CEMENT CONCRETE

INTRODUCTION
 WHAT IS CEMENT??

• Cement is a very fine powdery substance chiefly made up of limestone

(calcium), sand or clay (silicon), bauxite (aluminIum) and iron ore, and may
include shells, chalk, marl, shale, clay, blast furnace slag, slate.
• It is a binding agent that sets and hardens to adhere to building units such as
stones, bricks, tiles, etc.
 WHAT IS CONCRETE??

• Concrete is a building material composed of Portland cement, fine aggregates

(sand) and coarse aggregates mixed with water which hardens with time.
• Uses : Construction of foundations, columns, beams, slabs and other load
bearing elements.
 WHAT IS CEMENT CONCRETE??

• It is a mixture of cement, sand, pebbles or crushed rock and water, which are
placed in forms and allowed to cure, once cured it becomes hard like a stone.
• It is a frequently used building material.
• It can be moulded into durable structural items of various sizes and shapes.
• It possess adequate plasticity for the mechanical working.
COMPOSTION OF CEMENT CONCRETE
 CEMENT

• MOST OF THE CONSTRUCTION IS DONE WITH ORDINARY PORTLAND

CEMENT AT PRESENT
• SPECIAL VARITIES OF CEMENT LIKE RAPID HARDING CEMENT AND
HIGH ALUMINA CEMENT ARE USED UNDER SPECIAL CIRCUMSTANCES.
• THE CEMENT SHOULD COMPLY WITH ALL THE STANDARD
REQUIREMENTS.
 WATER

• LEAST EXPENSIVE AND MOST IMPORTANT INGREDIENT OF CONCRETE.

• MUST BE CLEAN AND FREE FROM HARMFUL IMPURITIES SUCH AS OIL,
ALKALI, ACID ETC.
• IN GENERAL, THE WATER THAT IS FIT FOR DRINKING SHOULD BE USED TO
MAKE THE CONCRETE.
• THE Ph VALUE OF WATER MUST NOT BE LESS THAN 6.
 AGGREGATES

• CLASSIFIED INTO 2 CATEGORIES :

1. NATURAL AGGREGATES.
2. ARTIFICIAL AGGREGATES.

• NATURAL AGGREGATES:
DIVIDED INTO 3 TYPES
1. CRUSHED ROCK AGGREGATE
2. GRAVEL
3. SAND
• NATURAL AGGREGATES ARE FOUND IN OUR
ENVIRONMENT IN DIFFERENT FORMS. THEY HAVE
DIFFERENT SIZE AND SHAPE. THEY CAN RESIST THE HIGH
COMPRESSIVE LOAD.

• THE MAIN ORIGIN OF NATURAL AGGREGATES IN FROM

BEDROCKS. THERE ARE THREE CLASSIFICATIONS OF
BEDROCKS IGNEOUS ROCKS, SEDIMENTARY ROCKS AND
METAMORPHIC ROCKS.
• SAND

1. SAND IS ONE OF THE MAIN CLASSIFICATIONS OF

NATURAL AGGREGATE.YOU ALREADY KNOW THAT
SAND IS A FINELY DIVIDED GRANULAR MATERIAL.
2. THE SAND IS COARSER THAN SILT AND FINER THAN
GRAVELS. THE MAJOR COMPOUND THAT CONSIST IS
SAND IS SILICA. THE SILICA IS OCCUPYING IN THE
SAND IN THE FORM OF QUARTZ.
3. THE DIAMETER OF THE SAND PARTICLES RANGES
FROM 0.075MM TO 4,75MM. THE SAND IS USED AS THE
FINE AGGREGATES FOR THE PURPOSE OF CONCRETE
MAKING.
• GRAVEL

1. THE GRAVEL IS ANOTHER TYPE OF AGGREGATES AND

IS MAINLY USED FOR AS COARSE AGGREGATES IN
CONCRETE. BANK GRAVEL, BENCH GRAVEL AND
CRUSHED STONE ARE THE EXAMPLES OF GRAVEL.

