CONCRETE TECHNOLOGY

CONCRETE
• Is considered as an artificial stone obtained by binding
together the particles of inert fine and coarse
materials with cement paste
• Is the most widely used man made construction
material in the world
• Cementious material + water + aggregates (fine &
coarse) + admixtures (optional) - mixed in required
proportions – placed in forms + curing – becomes
hardened into rock like mass is known as concrete
• Concrete is versatile building material because it has
strength from M10 to M100 and zero slump to
maximum slump
12/25/2018 BY : Er. SAROJ PHAIJU 1
 CONCRETE
Q. Concrete is neither as strong nor as tough as
steel, so why is it the most widely used
Engineering materials?
At least 3 primary reasons:
• Concrete possesses excellent resistance to
water
• Ease with which structural concrete elements
can be formed into a variety of shapes and
sizes
• It is usually the cheapest and most readily
available material on the job
12/25/2018 BY : Er. SAROJ PHAIJU 2
 CHAPTER # 1
Constituents of Concrete

12/25/2018 BY : Er. SAROJ PHAIJU 3

 1.1 Aggregates
• Gives body to concrete & occupies 70 to 80% in
concrete by volume
• Primarily, naturally occurring, inert granular
material such as sand, gravel or crushed stones.
Recycled materials and synthetic products are
included in aggregates due to technology
• Fine and coarse aggregates
• Fine aggregates helps in producing workability &
uniformity in mixture and assists cement paste to
hold coarse aggregate particle in suspension,
which promotes plasticity in mixture & prevents
possible segregation.
12/25/2018 BY : Er. SAROJ PHAIJU 4
 1.1.1. Classifications
Classification according to geological origin
i. Natural aggregates
• Obtains from natural deposits of sand, gravel and
crushed rock derived from natural sources
• Sand & gravel are naturally deposited in river or
in quarries, which have been reduced to their
present size by natural agents
• Crushed aggregates are made by breaking rock
into required size by crushing & screening
• Igneous rock, metamorphic rock or sedimentary
rocks
12/25/2018 BY : Er. SAROJ PHAIJU 5
 1.1.1. Classifications
Classification according to geological origin
ii. Artificial aggregates
• Thermally processed materials such as broken
bricks, which are used for making light weight
concrete are called synthetic aggregates
• Aggregates made from industrial byproducts
• Municipal waste and recycled concrete from
demolished building and pavements

12/25/2018 BY : Er. SAROJ PHAIJU 6

 1.1.1. Classifications
Classification according to Size
i. Fine aggregates
• Particle size < 4.75mm
• Range of 4.75mm to .075mm
• Natural sand & crushed stone sand
• Fine aggregates may be described as coarse,
medium & fine sands
• As per IS:383-1970, based on particle size
distribution, fine aggregates are classified into
4 zones: zone I to zone IV
12/25/2018 BY : Er. SAROJ PHAIJU 7
 1.1.1. Classifications
 Classification according to Size
ii. coarse aggregates
• Particle size > 4.75mm
• Ranges from 4.75mm to 80mm, but for mass concrete,
it may contain upto 150mm
• It may be natural or uncrushed gravel, crushed gravel
or stone, mixture of above two
• The graded coarse aggregates is described by its
nominal size of 40mm, 20mm, 16mm, 12.5mm etc
• Choice of maximum size of aggregate depends on
o Thickness of element,
o Cover
o Mixing, handling & placing techniques
12/25/2018 BY : Er. SAROJ PHAIJU 8
 1.1.1. Classifications
Classification according to Size
iii. All-in aggregates
• These are combined aggregates available in
nature having different particle size of fine &
coarse
• Lacking particle size is added to fulfill the
grading of aggregates
• Generally, not used for making high quality
concrete

12/25/2018 BY : Er. SAROJ PHAIJU 9

 1.1.1. Classifications
Classification according to Size
iv. Single size aggregates
• Aggregates dominated by single size particles
or particles within a narrow limit of size
fraction
• e.g. 20mm single size aggregates means most
of aggregates are passed from 20mm sieve &
major portion of which are retain on 10mm
sieve

12/25/2018 BY : Er. SAROJ PHAIJU 10

 1.1.1. Classifications
Classification according to Shape
i. Rounded aggregates
• Mostly natural aggregates rounded surface e.g.
river or seashore gravel, desert or wind blown
sands
• Minimum voids, 32% to 34%
• Minimum surface area to volume, thus requiring
minimum cement paste to make concrete
• Interlocking between particles is less or poor i.e.
poor bonding
• Unsuitable for high strength concrete

