Unit 01 - Phase 02

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UNIT – II: Masonry Products & Concrete

(Contact Hours: 10)
Building stones – classification, processing, characteristics, durability aspects, tests,
application and selection, preservation etc.
Bricks – classification, manufacturing, characteristics, durability aspects, tests,

application and selection, sustainability aspects, laying etc.
Limes – Cementing action, manufacturing, slaking, storage, properties, classification,

tests, applications etc.
Mortars – Classification, preparation, strength, tests, applications etc.
Concrete – Constituent materials, properties, characteristics, tests, production,

properties, masonry units etc.
Dr. P. SUDHEER (Asst.Professor)

Department of Civil Engineering
MVGR C E (Autonomous)
Dr. P. Sudheer (Asst.Prof) 1
STONES
1. Stone is a natural material for construction.
2. Building stones are obtained from quarry by disintegration (Break down)

of big rocks.
3. Man has been using stones from very ancient times for constructing
foundations, walls, pillars, lintels, beams, floors, roofs, etc., of buildings
also for major engineering works such as weirs, dams etc.
4. Ancient temples and other important historical buildings in India and abroad
were built with red sand stone.
5. The Secretariat, Assembly Buildings and Rashtrapati Bhawan in New Delhi

were built with pink and grey sand stones.
6. Taj Mahal at Agra and the Victoria Memorial in Calcutta were built with
marble.

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RASHTRAPATI BHAWAN IN NEW DELHI
TAJ MAHAL AT AGRA

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VICTORIA MEMORIAL IN CALCUTTA
BUILDING STONES
1. The stone which is used for the construction of engineering structures is
known as building stone.
2. Stones when derived from rocks are very irregular in shape and size.
3. Therefore, we have to dressed irregular to regular in shape and size for
speedy construction.
4. Stone possesses long lasting properties and is naturally available in large
quantity, it is therefore, considered as one of the most and popular important
engineering material of construction.

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UTILITY OF STONE
1. Now a days, brick-in-mortar and concrete are replacing stone as a building
material almost everywhere, because good building stones are not easily and
cheaply available in all parts of India and are difficult to handle due to their
heavy weight.
2. Moreover, they are costly in construction as they involve heavy transportation
and dressing charges. Their use is, therefore, restricted to the construction of
heavy and permanent engineering structures such as dams, docks, harbors, light
houses, abutments and piers of bridges.
3. Their use is also recommended for building work in hilly areas, where a good
quality of stone is easily and cheaply available.
4. Stone are being commonly used as an aggregate for concrete, as slabs for
paving floors, as flags for paving streets, as ballast in railway tracks and as road
metal.

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GEOLOGICAL CLASSIFICATION OF ROCKS
1. IGNEOUS ROCKS
2. SEDIMENTARY ROCKS
3. METAMORPHIC ROCKS
IGNEOUS ROCKS
• Igneous rocks:- The rocks formed directly by solidification of molten
material, either inside or on the surface of earth are called igneous
rocks. These are primary or first formed rocks.
• The “magma” along with other gases also moves from one place to
another underneath the earth and as soon as it finds a weak portion in
the earth’s crust, it comes out with great pressure in the form of
“Lava”.
• The lava so erupted out solidifies due to atmospheric action, thus they
are known as eruptive rocks when formed over the earth by
solidification of lava due to volcanic eruption such as basalt and trap.
• Examples:- Granite, basalt, trap etc.

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trap

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trap

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SEDIMENTARY ROCKS
Sedimentary rocks:- The rocks formed by the consolidation of

particles of the pre-existing rocks under the effects of the
weathering agencies such as wind, running water, etc. are called
sedimentary rocks. These are secondary rocks.
Examples:- Conglomerate, sand stone, lime stones, etc.

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LIME STONE

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METAMORPHIC ROCKS
Metamorphic rocks: - The rocks formed from the pre-existing

rocks within the earth’s crust under the influence of variation in
temperature and pressure are called metamorphic rocks.
The existing rocks may be igneous, sedimentary or even

metamorphic are having their original structure and composition
totally changed.
Examples: Marble, slate , Gneiss etc.

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Some metamorphic rocks with their parent rocks are given below
S.No FINAL ROCK CHANGES FROM ORIGINAL STRATA
1 Marble lime stone sedimentary rock
2 Slate shale sedimentary rock
3 Quartzite sand stone sedimentary rock
4 Gneiss granite Igneous rock
PHYSICAL CLASSIFICATION OF BUILDING STONE
Un-Stratified :- The rocks which cannot be easily splitted up into layers are
called un stratified rocks. (Igneous Rocks)
Examples: Granite, basalt, trap etc.
Stratified :- The rocks which can be easily splitted up into layers are called
stratified rocks. (Sedimentary Rocks)
Examples: Sand Stone, Lime stone etc.
Foliated rocks:- The rocks which can be splitted up into thin sheets are known
as foliated rocks. (Metamorphic Rocks)
Examples: Marble, Slate, etc.

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ROCK LAYERS
ROCK SHEETS

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CHEMICAL CLASSIFICATION OF BUILDING STONE
Siliceous Rocks: Rocks mainly having Sand or Silicates(SiO2).
Example: Granite, Basalt, Trap, etc...
Argillaceous Rocks: Rocks having Alumina(Al2 O3) or Clay.
Example: Granite, Slate, shale, etc...
Calcareous Rocks: Rocks having Calcium Carbonate(CaCo3) or

Lime.
Example: Limestone, Marble, etc...

PROPERTIES OF A GOOD BUILDING STONE

The following characteristics are considered while making selection of a good
building stone for different engineering works,
1. Appearance:- The stone to be used for face work must have a uniform and
pleasing color. It must be free from cavities, cracks, flaws and patches of
loose and soft material etc.
2. Strength:- A good building stone should have sufficient crushing strength to
withstand the load of superstructure. In general, it should not be less than
1000kg/cm2
3. Hardness, toughness and resistance to abrasion:- the stone to be used in
stairs, pavements, as railway ballast or road metal must be sufficiency hard,
tough and resistant to abrasion i.e. it must be able to resist wear and tear.
4. Durability:- A good building stone must be durable enough to resist the effect
of weathering agencies e.g. rain, wind. Temperature etc. It should have fine
grained, compact and crystalline stature.

