Cement Concrete

What is Cement Concrete?

Cement Concrete

Cement Paste Phase Aggregate Phase

(OPC, PPC....)

Cement + Admixtures + Water Coarse Fine

SP, VMA, SRA... Synthetic Recycled

Mineral + Chemical River Msand

Synthetic Natural Recycled
Pozzolanic + Inert Fillers
FA, slag, silica fume, Metakaolin Light wt. Normal wt. Heavy wt.

2
 Why Concrete?
5.5 billion tonnes of concrete per year
• Excellent water resistance
• Ease of moulding in to any shape and size
• Availability of raw materials
• Economy
• Less energy consumption(relatively with steel)
• Sustainable
• Durable
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 Pantheon
World's largest unreinforced concrete dome
Rome - 126 AD

Colosseum
Elliptical amphitheatre
Rome - 80 AD

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Cement
 History of Cement
• Lime - Hydraulic Cement - Portland Cement

• John Smeaton (Civil Engineer) -1756 - Eddystone Lighthouse - discovered that

the best limes for mortar contained a high degree of clayey matter

• Ultimately, this kind of lime was used in equal quantities with

pozzolana for the construction of Light house

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 Portland Cement
• L. J. Vicat: Prepared artificial hydraulic lime by calcining an intimate mixture of limestone
(chalk) and clay – principal forerunner to Portland Cement

• 1824 – Joseph Aspdin, while obtaining a patent for his hydraulic cement, termed it as Portland
cement, due to the resemblance of hardened cement in appearance and quality of Portland
stone (limestone from Dorset, UK)

K
tla n d, U
r
Isle of Po 7
 BIS Classification
BIS classifies cements into the following major categories:
Ordinary Portland Cement 33 grade – IS:269
43 grade – IS:8112
53 grade – IS:12269
Portland Cement, Low Heat – IS:12600
Rapid Hardening Portland Cement – IS:8041
Portland-Pozzolana Cement (PPC) – IS:1489
Portland-Slag Cement (PSC) – IS 455
OPC vs. PPC
1.Availability
2. Strength and durability of concrete 8
 Properties of cement
The properties of cement typically measured in any laboratory include:
Normal consistency (Vicat apparatus) IS 4031 Part 4
Normal consistency is an empirical measure that indicates the minimum water required to
produce a certain level of fluidity in the cement paste. It also enables the design of the paste
for the setting time and compressive strength experiments.

Setting time (Vicat apparatus) IS 4031 Part 5

Initial setting time (> 30 min.), Final Setting time (< 600 min.) – Quality control test for
cement. Initial and final setting times of cement - Vicat apparatus (ASTM C 91, 2008).

False Set (Vicat apparatus) IS 4031 Part 14

If early development of stiffness can be dispelled and plasticity regained by further mixing
without addition of water then it is termed as false set.

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 Properties of cement
The properties of cement typically measured in any laboratory include:

Heat of Hydration (Calorimeter) IS 4031 Part 9

Water Retentivity (Water retention apparatus) IS 4031 Part 13

Water retentivity of Masonry cement - that resists rapid loss of water to highly absorbent
masonry units

Soundness (Le Chatelier apparatus) IS 4031 Part 3

The soundness of cement is related to its ability to retain its volume upon hydration.
Unsoundness can cause cracks, undue expansion and disintegration of concrete.
Depends on free lime, magnesia (Max. 5 %)

Chemical Analysis IS 4032

Gives oxide composition, loss of ignition, insoluble residue
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 Properties of cement
Compressive strength* IS 4031 part 6
Measured in mortar.
28 day strength with intermediate strengths (3 and 7 days essential)
Fineness (Blaine air permeability test) IS 4031 Part 2
OPC ≥ 225 m2/kg (IS 12269)

PSD - Laser particle size and shape analyser

Size of 150 to 1 µm
Avg. particle size 15 µm.

Specific gravity (Le Chateliers Flask) IS 4031 Part 11

using an inert liquid
Typical values 3.10 – 3.16.
Bulk density 1440 kg/m3
11
Gas Pycnometer
Cement storage (IS 4082) and strength loss
Store in dry and free from moisture
Store in a raised platform – 150 mm (approx)
Cover with Tarpaulin
Air tight doors and windows
First in First out

Expected loss of cement strength for period of storage

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Santhakumar, A. R., 2012
 Aggregates in concrete

(Fine and Coarse)

IS 2386 and IS 383 (2016)

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 Introduction
• Why aggregates?

