AR 8521 - BUILDING MATERIALS AND CONSTRUCTION 4

UNIT 1
INTRODUCTION TO CEMENT AND CONCRETE
( ANNA UNIV – REG . 2017 )

COMPILED BY AR.MOHAMED UVAIZ

INTRODUCTION
 TYPES OF CEMENT:
1. Ordinary Portland Cement
2. Rapid Hardening Cement (or) High Early Strength cement
3. Extra Rapid Hardening Cement
4. Sulphate Resisting Cement
5. Quick Setting Cement
6. Low Heat Cement
7. Portland Pozzolana Cement
8. Portland Slag Cement
9. High Alumina Cement
10. Air Entraining Cement
11. Super sulphated Cement
12. Masonry Cement
13. Expansive Cement
14. Coloured Cement
15. White Cement
 1.ORDINARY PORTLAND CEMENT:
• It is called Portland cement because on hardening (setting) its colour resembles to rocks
near Portland in England. It was

• Introduced in 1824 by Joseph Asp din, England.

• Most important type and commonly used type of cement.
• Classified into three grades, namely OPC33 grade, OPC43 grade and OPC53 grade.
These above grades imply the maximum/minimum strength of the cement after 28 days.

• OPC Cement is prepared from a mixture of limestone and raw argillaceous & calcareous
materials and gypsum like argillaceous, calcareous, gypsum.

• PPC Cement is prepared by adding Pozzolanic materials(VOLCANIC ASH) to OPC

Cement.

• PPC has faster setting time,less heat generation, cheaper than OPC and more durable.
Portland Cement
“An extremely finely ground product by calcinising together , at above 1500 oC , an
intimate and properly proportioned mixture of argillaceous (clay) and calcareous
(lime) raw materials, without the addition of anything subsequent to calcination ,
excepting the retarder gypsum”

Clinker CCN Mass %

Tricalcium silicate (CaO)3 · SiO2 C3S 45–75%
Dicalcium silicate (CaO)2 · SiO2 C2S 7–32%
Tricalcium aluminate (CaO)3 ·
C3A 0–13%
Al2O3
Tetracalcium aluminoferrite
C4AF 0–18%
(CaO)4 · Al2O3 · Fe2O3
Gypsum CaSO4 · 2 H2O 2–10%
Calcium Oxide - CaO
Pile of Portland cement 2%

Magnesium Oxide - MgO 4%

Chemical Composition of Portland Cement

Raw materials of Portland Cement and it’s use

Calcareous materials, CaO [eg.

Limestone ]
•Principal Constituent and its proportion can be
regulated
•Excess of lime reduces the strength and makes
the cement expand & disintegrate
•Lesser amount of lime also reduces the strength
by quick setting
Argillaceous materials, Al2O3 and SiO2
[eg. Clay ]
•Imparts strength
•Makes quick setting
•Excess of alumina weakens the cement
Powdered Coal
. or fuel oil
•For burning

Gypsum (CaSO4 2H2O)

•Retards and enhances quick setting
 CEMENT
THE CEMENT MANUFACTURING PROCESS
THE CEMENT MANUFACTURING PROCESS
Quarry
dumper
loader

