READY MIX CONCRETE

Ready mix concrete is a type of concrete that is manufactured in a factory and

transported to a construction site in ready to use form. It consists of cement,
aggregates (sand, gravel, or crushed stone), water, and some other additives or
admixtures. The concrete ingredients are precisely measured and mixed according
to specific formulations to ensure consistency and quality. RMC is transported in
specialized trucks, often called concrete mixers, and it can be directly poured or
pumped into place at the construction site, eliminating the need of onsite mixing
and reducing labor and time requirements.
TYPES OF MIXERS USED TO TRANSPORT RMC:

There are two main types of mixers used for transportation of RMC to the
construction site: Drum mixers and volumetric mixers.
DRUM MIXERS: Drum mixers are the most commonly used trucks for
transporting RMC. They have a large rotating drum that mixes the concrete
ingredients by rotating. Drum mixers may be either tilt drum mixers or non
tilting drum mixers. Tilt drum mixers have a tilting mechanism allowing the
concrete to be discharged by tilting the drum. While non tilting mixers rely on
chute or conveyer mechanism for unloading concrete. Drum mixers are
efficient and can carry a large volume of concrete.
VOLUMETRIC MIXERS: Volumetric mixers are newer type of mixers used for
transport of RMC. They are versatile and can produce different quantities of
concrete on site. They have separate compartments for cement, aggregates,
water and admixtures. The ingredients are proportioned and mixed as needed
allowing flexibility in adjusting the concrete mix on the spot. Volumetric mixers
are particularly useful for small or medium sized projects or when a specific
mix design is needed.
Both volumetric and drum mixers are designed to ensure that the concrete
remains well mixed during transportation, and preventing segregation or setting
before reaching the construction site. The choice of mixer depends on the size of
project, transportation distance and specific job requirements.

MANUFACTURE OF RMC:

The manufacturing process of ready mix concrete (RMC) involves several steps:

Batching: The process begins with the precise measurement of the raw
materials needed for the concrete mix. This includes cement, aggregates (such
as sand, gravel, or crushed stone), water, and sometimes additional additives
or admixtures. The measurements are carefully calculated based on the
desired mix proportions.
Mixing: Once the ingredients are accurately measured, they are mixed together
in a concrete mixer. The mixer can be a stationary plant or a mobile unit. The
mixing process ensures that the cement, aggregates, water, and additives are
thoroughly combined to form a uniform and consistent concrete mixture. This
process may involve different types of mixers, such as drum mixers or pan
mixers, depending on the batching plant.
Transportation: After the concrete is mixed, it is loaded into specialized trucks
known as transit mixers or agitator trucks. These trucks have rotating drums to
keep the concrete in a liquid state during transportation. This helps maintain
the uniformity of the mix and prevents segregation or setting of the concrete.
 Delivery: The transit mixers transport the RMC to the construction site. It is
important to ensure that the transit time is minimized to maintain the fresh
properties of the concrete. Upon reaching the site, the RMC can be directly
poured or pumped into the desired location for placement.
The manufacturing of RMC is carried out in controlled environments, such as
batching plants, to ensure consistent quality and adherence to specific mix
designs. This process allows for efficient production, accurate mix proportions,
and timely delivery of ready-to-use concrete to construction sites.

Types of Ready Mixed Concrete

There are three types of ready mix concrete (RMC) depending upon the mixing of
the various ingredients as given below:
1. Transit mixed concrete
2. Shrink mixed concrete
3. Central mixed concrete

1. TRANSIT MIXED CONCRETE

It is also called dry batched concrete because all the basic ingredients including
water are charged directly into the truck mixer. The mixer drum is revolved fast at
charging speed during the loading of the material and after that it continues
rotating at a normal agitating speed. In this type of ready mix concrete, also three
types of variations are possible as given below:
Concrete mixed at job site : While being transported towards the destination,
the drum is revolved at a slow or agitating speed of 2 rpm, but after reaching
the site just before discharging the material, it is revolved at maximum speed
of 12 to 15 rpm for nearly 70 to 100 revolution for ensuring homogeneous
mixing.
Concrete mixed in transit The drum speed is kept medium during the transit
time, i.e. approximately 8 rpm for about 70 revolutions. After 70 revolutions, it
is slowed down to agitating speed of 2 rpm till discharging the concrete.
Concrete mixed in the yard The drum is turned at high-speed of 12 to 15 rpm
for about 50 revolutions in the yard itself. The concrete is then agitated slowly
during transit time.

2. SHRINK MIXED CONCRETE

The concrete is partially mixed in the plant mixer and then balance mixing is done
in the truck mounted drum mixer during transit time. The amount of mixing in
transit mixer depends upon the extent of mixing done in the central mixing plant.
Tests should be conducted to establish the requirement of mixing the drum mixer.
3. CENTRAL-MIXED CONCRETE

It is also called central batching plant where the concrete is thoroughly mixed
before loading into the truck mixer. Sometimes the plant is also referred as wet-
batch or pre-mix plants. While transporting the concrete, the truck mixer acts as
agitator only. Sometimes, when workability requirement is low or the lead is less,
non-agitating units or dump trucks can also be used.

