BLENDED CEMENT IN Quality construction

UDAI KAFLAY PENDEN CEMENT AUTHORITY LTD.

QUALITY OF CONCRETE
FRESH CONCRETE Workability HARDENED CONCRETE Mechanical Strength Durability
The only parameter that can be measured with reasonable ease and speed is the Compressive Strength or the Mechanical Strength. Thus, Concrete is commercially classified according to its Compressive Strength, like M-5, M-10, M-15, M-20, etc.

QULAITY CONTROL OF RAW MATERIALS IN CONCRETE PRODUCTION

1.0 CEMENTS
PENDEN ORDINARY
(33 Grade OPC)

1981 1985 1996 1999

Portland Pozzolana Cement

(Calcined Clay based)

(For CHPC)

PENDEN SUPREME (43 Grade OPC) PENDEN SPECIAL (Portland Slag Cement) PENDEN PREMIUM (Flyash Based) (Portland Pozzolana Cement)
(For THPA)

2005

PHYSICAL PROPERTIES COMPARISION

Parameters Blaines (m2/kg) Sieve Analysis
(% > 90 m)

PENDEN ORDINARY 310.0 7.4 125 185 1.5 0.17 26.0 35.7 46.0

PENDEN SUPREME 346.6 5.1 114 168 1.1 0.14 28.2 37.8 49.0

PENDEN SPECIAL 357.8 3.10 142 200 0.85 0.08 25.5 37.0 54.5

PENDEN PREMIUM 387.0 2.56 137 188 1.10 0.09 28.9 36.5 52.0

Initial (minutes) Final (minutes) Le-Chatelier (mm) Autoclave (%) 3 Days (MPa) 7 Days (Mpa) 28 Days (MPa)

COMPARISION OF PENDEN CEMENT PRODUCTS WITH INDIAN STANDARDS REQUIRMENTS

IS 269 3 Day 7 Day 28 Day 160 220 330

IS 455 160 220 330

IS 1498 IS 8112 IS 12269 160 220 330 220 330 430 270 370 530

OPC 282 373 490

PSC 255 368 535

PPC 270 365 520

CEMENT TYPE

3 Day

7 Day

28 Day

160

160

160

220

270

282

255

DURATION (Days)

550 500 450 400 350 300 250 200 150 100

530 430 330 220 220 330 220 330 330 370 373

535 490

520

COMPRESSIVE STRENGTH (kg/cm2)

368

365

270

2.0

AGGREGATES

Since aggregates occupy three-quarters of the volume of Concrete, the properties of aggregates have a major influence on the properties of concrete.

2.1

Properties of Aggregates
Sieve Analysis, Specific Gravity, Moisture Content, Moisture Absorption, Dry-rodded unit weights. Chemical Reactivity, Soundness, Resistance to Abrasions

2.2
2.2.1 2.2.2 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8

Aggregates Quality
Sizes Particle Shape Texture Strength & Abrasions Resistance to Freezing and Thawing (critically saturated)
(porosity, adsorption and pore structure insufficient unfilled))

Moisture Content, Absorption & Wetting & Drying Impurities

Aggregates . . .
Moisture Content & Absorption
Lightweight Aggregate can absorb 5 29% by weight of dry Aggregate. Normalweight Aggregate absorbs LESS than 2%

Impurities
Clay swells and shrinks on wetting & drying. (3% in fines, 3-10% in coarse aggregates) Excessive quantities of silt and fine dust increase water requirement. ORGANIC SUBSTANCE can inhibit the hydration process thereby delaying setting time and reducing strength. CHLORIDES, minimum. SULPHATES and REACTIVE SILICA should be

3.0 MIXING WATER

Water that is fit to drink is generally regarded as acceptable for use in mixing concrete. Water containing one thousand ppm of normally found minerals acids can be tolerated. BUT even small amount of various sugars and sugar derivatives should not be used.

4.0 ADMIXTURES
Chemical Admixtures for Concrete are used for improving various properties of Concrete by effect of its surface activity.

