CC 203

CONCRETE TECHNOLOGY

TOPIC 1
CONCRETE MATERIALS AND MIXTURE

Lecturer name :
MOHD HAZMAN BIN ABDUL AZIZ
 TOPIC 1 :CONCRETE MATERIAL AND MIXTURE
SUB TOPIC
– Basic properties of concrete.
– Basic knowledge of cement.
– Storage method of cement.
– Fine aggregate and coarse aggregate.
– Properties of water used in concrete mixture.
– Basic concept of concrete mix.
– Fresh concrete.
– Additives in concrete mix.
– Standard laboratory testing of cement and
aggregate.
 SUB TOPIC 1.1

 Basic properties of concrete

- Materials in concrete mixture ( cement,
fine aggregate, coarse aggregate ,
admixture and water )
- Concrete strength according to
materials composition.
- Differentiate concrete from other civil
engineering materials.
 DEFINITION OF CONCRETE

 Concrete is a substance produced when

the cement, sand, coarse aggregate and
water are mixed and blended according to
mix ratio allowed to harden to form a
structural member.
MATERIALS OF CONCRTE MIX

Water Cement

Aggregate
Admixture
(fine + coarse)
 Cement

 It is a basic ingredient of concrete, mortar,

and plaster.
 material produced by burning a mixture of
limestone and clay.
 Is the product obtained by grinding clinker
formed by burning raw-materials
(argillaceous and calcareous) primarily
consisting of lime (CaO), silicate (SiO2),
alumina (Al2O3), and iron oxide (Fe2O3).
 Have two type is hydraulic or non-hydraulic.
 Argillaceous + Calcareous
Silica Lime
Alumina
Ferum oxide
Argillaceous – clay, sandstone, shale
Calcareous – limestone, chalK

 Hydraulic cement – able to set and harden

under water e.g. OPC, Slag Cement, ggbs

 Non-Hydraulic cement – will not set and harden

under water but require air to harden e.g. lime,
gypsum
 Aggregate
 Classified by ASTM C33 is fine and coarse.

Fine Aggregate
 consists of sourse is river sand, mining sand and
sea sand.
 Size less than 5mm.( 2.36,1.18 & 0.600mm )
Coarse Aggregate.

 consists of sourse is lime stone, granite and

sand stone.
 Size – more than 5mm. (10,20 &40mm )
 AGGREGATE

 Crushed – sharp
angular particles, from
quarry, rough surface,
good bond strength, low
workability

 Uncrushed – round
shapes, smooth surface,
from river, low bonding
properties, high
workability
 Water
 Materials of hydartion process.
 Clean no (acid, alkali, sulfate, clay, sugar dan
chloride)
 Water cement ratio ( BS 0.45 – 0.65 )
 Purpose/Peranan
- For hydration and workability.
– washing/membasuh.
– curing/mengawet.
ADMIXTURE
 Material added to concrete or mortar to change one or
more properties at the fresh/hardened

 Purpose / Peranan
– increased plasticity, accelerating the setting,
improving the strength development, and reducing
the heat of hydration
– some modify workability characteristics and setting
rate of fresh concrete, others change the properties
both at mixing and hardened stages

 Introduced before, during or after mixing

ADMIXTURE

Water repelling agent Accelerators agent

Concrete strength according to materials
composition

 Quality material - material used .

 Mix ratio.
 Grading of aggregates .
 Volume of water used .
 Compaction when placed in the mold.
 Preservation are carried out after hardening.
 Mixing and transport .
 Curing.
Differentiate concrete from other civil
engineering materials.

 Strength.
 Low cost
 Readily available
 Malleable
 Hardy
 Fire resistance
 Tidy
 Not shrink
 SUB TOPIC 1.2

 Basic knowledge of cement

- Types of cement in the market.
- Chemical composition of cement.
- Hydration process of water in
cement.
- Function of chemical substances in
cement.
 Introduction of cement

 Cement is a substance produced by

burning a mixture of limestone and clay.
Properties of cement is cohesive and
adhesion , which enable it to bind the
component materials fine and coarse
aggregates to be compact.
 Types of cement

 Ordinary Portland Cement (OPC)

 Rapid Hardening Portland Cement (RHPC)
 Low Heat Portland Cement (LHPC)
 Sulphate Resisting Portland Cement
(SRPC)
 Modified Portland Cement (MPC)
 Blast furnace Portland Cement (PBC)
 High Aluminium Portland Cement (HAPC)
 Ordinary Portland Cement ( OPC )

 By far the most common cement used in

general concrete construction when there is
no exposure to sulphates in the soil or
groundwater
 Minimum fineness of 225 m2/kg
 Rate of hardening is moderate
 Standards; BS 12, MS 522
RAPID HEARDENING PORTLAND CEMENT ( RHPC )

 Rapid strength gain due to higher C3S content

(70%)
 Minimum fineness of 325 m2/kg
 Used when formwork is to be removed early
for reuse or where sufficient strength for
further construction is required quickly
 Should not be used in mass concrete
construction or in large structural sections
because of its higher rate of heat
development
Cont.

