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CEMENT CONCRETE
Definition:
The cement concrete is a mixture of cement,
sand, gravel and water in predetermined
proportions, which when placed in the
skeleton of forms and allowed to cure, set into
hard solid mass.
Ingredients:
1. Cement
Portland cement is ordinarily used
Lime was older age cementing material
Variety cements like rapid hardening cement and high alumina
cement can be used
2. Aggregates
Fine aggregates <4.75mm
Natural river sand
Finely crushed stone
Coarse aggregate >4.75 mm
Broken stone is mostly used
Size may vary as per requirement
Should be hard, durable, clean
3. Water
Acts as lubricant for the fine and coarse aggregates and acts
chemically with the cement to form the binding paste for the
aggregate and reinforcement.
Should be clean and free from injurious amount of deleterious
materials.
M SAND
Properties of concrete
Strength
Elasticity
Cracking
Shrinkage cracking
Tension cracking
Strength
Elasticity
Function of the modulus of elasticity of the aggregates and the
cement matrix and their relative proportions.
The American Concrete Institute allows the modulus of
elasticity to be calculated using the following equation:
where
wc = weight of concrete (pounds per cubic foot) and where
Cracking
All concrete structures will crack to some extent.
Cracks due to tensile stress induced by shrinkage or stresses
occurring during setting or use
Shrinkage cracking
Occur when concrete members undergo
restrained volumetric changes (shrinkage) as a
result of either drying, autogenous shrinkage or
thermal effects.
The number and width of shrinkage
cracks that develop are influenced by
-the amount of shrinkage that occurs
-the amount of restraint present
-the amount and spacing of reinforcement
provided.
Tension cracking
Most common in concrete beams
where a transversely applied load
will put one surface into
compression and the opposite surface
into tension due to induced bending.
The size and length of cracks is
dependent on
- The magnitude of the bending
moment
- The design of the reinforcing in the
beam at the point under
consideration.
Proportion Specifications
1:2:4 (cement : sand : stone ballast) by volume when specified. Minimum
compressive strength of concrete of 1:2:4 proportion shall be 140 kg/cm2 in
7 days.
Hand mixing
Mixing shall be done on masonry platform or sheet iron tray.
Machine mixing
Stone ballast, sand and cement shall be put into cement concrete mixer to
have the required proportions.
Formwork
Formwork centering and shuttering shall be provided as required as per the
standard specification before laying concrete to confine to support or to
keep the concrete in position. The inner surface of shuttering shall be oiled
to prevent concrete sticking to it.
Laying Technique
Concrete shall be laid gently (not thrown) in layers not exceeding 15cm and
compacted by pinning with rods and tamping with wooden tampers or with
mechanical vibrating machine until a dense concrete is obtained.
Curing Method
After about two hours of laying of concrete, when the concrete has begun
Proportioning:
The process of relative proportions of cement,
sand, coarse aggregate and water, so as to
obtain aconcreteof desired quality is known as
theproportioning of concrete.
Arbitrary Method
Fineness Modulus Method
Minimum Void Method
Maximum Density Method
Water Cement Ratio Method
ARBITRARY METHOD
The general expression for the proportions of cement, sand and coarse aggregate is
1 : n : 2n by volume.
1 : 1 : 2 and 1 : 1.2 : 2.4 for very high strength.
1 : 1.5 : 3 and 1 : 2 : 4 for normal works.
1 : 3 : 6 and 1 : 4 : 8 for foundations and mass concrete works.
1:3:6
1:2:4
1 : 1.5 : 3
1:1:2
Where, P = desired fineness modulus for a concrete mix of fine and coarse aggregates .
P1= fineness modulus of fine aggregate
P2 = fineness modulus of coarse aggregate.
(3) Minimum Void Method (Does not give satisfactory result)
The quantity of sand used should be such that it completely fills the voids of coarse
aggregate. Similarly, the quantity of cement used shown such that it fills the voids of
sand, so that a dense mix the minimum voids is obtained.
In actual practice, the quantity of fine aggregate used in the mix is about 10% more
than the voids in the coarse aggregate and the quantity of cement is kept as about 15%
more than the voids in the fine aggregate.
Slump test:
In this test, concrete is compacted in a vessel of the shape of the frustum of a cone and
open at both the ends. The mould is filled with freshly mixed concrete in four layers, each
compacted separately. Mould is then raised immediately, which allows concrete to subside
and slump is measured.
There are chances of many shapes of slump to occur. Three forms of
slump may occur. They are known as true slump, shear slump and
collapse slump.
The shear slump is obtained when the specimen collapses or shears off
laterally.
The collapse slump is obtained in case of very wet concrete mixes.
If shear and collapse slumps are obtained, the concrete is considered
unsatisfactory for placing.
Compacting factor =
compacted concrete
Weight of partially
Weight of fully
compacted concrete
Curing of concrete:
Curing is the process of controlling the rate
and extent of moisture loss from concrete
during cement hydration.
The concrete surfaces are kept wet for a
certain period of time after placing of concrete
so as to promote the hardening of cement. All
processes involved is termed curing. The
period of curing depends on the type of
cement and nature of work. For ordinary
portland cement, the curing period is about 7
to 14 days.