Quarry face

1. BLASTING 2. TRANSPORT

storage at
crushing the plant

conveyor

3. CRUSHING & TRANSPORTATION

 Raw grinding and burning
RAW GRINDING

storage at Raw mill

the plant
conveyor
Raw mix

BURNING
preheating

cooling

clinker

Grinding, storage, packing, dispatch

silos

clinker
storage Finish grinding dispatch

Packing
USES OF CEMENT :
1. Cement slurry is used for filling cracks in concrete structures.
2. Cement mortar is used for masonry work, plastering and pointing.
3. Cement is used to manufacture lamp posts, telephone posts, railway
sleepers, piles etc.
4. For manufacturing cement pipes, garden seats, dust bins, flower pots etc.
cement is commonly used.
5. Cement concrete is used for the construction of various structures like
buildings, bridges. water tanks, tunnels, docks, harbour etc.
6. It is useful for the construction of roads, footpaths, courts for various
sports etc.
 8 TYPES OF TESTS ON CEMENT TO CHECK THE QUALITY
1. Fineness Test - Finer the grains more is the surface area and faster the development of
strength. The fineness of cement can be determined by Sieve Test or Air Permeability test.
2. Consistency Test - This test is conducted to find the setting times of cement using a standard
consistency test apparatus, Vicat's apparatus.
3. Setting Time Test - Vicat's apparatus is used to find the setting times of cement i.e., initial
setting time and final setting time.
4. Strength Test - The strength of cement cannot be defined directly on the cement. Instead
the strength of cement is indirectly defined on cement-mortar of 1:3.
5. Soundness Test - This test is conducted in Le Chatelier's apparatus to detect the presence
of uncombined lime and magnesia in cement.
6. Heat of Hydration Test - During the hydration of cement, heat is produced due to chemical
reactions. This heat may raise the temperature of concrete to a high temperature of 50°C. To
avoid these, in large scale constructions low-heat cement has to be used.This test is carried
out using a calorimeter adopting the principle of determining heat gain.
7. Tensile Strength Test - This test is carried out using a cement-mortar briquette in a tensile
testing machine
8. Chemical Composition Test :
Different tests are conducted to determine the amount of various constituents of cement. The
requirements are based on IS: 269-1998, is as follows:
• The ratio of the percentage of alumina to that of iron oxide should not be less than 0.66.
• Lime Saturation Factor (LSF), i.e., the ratio of the percentage to that of alumina, iron oxide
and silica should not be less than 0.66 and not be greater than 1.02.
• Total loss on ignition should not be greater than 4%.
• Total sulphur content should not be greater than 2.75%.
• Weight of insoluble residue should not be greater than 1.50%.
• Weight of magnesia should not be greater than 5%.

Field Tests of Cement before mixing the cement at construction sites:

1.Colour Test of Cement : The colour of the cement should not be uneven. It should be
a uniform grey colour with a light greenish shade.
2.Presence of Lumps : The cement should not contain any hard lumps. These lumps are formed
by the absorption of moisture content from the atmosphere. The cement bags with lumps should
be avoided in construction.
3.Cement Adulteration Test : The cement should be smooth if you rubbed it between fingers.
If not, then it is because of adulteration with sand.

4.Float Test : The particles of cement should flow freely in water for sometime before it sinks.
5.Date of Manufacturing : It is very important to check the manufacturing date because
the strength of cement decreases with time. It's better to use cement before 3 months from the
date of manufacturing.
 CEMENT MORTAR & PLASTERTING

• Cement mortar is homogeneous paste of fixed proportion of cement, sand

and water.(10mm to 20mm)
Preparation:
A.Selection Of Raw Materials:

1. Portland cement : must be pure, undamaged. Ordinary Portland cement is

most suitable.
2. Sand: Good quality for making strong and durable mortar – pure in composition
and free from impurities and sharp grained in structure.

B. Proportioning Of The Raw Materials

• For ordinary masonry work – 1 cement: 3 sand to 1 cement: 6 sand
• For reinforced brick work & work in moist condition - 1 cement: 2 sand to 1
cement: 3 sand
• For Architectural work – 1 cement : 3 sand
• For load bearing structures - 1 cement: 2 sand to 1 cement: 3 sand

C. MIXING OF RAW MATERIALS

(i) Hand Mixing: For small quantity of mortar
• First clean dry sand is spread on a pucca platform and cement of required
quantity is spread over it.
• Whole mass is mixed dry by spades and required quantity of water is added.
(ii) Machine Mixing: For large quantity of mortar required continuously at a fast rate
• Cement and sand in specified proportion are put into the drum of the mixer
and required quantity of water is added.
• Drum is revolved for a sufficient period to form uniform mixture of
required consistency.
 PRECAUTIONS
• The setting process starts - should be used within 30 minutes after adding water
to the cement and sand mixture.
• The Structural Units – bricks and stones must be soaked in water before
laying on the wall. If dry units, it will absorb moisture quickly.
• If Cement Sand Mortar – place should be kept wet at least for seven days.
USES OF CEMENT MORTARS
 PLASTERING
• Lean mortars used mostly for covering masonry surfaces.
• Protective Plasters & Decorative Plasters
• To protect the surface from atmospheric influences
• 12–15 mm for smooth side of wall & 18–20 mm for rough side of wall.