• Occupies 60-80 % of the volume of concrete

• 4.5 billion tons of aggregates in concrete used worldwide

• Challenges – environmental concerns; shortage and alternative resources

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 Fine aggregate (4.75 mm to 150 micron)
• River sand (from river beds)
• Crushed stone sand or Manufactured sand (by crushing hard stone)
• Crushed gravel sand or Manufactured sand (by crushing gravels)
• Light weight aggregates/ Synthetic aggregates (Natural – Vermiculite, Synthetic - fly ash)
• Sea Sand (Sea shore)
• Recycled aggregates and Recycled Concrete Aggregates
• Desert sand

Coarse aggregate (4.75 mm to 40 mm)

• Uncrushed stone (rounded aggregates)
• Crushed stone (angular aggregates)
• Light weight aggregates/ Synthetic aggregates (Natural – Pumice, Synthetic - fly ash)
• Heavy weight aggregates (Hematite, Magnetite or steel shots)
• Recycled aggregates
16
Characteristics and Significance IS 2386 (Part 1-8) and IS 383
Particle size distribution - Packing density
Density (specific gravity) - Mixture design calculations
Strength (Crushing Value) - Acceptability
Stiffness (Modulus of elasticity) - Dimensional stability
Toughness - Impact resistance
Hardness - Abrasion resistance
Soundness - Volume change
Water absorption - Quality control
Shape - Flow properties
Texture - Workability & Paste aggregate bond
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 Water
• Potable water to be used.
• PH
• For non-potable water, limits are placed on

Other problems such as efflorescence can occur when non-potable water is

used
• Sea water 18
MINERAL ADMIXTURES

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 Types of Mineral admixtures/Pozzolanas
• Natural
• Volcanic glasses
• Volcanic tuff
• Shales
• Diatomaceous earth
• Industrial
• Fly ash (Class F and Class C)
• Ground granulated Blast furnace slag
• Silica fume
• Metakaolin
• Lime stone powder
• Agro based
• Rice husk ash
• Bagasse ash
• Palm oil Fuel ash
• Inert filler (rock dust)

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 Typical compositions

% by PC GGBS F-FA C-FA SF

mass
SiO2 21 35 50 35 90
Al2O3 5 8 25 20 2
Fe2O3 2 3 10 5 2
CaO 65 40 1 20 -

PC: Portland cement, GGBS: Ground granulated blast furnace slag, F-

FA: Type F fly ash, C-FA: Type C fly ash, SF: Silica fume

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 Microscopic Images of Materials

OPC 53

Fly Ash
Ultra fine Fly
Ash

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 Microscopic Images

GGBS Ultra Fine slag

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 Cost & Replacement levels
• Cement OPC 53 - 6.50 INR/kg
• Fly ash (F) - 2.40 INR/kg
• Ultra-fine fly ash - 9.50 INR/kg
• GGBS - 2.00 INR/kg
• Ultra-fine GGBS - 18.00 INR/kg
• Silica fume - 25.00 INR/kg

· Replacement level

· Benefits are due to the pozzolanic reaction that produces additional C-S-H, as
well as due to the particle packing (filler effect) of the pozzolanic particles
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CHEMICAL ADMIXTURES

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 What is a chemical admixture?
• Any chemical additive to the concrete mixture that enhances the properties of
concrete in the fresh or hardened state

• Broad Classification

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Standards relevant to Chemical Admixtures
ASTM C 1017:1998
IS 9103:2004
ACI 212-4R:1993
EN 934-2:2000
JIS A 6204:1995

ASTM Classification (ASTM C 494:1992)

Type A – Water Reducing
Type B – Retarding
Type C – Accelerating
Type D – Water Reducing and retarding
Type E – Water Reducing and accelerating
Type F - High range water reducing
Type G - High range water reducing and 27
Water Reducers
 Broad classification
Water Reducers

Normal Mid-range High range

5 - 8% water reduction 8 - 15% water reduction 15 - 40% water reduction

Water reducers can be used in 3 ways. For a given dosage,

1. Consistency Increase
2. Strength Increase
3. Cement saving
Water reducer (WR) = Plasticiser
High range water reducer (HRWR) = Super Plasticizer (SP) 29
 Cost Benefit Analysis

