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Construction Techniques,Equipment and Practice

UNIT – I

CONCRETE TECHNOLOGY

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SYNOPIS

CEMENT : Defnition, Grades, Tyes, Man!"a#t!re, Testin$CONCRETE : Defnition

Man!"a#t!re % &at#'in$, (i)in$ , transortin$, *a#in$,

#o(a#tion, #!rin$, fnis'in$

 Testin$ – "res' + 'ardened non%destr!#ti-e.

 /!a*ity o" #on#rete

 0*i#ation

 Con#rete C'e(i#a*s

MI1 DESIGN : 2IS + 0CI (et'od

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Ce(ent

DefnitionCe(ent is a s!&stan#e a#ts as a &indin$ a$ent "or (ateria*s3

It is o&tained &y &!rnin$ t'e (i)t!re o" #a*#areo!s (ateria*

s!#' as *i(estone and ar$i**a#eo!s (ateria*s s!#' as #*ay

at a 'i$' te(erat!re3

 T'ere are t4o (ain #onstit!ents in ort*and #e(ent:

 0r$i**a#eo!s (ateria*s % #*ay

 Ca*#areo!s (ateria*s – #a*#i!( #ar&onate3 

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Co(osition o" ordinary #e(ent

INGRIDENT PERCENT

  Lime 62

  Silica 22

  Alumina 5

  Calcium sulphate 4

Iron oxide 3

  Magnesia 2

  Sulphur 1

  Alkalies 1

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Settin$ a#tion o" #e(ent

  5'en 4ater is added to #e(ent, in$redients o" #e(ent rea#t

#'e(i#a**y 4it' 4ater and "or(s #'e(i#a* #o(o!nds 4'i#'

i(art stren$t' to t'e #e(ent3 T'is is 6no4n as settin$ a#tion o"

#e(ent3

 Chemical #o(o!nds rod!#ed are

 Tri#a*#i!( a*!(inate

 Tri#a*#i!( si*i#ate

 Di#a*#i!( si*i#ate

 Tetra –#a*#i!( a*!(ino "errite3

  suall! cement attains a"out #$% o& its &inal strength in 2' da!s and a"out

($% o& its &inal strength in one !ear or so)

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Man!"a#t!re o" ort*and #e(ent

   T'ere are t'ree oerations in-o*-ed in (an!"a#t!re o"

ort*and #e(ent:

Mi)in$ o" ra4 (ateria*s

2!rnin$Grindin$

Mi)in$ o" ra4 (ateria*s

   T'ere are t4o (et'ods in (i)in$ o" ra4 (ateria*s o"

#e(ent:

Dry ro#ess

5et ro#ess3 

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0r$i**a#eo!s

(ateria*

#r!s'in$

7ine$rindin$

stora$e

Ca*#areo!s

(ateria*

#r!s'in$

7ine$rindin$

stora$e

Mi)in$ in #orre#troortion

Dryro#ess

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Stora$e tan6s "or ra4(i)

Rotary 6i*n

7or(ation o" #*in6ers

#oo*er

Grindin$ o" #*in6ers in&a** (i**s and t!&e

(i**s

Stora$e in si*os

5ei$'in$ +a#6in$ in&a$s

distri&!tion

$ys!(

Coa*d!st

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5etro#ess

Ca*#areo!s(ateria**i(estone

0r$i**a#eo!s(ateria*

#*ay

#r!s'in$ #r!s'in$

stora$e stora$e

#'anne*

Grindin$ (i**

7or(ation o" s*!rry

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Corre#tin$ &asin

Stora$e tan6

!(in$

Rotary 6i*n

7or(ation o"#*in6ers

#oo*er

Grindin$ o" #*in6ers in &a**(i**s

Stora$e in si*os

5ei$'in$ and a#6in$ in&a$s

distri&!tion

$ys!(

Coa* d!st

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2!rnin$

*urning is carried out in rotar! kiln)

+iameter o& kiln is 25$,3$$ cm- length is ($,12$ m and inclined a"out 1 in

2$ to 3$)

It is supported on rollers)

.e&ractor! lining is pro/ided on the inner sur&ace)

Slurr! is in0ected at upper end and it descends to "urning one car"on,

dioxide gets e/aporated and &orms nodules)

emperature is a"out 15$$,1#$$ c)