ADVANTAGES AND DISADVANTAGES OF RMC:

ADVANTAGES:
1. Quality and consistency: RMC is manufactured in a controlled environment
ensuring high quality and consistent concrete. The accurate measurement of
ingredients and automated mixing results in a uniform mix, leading to reliable
strength and durability.
2. Time and labor: RMC eliminates the need for on site mixing saving time and
labor. The workers can focus on other tasks while premixed concrete is directly
delivered onto the site, ready for immediate use.
3. Reduced wastage: RMC leads to reduced wastage as it is manufactured in a
controlled environment with accurate measurements. This leads to reduced
costs and environmental impact.
4. Flexibility and cutomization: RMC can be tailored to specific project
requirements, such as strength, slump or other desirable properties. Additives
and admixtures can be added easily to enhance the properties and address
specific construction challenges.

DISADVANTAGES:
1. Cost: RMC is expensive as compared to onsite mixing due to factors such as
transportation, setting up of a batching plant, and labor. Initial investments for
the necessary infrastructure and equipment may also be high.
2. Limited shelf life: RMC has a limited shelf life and starts deteriorating with
time. It needs to be used in a limited time frame, known as workability window
to ensure optimum performance. If not used on time RMC may be required to
be discarded.
3. Dependency on suppliers: RMC requires dependency on the suppliers for
timely delivery of concrete. Delays in delivery may cause disruption of
construction schedule resulting in project delays or increased cost.
4. Flexibility and modification: Once delivered to the site, RMC cannot be easily
modified or adjusted. Adjustments may require additional batches leading to
increased costs.
 FERROCEMENT / FERROCRETE

Ferrocrete also known as ferrocement is a construction material composed of

a matrix of cement mortar reinforced with closely spaced thin diameter wire
mesh and thin steel rods.
It is a versatile and durable material.
Ferrocrete is known for its high strength to weight ratio and flexibility. The wire
mesh or steel reinforcement provides tensile strength, and the cement mortar
matrix provides compressive strength. This combination makes ferrocrete
resistant to cracking, bending, and impact.
Ferrocrete being a versatile material can be used for the construction of
buildings, bridges, water tanks, hulls for boats, shell roofs, etc. Because of its
flexibility, it can be used for the construction of complex designs and shapes.
The mortar used for ferrocrete is typically a rich mix of cement and sand. 1:1
for structural/ habitable purposes and 1:2 for non structural applications. No
coarse aggregate is used, so the material is different from traditional concrete.
The thin wire mesh is made up of steel or metal. It is woven, expanded, or
welded metal mesh made up of a diameter of 0.5 mm to 1 mm .
Ferrocrete is also known for its resistance to environmental factors such as
fire, corrosion, seismic activity. It is strong hard and durable.

CONSTRUCTION OF FRAMEWORK:

The desired shape may be built from a multilayered construction of mesh,

supported on an armature or grid made up of rebars tied with wire. The steel
must be galvanized or stainless steel for optimal performance.
An appropriate mix of portland cement, sand and water is applied to penetrate
the mesh.
The assembly may be kept moist during hardening to allow the cement mortar
to set and harden slowly and prevent any cracks that may weaken the
structure.
Steps must be taken to prevent trapped air in the interior during the wet stage
as it can also cause cracks that will weaken the structure.
Trapped air creates voids that allows water to collect and degrade the steel
rebars.
Modern practices involve spraying the mixture at pressure ( Known as
shotcrete) or other methods to drive off trapped air.

REINFORCEMENT USED FOR FERROCEMENT

Skeleton steel: It forms the skeleton of the structure. It consists of steel rebars
or rods typically 6mm- 8mm in diameter and spaced 75 to 100mm c/c. Mostly
mild steel is used such as Fe410, or Fe500.
Steel wire mesh or fibre reinforced polymeric mesh: The steel mesh is typically
made up 0.5mm to 1.5 mm diameter wires spaced 6mm to 20 mm c/c. There
are different types of mesh namely, woven wire mesh, welded wire mesh,
chicken or hexagonal wire mesh, and expanded metal mesh.
The woven mesh has square openings and welded mesh has square or
hexagonal openings.
The expanded metal mesh has more stiffness and has better crack and impact
resistance. It cannot be used for sharp curves.
Fiber reinforced polymeric mesh : Use of polymeric mesh imparts more
durability and wards off the threat of corrosion. It also reduces the overall
cost.

ADVANTAGES AND DISADVANTAGES.

