Concrete Technology

Unit 2 : Fresh Concrete

Unit Content
• Concrete
• Fresh & hard Concrete
• PCC & RCC
• Concrete Operation & its supervision- Mixing, Transporting, Placing,
and Compaction of concrete Curing, Methods of curing
• Workability: Factors affecting workability
• Measurement of workability
• Grade of Concrete
Concrete

• Concrete is a composite material made of cement, fine aggregate,

coarse aggregate and water, when these materials are mixed together
in required proportions they form a fluid mass (fresh concrete) and
hardens to form durable mass like stone (hardened concrete).
• Cement mixed with water acts as binding agent, fine aggregate acts as
filler and coarse aggregate contributes to strength of concrete.
Fresh & Hardened Concrete
• Fresh Concrete- The fresh
mixtures of coarse aggregate,
fine aggregate, cement and
water in suitable proportions
is termed as Fresh Concrete.
• Hardened Concrete- As the
time passes above mentioned
mixture gets hardened. This
hardened mixture is termed as
hardened concrete.
Basic Types of Concrete:
• Plain Cement Concrete (PCC) – Only Concrete. Cement – Good in
Compressive strength,
• Concrete is weak in tension & strong in compression
• Example : Road, Building concrete bed

• Reinforced cement concrete (RCC) – Concrete with reinforcement,

Use steel bars to provide strength, Steel is good in tensile strength, So
RCC are good in Compressive as well as tensile strength.
• Example : Column, Beam
Concrete Operation
 Batching

Measures quantities by weight, and is generally more accurate Measures quantities by volume, and is generally less
than volume batching. Weigh batching is more consistent. accurate than weight batching. Volume batching is
Weigh batching is considered more accurate . Weigh batching is suitable for small-scale construction projects where
commonly used in large construction projects requiring high precision isn't critical.
quality concrete A concrete mix might be specified as 1:2:3
A concrete mix might be specified as 1:2:3 (cement:sand:aggregate by volume), meaning for every
(cement:sand:aggregate by weight), meaning for every 1kg of 1 cubic meter of cement, 2 cubic meters of sand, and 3
cement, 2kg of sand, and 3kg of aggregate would be added. cubic meters of aggregate would be added.
Types of Mixing
1. Nominal Mix : A rough method of concrete mix design that uses a
fixed ratio of cement to aggregate by volume. Nominal mixes are
used for ordinary concrete constructions, such as small concrete
works, and for concrete grades up to M20.
2. Design Mix : A more precise method of concrete mix design that
involves testing each ingredient in a laboratory. Design mixes are
used for more extensive and important concrete works, and for
concrete grades M25 and above.
Hand Mixing
Machine Mixing – Tilting Mixer
Hydraulic Hopper Mixer
Non Tilting Mixer
Pan Type Mixing
Machine Mix - RMC
Transportation of Concrete

Mortar Pan Wheel Barrow

Transit Mixer Belt conveyor

Pump Crane & Bucket

Placing
Compaction

Needle Vibrator Table Vibrator

Surface Vibrator
Finishing
Curing Polythene Curing

Ponding Curing

Spray Curing Using Gunny Bags Curing

Different Grades of Conerete (ordinary concrete,
standard concrete & high strength as per
provisions of IS 456-2000)
• Concrete mixes have been classified into various grades by Bureau of
Indian Standards like M10, M15, M20, etc.
• In the designation of a concrete mix M refers to the Mix and Number
refers to the characteristic compressive strength of 150 mm cube at
28 days expressed in N/mm².
Properties of Fresh Concrete