 In "urning one the lime and cla! in the slurr! get chemicall! &used to &orm

hard "alls o& portland cement knon as clinkers Sie 5 to 1$mm)

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Rotary 6i*n

 "ro( stora$e tan6  s*!rry d!st nod!*es

  rotary arran$e(ent #oa*d!st

  &!rnin$

  8one

 re"a#toy

*inin$

air

S!ort #oo*er  #*in6ers

 

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Grindin$

Grindin$ is done in &a** (i**s and t!&e (i**s3

Gys!( is added a&o!t 3 to 4 er#ent d!rin$

$rindin$3

Gys!( #ontro*s initia* settin$ ti(e o" #e(ent3

7ine*y $ro!nd #e(ent is stored in si*os3

It is 4ei$'ed and a#6ed in &a$s3

Ea#' &a$ #ontains 5$9$ o" #e(ent3

 T'e &a$s are stored in dry *a#es3

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Proerties o" #e(ent

It is an e)#e**ent &indin$ (ateria*3

Gi-es stren$t' to (asonry3

Possesses a $ood *asti#ity3

Oers a $ood resistan#e to (oist!re3 Easi*y 4or6a&*e3

It 'ardens ;!i#6*y a"ter addition o" 4ater3

 T'e #o*o!r o" #e(ent s'o!*d &e !ni"or(3

Ce(ent s'o!*d &e "ree "ro( *!(s3

Ce(ent s'o!*d "ee* s(oot' 4'en to!#'ed or r!&&ed in

&et4een fn$ers3

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I" a s(a** ;!antity o" #e(ent is t'ro4n into a &!#6et o" 4ater, it

s'o!*d sin6 and s'o!*d not

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Uses o" #e(ent

It is !sed "or #onstr!#tin$ en$ineerin$ str!#t!res s!#' as

da(s, &rid$es, stora$e reser-oirs3

Used "or (a6in$ =oints "or ies, drains3

Used "or rearation o" "o!ndations, "ootat'3

Used "or (an!"a#t!re o" re#ast ies, "en#in$ osts3

Used "or (asonry 4or6, *asterin$, ointin$3

Used "or *ayin$

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 Tyes o" #e(ent

/!i#6 settin$ #e(ent

Lo4 'eat #e(ent

Hi$' a*!(ina #e(ent

E)andin$ #e(ent

Raid 'ardenin$ #e(ent

0#id resistant #e(ent

S!*'ate resistin$ #e(ent

5'ite #e(ent

Co*o!red #e(ent

2*ast "!rna#e #e(ent

Po88o*ana #e(ent

0ir – entrainin$ #e(ent

Masonry #e(ent

Oi*%4e** #e(ent

Redi%set #e(ent

Hi$' stren$t' #e(ent

Hydro'o&i# #e(ent

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 Testin$ o" #e(ent

 Testin$ o" #e(ent #an &e &ro!$'t !nder t4o #ate$ories:

• 7ie*d testin$

• La&oratory testin$

7ie*d testin$ – s!>#ient to s!&=e#t t'e #e(ent to fe*d tests

4'en it is !sed "or (inor 4or6s3

 Oen t'e &a$ and ta6e a *oo6 at t'e #e(ent3 T'ere s'o!*d

not &e any -isi&*e *!(s3 T'e #o*o!r o" t'e #e(ent s'o!*d

nor(a**y &e $reenis' $rey3

 T'r!st yo!r 'and into t'e #e(ent &a$3 It (!st $i-e yo! a

#oo* "ee*in$3

 Ta6e a in#' o" #e(ent and "ee* &et4een t'e fn$ers3 It

s'o!*d $i-e a s(oot' and $ritty "ee*in$s3

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  Ta6e a 'and"!* o" #e(ent and t'ro4 it on a &!#6et "!** o"

4ater, t'e arti#*es s'o!*d

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 Stren$t' test:

Co(ressi-e stren$t' is (ost i(ortant3

 T'e standard sand is !sed "or fndin$ t'e stren$t' o" #e(ent3

7ineness test

7ineness o" #e(ent is i(ortant &earin$ on t'e rate o"

'ydration and on rate o" $ain o" stren$t'3

7iner #e(ent oers a $reater s!r"a#e area and 'en#e "aster

and $reater t'e de-e*o(ent o" stren$t'3

7ineness o" #e(ent is tested in t4o 4ays:

2y sie-in$3

2y deter(ination o" se#if# s!r"a#e &y air% er(ea&i*ity3

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Settin$ ti(e test

0n ar&itrary di-ision 'as &een (ade "or t'e settin$ ti(e o"

#e(ent as initia* settin$ and fna* settin$ ti(e3

  Initia* settin$ ti(e% is t'e ti(e e*ased &et4een t'e

(o(ent t'at t'e 4ater is added to t'e #e(ent to t'e ti(e

t'at t'e aste starts *osin$ its *asti#ity3

 7ina* settin$ ti(e – t'e ti(e e*ased &et4een t'e (o(ent

t'e 4ater is added to t'e #e(ent and t'e ti(e 4'en t'e

aste 'as #o(*ete*y *ost its *asti#ity and 'as s!>#ientfr(ness to resist ress!re3

 T'e test is #arried o!t in -i#at aarat!s3

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on#re

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on#ree

Defnition

Con#rete (ay &e defned as a &!i*din$ (ateria* o&tained &y (i)in$

#e(ent, fne, #oarse a$$re$ates and 4ater in s!ita&*e roortions3

 It is *asti# (i)t!re a"ter #!rin$ it &e#o(es 'ard (ass3

 T'e #oarse a$$re$ates are &ro6en stone, &ro6en &ri#6s or $ra-e*, t'e fne

a$$re$ate is sand or s!r6i and t'e &indin$ (ateria* is *i(e or #e(ent3

7res' #on#rete or *asti# is a "res'*y (i)ed (ateria* 4'i#' #an &e

(o!*ded into any s'ae3

 T'e re*ati-e ;!antities o" #e(ent, a$$re$ates and 4ater to$et'er #ontro*

t'e roerties in t'e 4et state as 4e** as in t'e 'ardened state3

Constit!ents o" Con#rete

Ce(ent

7ine a$$re$ate and Coarse a$$re$ate

5ater

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0d-anta$es o"Con#rete

It is *asti# 4'en "res'*y reared and #an &e (o!*ded to any

s'ae3

Con#rete does not *ose its stren$t' 4it' a$e and does not re;!ire

(aintenan#e3

 T'e roortion o" (i) #an &e s!ita&*e desi$ned to $i-e #on#rete

o" re;!ired stren$t'3

It is d!ra&*e and not ae#ted &y 4eat'er3

It aords ;!i#6ness and ease o" a #onstr!#tion3

It #an &e $i-en -ario!s fnis'es3

Con#rete is 4ater ree**ent and #an &e (ade 4ater roo"3

Con#rete #an &e (ade fre roo" or *i$'t 4ei$'t or #'e(i#a*

resistant &y !sin$ s!ita&*e ad(i)t!res3

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Proerties o"Con#rete

Con#rete 'as 'i$' #o(ressi-e stren$t' deends on t'e

roortion o" #e(ent, sand, #oarse a$$re$ates and 4ater !sed3

It 'ardens 4it' a$e and ro#ess o" 'ardenin$ #ontin!o!s "or

*on$ ti(e e-en a"ter it 'as attained s!>#ient stren$t', &!t t'e

rate o" 'ardenin$ de#reases 4it' a$e3

It is "ree "ro( #orrosion and at(os'eri# ee#ts3

It is 4ea6 in tension3 Stee* rein"or#e(ent is *a#ed in #e(ent

#on#rete at s!ita&*e *a#es to ta6e ! t'e tensi*e stresses #a**edas RCC3

It s'rin6s in t'e initia* sta$e and d!rin$ 'ardenin$3 T'is #an &e

(ini(i8ed &y roer #!rin$3

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5or6a&i*ity

   T'e roerty o" "res'*y (i)ed #on#rete 4'i#' deter(ines t'e ease and

'o(o$eno!s 4it' 4'i#' it #an &e (i)ed, *a#ed, #o(a#ted and fnis'ed

7a#tors 0e#tin$ 5or6a&i*ity

5ater #ontent

Mi) roortions

Si8e o" a$$re$ates

S'ae o" a$$re$ates

S!r"a#e te)t!re o" a$$re$ates

Gradin$ o" a$$re$ates

Use o" ad(i)t!res

 