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CHARACTERISTICS OF A GOOD BUILDING STONE
5. Texture:- A good building stone should have a close grained and compact
texture.
6. Workability:- The stone to be used for ornamental carvings and

architectural appearance, should be easily and economically dressed.
7. Seasoning:- The stone to be used for an important interior work should be

well seasoned. Presence of moisture (quarry sap) makes the stone soft and
it is liable to an early decay when used in structural work.
8. Porosity:- A good building ne should be less porous it should not absorb

than 5% of water. Any stone absorbing 10% of water should be rejected.
CHARACTERISTICS OF A GOOD BUILDING STONE
9. Resistance to fire:- a good building stone should be able to resist high

temperature. Its mineral constitutes should have equal co-efficient of
expansion.
10. Specific gravity: The stone to be used on heavy engineering works, docks,
harbours, gravity dams etc. must have high specific gravity. In general, it
varies from 2.4 to 2.8.
11. Resistance to electricity:- A good building stone should be non absorbent

like marble and slate so that it can offer good resistance to electricity

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BUILDING STONES PROPERTIES AND USES
GRANITE PROPERTIES
• It is hard, very strong and durable its crushing strength is 1000 to 1400
kg/sq.cm.
• It is grey, green, pink, red and some times black in color.
• It has got high specific gravity (2.63 to 2.65). Its weight is nearly 2640
kg/cu m.
• It is less porous (porosity is less then 1%)
• It is fine grained and can take a good polish.
• It has got a crystalline, uniform and dense texture which makes it more
suitable for ornamental works.
• Its workability is less and it is costly to dress.
• It is not fire proof as it cracks badly under a strong fire.


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GRANITE USES AND AVAILABILITY
• It is used as large building blocks for heave engineering works, such as

piers and abutments of bridges, light houses, harbours etc.
• It fine grained quality is used for decorative monumental facing works

where high polish is desired.
• It is used for constructing steps, sills and columns.
• It is also advantageously used as aggregate in concrete, as ballast in

railway tracks and as road metal.
Availability:- Granite is available at the following localities in India,
Kashmir, Jhansi (U.P), Jabbalpore (M.P), Ajmer (Rajasthan), Bangalore

(Mysore), Gujarat, secundrabad , Madras etc.
BASALT AND TRAP -PROPERTIES
• Their crushing strength is 700 to 850 kg/sq.cm.
• They are hard and tough
• They are greenish grey to dark grey in colour.
• Their specific gravity (2.9 to 2.96) is more than that of granite

their weight is nearly 2900kg/cm3.
• They are less porous, their porosity is less than 0.5%
• They are having compact and non-crystalline texture.
• They are difficult to work

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BASALT AND TRAP USES AND AVAILABILITY
• They are most suitable as road metal, railway ballast and as aggregates in
concrete. They are also used as flag stones for paving streets and for
constructing steps.
• They are used in rubble masonry for building purposes where cheaply and
easily available.
Availability:- They are available at the following localities in India
• western Ghats of India, known as Deccan trap. They are also available at
Rajmahal Hills (Bihar) known as Rajmahal Trap.
• Varieties of basalts Like, Bombay Basalt, Blue basalt, red basalt and
yellow basalt are found and used in Maharasatra, Gujarat etc.
SAND STONE -PROPERTIES
• it's crushing strength is 400 to 650 kg/cm2
• it is white, grey, yellow, light brown, and red in colour.
• its specific gravity is 2.3 to 2.4. its weight is nearly 2350 kg/cu m.
• it is more porous (porosity is 5% to 6%)
• it is fine grained to coarse grained in texture
• its fine grained and compact variety ca be easily carved and coarse grained
is generally hard.
• it is easy to work and little affected up to a temperature of 800c

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SANDSTONE USES AND AVAILABILITY
• its compact and fine grained variety is used in masonry and other works of
architectural appearance.
• The sand stone composed of angular, sharp edged grains is used in heavy
engineering works such as monumental building, dams, docks etc.
Availability:- the sand stone is available at the following localities in India
• sand stone of fine and uniform grains is found in (U.P), Gwalior,

Jabbalpore, Sambalpur, and Raipur (M.P.) , Nagpur (Maharasatra).
MARBLE-PROPERTIES
• its crushing strength is from 500 to 600 kg/cm2
• The usual colour of marble is white, but it is also available in different

shades of colours such as grey, black, red, brown, yellow and combination
of these
• it is compact and crystalline in structure due to which it can take a fine

polish . it is les durable
• it can be easily Dressed.
• its specific gravity is 2.72 and its weight 2720 kg/cum
• its absorption is 1 to 3%

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MARBLE USES AND AVAILABILITY
• it is mainly used for ornamental pieces, table slabs, window sills, floor
finishes, steps etc.
• it is also used for electrical switch boards wall lining and other decorative
purposes
Availability:- Marble is available at the following localities in India.
• white variety is available in Jodhpur and Ajmer (Rajasthan) Jabalpur

(M.P.) Green marble is available at Baroda (Gujarat).
SLATE -PROPERTIES
• its crushing strength varies from 700 to 2100 kg/cm2
• it is hard tough and is least absorptive
• it also offers good abrasive resistance.
• it is a good heat and electrical insulator.
• its water absorption varies from 0.5 to 1%.

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SLATE USES AND AVAILABILITY
• it is a valuable material for roofing and black boards
• Thick slabs of harder variety of slates are used for flooring steps shelves.
• being non absorbent it is also used in baths cisterns and urinal partitions etc.
• it is also used for making electrical switch boards and other such electrical
equipment being a good insulator.
Availability:- slate is available at the following localities in India
• simla, kangra, gurgaon, Gurdaspur, Alwar, Rajasthan, (MP) (Haryana)

(Gujarat)
STONE QUARRYING

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40 mm
20 mm
10 mm

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METHODS OF QUARRYING
WEDGING HEATING
HAND TOOLS BLASTING
QUARRYING
QUARRYING BY HAND TOOLS
• This method suitable for very Soft and stratified rocks.
• Shovels, pick axes, hammers and chisels etc are used of the purpose.
• In this method stones taking from quarry by Digging and excavation.

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QUARRYING BY WEDGING
• This method is suitable for quarrying stratified rocks.

• The operation is started near a vertical face in the absence of
which one is created by cutting a channel in it.
• Then make 10 cm to 15 cm deep holes about 30 cm apart are
bored or drilled along the boundary of the slab to be quarried.
• Steel hammers called sledge, hammers simultaneously in all
the holes in a row.
• Use of steel feathers with plugs is to be preferred. It will split
the slab along the line of holes drilled.

