Innovation in production and Mfg. of cover blocks as a civil Eng.

Products
2020

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

(MUMBAI)
A
PROJECT REPORT
ON

“MANUFACTURING OF PRECAST CONCRETE PRODUCTS”

SUBMITTED BY –

• SAHANE YASHOVARDHAN SHIVAJI

• NIKAM DIGVIJAY SASHIKANT
• RAUNDAL SHANTANU GIRISH
• PATIL SUMIT MANGESH
• SHIRSHAT UDAYRAJ RAJESH

GUIDED BY:–
Mr. A. D. KALE

CO –GUIDED BY :-
Mr.P.S.CHAUDHRI

DEPARTMENT OF CIVIL ENGINEERING

K. K. WAGH POLYTECHNIC, NASHIK
(2019-20)

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 Innovation in production and Mfg. of cover blocks as a civil Eng. Products
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Karmaveer Kakasaheb Wagh Education Society’s

KARMVEER KAKASAHEB WAGH POLYTECHNIC
Nashik, Dist – Nashik 422003

Certificate

Certified that the project report entitled

“Manufacturing of Precast Concrete Products”
has been successfully completed by

• SAHANE YASHOVARDHAN SHIVAJI

• NIKAM DIGVIJAY SHASHIKANT
• RAUNDAL SHANTANU GIRISH
• PATIL SUMIT MANGESH
• SHIRSHAT UDAYRAJ RAJESH

As partial fulfillment of Diploma Course In Civil Engineering under the Maharashtra State
Board Of Technical Education, Mumbai during academic year 2019-20
The said work has been assessed by us we are satisfied that the time up to the standard envisaged
for the level of the course, and that the said work may be presented to the external examiner.

GUIDE CO- GUIDE HOD(CE)

Sign of External Examiner PRINCIPAL

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ACKNOWLEDGEMENT

With deep sense of gratitude we would like to thanks all the people who have let our path
with their kind guidance. We are very grateful to these intellectuals who did their best to help
during our project work.
The special gratitude goes to our guide Mr. A. D. Kale . and co guide of Ar. P. S.
Chaudhari staff members, of Civil Eng. Department for his expensive, excellent and precious
guidance in completion of this work. We thanks to all the colleagues for their preciable help for
our working project.
It is our proud privilege to express deep sense of gratitude to, Prof. P.T. Kadave sir
Principal of K. K. Wagh Polytechnic, Nashik, for his comments and kind permission to complete
this project. We remain indebted to H.O.D. Mr. A. D. Kale Department of Civil Engg. For their
timely suggestion and valuable guidance.
We are also thankful to our parents who provided their wishful support for our project
completion successfully.
Lastly we thank to our all friends and the people who are directly or indirectly related to
our project work.

Yours sincerely,

SAHANE YASHOVARDHAN SHIVAJI

NIKAM DIGVIJAY SHASHIKANT
RAUNDAL SHANTANU GIRISH
PATIL SUMIT MANGESH
SHIRSHAT UDAYRAJ RAJESH

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 Innovation in production and Mfg. of cover blocks as a civil Eng. Products
2020
ABSTRACT

Innovation in production and Mfg. of cover blocks as a civil Eng. Products Cover
block is a construction product produced by casting concrete in a reusable mold or "form" which
is then cured in a controlled environment, transported to the construction site and lifted into place.
In contrast, standard concrete is poured into site-specific forms and cured on site. Concrete is
distinguished from precast concrete by using a fine aggregate in the mixture, so the final product
approaches the appearance of naturally occurring rock or stone.
There are many different types of precast concrete forming systems for architectural and
construction applications, differing in size, function, and cost. Precast panels are also used to
clad all or part of a building facades or free-standing walls used for landscaping, soundproofing,
and security walls, and some can be prestressed concrete structural elements. Storm water
drainage, water and sewage pipes, and tunnels make use of precast concrete units.
When manufacturers design a new block, they must consider not only the desired shape, but
also the manufacturing process required to make that shape. Shapes that require complex molds or
additional steps in the molding process may slow production and result in increased costs. In some
cases, these increased costs may offset the benefits of the new design. Our main point is to make
a product which is made up of low cost construction equipment’s and gives a good quality product
which will bring profit to manufacturing company .
As we did a survey over all the moulds and vibrators available in market we concluded that
the price is high and we can make a better mould and vibrator with cheap material and of good
quality as per our requirement and convenience and give a quality product to the consumer and
expand our business.as per our mix proportion we can provide a quality product in less time with
less efforts and mostly economical .
The prices as compared to market is less which make because of which people will most
probably consume our product.this is how we plan to become a entrepreneur and make good
money.

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 Innovation in production and Mfg. of cover blocks as a civil Eng. Products
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CONTENTS

Sr. No. Name Of Topic Page No.

INTRODUCTION

General Information
What Is Cover Block?
1 Background Of The Study 8-10
Advantages Of Cover Block
What Are The Potential Problems Of Excessive Concrete Cover?

2 LITERATURE REVIEW 11-12

3.1METHODOLOGY

3.1.1To develop a equipment’s

Vibrator
Mold
Mixer
3.1.2 Mix Proportion For Cover Blocks Manufacturing

3 3.1.3The Manufacturing Process 13-24

Mixing
Molding
Curing
Cubing
Quality Control
The Future
Photograph Of Equipment Designed To Construct A Cover Spacer
Block
Experimental program

PROCESSES Of Casting Available In Market

(TYPES OF SPACER MATERIAL )
Plastic Spacers And Bar Supports
4 Concrete Spacers And Bar Supports 25-27
Concrete Spacers With Plastic Clips And Other Fixing
Mechanism

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5 TEST RESULT 28

6 CONCLUSION 29

7 REFERENCES 30

8 COST ANALYSIS 31

List of Figures:-

Fig. No. Name Of Figure Page no.

