BUILDING MATERIALS & CONCRETE TECHNOLOGY

SUBJECT: BUILDING MATERIALS & CONCRETE TECHNOLOGY

II YEAR B.TECH, CIVIL ENGINEERING

BY

DR V.MADHUSUDHAN RAO, FRSC

 Fresh Concrete:

Manufacturing Process
A good quality concrete is essentially a
homogeneous mixture of cement, coarse
and fine aggregates and water which
consolidates into a hard mass due to
chemical action between the cement and
water. Each of the four constituents has a
specific function.
 Fresh Concrete:

Manufacturing Process
1.The coarser aggregate acts as a filler.
2.The fine aggregate fills up the voids between
the paste and the coarse aggregate.
3.The cement in conjunction with water acts as a
binder.
4.The mobility of the mixture is aided by the
cement paste, fines and nowadays, increasingly
by the use of admixtures.
 Concrete:

Manufacturing Process
1.Most of the properties of the hardened concrete
depend on the care exercised at every stage of the
manufacture of concrete.

2.A rational proportioning of the ingredients of

concrete is the essence of the mix design.

3.It may not guarantee of having achieved the

objective of the quality concrete work
 Fresh Concrete:

Manufacturing Process
1.Quality control is to ensure the production of
concrete of uniform strength from batch to batch.

2. Some rules to be followed in the various stages of

concrete production

3. The stages of concrete production are:

 Concrete:

Manufacturing Process
The stages of concrete production :
1.  Batching or measurement of materials
2.  Mixing
3.  Transporting
4.  Placing
5.  Compacting
6.  Curing
7.  Finishing
 Fresh Concrete:
:
Batching:
1.Volume Batching

2.Weight Batching:
 Concrete:
Mixing
1.Thorough mixing of the materials is essential for
the production of uniform concrete.
2.The mixing should ensure that the mass
becomes homogeneous, uniform in colour and
consistency.
3. Methods adopted for mixing concrete:
(i ) Hand mixing (ii )Machine mixing :
 Concrete:
Hand Mixing
 Concrete:
Machine Mixing
 Concrete:
Vibration of Concrete: The vibration of concrete is
a critical step in concrete construction.
1.Whenever we pour concrete, tiny air bubbles
form  
2.Vibration is to Remove of Air Bubbles

A concrete vibrator produces stronger concrete

by vigorously shaking the concrete.
 Concrete:
Vibration of Concrete

The process to eliminate air bubbles present in

the freshly poured concrete and provide a
compact concrete mass.