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Wedge
Feather

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QUARRYING BY HEATING
• This method is suitable where only smaller blocks of more or

less regular shape are required and suitable rocks bedded
horizontal layers of not much thickness are to be quarried.
• It consists in piling a heap of fuel on a small area of the

exposed face of rock and burning a steady fire for some hours. It
results in uneven expansion because of unequal heating of the
two layers and consequent separation of the upper and lower
layers.
QUARRYING BY BLASTING
• It is quarrying stones with explosives. It is dangerous and

difficult process.
• Blasting may some times have to be done to excavate

foundations for buildings road structures in rock works and for
tunnelling.
• The operation for blasting constitutes the boring or drilling of

holes, charging them with some suitable explosive and then firing.
• Charge with various implements used in quarrying are the

jumper or boring bar, scraping spoon, priming needle and the
tamping bar.

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PROCESS OF BLASTING
DRILLING OF HOLES
CHARGING OF HOLES
TAMPING OF HOLES WITH CLAY
FIRING

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TOOLS FOR CHARGING
QUARRYING BY BLASTING
The diameter and the depth of each hole depends upon the quantity
and nature of rock to be loosened, the type and the quantity of
explosive used.
S.No Depth of Hole Diameter of Hole
1 1 to 2 m 2.5 cm
2 2 to 3.5 m 4.0 cm
3 3.5 to 5 m 6 to 7.5 cm

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PRECAUTIONS IN BLASTING
1. Avoid the human movement around the blasting area up to 100m.
2. The holes are charged with the right quality of explosive to be used.
3. The hole is filled in layers with burnt clay powder or sand.
4. Each layer is well tamped with a brass tamping rod.
5. Temping should be done extremely well sufficient length of the fuse is

left out side the hole for safety before the explosion take place.
5. Never redrilled the misfire blast hole.
6. No attempt should be made to find out the cause of misfire.
7. Second hole drilled 1m about away from the misfire hole.
DRESSING OF STONES

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DRESSING OF STONES
• Dressing of stones is a process in which their surfaces are

prepared to a form or fit to be used for any constructional
purpose.
• Dressing is according to the type of work and demand.
Purpose of Dressing:
• To give them good looking.
• To provide horizontal and vertical joints in the masonry.
• To make them fit, to be used for particular purpose.
TYPES OF DRESSING
DRESSING
ROUGH DRESSING FAIR DRESSING

(DRESSING AT QUARRY SITE) (DRESSING AT BUILDING SITE)

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TYPES OF DRESSING
The different types of dressing of stones are,

1. Hammer Dressed or Quarry-faced Surface
2. Rough tooled surface
3. Tooled Surface
4. Cut stone Surface
5. Rubbed Surface
6. Polished Surface
ROUGH DRESSING
1. Hammer Dressed or Quarry-faced Surface:
This is the roughest form of surface finish. Stone as removed from
the quarry has large projections which are knocked off with the
quarry hammer and it is finally broken up into blocks of suitable
sizes and shapes.
2. Rough tooled surface:

In this type the projection of the stone block are removed by means
of chisels and the surface is nearly dressed to ensure proper
bonding.
3. Tooled Surface:
In this type of surface finish continuous parallel chisel marks are
produced throughout the width of the stone.

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Hammer Dressed Surface
Rough tooled surface
Tooled Surface
FAIR DRESSING
4. Cut stone Surface:

In this type surface is dressed by using a sharp chisel so that the
chisel marks are practically invisible.
5. Rubbed Surface:
This type of surface finish is obtained by grinding or rubbing on
cut stone surface by hand or machine until it gets perfectly smooth.
6. Polished Surface:
The rubbed surfaces of granite, marble of lime stones are polished
to enhance their texture. Polishing may be done by manual labour
using sand and water, pumice stone etc. or by rubbing with
machines.

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Cut stone Surface
Rubbed Surface
Polished Surface

(Contact Hours: 10)





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INTRODUCTION OF BRICKS
BRICKS
• Brick is the most important Building material
• it is an clay product
• Bricks are cheap, durable and more workability materials.
• These are available generally rectangular in shape
• Specific gravity of clay bricks ranges from 1.6 to 2.5
• Generally its weight is nearly 100 kg/Cu.cm
• Size as per standards, (19 X 9 X 9 cm)
• Market available size (21.5 X 10.25 X 6.5 cm)

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TYPES OF BRICK
1. Red clay burnt bricks
2. Fly ash bricks
3. Concrete bricks
DIMENSIONS OF BRICK

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PARTS OR FACES OF BRICK
CHARACTERISTICS OF GOOD CLAY BRICKS
1. Good size and shape.
2. Good color like Red, cherry or copper.
3. Good texture and free from cracks and flaws.
4. It should hard and durable.
5. Water absorption should not exceed 20% on its weight.
6. Strength should not less than 10 N/Sq.mm
7. Brick earth should free from salts and organic matters.

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CLASSIFICATION OF RED CLAY BRICKS
FIRST CLASS
SECOND CLASS
THIRD CLASS
FOURTH CLASS
First Class Bricks:

• They are red, cherry and copper in color.
• Free from cracks and flaws.
• Good shape and size.
• It should give good metallic or ringing sound.
• Water absorption in between 12 to 15%.
• Crushing strength should not be less then 10 N/Sq.mm
Second Class Bricks:
• Small cracks and flaws are allowed.
• Water absorption in between 16 to 20%.
• Crushing strength should not be less then 7 N/Sq.mm.
• used for hidden masonry.

