1) Write a short note on chemical admixtures.

Chemical admixtures are used in construction industry for building strong, durable and water proof structures. (1) Accelerators Accelerated strength gain. (2) Retarders (3)Plasticizers (a)Air-entraining agents , (b)Finely divided minerals (4)Water Proofers

(i) ACCELERATORS:It reduce the setting time and generally produce early removal of forms and early setting of concrete repair and patchwork. For plain Concrete cacl2 is used as accelerator .1-2% by weight of cement- is mixed with concrete The presence of cacl2 can cause corrosion of embedded steel. For pre stressed and reinforced concrete cacl2 cannot be used, Instead calcium formate is used.

(ii) RETARDERS:It increasing the setting time of concrete mix and reduce the water cement ratio. These chemicals are derived from (1)Ligno sulphonic acids and their salts. (2)Hydroxylated carboxylic acid and their salt. (3)Naphlthelene fromaldehyde.

(iii) PLASTICIZERS:A Plasticizer is defined as an admixture added to wet concrete mix to impart adequate work ability properties. Finely divided minerals:- They are cementitious or pozzolanic. Natural cements, hydraulic lime and slag cement belong to the former category where as fly ash and heat- treated clays belong to the latter. Air-Entraining agents:- It help in protecting concrete subjected to repeated freeze-thaw cycle. Concrete with entrained air has higher workability and cohesiveness. Segregate and Bleeding are reduced by using air entraining agents. This agents are derived from syenthetic detergents, salts of sulphonated ligimin ,fatly acids.

(iv) WATER PROOFERS:These chemicals are added to concrete or mortar at the time of preparation to make the structure water proof. They react with the lime contained in cement to form capillaries. Ex; calcium soaps, Resins, Vegetables oils, coal.etc inorganic salts which block the pores and

2 . Write short note on Expansive Cement.

Expansive Cement is a cement containing hydraulic cement, expand during the early hydration period after setting. Calcium silicates that upon being mixed with water forms a paste, that during the early hydrating period occurring after setting, increase in volume significantly more than Portland cement paste. Expansive cement is used to compensate for volume decrease due to shrinkage and to induce tensile stress in reinforcement. It is used to minimize cracking caused by drying shrinkage in concrete slabs. Pavements and structures is termed shrinkage compensating concrete. Types of Expansive cements: These are 3 types they are a. b. c. Contains anhydrous calcium aluminate Contains calcium aluminate and calcium sulfate Contains tricalcium aluminate and calcium sulfate Drying shrinkage in structures will induce tensile stresses. These drying shrinkage stresses usually exceed the concrete tensile strengths, causing cracking. The Advantage of using expansive cement to induce stresses large enough to compensate for drying. Shrinkage stresses and minimize cracking.

3. Explain carbonation- chemical attack on concrete.

It is a process by which Co2 from the air penetrates into concrete and reacts with calcium hydroxide to form calcium carbonate. The carbonation of concrete is one of the main reasons for corrosion of reinforcement. Rate of carbonation: It depends on the following factor. 1) 2) 3) 4) Level of pore water Grade of concrete Permeability of concrete Depth of level

Measurement of depth of carbonation :

Non Destructive testing.

A Simple method for establishing the content of carbonation is to treat the freshly broken surface of concrete with a solution of phenolphthalein in diluted alcohol . If the ca(OH)2 is un affected by co2 the color turns out to be pink. If the concrete is carbonated it will remain uncolored. It should be noted that the pink color indicates that enough ca(OH)2 is present but it may have been carbonated to a lesser extent.

4. With a stress-strain curve, explain the behavior of fibre reinforced concrete. Behavior in Tension:
The most significant effect of incorporating fibers is to delay and control the tensile cracking of this composite material. The fibers provide a ductile members in a brittle matrix and resulting composite has ductile properties. The fibre and the matrix share the tensile load until the matrix cracks and then almost the full force gets transferred to the fibre. This is a predominant feature of fibre reinforced concrete.

Behavior in compression:
FRC has significant increase in ductility beyond ultimate load, resulting in substantially higher toughness. This increased toughness is advantageous in preventing sudden failures under earth quake.

5. What is Ferro cement? What are its applications? What are Its advantages?
Ferro cement is a type of thin wall reinforced concrete commonly constructed of hydraulic cement mortar reinforced with closely spaced layers of continuous and relatively small size wire mesh.

Applications:1. Water supply and sanitation application-Water tank, Sedimentation tank, septic tank
etc 2. Housing Application: Domes, Shelters, wall panels corrugated roofing sheets, precast housing element. 3. Permanent form work: for pre stressed concrete columns, beams, slabs etc.

Materials used for ferrocement) cement mortar mix: It is a mixture of Portland cement . fine
aggregates, water and admixtures if required. b) Steel mesh Reinforcement: Steel mashes are the primary reinforcement for Ferro cement. The meshes can be square or chicken mashes of hexagonal shape.

Advantages of FRP:
Good resistance towards corrosion - High strength - Lower unit weight - Easy to Handle Good damping and fatigue behavior - Convenient use for repairing structures

Disadvantages of FRP: Low shear strength - High cost - Low Ductility - Susceptibility to stress

DISTRESS MANAGEMENT
Reinforced concrete is the major construction material used in almost all types of construction, residential, industrial, bridges, irrigation structures etc. The material posses strength, serviceability and durability Cement concrete provides adequate protection to rebar which is a metal susceptible to corrosion. It is also capable of with standing attacks from aggressive chemicals. In spite of its proven ability to be durable, deterioration of concrete and corrosion of rebar have occurred in several structures in the recent past, indicating that concrete is not as durable as it is expected to be. It requires additional protection to perform well. The decay of concrete may result in any of the following manner. 1. Cracks 2. Yielding of steel 3. Deflection 4. Swelling 5 . Discoloration 6. Spalling 7.Snapping 8. Erosion

The decay of concrete may be divided into 2 types 1) Attack on concrete

2) Attack on rebars in the form of rusting.