1 Molds Use For Casting Cover Blocks 20

2 Mixing Of Proportions 21
3 Casting Of Cover Blocks 22
4 Vibration plate 23
5 Pond Curing 24
6 Plastic Spacer With Bar 25
7 Concrete Spacer With Bars 26
8 Concrete Spacer With Plastic Clips 27
9 Compressive Strength Test 28

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CHAPTER 1

INTRODUCTION

1.1General Introduction

A concrete block is primarily used as a building material in the construction of walls. It is sometimes
called a concrete masonry unit (CMU). A concrete block is one of several precast concrete products
used in construction. The term precast refers to the fact that the blocks are formed and hardened
before they are brought to the job site. Most concrete blocks have one or more hollow cavities, and
their sides may be cast smooth or with a design. In use, concrete blocks are stacked one at a time
and held together with fresh concrete mortar to form the desired length and height of the wall.
Concrete mortar was used by the Romans as early as 200 B.C. to bind shaped stones together in the
construction of buildings. During the reign of the Roman emperor Caligula, in 37-41 A.D., small
blocks of precast concrete were used as a construction material in the region around present-day
Naples, Italy. Much of the concrete technology developed by the Romans was lost after the fall of
the Roman Empire in the fifth century. It was not until 1824 that the English stonemason Joseph
Aspdin developed portland cement, which became one of the key components of modern concrete.
The first hollow concrete block was designed in 1890 by Harmon S. Palmer in the United States.
After 10 years of experimenting, Palmer patented the design in 1900. Palmer's blocks were 8 in
(20.3 cm) by 10 in (25.4 cm) by 30 in (76.2 cm), and they were so heavy they had to be lifted into
place with a small crane. By 1905, an estimated 1,500 companies were manufacturing concrete
blocks in the United States.
These early blocks were usually cast by hand, and the average output was about 10 blocks per person
per hour. Today, concrete block manufacturing is a highly automated process that can produce up
to 2,000 blocks per hour.

1.2 Raw Materials

The concrete commonly used to make concrete blocks is a mixture of powdered portland cement,
water, sand, and gravel. This produces a light gray block with a fine surface texture and a high
compressive strength. A typical concrete block weighs 38-43 lb (17.2-19.5 kg). In general, the
concrete mixture used for blocks has a higher percentage of sand and a lower percentage of gravel
and water than the concrete mixtures used for general construction purposes. This produces a very
dry, stiff mixture that holds its shape when it is removed from the block mold. 3

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If granulated coal or volcanic cinders are used instead of sand and gravel, the resulting block
is commonly called a cinder block. This produces a dark gray block with a medium-to-coarse surface
texture, good strength, good sound-deadening properties, and a higher thermal insulating value than a
concrete block. A typical cinder block weighs 26-33 lb (11.8-15.0 kg).
Lightweight concrete blocks are made by replacing the sand and gravel with expanded clay, shale, or
slate. Expanded clay, shale, and slate are produced by crushing the raw materials and heating them to
about 2000°F (1093°C). At this temperature the material bloats, or puffs up, because of the rapid
generation of gases caused by the combustion of small quantities of organic material trapped inside. A
typical light-weight block weighs 22-28 lb (10.0-12.7 kg) and is used to build non-load-bearing walls
and partitions. Expanded blast furnace slag, as well as natural volcanic materials such as pumice and
scoria, is also used to make lightweight blocks.

1.3What is Concrete Cover Block?

A cover block is basically a spacer that is used to lift the rebar matrix off the ground
so that concrete may flow below the rebar.
In order to prevent corrosion of the rebar, it has to be totally sheathed in concrete. It usually
needs about 2 to 3 inches of coverage on all sides. So the cover block lifts the rebar up by
about 2 to 3 inches and becomes a permanent and integral part of the poured concrete, make
certain that no part of the rebar sags and minimizes that required concrete coverage
throughout the pour.
A rebar spacer is a device that secures the reinforcing steel or "rebar" in reinforced concrete
structures as the rebar is assembled in place prior to the final concrete pour. The spacers are
left in place for the pour to keep the reinforcing in place, and become a permanent part of
the structure.
The main categories of rebar spacers are:

Linear Spacers (Π-section profiles, H-section profiles, or other 3 dimensional shapes),

Point Spacers (wheel spacers, various tower or chair-like
shapes) Rebar spacers can be divided in three raw materials
categories:

1. Concrete spacers
2. Plastic spacers
3. Metal spacers
The concrete spacers have the advantage of the same raw material which will improve the
water tightness and strength of the concrete. Plastic spacers have the advantage of the low
cost production and fast processing.

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1.4 Background of the Study
We search number of precast concrete products available in market. On that we
search which product is required mostly on site. We need such material having initial project
cost, materials cost and labour cost is frequently low. After surveying we found that cover
block one of the material which required more on site as compare to other precast concrete
products. We also know what are the advantages of cove blocks and how cost is save.
Then we search which type of cover block are available in market and what are their
advantages and disadvantage.

1.5Advantages of Cover Block

Concrete Spacers prevent rebar’s from corrosion, protect them from fire to certain length
of time and help to provide proper transfer of stresses from concrete to steel rebar’s,
by helping provide proper cover to rebar’s.

a) Maintain the required cover.

b) Prevent steel bars from getting exposed to the atmosphere so that steel corrosion may result.
c) Place and fix reinforcement based on design drawings.
d) Protection of the Rebar from the environment by providing a physical barrier.
e) It provides thermal insulation, which protects the reinforcement bars from fire.
f) To give reinforcing bars sufficient embedding to enable them to be stressed without slipping.
g) Ensures that concrete completely encircles Rebar allowing passivation.
h) Ensures that concrete completely encircles Rebar allowing complete bond to develop. Allows the
Rebar to assume position and act as designed.
i) Prevents staining.
j) Provides a time lag in case of fire.