Class Relative cost

Lignosulphonates 1
Sulphonated melamine formaldehyde 4
(SMF)
Sulphonated naphthalene formaldehyde 2
(SNF)
Polycarboxylic ether (PCE) 4

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Mixture Design of Concrete

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 Mixture details – Field Experience

Mix Strength (MPa) =C :FA :CA (by

vol.)
M 5 =1 :5 :10
M 7.5 =1 :4 :8
M 10 =1 :3 :6
M 15 =1 :2 :4
M 20 =1 :11/2 :3
M 25 =1 :1 :2

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Nominal Mixtures (as per IS 456:2000)
Grade of Total Proportion of Maximum w/c
concrete quantity (kg) fine to coarse quantity of
of dry aggregate, by water per 50
aggregate mass kg cement
(fine and (litres)
coarse) by
mass per 50
kg of cement
M5 800 Generally 60 1.20
M7.5 625 1:2 but 45 0.90
subjected to
M10 480 34 0.68
an upper
M15 350 limit of 1:1.5 32 0.64
M20 250 and a lower 30 0.60
limit of 1:2.5 33
 Mixture design (IS 10262:2009, IS 456:2000)
• Mixture design is an optimisation process which involves selection and determination
of appropriate proportions of materials used for a specific requirement such as
workability, strength and durability.

• Primarily based on strength, durability are usually covered by codes in terms of

minimum and maximum w/c, cement contents.

• Use of admixtures and its effect on mixture design are not directly addressed in most
guidelines.

• Mixture design should satisfy three criteria:

i) Fresh concrete -workability
ii) Hardened concrete - required strength, durability
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iii) Maximum overall economy (primarily cost of cement).
 Standard Mixture Design methods

Guidelines for mixture proportioning in

• BIS (Bureau of Indian Standards)10262 and IS 456
• ACI (American Concrete Institute) 211
• DOE (Department of Environment) method
• USBR (United States Bureau of Reclamation) method

Trials mixtures

Fundamental principle of conventional methods: Workability and Strength = f (w/c)

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IS 10262 (2009)

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General Data for Mixture Proportioning
• Characteristic Strength
• Type of cement
• Exposure conditions
• Minimum cement content
• Maximum cement content
• Maximum w/c ratio
• Type of aggregate
• Max. nominal size of aggregate
• Workability
• Maximum Temperature of concrete during placing
• Method of transporting and placing
• Admixture required/ not required, Type of admixture
• Early age strength requirements (if required) 37
Data about the raw materials
1. Grade of Cement

2. Specific gravity of cement, pozzolan (if any), fine and coarse agg.

3. Surface moisture (%), water absorption (%) of fine and coarse agg.

4. Sieve analysis of fine (Zone information) and coarse aggregates.

5. Chemical admixtures solid content and its specific gravity.

Cost of all the raw materials

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 Target strength for mixture proportioning
f `ck = fck + 1.65 × s
f `ck = Target mean compressive
strength at 28 days in MPa
f ck = Characteristic compressive
strength at 28 days in MPa
• s = Standard deviation in MPa

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Selection of water cement ratio
(IS 10262:1982)

40
Selection of water cement ratio (IS 456)

• Supplementary cementitious materials shall also be considered

in w/c calculations 41
 Selection of water content

Applicable for angular coarse aggregate and for slump of 25-50 mm.
For the same workability, the water demand can be reduced by 10 kg, 20
kg and 25 kg when sub angular, gravel with crushed particles and
rounded gravel are used respectively.
Water content should be increased by 3 % for every 25 mm additional 42
slump or usage of chemical admixtures is recommended.
 Calculation of cementitious materials

• The cement and supplementary cementitious materials content per unit volume
can be calculated from free w/c ratio and water content per unit volume of
concrete

• The cementitious material content so calculated should be checked against

minimum content for durability requirements and greater of the two values should
be adopted.

• The maximum water cement ratio should also be checked and lesser of the two
values should be used.

