Concrete Technology

Dr. P. DINAKAR
Department of Civil Engineering
Portland Cement

Portland Cement

Concrete

Concrete - Introduction
Definition of Concrete
Concrete is a composite material composed of coarse
granular material (the aggregate of filler) embedded in a
hard matrix of material (the cement or binder) that fills
the space between the aggregate particles and glues
them together.

Concrete = Filler + Binder

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Concrete - Introduction

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Advantages of Concrete
Cement Rs. 3500 4000/T
Aggregate Rs. 300 - 400/T
Concrete Rs. 3000 4000/m 3
S. Steel Rs. 30000 - 35000/T
Polymer Composites 300000 350000/T

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Advantages Ability to Cast

Bahai Tower in Chicago

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Advantages Energy Efficient

Let us make a comparison among:
Concrete 450 ~ 750 kwh/T
Reinforced concrete 850 ~ 3200 kwh/T
Steel 8000 kwh/T

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Advantages Excellent resistance to water

Can gain strength in water
Can withstand water without serious deterioration
Examples: dam, pipeline

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Advantages High Temperature Resistance

Let us make a comparison among:
Steel looses strength @ T = 600oC
Composites looses strength @ T = 100 -250oC
Concrete can withstand fire for 2-6 hours

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Advantages Ability to consume waste

Use waste as supplementary cementitious materials
Fly ash
Slag

Use waste to replace part of aggregate as filler

Glass particles
Rubber tyre
Recycled aggregates

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Advantages Ability to work with steel

Similar coefficient of thermal expansion

Steel -----1.2 x 10-5 (copper 10-8)

Concrete -----1.0 ~ 1.2 x 10-5

High alkaline environment

pH value 12 ~ 13.5

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Advantages Less maintenance required

No coating or painting is needed for concrete

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Limitations Quasi brittle nature

Improvement

Reinforced concrete

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Limitations Low tensile strength

Ft~ 0.1 fc (for high strength concrete even lower)

Improvement

Fiber reinforced concrete

Polymer concrete

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Limitations Low toughness

Improvement

Fiber reinforced concrete

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Limitations Long curing time

Improvement

Steam curing
Precast

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Precast

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Classification of concrete
Based on unit weight
Ultra light concrete < 1200 kg/m 3
Lightweight concrete 1200-1800 kg/m 3
Normal-weight concrete ~ 2400 kg/m 3
Heavyweight concrete > 3200 kg/m3

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Classification of concrete
Based on strength
Low-strength concrete

< 20 MPa compressive strength of cylinder/cube

Moderate-strength concrete

20~50 MPa compressive strength of cylinder/cube

High-strength concrete

50~200 MPa compressive strength of cylinder/cube

Ultra high-strength concrete

> 200 MPa compressive strength of cylinder/cube

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Classification of concrete
Based on additives
Normal concrete
Fiber reinforced concrete
Polymer concrete
Micro Silica (M.S.) concrete

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Three phase theory

Three phases:
Aggregate
Hardened cement paste (hcp)
Interfacial transition zone (ITZ)

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Transition zone

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Interfacial Transition zone

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Transition zone
A thin shell layer (10-50 m thick) around large

aggregate.
Formation: Water films around large aggregate during

mixing.
Characteristic: Larger CH crystals; more porous

framework; relatively weak

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Transition zone Influence on concrete properties

Fraction of transition zone in size is much smaller than

other two phases, its influence on concrete properties is

far greater.

It lowers the strength

It increases the permeability

It prompts non-linear behavior

It favours crack formation

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Transition zone

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Transition zone
Points to note:
Aggregate and cement
paste linear up to failure
Concrete stress-strain
response (elastic) in
between aggregate and
cement paste
Concrete does not have a
linear behavior up to failure
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Transition zone
The transition zone, generally the weakest link of the

chain, is considered the strength-limiting phase in

concrete.
It is because the presence of the transition zone that

concrete fails at a considerably lower stress level than

the strength of either the two main components.