Workability

Segregation

Bleeding
Segregation
• Segregation is the separation of the ingredients in concrete, which can
happen during mixing, transportation, or placement. It can lead to poor
concrete placement and a loss of strength.
What causes segregation?
•Improper mixing: Mixing that's not thorough or done for long enough can
cause segregation.
•Incorrect water-cement ratio: A high water-cement ratio can cause some
areas to have more water than others.
•Vibration: Over- or under-vibration can cause particles to settle unevenly.
•Transportation: Dropping concrete from heights, or transporting it over
long distances, can cause segregation.
•Weather: Adverse weather conditions can cause segregation.
What are the effects of segregation?
Honeycombing: Segregation can cause the concrete to have a
honeycombed appearance. Honeycombing is a defect in concrete
that occurs when air bubbles form in the concrete, creating hollow
spaces and cavities
Decreased density: Segregation can decrease the density of the
concrete.
Loss of strength: Segregation can cause the concrete to lose
strength.
Cracks: Segregation can cause cracks to form in the concrete.
Honeycombing
Bleeding
• Bleed in concrete
is the result of excess
water being forced to
the surface.
Causes of bleeding

1.High Water-Cement Ratio: A high water-cement ratio increases the

likelihood of bleeding as it provides more free water to segregate
from the mix.
2.Improper Aggregate Gradation: If the aggregate used in the mix is
not properly graded, it can lead to increased bleeding. The absence of
fine particles creates voids, allowing water to rise.
3.Inadequate use of Admixtures: Certain admixtures, if not used
correctly, can increase the rate of bleeding. For instance, air-
entraining agents can create tiny air pockets in the mix, promoting
water segregation.
 Effects of Concrete Bleeding

• The effects of concrete bleeding can be harmful to the overall quality

of the concrete structure:
1. Weakens Surface Layer: The excess water weakens the surface layer
of the concrete, reducing its durability and resistance to abrasion.
2. Promotes Scaling: Bleeding can lead to scaling, where the surface
layer peels off, exposing the aggregate underneath.
3. Creates Voids: As the water evaporates from the surface, it leaves
behind pores and voids, reducing the strength of the concrete.
4. Promotes Cracking: The differential settlement caused by bleeding
can lead to the formation of cracks in the concrete structure.
Solution
• Use of Supplementary Cementitious Materials (SCMs): SCMs such as
fly ash or slag cement can help in reducing the bleed water by
improving the particle packing of the cement paste.
• Use air-entraining admixtures to create microscopic air bubbles that
reduce bleeding
•Use evaporation retarders to slow down the rate of evaporation of
bleed water
•Ensure proper compression and vibration technique to minimize void
and reduce segregation
Workability of Concrete
• Workability is the property of freshly mixed concrete or mortar that determines
its ease of mixing, placing, compacting, and finishing without segregation or
bleeding.
• It reflects the fluidity or plasticity of the mix and is crucial for ensuring proper
placement and durability.
• Key Characteristics of Workability
1.Ease of Handling: The ability of concrete to be transported and handled
efficiently.
2.Ease of Placement: Concrete should fill the formwork uniformly without
excessive effort.
3.Compaction Without Segregation: The mix should compact fully without
separation of aggregates or water.
4.Finishability: It should allow smooth finishing of surfaces.
 Factors Affecting Workability
1. Water-Cement Ratio:
1. Higher water content increases workability but can reduce strength.
2. Optimal water-cement ratio ensures a balance between workability and strength.
2. Aggregate Size and Shape:
1. Rounded aggregates improve workability.
2. Angular or flaky aggregates reduce it.
3. Well-graded aggregates enhance workability.
3. Cement Content:
1. Higher cement content improves cohesiveness and workability.
4. Use of Admixtures:
1. Plasticizers and superplasticizers increase workability without adding water.
2. Retarders or air-entraining agents can also improve workability.
5. Temperature:
1. High temperatures reduce workability by accelerating setting time.
6. Mixing Time and Method:
1. Proper and adequate mixing ensures uniform workability.
Measurement of Workability
1. Slump cone test
• The Slump Cone Test is the most widely used method to measure the
workability or consistency of fresh concrete. It provides an indication
of how easily the concrete flows and is suitable for most concrete
mixes except for highly workable or very dry ones.
• Purpose : To determine the consistency of fresh concrete by
measuring the vertical slump of a concrete cone.
• Apparatus Required