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 Estimation of Coarse aggregate content

• Applicable for w/c ratio of 0.5

• Adjustment : increase/decrease the proportion of volume of coarse
aggregate by 0.01 for every decrease/increase of 0.05 w/c ratio
• Coarse aggregates of different sizes may be combined in suitable
proportions and Overall grading conforming to Table 2 of IS 383

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 Estimation of fine aggregate proportion

• The total aggregate volume can be estimated by deducting the absolute volume of
cementitious materials, water, chemical admixtures (mass/ specific gravity) from
unit volume of concrete

• Knowing the volume of coarse aggregate, the volume of fine aggregate can be
calculated by deducting the coarse from total volume of aggregate.

• The quantity can be calculated by multiplying the volume obtained with specific
gravities of coarse and fine aggregate.

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Mixture Proportions
• Cement = …… kg/m3
• Fine aggregate = …… kg/m3
• Coarse aggregate = …… kg/m3
• Water = …… kg/m3
• Supplementary cementitious = …… kg/m3

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Trials mixtures has to be performed
for the mixture proportions
obtained.

Any error in the result should be

rectified by slightly adjusting the
material proportions based on
previous experience.
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Sample problem (without Pozzolan)
• Characteristic Strength – M40
• Type of cement – OPC
• Exposure conditions -Severe (Reinforced concrete)
• Minimum cement content – 320 kg/m3
• Maximum cement content – 450 kg/m3
• Maximum w/c ratio – 0.45
• Type of aggregate – Crushed angular aggregate
• Max. nominal size of aggregate – 20 mm (SSD)
• Workability – 100 mm
• Chemcial Admixture – Superplasticiser (SP)

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Data for Materials
1. Grade of Cement – 53 grade
2. Specific gravity
Cement – 3.15
Fine aggregate – 2.74
Coarse aggregate – 2.74
3. Water absorption (%)
Fine aggregate – 0.5
Coarse aggregate – 1.0
3. Surface moisture (%)
Fine aggregate – NIL
Coarse aggregate – NIL
4. Sieve analysis coarse aggregates – Conforming to Table 2 (IS
383)
5. Sieve analysis fine aggregates – Conforming to grading zone I
of Table 4 (IS 383)
6. Chemical admixtures – Superplasticiser (30 % water reduction)
Specific Gravity = 1.1, Solids content = 40 %
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Target strength for mixture proportioning
f `ck = fck + 1.65 × s
f `ck = 40+ 1.65 × 5
= 48.25 N/mm2

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Selection of water cement ratio
(IS 10262:1982)

Based on Target Strength

W/C = 0.36
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Selection of water cement ratio (IS 456)

• Based on Figure, adopt w/c = 0.36 < 0.45

• Hence O.K

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 Selection of water content
Maximum water content for 20
mm aggregate = 186 litres (for
slump of 25-50 mm)

Slump required = 100 mm

Water content for 100 mm

slump = 186 + (6/100)186
= 197 litres

SP water reduction = 30 %.

Therefore, Total water content = 197 – 197 × (30/100) = 138 litres

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 Calculation of cementitious materials

• W/C = 0.36

• Water content (W) = 138 litres

• Cement Content (C) = 138/0.36 = 383 kg /m3

• From Table 5 of IS 456, minimum cement content for severe exposure conditions = 320 kg
/m3

383 kg /m3 > 320 kg /m3 , Hence O.K.

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Estimation of proportion of Coarse
aggregate to the total aggregate vol.

From table
• Volume of coarse aggregate (for w/c of 0.36) = 0.60

• Corrected Volume of coarse aggregate (for w/c of 0.36) = 0.60 + 0.03

= 0.63 55
Estimation of vol. of fine aggregate to
total aggregate vol.
• Volume of fine aggregate = 1- 0.63 = 0.37

Estimation of water content in SP

Solid content of SP = 40 %
Water content in SP = 60 %
Optimum dosage of SP = (1 % by weight of Cement) = 383  1/100
= 3.83 kg/m3
So water content in SP = 3.83  60/100 = 2.30 litres

Total water to be added to concrete = 138 -2.30 = 135.70 litres.

