CONCRETE TECHNOLOGY

CONCRETE
• Is considered as an artificial stone obtained by binding
together the particles of inert fine and coarse
materials with cement paste
• Is the most widely used man made construction
material in the world
• Cementious material + water + aggregates (fine &
coarse) + admixtures (optional) - mixed in required
proportions – placed in forms + curing – becomes
hardened into rock like mass is known as concrete
• Concrete is versatile building material because it has
strength from M10 to M100 and zero slump to
maximum slump
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 CONCRETE TECHNOLOGY

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 CONCRETE
Q. Concrete is neither as strong nor as tough as
steel, so why is it the most widely used
Engineering materials?
At least 3 primary reasons:
• Concrete possesses excellent resistance to
water
• Ease with which structural concrete elements
can be formed into a variety of shapes and
sizes
• It is usually the cheapest and most readily
available material on the job
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 CHAPTER # 1
Constituents of Concrete

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 1.1 Aggregates
• Gives body to concrete & occupies 70 to 80%
in concrete by volume
• Strongly influence the concrete strength
specially for high grade
• Fine and coarse aggregates
• Fine aggregates helps in producing
workability & uniformity in mixture and
assists cement paste to hold coarse aggregate
particle in suspension, which promotes
plasticity in mixture & prevents possible
segregation.
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 1.1 Aggregates

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 Classifications
1) Classification according to geological origin
1. Natural aggregates
2. Artificial aggregates
2) Classification according to Size
1. Fine aggregates (sand ≤ 4.75mm)
2. Course Aggregates(Gravel > 4.75mm)
3. All-in aggregates
4. Single size aggregates
3) Classification according to Shape
1. Rounded aggregates
2. Irregular/Partly rounded
3. Angular aggregates
4. Flakey & Elongated aggregates
4) Classification according to Unit weight
1. Normal weight aggregates
2. Heavy weight aggregates
3. Light weight aggregates
5) Classification according to Surface texture

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 1.1.1. Classifications
Classification according to geological origin
i. Natural aggregates
• Obtains from natural deposits of sand, gravel and
crushed rock derived from natural sources
• Sand & gravel are naturally deposited in river or
in quarries, which have been reduced to their
present size by natural agents
• Crushed aggregates are made by breaking rock
into required size by crushing & screening
• Igneous rock, metamorphic rock or sedimentary
rocks
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 1.1.1. Classifications
Classification according to geological origin
ii. Artificial aggregates
• Thermally processed materials such as broken
bricks, which are used for making light weight
concrete are called synthetic aggregates
• Aggregates made from industrial byproducts
• waste and recycled concrete from demolished
building and pavements

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ii. Artificial aggregates
• Air cooled slag - Air-cooled slag is lump ore getting
from blast furnace on cooling.
• Sintered fly ash - available from thermal power
plants

Air cooled slag

Sintered fly ash

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 1.1.1. Classifications
Classification according to Size
i. Fine aggregates
• Particle size < 4.75mm
• Range of 4.75mm to .075mm
• Natural sand & crushed stone sand
• Fine aggregates may be described as coarse, medium
& fine sands
• As per IS:383-1970, based on particle size distribution,
fine aggregates are classified into 4 zones: zone I to
zone IV

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 1.1.1. Classifications
 Classification according to Size
ii. coarse aggregates
• Particle size > 4.75mm
• Ranges from 4.75mm to 80mm, but for mass concrete,
it may contain up-to 150mm
• It may be natural or uncrushed gravel, crushed gravel
or stone, mixture of above two
• The graded coarse aggregates is described by its
nominal size of 40mm, 20mm, 16mm, 12.5mm etc
• Choice of maximum size of aggregate depends on
o Thickness of element,
o Cover
o Mixing, handling & placing techniques
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 1.1.1. Classifications
Classification according to Size
iii. All-in aggregates
• These are combined aggregates available in
nature having different particle size of fine &
coarse
• Lacking particle size is
added to fulfill the grading
of aggregates
• Generally, not used for
making high quality
concrete
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 1.1.1. Classifications
Classification according to Size
iv. Single size aggregates
• Aggregates dominated
by single size particles or
particles within a narrow
limit of size fraction