1.Slump Cone:
1. Height: 30 cm (12 inches).
2. Bottom Diameter: 20 cm (8 inches).
3. Top Diameter: 10 cm (4 inches).
2.Tamping Rod:
1. Steel rod with a rounded end, 16 mm diameter, and 60 cm length.
3.Non-Absorbent Base Plate: Flat and rigid surface for placing the slump
cone.
4.Measuring Scale: To measure the slump.
• Step-by-Step Procedure
• 1. Preparation
1. Mix the concrete thoroughly to achieve a uniform consistency.
2. Ensure all equipment is clean and damp (but not wet) to prevent absorption of water from the mix.
• 2. Setting Up the Cone
1. Place the slump cone on a firm, flat, non-absorbent base plate.
2. Hold the cone firmly in position during the test (either by hand or by foot).
• 3. Filling the Cone
1. Layer 1: Fill the cone to one-third of its height.
1. Tamp the layer 25 times with the tamping rod. Ensure uniform distribution of tamping across the layer.
2. Layer 2: Fill the cone to two-thirds of its height.
1. Again, tamp this layer 25 times with the rod. Ensure the rod penetrates slightly into the previous layer for
proper compaction.
3. Layer 3: Fill the cone to the top.
1. Tamp this layer 25 times, ensuring the top is level.
• 4. Striking Off the Excess
1.Strike off the excess concrete at the top of the cone with a trowel or flat
surface.
2.Ensure the top is flush with the cone.
• 5. Lifting the Cone
1.Hold the cone firmly and lift it vertically upwards in a smooth motion.
2.Avoid any horizontal movement or jerking during the lifting process.
• 6. Measuring the Slump
1.Allow the concrete to settle or "slump."
2.Place the cone upside-down next to the slumped concrete.
3.Measure the difference in height between the top of the slump cone
and the highest point of the slumped concrete using a measuring scale.
- Observation and Results (Slump Values and Their Interpretation):
• True Slump: The concrete slumps uniformly without disintegration.
• Shear Slump: The concrete slumps sideways due to poor cohesion
(indicates lack of stability).
• Collapse Slump: The concrete collapses entirely, indicating very high
workability.
Vee-Bee Test
• The Vee-Bee Consistometer Test is a method used to measure the
workability of fresh concrete, particularly for low to medium
workability mixes. It quantifies the time required for the concrete to
transform from a slump cone shape to a cylindrical shape under
vibration.
- Purpose
• To determine the consistency of fresh concrete by measuring the time
taken for it to fully remold under vibration.
• Apparatus Required
1.Vee-Bee Consistometer:
1. A vibrating table with a cylindrical container.
2. Slump cone.
3. Transparent glass or plastic disc with a handle for leveling concrete.
2.Tamping Rod:
1. Steel rod with a rounded end, 16 mm diameter, and 60 cm length.
3.Measuring Timer:
1. Stopwatch or timer to measure remolding time.
• 1. Preparing the Concrete Mix
• Mix the concrete thoroughly to achieve a uniform consistency.
• Ensure the apparatus and tools are clean and damp (but not wet).
• 2. Setting Up the Apparatus
1.Place the cylindrical container of the Vee-Bee consistometer on the vibrating
table.
2.Place the slump cone inside the cylindrical container.
• 3. Filling the Slump Cone
1.Layer 1: Fill the slump cone to one-third of its height.
1. Compact this layer with 25 strokes of the tamping rod.
2.Layer 2: Fill the slump cone to two-thirds of its height.
1. Compact this layer with another 25 strokes, ensuring penetration into the first layer.
3.Layer 3: Fill the cone to the top.
1. Tamp this layer 25 times, level the top with a trowel, and ensure it is flush with the
cone's surface.
• 4. Conducting the Slump Test
1.Slowly and vertically lift the slump cone to allow the concrete to slump naturally.
2.Note the initial shape of the slumped concrete within the container.
• 5. Placing the Transparent Disc
1.Place the transparent disc with a handle on top of the slumped concrete.
2.Adjust the disc gently until it rests evenly on the concrete surface.
• 6. Applying Vibration
1.Switch on the vibrating table to start the vibration process.
2.Observe the transformation of the concrete as it remolds from its initial slumped
shape to a cylindrical shape, filling the container uniformly.
• 7. Measuring the Vee-Bee Time
1.Use a stopwatch to measure the time taken for the concrete to completely transform
into a cylindrical shape under vibration.