LIGHTWEIGHT CONCRETE:

Lightweight concrete is a type of concrete that is lighter as compared to

traditional concrete. Light weight concrete has a density of about 1700 to
1800 kg/m^3. While traditional concrete has a density of 2500kg/m^3. It is
achieved by incorporating lightweight aggregates or air voids in the concrete
mix. The lightweight aggregates used may include materials like expanded clay,
shale or perlite that are lighter and less dense as compared to traditional
aggregates like gravel or crushed stone.
The reduced weight of LWC makes it advantageous for various applications. It
provides better thermal insulation, Reduced dead weight on structure and
improved fire resistance. Additionally it also imparts better acoustic insulation
and is easier to handle and transport.
The manufacture of LWC involves blending the light weight aggregates with
cement, water and sometimes admixtures or additives. The mixture forms a
cellular structure with air voids which contribute to the light weight and
reduced density of LWC. The properties of the specific LWC may vary
depending on the type and proportion of the LW aggregate, and also the mix
design.
TYPES OF LIGHT WEIGHT CONCRETE:

There are several types of lightweight concrete, each with its own unique
characteristics and applications. Here are some of the most common types:
1. Lightweight Aggregate Concrete: This type of lightweight concrete
incorporates lightweight aggregates as a replacement for traditional
aggregates like gravel or crushed stone. The lightweight aggregates used can
be natural materials such as expanded clay, shale, or slate, or synthetic
materials like expanded polystyrene beads. Lightweight aggregate concrete
offers reduced weight, improved thermal insulation, and enhanced fire
resistance.
2. Aerated Concrete: Also known as cellular concrete or gas concrete, aerated
concrete is produced by introducing air voids into the concrete mixture. This is
typically achieved by adding aluminum powder or generating gas bubbles
using foaming agents. The resulting concrete has a cellular structure, making it
lightweight and highly insulating. Aerated concrete is commonly used in walls,
blocks, and panels for both load-bearing and non-load-bearing applications.
3. Foam Concrete: Foam concrete, or foamed concrete, is a lightweight concrete
made by mixing a foam agent into the concrete mixture. The foam agent
creates air bubbles throughout the mixture, resulting in a cellular structure.
Foam concrete is known for its low density, high thermal insulation, and
sound-absorbing properties. It is often used in insulation, filling voids, and as a
lightweight fill material.
4. No-Fines Concrete: No-fines concrete is a type of lightweight concrete that
does not contain fine aggregates (sand). Instead, it consists of a cementitious
paste mixed with coarse aggregates. The absence of fine aggregates creates air
pockets within the mixture, reducing its weight. No-fines concrete is commonly
used in applications where drainage and thermal insulation are important,
such as in road construction, landscaping, and lightweight floor screeds.
5. Lightweight Insulating Concrete: This type of lightweight concrete is
specifically designed for its thermal insulation properties. It typically consists
of lightweight aggregates, such as expanded perlite or vermiculite, mixed with
cement and water. Lightweight insulating concrete is commonly used in flat
roof insulation systems, where it provides both insulation and a level surface
for the roof membrane.

AUTOCLAVE AERATED CONCRETE:

The manufacturing process of autoclaved aerated concrete (AAC) involves several
steps. Here is a brief overview:
1. Raw Material Preparation: The primary ingredients used in AAC production are
cement, lime, water, sand, and a foaming agent. The sand is finely ground, and
the other materials are precisely measured and prepared according to specific
mix designs.
2. Mixing: The raw materials are mixed thoroughly to achieve a uniform mixture.
This is typically done in a large mixing vessel or a specialized AAC mixer. The
mixing process ensures that all the ingredients are evenly distributed
throughout the mixture.
3. Forming: Once the mixture is ready, it is poured into molds or forms. These
forms can be of various shapes and sizes, such as blocks, panels, or slabs. The
forms are typically lined with release agents to prevent sticking and facilitate
easy removal of the finished AAC products.
4. Pre-Curing: After the mixture is poured into the forms, it undergoes a pre-
curing phase. During this phase, the chemical reactions between the cement
and lime begin, causing the mixture to rise and expand. This expansion is
facilitated by the inclusion of aluminum powder or a similar foaming agent,
which generates gas bubbles within the mixture.
5. Cutting: Once the pre-curing phase is complete, the partially solidified AAC
blocks or panels are cut into the desired sizes. This can be done using wire
cutting machines or specialized saws. The cutting process ensures precise
dimensions and smooth surfaces for the finished AAC products.
6. Autoclaving: After cutting, the AAC products are placed into autoclaves, which
are high-pressure vessels. The autoclaves provide controlled steam curing at
elevated temperatures, typically around 180-200 degrees Celsius (356-392
degrees Fahrenheit). This curing process allows for further chemical reactions
to occur, resulting in the formation of calcium silicate hydrate (CSH) crystals
that give AAC its strength and unique properties. The autoclaving process
usually takes several hours.
7. Demolding and Curing: Once the autoclaving is complete, the AAC products
are removed from the molds or forms and allowed to cool. They are then
transferred to curing chambers or storage racks, where they continue to cure
and gain strength over time. The curing duration can vary depending on the
product specifications and manufacturer guidelines.
8. Finishing and Packaging: After sufficient curing, the AAC products undergo
finishing processes, such as trimming, sanding, and surface treatment, to
achieve the desired appearance and quality. Finally, they are packaged and
prepared for distribution and shipment to construction sites.
 NO FINES CONCRETE
No-fines concrete is a type of lightweight concrete that is characterized by its
absence of fine aggregates, such as sand. Instead, it consists primarily of
coarse aggregates, typically ranging in size from 10mm to 20mm. The coarse
aggregates are bound together by a cementitious paste, usually a mix of
cement and water.

The unique characteristic of no-fines concrete is the presence of air voids

within the mixture due to the absence of fine aggregates. These air voids
create a cellular structure, resulting in a lightweight material with reduced
density. The voids also provide several benefits, such as improved thermal
insulation and enhanced drainage properties.