2. THE SIZE OF GRAVEL RANGES FROM 4MM TO 64 MM.

THE GRAVELS ARE ALSO CLASSIFIED INTO DIFFERENT
NAMES BASED ON THEIR SIZE.
 REINFORCEMENT

• REINFORCING STEEL IS A MATERIAL USED TO STRENGTHEN

CONCRETE.
• WOVEN INTO A MAZE AND PLACED INSIDE OF FORMS OR SUSPENDED
TO ALLOW THE REINFORCING STEEL TO LIE IN THE CENTER OF A
POURED SLAB, THE IRON ROD GIVES ADDED STRENGTH TO THE
ALREADY STRONG CEMENT.
 ADMIXTURES

• SOMETIMES THE INGREDIENTS OTHER THAN THE ABOVE ARE ADDED IN

CONCRETE TO GIVE IT A CERTAIN IMPROVED QUALITIES OR FOR
CHANGING DIFFERENT PHYSICAL PROPERTIES IN ITS FRESH AND
HARDENED STAGES.
• THESE INGREDIENTS OR SUBSTANCES ARE KNOWN AS THE ADMIXTURES.
• THE ADDITION OF ADMIXTURES MAY IMPROVE THE CONCRETE WITH
RESPECT TO ITS:-
1. STRENGTH
2. HARDNESS
3. WORKABILITY
4. WATER-RESISTING POWER. ,ETC.
 COMMONLY USED ADMIXTURES

• ALUM
• ALUMINIUM SULPHATE
• BRIUM OXIDE
• BITUMEN
• CALCIUM CHLORIDE
• COAL ASH
• COMMON SALT
• IRON OXIDE
• LIME
• MINERAL OIL
• ORGANIC OILS
• POTASSIUM CHLORIDE
• SILICATE OF SODA
• TAR PRODUCTS
• VOLCANIC ASHES
• ZIC CHROMATE.,ETC.
MANUFACTURE OF CONCRETE
The Manufacturing
Process
The manufacture of concrete is fairly simple. First, the cement (usually Portland cement) is
prepared. Next, the other ingredients—aggregates (such as sand or gravel), admixtures (chemical
additives), any necessary fibers, and water—are mixed together with the cement to form concrete
The concrete is then shipped to the work site and placed, compacted, and cured.
Preparing Portland cement
1 The limestone, silica, and alumina that make up Portland cement are dry ground into a very fine
powder, mixed together in predetermined proportions, preheated, and calcined (heated to a high
temperature that will burn off impurities without fusing the ingredients). Next the material is
burned in a large rotary kiln at 2,550 degrees Fahrenheit (1,400 degrees Celsius). At this
temperature, the material partially fuses into a substance known as clinker. A modern kiln can
produce as much as 6,200 tons of clinker a day.
2 The clinker is then cooled and ground to a fine powder in a tube or ball mill. A ball mill is a
rotating drum filled with steel balls of different sizes (depending on the desired fineness of the
cement) that crush and grind the clinker. Gypsum is added during the grinding process. The final
composition consists of several compounds: tricalcium silicate, dicalcium silicate, tricalcium
aluminate, and tetracalcium aluminoferrite.
Mixing
3 The cement is then mixed with the other ingredients: aggregates (sand, gravel, or crushed
stone), admixtures, fibers, and water. Aggregates are pre-blended or added at the ready-mix
concrete plant under normal operating conditions. The mixing operation uses rotation or
stirring to coat the surface of the aggregate with cement paste and to blend the other
ingredients uniformly. A variety of batch or continuous mixers are used.
4 Fibers, if desired, can be added by a variety of methods including direct spraying, premixing,
impregnating, or hand laying-up. Silica fume is often used as a dispersing or densifying agent
special trucks, and pumping. Pumping transports large quantities of concrete over large distances
through pipelines using a system consisting of a hopper, a pump, and the pipes. Pumps come in
several types—the horizontal piston pump with semi-rotary valves and small portable pumps
called squeeze pumps. A vacuum provides a continuous flow of concrete, with two rotating
rollers squeezing a flexible pipe to move the concrete into the delivery pipe.