3.1 3.2 3.3 3.4 Dosages

Accelerating Retarding Water Reducing, Air-entertaining. Solid / Powder

Maximum Minimum 50 g/kg. of cement 2 g/kg. of cement

Liquid

3 litres / m3 of Concrete Smaller quantities are allowed only if they are dispersed in part of the mixing water.

QUALITY CONTROL DURING PRODUCTION PLACEMENT AND POST PRODUCTION OF CONCRETE

WORKABILITY
CONCRETE can be placed in the formwork and compacted with minimum effort, without Segregation & Bleeding

CHARACTERESTICS
STABILITY : Should be stable and not segregate during transportation and placing. MOBILITY & : Cohesive and mobile for placing in the PLACEABILITY form, around the reinforcement and should be able to cast into required shape. COMPACTABILITY : Amenable to proper and thorough Compaction. FINISHIBILITY : Possible to obtain satisfactory finish.

Factors Affecting Workability

Concerning Mix Water Cement Ratio Type of Cement C3A content Fineness Gypsum content Alkali content Type of Aggregates Maximum Size Grading Fine Particle Content Cement Aggregate Ratio Mineral Additions Admixtures Water Reducing Agents Air Entrained Agents Not Concerning Mix Mixing Condition Temperature Time (Workability Loss)

FACTORS EFFECTING WORKABILITY

Concerning Mix For Better Workability Minimise Particle Interference Total Specific Area Voids Content Aggregate Size (Larger Better) Aggregate Shape Aggregate Texture Fine & Coarse Aggregate Mix

Use of Fine sand increases Water Demand, or For Same Water Content, Workability Decreases. Water Cement Ratio : Cement paste around aggregates Fill the voids Workability increases with Water Content.

FACTORS EFFECTING WORKABILITY

Not Concerning Mix

TIME
Fresh Concrete looses Workability with Time mainly because of Loss of Moisture : Absorption by aggregates, Evaporation Losses Consumption in Chemical Reaction (Reduce from 12 mm to 5 mm in an hour)

TEMPERATURE
Increase in Temperature, Decreases Workability The Choice of Workability depends upon Type of Compacting Equipment Size of the Section Concentration of Reinforcement

SEGREGATION
It is the ability of the concrete mix to separate various constituents owing to the size and specific weight difference of the particles. Internal Segregation - Within framework or mold External Segregation During transportation or improper handling.

Remedial Measure : Avoid the followings:

Maximum aggregate size above 25 mm, Increase of coarse aggregate fraction, Use of aggregate with improper grading, Use of equal specific weights of aggregates, (Coarse and Fine Aggregate) Use of flat or elongated aggregates, Decrease in cement content, Too high or too low Water Cement Ratio.

BLEEDING
Bleeding is HIGHER for HIGHER Workability , HIGHER Water Cement Ratio, LOWER Cement content. Water reducing admixtures containing finely divided mineral additions REDUCE Bleeding ligno-sulphates REDUCES bleeding rate hydrocarboxylic INCREASES bleeding rate accelerating water reducing agents DO NOT ENHANCE bleeding Silica fume REDUCE bleeding rate but has CRACKING RISK.

Bleeding Effects

Excessive Bleeding IMPAIRS STRENGTH DURABILITY Excessive Bleeding RESULTS in Non-uniformity of Strength Increased Transverse Permeability Plastic Settlement Cracking Poor Bonding between cement matrix and underlying coarse aggregate & reinforcement Bleeding is beneficial in hot and windy weather. If Evaporation exceeds the Bleeding Rate, Plastic Cracks develop.

COMPRESSIVE STRENGTH
It can be measured easily and is often taken as an index of the OVERALL Quality wherein many of the desired properties are related

Shear Strength Tensile Strength Modulus of Elasticity Bond Impact Abrasion Resistance Durability

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FACTORS AFFECTING COMPRESSIVE STRENGTH

Water Cement Ratio

Lowering Water/Cement Ratio Increases Strength

Characteristics of Cement Characteristics of Aggregates Proportion of Aggregates

Increasing Aggregate/Cement Ratio Increases Strength

The Degree of Compaction

Increase in Compressive Strength by Lowering Water/Cement Ratio may be restricted if compaction is insufficient.