The total water content in the concrete is 138 litres. However, total
water content to be added as “water” is 135.70 litres. Remaining 2.3
litres is supplied by water in SP. By this process, the w/c ratio remains
56
same.
 Mixture Calculations
• Total volume of concrete = 1 m3
• Volume of cement = Mass/Specific gravity1/1000 = 383/3.15 1/1000
= 0.121 m3
• Volume of water = 135.7/1 1/1000 = 0.136 m3

• Volume of chemical admixture = 3.83/1.1 1/1000

(1 % By Weight of Cement) = 0.0035 m3

• Volume of total aggregate = 1 – (0.121+0.136+0.0035) = 0.739 m3

• Mass of coarse aggregate = 0.739vol. of CA  Sp.gravity of CA1000

= 0.739  0.63  2.74 1000 = 1275 kg
• Mass of fine aggregate = = 0.739  0.37  2.74 1000 = 749 kg

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Mixture Proportions
• Cement = 383 kg/m3
• Fine aggregate = 749 kg/m3
• Coarse aggregate = 1275 kg/m3
• Water = 136 kg/m3
• Chemical admixture = 3.83 kg/m3

• A trial has to be performed for evaluating the properties of concrete

and adjust to get the proper fresh and hardened properties.
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Sample problem (with Pozzolan-Flyash)
All the other steps remain same except the Calculation of cementitious/
supplementary material content:

Calculation of cementitious/ supplementary material content:

Cementitious (Cement + Fly ash) content = 383 kg/m3
Fly ash content (25 %) of total powder content
Fly ash content = 383  0.25 = 96 kg/m3
Cement content = 383 - 96 = 287 kg/m3
w/cementitious material = 138/383 = 0.36
In certain situations, increase in cementitious material may be done.

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Fresh Concrete Properties

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 Terminologies used in fresh state of concrete
• Workability (Slump)

• Stiffening

• Setting time

• Initial set

• Final Set

• Hardening
 Workability
• For mixes requiring high consistency, use of water-reducing admixtures should
be considered rather than adding more water.

• For high strength concrete, as low w/c is to be maintained, the workability

should be achieved by use of admixtures, such as water reducers and air-
entrainers.

• Conventional concrete workability tests (Empirical) are the slump test (IS
1199), compaction factor test, Vebe test, flow test, Kelly ball test, and the K-
slump tester.

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 Setting of concrete
• The hydration of cement is responsible for the setting and strength gain of
concrete.

• After mixing, placing and consolidation, concrete undergoes a series of changes in

its structure, transforming from a viscous semi-solid into a relatively stiff
viscoelastic solid.

• Initial Setting time & Final Setting time of concrete

• The setting time of concrete is determined by

the penetration resistance test (IS 8142, ASTM C 403)

• IST = 3.43 N/mm2, FST = 26.97 N/mm2 63

 Curing
• Curing of concrete essentially means the provision of a 100% humid atmosphere
around the finished concrete. It is necessary for ensuring proper hydration of
concrete.
• Curing also helps to some extent in the control of early age cracking that may
arise due to thermal and shrinkage effects.
• Methods of curing
• Ponding
• Fogging & Sprinkling
• Wet coverings
• Impervious papers, Plastic sheet covering, insulating blankets
• Membrane forming compounds
• Internal Moist curing, Forms left in place
• Steam curing
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Hardened properties of concrete

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 Hardened Properties of concrete
• Compressive strength (IS 516, IS 456)
• Tensile strength
• Split Tensile strength (IS 5816)
• Flexural Strength (IS 516, ASTM C 78)
• Modulus of Elasticity (IS 516)
• Poisson ratio
• Ductility
• Toughness
Non-Destructive Testing of concrete
• Covermeter/ Profometer
• Schmidt rebound hammer test (IS 13311 Part 2)
• Penetration resistance or windsor probe test
• Impact echo test
• Ultrasonic pulse velocity test (IS 13311 Part 1)
• Infrared thermography
• Half-cell electrical potential test
Durability of Concrete

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 Deterioration
• Water permeability (IS 3085, DIN 1048)
• Sulphate attack
• Acid attack
• Chloride attack
• Alkali aggregate reaction or alkali silica reaction
• Carbonation (Accelerated test – BS EN 13295)
• Corrosion
 Summary
• Good concrete performance in aggressive environments can only come about
with the combined action of a number of factors:
• Proper selection of materials
• Proper mixture design
• Adequate compaction and curing
• Quality of construction
• Optimum cover thickness
• Reduction of cracking
• Correct maintenance
 Mixture Design – Workability
Placing conditions Degree of CF/
workability Slump/
flow (mm)
Blinding concrete, shallow sections, Pavements Very low 0.75-0.8
using pavers
Mass concrete; Lightly reinforced sections in slabs, low 25-75
beams, walls, columns; Floors; Hand placed
pavements; Canal lining; Strip footings
Heavily reinforced , sections in slabs, Medium 50-100
beams, walls, columns
Slipform work; Pumped concrete Medium 75-100
Trench fill; In-situ piling High 100-150
Tremie concrete Very high Slump
flow