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Constitutive relationships
Stress-strain curve: Linear up to ~ 40% of ultimate load,

then non-linear
Non-linearity due to heterogeneity of concrete (presence

of ITZ and microcracks)

Strain corresponding to ultimate stress ~ 0.003 (normal

strength concrete)
Behaviour in tension also similar

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Fresh Concrete - Definition

A fully mixed mixtures in a plastic stage before notable

strength being developed

Cover the cement hydration stages of 1 and 2, as well

as initial part of stage 3

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Relevance of fresh concrete properties

Why are we interested in the properties of fresh
concrete?
Influence the final quality of hardened concrete
Help to detect variations in material and process
Uniform fresh concrete - Uniform hardened
Last chance to identify unsatisfactory quality

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Fresh Concrete Workability (definition)

A general term to describe the properties of fresh

concrete.
Consistency (or fluidity)
--describes the ease of concrete flow
Cohesiveness

--describes the ability to keep the uniformity of

concrete (no concentration of a single component)

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Factors Affecting Workability Water Content

Extra water can lubricate the particles in mixture: the

more the water, the easier the flowing. However, too

much water will cause segregation

w/c ratio

Fluidity

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Influence of Water on Workability

Only very minor adjustments to workability should be

made by the addition of water alone

Reduce strength and durability

Potential for drying shrinkage cracking

Therefore, adjustments to workability made by the

addition of water should always be accompanied by an

addition of cement to maintain a fix W/C

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Factors Affecting Workability Aggregate

Aggregate/cement ratio
Fine aggregate/Coarse aggregate
Maximum aggregate size
Aggregate shape and texture

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Influence of aggregates on Workability

Grading

affect workability, because the water demand

necessary to wet all the solids in the mix will depend
on the surface area of the aggregates
The larger the particle size the greater the workability
for a given cement content and W/C
Particle shape

Rounded or roughly cubically shaped aggregates will

produce more workable concrete than that produced
using flaky or elongated particles

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Factors Affecting Workability Cement

Fineness
Fluidity

with

fineness

Cement Content: Lubrication effect of paste

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Factors Affecting Workability Admixtures

Air entraining agent

--air bubbles lubricates

Super-plasticizers

--release water; retarding, air entraining effect

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Factors Affecting Workability Temperature

Can influence the hydration rate and water loosing rate

Temperature

Workability

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Influence of Temperature on Workability

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Influence of temperature on Workability

ASTM C 1064
Glass or digital readouts

thermometers are
available

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Tests to measure Consistency

Four widely used tests

Slump test

Compacting factor test

Vebe Test

Flow Test

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Measurement of Consistency Slump Test

Requirement

Slump Cone

Tamping Rod

Ruler

Suitable
for
normal mixes of
medium to high
workability
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Measurement of Consistency Slump Test

Although it is a different characteristic from workability,

in practice the two terms are often confused and

merged into one - the slump of concrete

Slump ASTM - 143

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Measurement of Consistency Slump Test

Workability Terminology

Very stiff

Stiff

Plastic

Soft (wet)

Flowing

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Measurement of Consistency Slump Test

Method
1.

2.

3.

Concrete put in cone in 4 layer, each layer tamped 25

times
Concrete put in cone in 4 layer, each layer tamped 25
times
Slump measured

Not suitable for dry mixes & highly flowable mixes

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Measurement of Consistency Slump Test

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Workability Requirements
Slump (mm)
Maximum

Minimum

Reinforced foundation walls and

footings

75

25

Plain footings, caissons and

substructure walls

75

25

Beams and reinforced walls

100

25

Building columns

100

25

Pavements and slabs

75

25

Mass Concrete

50

25

Concrete Construction

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Compacting Factor Test

Thought to be more sensitive

Suitable for all mixes

Method
1.

2.

3.

Mixed concrete put in top

hopper
Allowed to fall into 2nd hopper
then cylinder
Cylinder struck off, concrete
weighed and compared with
weight of fully compacted
cylinder
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Measurement of Consistency Compaction Factor

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Measurement of Consistency Compaction Factor

Compacting factor = mp/mf
mpmass of partially compacted cylinder
mfmass of fully compacted cylinder (using rod)
Range between 0.8 to 0.92

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Vee Bee Test

Vebe Test Time for standard cone to be compacted flat

by glass plate on vibrating table eg., for workable
concrete the Vebe time = approx. 3 sec

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Flow test

Flow Test the measured spread in mm of a standard

cone on a dropping table (40mm, 15 times)

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Flow test

Flow Test the measured spread in mm of a standard

cone on a dropping table (40mm, 15 times)

