CONCRETE:
Concrete is made by combining cement, water, fine aggregate (sand), coarse aggregate (gravel or
crushed stone), and sometimes admixtures. The goal is to make a uniform, strong, and durable
material.
TYPES OF CONCRETE:
Concrete is mainly classified based on whether or not it contains reinforcement (steel bars) into
two types.
i. Plain Cement Concrete (PCC): PCC is a mixture of cement, sand, aggregate, and water
without any reinforcement (steel bars). It is very strong in compression but weak in tension.
It is not suitable for structural members carrying loads. (M5 to M15 grades)
Uses: Foundation bed (below footings and columns), Flooring underlayer (base course for
tiles or pavements), Pavements, drains, and non-structural members
ii. Reinforced Cement Concrete (RCC): RCC is concrete in which steel reinforcement bars
(rebars) are embedded to resist tensile and bending stresses.
The steel and concrete act together as a composite material (M20 to M40 grades). Concrete
resists compressive stresses and steel resists tensile stresses.
Uses: Beams, slabs, columns, lintels, staircases, and footings. It is used for all Structural
and load bearing components.
PRODUCTION OF CONCRETE:
Concrete production involves a series of systematic steps to obtain a strong, durable, and workable
material. They are as follows:
1. Material Selection: This is the first and most essential step in making quality concrete. Each
material must meet certain standards (as per IS codes) to ensure strength and durability.
a. Cement: Should be fresh and free from lumps. Common types: Ordinary Portland Cement
(OPC – 33, 43, 53 grade), PPC (Portland Pozzolana Cement).It Stored in dry conditions to
avoid moisture absorption.
b. Fine Aggregate (Sand): Should be clean, hard, and free from clay, silt, or organic matter.
Graded as per IS 383 (Zone I–IV).It Helps fill voids between coarse aggregates.
c. Coarse Aggregate: Should be strong, angular, and well-graded (typically 10 mm, 20 mm
sizes). Must be clean and free from dust or impurities. Provides strength and bulk to the
concrete.
d. Water: Should be clean and potable (drinkable) quality. Impurities like oil, acid, or alkalis
can weaken the concrete. Water-cement ratio controls both workability and strength.
e. Admixtures (if used): Chemical or mineral additives used to modify concrete properties.
Examples: plasticizers (to increase workability), retarders (to delay setting), accelerators
(to speed up strength gain).
2. Batching: Process of measuring the correct quantity of each material (cement, sand, aggregates,
water, etc.) to get the correct mix proportion for desired strength and workability.
i. Types of batching:
a. Volume Batching: Materials are measured by volume (using boxes or gauges).
Less accurate so used in small works. Example: 1 box cement: 2 boxes sand : 4
boxes aggregate.
b. Weight Batching: Materials are weighed on scales. It is more accurate and used
in large and quality works.
ii. Mix Design:
Mix design is the process of determining proportions of ingredients to achieve the
required strength, workability, and durability at minimum cost. It ensures the concrete
meets the desired grade (M5–M80) and site conditions. M5 to M20 grade concrete, is
Used for simple, small-scale works.
3. Mixing: It is the process of combining all materials to form a uniform, workable concrete mass.
Types of Mixing:
a. Hand Mixing: it is done on a clean platform or steel tray. It is suitable for small-scale
works.
b. Machine Mixing: It is done in a mechanical mixer (drum type or pan type).and it
ensures better and faster mixing. Generally used in large-scale or structural projects.
c. Ready Mix Concrete: Concrete prepared at a central batching plant and transported to
site by transit mixers. High-quality and consistency is achieved in this type of mixing.
4. Transporting: It is the process of moving fresh concrete from the place of mixing to the place
of placement. Place concrete within 30–45 minutes of mixing (to prevent setting)
Methods of transporting:
a. Manual Method: Manually transported using wheelbarrows, head pans, buckets.
b. Mechanical Method: Transported by chute, conveyor belt, pump, transit mixer, or
crane bucket.
5. Placing: Laying the fresh concrete in the desired position within formwork.
6. Compaction: Removing entrapped air voids from freshly placed concrete to make it dense and
strong.
Methods of compaction:
a. Hand Compaction: Rodding, tamping, or spading (for small jobs).
b. Mechanical Compaction: Vibrators are used for compaction.
7. Finishing: Giving the desired surface texture and smoothness to concrete. After compaction,
the surface is leveled using trowels and edges and corners are shaped properly.
8. Curing: It is the process of maintaining adequate moisture, temperature, and time for the
concrete to gain full strength.
Methods of Curing:
a. Water curing: Ponding, sprinkling, or covering with wet cloth
b. Membrane curing: Applying a curing compound that prevents moisture loss.
c. Steam Curing: Used in precast and prefabrication works. It speeds up strength gain