Fresh concrete can be vibrated by hands or by

concrete vibrating machines
 Concrete:
Vibration of Concrete
Surface Vibration
Surface vibrators or jumpers are used to vibrate
the concrete directly poured onto the surface. It
is directed manually onto the surface to perform
vibration. It provides a smooth surface and a
nice appearance to the final concrete. This
method is limited to slab construction with
depth less than 6 feet.
 Concrete:
Vibration of Concrete
Surface Vibration
 Concrete:
Vibration of Concrete
Internal Vibration
Internal vibrators are the most commonly
used vibrators in concrete construction.
A probe-like internal vibrator is placed
onto the wet concrete and slowly
withdraws it after vibration
 Concrete:
Vibration of Concrete: Internal Vibration
 Concrete:
Concrete Workability:
Concrete workability basically refers to how easily
freshly mixed concrete can be placed, consolidated
and finished with minimal loss of homogeneity.
 workability of concrete is determined by how fluid the
mix is (i.e. the cement to water ratio)
 Concrete:
Concrete Workability:
The desired workability is not same for all types of
concrete.
More workability is required for a thin inaccessible
section or heavily reinforced section rather than a
mass concrete body.
Hence, we can’t set a standard workability for all
casting works. 
 Concrete:
Concrete Workability:
Desirable Workability for Construction depends on
Two Factors:
1.Section size, amount and spacing of reinforcement: 
When a section is narrow, complicated, several narrow
corners, inaccessible parts; a highly workable concrete
is desirable to obtain full compaction When the
section is crowded with steel reinforcement and
spacing of bars is relatively small, compaction can be
difficult and hence highly workable concrete is
recommended in such cases
 Concrete:
Concrete Workability:
Desirable Workability for Construction depends on
Two Factors:
2.Method of compaction: If concrete is compacted
manually, more workability is recommended because
hand compaction is not very much uniform and
effective. If there is a scope of the vibrator or machine
compaction, we can choose workability from a wide
range
 Concrete:
Concrete Workability:
Strength of Concrete & Workability Relationship
The strength of concrete depends on density ratio or
compaction and compaction depend on sufficient
workability.
Fresh concrete must have a workability as compaction
to maximum density is possible with a reasonable
amount of work
 Concrete:
Methods of Improving Workability of Concrete
1.Increasing water/cement ratio
2.Using larger aggregate
3.Using well-rounded and smooth aggregate instead of
irregular shape
4.Increasing the mixing time and mixing temperature
5.Using non-porous and saturated aggregate
6.With addition of air-entraining mixtures
7.Adding appropriate admixtures
 Concrete:
Measurements of workability/Workability Tests
1. Slump test
2. Compacting Factor Test
3. Vee-Bee test
4. Kelly Ball Test
 Concrete:
Measurements of workability/Workability Tests
 Concrete:
Effect of time and temperature on workability
With the passage of time after mixing ingredients of
concrete with water, workability of concrete starts
shrinking.
This happens because of fluidity loss from the concrete.
Fluidity is the amount of available water in concrete that is
being utilized in hydration of cement compounds for the
sake of bonding.
When hydration of cement compounds C3S and C3A occurs
than water within a concrete gets absorbed by these
compounds and now the least amount of water will remain
for workable concrete.
 Concrete:
Effect of time and temperature on workability
When temperature increases, then in the same proportion
workability of fresh concrete decreases.

The reason that stands behind is “ when temperature

increases then evaporation rate also increases due to that
hydration rate decreases and hence, concrete will gain
strength earlier 
 Concrete:
Bleeding and segregation
Bleeding is a form of segregation in which water
present in the concrete mix is pushed upwards due to
the settlement of cement and aggregate.

The specific gravity of water is low, due to this water

tends to move upwards. Bleeding of the water
continues until the cement paste has stiffened enough
to end the sedimentation process.
Bleeding ordinarily occurs in the wet mix of concrete
 Concrete:
Bleeding and segregation
1.The Prime factor for bleeding in concrete is the high
dosage of Water cement ratio.
2.Higher water-cement ratio weakens concrete and
leads to excessive bleeding.

The bleeding in concrete is not harmful if the rate of

evaporation of water is equal to the rate of bleeding.
Normal bleeding is quite good, and it enhances the
workability of concrete
 Concrete:
How bleeding effects concrete stability:
1.During Bleeding certain amount of cement moved
along with water to the concrete surface.

2.When the top surface is worked up with the trowel,

the aggregate goes down and cement paste forms at
the top surface this is called ‘Laitance in concrete.’ 

3.Due to the formation of Laitance, structures may

lose its wearing capacity and decreases its life.
 Concrete:
How bleeding effects concrete stability:
4..Due to Bleeding channels are formed, concrete
becomes permeable ,

5. Water voids are formed in the matrix and reduces

the bond between aggregate and the cement paste.

6.Forming of water at the top surface of concrete

results in delaying the surface finishing.
 Concrete:
How the bleeding in concrete is controlled:-
:
1.Bleeding in concrete is controlled by Adding
minimum water content in the concrete mix.

2.Encouraging the use of air en-training admixtures in

the mix.

3.By adding more cement in the mix

.
 Concrete:
Segregation in concrete:-
:
Segregation is the “Separation of constituent materials
in concrete.”.
1.Separation of Coarse aggregate from the concrete
mixture,
2.Separation of Cement pastes from the concrete
during its plastic stage.
3.Separation of water from the concrete mix (Bleeding
in concrete
 Concrete:
Segregation in concrete:-
:
The primary cause of Segregation in concrete is the
differences in specific gravities of the constituents, 
Specific gravity of Cement is in between 3.1-3.6g/cc,
and for aggregate it lies between 2.6-2.7g/cc due to
this differences, the aggregate separates from the
matrix and causes segregation in concrete.
 Concrete:
Other factors causing segregation in concrete:-
:
1.Transporting concrete mixes for long distances.