 For construction at low temperatures, the use

of RHPC may provide a satisfactory safeguard
against early frost damage.

 The setting time and chemical composition of

RHPC and OPC is relatively the same.
Sulphate Resisting Portland Cement (SRPC)
 This cement has low C3A (3.5%) content so as to
avoid sulphate attack from outside the concrete
 Minimum fineness of 250 m2/kg
 Active salts are magnesium and sodium
sulphates
 Sulphate attack is greatly accelerated if
accompanied by wetting and drying (splash
zone)
 The heat develop by SRPC is not much higher
than the low-heat cement, which is an
advantage.
Cont.

 For construction at low temperatures, the

use of RHPC may provide a satisfactory
safeguard against early frost damage.

 The setting time and chemical composition of

RHPC and OPC is relatively the same.
Low heat portlang cement ( LHPC )

 Cement is used to prevent cracks due to the

increase in concrete temperature during
hydration.
 This cement has a slower rate of increase in
strength but did not change its maximum
strength.
 Cement was used to build large structures
 Modified Portland Cement (MPC)

 Cement produces less heat than normal

portland cement, sulphate resistant to the
attack is simple.

 Ordinary portland cement is modified by

adding chemicals to be adjusted to the use.
 Portland-Blastfurnace Cement (PBC)

 Made by intergrinding or blending Portland cement

clinker with granulated blastfurnace slag.
 Known as slag cement.
 Slag contains lime, silica and alumina, but not in
the same proportions as in Portland cement.
 Minimum fineness of 275 m2/kg.
 Early strength are generally lower than OPC but
later strength are similar or even higher.
Cont.

 Typical uses are in mass concrete because of

low heat of hydration and in seawater
construction due to better sulphate resistance
(lower C3A content) than with the OPC.

 The amount of slag replacement between 25

to 70% of the mass of the mixture.
 High Aluminium Portland Cement (HAPC)

 contain high aluminia, called cement sparkles.

 be resistant to chemical attack, quickly

hardened

 the slow freezing of the OPC, but the freeze

will apply immediately for a four to five hours
and thirty minutes to freeze expired.
 HYDRATION PROCESS

CEMENT

HYDRATION
PROCESS PASTA
CEMENT

CONCRETE
WATER

AGGREGATE
( FINE & COARSE )
 Hydaration Processs Cycle

 When the materials are mixed water and

cement together through a chemical
process called hydration and produce a
cement paste. Cement paste acts as a
binder with aggregate to produce a
concrete.
 CHEMICAL COMPOSITION IN CEMENT
Compound Chemical Abb. Percent Rate of
formula (range) reaction
with water

Tricalcium 3CaO.SiO2 C 3S 35-65% Medium

silicate

Dicalcium 2Cao.SiO2 C 2S 15-40% Slow

silicate

Tricalcium 3CaO.Al2O3 C 3A 0-15% Fast

Aluminate

Tetracalcium 4CaO.Al2O3.Fe2O3 C4AF 6-20% Medium

Aluminoferrite
CHEMICAL FUNCTIONS

 C3S for faster gain in strength and produces higher heat of

hydration.

 C2S reacts slowly, provide later strength, highly chemical

resistance (sulphate, chloride)

 C3A is undesirable, contribute little or nothing to the strength

of cement except at early ages.

 C4AF does not affect the behaviour of cement hydration

significantly.
 SUB TOPIC 1.3

 Storage method of cement.

- Storage method in a factory.
i ) Bag cement.
ii) Silo / Warehouse
 Cement bag

• Stored in a waterproof.
• An area that is suitable for good air circulation
• The floor is dry
• All have opening and closing can be closed
• Arranged vertically not more than 1.5m (5 ft )
• Space platform from the floor is
least 23 cm and 30 cm from the wall.
 cement
1½m@
5 kaki
30 cm
23 cm
 Silo

• Stored in dry conditions to prevent freezing of the

air.
• Should be in a waterproof.
• Examination should be done regularly.
• An area that is suitable for good air circulation.
• Avoid wastage, if the bag of
cement leakage or rupture work in a
controlled and effective storage.
• Silo is a place to store the cement at
the concrete mixing plant.
SILO METHOD
 SUB TOPIC 1.4

 Fine Aggregate and Coarse Aggregate.