• e.g. 20mm single size aggregates means most

of aggregates are passed from 20mm sieve &
major portion of which are retain on 10mm
sieve
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 1.1.1. Classifications
Classification according to Shape
i. Rounded aggregates
• Mostly natural aggregates
rounded surface e.g. river
or seashore gravel, desert
or wind blown sands
• Minimum voids, 32% to 34%
• Minimum surface area to volume, thus requiring
minimum cement paste to make concrete
• Interlocking between particles is less or poor i.e.
poor bonding
• Unsuitable for high strength concrete
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 1.1.1. Classifications
Classification according to Shape
ii. Irregular/Partly rounded
aggregates
• Aggregates with partly
rounded surface e.g.
pit sand & gravels
• Voids 35% to 38%
• Requires more cement paste for a given workability
• Interlocking between particles is better than rounded
aggregates
• unsuitable for high strength concretes
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 1.1.1. Classifications
Classification according to Shape
iii. Angular aggregates
• Has sharp, angular and
rough surfaces
• Obtained from crushed
stones i.e. crushed aggregates
• Maximum void, 38% to 40%
• Interlocking between particles is good, therefore forms
good bonds
• Requires more cement paste to make workable
concrete
• Suitable for high strength concrete
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 1.1.1. Classifications
 Classification according to Shape
iv. Flakey & Elongated aggregates
• Flakey: if least dimension
(thickness) < 3/5th of mean dimension
• Elongated: if greatest dimension
(length) > 9/5th of its mean dimension
• Mean dimension: average of sieve
sizes through which the particles
passed & are retained, respectively
• Adversely affect the durability of concrete as they tend to
be oriented in one plane with voids forming underneath
• Should restricted to 10 to 15%
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 1.1.1. Classifications
Classification according to Shape
iv. Flakey & Elongated aggregates
• Elongation index : % by wt. of elongated particles
present
• Flakeyness index : % by wt. of flakey particles present

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 Flakiness Index & Elongation Index
(IS2386:Part1)

• Flakiness index is percentage by weight of particle in it whose

least dimension is <0.6 times their mean dimension
Ex. Passing through 20mm & retained on 16mm sieves,
=(20+16)/2 x 0.6=10.8mm

• Elongation index is percentage by weight of particle in it

whose greatest dimension is >1.8 times their mean dimension
Ex. Passing through 20mm & retained on 16mm sieves,
=(20+16)/2 x 1.8=32.4mm
 1.1.1. Classifications
 Classification according to Unit weight
i. Normal weight aggregates
• Sp. Gr. Between 2.5 to 2.7
• Bulk density between 1520 to 1680 Kg/m3
• Produce normal weight concrete with
approximately 24KN/m3(24 to 26)
• Crushing strength at 28 days between 15 to 40
MPa
• e.g. most natural sand & gravels, crushed
aggregates from granite, basalt, quartz etc.
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 1.1.1. Classifications
Classification according to Unit weight
ii. Heavy weight aggregates
• sp. Gr. 2.8 to 2.9
• Bulk density > 2080Kg/m3
• Produce concrete with unit wt. > 24KN/m3 (28 to
57KN/m3)
• e.g. magnetite, barytes, scrap iron
• They produce dense & crack free concrete, but
chances of segregation

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 1.1.1. Classifications
Classification according to Unit weight
iii. Light weight aggregates
• sp. Gr. < 2.5
• Bulk density < 1120Kg/m3, i.e. low density
aggregates
• Produce concrete with unit wt. < 24KN/m3
• e.g. natural - diatomite, pumice, volcanic cinder
Artificial – bloated clay, fly ash, blast furnace
slag
• Thermal insulation