The manufacturing process of no-fines concrete involves the following steps:

Aggregate Selection: Coarse aggregates, such as gravel or crushed stone, are

carefully selected based on their quality and size distribution. The aggregates
should be clean, free from dust or debris, and properly graded to ensure
optimal packing and structural integrity.

Mixing: The coarse aggregates are mixed with a cementitious paste consisting
of cement and water. The mixing process should be thorough to achieve a
uniform distribution of the paste throughout the aggregates. Sometimes,
additives or admixtures may be incorporated to enhance specific properties or
workability.

Placement: Once the mixture is ready, it is typically placed directly at the

construction site. It can be poured or spread manually or by using equipment,
depending on the application. Care should be taken to avoid excessive
compaction, as it may reduce the presence of air voids and compromise the
lightweight nature of the concrete.

Curing: No-fines concrete requires proper curing to achieve strength and

durability. The curing process involves maintaining a moist environment for
the concrete to prevent rapid moisture loss. It can be accomplished through
methods such as wet curing, curing compounds, or covering the concrete with
plastic sheets.

No-fines concrete finds applications in various construction projects,

including road construction, landscaping, and lightweight floor screeds
There are several types of lightweight aggregates used in construction to
produce lightweight concrete or other lightweight materials. Here is an
overview of some common types:

Expanded Clay: Expanded clay is made from clay or shale that is heated to a
high temperature in a rotary kiln. The heat causes the material to expand,
creating lightweight, porous pellets. Expanded clay aggregates are lightweight,
have excellent thermal insulation properties, and offer good resistance to fire
and moisture.

Expanded Shale: Expanded shale is produced by heating shale to a high

temperature in a rotary kiln, similar to the process for expanded clay. The
resulting expanded shale aggregates are lightweight, porous, and have good
strength and durability. They provide thermal insulation, fire resistance, and
resistance to water absorption.

Expanded Perlite: Perlite is a volcanic glass that is crushed and then heated to
a high temperature. The heat causes the perlite particles to expand and form
lightweight, cellular structures. Expanded perlite aggregates are highly
insulating, lightweight, and have good fire resistance properties. They are
commonly used in lightweight concrete and insulation applications.

Expanded Vermiculite: Vermiculite is a naturally occurring mineral that

undergoes a process of exfoliation, where it is heated to a high temperature,
causing it to expand and form lightweight, porous aggregates. Expanded
vermiculite offers good thermal insulation, fire resistance, and sound
absorption properties. It is used in lightweight concrete, insulation, and
horticulture applications.

Polystyrene Beads: Polystyrene beads, also known as EPS beads, are tiny
lightweight spheres made from expanded polystyrene. They are often used as
a lightweight aggregate in concrete to reduce weight and improve insulation
properties. Polystyrene beads are lightweight, offer good thermal insulation,
and are easy to handle and mix into concrete.
 WATERPROOFING:

Why waterproofing is needed?

Waterproofing is necessary for several reasons:
1. Protecting against water damage: Waterproofing prevents water from
penetrating in to various structures such as buildings, basements, roofs, or
foundations. It safeguards their structural integrity and prevents moisture
related issues such as leakages, rot and mold growth.
2. Preservation of materials: Water can cause degradation and deterioration of
several materials such as wood, concrete and metal. Waterproofing creates a
barrier and prevents water from coming into contact with these materials
extending their lifespan and maintaining their strength.
3. Health and safety: Excessive moisture intrusion can create a conducive
environment for the growth of mold, mildew and other harmful
microorganisms. Waterproofing helps inhibit their growth and reduce health
risks associated with poor indoor air quality, allergies or respiratory problems.
4. Energy efficiency: Waterproofing improves energy efficiency by preventing
unwanted water infiltration, which can lead to increased energy consumption
for heating or cooling purposes. By creating a barrier against water intrusion, it
reduces air leakage and minimizes heat transfer, helping you lower energy
costs.
5. Cost savings: Waterproofing during the initial construction phase or as a
maintenance measure can save significant costs in the long run. It prevents
expensive repairs due to water damage, mold remediation, or structural issues
caused due to water penetration.
6. Protection of belongings: Waterproofing helps protect valuable belongings,
equipment, or inventory stored in basements, garages or other vulnerable
areas. It ensures that water does not cause damage to these valuable
belongings.

TYPES OF WATER ATTACKS:

INTERNAL ATTACK:
1. Internal attack refers to the infiltration of water from within a structure or a
building.
2. Common causes of internal attack are plumbing leaks, burst pipes, faulty
appliances, or inadequate waterproofing of internal wet areas such as toilets,
kitchen, or bathrooms.
3. Internal attack can lead to damage to walls, floors, roof, and the growth of
mold and mildew.
4. It can also cause electrical hazards, weakening of structural components,
damage of materials.
5. Proper maintenance, and adequate waterproofing are important to prevent
internal attacks.
 EXTERNAL ATTACKS:
1. External attack refers to the infiltration of water from outside a building or
structure.
2. Common causes of external attack include heavy rainfall, flooding, improper
drainage systems, or groundwater seepage.
3. External attack can lead to basement leaks, foundation damage, erosion of soil
around the building and moisture related issues.
4. It can compromise the structural integrity of a building leading to cracks,
settling or even collapse.
5. Effective exterior water proofing measures such as installing proper drainage
system, sealing foundation walls, and maintaining proper grading can help
prevent external attacks.

