benches can be prepared The property of this concrete like thermal & sound
from sifcon which looks architecturally & insulation can be used in roofing. Also by using
aesthetically pleasing. Along with it due to its thin this concrete the dead load on the structure is
section the weight of the bench is also very less reduced. Thus by creating precast concrete
thus this benches reduce the dead load. panels the time for installation is also reduce.
Heavy duty container yard Corrugated Sheets Precast concrete walls Emergency Shelters Blocks Floating Slabs
floor

Exterior Concrete walls Roofing slabs Façade Panels Sound Absorbing Blocks Roof slabs
Dyscrete Air Entraining Stamped Concrete
Dyscrete is a dye-sensitized energy generating concrete made by coating Air entraining stamped concrete is a lightweight concrete having density
precast concrete components with layers of organic dyes. This cells rely on around 1200-1300 Kg/m³ obtained by adding foaming agent & this concrete is
photochemical process to convert light into energy. Thus by using this also stamped in any pattern by rubber stamp. This concrete possess water
concrete electricity can be generated from both direct & indirect light sources. repellent & thermal insulation property.
Shaded Walkways Tiles in Bathroom & Courtyard

Shaded walkways are provide for person to give Water seepage/leakage is a major problem in the
shade from direct sunlight. Creating the precast major problem in bathroom tiles. Thus the
panels or any structural member will not only problem of dampness can be overcome by
provide shade but also produce some amount of concrete. Also by stamping various amount of
energy which can be used in small purpose like different patterns can be obtained & its strength is
lightings at night, table fans & also as mobile relatively more than normal ceramic tiles & it also
phone charging stations. cheaper.
Street Light Concrete Louvers Parking shades Lightweight sound Concrete in cold regions Pathway Blocks/slabs
absorbing walls
Sulphur Concrete
Waterless & Cement less Concrete
Problem Statement Reducing environmental Improves mechanical

▪ Concrete is the most used building material for Construction works, which is impact as an replacement of properties. higher value of
responsible for 23% of the industrial carbon dioxide emission. cement and water modulus of elasticity & rupture
▪ Globally, cement production in 2017 accounted for approximately 8% -10% of
total carbon dioxide (CO₂) emissions.
▪ Also 250-300 liters of water in producing 1 m³ of concrete.
So, why not try to replace cement & water with an alternative material High resistance towards Benefits of using Low permeability which
chemical & sulphate attacks.
As it name suggests Sulphur concrete uses Sulphur as a major binder No requirement of coating.
Sulphur results into extreme corrosion
Concrete resistance
material. Thus along with Sulphur it consist of fine aggregates, coarse Saves time and money.
aggregates & Asphalt.
Raw Materials, its proportion & behaviour
Early strength gain at 70-80%

It posses high impact &
compressive strength in one
abrasion resistance
day
Manufacturing Process
Sulphur (15%) Asphalt (5%) Granite dust (15%)
• Process of sulphur concrete production is based on the sulphur’s properties of changing its viscosity with the
Main bonding agent High Thermal
Fire & Corrosion change of the temperature (119°C -122°C) sulphur completely turns from the solid into the liquid.
between the raw Insulation & Impact
Resistance • The technology of the sulphur concrete is very similar to the technology of the asphalt concrete.
materials Resistance
• At first, coarse and fine aggregates preheated in an oven at 150˚C. After one minute of dry mixing, modified
sulfur & Asphalt were also poured into the container. Mixing continued until the sulfur & Asphalt binder
liquefied & mixes with coarse aggregate then concrete is casted & cured.
• This moulds are then placed into water bath/steam bath for around one hour.
The world production of sulfur in 2019 amounted to Sulfur is the fifth most common element on
70 million tonne (Mt)
Earth. Today, sulfur is produced from
The major petroleum & natural gas industries in India
Limestone (15%) Diatomite (5%) Coarse Agg.(45%) which produces Sulphur are: petroleum, natural gas, and related fossil
1. Oil & Natural gas corporation resources, from which it is obtained mainly
More Heat Reduces heat
Main Filler material 2. Indian Oil Corporation as hydrogen sulfide. The resulting hydrogen
Resistance conductance by 55%
in the concrete mix 3. Royal Dutch shell
(Carbonate Agg.) & Viscosity increases sulfide from this process is converted into
4. Reliance industries Limited
Image 5.1: Raw Material 5. Bharat petroleum Corporation Ltd. elemental sulfur by the Claus process.