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 1.1.1. Classifications
Classification according to Surface texture
1) GLASSY: aggregates having glassy surface, e.g. black
flint
2) SMOOTH: aggregates with smooth surface, e.g.
chest, slate, marble
3) CRYSTALLINE : aggregates with crystalline surface
texture, e.g. basalt, dolerite, granite
4) GRANNULAR : aggregates formed essentially with
granular material, e.g. sand stone, oolite
5) HONEY COMBED OR POROUS : aggregates with
porous surface texture, e.g. pumice

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 1.1.2 Gradation
• Particle size distribution of aggregate is termed as
gradation – sieve analysis is conducted
• Proper gradation ensures that a sample of aggregate
contains all standard fraction of aggregates in required
proportion such that sample contain minimum voids
• Well graded aggregate > min. voids > min. paste to fill up
voids > less quantity of cement & water > increased
economy, higher strength, lower shrinkage, greater
durability
• For producing workable concrete, it is most important
factor and gradation increases workability by lubricating
the larger particles by fine particles
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 1.1.2 Gradation
Categories of aggregate grading
1. Well graded aggregate
2. Poor graded aggregate
3. Gap graded aggregates

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 1.1.2 Gradation
1. Well graded aggregate
• Has gradation of particles such that fairly evenly
spans the sizes from the finest to coarsest
• A slice of concrete shows a packed field of many
different particles sizes
• Good interlock and low permeability
• It is characterized by S-shaped in gradation curve

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 1.1.2 Gradation
2. Poor graded aggregate
• Has variation in particle sizes
• Contains the aggregate particles of almost of same
size
• Particles when packed together, leaves relatively
large voids in the concrete
• Characterized by steep curve
• Also called uniform graded
• Good interlock and low permeability

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 1.1.2 Gradation
3. Gap graded aggregate
• Consist of aggregate particles in which some
intermediate size particles are missing
• Also known as skip graded
• A core slice concrete shows a field of small sized
aggregate interspersed with slightly isolated, large
aggregate pieces embedded in a small sized
aggregate
• Characterized by a gradation curve with a hump in
between

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1.1.3 characteristics & Significance
1. Strength of Aggregates
2. Particle shape & surface texture
3. Specific gravity
4. Density (Bulk density)
5. Voids & porosity
6. Absorption capacity & moisture content
7. soundness

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1.1.3 characteristics & Significance
1. Strength of Aggregates
• Crushing strength, modulus of Elasticity,
toughness, hardness, abrasion value, impact
value, attrition test etc.
• These characters of aggregates are valuable in
preserving durability of concrete & resisting the
loads or forces
• Strength of parent rock don’t represent strength
of aggregate in concrete
• Mechanical properties of aggregate influence the
strength of concrete when cement provide
satisfactory or good result