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 5ater #ontent5ater #ontent in a $i-en -o*!(e o" #on#rete 4i** 'a-e si$nif#ant

in

4or6a&i*ity3

Mi) roortion

0$$re$ateA#e(ent ratio is an i(ortant "a#tor in

4or6a&i*ity3

 Hi$'er t'e a$$re$ateA#e(ent ratio, *eaner is t'e #on#rete3

Si8e o" a$$re$ate 2i$$er t'e si8e o" t'e a$$re$ate, *ess is t'e s!r"a#e area and *ess is

t'e a(o!nt o" 4ater3

It 4i** $i-e &etter 4or6a&i*ity3

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S'ae o" a$$re$ate

 T'e s'ae o" a$$re$ate in

0n$!*ar, e*on$ated or 2etter t'e $radin$, *ess t'e -oid #ontent and 'i$'er t'e 4or6a&i*ity3

Use o" a$$re$ate

Use o" air%entrainin$ and o88o*ani# (ateria* $i-es &etter

4or6a&i*ity3

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Meas!re(ent o" 4or6a&i*ity

   T'e "o**o4in$ tests are #o((on*y e(*oyed to (eas!re

4or6a&i*ity:

S*!( test – 9 S*!(er

Co(a#tin$ "a#tor test % Co(a#tin$ "a#tor aarat!s

7*o4 test – 7*o4 ta&*e

9e**y &a** test – 9e**y &a**

Bee &ee #onsisto(eter test% B2R

Se$re$ation : Searation o" t'e #onstit!ent (ateria*s o"

#on#rete

2*eedin$ : 5ater "ro( t'e #on#rete #o(es o!t o" t'e s!r"a#e o"

t'e #on#rete

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Pro#ess o" (an!"a#t!re o"#on#rete

 T'e -ario!s sta$es o" (an!"a#t!re o"

#on#rete are:

2at#'in$

Mi)in$

 Transortin$

P*a#in$

Co(a#tin$

C!rin$

7inis'in$

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 2at#'in$  T'e (eas!re(ent o" (ateria*s "or (a6in$ #on#rete is

6no4n as &at#'in$3

Bo*!(e &at#'in$ – Ga!$e &o)

5ei$' &at#'in$ – 4ei$'t (a#'ine

Mi)in$

Mi)in$ o" (ateria*s is essentia* "or t'e rod!#tion o" !ni"or(

#on#rete3

 T'ere are t4o (et'ods "or (i)in$ #on#rete:

Hand (i)in$

Ma#'ine (i)in$3

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 Transortin$#on#rete

Con#rete #an &e transortin$ &y a -ariety o" (et'ods and

e;!i(ents3

Mortar an

5'ee* &arro4, Hand #art

2!#6et and Roe 4ay

 Tr!#6 (i)er and D!(ers

2e*t #on-eyors

C'!te

S6i and Hoist

P!(s and Pie*ine

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P*a#in$ #on#rete P*a#in$ #on#rete 4it'in eart' (o!*d3

  e3$3: "o!ndation #on#rete "or a 4a** or #o*!(n3

P*a#in$ #on#rete 4it'in *ar$e eart' (o!*d or ti(&er *an6

"or(4or63

  e3$3: road s*a& and airfe*d s*a&3

P*a#in$ #on#rete in *ayers 4it'in ti(&er or stee* s'!tters3

  e3$3: (ass #on#rete in da( #onstr!#tion or #onstr!#tion o"

#on#rete a&!t(ent or ier3

P*a#in$ #on#rete 4it'in !s!a* "ro( 4or63

  e3$3: #o*!(ns, &ea(s and

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Co(a#tion o" #on#rete

Co(a#tion o" #on#rete is t'e ro#ess adoted "or e)e**in$ t'e

entraed air "ro( t'e #on#rete3

Hand #o(a#tion:

Roddin$

Ra((in$

 Ta(in$3

Co(a#tion &y -i&ration

 Interna* -i&rator need*e -i&rator.

 7or(4or6 -i&rator e)terna* -i&rator.