Purposes of curing
Protects the concrete surfaces from sun and wind
The presence of water is essential to cause the chemical reaction which accompanies the setting
of concrete. So it is necessary to retain water until the concrete has fully hardened.
The strength, durability and impermeability of concrete increases and shrinkage is reduced, if
curing is efficient.
The resistance of concrete to abrasion is considerably increased.
Form work
The form work or shuttering is a temporary ancillary construction used as a mould for the
structure, in which concrete is placed and in which it hardens and matures.
Stripping: operation of removing the form work
Panel forms: form works whose components can be reused several times
Stationary forms: made for individual non standard members and structures, no repeatable
elements.
Wooden shuttering
Economical
Commonly used
Steel shuttering
Costly
Repeated uses possible
Ease of stripping
Ensures smooth concrete surface
Strong, reliable
WATER PROOFING:
Water proofing of a surface is the treatment of the
surface to prevent passage of water like rain water
or ground water from one side of structure to the
other normal under normal or hydrostatic pressure
whereas damp proofing is treatment of a surface to
the stop rise of water by capillary action.
Damp proofing of foundation
Damp proofing of walls
Tanking of basement
Water proofing of wet areas
Water proofing of roofs
Water proofing materials and system:
Water proofing with bitumen membranes
Water proofing with elastomeric paints
Water proofing with epoxy formulation
Integral Water proofing cement plaster
and concrete
Water proofing by slurry coats by
capillary and crystallation systems.
Acrylic based
Polyurethane based
Hypalon based
Polyvinyl acetate copolymer based
Polymerized elastomeric bitumen, penetrating oils and
other admixture.
GUNITING CONCRETE
Guniting is the process of spraying a dry concrete
mixture. swimming pools are typically done with this.
also it is used to execute repair / refurbishing jobs.
An air compressor is used to power a spray rig. it is
sprayed over a rebar mesh that is held above the soil
with small bricks or simillar
NO AGGREGATE IS USED.
GUNITE CONCRETE DUE TO BEING
SO DRY IS VERY STRONG.
SPECIAL CONCRETES:
Special concrete is defined as concrete which meets special performance and uniformity
requirements that cannot always be achieved routinely by using only conventional materials and
normal mixing, placing and curing practices.
The requirements may involve enhancements of characteristics such as placement and
compaction without segregation, long-term mechanical properties, early-age strength, toughness,
volume stability, or service life in severe environments.
High strength concrete
Special aggregate concrete
Flowing concrete
Fly ash concrete
Shrinkage compensating concrete
Structural lightweight concrete
Colored concrete
Dampproofed concrete
Heavyweight or high density concrete
Steel fiber concrete
Cellular concrete
Latex modified concrete
Mixing of concrete:
The operation of manufacture of concrete is called mixing.
Hand mixing
Materials are stacked in a water tight platform
Materials should be thoroughly mixed in dry condition atleast three times
Predetermined amount of water is then added
Mixed till a homogeneous, workable mixture is obtained.
Used only in small works
Machine mixing
All materials of concrete are mixed thoroughly by mechanically rotating the
drum.
Coarse aggregate should be fed first, then sand and lastly cement.
When these ingredients get dry mixed thoroughly, water is added.
Concrete mixers are of 2 types
Batch mixers: used for small works, either tilting drum or closed drum
type is used
Continuous mixers: used in mass concreting work where a large and
continuous flow of concrete is required. In these mixers, processes of feeding,
Batching of concrete:
The process of measuring concrete mix
ingredients by either mass or volume and
introducing them into the mixer.
To produce concrete of uniform quality, the
ingredients must be measured accurately for
each batch.
Most concrete today is batched and mixed by
ready mixed concrete plants.
Transporting Concrete:
Concrete should be handled from the place of
mixing to the place of final deposit as rapidly as
possible.
For ordinary building works, the human ladder is
formed and the concrete is conveyed in pans
from hand to hand.
For important works various mechanical devices
may be used.
The concrete should be transported in such a way
that there is no segregation of the aggregates.
Under no circumstances, the water should be
added to the concrete during its passage from
mixer to the form work.
Placing of concrete:
Concrete should be placed and compacted before setting
commences and should not subsequently be disturbed.
The form work or the surface which is to receive fresh
concrete should be properly cleaned, prepared and well
watered
Concrete should not be poured into the forms only at one
point, but should be uniformly spread in all directions for
better compaction.
Concrete should be dropped vertically, but from a
reasonable height so as not to segregate the aggregates.
Use stiff mix to prevent bleeding i.e. the diffusion or
running of concrete through form work.
Concrete should be deposited in the horizontal layer of
150mm height. 400mm to 500mm for mass concrete
work.
Types of vibrators:
Internal or immersion vibrators
Steel tube called poker, connected to an electric motor is
inserted in fresh concrete.
Commonly used. More efficient
Surface vibrators
Mounted on platform or screeds
Used to finish surfaces such as bridge floors, road slabs,
station platform
Effective for compacting very dry mixes.
Form or shutter vibrators
Attached to the formwork and external centering of
walls, columns, etc.
Helpful for thin concrete sections, where internal
vibrators cannot be used.
Vibrating tables
In the form of rigidly built steel platform mounted on
flexible springs and they are operated by electromagnetic
action or electric motors.
Used for compacting stiff and harsh concrete like precast
structures