CONCRETE MAKING MATERIALS June 14 Page 2 This presentation contains certain forward looking statements concerning future business prospects and profitability of HCC, which are subject to a number of risks and uncertainties and actual results could materially differ from those in such forward looking statements, important developments that could affect the company's operations include a downtrend in the infrastructure sector, significant changes in political and economic environment in India, tax laws, labor relations, litigation etc. The company does not undertake to make any announcement in case any of these forward looking statements become materially incorrect in future or update any forward looking statements made from time to time by or on behalf of the company. DISCLAIMER CONCRETE MAKING MATERIALS June 14 Page 3 CONCRETE Concrete is a mix of Cement, fine aggregate, Coarse aggregate, water, Chemical Admixtures and some times supplementary cementitious materials like Fly ash, GGBS, Micro silica etc. which, when placed in the skeleton of forms, allowed to hydrate and cured, form a hardened mass with very high compressive strength. CONCRETE MAKING MATERIALS June 14 Page 4 INGREDIENTS OF CONCRETE Cement Aggregates : Fine Aggregates Coarse aggregates Water Admixtures & Construction Chemicals Supplementary Cementitious Material (SCM) CONCRETE MAKING MATERIALS June 14 Page 5 CEMENT CONCRETE MAKING MATERIALS June 14 Page 6
Chemical Composition of Cement
Oxides Percent, content CaO 60-67 Sio 2 17-25 Al2O 3 3-8 Fe 2 O 3 0.5-6.0 MgO 0.1-4.0 Alkalies (K 2 O, Na 2 O) 0.4-1.3 SO 3 1.3-3.0 Approx. Oxide Composition of OPC CONCRETE MAKING MATERIALS June 14 Page 7 CEMENT: (contd..) These compounds present in the raw materials when subjected to high clinkering temperature combine with each other to form compounds called Bogues compound
Tricalcium silicate 3 CaO.SiO 2 C 3 S Dicalcium silicate 2 CaO.SiO 2 C 2 S Tricalcium Aluminate 3 CaO.Al 2 O 3 C 3 A Tretracalcium Aluminoferrite 4 CaO.Al 2 O 3 .Fe 2 O 3 C 4 AF
CONCRETE MAKING MATERIALS June 14 Page 8 CEMENT: (contd..) Compound composition using Bogues Equation (In percent) C 3 S 54.1 C 2 S 16.6 C 3 A 10.8 C 4 AF 9.1
CONCRETE MAKING MATERIALS June 14 Page 9
CEMENT: (contd..)
Tri calcium silicate & dicalcium silicate constitute 70 to 80% of cement & are the most important compounds responsible for strength.
Also modifications in cement can be made which will lead to the production of different types of cement as will be discussed separately in further course of the discussion.
CONCRETE MAKING MATERIALS June 14 Page 10 Rate of heat of hydration of pure compounds 0 0.2 0.4 0.6 0.8 1 1 Days 10 Days 100 Days 180 Days Time (log scale) - days F r a c t i o n
H y d r a t e d C3S C2S C3A C4AF CONCRETE MAKING MATERIALS June 14 Page 11 CEMENT: (contd..) Thus it is obvious from the above graph that initial heat of hydration for both C 3 A & C 4 AF is more but increase in rate of hydration is slow as compared to C 3 S and C 2 S. CONCRETE MAKING MATERIALS June 14 Page 12
CEMENT: (contd..) CALCIUM SILICATE HYDRATES: During the course of reaction of C 3 S and C 2 S with water, Calcium silicate hydrates (C-S-H) and Ca(OH) 2 are formed. 2 C 3 S + 6H C 3 S 2 H 3 + 3Ca(OH) 2 2 C 2 S + 4H C 3 S 2 H 3 + Ca(OH) 2
CONCRETE MAKING MATERIALS June 14 Page 13 TYPES OF CEMENT 1) Ordinary Portland Cement a) O.P.C 33 Grade - IS:269:1989 b) O.P.C 43 Grade - IS:8112:1987 c) O.P.C 53 Grade - IS:12269:1987 2) Rapid Hardening Cement - IS:8041:1990 3) Sulphate Resisting Cement - IS:12330:1988 4) Portland Slag Cement - IS:455:1989 5) Low Heat Cement - IS:12600:1989 6) Portland Pozzolana Cement - IS:1489 (Part I) CONCRETE MAKING MATERIALS June 14 Page 14 PROPERTIES OF CEMENT IS:8112 (43 Grade) IS:12269 (53 Grade) IS:1489 (part I)(PPC) Specific Surface (Blaine's m 2 /kg) Min. 225 225 300 a) By Le-chatelier mould (mm) Max 10 10 10 b) By Autoclave (%) Max 0.8 0.8 0.8 a) Initial Set (minutes) Min. 30 30 30 b) Final Set (minutes) Max 600 600 600 a) 3 Days (MPa) Min. 23 27 16 b) 7 Days (MPa) Min. 33 37 22 c) 28 Days (MPa) Min. 43 53 33 Requirements As Per 1) Fineness 3) Setting Time 4) Compressive Strength 2) Soundness Description CONCRETE MAKING MATERIALS June 14 Page 15 AGGREGATES CONCRETE MAKING MATERIALS June 14 Page 16 INTRODUCTION: Aggregates are important constituents in concrete & give body to the concrete. Reduce shrinkage & Effect economy. Occupy 70-80 % of volume of concrete.
