Reference Codes

• CBC:2014 –
– Indian Railway Standard Code of Practice for Plain, Reinforced &
Prestressed Concrete for General Bridge Construction
• IS 456:2000 –
– Plain & reinforced cement concrete- code of practice (fourth revision)
Amendments up to 4
• IS 10262:2019 –
– Concrete Mix Proportioning – Guidelines (Second Revision)
• IS 383:2016 –
– Specification for coarse and fine aggregates from natural sources for
concrete (Third revision)
 Concrete

• Combination of Cementitious Material, Aggregates

and water along with Admixtures, if required.

• It is denoted by Grade M-X

Here, X is the Characteristic Strength of
Concrete in N/mm2 tested on 15 cm cube after
28 days
 Grade of Concrete

• Ordinary Concrete – M-10, M-15, M-20

• Standard Concrete – M-25 to M-60
• High Strength Concrete – Above M-60

IS:456 applicable upto M-100

CBC for M60 only
 Ingredients of concrete

1. Cement
2. Fine Aggregate - Sand
3. Coarse Aggregate
4. Water
 Cement

• Appropriate type of cement should be used as

per design.
– OPC 33 Grade as per IS:269
– OPC 43 Grade as per IS:8112
– OPC 53 Grade as per IS:12269
– Portland Pozzolana Cement as per IS:1489
– Portland Slag Cement as per IS:455
– Rapid Hardening Cement as per IS:8041
– Quick Setting cement as per IS:12330.
 Cement

• In Blended Cements like Portland pozzolana cement and Portland

slag cement, the strength gain is slow as compared to ordinary
Portland cement.

• Accordingly period of removal of form work and period of curing

etc. should be suitably increased.

• When Portland Pozzolana cement is used in plain and reinforced

concrete, it is to be ensured that proper damp curing of concrete is
done for at least for 14 days

• In case of Higher Grade cement, heat of hydration is at a much

faster rate initially.

• Release of heat is the highest In case of Grade 53 cement.

 Field Checks for Cement
• The stitching of bag should be intact and original.

• Check the grade of cement as per requirement.

• Check the date of manufacture---w-week, m-month, y- year. it
should be fresh & not older than 3 month. Older than 6
month should not be used.

• No lumps should be present.

• Should feel cool when hand is put in the bag of cement and
rubbing between fingers should be silky.
• When a handful of cement dropped in water, it should float
before sinking.
• Average weight of 5 bags of cement should be 50kg.
 Composition of cement
Introduction
Portland cement gets its strength from chemical reactions between the cement and water.
The process is known as hydration. This is a complex process that is best understood by first
understanding the chemical composition of cement.

Manufacture of cement
Portland cement is manufactured by crushing, milling and proportioning the following
materials:

• Lime or calcium oxide, CaO: from limestone, chalk, shells, shale or calcareous rock

• Silica, SiO2: from sand, old bottles, clay or argillaceous rock

• Alumina, Al2O3: from bauxite, recycled aluminum, clay

• Iron, Fe2O3: from from clay, iron ore, scrap iron and fly ash

• Gypsum, CaSO4.2H20: found together with limestone

T
 Composition of cement
The materials, without the gypsum, are proportioned to produce a mixture with the
desired chemical composition and then ground and blended by one of two processes -
dry process or wet process. The materials are then fed through a kiln at 2,600º F to
produce grayish-black pellets known as clinker. The alumina and iron act as fluxing
agents which lower the melting point of silica from 3,000 to 2600º F. After this stage,
the clinker is cooled, pulverized and gypsum added to regulate setting time. It is then
ground extremely fine to produce cement.
 Composition of cement
Chemical shorthand
Because of the complex chemical nature of cement, a shorthand form is used to denote
the chemical compounds. The shorthand for the basic compounds is:
 Composition of cement
Chemical composition of clinker

The cement clinker formed has the following typical composition:

 Composition of cement
Properties of cement compounds

These compounds contribute to the properties of cement in different ways

Tricalcium aluminate, C3A:-

It liberates a lot of heat during the early stages of hydration, but has little strength
contribution. Gypsum slows down the hydration rate of C3A. Cement low in C3A is
sulfate resistant.

Tricalcium silicate, C3S:-

This compound hydrates and hardens rapidly. It is largely responsible for portland
cement’s initial set and early strength gain.

Dicalcium silicate, C2S:

C2S hydrates and hardens slowly. It is largely responsible for strength gain after one week.
 Composition of cement
Properties of cement compounds

Ferrite, C4AF:

This is a fluxing agent which reduces the melting temperature of the raw materials in the
kiln (from 3,000o F to 2,600o F). It hydrates rapidly, but does not contribute much to
strength of the cement paste.