TYPES OF ATTACK BASED ON DURATION OF ATTACK:

Acute water attacks
1. Acute water attacks are sudden and short term attacks involving significant
amount water infiltration
2. Examples of acute attack include flash floods, heavy rainstorms, pipe bursts,
or sudden plumbing leaks.
3. Acute attacks can cause immediate and severe damage to structure and
belongings.
4. Prompt action is crucial to mitigate the damage, remove water and address
issues related to structure and material damage.

Chronic water attacks:

1. Chronic water attacks occur over an extended period , typically due to ongoing
or recurring water intrusion.
2. Examples of chronic attack include persistent attack, slow plumbing leaks or
continuous infiltration from external sources.
3. It can lead to gradual damage, including mold growth and material damage.
4. IDENTIFYING AND ADDRESSING THE SOURCE OF WATER INTRUSION IS
NECESSARY TO PREVENT FUTURE DAMAGE.

ORIENTATION OF SURFACE:
Horizontal: water does not flow.
Inclined: Water flows away.
Vertical: Water flows away immediately.
The shape and profile of the surface should be such that it collets the water and
allows it to flow away.

TEMTERATURE:
Temperature variation inside storage tank is low. Temperature variation on roof is
high.
Temperature of solar heated water is high therefore pipes used must be resistant
to temperature such as CPVC pipes.
PRESSURE:
Water under pressure is more dangerous for attack. Supply pipe pressure is high.
And drainage pipe, rainfall pressure is low.

Desirable properties of waterproofing material :

1. Impermeability
2. abrasion resistance
3. chemical resistance
4. UV resistance
5. temperature fluctuations resistance
6. durability
7. elasticity
8. flexibility
9. puncture resistance
10. easily applicable
11. smooth surface quality
12. Should not react with water
13. Fast setting
14. cost effective
15. adhesive to substrate
16. tear resistance
17. pressure resistance
18. crack bridging ability
19. flowable
20. lightweight

TYPES OF WATERPROOFING:

Integral waterproofing: Integral waterproofing refers to the process of making

a material or structure resistant to penetration by water from within. It
involves adding a certain chemical additive or admixture to the material during
the production or construction phase. The chemical works by filling in
microscopic voids and capillaries within the material, thereby preventing
water from seeping through. Integral waterproofing protects the material or
structure from damage due to water, such as leakages, dampness,
deterioration due to water related issues.
Crystalline treatment: Crystalline treatment, also known as crystalline
waterproofing, is a method to make concrete and masonry structures
watertight. It involves the application of a specialized crystalline material or
coating to the structure. This material penetrates the substrate and reacts
with the moisture and free lime present in the concrete to form insoluble
crystals. These crystals grow within the concrete and fill any capillaries or
pores, effectively blocking the passage of water. Crystalline treatment
provides long term waterproofing protection and prevents water leakage and
damage to the structure.
Cementitious waterproofing: Cementitious water proofing involves the application
of a cementitious coating to make a surface or structure impervious to water. It
typically uses a cementitious coating or specialized waterproofing mortar. The
material is mixed with water and directly applied to the surface forming a
protective covering and prevention water penetration. cementitious
waterproofing has good bonding with concrete and masonry substrates providing
a durable and waterproof barrier. Cementitious waterproofing is commonly used
in areas such as basements, foundations, and retaining walls to prevent water
infiltration and protecting the structure from damage.

1. Acrylic Waterproofing: Acrylic waterproofing is a type of waterproofing system

that uses acrylic-based materials. These materials are typically in liquid form
and can be applied as a coating or a paint-like substance onto the surface.
Once applied, acrylic waterproofing forms a flexible and protective layer that
prevents water penetration. It is commonly used for roofs, walls, and other
surfaces that require protection from moisture.
2. PU (Polyurethane) Waterproofing: PU waterproofing is a method that utilizes
polyurethane-based materials to create a waterproof barrier. Polyurethane is a
versatile material that can be applied as a liquid coating or a membrane. It
forms a seamless and durable layer that resists water penetration. PU
waterproofing is often used for basements, balconies, and other areas where a
high level of waterproofing is required.
3. Epoxy Waterproofing: Epoxy waterproofing involves the use of epoxy resin, a
strong and durable material, to provide waterproofing protection. Epoxy is
typically applied as a coating or a sealant to surfaces such as concrete, floors,
and walls. It forms a tough and impermeable barrier that effectively blocks
water. Epoxy waterproofing is commonly used in areas prone to heavy water
exposure, such as bathrooms, kitchens, and industrial facilities.
These waterproofing methods vary in their application techniques, properties,
and suitability for different surfaces and conditions. It's important to choose the
appropriate method based on the specific requirements and characteristics of the
project.
 ADHESIVES

ADHESIVES IN SIMPLE TERMS:

In building construction adhesives are substances that are used to join
different materials. They play a crucial role in various aspects of construction
such as bonding walls, floors, tiles and other building components. They can
be applied as a liquid, paste or tape, and as it dries or cures, it creates a firm
bond between the surfaces eliminating the need traditional fasteners like nails
and screws. Adhesives offer the advantages of flexibility, resistance to
vibration, and improved aesthetics as they can be hidden from view.
Adhesives are widely used in construction industry for their ability to securely
join materials, improve structural integrity, and simplifying the assembly
process.