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Third Class Bricks:

• Under burnt bricks.
• Water absorption in about 25%.
• used for temporary structures.
Fourth Class Bricks:

• Over burnt bricks.
• Irregular shape and size
• Water absorption is more than 25%.
• used for temporary structures.
MANUFACTURING OF CLAY BRICK

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MANUFACTURING OF BRICK
PRIPARATION OF BRICK EARTH
MOULDING
DRYING
BURNING
COLLECTION OF BRICKS
1. PRIPARATION OF BRICK EARTH

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INGREDIANTS OF GOOD BRICK EARTH
Brick earth contains the following ingredients
Silica (sand) – 50% to 60% by weight
Alumina (clay) – 20% to 30% by weight
Lime – 2 to 5% by weight
Iron oxide – ≤ 7% by weight
Magnesia – less than 1% by weight
SILICA :
Retain its shape, durability, and avoid shrinkage.
ALUMINA:
Absorb the water and remains it’s plasticity.
LIME:
Reduces the shrinkage on drying process, bonding.
IRON OXIDE:
Improves impermeability, strength, hardness and durability.
MAGNESIA: For color

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HARMFUL INGREDIANTS OF BRICK EARTH
Excess Lime:
Changes its color red to yellow, develop cracks at burning.
Pebbles and Gravel:

Create voids and rough surface.
Alkaline salts (Soda and Potash):

Absorb the excess water.
Organic matters:
Develops voids in bricks at burning process.
Excess water: Increase shrinkage.

PRIPARATION OF BRICK EARTH
UNSOILING
EXCAVATING
WEATHERING
BLENDING
TEMPERING

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Un soiling :
Remove 20cm of top layer of the earth.
Excavating:
Taking the soil sample before rains.
Weathering:
Heaped the soil on ground in layers of 60 – 120 cm up to
one month exposed to weather.
Blending:
Additional adding of missing ingredients.
Tempering:
Prepare the perfect plastic paste by manual or with
machines like PUG MILL.
PUG - MILL

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2. MOULDING
1. Hand Moulding
2. Table Moulding
3. Machine Moulding
MOULDS FOR CLAY BRICKS

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3. DRYING OF BRICKS
• Drying is a process to remove the moisture in fresh brick to

control shrinkage.
• Fresh brick contains about 7 to 30% moisture depending

upon the method of manufacturing.
• This process is done by stacking of fresh bricks by rows with

uniform intervals. (Air or natural drying).
• This process is also done by artificially by increase of

temperature up to 1100C to a period of 24 hrs
Artificial Drying
Air or Natural Drying

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4. BURNING OF BRICK
STAGES OF BURNING PROCESS

Bricks are burned at high temperature to gain the strength,
durability, and colour.
DEHYDRATION (400 – 6500 C)
OXIDATION (650 – 9000 C)
VITRIFICATION (900 – 11000 C)

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STAGES OF BURNING PROCESS
DEHYDRATION (400 – 6500 C)

Evaporation of balance water retained in the clay pores
OXIDATION (650 – 9000 C)

Remainder of carbon is eliminated.
VITRIFICATION (900 – 11000 C)

Convert the mass into glass state (cannot scratch with nail).
TYPES OF BURNING PROCESS
1. CLAMP BURNING
2. KILN BURNING
INTERMITTENT KILN
CONTINUOUS KILN

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CLAMP BURNING
INTERMITTENT KILN BURNING

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CONTINUOUS KILN BURNING
Hoffman’s Kiln Bull’s Trench Kiln

CLAMP (Vs) KILN
CLAMP BURNING KILN BURNING

` `
TEMPORARY STRUCTURE PERMANENT
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SINGLE TIME PROCESS CONTINUOUS
`
LOW PRODUCTION HIGH

`
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NORMAL QUALITY GOOD

`
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(Contact Hours: 10)




INTRODUCTION
to
LIME

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LIME
1. Lime is a binding (cementing) material in the construction for both mortar
and plaster.
2. Lime is obtained from lime stone (Caco3) by calcination process.
3. Limestone is a sedimentary rock, composed largely of the minerals calcite.
4. Good Limestone should not have the following impurities like Clay,
Silica, Magnesium and Iron compounds.
5. Classification of lime as under,
1) Poor lime, 2) Pure, Rich (or) Fat lime, 3) Hydraulic lime
IMPURITIES OF LIME
1. Clay: It is responsible for hydraulic property, means make lime insoluble in water.
2. Silica : (Sand), it effects cementing property.
3. Magnesium: It is responsible for slow setting.
4. Iron oxides: At high temperatures Iron (Fe) produces silicates
5. Good lime also should not have any sulphates and alkalis should causes its
final strength.

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CLASSIFICATION OF LIME
1. Poor lime: Calcium (Between 80 to 85 %) + Balance Having silica & iron.
2. Hydraulic lime: Calcium (Between 80 to 85 %) + Free from impurities.
3. Pure, Rich (or) Fat lime: (more than 85%) + Free from impurities.
LIME CYCLE

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LIME CYCLE
(Calcination)
Lime Stone (CaCo3) + 42.52 Kcal CaO + CO2

(Heat applied up to 8000C to 10000C) {CaO : Quick lime (Calcium Oxide)}
(Hydration)
Quick Lime(CaO) + H2O Ca(OH)2 + 15.6 Kcal
{Ca(OH)2 : Slack lime (Calcium Hydroxide)}
(Carbonation)
Slack Lime{Ca(OH)2 }+ CO2 CaCo3 + H2O
{CaCo3 : Carbonate Lime(Calcium Carbonate)}
LIME CYCLE
• CALCINATION
Burning of Lime stone (CaCo3) to get quick lime (CaO)
• HYDRATION
Adding of water to quicklime (CaO) to get slack lime (Ca(OH)2)
• CARBONATION
Slack lime (Ca(OH)2) react with CO2 and again convert to (CaCo3)

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CEMENT
CEMENT
1. Cement is replacement material for Lime as construction material.
2. Cement is a binder material and also having properties like adhesive and
cohesive.
3. Ordinary cement which we commonly known as Portland cement.
4. Portland is a place in U.K, initially the stone quarried from same place for
cement manufacturing by Joseph Aspdin in 1824.
5. In other words cement is a Mixture of calcareous, argillaceous, siliceous
and other Substance like magnesium, iron and sulphur oxides.
6. It is used as a Binding material in mortar and Concrete for construction.