By mixing these compounds appropriately, manufacturers can produce different types of

cement to suit several construction environments.
Structure of hydrated cement paste

Fracture surface of a PC mortar showing the gel-like nature of C-S-H

Structure of hydrated cement paste

Image of polished surface of a PC mortar; the bright particles are that of unhydrated
cement; the grayish background is the C-S-H, while the white rims around the aggregate
pieces are deposits of CH
HCP structure in Microscopic Level
In microscopic Level, the Hydrated
Cement Paste Structure Consists of the
following elements.
 HCP structure in Microscopic Level
1. Calcium Silicate Hydrate (C-S-H): The volume of C-S-H in HCP is 50%
to 60%. This imparts Vander walls force, which will influence the strength
of HCP. This hydration product has higher surface area. This is not a well-
defined compound.

2. Calcium Hydroxide (Ca(OH)2): This is also called as Portlandite. This

constitutes 20 to 25%volume of HCP. This has a lower surface area. This is
not a desirable product from hydration. This product is soluble in water and
gets leached out making the concrete porous. This is alkaline in nature and
maintains the pH value of concrete around 13.

3. Calcium Sulfoaluminate Hydrate: This product has minor role in the

HCP characteristics. The presence of this product will result in making the
concrete vulnerable to sulphate attack. These are needle shaped plate
product called as ettringite.
 Laboratory Tests on Cement
• Fineness test
• Standard consistency test
• Initial and final setting time
• Soundness test
• Strength test
 Fine Aggregate-Sand

• Aggregate most of which passes through 4.75mm IS

sieve is known as fine aggregate (Para 3.1 of IS:383).

• Sand is graded into four zones. (Table-9 of IS:383)

• The higher the Grading Zone, the finer the sand, with
Grading Zone I – Coarsest and Grading Zone IV-Finest.

• Zone IV aggregates generally should not be used in RCC

• Silt Content - The maximum quantity of silt in sand as

determined by the method prescribed in Annexure 26.3 of
IRUSS shall not exceed 8%.
 Coarse Aggregate
• Aggregate, most of which is retained on
4.75mm IS Sieve and gradation is as
permitted in IS:383

• It shall be roughly cubical in shape. Flaky and

elongated pieces shall be avoided.
• Nominal size and grading shall be as under :
― Nominal sizes of graded stone aggregate or gravel shall
be 40, 20, 16, or 12.5 mm as specified.

― Nominal sizes of single sized stone aggregate or gravel

shall be 63, 40, 20, 16, 12.5 or 10 mm as specified.
 GRADED STONE AGGREGATE
Table 3.1 of USSOR & Table 7 of IS:383
IS Sieve Percentage passing (by weight) for nominal size of
Designation
40 mm 20 mm 16 mm 12.5 mm
80 mm 100 -- -- --
40 mm 95 to 100 100 -- --
20 mm 30 to 70 95 to 100 100 100
16 mm -- -- 90 to 100 --
12.5 mm -- -- -- 90 to 100

10 mm 10 to 35 25 to 55 30 to 70 40 to 85
4.75 mm 0 to 5 0 to 10 0 to 10 0 to 10
 Classification of Aggregates
Aggregates form an essential part of many
construction projects, from large-scale
commercial to smaller domestic works.
• Classification of aggregates based on: Grain Size
• Classification of aggregates based on: Density
• Classification of aggregates based on:
Geographical Origin
• Classification of aggregates based on: Shape
SINGLE SIZED (UNGRADED) AGGREGATE
Table 3.2 of USSOR & Table 7 of IS:383
IS sieve Percentage passing (by weight) for nominal size of
Desig-
nation
63 mm 40 mm 20 mm 16 mm 12.5 mm 10 mm
80 mm 100 -- -- -- -- --
63 mm 85-100 100 -- -- -- --
40 mm 0-30 85-100 100
20 mm 0-5 0-20 85-100 100
16 mm 85-100 100
12.5mm 85-100 100
10mm 0-5 0-5 0-20 0-30 0-45 85-100
4.75mm 0-5 0-5 0-10 0-20
2.36mm 0-5
 Coarse Aggregate
Size of Coarse aggregate
• The nominal maximum size of coarse aggregate should
be-
– One fourth of the minimum thickness of the
members,
– 5mm less than the minimum clear distance between
the main bars

– 5mm less than the minimum cover to reinforcement

whichever is smaller.
 Classification of aggregates based on: Grain Size
Fine and Coarse Aggregate

• The size of fine aggregates is defined as 4.75mm or smaller. That is,

aggregates which can be passed through a number 4 sieve, with a
mesh size of 4.75mm. Fine aggregates include things such as sand,
silt and clay. Crushed stone and crushed gravel might also fall under
this category. Typically, fine aggregates are used to improve
workability of a concrete mix.

