Escolar Documentos
Profissional Documentos
Cultura Documentos
9/29/2014
CONCRETE
CONCRETE (Contd)
Mouldability,
Early Hardening
High Early Compressive Strength
Development of desired properties with Admixtures to be
used in Adverse Situations
Suitability for Guniting
Pumpability
Durability.
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Various ingredients
of
cement concrete
and
their Importance
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WATER
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Introduction
PURPOSE. of using Water with Cement is
to cause Hydration of the Cement.
Lubricant between coarse and fine aggregates, producing a
Workable and Economical concrete.
LESSER WATER
Workability decreases.
Non-Uniform mixing results in Weaker Concrete
Quality of Water
Almost any Natural Potable Water that has no pronounced taste or odour
is acceptable for the concrete mix.
Many sources of water unsuitable for drinking may also be used. However,
in case of a doubt, water samples should be tested for suitability.
Excessive impurities may affect
Setting Time
Strength
Durability
may cause Efflorescence
Surface Discolouration
Corrosion of Steel.
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AGGREGATES
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Cl of AGGREGATES
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Aggregates are the materials basically used as Filler with binding material
in the production of Mortar and Concrete.
They are derived from
Igneous, Sedimentary or Metamorphic rocks
Or manufactured from Blast Furnace Slag, etc.
Aggregates
INERTNESS.
Earlier Aggregates were considered to be chemically inert
but the Latest research has revealed that some of them are chemically active
certain types exhibit Chemical Bond at the interface of Aggregates and
Cement paste.
To increase the bulk density of Concrete, Aggregates are used in two (02)
markedly different sizes
the Bigger ones known to be CA (grit)
the Smaller ones FA (Sand).
CA form the main Matrix of Concrete and FA from the filler Matrix
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Eswar/ BTech2yr/ BMCT/ Unit5
between the CA
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ARTIFICIAL AGGREGATES
Broken Bricks, Blast Furnace Slag and Synthetic Aggregates
Broken bricks known as brick bats are suitable for Mass Concreting, e.g.,
Foundation Bases. They are NOT for RCC wks.
Blast Furnace Slag Aggregate
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Cl based on Size
CA
FA
All-in- Aggregate.
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CA - Cl based on Size
Natural disintegration
Artificial crushing of rocks.
Thickness of Section
Spacing of Rft
Clear Cover,
Mixing, Handling and Placing methods.
Aggregate > 20 mm size are gen NOT USED for RCC structural
members.
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Cl based on Shape
CLASSIFICATION
Aggregates are Cl as
Rounded
Irregular,
Angular
Flaky.
ROUNDED AGGREGATES
These are generally obtained from River or Sea shore
Produce Minimum Voids (about 32%) in the concrete.
They have MINIMUM Ratio of Surface Area to Volume
Cement paste required is MINIMUM
Poor Interlocking Bond makes it unsuitable for High Strength
Concrete and Pavements.
IRREGULAR AGGREGATES
Voids about 36%
Require MORE Cement Paste as compared to Rounded Aggregate.
Because of irregularity in shape they develop GOOD BOND and are
suitable for making Ordinary Concrete.
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Cl based on Shape
ANGULAR AGGREGATES
They have Sharp, Angular and Rough Particles
Maximum VOIDS (40%).
provide Very Good BOND than the earlier two
Most Suitable for High Strength Concrete and Pavements
Requirement of Cement Paste. Relatively More.
FLAKY AGGREGATES
These are sometimes wrongly called as elongated aggregate.
However, both of these influence the concrete properties adversely.
Least Lateral Dimension (thickness) < 0.6 x Mean Dimension.
e.g. Mean Sieve Size or Mean Dimension for an Aggregate piece passing
through 50 mm and retained on 40 mm sieve is (50 + 40)/2 = 45.0 mm.
If the Least Lateral Dimension < 0.6 45 = 27.0 mm, the aggregate is classified
as FLAKY.
Flaky aggregate generally orient in one plane with Water and Air Voids
underneath.
They Adversely affect Durability. Restricted to 15% max.
ELONGATED AGGREGATES
Length = 1.8 x Mean Dimension.
Influence the Concrete properties adversely.
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Note
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Cl based on Unit Wt
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*Quality of Aggregates
Hard,
Strong
Non-Porous
free from Elongated and Laminated particles
Should be Suitable for the purpose required.
Porosity.
<10%. Stones absorbing >10% water after 24 hrs
immersion in water are considered Porous.
Porous materials corrode rft.
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Characterstics of Aggregate
The Properties to be Considered while
selecting aggregate for concrete are
Strength,
Particle Shape
Specific Gravity
Bulk Density
Voids
Porosity,
Moisture Content
Bulking.
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STRENGTH
Strength should be at least equal to that of the
Concrete.
Rocks commonly used as Aggregates have a
Compressive Strength >> usual range of Concrete
Strength.
A typical Stress-Strain Curve for Aggregate is
shown in Fig. 6.1.
The Tests conducted for strength evaluation are
Crushing test
Impact-test
10% Fines test.