- Criteria of aggregate.
- Properties of aggregate.
 Criteria of aggregate

 Size.
 Shape.
 Surface Texture.
 Grading.
 Properties of aggregates

A number of physical and mechanical

properties affect durability, strength, and
performance of construction products
manufactured using aggregates

 The aggregate particles should retain their

strength, shape, and texture when used with
materials such as cement
 Physical

 Crushed – sharp angular

particles, from quarry,
rough surface, good bond
strength, low workability

 Uncrushed – round
shapes, smooth surface,
from river, low bonding
properties, high
workability
 Mechanical
 Compressive strength
 Specific gravity
 Bulk density
 Porosity
 Voids
 Absorption
 Modulus of elasticity
 Moisture content
 Shrinkage
 Grading and fineness
 Chemical reactivity
 SUB TOPIC 1.5

 Properties of water used in concrete mix.

- Quality of water in concrete mixture.
- Role of water in concrete mixture.
 Quality of water in concrete mixture

 The water used for mixing and curing should be

clean and free from alkalis, acid, oils, salt, sugar,
organic materials.

 Water is filt drink or taken from an approved

source.

 The pH value of water should be not less than 6.

 THE ROLE OF WATER IN CONCRETE MIXTURE

 spreading water cement (or lime) for each

item covered by the meeting stone .

 water to give pleasure working on concrete

mix

 Water is a chemical reaction of the cement to

bind all the stones in the concrete mix.
 SUB TOPIC 1.6

 Basic concept of concrete mix.

- Define of concrete mixture.
- Types of mix ratio.
- Relation of mix ratio and strength.
- Types of mixture :-
i ) Standard Mix / Fixed Mix.
ii) Design Mix.
iii) Nominal Mix.
 Concrete Mixture

Define
 Concrete mix design is a process of selecting
the appropriate constituents of concrete
materials to produce concrete mixes that can
be strong, high workability and economical.
TYPES OF MIX RATIO
Ratio used

wall on site in for the working

1: 5: 10 hard soil, box culvent

1: 3: 6 concrete floor, body

1: 2: 4 reinforced concrete footing,

slab, columns, beams and other.

1: 1.5: 3 Pre stressed concrete, tanks,

and others.
 The Relation of Mix Ratio and Strength
Concrete Grade Strength (N /mm ²) Uses
7 7 Concrete without reinforc
10 10 ement

15 15 Reinforced
concrete with lightweight
aggregates
20 20 Reinforced
25 25 concrete with aggregate v
olume
30 30 First reinforced
concrete firm
40 40 Stressed reinforced
50 50 concrete
 STANDARD MIX

 Mixing based on the weight

 Refer spec. on BS (CP 110)

 At the construction site contractor must be

followed the consultan based the
BS( CP 110 ).
 DESIGN MIX

 Mixing rate based on volume

 The contractor is responsible for selecting the

mixing ratio for the strength and level of work
performed.

 Some of the mixture should be modified in

the mix.
 Nominal Mix

 Mixing based on the volume and weight.

 Mix set was to have only minimum strength.
 Not recommended at construction site.
 Can be carried out with the weight if the
density have given.
Density ( D ) = Mass ( M ) / Volume ( V )
 Example 1
Calculate the mass of material which is needed for
nominal mix with ratio of 1:2:4 based on 150 kg
cement, where mixing is done based on mass:

Given the density of materials :

Cement - 1440 kg/m3
Fine aggregate - 1640 kg/m3
Coarse aggregate - 1390 kg/m3
• Solution
V=M M=V×D
D

a) Volume of Cement= 150 kg = 0.104m3

1440 kg/m3

b) Volume of fine aggregate =0.104×2 (mix ratio) = 0.208m3

Mass of fine aggregate = 1640 kg/m3 × 0.208m3
= 341 kg

c) Volume of Coarse aggregate = 0.104m3 × 4 ( mix ratio )

= 0.416m3
Mass of Coarse aggregate = 0.416m3 ×1390kg/m3
= 578 kg

d ) Volume of water = 0.55 x 150kg( cement )