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1.6 What are the potential problems of excessive concrete covers?

In reinforced concrete structures cover is normally provided to protect steel reinforcement

from corrosion and to provide fire resistance. However, the use of cover more than required
is undesirable in the following ways:
(i) The size of crack is controlled by the distance of longitudinal bars to the point of section
under consideration. The closer a bar is to this point, the smaller is the crack width.
Therefore, closely spaced bars with smaller cover will give narrower cracks than widely
spaced bars with larger cover. Consequently, with an increase in concrete cover the crack
width will increase.
(ii) The weight of the concrete structure is increased by an increase in concrete cover. This
effect is a critical factor in the design of floating ships and platforms where self-weight is
an important design criterion.
(iii) For the same depth of concrete section, the increase of concrete cover results in the
reduction of the lever arm of internal resisting force.

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CHAPTER 2

LITERATURE REVIEW

2.1Types of Spacers for Reinforced

2.1.1Concrete Plastic Spacers

• Plastic spacers are manufactured in several styles that are ideal for different applications.

Track spacers, for example, are continuous strips of plastic resembling a track, and are

ideal for use as base reinforcement in suspended concrete slabs. Track spacers are typically

used on metal decking. Wheel spacers are designed as a clip-on wheel-shaped spacer that

is used when reinforcing columns, walls and beams. Pile cage spacers are round as well,

but usually have more of a horseshoe shape. This type of plastic spacer is usually used

during the manufacture of precast concrete panels.

Fig no.2.1.1

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2.1.2 Wire Spacers

• Wire spacers are typically made of steel and are used to support mesh reinforcement in
concrete slabs. Two main types of wire spacers are available. Hoop spacers are large
circular devices that are about 3 feet in diameter. Three to four hoops are typically needed
per sheet of mesh to provide proper reinforcement. Deckchairs are the other commonly
used type of wire spacers. These resemble the base of a chair, and are used to support fabric
reinforcement while preventing damage to the polythene membrane used in the slab.
Deckchairs are ideal for use in ground floor slabs and can also be used to support dowel
bars

Fig2.1.2

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CHAPTER 3

METHODOLOGY
COVER BLOCKS can be manufactured using 3 different mixing ratios of different
materials. You can select the best suitable mixing ratio according to the availability of raw
materials and market requirement.

A business is all about making profit, so, one should keep an eye on the profitable mixing
ratio to manufacture fly ash brick at very low cost. At the same you should maintain the quality
too; here we come with proven 3 different types of mixing ratios for manufacturing flyash brick

3.1 Mix Proportion for COVER BLOCKS manufacturing using

1. Fly ash
2. Cement
3. 6 mm natural river bed sand
4. Wash sand (Artificial sand )
5. Water

Sr. No.
Fly ash 1:03:06
10
Cement 20 m10 Ceme FA, 3 Cement
Cement 0.75 nt,… Fly
6 mm 25 Fly Ash
Fly Ash 0.25 Ash…
natural CA, 6 FA
FA 3
river bed
sand CA 6

Wash sand 35
(Artificial 1:02:04
sand )
Water 40 m15 0.75 0.25 Cement
Cement 0.75 2 Fly Ash
Fly Ash 0.25
CA, 4 FA
FA 2
CA 4

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1:1.5:3
m20
Cement 0.75 0.75 0.25 Cement
Fly Ash 0.25 2 Fly Ash
FA 1.5
CA, 4 FA
CA 3

1:01:02

m25m 0.75 0.25 Cement

Cement 0.75 2 Fly Ash
Fly Ash 0.25
FA 1 CA, 4 FA
CA 2
6.

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3.1.1Raw Materials
The concrete commonly used to make concrete blocks is a mixture of powdered portland
cement, water, sand, and wash sand. This produces a light gray block with a fine surface texture and
a high compressive strength. A typical concrete block weighs 38-43 lb (17.2-19.5 kg). In general,
the concrete mixture used for blocks has a higher percentage of natural river bed sand and a lower
percentage of wash sand and water than the concrete mixtures used for general construction
purposes. This produces a dry, stiff mixture that holds its shape when it is removed from the block
mold.
If granulated coal or volcanic cinders are used instead of sand and gravel, the resulting
block is commonly called a cinder block. This produces a dark gray block with a medium-to-
coarse surface texture, good strength, good sound-deadening properties, and a higher thermal
insulating value than a concrete block. A typical cinder block weighs 26-33 lb (11.8-15.0 kg).
Lightweight concrete blocks are made by replacing the sand and gravel with expanded clay, shale,
or slate. Expanded clay, shale, and slate are produced by crushing the raw materials and heating
them to about 2000°F (1093°C). At this temperature the material bloats, or puffs up, because of
the rapid generation of gases caused by the combustion of small quantities of organic material
trapped inside. A typical light-weight block weighs 22-28 lb (10.0-12.7 kg) and is used to build
non-load-bearing walls and partitions. Expanded blast furnace slags, as well as natural volcanic
materials such as pumice and scoria, are also used to make lightweight blocks.
In addition to the basic components, the concrete mixture used to make blocks may also contain
various chemicals, called admixtures, to alter curing time, increase compressive strength, or improve
workability. The mixture may have pigments added to give the blocks a uniform color throughout,
or the surface of the blocks may be coated with a baked-on glaze to give a decorative effect or to
provide protection against chemical attack. The glazes are usually made with a thermosetting
resinous binder, silica sand, and color pigments.