The Attack of concrete may be due to:Erosion by wind or water - Abrasion by wheel - Impact loads - Over loading of structures Fire - Freezing and thawing - Chemical reaction - Attack of sulphates from ground water - Formation of expansive gel in the region between cement and aggregates & Poor construction practices such as ( Incorrect mix designs, Improper cover, Improper construction joint ,Improper expansion joint, Inadequate concrete vibration, poor curing )

The attack on rebars:Concrete is exposed to different atmospheric gases, vapors and liquids these penetrate into concrete surface due to defects such as : Poor joints - Porous region Cracks - Defects due to grouting of fitting and fixtures - Areas of in sufficient cover - Areas of in effective maintenance and repair.

Corrosion of Rebars :
Rebar corrosion occurs when the concrete fails to give adequate protect to the embedded steel

Major factors of corrosion are:

1.) carbonation 2.) chloride and sulphate attack.

1) carbonation:
Atmosphere contains CO2, H2O and O2. The carbonic acid formed by co2 and H2O penetrates into the concrete and reduces the pH of concrete surrounding the bars. When the pH is reduced to 8.4, an irreversible corrosion process starts. Ca(OH)2 + CO2 + H2O = CaCo3 +2H2O

2) Chloride and sulphate attack :

The coastal environment up to about 50km distance from the sea. Shore has got a high degree of chloride in the atmosphere on account of marine spray. The ingress of chloride though concrete depassivates the embedded rebar and in the presence moisture and O2. The the corrosion product increases in its volume including expansive forces to the surrounding concrete cover and when the stresses induced by the expansive forces exceed the tensile strength of concrete, concrete over cracks and further corrosion will take place and eventually the concrete cover will spall off. The subsoil and industrial discharges contain a large percentage of chlorides and sulphates. The sulphates attack the concrete by producing voluminous calcium- sulpho-aluminates and makes it crack and spall. The foundation also may be subjected to chloride and sulphate attack. In such a case, the steel bars in foundation need to be properly protected.

Effects of Rebar corrosion:

Corrosion of Reinforcement and its effect on concrete are 1) Reduction in effective cross sectional area of steel reinforcement. 2) Volume of corrosion products increase 8 Times. This increased volume exerts pressure or surrounding concrete, causing separation of concrete cover and as a result spalling takes place at a faster rate exposing the area of steel rebar for corrosion. 3) The other effects of corrosion are: Stress corrosion - Stress corrosion cracking - Corrosional fatigue All these factors decrease the life of a structure.

Corrosion triangle:
Corrosion is generally compared to a triangle with these constituting elements namely 1. The substance for oxidation, iron. 2. The conductive atmosphere. 3. Promoter of oxidation, oxygen Just as in a triangle, by removal of one or more sides, the corrosion stops by removing one of the three components by a suitable protective method, starving effect, sacrificial anode or other means.

General requirements of building design In corrosion protection:

In order to prevent initiation of corrosion the concrete structure should comply with the following requirements. 1. All reinforced structural members be of corrosion resistant construction. 2. Structural steel work and other steel fittings embedded in reinforced concrete member should be protected by suitable means to prevent initiation of corrosion.

Methods of controlling corrosion:

Some of the prominent methods of controlling corrosion are: 1. 2. 3. 4. 5. 6. Coating of steel Coating of concrete Larger cover thickness Better quality concrete ( more dense and compacted ) Corrosion inhibitors Cathodic protection and barrier coating to concrete

Coating to steel:
Steel can be protected if the corrosion process is interrupted by providing a suitable coating which can insulate steel from corroding agents. For a protective coating to be effective it must; a. Coat the surface of the reinforcing steel bar providing a uniform thickness on flats, ribs. b. Be tough and well adherent to steel to resist normal transportation and handling stress at job site. c. Provide sufficient flexibility to allow easy post-coating fabrication of the bar at the site without the film peeling off. d. Resist corrosive environment with out loss of bond. e. Provide easy & economical application method amenable to a high degree of quality assurance. Out of 47 coatings tried in USA, UK, Japan, Australia & in India,

.FUSION BOND EPOXY COATING TECHNIQUE was found to be the most suitable one in the
extreme environment. (i) Epoxy coated bars with a coating thickness of 200-300 mm remain unaffected & maintained all the original characteristics glass coating, hardness & coating adhesion even with a small cover of 20mm. Corrosion damage was less for galvanized bars. In cracked concrete containing contaminated aggregate& mixed with sea water, epoxy coated bars showed excellent performance. This coated bars with uniform coating provides long term protection against corrosion.

(ii) (iii)

FBEC Material: It is a blend of epoxy resins + curing agents + fillers + pigments +

catalysts + leveling & flow control agents.

Coat application process :

(i) (ii) (iii) (iv) (v) (vi) Cleaning the bars by shot blasting after pre heating Heating the cleaned bar in a pollution free heater to a temperature of about 218 0c to 232 0c as per the recommendation of the powder manufacturer. Apply electrostatic spray coating of epoxy powder for a time of 10 to 20 sec with uniform thickness. Cure by residual heat & with water. Online testing before packing & dispatch.

Powder should be tested for :

(i) (ii) (iii) (iv) (v) (vi) (vii) Chemical resistance Resistance to voltage Permeability to chloride Adhesion of coating Bond strength of concrete Abrasion resistence Impact test & hardness test.