Ref: IS 456 :2000 72

Mixture Design – Durability consideration
• Durability -function of the response of material to the environment.
Category Table 3: IS 456 :2000 Exposure conditions
Mild Concrete surfaces protected against weather or aggressive
conditions, except those situated in coastal area
Moderate Concrete surfaces sheltered from severe rain or freezing whilst
wet; Concrete exposed to condensation and rain, Concrete
continuously under water; Concrete in contact or buried under non
aggressive soil/ground water; Concrete surfaces sheltered from
saturated salt air in coastal area
Severe Concrete surfaces exposed to severe rain, alternate wetting and
drying or occasional freezing whilst wet or severe condensation;
Concrete completely immersed in sea water; Concrete exposed to
coastal environment
Very Severe Concrete surfaces exposed to sea water spray, corrosive
fumes/severe freezing conditions whilst wet; Concrete in contact
with/buried under aggressive sub-soil/ground water
Extreme Surface of members in tidal zone; Members in direct contact with
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liquid/solid aggressive chemicals
 Mixture design - Durability consideration
Category Plain concrete Reinforced concrete
Table 5: Min. Max. free Min. Min. Max. free Min.
IS 456 :2000 cement water- grade of cement water- grade of
content cement concrete content cement concrete
kg/m3 ratio kg/m3 ratio
Mild 220 0.60 - 300 0.55 M20
Moderate 240 0.60 M15 300 0.50 M25
Severe 250 0.50 M20 320 0.45 M30
Very 260 0.45 M20 340 0.45 M35
severe
Extreme 280 0.40 M25 360 0.40 M40
Values given in table is applicable for only max. CA size of 20 mm.
For max. size is 10 mm, 40 kg/m3 of cement should be added and for
max. size is 40 mm, 30 kg/m3 must be subtracted from the values.
Max. cement content of 450 kg/m3 (IS 456:2000) for minimizing the
shrinkage and thermal cracking risk. 74
Gradation of Coarse aggregates (IS 383)

75
Hydraulic and non-hydraulic cements
• Hydraulic cement (e.g., Ordinary Portland Cement)
• Hardens by reaction with water
• Hydrated products are resistant to water
• Do not require pozzolanic materials to develop the resistance to water

• Non-hydraulic cement (e.g., Gypsum and lime cements)

• Hardens by reaction with water
• Hydrated products are NOT resistant to water

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 Hydraulic and non-hydraulic cements

(Plaster of paris)

Gypsum crystals
http://edafologia.ugr.es/comun/trabajos/orla99/texto.htm; Mehta and Monteiro

• Reaction product (i.e., gypsum cement) is unstable in water

77
Hydraulic and non-hydraulic cements

• Hydrated lime is unstable in water  Non-hydraulic

• Calcium Silicate Hydrate is stable in water  Hydraulic
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 Vicat Apparatus

http://www.everflowscientific.com/soil.html 79
 Calorimeter

http://www.humboldtmfg.com/c-4-p-296-id-4.html 80
Water Retention apparatus

http://www.humboldtmfg.com/c-4-p-288-id-4.html
81
Le Chatelier`s Apparatus

http://www.testingequipment.in/le-chatelier-mould.htm

82
Blaine air permeability apparatus

http://en.eylullab.com/blaine-gecirimlilik-aparati.aspx 83
Laser Particle Size and Shape analyser
100
Cement

80

Percentage Passing (%)

60

40

20

0
1E-3 0.01 0.1 1 10
Sieve size (mm)

84
Le Chatelier`s Flask

85
Sieve Analysis – Particle size distribution
Sieve size Weight % weight cumulative % % weight
(mm) retained(g) retained weight retained passsing
4.75 5 1.00 1.00 99.00
2.36 15.5 3.10 4.10 95.90
1.18 87.5 17.50 21.60 78.40
0.6 246 49.20 70.80 29.20
0.3 139 27.80 98.60 1.40
0.15 7 1.40 100 0.00
Total wt 500 296

Fineness modulus = 296/100 = 2.96 86