12/25/2018 BY : Er. SAROJ PHAIJU 11

 1.1.1. Classifications
Classification according to Shape
ii. Irregular/Partly rounded aggregates
• Aggregates with partly rounded surface e.g.
pit sand & gravels
• Voids 35% to 38%
• Requires more cement paste for a given
workability
• Interlocking between particles is better than
rounded aggregates
• Not suitable for high strength concretes
12/25/2018 BY : Er. SAROJ PHAIJU 12
 1.1.1. Classifications
Classification according to Shape
iii. Angular aggregates
• Has sharp, angular and rough surfaces
• Obtained from crushed stones i.e. crushed
aggregates
• Maximum void, 38% to 40%
• Interlocking between particles is good,
therefore forms good bonds
• Requires more cement paste to make
workable concrete
• Suitable for high strength concrete
12/25/2018 BY : Er. SAROJ PHAIJU 13
 1.1.1. Classifications
 Classification according to Shape
iv. Flakey & Elongated aggregates
• Flakey: if least dimension (thickness) < 3/5th of mean
dimension
• Elongated: if greatest dimension (length) > 9/5th of its
mean dimension

12/25/2018 BY : Er. SAROJ PHAIJU 14

 1.1.1. Classifications
Classification according to Shape
iv. Flakey & Elongated aggregates
• Mean dimension: average of sieve sizes through which
the particles passed & are retained, respectively
• Adversely affect the durability of concrete as they tend
to be oriented in one plane with voids forming
underneath
• Should restricted to 10 to 15%
• Elongation index : % by wt. of elongated particles
present
• Flakeyness index : % by wt. of flakey particles present
12/25/2018 BY : Er. SAROJ PHAIJU 15
 1.1.1. Classifications
 Classification according to Unit weight
i. Normal weight aggregates
• Sp. Gr. Between 2.5 to 2.7
• Bulk density between 1520 to 1680 Kg/m3
• Produce normal weight concrete with
approximately 24KN/m3(24 to 26)
• Crushing strength at 28 days between 15 to 40
MPa
• e.g. most natural sand & gravels, crushed
aggregates from granite, basalt, quartz etc.
12/25/2018 BY : Er. SAROJ PHAIJU 16
 1.1.1. Classifications
Classification according to Unit weight
ii. Heavy weight aggregates
• sp. Gr. 2.8 to 2.9
• Bulk density > 2080Kg/m3
• Produce concrete with unit wt. >
24KN/m3 (28 to 57KN/m3)
• e.g. magnetite, barytes, scrap iron
• They produce dense & crack free
concrete, but chances of segregation
12/25/2018 BY : Er. SAROJ PHAIJU 17
 1.1.1. Classifications
Classification according to Unit weight
iii. Light weight aggregates
• sp. Gr. < 2.5
• Bulk density < 1120Kg/m3, i.e. low density
aggregates
• Produce concrete with unit wt. < 24KN/m3
• e.g. natural - diatomite, pumice, volcanic cinder
Artificial – bloated clay, fly ash, blast furnace
slag
• Thermal insulation

12/25/2018 BY : Er. SAROJ PHAIJU 18

 1.1.1. Classifications
Classification according to Surface texture
1) GLASSY: aggregates having glassy surface, e.g. black
flint
2) SMOOTH: aggregates with smooth surface, e.g.
chest, slate, marble
3) CRYSTALLINE : aggregates with crystalline surface
texture, e.g. basalt, dolerite, granite
4) GRANNULAR : aggregates formed essentially with
granular material, e.g. sand stone, oolite
5) HONEY COMBED OR POROUS : aggregates with
porous surface texture, e.g. pumice

12/25/2018 BY : Er. SAROJ PHAIJU 19

 1.1.2 Gradation
• Particle size distribution of aggregate is termed as
gradation – sieve analysis is conducted
• For producing workable concrete, it is most important
factor
• Proper gradation ensures that a sample of aggregate
contains all standard fraction of aggregates in required
proportion such that sample contain minimum voids
• Well graded aggregate > min. voids > min. paste to fill up
voids > less quantity of cement & water > increased
economy, higher strength, lower shrinkage, greater
durability
• Gradation increases workability , fine material lubricates
the larger particles
12/25/2018 BY : Er. SAROJ PHAIJU 20
 1.1.2 Gradation

Categories of aggregate grading

1. Well graded aggregate
2. Poor graded aggregate
3. Gap graded aggregates

12/25/2018 BY : Er. SAROJ PHAIJU 21

12/25/2018 BY : Er. SAROJ PHAIJU 22
12/25/2018 BY : Er. SAROJ PHAIJU 23
 1.1.2 Gradation
1. Well graded aggregate
• Has gradation of particles such that fairly evenly spans
the sizes from the finest to coarsest
• A slice of concrete shows a packed field of many different
particles sizes
• Good interlock and low permeability
• It is characterized by S-shaped in gradation curve
2. Poor graded aggregate
• Has variation in particle sizes
• Contains the aggregate particles of almost of same size
• Particles when packed together, leaves relatively large
voids in the concrete BY : Er. SAROJ PHAIJU
12/25/2018 24
12/25/2018 BY : Er. SAROJ PHAIJU 25
 1.1.2 Gradation
• Characterized by steep curve
• Also called uniform graded
• Good interlock and low permeability
3. Gap graded aggregate
• Consist of aggregate particles in which some
intermediate size particles are missing
• Also known as skip graded
• A core slice concrete shows a field of small sized
aggregate interspersed with slightly isolated, large
aggregate pieces embedded in a small sized aggregate
• Characterized by a gradation curve with a hump in
between
12/25/2018 BY : Er. SAROJ PHAIJU 26
1.1.3 characteristics & Significance
1. Strength of Aggregates
2. Particle shape & surface texture
3. Specific gravity
4. Density (Bulk density)
5. Voids & porosity
6. Absorption capacity & moisture content
7. soundness