1. Internal plaster:
6mm thick single coat plaster- It is applied on ceilings in single coat
12mm thick single coat plaster- It is 12mm thick and applied on walls and ceilings in single coat
20mm thick double coat plaster- it is applied in two coats of 12mm and 8mm one after the other respectively.
2. External plaster- 25mm thick plaster applied in two coats of 15mm and 10mm each, one after the other.
Cement Plaster: lean mix of Portland cement and sand with water.
• Proportion for all purpose – 1 cement : 3 sand
• The surface of the plaster is kept wet for at least 3 days after application by
sprinkling water on it at regular intervals.
• 1 cement: 1 lime: 6 sand for external plasters, below damp proof course
• 1 cement: 2 lime: 9 sand for external plasters on walls

GUNITING PLASTER
 CONCRETE
Concrete is a composite material in which a binding material mixed in
water on solidification binds well graded fine and coarse aggregates.
• Cement and lime are generally used as binding materials
• Sand is used as fine aggregates
• Crushed stones,gravel,etc are used as coarse aggregate
 QUALITIES OF GOOD CONCRETE
1. STRENGTH – STRONG IN COMPRESSION
2. DURABILITY – AGAINST WEATHERING AGENTS
3. DENSITY – WELL COMPACTED
4. WATER TIGHTNESS – WATER RETAINING
5. WORKABILITY – EASILY WORKABLE
6. RESISTANCE TO WEAR AND TEAR – ABRASIVE FORCES

CEMENT CONCRETE In cement concrete useful proportions of its

1 part cement : + 1-8 part sand : + 2-16 parts coarse aggregates.

1. Plain cement concrete (PCC)

The cement concrete in which no reinforcement
2. Reinforced cement concrete(RCC)
1part of cement:1to2parts of sand: 2to4parts of crushed stones or gravel + Steel
Bars Based on design ( for taking tensile stress)
3. Pre-stressed cement concrete - OFF SITE
CONCRETE MIXING RATIO FOR VARIOUS WORKS :

v Concrete in columns, beams 1:1:2(m25 grade)

(25n/mm2 – strength 28days later)(15cmx15cmx15cm cube) (m=mix)
v Water retaining structures,
Piles, precast work or dense Concrete 1:1.5:3(m20 grade)
(20n/mm2 – strength 28days later)(15cmx15cmx15cm cube)

v RCC beams, slabs, columns 1:2:4

v Foundations for buildings, 1:3:6

Mass reinforced works

v For mass concrete work. 1:4:8

M10, M15, M20 and M25

(1:3:6), (1:2:4), (1:1.5:3) and (1:1:2)
WATER-CEMENT RATIO :
In the preparation of concrete the water cement ratio is very
important
Adding to much water will reduce the strength of concrete and
can cause segregation.

CONCRETE RATIO WATER

1:3:6 34 litre
1:2:4 30 litre
1:1.5:3 27 litre
1:1:2 25 litre
SLUMP TEST : Slump test is a test conducting before concrete to be used
for casting. The test is to determine water content in the concrete.
 WORKABILITY OF CONCRETE

It is the amount of work required to place concrete and to compact it

thoroughly.

Workability of concrete increases with the addition of water but it reduces

the strength that’s why it is not a desirable way of increasing the
workability.

Use of aggregates which are round and have smooth surfaces

increases the workability.

Use of certain chemical additives such as lisapole liquid increase

water tightness also and workability.
 COMPACTION FACTOR TEST
Cement concrete to be tested is placed in the hopper
A and its bottom released. The concrete falling in
hopper B achieves some compaction.