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GLOBAL PRODUCTION PER YEAR
CHEMICAL COMPOSITION OF CEMENT
CONSTITUENT PERCENTAGE
Lime - Calcium oxide(CaO) 60 - 65%
Silica - Silicon oxide (SiO2) 15 - 25%
Alumina - Aluminum Oxide (Al2O3) 5 - 8%
Iron Oxide-Ferrous Oxide (Fe2O3) 1 – 6%
Magnesia – Magnesium Oxide (MgO) 1 - 4%
Sulphur oxide(SO3) 1 – 2%
Alkalis, Soda + Potash (Na2O+K2O) 0.2 – 1%

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MANUFACTURING OF CEMENT
MAIN STAGES
MIXING
BURNING
GRINDING
PACKING

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MACHINERY REQUIRED FOR CEMENT PRODUCTION
RAW MATERIAL MIXING – Ball Mill
BURNING – Rotary Kilns
GRINDING – Tube or Ring Mill
RAW MATERIALS IN CEMENT MANUFACTURING

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MIXING PROCESS WITH BALL MILL
STRUCTURE OF BALL MILL

1. Diameter of Ball mill ranges from 1.5 to 2.0 m
2. Length of mill 5.0 to 15 m and it rotates min 10 runs per minute.
3. Using Iron balls for homogeneous mixing of raw material.
4. Mixing process done by 2 types, 1. Dry process, 2. Wet process

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BURNING PROCESS WITH ROTARY KILN
STRUCTURE OF ROTARY KILN
1. Diameter of Rotary kiln ranges from 2.0 to 3.5 m
2. Length of kiln ranges from 30 to 110 m
3. It should be at an inclination between (1 in 15) to (1 in 30).
4. It rotates min 1 runs per minute.
5. Heat is applying from its lower end and removed from higher end.

BMC 1/27/2022
BURNING PROCESS WITH ROTARY KILN
ZONES IN BURNING PROCESS
DRYING ZONE – 5000C
CALCINATION ZONE – 10000C
CLINCKERING ZONE – 14000C

BMC 1/27/2022
KILN REACTIONS
COMPOSITION IN CEMENT CLINCKER
BOGUE COMPOSITIONS (OR) COMPOUNDS
Name of Compound Formula Abbreviated Formula
Tricalcium silicate 3 CaO.SiO2 C3S (Alite)
Dicalcium silicate 2 CaO.SiO2 C2S (Belite)
Tricalcium aluminate 3 CaO.Al2O3 C3A
Tetracalcium aluminoferrite 4 CaO.Al2O3.Fe2O3 C4AF

BMC 1/27/2022
GRINDING PROCESS WITH TUBE MILL
GRINDING AND PACKING

BMC 1/27/2022
TYPES OF CEMENT
1.Ordinary Portland Cement
2.Rapid Hardening Cement
3.Sulphate Resisting Cement
4.Portland Slag Cement
5.Portland Pozzolana Cement
6.Quick Setting Cement
7.Low Heat Cement
PROPERTIES OF VARIOUS TYPES OF CEMENT
RAPID HARDENING CEMENT :
This cement contains more percentage of C3S and less percentage of C2S.
This is to get high early strength cement.
It is due to finer grinding and increased lime content.
The strength obtained by this in 04 days is same as obtained by O.P.C in 28 days.
This cement is used in road repairs which are to be opened for traffic quickly.
This is also suitable for use in cold weather areas.

BMC 1/27/2022

SULPHATE RESISTING CEMENT :
It is modified form of O.P.C and is specially manufactured to resist the sulphates.
It has a lower percentage of Tricalcium aluminate.
`In certain regions/areas where water and soil may have alkaline contents.
PORTLAND POZZOLANA / SLAG CEMENT :
The cement is Produced by Inter grinding Portland Cement Clinker with Pozzolana.
It gains Strength very slowly and therefore requires curing for a long period.
It’s replacement Proportion with cement varies from 15 to 50%

QUICK SETTING CEMENT :
When concrete is to be laid under water, quick setting cement is to used.
This cement is manufactured by adding small % of aluminium sulphate (Al2SO4)
which accelerates the setting action.
LOW HEAT CEMENT :
In this the heat of hydration is reduced by tri calcium aluminate (C3A) and increasing
the proportion of C2S .
It contains less percentage of lime than OPC.
It is used for mass concrete works such as dams or massive concrete structures etc.

BMC 1/27/2022
FIELD TESTS FOR CEMENT
FIELD TESTS FOR CEMENT

(a) The color of the cement should be grey color with a light greenish shade.
(b) The cement should feel smooth when touched or rubbed in between
fingers.
(c) The cement should be free from any hard lumps. Such lumps are formed by
the absorption of moisture from the atmosphere. Any bag of cement
containing such lumps should be rejected.
(d) If hand is inserted in a bag of cement or heap of cement, it should feel cool
and not warm.
(e) If a small quantity of cement is thrown in a bucket of water, the particles
should float for some time before it sink.
(f) A thick paste of cement with water is made on a piece of glass plate and it is
kept under water for 24 hours. It should set and not crack.

BMC 1/27/2022
LABORATORY TESTS ON CEMENT
1. Fineness (by IS sieve method)
2. Specific gravity
3. Normal Consistency
4. Initial and Final setting time
5. Soundness
6. Compressive strength
MORTAR

BMC 1/27/2022
MORTAR
1. Mortar is a construction material produced with cement or lime and
fine aggregate also with sufficient amount of water.
2. In other words, Mortar is a bonding agent which is generally
produced by mixing cementing or binding material (lime or cement)
and fine aggregate (sand, surki, sawdust, etc.) with water.
3. Mortar is used to bind different building blocks like bricks, stones,
etc. and cover the surfaces like wall and concrete members by
plastering technique.
MORTAR APPLICATION AREAS
MORTAR
MASONRY WORKS PLASTERING WPRKS

BMC 1/27/2022
DIFFERENT MORTAR MIXES FOR MASONRY
S.NO TYPE OF STRUCTURE Width of Joint MIX
1 Rough Stone Masonry 15 to 25 mm (1:8)
2 Ashlars Stone Masonry 15 to 20 mm (1:6)
3 Brick Masonry (Full) 10mm (1:5)
4 Brick Masonry (Half Brick) 10 mm (1:4)
5 Big Blocks Masonry 05 to 08 mm (1:3)
DIFFERENT MORTAR MIXES FOR PLASTERING
S.NO TYPE OF STRUCTURE LAYERS REQUIRED THK and MIX
15mm with CM(1:8)

1 Rough Stone Masonry 3 – Layers (28mm) 08mm with CM (1:6)
05mm with CM (1:4)
15mm with CM (1:6)
2 Ashlars Stone Masonry 2 – Layers (25mm)
10mm with CM (1:4)
2 – Layers 12mm with CM (1:6)
3 Brick Masonry
(20mm for Outside) 08mm with CM (1:4)
1 – Layers
4 Brick Masonry 12mm with CM (1:6)
(12mm for In-side)
5 Big Blocks Masonry 1 – Layer (8mm) 08mm with CM (1:4)
6 Concrete members 1 – Layer (6mm) 06mm with CM (1:3)

BMC 1/27/2022
PROPERTIES OF GOOD MORTAR

1. The main quality that mortar should possess is adhesion. Good mortar should provide
good adhesion to building units (bricks, Stones etc.).
2. Mortar should be water resistant. It should have the capability of resisting the
penetration of water.
3. Deformability of mortar should be low.
4. Mortar should be cheap.
5. Mortar should be easily workable in the site condition.
6. The mobility of mortar should be good. It helps the mortar to be paved thinly and
evenly.
7. It should possess high durability.
8. To improve the speed of construction, good mortar should set quickly.