Transport to work site

5 Once the concrete mixture is ready, it is transported to the work site. There are many
methods of transporting concrete, including wheelbarrows, buckets, belt conveyors,
Placing and compacting
6 Once at the site, the concrete must be placed and compacted. These two operations are
performed almost simultaneously. Placing must be done so that segregation of the various
ingredients is avoided and full compaction—with all air bubbles eliminated—can be achieved.
Whether chutes or buggies are used, position is important in achieving these goals. The rates of
placing and of compaction should be equal; the latter is usually accomplished using internal or
external vibrators. An internal vibrator uses a poker housing a motor-driven shaft. When the
poker is inserted into the concrete, controlled vibration occurs to compact the concrete.
External vibrators are used for precast or thin in situ sections having a shape or thickness
unsuitable
Curing for internal vibrators. These type of vibrators are rigidly clamped to the formwork,
which
7 Oncerests
it is on an elastic
placed support. Both
and compacted, the form and
the concrete mustthe concrete
cured beforeareit isvibrated.
finishedVibrating
to make tables
sure
are
thatalso used, where
it doesn't dry tooa table produces
quickly. vertical
Concrete's vibration
strength by using by
is influenced twoitsshafts
moisturerotating
levelinduring
opposite
the
directions.
hardening process: as the cement solidifies, the concrete shrinks. If site constraints prevent the
concrete from contracting, tensile stresses will develop, weakening the concrete. To minimize this
problem, concrete must be kept damp during the several days it requires to set and harden.
The first step in making concrete is to prepare the cement. One type of cement, Pordand cement,
is considered superior to natural cement because it is stronger, more durable, and of a more
consistent quality. To make it, the raw materials are crushed and ground into a fine powder and
mixed together. Next, the material undergoes two heating steps—calcining and burning. In
calcining, the materials are heated to a high temperature but do not fuse together. In burning,
however, the materials partially fuse together, forming a substance known as "clinker." The clinker i
then ground in a ball mill—a rotating steel drum filled with steel balls that pulverize the material.

After the Portland cement is prepared, it is mixed with aggregates such as sand or gravel,
admixtures, fibers, and water. Next, it is transfered to the work site and placed. During placing,
segregation of the various ingredients must be avoided so that full compaction—elimination of air
bubbles—can be achieved.
PROPERTIES OF CEMENT CONCRETE
 IT POSSESSES A HIGH COMPRESSIVE
STRENGTH.

Reasons for the higher compressive strength of

cement concrete
• High cement content, coupled with a low water cement
ratio
• Using either Rapid Hardening Cement or Extra Rapid
Hardening Cement
• Accelerators
 WATER/CEMENT RATIO

• The single most important indicator of

strength is the ratio of the water used
compared to the amount of cement (w/c
ratio)
• Basically, the lower this ratio is, g the higher
the final concrete strength will be.
• This concept was developed by Duff Abrams
of The Portland Cement Association in the
early 1920s and is in worldwide use today.
 THE MOST POTENTIALLY DESTRUCTIVE
WEATHERING FACTOR IS FREEZE -THAW
RESISTANCE

SPECIMENS SUBJECTED TO 150 CYCLES OF

• The most potentially destructive FREEZING AND THAWING
weathering factor is freezing and
thawing while the concrete is wet,
particularly in the presence of deicing
chemicals.

HIGH WATER-CEMENT RATIO

LOW WATER-CEMENT RATIO

IT IS A CORROSION RESISTANCE MATERIAL
AND ATMOSPHERIC AGENT HAS NO
APPRECIABLE EFFECT ON IT.
 IT HARDENS WITH AGE - THE PROCESS OF
HARDENING

This continues for a long time after the concrete has attained sufficient
strength. It is this property of cement concrete which gives it a distinct
place among building materials.
Higher strength in concrete could be achieved by using one of the following methods or a
combination some or many of the following:
• Higher cement content
• Reducing water cement ratio
• Better workability and hence better compaction
IT BINDS RAPIDLY WITH STEEL AND AS IT IS WEAK IN
TENSION,

The steel reinforcement is placed in

cement concrete at suitable places to take
up the tensile stresses. This is termed as
the reinforced cement concrete or simply
as R.C.C.
 TENDENCY TO SHRINK

• Under the following two conditions, it has a tendency to shrink:

• There is initial shrinkage of cement concrete which is mainly due to the loss of water through
forms, absorption by surfaces of forms etc.

• The shrinkage of cement concrete

occurs due to hardening. This tendency
of cement concrete can be minimized by
proper curing of concrete.
• Concrete is weak in tension; it will often
develop cracks due to such shrinkage
and temperature changes.
• The heat from the exothermic hydration
process adds to this problem.
 IT HAS A TENDENCY TO BE POROUS.