 Ta&*e -i&rator

 P*at"or( -i&rator

 S!r"a#e -i&rator s#reed -i&rator.3

Co(a#tion &y ress!re and =o*tin$

 Co(a#tion &y sinnin$3

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C!rin$ o" #on#rete

C!rin$ is t'e ro#ess o" (aintainin$ a satis"a#tori*y (oist!re

#ontent and "a-ora&*e te(erat!re3

 T'e "o**o4in$ are t'e #!rin$ (et'ods:

5ater #!rin$

Me(&rane #!rin$

0*i#ation o" 'eat

Mis#e**aneo!s

5ater #!rin$

5ater #!rin$ #an &e done in t'e "o**o4in$:

 I((ersion

Pondin$

Srayin$

5et #o-erin$

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Me(&rane #!rin$

2it!(ino!s #o(o!nds

Po*yet'y*ene

5aterroo" aer

R!&&er3

0*i#ation o" 'eat

 T'e e)os!re o" #on#rete to 'i$'er te(erat!re #an &e

done in t'e "o**o4in$ (anner:

 Stea( #!rin$ at ordinary ress!re

Stea( #!rin$ at 'i$' ress!re

C!rin$ &y in"ra%red radiation

E*e#tri#a* #!rin$3

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Mis#e**aneo!s (et'ods o" #!rin$

Ca*#i!( #'*oride is !sed as a s!r"a#e #oatin$ or as a

ad(i)t!re3

7inis'in$

7inis'in$ oeration is t'e *ast oeration in (a6in$ #on#rete3

S!r"a#e fnis' #an &e $ro!ed as "o**o4s:

7or(4or6 fnis'es – #enterin$ 4or6

S!r"a#e treat(ent

0*ied fnis'es3

Mis#e**aneo!s 7inis'es : Non % S*i 7inis', Co*o!red fnis',

5ater resistant

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 Tests o" "res' #on#rete

S*!( test 9e**y &a** test3

 Tests on 'ardened #on#rete

Non%destr!#ti-e testin$%does not #a!se any destr!#ti-e o" t'e

e*e(ent3

Se(i%destr!#ti-e testin$%#a!se ne$*i$i&*e da(a$e o" t'e e*e(ent3

Non%destr!#ti-e testin$:

Re&o!nd 'a((er test3U*trasoni# !*se -e*o#ity test3

Se(i%destr!#ti-e testin$:

 5indsor ro&e test

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Re&o!nd 'a((er test

It #onsists o" srin$%#ontro**ed (ass t'at s*ides on a *!n$er

4it'in t!&!*ar 'o!sin$3

5'en t'e *!n$er is ressed t'e srin$ #ontro**ed (ass

re&o!nds3

Deends on s!r"a#e 'ardness o" #on#rete3

Re*ated to #o(ressi-e stren$t'3

 T'e re&o!nd is read on $rad!ated s#a*e and t'e -a*!e is

desi$nated as re&o!nd n!(&er or re&o!nd inde)3

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Uses: It is !sed "or esti(atin$ t'e #o(ressi-e stren$t'3

Esta&*is'in$ t'e !ni"or(ity o" #on#rete3

0ssessin$ t'e ;!a*ity o" one e*e(ent o" #on#rete in re*ation to

anot'er3

Li(itations:

Res!*ts are ae#ted &y t'e an$*e o" test, s!r"a#e s(oot'ness, and

(i) roortion3

It is on*y s!ita&*e "or #*ose%te)t!red #on#rete3

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Re&o!nd 'a((er

  #on#rete i(a#t srin$#o(ression srin$

s!r"a#e

  *!n$er 'a((er

  (ass 'o!sin$

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 Tyes o" #on#reteNor(a* density

0ir%entrainin$

Po*y(er #on#rete #o(osites

S!*'!r i(re$nate #on#rete

7i&re rein"or#ed #on#rete7RC.3

Ro**er #o(a#ted #on#rete

S!er *asti#i8ed

Co*o!red

P!(ed

Ready (i)ed #on#reteRMC.