2.Stop the timer as soon as the surface of the concrete becomes flat and the
transparent disc settles without any movement.
Observation and Results
The time recorded during the vibration process is known as the Vee-Bee
Time, and it indicates the workability of the concrete.
Compaction Factor Test
• The Compaction Factor Test is a laboratory test used to measure the
workability of concrete. It is particularly suitable for assessing
concrete mixes of low to medium workability where the slump test
may not provide accurate results.
• Purpose
• To determine the workability of fresh concrete by measuring the ratio
of the weight of partially compacted concrete to the weight of fully
compacted concrete.
• Apparatus Required
1.Compaction Factor Apparatus:
1. Two hoppers (upper and lower) with trapdoors.
2. A cylindrical container.
2.Tamping Rod:
1. Steel rod with a rounded end, 16 mm diameter, and 60 cm length.
3.Weighing Balance:
1. To measure the weight of partially and fully compacted concrete.
4.Mixing Tools:
1. Trowels, scoop, or any suitable tools to handle fresh concrete.
• Step-by-Step Procedure
• 1. Preparing the Concrete Mix
• Mix the concrete thoroughly to ensure uniformity in the composition.
• Ensure that all equipment is clean and damp (but not wet).
• 2. Setting Up the Apparatus
1.Place the compaction factor apparatus on a flat, stable surface.
2.Close the trapdoors of both the upper and lower hoppers.
• 3. Filling the Upper Hopper
1.Fill the upper hopper with freshly mixed concrete using a scoop.
2.Avoid compacting the concrete during this step.
• 4. Allowing the Concrete to Fall into the Lower Hopper
1.Open the trapdoor of the upper hopper to allow the concrete to fall freely
into the lower hopper.
2.Ensure no external vibration or compacting is applied.
• 5. Allowing the Concrete to Fall into the Cylindrical Mold
1.Open the trapdoor of the lower hopper, allowing the concrete to fall freely into the
cylindrical container below.
2.Level the surface of the concrete in the cylindrical container using a trowel, without
compacting it.
• 6. Weighing the Partially Compacted Concrete (W1)
1.Weigh the cylindrical container filled with partially compacted concrete and record the
weight (W1).
2.Subtract the weight of the empty cylindrical container to get the weight of the partially
compacted concrete.
• 7. Fully Compacting the Concrete
1.Empty the cylindrical container and refill it with the same concrete mix.
2.Compact the concrete fully using a tamping rod or a vibrator to ensure no air gaps remain.
3.Level the surface and weigh the container filled with fully compacted concrete (W2).
• 8. Calculation of the Compaction Factor
1. The compaction factor is calculated using the formula:
Compaction Factor=Weight of partially compacted concrete (W1)/Weight of fully compacted
concrete (W2)
Observation and Results
Effect of High Temperature on Fresh Concrete
a) Increased Water Evaporation
• High temperatures cause rapid water loss from fresh concrete, reducing workability.
• Leads to difficulties in mixing, placing, and finishing.
• Can cause plastic shrinkage cracks due to rapid moisture loss.
b) Faster Setting Time
• Cement hydration accelerates at higher temperatures, reducing the setting time.
• Rapid setting makes finishing operations difficult.
• Can lead to cold joints if delays occur between pours.
c) Strength Issues
• Early strength gain may be faster, but long-term strength development can be lower.
• Higher risk of thermal cracking due to temperature differentials in large pours.
Effect of Low Temperature on Fresh Concrete
a) Slower Hydration and Setting Time
• Cold temperatures slow down the hydration process, delaying the setting time.
• Can lead to prolonged finishing operations.
b) Freezing of Mixing Water
• If the temperature drops below 0°C, water in fresh concrete may freeze.
• Ice crystals expand and disrupt the concrete structure, leading to lower strength and
permanent damage.
c) Poor Strength Development
• At very low temperatures, cement particles do not hydrate properly, leading to low
early strength.
• If concrete does not achieve sufficient strength before freezing, it may lose long-term
durability.
d) Increased Risk of Honeycombing
• Improper consolidation due to stiffened concrete can cause voids and honeycombing,
reducing durability.
 Maturity Rule