12/25/2018 BY : Er. SAROJ PHAIJU 27

1.1.3 characteristics & Significance
1. Strength of Aggregates
• Crushing strength, modulus of Elasticity,
toughness, hardness, abrasion value, impact
value, attrition test etc.
• These characters of aggregates are valuable in
preserving durability of concrete & resisting the
loads or forces
• Strength of parent rock don’t represent strength
of aggregate in concrete
• Mechanical properties of aggregate influence the
strength of concrete when cement provide
satisfactory or good result

12/25/2018 BY : Er. SAROJ PHAIJU 28

 1.1.3 characteristics & Significance
2. Particle shape & Surface Texture
• They influence the properties of fresh concrete more
than hardened concrete
• Affects on workability of concrete & bond between
aggregates and mortar
• Particle shape refers to geometrical characteristics
e.g………….
• surface texture is measure of the smoothness or
roughness of aggregate surface, is based on visual
examination of the specimen such as ……………
• Compared to smooth & rounded particles, rough
textured, angular & elongated particles require more
cement paste to produce workable concrete mixtures,
thus increasing cost

12/25/2018 BY : Er. SAROJ PHAIJU 29

 1.1.3 characteristics & Significance
3. Specific Gravity
• gr. Sp = masssolid/masswater for same volume & temp.
• Due to voids in aggregate, sp. gr. are different:
 Absolute sp. Gr. -- vol. of solid material excluding the voids
 Apparent sp. Gr. -- vol. of solid materials including voids, 2.6
to 2.7 for common aggregates
• Sp. gr. gives valuable information on its quality & properties,
like higher sp.gr. -- harder & stronger it will be, light wt. &
heavy wt. aggregate
• Sp. Gr. Is used in calculation of concrete design mixes,
compaction factor etc.
• Sp.gr. Above or below the normal value indicates the
changes required in grading or shape of aggregates
12/25/2018 BY : Er. SAROJ PHAIJU 30
 1.1.3 characteristics & Significance
4. Density(Bulk density)
• Density = mass/volume
• Bulk density includes the volume of voids in particles,
apparent sp.gr. related to bulk density
• Bulk density shows how densely the aggregate is
packed and it is not possible to pack aggregates
together without void space
• Higher the bulk density , the lower is the void to be
filled by sand and cement
• Used for judging the quality of aggregates with normal
density aggregates and it determine the type of
concrete for which it may be used
• Conversion of proportion by weight into proportion by
volume

12/25/2018 BY : Er. SAROJ PHAIJU 31

 1.1.3 characteristics & Significance
5. Voids & Porosity
• Empty space between aggregate particles
• Difference between gross volume of aggregate
mass and volume occupied by particles alone
• Minutes holes or cavities formed in particle is
known as pores
• Natural aggregates are porous & size may range
from microscopic to macroscopic
• Pores in particle may continuous or discontinuous
• Porosity of aggregate particle leads the porosity
of concrete
• Permeability & absorption affect the bonding and
strength of concrete
12/25/2018 BY : Er. SAROJ PHAIJU 32
 1.1.3 characteristics & Significance
6. Absorption capacity & moisture content
• Pores in the aggregates are reservoirs of free moisture
• % of water absorbed by an aggregate when immersed
in water is called absorption of aggregate
• When all the pores are full i.e. saturated, & there is no
water film on the surface, then it is called Saturated
Surface Dry (SSD) aggregate
• Absorption Capacity is the total amount of moisture
required to bring an aggregate from oven dry to SSD
condition.
• Effective Absorption capacity is relates to Air dry to
SSD condition
• Surface moisture is amount of water in excess than
water required for the SSD condition

12/25/2018 BY : Er. SAROJ PHAIJU 33

 1.1.3 characteristics & Significance
6. Absorption capacity & moisture content

12/25/2018 BY : Er. SAROJ PHAIJU 34

 1.1.3 characteristics & Significance
7. Soundness
• It is resistance to the weathering i.e. alternate
wetting & drying or alternate freezing &
thawing
• Unsound aggregate changes its volume by
weathering, results in the deterioration of
concrete
• Porous aggregates which has high moisture
absorption are unsound aggregates

12/25/2018 BY : Er. SAROJ PHAIJU 35