Efficiency of Curing The Temperature during Curing The age of Concrete Condition of Test

WATER CEMENT RATIO

It governs the quality of the hardened Portland Cement binder. Strength and Impermeability properties of Concrete are improved by LOWERING the Water Cement Ratio. Firstly, in general, to obtain a workable mix, people use more water than is actually necessary for chemical combination with the cement. This water occupies space and when it dries out later, it leaves behind air voids Secondly, there is decrease in the absolute volume of the cement paste when dried and hardened.

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COMPRESSIVE STRENGTH AS A FUNCTION OF WATER CEMENT RATIO

340.00 330.00
STRENGTH (Kg/cm2)
COMPRESSIVE

337
320.00 310.00 300.00

313 0.35 0.40

WATER CEMENT RATIO (%)

AGGREGATES
The MORE ANGULAR the sand, the GREATER will be the WATER REQUIREMENT to produce a given consistency, The HIGHER the percentage of voids in a given sand, the LOWER will be the COMPRESSIVE STRENGTH , The detrimental effects of FREEZING and THAWING are greatly reduced when the stone sand is processed to have LESS VOIDS and thereby require LESS water.

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COMPACTION
The compactness of Hardened Concrete has a considerable influence on its fundamental properties, such as Strength, Impermeabilty and Durability. Compaction Reduces inter-particle friction Eliminates air pockets

Presence of 5% voids DECREASES Compressive Strength by about 35%

CURING
Curing is the process of maintaining a satisfactory moisture content in a favourable temperature in concrete during the hydration of the cementitious materials so that the desired properties of the concrete are developed. FUNCTIONS OF CURING To Prevent Loss of water from Evaporation Supplement Water consumed in Hydration Process Curing is essential in the production of quality concrete. The potential strength and durability of the concrete will be fully developed if it is properly cured for an adequate period. Loss of moisture at this stage results in Drying, Shrinkage and Development of Cracks.

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CURING
One year Strength of continuously Moist Cured concrete is about 50 % HIGHER than that of 28 Day Moist Cured concrete. No Moist Curing can lower the Strength by about 30% Moist Curing for first 7 to 14 day may result in Compressive Strength being 85 to 92% of that of 28 days Moist Curing Minimum Curing Time 7 Days Moist Curing (IS 456) 10 days for hot weather (IS 7861-I)

WATER TEMPERATURE
Higher Water temperature cause HIGHER concrete temperature, as the concrete temperature increases the water demand increases and STRENGTH decreases for the same consistency. Mixing water has the greater effect per unit of weigh of any of the ingredients on the temperature as its specific heat is 4 5 times higher that cement and aggregates.

14

CONCRETE TEMPERATURE
Concrete maintained at Higher temperature during setting and early hardening has LOWER STRENGTH at later ages. Avoiding High Concrete temperature during Curing REDUCE random Cracking RESULTS GREATER Strength at Later ages.

STREAM CURING
To Develop HIGH Early Strength for early removal of formwork specially for Precast Concrete.

CONCRETE TEMPERATURE
The rate of reaction between cement and water varies with temperature. It proceeds slowly at low temperature down to 12 C and rapidly at high temperature somewhat below the boiling point of water. Below 10 C are unfavourable for the development of Early Strength Below 5 C the development of early Strength is greatly retarded At freezing temperature, little strength develops Curing at temperature in excess of 70 C is not as beneficial as prolonged curing at lower temperature. Autoclaving at temperature above 160 C may produce strength in few hours equal to 28 days of curing at 20 C.

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DURABILITY
. . . ability of concrete to RESIST weathering action, chemical attack, abrasion and other conditions of service.
DURABLE CONCRETE will RETAIN its ORIGINAL FORM , QUALITY and SERVICEABILITY when exposed to Environment. DURABILITY is a function of The Choice of Cement and its dosage The Choice of Aggregates (form, cleanliness, stability, etc.) The Water (quality, content and water-cement ratio) The use of appropriate Admixtures The batching and casting methods The curing of Concrete

Durability . . .
Of late, the focus of construction has been shifted from STRENGTH to DURABILITY High Strength cements have played havoc in building sector. These resulted in Development of Shrinkage Cracks, Vulnerability to Severe Environment, Reduced Life of the Structure.