CONCEPT OF ADHESIVES:
Adhesives are substances that are used to join two or more surfaces together by
forming a bond between them. they are commonly called glues, cements, or
pastes and are available in various forms including liquid, solid and films. They
work by forming a chemical or physical bond between the surfaces. In chemical
bond, the adhesive reacts with the surface creating a strong bond. In a physical
bond, the adhesive adheres to the surface by surface tension creating a bond that
may be weaker than a chemical bond.
Adhesives have many applications and are used in a wide range of industries from
construction to automotive, packaging, and electronics. They can be classified
into several types based on their chemical composition, including:
1. synthetic adhesives: they are made using synthetic polymers, like epoxy
resins, cyanoacrylate and polyurethane.
2. natural adhesives: they are derived from natural sources such as animal hides
and bones, vegetable starches, and natural resins.
3. inorganic adhesives: they are made from inorganic materials like glass and
ceramic.
4. Pressure sensitive adhesives: characterized by their adherence to surfaces by
application of light pressure.
5. Hot applied adhesives: they are applied in a molten state and solidify when
they cool down.
Adhesives are versatile and provide several advantages over traditional joining
methods like welding, screws, etc. They can join dissimilar materials, reduce the
weight and cost, provide a smooth and even surface.
 TYPES OF ADHESIVES:

1. Epoxy adhesives: these are two part adhesives that consist of a resin and a
hardener. When mixed together hey form a strong and durable bond that is
resistant to water, heat , and chemicals.
2. Cyanoacrylate adhesives: Also known as superglue, these adhesives almost
instantaneously form a bond when exposed to moisture. They are ideal for
bonding small parts and for use in electronics.
3. Polyurethane adhesives: These adhesives can be applied to a variety of
surfaces including wood, metal, plastic and rubber. They are waterproof and
flexible making them ideal for outdoor applications.
4. Contact adhesives: These adhesives are applied to both the surfaces that are
to be bonded and are allowed to be dried before being pressed together. They
are suitable for large areas and are commonly used in automotive and
construction industries.
5. Hot melt adhesives. These are solid at room temperature but are molten
before application. they are commonly used for packaging and woodworking
applications.
6. Acrylic adhesives: These are known for their strength and resistance to
environmental factors like high temperature and moisture. They are commonly
used in automotive and aerospace industries.
7. Silicone adhesives: they are flexible and resistant to heat and chemicals. They
are commonly used in construction and automotive industries.
8. UV curing adhesives: these cure by exposure to UV rays making them ideal for
bonding glass and plastics.

CYANOACRYLATE ADHESIVES:
1. Surface Contact: When a cyanoacrylate adhesive is applied to a surface, it
comes into contact with moisture, which can be present in the form of
humidity or on the surface itself.
2. Polymerization: The moisture initiates a chemical reaction known as
polymerization. The cyanoacrylate monomers in the adhesive start to react
and form long chains, creating a polymer structure. This process occurs
rapidly, typically within seconds or minutes, depending on the specific
adhesive and environmental conditions.
3. Bond Formation: As the polymer chains form, they link together and create a
strong bond between the surfaces. The adhesive hardens and solidifies,
creating a durable and often transparent bond.
SILICONE ADHESIVES:

Silicone adhesives are a type of adhesive that are made from silicone
polymers. They are known for their flexibility, heat resistance, and ability to
adhere to a wide variety of surfaces, including metals, plastics, glass, and
ceramics.

Silicone adhesives form a strong bond that can withstand high temperatures,
making them useful for applications where heat resistance is required. They
are also resistant to water, chemicals, and weathering, which makes them
suitable for outdoor or wet environments.

These adhesives come in various forms, such as pastes, gels, and sealants,
allowing for different application methods. They can be used for bonding,
sealing, and gasketing purposes in industries like automotive, electronics,
construction, and household repairs.

Silicone adhesives provide reliable and durable bonds, and their flexibility
allows them to absorb vibrations and movements without cracking or losing
adhesion. They are easy to work with and can be applied using a caulking gun
or by squeezing the adhesive from a tube.

In summary, silicone adhesives are versatile, heat-resistant, and water-

resistant adhesives that can bond a wide range of materials together, making
them suitable for various applications.

EPOXY ADHESIVES:
1. Mixing: Epoxy adhesives are typically sold as two separate components—a
resin and a hardening agent. When you're ready to use the adhesive, you mix
these two components together in the specified ratio. The mixing ensures that
the resin and hardening agent combine thoroughly.
2. Chemical Reaction: Once the resin and hardening agent are mixed, a chemical
reaction called curing or polymerization begins. The curing process is initiated
by various factors like heat, moisture, or the presence of specific additives,
depending on the specific epoxy adhesive formulation.
3. Cross-Linking: During the curing process, the resin and hardening agent
molecules undergo cross-linking. This means that the individual molecules join
together, forming a three-dimensional network of strong and durable polymer
chains.
4. Bond Formation: As the epoxy cures and the polymer chains form, the
adhesive becomes solid and ha
Acrylic Adhesives:

Acrylic adhesives are based on acrylic polymers, which are typically in a liquid or
semi-liquid form.