CLASSIFICATION:
Aggregates can be classified as: Normal weight aggregates Heavy weight aggregates CONCRETE MAKING MATERIALS June 14 Page 17 FINE AGGREGATES: Natural or manufactured sand with particles up to 10mm. Generally, sand particles almost entirely pass the 4.75mm sieve and are predominantly retained on the 75m sieve. COARSE AGGREGATES : Natural gravel or manufactured material. The particles are predominantly retained on the 4.75mm sieve. CONCRETE MAKING MATERIALS June 14 Page 18 SIZE OF AGGREGATES MAS that can be used are governed by the following factors: Thickness of section Spacing of reinforcement Clear Cover Mixing, Handling, & placing techniques. MAS of 20mm is widely used for structural & Road Works. MAS of 10mm is used in shotcrete. MAS of 80 to 150mm is used for mass concreting. CONCRETE MAKING MATERIALS June 14 Page 19 SHAPE OF AGGREGATES The shape of aggregates is an imp. characteristic since it affects the workability of concrete.
Flaky particles have influence on workability, cement requirement, interlocking, strength, & durability. CONCRETE MAKING MATERIALS June 14 Page 20 Aggregates: (contd)
The grading, the shape and the texture of aggregates can significantly influence concrete workability.
The amount of water required for a target workability is related to aggregate properties:
Nominal maximum size of the coarse aggregate.
Shape and texture of particles of fine and coarse aggregates.
Grading of coarse aggregate. CONCRETE MAKING MATERIALS June 14 Page 21 Aggregates: (contd) Angular sand (manufactured sand) can significantly increase the water demand and the cement content for a required slump. Very coarse sands and coarse aggregates can produce harsh, unworkable mixes. Changes in grading (or the shape / texture) of the aggregates can cause changes in the water demand of concrete, segregation and affect uniformity of concrete from batch to batch. CONCRETE MAKING MATERIALS June 14 Page 22 PROPERTIES OF COARSE AGGREGATES: Properties Road Works Structural Concrete Deleterious Material (Dust) Max. 3% passing 0.075 mm sieve Max. 3% passing 0.075 mm sieve Aggregate Crushing Value Max. 30% Max. 45% Aggregate Impact Value Max. 30% Max. 45% Aggregate Abrasion Value (Los Angeles) Max. 30% Max. 50% Soundness Test a) Sodium Sulphate Max. 12% Max. 12% b) Magnesium Sulphate Max. 18% Max. 18% Flakiness Index - Max. 35% Flakiness & Elongation Index (Combined) Max. 30% Max. 30% Water Absorption Max. 2% Max. 2% a) Mortar Bar Test Max. expansion 0.1% Max. expansion 0.1% b) Chemical Test Ref er to Fig. 6 in IS: 2386 (Part VII) Ref er to Fig. 6 in IS: 2386 (Part VII) Alkali Aggregate Reactivity Coarse Aggregates CONCRETE MAKING MATERIALS June 14 Page 23 PROPERTIES OF FINE AGGREGATES Properties Road Works Structural Concrete 1) Fineness Modulus - 2.5to 3.5 2)Water Absorption Max. 2% Max. 2% 3) Soundness Test: a) Sodium Sulphate Max. 10% Max. 10% b) Magnesium Sulphate Max. 15% Max. 15% CONCRETE MAKING MATERIALS June 14 Page 24 Limits of Deleterious materials for fine aggregates Descrip. Fine aggregate Coarse aggregate Uncrushed Crushed Uncrushed Crushed Coal and lignite 1.0 1.0 1.0 1.0 Clay lumps 1.0 1.0 1.0 1.0 Material finer than 75 mic. 3.0 15.0 3.0 3.0 Soft fragments - - 3.0 - Shale 1.0 - - - Total of all (except mica) 5.0 2.0 5.0 5.0 CONCRETE MAKING MATERIALS June 14 Page 25 Grading of Coarse Aggregates as per Table 2 of IS:383-1970 I.S Seive (mm) % Passing 63mm 40mm 20mm 16mm 12.5mm 10mm 80 100 - - - - - 63 85 to 100 100 - - - - 40 0 to 30 85 to 100 100 - - - 20 0 to 5 0 to 20 85 to 100 100 - - 16 - - - 85 to 100 100 - 12.5 - - - - 85 to 100 100 10 0 to 5 0 to 5 0 to 20 0 to 30 0 to 45 85 to 100 4.75 - - 0 to 5 0 to 5 0 to 10 0 to 20 2.36 - - - - - 0 to 5 CONCRETE MAKING MATERIALS June 14 Page 26 Grading of Fine Aggregates as per Table 4 IS:383-1970 I.S Seive(mm) % Passing River Sand Crushed Sand (Manufactured Sand) Zone I Zone II Zone III Zone IV 10 100 100 100 100 The Permissible Limit on 150 micron Seive is increased to 20 Percent ( all other limits remaining same) 4.75 90-100 90-100 90-100 95-100 2.36 60-95 75-100 85-100 95-100 1.18 30-70 55-90 75-100 90-100 0.6 15-34 35-59 60-79 80-100 0.3 5-20 8-30 12-40 15-50 0.15 0-10 0-10 0-10 0-15 CONCRETE MAKING MATERIALS June 14 Page 27 Aggregates: (contd) Once the individual grading of coarse & fine aggregates are fixed then they are combined to get the most suitable grading.