(Contact Hours: 10)





BMC 1/27/2022
FRESH CONCRETE
ORDINARY CONCRETE
 Concrete is the most widely used construction

material.
 It has flexibility and mould-ability and High

compressive strength.
 It is a homogeneous mix made with cement,

fine aggregate, coarse aggregate & water.

3

BMC 1/27/2022
REQUIREMENTS OF CONCRETE INGRADIENTS
1. Cement : OPC 33, 43, and 53 Grade, PPC and PSC
2. Fine Aggregate : Particle size less than 4.75mm (Zone-II)
3. Coarse aggregate : Generally Avg. size should be 20mm
(Igneous rock : Granite)
4. Water : Potable water (pH should be 7)
FINE AGGREGATE

BMC 1/27/2022
FINE AGGREGATE (SAND)
1. If particle size having less than 4.75mm, then it is called as F.A
2. Generally we called sand as F.A, it is available at river beds.
3. It is naturally available material.
4. It is a main ingredient in concrete.
5. The composition of sand depending on the available local rock conditions.
6. Generally sand having it’s main ingredient as silica in the form of quartz.
7. It is classified according to it’s particle size as per IS:383 into Zone - I to IV.
ZONES ACCORDING TO IS:383
1. ZONE – I : Coarser Fine Aggregate - Big Structures
2. ZONE – II : Moderate Coarser Fine Aggregate - Concrete Works
3. ZONE – III : Fine - Fine Aggregate - Walls and Plaster
4. ZONE – IV : Very Fine - Fine Aggregate - Temporary structures

BMC 1/27/2022
ZONES DEVIDED BY HELP OF FINENESS MODULUS
Recommendations as per IS:383
Fine sand : Fineness Modulus: 2.2 to 2.6
Medium sand : Fineness Modulus: 2.6 to 2.9
Coarse sand : Fineness Modulus: 2.9 to 3.2
Fineness modulus of fine aggregate =
IS SIEVES REQUIRES FOR FINENESS MODULES
4.75 mm
2.36 mm
1.18 mm
600 Microns
300 Microns
150 Microns
PAN

BMC 1/27/2022
GRADING ZONES OF F.A.
GRADING CURVE FOR F.A. ZONES

BMC 1/27/2022
BULKING OF SAND
BULKING OF FINE AGGREGATE

1. Moist sand occupies larger volume if it is loosely filled than dry sand.
2. Due to moisture, thin-film of water forms around sand grain which results
in increase of volume.
3. This effect of increase in volume (if loosely filled in) due to moisture
content is called “Bulking of sand”. The bulking of sand is largely depends
on grain size – Small the grain size, larger will be bulking effect and vice
versa.
4. Moisture content 5 to 8 % moisture can result in 20-35 % increase in
volume.
5. Bulking increases with increase in moisture content up to a certain limit and
beyond that the further increase in moisture content results in decrease in
volume.

BMC 1/27/2022
STATES OF MOISTURE ABSORTION
BULKING OF FINE AGGREGATE

BMC 1/27/2022
COARSE AGGREGATE
COARSE AGGREGATE
1. If particle size having more than 4.75mm, then it is called as C.A
2. It is obtained from stone crushers by crushing of stones.
3. It is naturally available material.
4. It is the main ingredient in concrete.
5. Generally C.A available in various sizes 20mm, 30mm and 40mm.
6. Maximum particle size of C.A is 80 mm.
7. Generally C.A having it’s main ingredient as Alumina.

BMC 1/27/2022
SIZES OF C.A & F.A FOR VARIOUS WORKS
S.NO TYPE OF WORK C.A F.A
1 Non Reinforced Works 40 to 75 mm Z-I
2 For foundations and Pavements 25 to 40 mm Z-I
3 Reinforced Concrete Structures 20 mm Z-II
4 Thin R.C.C structural Members 10 mm Z-II
PROPERTIES OF C.A vs F.A
S.NO TYPE OF WORK F.A C.A
Close grained and Close grained and

1 SHAPE AND TEXTURE
compact compact
2 STRENGTH 1100 kg/cm2 1700 kg/cm2
3 SPECIFIC GRAVITY 1.9 to 2.1 2.4 to 2.9
4 DENSITY 1400 kg/m3 1900 kg/m3
5 POROSITY LESS THAN 5% LESS THAN 5%
6 MOISTURE CONTENT 2 TO 3% 2 TO 3%

BMC 1/27/2022
LABORATORY TESTS FOR F.A
S.NO AIM OF TEST NAME OF THE TEST
1 Particle size and type (Zone) of sand IS : Sieve analysis test
2 SPECIFIC GRAVITY & DENSITY PYCNOMETER TEST
3 Optimum Moisture content for bulking Bulking of sand test
LABORATORY TESTS FOR C.A
S.NO AIM OF TEST NAME OF THE TEST
1 Particle size of Coarse aggregate IS : Sieve gradation test
2 SPECIFIC GRAVITY & DENSITY IS : Wire basket test
3 ABRASION VALUE OF C.A Los angels abrasion test
4 ATTRITION VALUE OF C.A Deval attrition test
5 Particle Shape of Coarse aggregate Flakiness index test
6 Particle Shape of Coarse aggregate Elongated index test

BMC 1/27/2022
PHYSICAL & MECHANICAL PROPERTIES OF C.A. & F.A.
AGGREGATES
Coarse Aggregates Fine Aggregates
Specific Gravity & Water Absorption Specific Gravity & Water Absorption
Bulk Density & Porosity Bulk Density & Porosity
Toughness & Hardness Bulking of Sand
Shape, Texture and Strength
MANUFACTURE OF CONCRETE
WEIGHT BATCHING VOLUME
MANUAL MIXING MECHANICAL
TRANSPORTING PLACING POSITIONING
COMPACTING CURING