These adhesives work by the evaporation of solvents or the application of heat,

which allows them to form a strong bond as the adhesive cures.

Acrylic adhesives can bond a wide range of materials, including plastics, metals,
glass, and wood.

They provide excellent adhesion, high strength, and resistance to temperature,

chemicals, and UV radiation.

Acrylic adhesives are commonly used in industries such as automotive,

construction, and electronics.

Polyurethane (PU) Adhesives:

PU adhesives are based on polyurethane polymers and are available in different

forms, including liquids, pastes, or reactive hot melts.

These adhesives work through a chemical reaction called cross-linking or curing,

which occurs when the adhesive is exposed to moisture or air humidity.

PU adhesives offer excellent bonding strength and flexibility, making them

suitable for bonding materials with different expansion and contraction rates.

They have good resistance to impact, heat, and chemicals, making them suitable
for a wide range of applications.

PU adhesives are commonly used in industries such as automotive, construction,

furniture, and footwear.
 SEALANTS:

Sealants are protective coatings applied to prevent the ingress of moisture, dirt,
contaminants, or other substances. The primary function of sealants is to create a
barrier that maintains the integrity and durability of the underlying material.

Sealants can be made from various materials such as silicone, polyurethane,

acrylic, epoxy, or rubber compounds. Each sealant has its unique properties and is
suitable for different applications.
Here are some key concepts related to sealants:
1. Application: Sealants are applied in liquid or paste form using a caulking gun,
brush , or a spray. The method of application depends on the type of sealant
and the surface it is being applied to.
2. Adhesion. Sealants adhere to the surface by forming a chemical bond, creating
a long lasting seal. The adhesion capability of the sealant depends on the
formulation of the sealant and compatibility with the surface.
3. flexibility: Many sealants are designed to accommodate the movement and
expansion of the materials they are applied to. They can stretch and compress
to some extent without losing their sealing properties. This is particularly
useful in areas where there may be structural shifts or vibrations.
4. Waterproofing: Sealants are often used to create a watertight barrier, to
prevent the intrusion of water in joints, gaps, and cracks. This is particularly
useful in areas such as bathrooms, kitchens, windows, roofs, and areas where
water exposure is a concern.
5. Weather resistance: Sealants can withstand various weather conditions
including temperature fluctuations, UV radiations, rain, and wind. Weather
resisting sealants can help maintain the integrity of the sealed surfaces over
time.
6. Chemical resistance: Some sealants are formulated to resist chemicals, acids,
or solvents making them suitable for use in industrial applications and areas
where chemical resistance is required.
7. Aesthetics: Sealants are often used to fill joints, seams or cracks to improve
the appearance of a surface. Colored and clear sealants are available to match
the surrounding materials.

TYPES OF SEALANTS:

There are various type of sealants available. Each is suitable for different
applications with unique properties. Here are the most common types of sealants:

1. Silicone sealants: Silicone sealants are known for their excellent flexibility,
adhesion, resistance to high temperatures, and UV resistance. They are
commonly used in construction, automotive and electric applications. They
offer a durable seal in areas exposed to water such as bathrooms, kitchens,
and windows.
 Polyurethane sealants: Polyurethane sealants are known for their high
strength and flexibility. They adhere to a variety of substrates and can
withstand movements making them suitable for sealing expansion joints,
concrete cracks, gaps in buildings and bridges. They are used in automotive
industries to join materials with different expansion coefficients.
Acrylic sealants: Acrylic sealants are economical and easy to work with. They
are adhesive to various substrates and can be painted over when cured. They
are commonly used for sealing joints, gaps, or cracks in interior applications
such as baseboards, moldings, and window frames. However they cannot be
used in areas exposed to water or extreme weather conditions.
Butyl rubber sealants : Butyl rubber sealants have a strong adhesion to a
variety of substrates and are highly resistant to moisture and UV radiations.
They are commonly used for roofing materials, windows and other outdoor
areas. They are also resistant to chemicals and can withstand extreme
temperatures.
Epoxy sealants: Epoxy resin sealants are known for their exceptional strength
and durability. They are adhesive to various surfaces and are resistant to
temperature, moisture and chemicals. They are commonly used in industrial
settings such as sealing concrete floors, metal joints, repairing cracks in
structure.

GLASS

Glass is a solid material that is made by melting certain substances and allowing
them to cool down and harden. It primarily consists of silica which is found in
sand, and other materials such as soda ash and limestone. The ingredients are
heated to a high temperature until they become molten liquid. As the liquid cools
down , it hardens and forms a transparent material called glass. The exact
composition may vary depending on the type of glass, but silica is the main
component in most glasses. Glass can be molded into different shapes and sizes
and used for variety applications like windows, doors, bottles and lenses.