The bottom of hopper B is now released so that

concrete now falls in cylinder C. surplus concrete is
removed from the top of cylinder. Concrete in the
cylinder is now weighed. Let this weight be W1 .
After cleaning the cylinder it is refilled with concrete in
layers of 5cm each. Every layer of concrete is
thoroughly compacted with an iron rod. Concrete in the
cylinder is weighted again. Let this weight be W2 .
The ratio of the two weights is known as
compaction factor.
Compaction Factor= W1/W2

A compaction factor of 0.85 represents a mix of poor

workability, 0.92 represents medium and 0.95
represents good workability.
 CURING OF CONCRETE

To do curing, any one of the following method

can be used:
i. The surface of concrete is coated with a layer
of bitumen or similar other waterproofing
compound which gets into the pores of
concrete and prevent loss of water from
concrete.
ii. Concrete surface is covered with waterproof
paper or with a layer of wet sand. It could also
be covered with gunny bags.
iii. Curing should be done for a period of three weeks
but not less then 10 days.
WHAT IS BIS?
The Bureau of Indian Standards (BIS) is the national Standards Body of India working under
the aegis of Ministry of Consumer Affairs, Government of India. One of the major functions of
the Bureau is the formulation, recognition and promotion of the Indian Standards. These cover
important segments of economy, which helps the industry in upgrading the quality of their
products and services.
 DPC – DAMP PROOF COURSE
A damp proof course (DPC) is a horizontal barrier in wall designed to resist moisture rising through the structure
by capillary action.
• Concrete normally allows moisture to pass through so a vertical vapor barrier is needed. Barriers may be a coating or
membrane applied to the exterior of the concrete.
• In a masonry cavity wall, there is usually a DPC in both the outer and inner wall
• In the outer wall it is normally 15cm to 200cm above ground level.
• The DPC in the inner wall is usually below floor level - under a suspended timber floor structure
• with a solid concrete floor, it is usually found immediately above the RCC floor slab.
 • Moisture rising up the walls from ground ( upwards of a building )
• Due to Rain – water can penetrate and travel from top to bottom of a structure (downwards)
• Rain incident against exterior walls
• Condensation effect

MATERIALS FOR DPC

1. HOT BITUMEN
2. MASTIC ASPHALT/BITUMINOUS ASPHALT
3. METAL SHEETS
4. SPECIAL BRICKS, HAVING WATER ABSORPTION NOT LESS THAN 4.5 % OF THEIR WEIGHT
5. STONES
6. CEMENT MORTAR
7. CEMENT CONCRETE
8. PLASTIC SHEETS
9. WATERPROOFING COMPOUNDS

IN MOST BUILDING
CONCRETE MIX (1:1.5:3) OVER FULL WIDTH OF WALL AND ( 10CM - 15CM THICK )
+
WATER PROOFING COMPOUND PAINTED ON TOP OF TWO COATS.
BITUMEN : BINDER FOR ASPHALT ASPHALT – AGGREGATE,SAND,STONE DUST & BITUMEN
EFFECTS OF DAMPNESS

1. Travel of moisture on wall causes unsightly patches.

2. It may cause softening & crumbling of plasters.
3. Wall decoration or paint is damaged.
4. Continuous presence of moisture in wall may cause florescence which result in disintegration
of bricks, stones, tiles.
5. Flooring gets loosened due to reduction in adhesion when moisture enters through the floor.
Floor coverings are damaged.
6. Timber fittings such as doors, windows etc in contact with damp walls, damp floors get
deteriorated.
7. Electrical fittings get deteriorated, giving rise to leakage of electricity & danger of short
circuiting.
8. Dampness promotes & accelerated growth of termites.
9. Moisture causes rusting & corrosion of metal fittings.
METHODS OF DAMP PROOFING

(1) MEMBRANE DAMP PROOFING

 (2) INTEGRAL DAMP PROOFING

WATER PROOFING COMPOUND + CONCRETE MIX = IMPERMEABLE CONCRETE MIX

1. Chalk, fullers earth + concrete = fill the voids of concrete

2. Alkaline silicates/aluminium sulphate / calcium chlorides etc = reacts chemically with
concrete to produce water proof concrete.
3. Stearates of calcium, sodium, ammonia etc.= work on water repulsion principle
4. Commercially available compounds like Pudlo, Impermo, Dr.fixit etc.
(3) SURFACE TREATMENT