BMC 1/27/2022
EQUIPMENTS REQUIRED FOR CONCRETING
1. BATCHING: It is the process of measuring concrete mix

ingredients either by volume or by mass and introducing them
into the mixture.
 Measuring buckets, Trolleys are generally used for batching
2. MIXING: It is a technique to mix the all required ingredients
of concrete uniformly to get homogeneous concrete matrix.
 Concrete mixers are generally used for mixing process.
CONCRETE BATCHING
 Batching is the process of measuring concrete mix ingredients
either by volume or by mass and introducing them into the
mixture.
 Traditionally batching is done by volume but most specifications

require that batching be done by mass rather than volume.
 Basically the equipment that is used for Batching are Measuring

buckets, Trolleys.
 Proper batching improves the workability of concrete by reducing

segregation in concrete and also helps to get a smooth surface of
the concrete.

BMC 1/27/2022
CONCRETE BATCHING
 The equipment falls into three categories in both batching process
as follows:
1. Manual batching
2. Semi-automatic batching
3. Fully-automatic batching
 VOLUME BATCHING: GAUGE BOX or MEASURING BOX
• In volume batching, materials are measured on the basis of

volume. It is less precise method of batching.
• Measurement boxes or gauge boxes of known volume are used to

measure materials.
CONCRETE BATCHING
 WEIGHT BATCHING:
• In this method, Materials are measured on the basis of weight. It is

accurate method of batching.
• Weigh batchers or other types of weighing equipment are used to

measure weight of materials.
SEMI-AUTOMATIC WEIGH BATCHER FULLY-AUTOMATIC WEIGH BATCHER

BMC 1/27/2022
CONCRETE MIXING
 It is the technique to mix the all required ingredients of concrete
uniformly to get homogenous concrete mix.
 Depending up on the requirement, quality, quantity, etc the

method of mixing is decided.
 Generally concrete mixers are used for these concrete mixing

purposes.
 Generally there are two methods for mixing the concrete,
1. Manual Mixing
2. Mechanical Mixing
CONCRETE MIXING
 MANUAL MIXING:
• In this type, the mixing is done by manual labors.
• This method is adopted for small construction works.
• Requirement of cement is more than machine mixing(Nearly 10%)
• Normally the mixing time is 3-4 Minutes.

BMC 1/27/2022
CONCRETE MECHANICAL MIXERS
 A concrete mixer is a device that homogeneously

combines cement, aggregates such as sand and granite,
and water to form fresh or green concrete.
 A typical concrete mixer uses a revolving drum to mix

the components.
 The concrete mixer was invented by Columbus

industrialist Gebhardt Jaeger.
TYPES OF CONCRETE MIXERS
1. PAN MIXER

BMC 1/27/2022
TYPES OF CONCRETE MIXERS

2. DRUM MIXER
CONCRETE PLACING
 Concrete placing is a process to deposit the required quantity of
concrete to its required position and respect purpose.
 Following points to be considered at the time of placing,
1. Select suitable tools and equipments to dump
2. Check the formwork in all respects
3. Avoid segregation possibilities
4. Complete the final position with in 30 minutes.
5. Maintain layers up to 300 to 600mm for deep sections.

BMC 1/27/2022
CONCRETE PLACING
PLACING
BY BY
(TOOLS and MAN POWER) MACHINERY
CONCRETE PLACING WITH MACHINERY
 Concrete placing with machinery by two ways,
1. Placing with pumps
It is best suitable for Under ground and high-rise

constructions
2. Placing with Tremie pipes
It is best suitable for Under water and pile foundations

BMC 1/27/2022
CONCRETE COMPACTION
 Compaction is a process of expelling the entrapped air.
 Concrete compaction is a technique to get massive concrete

without any internal voids.
 Because, 1% air in the concrete approximately reduces the

compressive strength by 6% approx.
 There are two methods of compaction adopted in the field as

given below.
1. Hand compaction – Rodding and Ramming
2. Mechanical Compaction – Internal and External

VIBRATE NEEDLES FOR CONCRETE INTERNAL COMPACTION

BMC 1/27/2022
PAN (or) FLAT VIBRATORS
CONCRETE FINISHING
 Concrete finishing is a technique to get smooth or levelled
compacted surface for better usage and good appearance.

BMC 1/27/2022
CONCRETE WORKABILITY
CONCRETE WORKABILITY
 Concrete is said to be workable when it is easily placed and
compacted homogeneously i.e. without bleeding or
Segregation.
 Unworkable concrete needs more work or effort to be

compacted in place, also honeycombs may also be visible in
finished concrete.
 Workability is one of the physical parameters of concrete

which affects the strength and durability as well as the cost
of labor and appearance of the finished product.

BMC 1/27/2022
FACTORS AFFECTING WORKABILITY
 Water content in the concrete mix
 Amount of cement & its Properties
 Aggregate Grading (Size Distribution)
 Nature of Aggregate Particles (Shape, Porosity etc.)
 Temperature of the concrete mix
 Mode of compaction
 Method of placement of concrete
 Method of transmission of concrete
CONCRETE SEGREGATION
 Segregation is when the coarse and fine aggregate, and cement
paste, become separated.
 Segregation may happen when the concrete is mixed,

transported, placed or compacted i.e. due to high W/C ratio and
poring from big heights.
 Segregation makes the concrete

• Weaker,
• Less durable,
• And will leave a poor surface finish

BMC 1/27/2022
CONCRETE SEGREGATION
HOW TO AVOID SEGREGATION

 Check the concrete is not 'too wet' or 'too dry’ and make sure the concrete
is properly mixed.
 It is important that the concrete is mixed at the correct speed in a transit

mixer for at least two minutes immediately prior to discharge.
 The concrete should be placed as soon as possible and never let the concrete
fall more than one-and-a-half meters.