•The maturity rule states that concrete strength is a function of both time and
temperature rather than just time alone.
•It is based on the idea that higher temperatures accelerate cement hydration,
leading to faster strength gain, while low temperatures slow down hydration.
•The maturity method helps in determining when concrete has achieved the
required strength for formwork removal, post-tensioning, or loading.
 Applications of Maturity Rule
a) Early Strength Estimation
• Helps in determining when concrete has achieved sufficient strength for formwork removal,
prestressing, and loading.
b) Quality Control & Safety
• Provides real-time strength monitoring without the need for frequent destructive testing (like
cube/compressive strength tests).
• Ensures concrete has reached the required compressive strength before critical operations.
c) Cold and Hot Weather Concreting
• In cold weather, maturity helps in determining if concrete has gained enough strength before
exposure to freezing.
• In hot weather, it prevents premature removal of formwork by ensuring required strength is
achieved.
d) Optimizing Construction Schedules
• Helps in making data-driven decisions to speed up construction while ensuring safety.
• Reduces costs associated with delays due to inadequate strength development.
Maturity Index
•It represents the temperature-time factor (TTF), which quantifies how
much heat energy concrete has been exposed to over time.
•A higher maturity index (M) means the concrete has been
exposed to higher temperatures for longer, leading to faster
strength gain.
•A lower maturity index means slower strength development
due to lower temperatures or shorter curing times.
 fc​=fo​+kM
fc​ is the compressive strength in MPa
fo = Initial strength (usually between 5 MPa to 10
MPa)
k = Experimentally determined constant (depends on
mix design and curing)
M = Maturity Index (°C·hours or °C·days)

fc​=10+0.07M
Using the Nurse-Saul equation:
M= ∑(T−T0)Δt
Numerical
1. A concrete slab is cured under varying temperatures. The following
temperature readings were recorded at regular 6-hour intervals, Find
Strength of Concrete after 24hrs.
Time Interval Temperature (°C)
(hours)
0-6 20
6 - 12 22
12 – 18 25
18 - 24 23
2. A concrete sample is exposed to the following temperature variations
over 48 hours.
Calculate:
1.The Maturity Index (M) in °C·hours using the Nurse-Saul equation.
2.The compressive strength of concrete using the equation: fc=5+0.06M
Time Interval Temperature (°C)
(hours)
0 – 12 18
12 – 24 20
24 – 36 22
36 – 48 25
Using the Nurse-Saul equation:
M=∑(T−T0)×Δt
• First 12 hours:
M1=(18−0)×12=216
• Next 12 hours:
M2=(20−0)×12=240
• Next 12 hours:
M3=(22−0)×12=264
• Next 12 hours:
M4=(25−0)×12=300
• Total maturity index after 48 hours:
M=216+240+264+300=1020 °C.hr
Using the given equation:
fc=5+0.06M
• fc=5+(0.06×1020) = 66.2 MPa