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Concrete Placement
Not a Liquid - an Unstable mixture

Will segregate if handled improperly

Deposit in Formwork (methods)

Direct From the Truck

Bucket
Pump

Consolidate Mix
Apply Finish (if Required)

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Concrete Placement (1929)

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Placement Today - Directly From the Transit Mixer

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Concrete Bucket being Filled

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Placement of a Wall with a Crane & Concrete Bucket

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Placing of Concrete through bucket

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Placement with a Concrete Pump

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Placement of Concrete with a Boom Pump

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Placing of Concrete

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Placement with a Conveyor

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Vibration of concrete

The purpose of compaction of concrete is to achieve

highest possible density of concrete by removing the
entrapped air

Types of vibrators

Internal vibrators

External vibrators

Vibrating tables
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Compaction of Concrete

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Compaction of Concrete

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Compaction of Concrete

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Improperly Consolidated - Honeycomb

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Improperly Consolidated Concrete

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Improperly Consolidated Concrete

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Workability & Consistency

Cohesiveness of concrete

Is a measure of its ability to resist the segregation of its

constituents during handling, placing and compaction
Cohesive
Non
Cohesive

Segregation
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Cohesiveness

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Cohesiveness of concrete
Factors affecting the cohesiveness of concrete:

Water
- The higher the water content the greater is the risk of
segregation and bleeding

- High water content retards the stiffening of concrete allowing

sedimentation of heavier particles
Cold weather can also retard setting and promote bleeding
Dry mix can be friable and also prone to segregation

Grading
- Mixes that are deficient in fine particles tend to segregate more
readily during handling and bleed after finishing (entrained air
can help)
- Excessive fines make concrete sticky and very cohesive
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Setting time
Can be determined by the test method described in ASTM C

403 by means of penetration resistance measurements

Made on mortar sieved from the concrete mixture
Initial and final time of setting corresponds to a penetration

resistance equals 500 psi (3.4 MPa) and 4000 psi (27.6 MPa)
Typical values range

Initial set: 2 to 6 hours

Final set: 4 to 12 hours
Factors affecting setting time of concrete:

W/C ratio
Cement type and content
Temperature
admixtures
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Measurement Setting time

Final set

Initial set

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Segregation and Bleeding

Segregation

(concentration of heavy particles)

Bleeding

(concentration of water)

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Bleeding and settlement

Bleeding is the development of a layer of water at the top or surface

of freshly placed concrete. Water concentration at bottom of

aggregate and the reinforcing steel
Bleeding is normal and should not diminish the quality of properly

placed, finished and cured concrete. It occurs on the surface of

specimen due to the compacting process.
Some bleeding is helpful to control plastic cracking

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Excessive bleeding?

Cracks

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Fresh Concrete : Segregation (Separation)

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Fresh Concrete Slump Loss

It is defined as the loss of fluidity in fresh concrete with

time.
Due to: hydration of cement, loosing of water
Can be delayed or retarded by admixture

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Fresh Concrete Curing of Concrete

Curing is a process to control the loss of moisture from

concrete after placed and finished

Provides adequate time for the hydration of cement

particles therefore assures adequate strength

development and durability of the concrete
Curing period depends on:

The properties required of the concrete

The purpose for which it is to be used

And the ambient conditions (T, RH..)

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Fresh Concrete Curing of Concrete

Curing may be done in three ways:

By preventing an excessive loss of moisture from the

concrete for some period of time

1.

Leaving formwork in place

Covering concrete with an impermeable membrane

after formwork have been removed

Or by a combination of such methods

By continuously wetting the surface

2.

3.

Ponding or spraying the surface with water

By raising the temperature on concrete (steam curing) to
accelerate the rate of strength gain at early age
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Curing methods and materials

Methods of curing concrete fall broadly into three

categories:
1. Those which prevent moisture loss by continuously

wetting the surface of the concrete (spraying water,

saturated wet coverings)
2. Those which minimize moisture loss from the concrete

by covering it with a relative impermeable membrane

(plastic sheets, curing compound..)
3. Those which keep the surface moist and, at the same

time, raise the temperature of the concrete, thereby

increasing the rate of strength gain
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Influence of Curing on strength development

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Curing methods and materials