This is due to the presence of voids which are formed during and after its placing. The two precautions
necessary to avoid this tendency are as follows:
• There should be proper grading and consolidating of the aggregates.
• The minimum water-cement ratio should be adopted.
EFFECT OF VOIDS IN CONCRETE ON MODULUS OF
ELASTICITY, COMPRESSIVE STRENGTH, AND
FLEXURAL STRENGTH
IT FORMS A HARD SURFACE, C APABLE OF
RESISTING ABRASION.
TYPES OF CEMENT
CONCRETE
 PLAIN CEMENT CONCRETE ( PCC)(ORDINARY
CONCRETE )
• MOST COMMONLY USED TYPES OF CONCRETE.
• CONSTITUENTS ARE CEMENT, SAND AND COARSE
AGGREGATES DESIGNED, AND MIXED WITH A SPECIFIED
QUANTITY OF WATER.
• NOMINAL MIX DESIGN IS 1:2:4. OF CEMENT , SAND AND
AGGREGATE
• PLAIN CEMENT CONCRETE (PCC) HAS THIS WEAK
CHARACTERISTICS IN THE PRESENCE OF TENSION.
• IT CAN BE MOULDED INTO ANY FORM .

USES
• CONSTRUCTION OF PAVEMENTS, FOOTINGS , COPINGS ETC
• WHERE VERY HIGH TENSILE STRENGTH IS NOT REQUIRED.
 LIGHT WEIGHT CONCRETE

• CONCRETE HAVING DENSITY BETWEEN 3 - 18 KN/M²

• VARIOUS TYPES OF AGGREGATES THAT ARE USED IN THE MANUFACTURING
INCLUDE NATURAL MATERIALS LIKE PUMICE AND SCORIA, ARTIFICIAL MATERIALS
LIKE EXPANDED SHALES AND CLAYS AND PROCESSED MATERIALS LIKE PERLITE
AND VERMICULITE.
• THE SINGLE IMPORTANT PROPERTY OF LIGHTWEIGHT CONCRETE IS ITS VERY
LOW THERMAL CONDUCTIVITY.
• THE STEEL BARS USED GETS CORRODED EASILY DUE TO THE MOISTURE
ENTERING THROUGH THE PORES.

USES
• FOR THERMAL INSULATION
• FOR PROTECTING STEEL STRUCTURES, THEY ARE ALSO USED IN LONG SPAN
BRIDGE DECKS
• AS BUILDING BLOCCKS – AUTOCLAVED AERATED CONCRETE (AAC BLOCKS) MADE
FROM CEMENT , SAND AND FLY ASH
 RCC (REINFORCED CEMENT CONCRETE)

• MOST IMPORTANT CONCRETE TYPE

• IN THIS CONCRETE TYPE, STEEL IN VARIOUS FORMS IS USED AS REINFORCEMENT TO GIVE VERY HIGH
TENSILE STRENGTH.
• COMBINED ACTION OF PLAIN CONCRETE (HAVING HIGH COMPRESSIVE STRENGTH) AND STEEL (HAVING
HIGH TENSILE STRENGTH).
• THE STEEL REINFORCEMENT IS CAST IN THE FORM OF RODS, BARS, MESHES, AND ALL CONCEIVABLE
SHAPES.
 WATER PROOFING CONCRETE

• HIGH DENSE CONCRETE MADE OF HIGH CLASS PORTLAND CEMENT.

• CLEAN AND NON POROUS AGGREGATES ARE USED .
• HYDROPHOBIC CEMENT IS USED
• WATER PROOFING COMPOUNDS LIKE PUDLO , IMPERMO ETC ARE USED.
USES
• CERTAIN TYPES OF WORKS LIKE WATER TANKS , RESERVOIRS
• BASEMENT , ROOFS , SWIMMING POOLS
• SEWAGE UNITS ETS
 PRECAST CONCRETE
• TYPES OF CONCRETE SHAPES THAT ARE CAST INTO MOLDS IN A FACTORY
WHERE AS THE CAST IN SITU CONCRETE IS PREPARED IN THE SITE
• HOWEVER, THEY ARE NOT USED IN CONSTRUCTION UNTIL THEY
COMPLETELY SET AND HARDENED IN A CONTROLLED CONDITION
• IT CAN BE MADE TO DESIRED SHAPES, SIZES AND ACCURACY
• IT CAN BE DISMANTLED AND USED ELSEWHERE