BMC 1/27/2022
CONCRETE BLEEDING
 The appearance of water along with cement particles on the
surface of the freshly laid concrete.
 This happens when there is excessive quantity of water in the
mix or due to excessive compaction.
 Bleeding causes the formation of pores and renders the
concrete weak.
CONCRETE BLEEDING

BMC 1/27/2022
TESTS ON CONCRETE
TESTS ON FRESH CONCRETE
Workability of Fresh Concrete By Slump Test
Workability of Fresh Concrete By Compacting Factor Test
Workability of Fresh Concrete By VEE-BEE Consistometer Test
TESTS ON HARDENED CONCRETE
Compressive strength of Concrete
Split Tensile strength of Concrete
Modulus of Elasticity of Concrete
Flexural strength of Concrete

(Contact Hours: 10)





BMC 1/27/2022
HOLLOW CONCRETE BLOCKS
HOLLOW CONCRETE BLOCKS
 Concrete Masonry Units or CMU are known as hollow concrete

blocks or concrete bricks.
 Concrete blocks are composed of Portland cement and
aggregate.
 The high-density blocks may use sand while low density blocks
use industrial waste instead of aggregate.
 The hollow concrete blocks are manufactured , hardened and
cured before reaching the site and is a very durable and strong
material .

BMC 1/27/2022
CHARACTERISTICS AND ADVANTAGES OF CMU

 They have a uniform size and have two hollow cores made it very light in
weight.
 The cores comprise of air pockets, which make it a very good for heat
insulation.
 They are very good for acoustics and sound insulation.
 They are economical and cost effective.
 It has a rough texture which allows good bonding between the concrete
blocks and the mortar.
 Good resistance against external weather conditions.
 It is an ecofriendly material as fly ash can also be used to manufacture these
blocks.
 Cement Masonry Units are fire resistant.
FAL- G BLOCKS

BMC 1/27/2022
FAL - G BLOCKS
 Fal-G bricks also known as fly ash bricks (FAB)
 Fal-G contains Fly ash + Lime + Gypsum
 Fly ash brick (FAB) is a building material, specifically masonry
units, containing class C or class F fly ash.
 Fly ash brick activity has been revolutionized in India on 1991.
 FaL-G technology developed and patented by Dr
Bhanumathidas and Kalidas in the same year 1991.
RAW MATERIALS FOR FLY ASH BRICKS
MATERIAL MASS
Fly ash 60%
Sand/Stone dust 30%
OPC/(Lime + Gypsum) 10%
Total formula of material 100%
The strength of fly ash brick manufactured with the above compositions is
normally of the order of 7.5 N/mm2 to 10 N/mm2. Fly ash bricks are lighter and
stronger than clay bricks.

BMC 1/27/2022
CHARACTERISTICS AND ADVANTAGES OF FAB
 It reduces dead load on structures due to light weight.

 High fire Insulation.
 Due to high strength, practically no breakage during transport
and use.
 Due to uniform size of bricks mortar required for joints are less
and plaster reduces almost by 50%.
 Due to lower water penetration, seepage of water through bricks
is considerably reduced.
 These bricks do not require soaking in water for 24 hours.
Sprinkling of water before use is enough.

Unit 01 - Phase 02

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BMC 1/27/2022

UNIT – II: Masonry Products & Concrete

Bricks – classification, manufacturing, characteristics, durability aspects, tests,

Limes – Cementing action, manufacturing, slaking, storage, properties, classification,

Mortars – Classification, preparation, strength, tests, applications etc.

Concrete – Constituent materials, properties, characteristics, tests, production,

Dr. P. SUDHEER (Asst.Professor)

2. Building stones are obtained from quarry by disintegration (Break down)

5. The Secretariat, Assembly Buildings and Rashtrapati Bhawan in New Delhi

Dr. P. Sudheer (Asst.Prof) 1

RASHTRAPATI BHAWAN IN NEW DELHI

Dr. P. Sudheer (Asst.Prof) 3

TAJ MAHAL AT AGRA

Dr. P. Sudheer (Asst.Prof) 4

Dr. P. Sudheer (Asst.Prof) 2

VICTORIA MEMORIAL IN CALCUTTA

Dr. P. Sudheer (Asst.Prof) 5

1. The stone which is used for the construction of engineering structures is

known as building stone.

3. Therefore, we have to dressed irregular to regular in shape and size for

4. Stone possesses long lasting properties and is naturally available in large

quantity, it is therefore, considered as one of the most and popular important

engineering material of construction.

Dr. P. Sudheer (Asst.Prof) 6

Dr. P. Sudheer (Asst.Prof) 3

Dr. P. Sudheer (Asst.Prof) 8

Dr. P. Sudheer (Asst.Prof) 4

GEOLOGICAL CLASSIFICATION OF ROCKS

Dr. P. Sudheer (Asst.Prof) 9

Dr. P. Sudheer (Asst.Prof) 5

Dr. P. Sudheer (Asst.Prof) 11

Dr. P. Sudheer (Asst.Prof) 12

Dr. P. Sudheer (Asst.Prof) 6

Dr. P. Sudheer (Asst.Prof) 13

Dr. P. Sudheer (Asst.Prof) 7

Sedimentary rocks:- The rocks formed by the consolidation of

Examples:- Conglomerate, sand stone, lime stones, etc.

Dr. P. Sudheer (Asst.Prof) 15

Dr. P. Sudheer (Asst.Prof) 16

Dr. P. Sudheer (Asst.Prof) 8

Dr. P. Sudheer (Asst.Prof) 17

Dr. P. Sudheer (Asst.Prof) 18

Dr. P. Sudheer (Asst.Prof) 9

Dr. P. Sudheer (Asst.Prof) 19

Dr. P. Sudheer (Asst.Prof) 20

Dr. P. Sudheer (Asst.Prof) 10

Metamorphic rocks: - The rocks formed from the pre-existing

The existing rocks may be igneous, sedimentary or even

Examples: Marble, slate , Gneiss etc.

Dr. P. Sudheer (Asst.Prof) 21

Dr. P. Sudheer (Asst.Prof) 22

Dr. P. Sudheer (Asst.Prof) 11

Dr. P. Sudheer (Asst.Prof) 23

Dr. P. Sudheer (Asst.Prof) 24

Dr. P. Sudheer (Asst.Prof) 12

Dr. P. Sudheer (Asst.Prof) 25

Dr. P. Sudheer (Asst.Prof) 26

Dr. P. Sudheer (Asst.Prof) 13

S.No FINAL ROCK CHANGES FROM ORIGINAL STRATA

1 Marble lime stone sedimentary rock

2 Slate shale sedimentary rock

3 Quartzite sand stone sedimentary rock