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3.1.2Design
The shapes and sizes of most common concrete blocks have been standardized to ensure
uniform building construction. The most common block size in the United States is referred to as an
8-by-8-by-16 block, with the nominal measurements of 8 in (20.3 cm) high by 8 in (20.3 cm) deep
by 16 in (40.6 cm) wide. This nominal measurement includes room for a bead of mortar, and the
block itself actually measures 7.63 in (19.4 cm) high by 7.63 in (19.4 cm) deep by 15.63 in (38.8
cm) wide.

Many progressive block manufacturers offer variations on the basic block to achieve
unique visual effects or to provide desirable structural features for specialized applications.
For example, one manufacturer offers a block specifically designed to resist water leakage through
exterior walls. The block incorporates a water repellent admixture to reduce the concrete's
absorption and permeability, a beveled upper edge to shed water away from the horizontal mortar
joint, and a series of internal grooves and channels to direct the flow of any crack-induced leakage
away from the interior surface.
Another block design, called a split-faced block, includes a rough, stone-like texture on one face
of the block instead of a smooth face. This gives the block the architectural appearance of a cut
and dressed stone.
When manufacturers design a new block, they must consider not only the desired shape, but also
the manufacturing process required to make that shape. Shapes that require complex molds or
additional steps in the molding process may slow production and result in increased costs. In some
cases, these increased costs may offset the benefits of the new design and make the block too
expensive.
3.1.3The Manufacturing Process
The production of concrete blocks consists of four basic processes: mixing, molding,
curing, and cubing. Some manufacturing plants produce only concrete blocks, while others may
produce a wide variety of precast concrete products including blocks, flat paver stones, and
decorative landscaping pieces such as lawn edging. Some plants are capable of producing 2,000
or more blocks per hour.
The following steps are commonly used to manufacture concrete blocks.

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3.1.4 Mixing
The sand and gravel are stored outside in piles and are transferred into storage bins in the plant by a
conveyor belt as they are needed. The portland cement is stored outside in large vertical silos to protect it
from moisture.
As a production run starts, the required amounts of sand, gravel, and cement are transferred by gravity or
by mechanical means to a weigh batcher which measures the proper amounts of each material.
The dry materials then flow into a stationary mixer where they are blended together for several minutes.
There are two types of mixers commonly used. One type, called a planetary or pan mixer, resembles a
shallow pan with a lid. Mixing blades are attached to a vertical rotating shaft inside the mixer. The other
type is called a horizontal drum mixer. It resembles a coffee can turned on its side and has mixing blades
attached to a horizontal rotating shaft inside the mixer.
After the dry materials are blended, a small amount of water is added to the mixer. If the plant is located
in a climate subject to temperature extremes, the water may first pass through a heater or chiller to
regulate its temperature. Admixture chemicals and coloring pigments may also be added at this time.
The concrete is then mixed for six to eight minutes.

3.1.5 Moulding
Once the load of concrete is thoroughly mixed, it is dumped into an inclined bucket conveyor and
transported to an elevated hopper. The mixing cycle begins again for the next load.
From the hopper the concrete is conveyed to another hopper on top of the block machine at a measured
flow rate. In the block machine, the concrete is forced downward into molds. The molds consist of an
outer mold box containing several mold liners. The liners determine the outer shape of the block and the
inner shape of the block cavities. As many as 15 blocks may be molded at one time.
When the molds are full, the concrete is compacted by the weight of the upper mold head coming down
on the mold cavities. This compaction may be supplemented by air or hydraulic pressure cylinders acting
on the mold head. Most block machines also use a short burst of mechanical vibration to further aid
compaction.
The compacted blocks are pushed down and out of the molds onto a flat steel pallet. The pallet and
blocks are pushed out of the machine and onto a chain conveyor. In some operations the blocks then pass
under a rotating brush which removes loose material from the top of the blocks.
3.1.6Curing
The pallets of blocks are conveyed to an automated stacker or loader which places them in a curing rack.
Each rack holds several hundred blocks. When a rack is full, it is rolled onto a set of rails and moved
into a curing kiln.
10 The kiln is an enclosed room with the capacity to hold several racks of blocks at a time. There are two
basic types of curing kilns. The most common type is a low-pressure steam kiln. In this type, the blocks
are held in the kiln for one to three hours at room temperature to allow them to harden slightly. Steam is
then gradually introduced to raise the temperature at a controlled rate of not more than 60°F per hour
(16°C per hour). Standard weight blocks are usually cured at a temperature of 150-165°F (66-74°C),
while lightweight blocks are cured at 170-185°F (77-85°C). When the curing temperature has been
reached, the steam is shut off, and the blocks are allowed to soak in the hot, moist air for 12-18 hours.
After soaking, the blocks are dried by exhausting the moist air and further raising the temperature in the
kiln. The whole curing cycle takes about 24 hours.

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Another type of kiln is the high-pressure steam kiln, sometimes called an autoclave. In this type, the
temperature is raised to 300-375°F (149-191°C), and the pressure is raised to 80-185 psi (5.5- 12.8 bar).
The blocks are allowed to soak for five to 10 hours. The pressure is then rapidly vented, which causes the
blocks to quickly release their trapped moisture. The autoclave curing process requires more energy and a
more expensive kiln, but it can produce blocks in less time.