• SCAFFOLDING AND FORMWORK COST IS REDUCED

• IT MAY BREAK DURING TRANSPORTATION
• SPECIAL LIFTS ARE REQUIRED FOR INSTALLATION

USES
• PRECAST POLES,
• FENCE POSTS,
• CONCRETE LINTELS,
• STAIRCASE UNITS,
• CONCRETE BLOCKS,
 READY MIX CONCRETE (RMC)

• THIS CONCRETE TYPE IS PREPARED IN CONCRETE PLANTS AND OR TRANSPORTED BY THE HELP OF TRUCK
MOUNTED TRANSIT MIXTURES
• TRUCK CARRIES THE MIX IN A REVOLVING CHAMBER WHICH KEEPS THE MIX AGIGATED PREVENTS THE
SEGREGATION OF AGGREGATE PARTICLES .
• ONCE THEY ARE REACHED AT THE SITE THEN, THERE IS NO FURTHER TREATMENT NECESSARY.

• SERVE CONCRETE TO WIDE AREA

• WASTAGE OF MATERIAL IS AVOIDED
• REDUCES THE LABOUR
• STORAGE SPACE FOR MATERIALS ON STE IS NOT REQUIRED.
 NO FINES CONCRETE
• IT CONSISTS OF CEMENT , COARSE AGGREGATE AND
WATER
• FINE AGGREGATE IS OR SAND IS ELIMINATED
• IT’S A TYPE OF LIGHT WEIGHT CONCRETE

• BETTER INSULATING CHARACTERS

• SAVES MATERIAL COST
• POSSIBLE TO USE CHEAP FORMWORK

• LONG TIME TO REMOVE THE FORMWORK

• COMPRESSIVE BOND AND FLEXURAL STRENGHT ARE
COMPARATIVELY LOWER.
USES
• LOAD BEARING WALLS
• RETAINING WALLS
• DAMP PROOF SUB BASE MATERIAL
 COLOURED CONCRETE
• COLOUR PIGMENT IS ADDED TO 8- 10 % OF THE CEMENT
• COLOURED CEMENT IS USED FOR THE PREPARATION OF CEMENT CONCRETE
USES
• PARKING LANES
• ORNAMENTAL FINISHES IN BUILDINGS
• SEPERATING LINES OF TRAFFIC ROADS
• PEDESTRIAN CROSSINGS
 SHOT CRETE.
• SHOTCRETE IS A CONCRETE PREPARED IN THE SAME
MANNER AS ORDINARY.
• BUT THE DIFFERENCE IS THAT THEY ARE PLACED
DIFFERENTLY.
• THEY ARE PLACED WITH THE HELP OF HIGHER AIR
PRESSURE THROUGH NOZZLES.
• THE BENEFIT OF THIS TECHNIQUE IS THAT THE
COMPACTION AND PLACING OF CONCRETE WILL BE
DONE SIMULTANEOUSLY.
FIBER REINFORCED CONCRETE (FRC).
• STEEL FIBERS 10 TO 20 MICRONS IN DIAMETER AND
10 TO 50 MM IN LENGTH IS USED.
• FIBER INCREASES RESILIENCE, TENSILE STRENGTH,
FLEXIBILITY, AND OTHER QUALITIES.
• THE FIBERS MAY BE OF DIFFERENT MATERIALS LIKE
STEEL, POLYMER, GLASS, CARBON, OR EVEN
NATURAL FIBERS LIKE COCONUT FIBER.
• FIBER REINFORCED CONCRETE CAN ALSO BE USED
IN PLACES WHERE INCREASED RESISTANCE TO
CRACKING IS REQUIRED.
USES
• MOSTLY AS OVERLAYS FOR PAVEMENTS IN BRIDGES,
• AIRPORTS, AND OVER INDUSTRIAL FLOORS.
 OTHER TYPES OF CONCRETE

• RAPID HARDENING CONCRETE. – HARDENING CEMENT

• ASPHALT CONCRETE. – AGGREGATE
• LIME CONCRETE – ADMIXTURE
• STAMPED CONCRETE. – DYE ON PLASTICE STAGE
• PERMEABLE CONCRETE – COARSE AGGREGATE
• SILICA FUME CONCRETE. – AGGREGATE
• FERRO CEMENT CONCRETE.- WIRE MESH
• PRE-PACKED CONCRETE. – AGGREGATE IN PUT SEPERATELY