DURABILITY of Concrete is impaired due to: Inability of achieving compaction leading to honey combing Corrosion of reinforcements due to chloride diffusion and carbonation of concrete, cracking of concrete, Volume changes due to sulphate attack, shrinkage, alkali silica reaction, cracking of concrete, etc.

16

DURABILITY & CONCRETE FAILURES (Causes)

EXTERNAL Weathering Attack by Natural / Industrial liquids, Bacterial Growth INTERNAL Alkali Aggregate Reaction Volume Change due to non-compatibility of Thermal & Mechanical properties of Aggregates & Cement paste. Presence of Sulphates Presence of Chlorides Ingress of Moisture / Air

RECOMMENDATION FOR DURABLE CONCRETE

Limits for Maximum Water-Cement Ratio Minimum Cement Content Cover Thickness Type of Cement Chloride Content in Concrete Sulphate Content in Concrete

CONSIDERATIONS
Situation of Placing Congestion of Reinforcement Cover Thickness Workability of Concrete Characteristics of aggregates

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HONEYCOMB
It occurs when the mortar does not fill the space between the coarse aggregates. Its presence indicates that first stage of consolidation has not been completed.

CAUSES - Use of improper or faulty vibrators,

Poor vibrations procedures, Unsystematic insertion of mortar at haphazard angles, Insufficient paste to fill the voids, Improper ratio of sand to total aggregate, Poor aggregate grading, Improper workability, Insufficient clearance between the reinforcement bars.

Entrapped Air Voids

The amount of entrapped air in concrete is depended upon:

Vibratory equipment, Vibration Procedures, Properties of concrete mix, Location in the placement.
To reduce air voids, the distance between internal vibrator insertions should be reduced and the time at each insertion increased.

18

Pour Line
These are dark lines showing on the formed surface demarking the boundary between adjacent batches of concrete. They indicate that when vibrating a layer, the vibrator was not lowered far enough to penetrate the layer below.

SAND STREAKING
CAUSES Heavy bleeding along the form, Character of the materials, Proportions of the materials, Method of depositing concrete, Harsh and wet mix with Less Cement and More Water, Poorly Graded Aggregate, Dropping concrete mix through reinforcing steel, Using Thick Lifts without adequate Compaction, Vibrators attached to leaking form.

19

DENSE & IMPERMEABLE CONCRETE MASS MORE DURABLE

Resistance to Sulphate Attack Resistance to Acid Attack Resistance to Chloride Ingression Carbonation Shrinkage Alkali Silica Reaction (ASR) Permeability of Cement Paste INCREASES exponentially with INCREASE in Water-Cement ratio above 0.45. Cement Content Ensure sufficient alkalinity to provide Passive Environment To overfill the voids between the aggregates

DURABILITY

REDUCED PERMEABILITY RESULTS IN HIGH RESISTANCE TO SULFATE ATTACK HIGH RESISTANCE TO CHLORIDE INGRESSION MINIMISING THE RISK OF ALKALI SILICA REACTION HIGH RESISTANCE TO ACIDS AND CHEMICALS (REDUCED LEACHING) RESISTANCE TO CARBONAGE SHRINKAGE

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Sulphate Attack
Sulphate attack causes expansion, loss of strength and eventually transform the materials into musky mass. The rate and depth of sulphate attach depends upon the characteristics of concrete strength, porosity, permeability and chemical composition of hardened cement paste. Combination of sulphate with Calcium ion liberated during hydration of cement to form gypsum, Combination of sulphate ion, gypsum and hydrate Calcium Aluminate to form Calcium Sulfo-aluminate hydrate (ettringite), Both these chemical reactions result in increase in solid volume. The formation of ettringite is the cause of most of the expansion and disruption of concrete by sulphate solution.