BITUMEN COATING
 (4) CAVITY WALL CONSTRUCTION

• Main wall of building is shielded by an outer skin wall, leaving a cavity between the two
wall and prevents moisture from outer to inner wall.
 (5) GUNITING
• This consists of depositing layer of rich cement mortar by pressure to the exposed surface of wall,
pipes.
• Cement mortar is 1:3 cement sand mix.
• Mortar is sprayed on clean surface with cement gun under 2 to 3 kg/cm2 pressure.
• Nozzle of machine is kept at a distance about 75 to 90 cm from wall.
• Curing of mortar is done for 10 days

•
 (6) PRESSURE GROUTING
• In this method, cement grout is filled in cracks, voids in the structure of building by pressure.
• Foundation of building are subjected to grouting to make water penetration resistant.
• This method is effective to control entry of ground water through foundations.
 WATER PROOFING
1. SHEET BASED WATERPROOFING MEMBRANES:
1. These are membranes that arrive at the site in the form of rolls.
2. These are then unfurled and laid on a firm surface.
3. The most common type of sheet based membrane is a bituminous waterproofing membrane.
4. This type of membrane is stuck to the substrate with a hot tar based adhesive using blowtorches.
5. Self-adhesive compounds comprise asphalt, polymers and filler; additionally, certain resins and oils may be added to
improve adhesion characteristics.
6. The self-adhesive type has low shelf life as bonding properties of the membrane reduces with time.
2. CEMENT & BITUMEN BASED WATERPROOFING METHOD :

1. Cement or bitumen based products applied internally, externally or sandwiched within the structure.
2. Can be used for new build constructions.
3. This method is often used in the internal wet areas such as toilets.
4. This method is usually a rigid or semi-flexible type waterproofing, but since it is used in internal areas such as
toilets, it is not exposed to sunlight and weathering.
5. Thus cementitious waterproofing does not go through contract and expansion process.
3. LIQUID APPLIED WATERPROOFING MEMBRANES

1. Liquid membrane is a thin coating which consists of usually a primer coat and two coats of top coats which are applied by
spray, roller, or Brush.
2. These are generally considered to be superior to sheet based membranes as they are joint-free. However care must be
taken in application to provide just the right thickness.
3. The membrane can tear or break if it is too thin.
4. The adhesion of the membrane to concrete must be good.
4. CRACKS -FREE SILICONE POLYMERS THE BEST WATERPROOFING METHOD:

1. Silicone Polymers can offer higher flexibility. which are then either sprayed or brush-applied on the surface.
2. 4 Coat Application.
3. The liquid cures in the air to form a seamless, Cracks -free membrane.
4. The thickness can be controlled by applying more of the liquid chemical per unit area.
5. Heavy duty durable terrace waterproofing system. composed of specially developed highly elastic & durable Silicone
polymers, incorporated graded fillers, light fast & weather durable, micro-fibers, additives.
6. Is suitable for both indoor & outdoor Roof and sealing work
ADVANCED TECHNIQUE OF WATERPROOFING – SPRAYED WATERPROOFING SYSTEM

1. Application of waterproofing composition is done by a special Waterproofing Sprayer gun or airless

sprayer.
2. Composition which is sprayed on the surface consists of the liquid Silicone Polymers is applied on the
surface.
3. Like Terrace, Roof Slope, Cement - Metal Sheds, Old /New Bathrooms, Exterior Basement Wall etc.,
FOR WATER PROOFING THINGS TO CONSIDER :
1. TILE SLOPING FOR WASHROOMS/TOILET/ROOF TILES TOWARDS DRAIN.
2. BASEMENT + TOILET + ROOFTOP + SWIMMING POOL + WATER TANK + SUMP +UNDERGROUND WORK

FOR TOILET
1. 1ST FLOOR OR MORE FLOORS – SUNKEN SLAB WATER LEAKAGE POSSIBLE
2. FIRST PIPE LEAKAGE TO BE CHECKED
3. SECOND BITUMEN APPLICATION
4. THIRD SURFACE CLEANING AND PREPARATION
5. FOURTH DR.FIXIT FIRST APPLICATION CEMENT SLURRY + DR.FIXIT 2 COAT BOTH DIRECTION + DR.FIXIT PIDIFIN 2K (LIQUID +
POWDER) + PIPE LINE CHECK + P.C.C/BRICK BAT MOSTLY FILLING + CEMENT MORTAR + CEMENT SLURRY FOR FOR TILING +
WALL DADO ALSO.