3.1.7 Cubing
The racks of cured blocks are rolled out of the kiln, and the pallets of blocks are unstacked and placed on
a chain conveyor. The blocks are pushed off the steel pallets, and the empty pallets are fed back into the
block machine to receive a new set of molded blocks.
If the blocks are to be made into split-face blocks, they are first molded as two blocks joined together.
Once these double blocks are cured, they pass through a splitter, which strikes them with a heavy blade
along the section between the two halves. This causes the double block to fracture and form a rough, stone-
like texture on one face of each piece.
The blocks pass through a cuber which aligns each block and then stacks them into a cube three blocks
across by six blocks deep by three or four blocks high. These cubes are carried outside with a forklift and
placed in storage.

3.1.8Quality Control
The manufacture of concrete blocks requires constant monitoring to produce blocks that have the required
properties. The raw materials are weighed electronically before they are placed in the mixer. The trapped
water content in the sand and gravel may be measured with ultrasonic sensors, and the amount of water to
be added to the mix is automatically adjusted to compensate. In areas with harsh temperature extremes,
the water may pass through a chiller or heater before it is used.
As the blocks emerge from the block machine, their height may be checked with laser beam sensors. In
the curing kiln, the temperatures, pressures, and cycle times are all controlled and recorded automatically
to ensure that the blocks are cured properly, in order to achieve their required strength.

3.1.9 The Future

The simple concrete block will continue to evolve as architects and block manufacturers develop new
shapes and sizes. These new blocks promise to make building construction faster and less expensive, as
well as result in structures that are more durable and energy efficient. Some of the possible block designs
for the future include the biaxial block, which has cavities running horizontally as well as vertically to
allow access for plumbing and electrical conduits; the stacked siding block, which consists of three
sections that form both interior and exterior walls; and the heatsoak block, which stores heat to cool the
interior rooms in summer and heat them in winter. These designs have been incorporated into a prototype
house, called Lifestyle 2000, which is the result of a cooperative effort between the National Association
of Home Builders and the National Concrete Masonry Association.As we can develop a better product
with low cost equipments and make good money asa a entrepreneur.

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3.2.1Precast block plastic mould

Fig 3.2.1

Rs 85
Material Plastic/ Rubber

Usage/Application Industrial

Shaping Mode Injection Moulding

Shape Square

Brand Vishwakarma Welding

Finishing Galvanized/ Polished

Mould Type Block Mould

Being a prominent firm of experienced professionals and using latest technology, we are affianced in
offering Precast Cover Block Mould Plastic, This block mould is prepared in compliance with using
finest quality material under the guidance of a skilled team of professionals. The provided block mould
is strictly checked ondifferent quality parameters assuring its flawlessness at user’s end. We provide this
block mould in various customized options as per the needs of customers.

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Features:

1. Sturdy construction
2. Heat resistance
3. Dimensional accuracy

3.2.2Cover block PVC moulds

Fig 3.2.2

Rs 130

Material PVC

Usage/Application Industrial

Thickness 80 mm

Shape Rectangular, Square, Zig-Zag

Molding Type Injection Moulding

Surface Finish Galvanized/ Polished

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Brand Vishwakarma Welding

Area/Black 4 sq.ft

Being a prominent firm of experienced professionals and using latest technology,

we are affianced in offering Cover Block Mould PVC, This block mould is
manufactured in compliance with using finest quality material under the guidance of
a skilled team of professionals. The provided block mould is strictly checked on
different quality parameters assuring its flawlessness at user’s end. We provide this
block mould in various customized options as per the needs of customers.

3.2.3Precast cover block PVC Mould /

Fig 3.2.3

Rs 135
Material PVC

Usage/Application Industrial

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PVC Type Silicon, Rubber

Shape Rectangular, Square, Zig-Zag

Mould Type Block Mould

Thickness 60 mm

Area/Block 1 sq.ft

Being a prominent firm of experienced professionals and using latest technology, we

are affianced in offering Precast Cover Block Mould PVC, This block mould is
prepared in compliance with using finest quality material under the guidance of a
skilled team of professionals. The provided block mould is strictly checked on
different quality parameters assuring its flawlessness at user’s end. We provide this
block mould in various customized options as per the needs of customers.

Features:

• Sturdy construction
• Heat resistance
• Dimensional accuracy

Cover block rubber mould

Material Rubber

Usage/Application Cover Block Moulding

Types Of Rubber Molding Injection Molding

Pattern Type Zig-Zag, Italian

Shape Rectangular, Square, Zig-Zag

Thickness 80 mm

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2020
Area/Block 2 sq.ft

Being a prominent firm of experienced professionals and using latest technology,

we are affianced in offering Cover Block Rubber Mould, This block mould is
manufactured in compliance with using finest quality material under the guidance of
a skilled team of professionals. The provided block mould is strictly checked on
different quality parameters assuring its flawlessness at user’s end. We provide this
block mould in various customized options as per the needs of customers.

Features:

• Sturdy construction
• Heat resistance
• Dimensional accuracy

3.2.4 Precast covering block rubber mould /

Fig 3.2.1

Rs 110

Material Rubber

PVC Type Silicon, Rubber

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Shape Rectangular, Square, Zig-Zag

Types Of Rubber Molding Injection Molding

Mould Type Block Mould

Area/Block 1 sq.ft

Being a prominent firm of experienced professionals and using latest technology,

we are affianced in offering Precast Covering Block Rubber Mould, This block
mould is manufactured in compliance with using finest quality material under the
guidance of a skilled team of professionals. The provided block mould is strictly
checked on different quality parameters assuring its flawlessness at user’s end. We
provide this block mould in various customized options as per the needs of
customers.