Chloride Attack
Chloride can harmfully affect the durability of both concrete and reinforcement. The chloride ion content of concrete must be kept lower and the ionic penetration from outside must be prevented or hindered. Chloride dissolved in water increases the rate of leaching of portlandite thus increasing the porosity or mortar and concrete. As a result of the attack, the concrete swells, losses stiffness and strength and becomes more sensitive to other environmental attacks (sulphate, frost, etc.) Chloride attack will result in the corrosion of the concrete reinforcement. Chloride attack can take place if oxygen and moisture are present.

21

Diffusion of Chloride Ions at 25 C in Cement Paste of Water to Cement ratio 0.5

Type of Cement Sulphate Resistance Portland Cement (SRPC) Ordinary Portland Cement (OPC) Portland Pozzolana Cement (PPC) (70% OPC 30% Flyash) Portland Slag Cement (PSC) (35% OPC, 65% Slag) Diffusivity
(x10-9 cm2/sec)

100.00 44.70 14.70 4.10

The rate and depth of Chloride penetration into concrete depend upon the permeability of concrete. It can be decreased by Decreasing the water/cement ratio Increasing the cement content Increasing the length of curing

Acid Attack
The deterioration of Concrete by acids is primarily the result of reaction between these chemicals and Calcium Hydroxide of the hydrated Portland Cement. In most cases, the chemical reaction results in the formation of water soluble calcium compounds which are then LEACHED away by aqueous solutions.

A Dense Concrete with Low Water Cement Ratio provides an acceptable degree of protection against Acid Attack.

22

Carbonation
Effect of Carbon Dioxide Carbon dioxide contained in the air is potentially dangerous for concrete durability because it can attack all of the hydrates in the hardened cement. This alarming prospective concerns only low strength porous concrete.

Carbonation Shrinkage When concrete is exposed to carbon dioxide, a reaction producing carbonates takes place which is accompanied by shrinkage. The source of carbon dioxide can be either the atmosphere or water carrying dissolved carbon dioxide.

Alkali Silica Reaction

Although aggregates is commonly considered to be inert filler in concrete, some aggregates may react with alkalis present in the pore fluids of concrete. Under such adverse conditions and in presence of moisture, this may lead to expansion and subsequent cracking of the Concrete.

A Dense Concrete with Low permeability and Low Water Cement ratio provides Resistance against Alkali Silica Reaction.

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5Cs OF DURABLE CONCRETE CONSTITUENT MATERIALS COVER COMPACTION CURING CARE

COMPRESSIVE STRENGTH OF M20 CEMENT CONCRETE CUBES

400
COM P RE S S IV E S TRE NGTH (kg/cm 2) 379 368 352 335 318 320 310 278 271 260 218 OPC 3 Day 7 Day 28 Day 218 278 293 216 PPC 216 278 318 220 PSC 220 271 320 229 227 300 287 268 261 231 227 DURATION (Days) 293 278 345

350 300 250 200

OPC:PP OPC:PS PSC:PP OPC:PP OPC:PP C C C C:PSC C:PSC(M 260 310 379 229 300 368 227 268 335 231 287 352 227 261 345

CEMENT TYPE
PCAL Laboratory Result

3 D ay 7 D ay 28 D ay

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M 20 CIVIL CONCRETE CUBE TESTS

S T R E N G T H (M P a ) 30.00 25.00 20.00 15.00 10.00 5.00 0.00 3 Day 7 Day DURATION (DAYS) 28 Day

PSC

PPC

OPC

M30 CIVIL CONCRETE CUBE TESTS

50.00 46.80 45.86 S TRE NG TH (M P a) 40.00 30.70 30.00 20.00 10.00 0.00 3 Day 7 Day 28 Day DURATION (DAYS) 32.80 35.40 37.80 42.50 44.50

PSC

PPC

OPC

37.30

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M 40 CIVIL CONCRETE CUBE TESTS

45.00 40.00 35.00 30.00 25.00 20.00 15.00 10.00 5.00 0.00

STRENGTH (MPa)

3 Day

27.77

7 Day DURATION (DAYS)

36.97

28 Day

TASHI DELEK

42.37

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