Probable Application Drawings
▪Sulphur Concrete high resistance towards chemical & sulphate attacks, thus it can be used in Industries which
are prone to this type of attacks such as Food Processing Plants, Mineral Processing, Fertilizer, Chemical
Production Industries, Sodium Sulphate Plants, Potash Plants.
▪Thus the best suitable application for this concrete is a precast slab which can be used in above industries.
Production cost of sulphur concrete vs conventional Industrial Flooring

Sr No. Material Weight (Kg/m³) Price (Rs.)/Kg Cost (Rs.)/m³
Image 5.3: Slab Drawings
1 Sulphur (15%) 410 5 2050
2 Asphalt (5%) 81 22 1782
3 Coarse Aggregate (45%) 1100 0.6 660
4 Diatomite (5%) 115 3.5 403
5 Granite Dust (15%) 615 0.5 308
6 Limestone Powder (15%) 500 1.4 700
Total 5903
Sr No. Particulars Energy (Kwh/m³) Price (Rs.)/Kwh Cost (Rs.)/m³

1 Production of Sulphur concrete 78 6 468
Image 5.2: conventional
2 Steam curing/water curing 105 6 630 industrial flooring
Total 1098 Image 5.4: Slab 3D Drawings
Table 5.1: Production Cost Joinery Details (Dowel Joint)

Total Cost of Production of 1 m³ Sulphur Concrete is Rs. 7000
▪ The concrete used for Industrial Flooring should be ranging between M35 to M50 grade.
▪ The coating can be epoxy coating or PU Coating. Mostly PU Coating is being used in chemical industries.
▪ The cost of M40 grade of concrete is between Rs.6000 to Rs.6500/m³.
▪ The cost of PU coating of approx. 4 or 5 mm is between Rs.1400 to Rs. 2000/m². Joinery between two concrete panels. Isolation Joints
▪ Thus the total cost of Industrial flooring comes out to be Rs.13,000 to Rs16,500/m³.
Testing Methods
▪Compressive strength test: As per IS 516:1959 (reaffirmed 2004)
▪Split Tensile strength test-IS 5816 (1999): Method of Test Splitting Tensile Strength of Concrete
▪Chemical Resistance Tests: The cylindrical specimens were immersed in three different aggressive
chemical environments: 10% HCl solution, 20% H₂SO₄ solution, and 3% NaCl solution.
▪Thermal Expansion Tests: The expansion and contraction of sulfur concrete due to temperature changes
can impact the durability. Expansion Joints
Compaction Joints
▪Resistance of Freezing and Thawing Tests: As per ASTM C 666 Image 5.5 Joinery Details

Learning Outcome
It summarizes what we learned throughout the course by performing different exercises and how concrete behaves as a material. Learnt about special
types of concrete with the help of the knowledge of concrete and different types of materials that can be used in it. Performing all this tests gave me a
lot of insights about conventional concrete. All the exercises helped me to have more reasoning and observation ability of thinking and few exercises
helped to understand the importance of group work and how would efficient discussions and distribution would lead to completion of work on time.
This process involved reading of lot of literatures though which we came across many new things related to concrete which change our the view point
towards concrete. we got hands on experience about the entire process of creating a library with concrete with special concrete. We also had
experience of formwork preparation & we came across many different tools in the workshops

Kasturbhai Lalbhai Campus,
University Rd, Navrangpura,
Ahmedabad, Gujarat 380009

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CT 2015

Submitted by: Devarsh Shah | UG180151

Module 1: Exploring Raw Materials in Concrete……………………………………………………………………………..……………. 01-18

Devarsh Shah (UG180151)

Devarsh Shah (UG180151)

1. Exploring Raw Materials in Concrete

2. Concrete Trials by Volumetric Batching

3. Exploring Special Materials in Concrete

Concrete Studio - Batch Spring 2020 4. Material Library

5. Project Work-Special Concrete

Devarsh Shah (UG180151)

To determine amount of water required to make a cement paste of standard consistency.

Penetration of Plunger (MM)

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OPC 53 Min. 30 Max. 600

Procedure: Figure 1.2.1: Vicat Apparatus (all dimension in mm)

Mins. After adding water

Figure 1.3.1: Le-Chatilier Apparatus)

Indicator reading after 24 hours (L1) mm 23.5 18.5 21.5

1 2 3 Indicator reading after boiling (L2) mm 25 20 22.5

Devarsh Shah (UG180151) 4

Figure 1.4.1: Le-Chatilier Flask)

Sr.No. Particular Unit Observation

1 2 1 Wt. of Tested cement Sample(W) gm 64

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Oven - A well ventilated oven, thermostatically controlled, Result:

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4.75mm Graph 1.10.1: IS Sieve designation v/s % aggregate passing

600micron Sieve Vibrating Machine Image 1.10.2: Test Photographs

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IS Sieve Particular IS Sieve Particular Observations:

Sieve set as per IS Sieve set as per IS Conclusion:

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Image 1.12.2: Apparatus Required

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Water Bottle Pycnometer Measuring Cylinder

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1. Weight of the basket along with aggregates is taken as A1 in submerged condition.

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Image 1.15.2: Apparatus Required

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Sr no. Particulars Value

1 2 1 Weight aggregate A (gms) 375

The sample is sieved

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Image 1.17.1: Test Photographs

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Grade of concrete : M20(1:1.5:3) ; M25 (1:1:2)

Total Wet Volume

Total Dry Volume

Compressive Slump Test

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Figure 2.1.1: Slump Cone Apparatus

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Flow Table (%)

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Image 2.3.2 Flow Table Apparatus

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Compr. stremgth (N/mm2)