Features:

• Sturdy construction
• Heat resistance
• Dimensional accuracy

3.2.5 Cover block plastic mould

Fig 3.2.5

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Rs 120
Material Plastic

Usage/Application Cover Block Moulding

Shaping Mode Injection Moulding

Shape Rectangular, Square, Zig-Zag

Surface Finish Galvanized/ Polished

Brand Vishwakarma Welding

Being a prominent firm of experienced professionals and using latest technology, we

are affianced in offering Cover Block Mould Plastic Mould, This block mould is
manufactured in compliance with using finest quality material under the guidance of a
skilled team of professionals. The provided block mould is strictly checked on different
quality parameters assuring its flawlessness at user’s end. We provide this block mould
in various customized options as per the needs of customers.

Features:

• Sturdy construction
• Heat resistance
• Dimensional accuracy

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3.2.6 Plastic cover mould

Fig 3.2.6

Rs 150
Material Plastic

Usage/Application Industrial

Shaping Mode Injection Moulding

Brand Vishwakarma Welding

Finishing Galvanized/ Polished

Mould Type Block Mould

Being a prominent firm of experienced professionals and using latest technology, we are
affianced in offering
Cover Block Mould Plastic Mould, This block mould is manufactured in compliance
with using finest quality material under the guidance of a skilled team of professionals.
The provided block mould is strictly checked on different quality parameters assuring its
flawlessness at user’s end. We provide this block mould in various customized options

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as per the needs of customers.

Features:
•Sturdy construction •Heat resistance •Dimensional accuracy

3.2.7 Precast cover block mould plastic

Material Plastic

Usage/Application Cover Block Moulding

PVC Type Silicon, Rubber

Shape Rectangular, Square, Zig-Zag

Mould Type Block Mould

Texture Step, Ant, Plain

Being a prominent firm of experienced professionals and using latest technology, we

are affianced in offering
Precast Covering Block Mould Plastic, This block mould is manufactured in
compliance with using finest quality material under
the guidance of a skilled team of professionals. The provided block mould is
strictly checked on different quality parameters assuring its
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Flawlessness at user’s end. We provide this block mould in various customized
options as per the needs of customers.

Shape Rectangular, Square, Zig-

Zag

Material PVC

Usage/Application Industrial

Shaping Mode Injection Moulding

Mould Type Block Mould

Brand Vishwakarma Welding

Finishing Galvanized/ Polished

Being a prominent firm of experienced professionals and using latest technology, we are
affianced in offering
Cover Block Mould PVC, This block mould is manufactured in compliance with using
finest quality material under the guidance

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of a skilled team of professionals. The provided block mould is strictly checked on
different quality parameters assuring its flawlessness
at user’s end. We provide this block mould in various customized options as per the needs
of customers.

Features:
•Sturdy construction •Heat resistance
•Dimensional accuracy

3.2.8Advantages of Cover Block

Concrete Spacers prevent rebars from corrosion, protect them from fire to certain length of time and help
to provide proper transfer of stresses from concrete to steel rebars, by helping provide proper cover to
rebars.

• a) Protection of the Rebar from the environment by providing a physical barrier.

• b) It provides thermal insulation, which protects the reinforcement bars from the fire.
• c) To give reinforcing bars sufficient embedding to enable them to be stressed without slipping.
• d) Ensures that concrete completely encircles Rebar allowing passivation.
• e) Ensures that concrete completely encircles Rebar allowing the complete bond to develop. Allows the
Rebar to assume the position and act as designed.
• f) Prevents staining.
• g) Provides a time lag in case of fire.

3.3.1Types of Concrete Vibrators

1. Immersion or needle vibrator
2. Extended or shutter vibrator
3. Surface Vibrator
4. Vibrating table

1. Immersion or Needle Vibrators

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Fig 3.3.1

Immersion or Needle Vibrators are most commonly used vibrator for concrete. It consists of a
steel tube (with one end closed and rounded) having an eccentric vibrating element inside it.
This steel tube called poker is connected to an electric motor or a diesel engine through a
flexible tube. They are available in size varying from 40 to 100 mm diameter. The diameter of
the poker is decided from the consideration of the spacing between the reinforcing bars in the
form-work.

The frequency of vibration varies up to 15000 rpm. However a range between 3000 to 6000
rpm is suggested as a desirable minimum with an acceleration of 4g to 10g.The normal radius
of action of an immersion vibrator is 0.50 to 1.0m. However, it would be preferable to
immerse the vibrator into concrete at intervals of not more than 600mm or 8 to 10 times the
diameter of the poker.

The period of vibration required may be of the order of 30 seconds to 2 minute. The concrete
should be placed in layers not more than 600mm high.

3.3.2. External or Shutter Vibrators

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Fig 3.3.2

These vibrators are clamped rigidly to the form work at the pre-determined points so that the
form and concrete are vibrated. They consume more power for a given compaction effect than
internal vibrators.

These vibrators can compact upto 450mm from the face but have to be moved from one place
to another as concrete progresses. These vibrators operate at a frequency of 3000 to 9000 rpm
at an acceleration of 4g.

The external vibrators are more often used for pre-casting of thin in-situ sections of such shape
and thickness as can not be compacted by internal vibrators.

3.3.3 Surface Vibrators for Concrete

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Fig 3.3.3

These are placed directly on the concrete mass. These best suited for compaction of shallow elements

and should not be used when the depth of concrete to be vibrated is more than 250 mm.

Very dry mixes can be most effectively compacted with surface vibrators. The surface vibrators

commonly used are pan vibrators and vibrating screeds. The main application of this type of vibrator is

in the compaction of small slabs, not exceeding 150 mm in thickness, and patching and repair work of

pavement slabs. The operating frequency is about 4000 rpm at an acceleration of 4g to 9g.

3.3.4Concrete Vibrating Table

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Fig 3.3.3

The vibrating table consists of a rigidly built steel platform mounted on flexible springs and is driven by

an electric motor. The normal frequency of vibration is 4000 rpm at an acceleration of 4g to 7g. The

vibrating tables are very efficient in compacting stiff and harsh concrete mixes required for manufacture

of precast elements in the factories and test specimens in laboratories.