• Coarse aggregates measure above the 4.75mm limit. These are more
likely to be natural stone or gravel that has not been crushed or
processed. These aggregates will reduce the amount of water
needed for a concrete mix, which may also reduce workability but
improve its innate strength.
 Classification of aggregates based on: Density
Light weight, Standard and High density aggregates

• Different density aggregates will have much different applications.

Lightweight and ultra lightweight aggregates are more porous than
their heavier counterparts, so they can be put to great use in green
roof construction, for example. They are also used in mixes for
concrete blocks and pavements, as well as insulation and
fireproofing.

• High density aggregates are used to form heavyweight concrete.

They are used for when high strength, durable concrete structures
are required – building foundations or pipework ballasting, for
example.
 Classification of aggregates based on:
Geographical Origin
• Natural – Aggregates taken from natural sources, such as riverbeds,
quarries and mines. Sand, gravel, stone and rock are the most
common, and these can be fine or coarse.

• Processed – Also called ‘artificial aggregates’, or ‘by-product’

aggregates, they are commonly taken from industrial or engineering
waste, then treated to form construction aggregates for high quality
concrete. Common processed aggregates include industrial slag, as
well as burnt clay. Processed aggregates are used for both
lightweight and high-density concrete mixes.
 Classification of aggregates based on: Shape
The different shapes of aggregates are:
• Rounded – Natural aggregates smoothed by weathering, erosion and
attrition. Rocks, stone, sand and gravel found in riverbeds are your most
common rounded aggregates. Rounded aggregates are the main factor
behind workability.
• Irregular – These are also shaped by attrition, but are not fully rounded.
These consist of small stones and gravel, and offer reduced workability to
rounded aggregates.
• Angular – Used for higher strength concrete, angular aggregates come in the
form of crushed rock and stone. Workability is low, but this can be offset by
filling voids with rounded or smaller aggregates.
• Flaky – Defined as aggregates that are thin in comparison to length and
width. Increases surface area in a concrete mix.
• Elongated – Also adds more surface area to a mix – meaning more cement
paste is needed. Elongated aggregates are longer than they are thick or wide.
• Flaky and elongated – A mix of the previous two – and the least efficient
form of aggregate with regards to workability.
 Laboratory Tests on Aggregate
• Specific Gravity
• Fineness Modulus
• Bulk Density
• Porosity
• Water Absorption
• Moisture Content
 Water
• Water used for mixing and curing shall be clean and
free from injurious quantities of alkalies, acids,
oils, salts, sugar, organic materials, vegetable
growth or other substances that may be deleterious
to bricks, stone, concrete or steel.
• Potable water is generally considered satisfactory
for mixing.
• Sea water shall not be used for mixing or curing.
Sea water contains salinity of 3.5% and causes
corrosion and reduction in strength of about 10-15%.
 Water
• Frequency of Testing for Quality - Water from each
source shall be tested before commencement of the
work and thereafter once in every three months till
completion of the work or when ordered.
• Compressive strength test should be carried out in
case of doubt regarding development of strength.
• Average 28 days compressive strength of at least
three 15cm concrete cubes prepared with water
proposed to be used shall not be less than 90 percent
of the average of strength of three similar concrete
cubes prepared with distilled water. The cubes shall
be prepared, cured and tested in accordance with the
requirements of IS:516.
 Water
• Percentage of Solids:
• Maximum permissible limits of solids when tested in
accordance with IS: 3025 shall be as under:
• Organic - 200 mg/litre
• Inorganic - 3000 mg/litre
• Sulphates (as SO4) - 500 mg/litre

• Chlorides (as Cl) –

• 500 mg/ litre for Prestressed Concrete Work
• 1000 mg/ litre for Reinforced Concrete work and
• 2000 mg/ litre for Plain Concrete Work.
 Chemical
composition
of cement
Cement
• Portland cement is the basic ingredient of
concrete. Concrete is formed when portland
cement creates a paste with water that binds with
sand and rock to harden.
• Cement is manufactured through a closely
controlled chemical combination of calcium,
silicon, aluminum, iron and other ingredients.
• Common materials used to manufacture cement
include limestone, shells, and chalk or marl
combined with shale, clay, slate, blast furnace
slag, silica sand, and iron ore. These ingredients,
when heated at high temperatures form a rock-like
substance that is ground into the fine powder that
we commonly think of as cement.
• To calculate the chemical composition of cement
EDAX test is used
Chemical composition of cement
Surface morphology of cement
Micro-structure of
concrete
In microscopic Level, the Hydrated
Cement Paste Structure Consists
of the following elements.
1. C-S-H gel
2. C-H gel and
3. Ettringites.
Thank You