The process of combining aggregates is a trial & error method.
A sample calculation for this is shown. CONCRETE MAKING MATERIALS June 14 Page 28 Combined Gradation Seive Size (mm) Individual Grading Combined Grading Limit 20 mm 10 mm C. Sand N. Sand 30% 20% 32% 18% L. Limit U. Limit 20 95.5 100 100 100 98.8 100 100 10 0.1 88.7 100 98.4 67.5 61 72 4.75 0 9.2 98.6 87.4 49.1 40 58 2.36 0 1.1 84.6 76.3 41.1 28 47 1.18 0 0 52.1 33.7 22.7 18 35 0.6 0 0 39.5 9.9 14.4 12 25 0.3 0 0 30.1 1.8 9.97 7 14 0.15 0 0 21.8 0.5 7.0 3 8 CONCRETE MAKING MATERIALS June 14 Page 29 Combined Gradation Graph 0 10 20 30 40 50 60 70 80 90 100 0.15 0.3 0.6 1.18 2.36 4.75 10 20 Seive Size (mm) %
P a s s i n g L.Limit U.Limit Act.Grad. COMBINED GRADATION GRAPH CONCRETE MAKING MATERIALS June 14 Page 30 ALL IN AGGREGATE FOR NORMAL CONCRETE AS PER TABLE 5 OF IS:383-1970: IS Seive (mm) % Passing 40mm 20mm 80 100 - 40 95 to 100 100 20 45 to 75 95 to 100 4.75 25 to 45 30 to 50 0.6 8 to 30 10 to 35 0.15 0 to 6 0 to 6 CONCRETE MAKING MATERIALS June 14 Page 31 COMBINED GRADATION FOR PUMP CONCRETE AS PER ACI 304.2R-91 IS Seive (mm) % Passing 25mm Max. Size 20mm Max. Size 25 100 - 20 80-88 100 13 64-75 75-82 9.5 55-70 61-72 4.75 40-58 40-58 2.36 28-47 28-47 1.18 18-35 18-35 0.6 12-25 12-25 0.3 7-14 7-14 0.15 3-8 3-8 0.075 0 0 CONCRETE MAKING MATERIALS June 14 Page 32
WATER
CONCRETE MAKING MATERIALS June 14 Page 33
Water is an important ingredient of concrete as it actively participates in the chemical reaction with cement.
Since water helps to form the strength giving cement gel, the Quality of water is required to be maintained.
A popular yardstick to measure the suitability of water for mixing concrete is that, if water is fit for drinking it is fit for making concrete. WATER
CONCRETE MAKING MATERIALS June 14 Page 34 Permissible Limits for Solids as per Table 1 IS:456-2000 Material Limits Organic 200 mg/ml Inorganic 3000 mg/ml Sulphates (as SO 3 ) 400 mg/ml Chlorides (as Cl) 2000 mg/ml Suspended matter 2000 mg/ml CONCRETE MAKING MATERIALS June 14 Page 35 Water: (contd ) Also the following guidelines are followed as per IS:456-2000:
The pH value of water shall be not less than 6.
Avg. 28 day comp. Strength of at least 3 cubes with the water proposed shall not be less than 90% of the avg. of strength of 3 cubes prepared with distilled water.
Initial Setting time of test block made with water proposed shall not be less than 30 min. & shall not differ by +/- 30 min. from the initial setting time of control test block. CONCRETE MAKING MATERIALS June 14 Page 36 ADMIXTURES CONCRETE MAKING MATERIALS June 14 Page 37 Admixture can be defined as a chemical product which, is added to the concrete batch immediately before or during mixing or during an additional mixing operation prior to the placing of concrete for the purpose of achieving specific modifications to the normal properties of concrete.