The advantages of consolidating concrete by vibration are:

• Greater density of the concrete

• Greater strength
• Improved bond with reinforcement steel
• Greater bond on construction joints
• Greater durability
• Improved product finish
• Reduction in the amount of required cement through the use of drier mixes

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Fig 3.3.4

Fig 3.3.4

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3.4.1 Types of Concrete Mixers

There are two broad types of concrete mixers:

1. Batch mixers

o Drum Types Mixer

▪ Tilting drum mixers
▪ Non-tilting drum mixer
▪ Reversing drum mixer
o Pan Type Mixer

Continuous mixers

3.4.2Batch Concrete Mixers

Batch mixers are widely used machines for concrete mixing. Concrete mix obtained by
this mixer is collected batch by batch and time by time. So, it is called as batch mixer.

After pouring all the materials into pan or drum, it mixes all of those for some time and
finally discharges. This process is repeated until required amount of concrete mix is
obtained.

In general Batch mixers are two types.

• Drum type mixers

• Pan type mixers

3.4.3Drum Type Mixers

In case Drum type mixers concrete ingredients are mixed in a drum which is actually in
double conical frustum shape.

Drum types mixers are classified into three types:

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• Tilting drum mixers
• Non-tilting drum mixers
• Reversing drum mixers
3.4.5Tilting Drum Mixers
Tilting drum mixer means the drum will discharge concrete by tilting downwards. It is
rapid discharge process and used for larger projects. Rapid means it delivers concrete by
gravity that is tilting the drum downwards because of this the concrete mix obtained will
be not subjected to segregation.

Low workable concretes which contains large sized aggregates of size greater than 7.5cm
are also mixed efficiently with this tilting type mixers.

But the mixing efficiency depends on some of the factors as follows:

• Shape of the drum

• Angle of the drum
• Size of blades
• Angle of blades
The only disadvantage of this mixer is sticking of concrete to bottom of drum. To
overcome this a method called buttering of mixer is applied in which some amount of
cement mortar is mixed in the mixer before mixing first batch of concrete.

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Fig 3.4.5

3.4.6Non-Tilting Drum Mixers

Non- tilting drum mixers are not allowed to tilt and the drum rotates about its horizontal
axis. For the discharge of concrete a chute is arranged in inclined position which will
receives the concrete mix from drum and discharges out.

In this case, the drum is opened at two ends and consists blades insides when materials are
poured through one end and mix is collected through another end.

Rapid discharge of concrete is not possible in this case. Due to this delay, the concrete
may be vulnerable to segregation.

The larger size aggregate is not discharged easily with the mix. So, size of aggregate mot
more than 7.5cm is preferable for this type of mixers. So, this type of mixers are generally
used for small projects.

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Fig 3.4.6

3.4.7Reversing Drum Mixers

Reversing drum mixers are similar to non-tilting type mixers but in this case reversal of
rotation takes place for different action.

The drum has two openings, one end is for pouring materials and other end is for
discharge of mix. The drum rotates about its horizontal axis. The rotation of drum takes
place in one direction for mixing and in opposite direction for discharging.

Two different set of blades are arranged for mixing and discharging. They are suitable for
dry concrete mixes.

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Fig 3.4.7

3.4.8Pan Type Concrete Mixers

Pan type mixers consists a circular pan in which concrete is mixed. The mixing is done by
blades which are arranged in star shape inside the pan.

There are two types of pan mixers are available. In one case, the circular pan is constant
and only star blades rotate about vertical axis of pan. In the other case, circular pan rotates
while the blades are at static position.

But in both cases, the mixing is efficient and concrete mixture is collected through central
hole provided in the pan. The rotating star blades contains special blades called scrapper
blades which will make concrete not to stick to the pan.

The blades can also be adjusted in height so, there is no room for concrete to store in the
pan. We can say among the all types of batch mixers pan type mixer are more efficient.

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Fig 3.48

3.4.9Continuous Concrete Mixers

Continuous mixer, the name itself telling its duty that the loading, mixing and discharging
of mix is continuously done until the work is complete or work break occurs. The loading
of materials is done continuously by screw feeders.

Fig 3.4.9

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3.4.10Advantages of concrete mixer

• Concrete is produced under controlled conditions.

• Placing and transportation is easy.
• Dust pollution is reduced.
• RMC uses bulk cement instead of bagged cement.
• A high speed of construction.
• Reduced noise and air pollution.
• Environment pollution is reduced.

3.4.10Disadvantages of concrete mixer

• Compared to other binding materials, the tensile strength of concrete is relatively low.
• Concrete is less ductile.
• The weight of compared is high compared to its strength.

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3.5.1Photos of Equipment designed to construct a cover spacer block

1. Mold (Paver block mould , cover block mould, self developed cover block mould)
2. Mixing Equipment
3. Casting
4. Vibrating Table(tyre)
5. Curing pond
6. Motor or mixer
7. Pipes

Fig 3.5.1

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Fig 3.5.1

Fig 3.5.1

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Fig 3.5.1

Fig 3.5.1 self developed mould

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Fig 3.5.1 Self developed mould

Fig 3.5.1 mould

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Fig 3.5.1

Fig 3.5.1 vibrator motor

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Fig 3.5.1 cover for motor

Fig 3.5.1 mixer motor

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Fig 3.5.1 ring bearing

.
Fig 3.5.1 micer parts

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Fig 3.5.1
Filling mortar under the guidance of our project guide AR.
P.S.CHAUDHARY