7erro #e(ent

Li$'t 4ei$'t

Re#y#*ed

Hea-y 4ei$'t

No s*!(

No fne

Ba#!!(

Sinned

Hot

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7RC

Co(osite (ateria* #onsistin$ o" (i)t!re o" #e(ent (ortar

and dis#ontin!o!s dis#rete, !ni"or(*y disersed s!ita&*e f&res3

 Tyes:

a. S7RC% stee* f&re rein"or#ed #on#rete

&. C7RC% #ar&on f&re rein"or#ed #on#rete

#. G7RC% $*ass f&re rein"or#ed #on#rete

d. H7RC% 'y&rid f&re rein"or#ed #on#rete3

) S7RC% stee* f&re rein"or#ed #on#rete

) Made ! o" r!sted stee*3

) Used in road a-e(ents, &rid$e de#6s3

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C7RC% #ar&on f&re rein"or#ed #on#rete

Has 'i$' tensi*e stren$t'3

D!ra&i*ity3

H7RC% 'y&rid f&re rein"or#ed #on#rete

Made ! o" o*yroy*ene, ny*on f&res,

as&estos3

D!ra&i*ity

Hi$' tensi*e stren$t'3

 

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/!a*ity o" #on#rete

Good 4or6a&i*ity

No se$re$ation

No &*eedin$

Hi$' stren$t' D!ra&i*ity

I(er(ea&i*ity

E*asti#ity

S'rin6a$e

Least t'er(a* e)ansion3

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0d-anta$es o" #on#rete

0-ai*a&i*ity o" #on#rete is easy3

Easy 'and*in$3

Easy transortation3

More e#ono(i#a*3

Mono*it'i# #'ara#ter $i-es &etter aearan#e3Disad-anta$es o" #on#rete

E)ansion =oints are re;!ired3

Constr!#tion =oints are ro-ided to a-oid #ra#6s3

S!stain *oads de-e*os #ree in str!#t!re3

D!e to *o4 tensi*e stren$t', #on#rete is re;!ired to &e

rein"or#ed to a-oid #ra#6s3

So*!&*e sa*ts in #on#rete #a!se eores#en#e o" (oist!re rea#ts

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Con#rete #'e(i#a*s

 T'ey are !sed in #e(ent as an additi-e, in (ortar and

#on#rete as ad(i)t!res3

S!#' additi-es and ad(i)t!res is #a**ed as #on#rete

#'e(i#a*s or #onstr!#tion #'e(i#a*s3

It in#*!des t'e "o**o4in$ (ateria*s:

P*asti#i8ers and s!er *asti#i8ers3

Retardin$ *asti#i8ers and retarders3

0##e*eratin$ *asti#i8ers and a##e*erators3

0ir%entrainin$ a$ent3

5ater roofn$ (ateria*3

Po*y(er &ondin$ a$ents3

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7*oor 'ardness and d!st roo"ers3

Con#rete #!rin$ #o(o!nds3

Po*y(er (ortar "or reair and (aintenan#e3

0d'esi-e "or ti*es, (ar&*es and $ranite3

Mo!*d re*easin$ a$ents3

Gro!tin$ a$ents3

De#orati-e and rote#ti-e aint3

Con#rete reair syste(3 Insta**ation aids3

/ i

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/!eries:

 T4o (ar6s:

5'at is #e(ent and *ist o!t its #'e(i#a* #o(ositionF

5'at are t'e ro#ess o" #e(ent (an!"a#t!rin$F

5'at are t'e (et'ods o" testin$ in #e(entF

5'at is (eant &y 4or6a&i*ityF

5'at is #on#rete and e)*ain (i) roortion o" #on#reteF

5'at are t'e testin$ (et'ods in-o*-ed in "res' #on#rete and

'ardened #on#reteF

5'at are t'e ;!a*ities o" #on#reteF

Des#ri&e t'e ad-anta$e o" #on#reteF

Des#ri&e t'e disad-anta$es o" #on#reteF

5'at Is (eant &y #on#rete #'e(i#a*sF

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16 (ar6s:

Des#ri&e t'e (an!"a#t!rin$ o" #e(entdry and 4et ro#ess.F

5'at are t'e dierent tyes o" #e(entF e)*ain t'eir

roerties and !sesF

Des#ri&e t'e fe*d testin$ and *a&oratory testin$ (et'od in

#e(entF

E)*ain in detai* t'e ro#ess o" #on#rete (an!"a#t!rin$F

E)*ain t'e (et'od o" non%destr!#ti-e testin$ in detai*F

5'at tests are !sed to deter(ine t'e 4or6a&i*ity o" "res'

#on#reteF e)*ain in detai*:

5'at are t'e dierent tyes o" #on#reteF e)*ain t'eir

roerties and !sesF

E)*ain t'e -ario!s tyes o" #on#rete #'e(i#a*s in detai*F

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 T'an6 yo!