GLASS MANUFACTURE IN SIMPLE TERMS:

Gathering of raw materials: The main ingredients for glass such as silica sand,
soda ash , and limestone are gathered and measured according to specific
proportions.
 Melting : Once gathered, the ingredients are placed in a furnace and heated to
a high temperature such as 1500 degrees Celsius until they become molten
glass.
Shaping: Once glass is in its molten state it is shaped into desired forms. There
are various methods of shaping the glass including blowing, pressing, and
drawing. These methods involve manipulating the glass by using molds,
blowing air into it, or drawing it through rollers depending on the desired
shape.
Annealing: After shaping, the glass undergoes a process called annealing. In
this process the glass is cooled slowly at a controlled rate to relieve the
internal stresses and make it stronger. This is necessary to prevent glass from
shattering easily.
Finishing: After the glass is hardened, it undergoes additional processes to
achieve the desired finish. This involves, polishing, grinding, cutting, applying
coatings or decorative elements.
Quality control: Throughout the manufacturing process, quality control
measures are taken to ensure that the glass meets the required standards. This
includes inspecting for defects, checking dimensions, and testing for durability
and strength.
Packaging: After the finishing processes the glass is ready to be packaged and
shipped to retail stores, construction sites and other industries that use glass.

FLOAT GLASS:
Float glass is a type of high quality flat glass used in windows and glass panels. It is
produced by pouring molten glass onto a bed of molten tin, which allows the glass
to float and spread out evenly. As it cools down and hardens , the glass forms a
smooth and uniform surface. Float glass is known for its clarity, transparency, and
excellent optical properties. It is commonly used in architectural applications,
automotive wind shields, and areas where high quality flat glass is required.

TEMPERED GLASS:
Tempered glass is a type of safety glass that has been treated to make it safer and
stronger than regular glass. It is made by heating the glass to a high temperature
and rapidly cooling it using a process called quenching. This process creates
internal stresses within the glass making it four to five ties stronger than regular
glass.
The main characteristic of tempered glass is that it breaks into small, relatively
harmless pieces when it shatters. This makes it useful in applications where safety
is a concern such as glass doors, shower enclosures, car windshields. If it does
break, tempered glass fractures into small pebble like pieces, rather than large
jagged shards.
Float Glass: Standard flat glass produced by floating molten glass on a bed of
molten tin. It is used for windows and basic architectural applications.

Tempered Glass: Glass that undergoes a heating and rapid cooling process to
make it stronger and safer. It breaks into small, less dangerous pieces when
shattered. Often used in doors, partitions, and windows requiring safety features.

Laminated Glass: Two or more glass layers bonded together with a transparent
interlayer, typically made of polyvinyl butyral (PVB). It provides safety and
security as it holds together when shattered, making it suitable for areas that
require impact resistance, such as storefronts and overhead glazing.

Insulated Glass: Consists of two or more glass panes separated by a spacer and
sealed to create an insulating space between them. This design helps to improve
thermal efficiency and reduce noise transmission.

Low-E Glass: Low-emissivity glass has a microscopically thin coating that helps to
reflect heat and UV rays, improving energy efficiency by reducing heat transfer. It
is often used in windows to enhance insulation and control solar heat gain.

Tinted Glass: Glass that is infused with color to reduce the amount of light and
heat transmission. It provides privacy and reduces glare from sunlight.

Frosted Glass: Glass with a textured surface that diffuses light, providing privacy
while allowing some light transmission. It is commonly used in doors, partitions,
and windows where visibility needs to be obscured.

PLASTIC:

Plastic is a material made from polymers, which are long chains of molecules.
They are synthetic substances that can be molded into different shapes when
heated and cooled. Plastic is lightweight, durable and versatile making it useful for
various purposes. However it is not biodegradable and can persist in the
environment for a long time, causing pollution.

TYPES OF PLASTIC IN CONSTRUCTION INDUSTRY:

PVC: It is a rigid plastic that is used for pipes, electrical insulation, window
frames and flooring. It is known for its durability and fire resistance,
affordability.
PE: polyethylene is a flexible plastic that is used for pipes, insulation and
waterproofing. It is lightweight, resistant to chemicals, and has good electrical
properties.
Polypropylene: It is a versatile plastic that is used for pipes, roofing, thermal
insulation and packaging. It is strong, chemical resistant and temperature
resistant.
 Polystyrene is a lightweight plastic used for packaging, insulation and
construction of temporary structures. It is durable but not as strong as other
plastics.
ABS: acrylonitrile butadiene styrene is a strong, impact resistant plastic used
for pipes, fittings and fixtures. It is commonly used for plumbing and drainage
system.

PROPERTIES OF PLASTIC:
lightweight: easy to handle , transport and install.
Durable: highly durable, can resist harsh environments and wear and tear
Versatile: Can be molded into different shapes.
Flexibility: can be bent without breaking.
Insulation: Have good thermal and electrical resistance
Chemical resistance: Exhibit resistance to various chemicals
Water resistant
Transparency: Acrylic and polycarbonate are transparent and can be used for
windows, display cases and lenses.
Recyclable: reduce environmental impact.
cost effective as compared to other materials.