Fig 3.5.1

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Fig 3.5.1

Fig 3.5.1
Filling of material

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Fig 3.5.1 mixer

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Fig 3.5.1

Fig 3.5.1

Fig 3.5.1

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Fig 3.5.1
Under the guidance of our honorable HOD A.D.KALE we proceed to our project

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Fig 3.5.1
We Used Vibrating Table To Remove Air And To Achieve Required Strength.
Vibrating

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CHAPTER 4

EXPERIMENTAL PROGRAM

4.1Types of casting / available in markets according material

4.1.1Plastic spacers and bar supports

Plastic spacers and bar supports do not bond well with concrete, therefore they are NOT
compatible materials. When the concrete is poured into the form, a small gap is created between
it and the plastic. Plastic has a coefficient of thermal expansion and contraction 10 to 15 times
that of concrete, and when subjected to temperature variations, the plastic continues to expand
and contract at that higher coefficient. At high temperatures, plastic can even melt. The result is
a separation between the spacers and the poured concrete, creating a free passage for corrosive
agents to reach the steel reinforcement from the exterior of the concrete product. This will cause
the steel – and eventually the concrete – to corrode.
Plastic spacers are also subject to corrosion when they come into contact with chlorides
and chemicals, where concrete has a much higher resistance.

Fig4.1.1

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4.1.2Concrete spacers and bar supports

Concrete spacers is also known as bar supports are made of the same material as the
poured concrete, so thermal expansion and contraction are equal. Because they are the same
material, the concrete and spacers will bond so no gaps found between them!
Concrete spacers and bar help to maintain material integrity and uniformity of the
concrete, and provide a cover over the reinforcement that protects against corrosion.

Fig4.1.2

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4.1.3Concrete spacers with a plastic clip or other fixing mechanism

The plastic clip or fixing mechanism is placed on the top of the spacer and does not come
into contact with the surface of the concrete. The plastic clip or fixing mechanism is embedded
only 5 mm into the spacer, which maintains the material integrity at the product’s surface. The
plastic in the clip or fixing mechanism is used only for easily attaching to and holding the
reinforcement, leaving the concrete part to do the work of the spacer.

Fig 4.1.3

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CHAPTER 5

TEST RESULTS

Image 9: Compressive Strength Test

AS PER IS SPECIFIED
5.1 Compressive strength of different grades of concrete at 7 and 28 days

Grade of Minimum Specified

Concrete compressive characteristic
strength compressive
(N/mm2 )at 7 strength
days (N/mm2 ) at
28 days
M20 13.5 20
M25 17 25
M30 20 30
M35 23 35

We achieve a M35 (i.e. (35N/mm2) strength after 7 days.

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CHAPTER 6

CONCLUSION

• The market price of universal cover block is Rs. 5.00 to 5.50/-

• The mix design price of universal cover block made by us is Rs. 0.53/-

AFTER MIX DESIGN OF UNIVERSAL COVER BLOCK THE COST REDUCES TO -

= 5.00 - 0.53 = 4.47/-

SO WE SAVE RS. 4.47/- PER UNIVERSAL COVER BLOCK.

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CHAPTER 7

REFERENCES

www.astraspacers.com

https://en.wikipedia.org/wiki/Rebar_spacer

https://dir.indiamart.com › Die Casting Mould & Moulding Tools › Moulds

https://www.quora.com/What-is-the-definition-of-cover-block-use-in-construction

https://www.quora.com/What-is-the-definition-of-cover-block-use-in-construction

www.kkindia.com/pdf/coverblocks_overview_general.pdf

https://www.youtube.com/watch?v=Qx_yrdXzTMU

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CHAPTER 8

COST ANALYSIS

OUR MIX DESIGN PROPERTION

Artificial Sand – Rs. 2750 / Brass
Wash Concrete Artificial Sand – Rs. 2860/Brass
Wash Plaster Artificial Sand – Rs.3960/ Brass
Fly Ash Pond – Rs.103/40kg
Cement – Rs.360 / 50 Kg
Water – 200kg
Kuch – 100 Kg
Dust – 80kg
10mm Down. Agg. – 1050
Kg Strength – M30 to M35

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COST OF TOOLS AND EQUIPMENT

Cost for making vibrating table - Rs. 4500

Cost of mold for casting cover block – Rs. 1700

COSTING OF MATERIAL PER BATCH OF COVER

SPACER BLOCK MOLD
*IT INCLUDES 42 NOS OF SPACER IN A MOLD, CASTED
PER BATCHES
Cement :- Rs.
6.47
Fly Ash :-
Rs.
0.1
6
Con. :- Rs.
Wash 0.91
Sand
Dust :-
Rs.
0.1
0
6 mm :- Rs.
down 0.85
Agg.
Kuch :-
Rs.
0.09
Total Material Cost :-Rs. 8.57

Water & Elect. Charges :-Rs. 4.00

Labour Charges :- Rs.10.00

Rs 22.57 Per 42 Nos

Per Piece :- Rs.0.53

TOTAL PROJECT COST:

COST OF TOOLS AND EQUIPMENT
LAND COST ( as per location)
COSTING OF RAW MATERIAL FOR MAKING
PRODUCTS (it’s depend on the supply chain management)
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M80 grade formulation for spacer

OPC 53 grade cement 20 kg

GGGBS. 5 kg ( optional )

FLY ASH 10kg

SAND FINE. 45.55 kg

SAND COARSE. 19.45 kg

CHEMICAL = 0.280 kg

STEEL FIBERS. 0.15 kg

PP 12 MM FIBER 0.20 kg

---------------------------------------

TOTAL. 100 kg

water to cement ratio is 0.21 to 0.22

Expected slump is 500 to 600 mm

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