= 82.5 kg @ liter
 SUB TOPIC 1.7

 Fresh Concrete
- Describe fresh concrete and workability
- The factor influencing workability:
a) Water / cement ratio
b) Aggregate / cement ratio
c) Shape and texture
d) Additivies substance
 Fresh concrete
 concrete mix design is a process of selecting
the materials in concrete mix and can be
strong,durable,high workability and
economical.
Workability
 work from mixing to placed concrete in the
mould.
 It represent the ability of concrete to be
mixing,transported,casting and casting.
 FACTORS INFLUENDING WORKABILITY
ii. Water / cement ratio
 to produce concrete mixes that are plastic and
easily worked.
 water should be used more than the limit, the
strength and density of concrete is reduced.
 if the water used is too less, the concrete will be
difficult to do and the hydration process is not
perfect.
 relationship between the ratio
of water and cement in the concrete
mix is known as the ratio of water - cement.
 Aggregate / cement ratio

 fine and coarse aggregates shall consist of a

variety of sizes to produce a minimum hole.

 cement consumption should be sufficient to

fill the holes in the sand and cement and
sand enough to cover the hole in
the coarse aggregates.
ii. Shape and texture

 Aggregates a smooth surface can provide

a good workability, but has a low bond is
strength.

 Aggregates a rough surface produces

a low workability, but the bond is strength
i. Additives substance

 additive can given mixed into the concrete

during the mixing progress.

 to increase or modify the standard work on

the concrete.

 both these materials, additives and ingredie

nts
added to the concrete advantages.
 SUB TOPIC 1.8

 Additives ( admixture) in concrete mixture

 - Define of admixture.
- Types of admixture
a) Catalyzing Subtances.
b) Retarding Subtances.
c) Water Decreasing Subtances.
d) Plasticizing Subtances.
e) Air Trapping Additives.
 Define of Admixture

 Agent chemical are include in concrete or

mortar to change the properties at the fresh
and hard concrete
 Have 2 group is chemical and mineral.
 Function :
i) to modify the workability characteristic
ii) to setting(hydration) rate of fresh concrete.
iii) to change the propeties of concrete.
 Types of admixture

a) Catalyzing Subtances.

 Accelerator materials are calcium chloride

 to increase the rate of concrete strength
 Adverse effects of corrosion on the bars of
bones.
 b) Retarding Subtances

 Act delay the process of chemical reaction

during the hydration process.
 helpful for concrete to be transported to long
distance.
 Used at hot area location
 Admixture is calcium sulphate and gypsum
 c) Water Decreasing Subtances

 Admixture is calcium sterat.

 To increase the workability so that placing the
concrete it ease.
 To increase the volume of water in concrete
mix.
 Designed to resist cracking
 d) Plasticizing Subtances

 Active at the surface that helps cement the

more effective spread in the water.
 When the material is blended in the concrete
it will speed up the properties of cohesion.
 Small quantities have to use 0.2% by weight
of cement.
 e) Air Trapping Additives

 As small quantity include in mixture.

 This agent can shape are bubble to

i) increase the workability.
ii) reduce of bleeding and segregation.
iii) improve the strength of concrete.
Materials of agent is :
a) Natural materials ( wood resin )
b) Oilly plant ( fat , oil zaitun , acid fat )
c) Fresh agent (alkali salt & organic suphate)
d) Water soluble salts (resin acids & fat acids
of plants.
e) Sodium salt of sulphuric acid ( petroleum,
hydrogen peroxide and aluminium )
Serbuk aluminium Asid Stearic

Hidrogen
peroksida Zaitun Oil

Asid Oleic Fat

 SUB TOPIC 1.9

 Standard Laboratory Testing for cement and

Aggregate.

a) Laboratory testing for cement

i ) Fineness test
ii ) Mortar test ( Cube cement test )
iii ) Softtening point
b) Laboratory testing for fine aggregate
i ) Silt @ Dust test
ii ) Sieve test (Particle Size Distribution)

c) Laboratory testing for coarse aggregate

i ) Sieve test (Particle Size Distribution)
 a) Laboratory testing for cement
i ) Fineness test

 Fineness of cement is tested in two ways :

(a) By sieving.
(b) By determination of specific surface
(total surface area of all the particles in one
gram of cement) by air-premeability
appartus. Expressed as cm2/gm or m2/kg.
Generally Blaine Airpermeability appartus is
used.
Objective :
to determine the fineness of cement
by dry sieving as per IS: 4031 (Part 1)
–1996.