Ponding and Immersion

Flat surfaces, pavements, floors

Earth, sand or mortar dikes around the perimeter of the
concrete to retain a pond of water
Keep uniform temperature of the concrete
DT between water and concrete < 11C (prevent thermal
cracks)
Water free of substances that will stain or discolor the
surface
Used only for small jobs

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Curing methods and materials

Ponding and Immersion

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Curing methods and materials

Fogging minimizes moisture

loss during and after placing
and finishing

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Curing methods and materials

Wet coverings

Fabric coverings saturated with cotton mats, rugs or other

moisture-retaining fabrics are commonly used for curing
Treated burlaps that reflect light and resistant to rot and fire are
available (ASTM C 171, AASHTO M182)
Must be free of any substance harmful to concrete or causes
discoloration
Should be placed immediately concrete has sufficiently hardened
/ including the edges of slab
Avoid wetting and drying / may cause crazing (cracks)
Avoid wet coverings of earth, sand or sawdust to prevent
possible discoloration of the concrete surface

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Curing methods and materials

Impervious paper

Consists of two sheets of kraft paper cemented together by

bituminous adhesive with fiber reinforcement (ASTM C 71)
Efficient means of curing horizontal surfaces and other elements
with simple shapes
Advantage: no need for periodic addition of water
Applied immediately after concrete has hardened and wetted

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Curing methods and materials

Plastic sheets

Consist of polyethylene film ASTM C 171

Effective moisture retarder
Easy to apply to complex as well as simple shapes
May be clear or colored
Polyethylene film may also be placed over wet burlap to retain
the water in the wet covering material
Disadvantage: can cause patchy discoloration

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Curing methods and materials

Curing compounds

Liquids formulated from wax emulsions, chlorinated rubbers,

synthetic and natural resins, and PVA emulsions

Sprayed directly onto concrete surfaces to form a relatively

impermeable membrane

Retards the loss of moisture from the surface

Should be able to maintain the

RH of the concrete surface
above 80% for seven days to
sustain cement hydration

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Curing methods and materials

Steam curing

Advantageous where early strength gain is needed

Or where additional heat is required to accomplish
hydration as in cold weather
Two methods of steam curing are used:

Live steam at atmospheric pressure (cast-in-place

structures and large pre-cast concrete units
High-pressure steam in autoclaves (for small
manufactured units)

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Curing methods and materials

Live steam at atmospheric pressure

Widely used in the pre-cast concrete industry

Cost justified by higher turnover of formwork & productivity

Generally done in an enclosure to minimize moisture and

heat losses
A typical steam-curing cycle consists of

1.
2.
3.
4.

Initial delay prior to steaming

Temperature increase period
Constant temperature period
Temperature decrease period

3 to 5 hours
2.5 hours (20C /h)
6 to 12 hours (to achieve fc)
2 hours

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Selecting a Method of Curing

Factors which affect the selection of a curing method include:

Type of member to be cured (slab, column, wall)

Specified finish for the concrete element (will the final

bond be affected by the curing compound)

Whether the curing process will influence the appearance

of the concrete

The construction schedule of the project (will work need to

continue in the area during curing ?)

The cost and availability of materials

Weather conditions, exposure and location

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Fresh Concrete Plastic Shrinkage

Plastic shrinkage
Result of improper curing
Surface layer shrinks; inside concrete is plastic

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Interaction Between Bleeding & Evaporation

Evaporation
surface water
Bleed water
Bleed water = evaporation
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Plastic Shrinkage Cracks

Usually associated with hot weather concreting or any time

when ambient conditions produce rapid evaporation

Occurs when water is lost from concrete during plastic state

(water evaporation > bleeding water)

by evaporation (bleeding, humidity, wind, TC)

by suction of underlying dry concrete or soil

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Plastic Settlement Cracks

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Time of Occurrence

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Plastic Shrinkage cracks

Special precautions in hot weather concreting
1. Moisten concrete aggregate that are dry and absorptive
2. Keep concrete temperature low by cooling aggregate and mixing
water
3. Dampen the subgrade and fog forms prior to placing concrete
4. Erect temporary windbreaks to reduce wind velocity over the
concrete surface
5. Erect temporary sunshades to reduce concrete surface
temperatures
6. Protect the concrete with temporary coverings such as
polyethylene during delay between placing and finishing
7. Fog the slag immediately after placing and before finishing
8. Add plastic fibres
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