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 1.1.3 characteristics & Significance
2. Particle shape & Surface Texture
• They influence the properties of fresh concrete more
than hardened concrete
• Affects on workability of concrete & bond between
aggregates and mortar
• Particle shape refers to geometrical characteristics
• surface texture is measure of the smoothness or
roughness of aggregate surface, is based on visual
examination of the specimen .
• Compared to smooth & rounded particles, rough
textured, angular & elongated particles require more
cement paste to produce workable concrete mixtures,
thus increasing cost
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 1.1.3 characteristics & Significance
3. Specific Gravity
• gr. Sp = masssolid/masswater for same volume & temp.
• Due to voids in aggregate, sp. gr. are different:
 Absolute sp. Gr. -- vol. of solid material excluding the voids
 Apparent sp. Gr. -- vol. of solid materials including voids,
(2.6 to 2.7 for common aggregates)
• Sp. gr. gives valuable information on its quality & properties,
like higher sp.gr. -- harder & stronger it will be, light wt. &
heavy wt. aggregate
• Sp. Gr. Is used in calculation of concrete design mixes,
compaction factor etc.
• Sp.gr. Above or below the normal value indicates the
changes required in grading or shape of aggregates
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 1.1.3 characteristics & Significance
4. Density(Bulk density)
• Density = mass/volume
• Bulk density includes the volume of voids in particles,
apparent sp.gr. related to bulk density
• Bulk density shows how densely the aggregate is
packed and it is not possible to pack aggregates
together without void space
• Higher the bulk density , the lower is the void to be
filled by sand and cement
• Used for judging the quality of aggregates with normal
density aggregates and it determine the type of
concrete for which it may be used
• Conversion of proportion by weight into proportion by
volume
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 1.1.3 characteristics & Significance
5. Voids & Porosity
• Empty space between aggregate particles
• Difference between gross volume of aggregate
mass and volume occupied by particles alone
• Minutes holes or cavities formed in particle is
known as pores
• Natural aggregates are porous & size may range
from microscopic to macroscopic
• Pores in particle may continuous or discontinuous
• Porosity of aggregate particle leads the porosity
of concrete
• Permeability & absorption affect the bonding and
strength of concrete
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 1.1.3 characteristics & Significance
6. Absorption capacity & moisture content
• Pores in the aggregates are reservoirs of free moisture
• % of water absorbed by an aggregate when immersed
in water is called absorption of aggregate
• When all the pores are full i.e. saturated, & there is no
water film on the surface, then it is called Saturated
Surface Dry (SSD) aggregate
• Absorption Capacity is the total amount of moisture
required to bring an aggregate from oven dry to SSD
condition.
• Effective Absorption capacity is relates to Air dry to
SSD condition
• Surface moisture is amount of water in excess than
water required for the SSD condition
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 1.1.3 characteristics & Significance
6. Absorption capacity & moisture content

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 1.1.3 characteristics & Significance
7. Soundness
• It is resistance to the weathering i.e. alternate
wetting & drying or alternate freezing &
thawing
• Unsound aggregate changes its volume by
weathering, results in the deterioration of
concrete
• Porous aggregates which has high moisture
absorption are unsound aggregates

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 Properties of Aggregates
1. Grading Zone
• Sieve Analysis
2. Durability, abrasion
• 2A-Aggregate Crushing Value (ACV)-(%)
• 2B-Ten % Fine Value (TFV) –(KN)
3. Particle shape and surface texture
• 3A-Elongation Index (EI) - (%)
• 3B-Flakiness Index (FI)– (%)
4. Clay Content – (%)
5. Absorption and surface moisture
• Moisture Content – (%)
6. StrengthTest
7A.Los Angeles Abrasion Test(LAAT)– (%)
7B.Aggregate Impact Value (AIV) – (%)
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 Sampling of Aggregates for use in
construction
• Cannot test for whole material used in the
field
• Small quantity taken which represents whole
material
• Need special attention during taking sample
• Wrong sampling may affects on reality
• 3 no. samples collection from each 1/3rd mid
zone from min. 30cm inside the surface
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 Quality of Aggregates depends upon
type of Crusher Plant also
Item Headworks, SIP, Headworks, Tunnel works, BBDMP,
Banke RJKIP, Kailali Surkhet

Production Natural and crushed Natural and crushed Natural and crushed
together (180,000m3) separately (52,000m3) together
(80,000m3)

Type Jaw Crusher only Jaw Crusher only Jaw, Cone & Impact
Crusher

Sizes (mm) 0-5, 5-20, 20-40 0-5, 5-20, 20-40 0-5, 5-10, 10-20

Flaky & Elongated Flaky & Elongated Very less Flaky &
Elongated
Quality
Normal ACV No change in ACV

Source: QC Er. Jagadiswar M. Shrestha

 Crusher Plant

Source: QC Er. Jagadiswar M. Shrestha

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 Jaw chusher

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 Crusher Plant

Source: QC Er. Jagadiswar M. Shrestha

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Shape of Aggregates produced from
Different Crusher Plant

Production with
Jaw crusher
only

Production with
Jaw, Cone &
Impact crusher
(BBDMP)

Source: QC Er. Jagadiswar M. Shrestha

 Thank you for well attention
End of 1.1 Aggregates

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