 Apparatus : - 90µm IS Sieve,

- Balance capable of weighing
10g to the nearest 10mg,
- a nylon or pure bristle brush,
- preferably with 25 to 40mm,
- bristle for cleaning the sieve.
PROCEDURE

iv) Weigh approximately 10g of cement to the nearest 0.01g

and place it on the sieve.
v) Agitate the sieve by swirling, planetary and linear
movements, until no more fine material passes through it.
vi) Weigh the residue and express its mass as a percentage
R1,of the quantity first placed on the sieve to the nearest
0.1 percent.
vii) Gently brush all the fine material off the base of the sieve.
viii) Repeat the whole procedure using a fresh 10g sample to
obtain R2. Then calculate R as the mean of R1 and R2 as a
percentage, expressed to the nearest 0.1 percent. When
the results differ by more than 1 percent absolute, carry
out a third sieving and calculate the mean of the three
values.
 Blaine Airpermeability
ii ) Mortar test ( Cube cement test )
 Objective :
to determine the cement sample is tested to
meet standards and can be used in concrete
mix.

 Theory :
Standard cube strength of cement tested is
must not be less than 23 N/mm2 after 28
days.

 Apparatus : - amount of cement

- 50 x 50 x 50 mm mould
Procedure
• Mix 1kg of cement for testing with water.
• Include the mixture into the 3 cube and
compacting the cement at 3 layer with 1
layer 25time. Let the mix harden for 1 day.
• After a day open the mould and then soaked
the 3 cube in water for 28 days.
• After 28 days the cube can testing with
compression mechine.
No of (mm )cube 1 2 3

Weight of cube(gm)

Compression machine
reading(kn)

Compressive strength
(N/mm2)

Average compressive
strength (N/mm2)
iii ) Softtening point.
 Objective :
to determine the most suitable water
content for cement mixer.

 Apparatus : - Ordinary portland cement

(400g)
- vicat apparatus.
- distilled water.
- cement mixing equipment
Procedure
 Weigh 400g of ordinary portland cement and placed
on glass plates.

 Provide 28% = 122ml of distilled water. Mix with

cement until the distribution. Do penetration test
and record the reading of the penetration distance.

 Remove the mixture and place on plate. Add 2% =

8ml distilled water and then insert it into the mold.

 Add water by 2% until the penetration of the needle

stop at a distance of 5mm from the bottom of the
mold.
 Vicat apparatus
b) Laboratory testing for fine aggregate

i ) Silt @ Dust test

Objective:
to determine the dust content of sand is tested to meet
standards and can be used in concrete mix.

Theory:
According with British standard for dust content in the fine
aggregate is should not exceed 8 %

Apparatus: Cylinder measurement 250 ml

Sand sample tested
Salt water mix
Rubber hammer
PROCEDURE :

1) Prepare the sand to be tested.

2) Include the sand into the cylinder until the past of level 130ml.

3) Include the salt water into the cylinder until the past of level sand.
4) Shake the mixture until blended and add more salt water to the 250ml
level.

5) Put the cylinder on a flat surface and tap slowly with a rubber
hammer.

6) Sprinkle water around the inside of the cylinder so the sand sticks to
the cylinder can be cleaned completely.

7) Let until the water in the cylinder to be clear and the dust fully settle.

8) Record high reading the levels of sand and dust.

 Results:

Bil Content Measurement(mm)

1 Height level of dust (A) 5 mm
2 Height level of sand (B) 125 mm

 % Dust in sand = a/b x 100%

=4%

 British Standard : Dust contant less than 8 %

ii ) Sieve test (Particle Size Distribution) of fine
aggregate.
Purpose :
 To determine the sample refer the British
Standard.

Apparatus :
 Set sieving BS 410 – Table 3
( 10,5,2.36,1.18,0.60,0.30 dan 0.150 )
 Vibrator machine.
 Scales dan trays.
 Procude :

 Prepare the amount of aggregate (min 500g).

 Weigh the aggregate to 1gm nearly.
 Include the aggregate into the BS sieve.
 Vibrate the aggregate at 3 - 5 minute.
 Weigh the aggregate weight at each set BS
sieve.
 Calculate the percentages of retained and
passing. Plot the graf top and bottom specific.
Set sieving and vibrator machine
c) Laboratory testing for coarse aggregate
i ) Sieve test (Particle Size Distribution)
Purpose :
 To determine the sample refer the British
Standard.
Apparatus :
 Set sieving BS 410 – Table 2
( 37.5,20,14,10 dan 5 )
 Vibrator machine.
 Scales dan trays.
 Procude :
 Prepare the amount of aggregate ( min 2kg).
 Weigh the aggregate to 1gm nearly.
 Include the aggregate into the BS sieve.
 Vibrate the aggregate at 3 - 5 minute.
 Weigh the aggregate weight at each set BS
sieve.
 Calculate the percentages of retained and
passing. Plot the graf top and bottom specific.
Set sieving and vibrator machine