Admixtures are commonly classified by their function in concrete but often they exhibit some additional action. CONCRETE MAKING MATERIALS June 14 Page 38 Concrete must be placeable and durable.
High degree of workability is required in case of thin walls, tremie concreting, pumping of concrete.
Durability includes limitation for water to cement ratio so that the concrete structure maintains its required strength and serviceability. Why do we need Admixtures CONCRETE MAKING MATERIALS June 14 Page 39 Admixtures: (contd) Admixtures are generally used to achieve the following: In Fresh Concrete:
Increase workability and/or pumpability without increasing the w/c ratio.
Improve cohesiveness and thereby reducing segregation or bleeding.
Improve to some extent set retardation
Entrain air bubbles in the fresh concrete. CONCRETE MAKING MATERIALS June 14 Page 40 Admixtures: (contd) In Hardened Concrete: Increase strength by reducing w/c ratio, maintaining the same workability
Reduce permeability and improve durability by reducing w/c ratio.
Reduce heat of hydration by reducing cement content. CONCRETE MAKING MATERIALS June 14 Page 41 Admixtures: (contd) The classification of ASTM C 494-92 is as follows: Type A - Water reducing Type B - Retarding Type C - Accelerating Type D - Water reducing and retarding Type E - Water reducing and accelerating Type F - High range water reducing (HRWRA) or Superplasticisers. Type G - High range water reducing & Retarding CONCRETE MAKING MATERIALS June 14 Page 42
Specialty admixtures :
Concrete curing compounds, Corrosion inhibitors, shrinkage control Viscosity modifying agents, coloring, permeability-reducing, etc. CONCRETE MAKING MATERIALS June 14 Page 43 Water reducing admixtures These are principally surface active agents (surfactants).
Fine cement particles being very small clump together and flocculate when water is added to concrete.
Plasticizers induce negative charge on the individual cement particles such that fine cement particles are dispersed due to inter particle repulsion. CONCRETE MAKING MATERIALS June 14 Page 44 Interaction of Water reducing admixtures Cement particles Negative charge induced. Interparticle repulsion occurs Water released Water CONCRETE MAKING MATERIALS June 14 Page 45 Conventional Water reducing admixtures Reduce water content up to 5%.
Lignosulfonates, polysaccharides (glucose and corn syrup, molasses).
Hydroxylated carboxylic acids and their salts: (Gluconate, Glucoheptanate, citrate). CONCRETE MAKING MATERIALS June 14 Page 46 Mid Range Water reducing admixtures Reduce water content up to 12%.
Formulated admixtures: poorly purified lignins, modified sulfonated naphthalene or melamine, carboxylic acid-based polymers, etc. CONCRETE MAKING MATERIALS June 14 Page 47 RETARDERS Retardation of concrete mix is required in the case of: Hot Weather Concreting
Preventing formation of cold joints.
Loss of workability in case of transportation over long distances. CONCRETE MAKING MATERIALS June 14 Page 48 Mechanism of Working These admixtures modify the crystal growth or morphology becoming adsorbed on formed membrane of hydrated cement and slow down the growth of calcium hydroxide nuclei. CONCRETE MAKING MATERIALS June 14 Page 49 Admixtures: (contd)
Common Chemicals Used in Retarding Admixtures:
Sugar
Carbohydrate derivatives
Soluble zinc salts
Soluble borates CONCRETE MAKING MATERIALS June 14 Page 50
Admixtures: (contd)
It should be kept in mind that while retarders help in retarding the setting time of the mix at the same time they reduce the final strength of the mix.
Hence the mix should be designed keeping this in mind and making suitable allowances for the same.
Great care is necessary in using retarders as incorrect quantities can totally inhibit setting and hardening properties of concrete. CONCRETE MAKING MATERIALS June 14 Page 51 Admixtures: (contd) Accelerators: Accelerators are required in the case of : Very low temperatures.
Earlier removing of formwork.
Reduce required period of curing.
In shotcrete for overhead & other applications.
CONCRETE MAKING MATERIALS June 14 Page 52 Admixtures: (contd) Common Chemicals Used in Accelerating Accelerators: Inorganic Calcium Chloride Calcium Nitrate Calcium Nitrite Shotcrete Aluminates & Silicates Water Glass ( Modified water Glass ) Alkali free.
CONCRETE MAKING MATERIALS June 14 Page 53 Mechanism is similar to water reducing admixtures.
Water reduction upto 25% can be achieved.
Use of HRWRA has made it possible to use low water to cement ratio maintaining high workability. High Range Water Reducing Admixtures CONCRETE MAKING MATERIALS June 14 Page 54 Sulphonated napthalene-formaldehyde condensates (SNF).