FOR ROOF
1. SURKHI CONCRETE FOR ROOF – LIME POWDER + BRICK BATS BROKEN BASED ON SLOPE (OR LIME CONC ALSO) + KADUKAI +
JAGGERY (OLD TYPE/TRADITIONAL METHOD)
2. SCREED CONCRETE 3 – 4 “ + WATER PROOF COMPOUND MIX + 12MM AGGREGATES LAID IN SLOPE TOWARDS DRAIN.
3. CHAMBERING AT SKIRTING LEVEL OF ROOF TERRACE : 3 / 4 “
4. FOR FUTURE EXT : SLAB + G.I SHED (PROPOSED SOME CASES TO AVOID WATER LEAKAGE)
5. FOR OVERHEAD WATER TANK/SUMP : NO FOOD POISIONING WATER PROOFING COMPOUND ON THE INTERIOR + PLASTERING
ON TOP OR TILING WORK ALSO
6. SWIMMING POOL OR SUMP ALMOST SAME METHOD : RCC WORK DUE TO PRESSURE OF WATER
7. HEIGHT RISEN FOR OVERHEAD TANK : PRESSURE AND NO DIRECT WATER LEAKAGE TO THE BELOW FLOORS.
8. ADMIXTURES AVAILABLE FOR WATER PROOFING NO NEED TO HEAT DR.FIXIT.
INDIAN WATER CLOSET SECTION IN TOILET
WASHROOM FLOOR SECTION
ROOFSLAB SECTION
SUNSHADE SECTION
WATERTANK SECTION
WRITE A BRIEF NOTE ON (SKETCH ONLY IF APPLICABLE )
( REFER INDIAN CONTEXT ONLY : FOR BRANDS / SUPPLIER NAME / COST / MEASUREMENT UNIT )

1. LOAD BEARING VS FRAMED STRUCTURE

2. STRUCTURAL COMPONENTS/ELEMENTS WHICH CARRY LOAD IN A BUILDING
3. COMPONENTS OF A BUILDING WHICH DO NOT CARRY LOAD
4. TYPES OF LOAD IN A BUILDING
5. PCC : WHERE IT IS USED & RCC : WHERE IT IS USED
6. FEW CEMENT BRANDS + RATE + MEASUREMENT UNIT
7. TYPES OF SAND USED FOR CONSTRUCTION + RATE + MEASUREMENT UNIT
8. AGGREGATES TYPES USED + SIZES/GRADES + MEASUREMENT UNIT
9. STEEL GRADES,BRANDS + RATE + MEASUREMENT UNIT
10. CONCRETE MIX DESIGN
11. CONCRETE MIX GRADES
12. PCC & RCC MIXING METHODS – HAND OR MACHINE
13. MIXTURE MACHINE / READY MIX
14. CONCRETE PUMPING MACHINE FOR HIGH RISE.
15. GREEN CONCRETE.
16. WHAT ARE CEMENT PLANTS ?
17. WHAT ARE STONE QUARRIES ?
18. NAME SOME SOURCES IN T.N WHERE SAND & FEW MASONRY MATERIAL IS PROCURED :
(RIVERSAND ,MSAND,PSAND,AGGREGATES,BRICKS,FLYASH BRICKS,AAC BLOCK)
19. FEW CONCRETE SUPPLIER NAMES (LEADING SUPPLIERS)
20. FORMWORK MATERIALS – SHUTTERING/CENTERING SHEETS , PROPS,SOFFITS ETC.
21. DPC & WPC – FEW BRANDS AND IN WHAT QUANTITY IT IS PURCHASED?
22. COMMON MACHINERIES USED IN A CIVIL WORK ( FOR SLAB COMPACTION,PLASTERING,ETC.)