2.Poorly proportioned mix, where sufficient matrix is

not there to bind the aggregates.

3.Dropping concrete from more than 1m.

4.Vibrating concrete for a long time

 Concrete:
How to minimize segregation in concrete:-
1.Segregation can be controlled by maintaining proper
:
proportioning the mix.

2.By peculiar handling, placing, transporting,

compacting and finishing of concrete

3.Adding air entraining agents, admixtures and

pozzolanic materials in the mix segregation controlled
to some extent.
 Concrete:
How to minimize segregation in concrete:-
1.Segregation can be controlled by maintaining proper
:
proportioning the mix.

2.By peculiar handling, placing, transporting,

compacting and finishing of concrete

3.Adding air entraining agents, admixtures and

pozzolanic materials in the mix segregation controlled
to some extent.
 Concrete:
Ready Mixed Concrete :
Ready Mixed Concrete is a tailor – made concrete that
is manufactured in a factory or within a batching plant
:
based on the standard required specifications. The
prepared concrete mix is then taken to the work site
within transit mixers mounted over a truck.
 Concrete:
Ready Mixed Concrete :
This type of concrete guarantee higher durability and
sustainability. As the work is carried out by an expert
:
supplier, the mixture formed is precise and of higher
quality. Special concrete mixtures too can be made
efficiently by this concrete manufacturing method.
 Concrete:
Types of Ready Mixed Concrete
There are three types of ready mix concrete (RMC)
depending upon the mixing of the various ingredients
:
1.Transit mixed concrete
2.Shrink mixed concrete
3.Central mixed concrete
 Concrete:
Types of Ready 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
 Concrete:
Types of Ready Mixed Concrete
1. Transit mixed concrete
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:
Types of Ready Mixed Concrete
1. Transit mixed concrete
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.
 Concrete:
Types of Ready Mixed Concrete
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
 Concrete:
Types of Ready Mixed Concrete
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.
 Concrete:
Advantages of Ready Mixed Concrete
1.Quality concrete is obtained as a ready-mix concrete
mix plant make use of sophisticated equipment and
consistent methods. There is strict control over the
:
testing of materials, process parameters and
continuous monitoring of key practices during the
manufacture.Poor control on the input materials,
batching and mixing methods in the case of site mix
concrete is solved in a ready-mix concrete method.
 Concrete:
Advantages of Ready Mixed Concrete
2.Better handling and proper mixing practice will help
to reduce the consumption of cement by 10 – 12%.
:
3. Use of admixtures and other cementitious materials
will help to reduce the amount of cement. The
concrete mixed is used with high versatility. It is placed
by following best concrete placing methods.
 Concrete:
Advantages of Ready Mixed Concrete
4.Cement is saved and the dust caused is reduced as
ready mix concrete make use of bulk concrete instead
of bags of cement.
:5. Cement saving will conserve the energy and the
resources. Less consumption result in less production
of cement hence less environmental pollution.

6. More durable structure is obtained thus increasing

the service life and saving the life cycle costs..
 Concrete:
Disadvantages of Ready Mixed Concrete
1.The transit time from the time of preparation of
concrete to the delivery site, will result in loss of
workability.
: s
2.This will demand for additional water or admixtures
to maintain the workability as per the specification.

3. At site, the QA/QC engineer are supposed to check

the workability through slump test before using it for
construction
 SHOTCREAT CONCRETE

Shotcrete, also called Gunite, concrete applied

by spraying.
Shotcrete is a mixture of aggregate and
portland cement, conveyed by compressed air
to the nozzle of a spray gun, where water is
added. The wet mixture is then sprayed in
place and may be carved or troweled almost
immediately.
SHOTCREAT CONCRETE

.
 SHOTCREAT CONCRETE

Shotcrete is used to reinforce both temporary

and permanent excavations. It may be
employed, in concert with lagging and other
forms of earth anchor, to stabilize an
excavation for an underground parking
structure or hi-rise buildings during
construction.