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STRENGTH (Contd)
Limit for the Crushing Value. Generally the
specifications prescribe
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The Str of the Bond between Aggregate and Cement paste thus has
an important influence on the Str of Concrete.
There is no standard test for bond but it is known that the rougher
the surface texture of the particles, the better the bond.
The role of particle shape is less well understood;
the greater specific surface of Angular Particles should enable Greater
Adhesive Force to be developed,
But, the Angular Shape probably causes more severe Concentrations
of Internal Stress.
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Flaky aggregate
require more Cement Paste,
produce Max Voids
Not Desirable.
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Sp Gr (Characteristics of Aggregate )
2.6-2.7.
Sp Gr and Porosity of Aggregates greatly
influence the Str and Absorption of Concrete.
Sp Gr of Aggregates indicates its Quality.
A low Sp Gr may indicate High Porosity and
Therefore, Poor Durability and Low Str.
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Porous Aggregate
Absorb more Moisture, resulting in
Loss of Workability of Concrete at a much faster rate.
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Moisture Content
(Characteristics of Aggregate)
Moisture Content. The Surface Moisture
expressed as a % of the Wt of the Saturated
Surface Dry Aggregate
A High Moisture Content
Increases the effective W/C Ratio to an
appreciable extent and
may render the Concrete Weak.
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PROCEDURE
Aggregate, whose F.M. is required, is placed on a Standard
Set of Sieves (80, 63, 40, 20, 12.5, 10, 4.75, 2.36, 1.18 mm
and 600, 300, 150 m) and the Set Vibrated.
The material Retained on each Sieve after Sieving
represent the fraction of Aggregate Coarser than the Sieve
in question, but, Finer than the Sieve Above.
FM = % Retained on the Sieves /100
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*Quality of Aggregates
Sand stones.
are Porous
Soft varieties of Sand-stones make Poor Concretes and also
produce Shrinkage Cracks
Lime stone.
Quite Good provided it is Hard, Crystalline and entirely free
from Dust.
Should not be used in wks subject to Excessive Heat.
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*Aggregates - Sizes
SIZES
CA. Mtrl retained on a 4.75mm IS Sieve
FA or Sand. Mtrl below 4.75mm IS Sieve.
Mtrl passing a 75 micron IS Sieve (No 200 BS sieve) is gen
considered as Clay, Fine Silt or Fine Dust in an Aggregate.
Ordering of CA
Ordered in Separate Sizes and Recombined in proper
proportion, while batching.
A 40 mm nominal max size aggregate will be ordered in 3
different Sizes
40mm to 20mm
20mm to 10mm
10mm to 4.75mm.
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Shape is Cl as:
Glassy
Smooth
Rough or Pitted
Crystalline
Honey Combed
Porous
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Effect of TEXTURE
Aggre with Rough surface produce Weaker Concrete.
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SAND
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FA or Sand
Sand is
Round/ Angular in Grains
often found Mixed in various Gradation of Fineness.
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FA or Sand
Impurities in Sand.
Clay, Silt, Salts, Mica and Organic matter cause
Weakness.
All Sands gen contain some % of Silt and Clay.
Mica is easily discernable from its shining surface.
A certain % of impurities are inevitable in Sand.
Permissive limits.
Silt 6%
Mica 2 to 3%
Free from Shell.
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Classisfication
Sand may be cl on the basis of
Source
Mineralogical Composition
Size of the Particles
Particle Size Distribution.
Cl based on Source
Natural Sandresulting from natural
disintegration of Rocks or deposited by Streams
Crushed Stone Sandproduced by crushing Hard
Stones
Crushed Gravel Sandproduced by crushing
Natural Gravel.
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Classisfication
Cl based on Mineralogical Composition
Quartz Sand
Felspar Sand
Carbonaceous Sand.
Cl based on Size
Coarse Sand F.M. 2.90-3.20;
Medium SandF.M. 2.60-2.90;
Fine SandF.M. 2.20-2.60.
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Gradings of FA
COARSER
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FINENESS INCREASING
FINER
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*FA or SAND
Sources
Sea Sand.
Particles too fine and too uniform for good class wk.
Sea Sand should not be used in its natural state. Salts will
attack rft
if Salt content is too high, (-)
it will retard Setting and Hardening of Cement
may cause Efflorescence
but it may not have any deleterious effect on Ultimat Str of the
Concrete.
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*FA or SAND
Pit Sand.
From Abandoned Beds of River.
Usually considered as the BEST.
Has Sharp Angular Grains (vs) River Sand which is Fine
with Rounded Grains.
Crushed Stone.
Screenings from Crushed stone often contain a high %
of Dust and Clay and may tend to be Flaky.
Flaky or Angular Particles may produce a Harsh
Concrete.
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Proportioning of Concrete
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PRODUCTION
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Quality Concrete
A Good Quality Concrete is essentially
a Homogeneous Mixture of Cement, CA, FA, Water
which consolidates into a Hard Mass, due to
Hydration.
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CA acts as a Filler.
FA fills up the voids between the Paste and the CA.
Cement in conjunction with Water acts as a Binder.
The Mobility of the Mixture is aided by the Cement
Paste, Fines and nowadays, increasingly by the use of
Admixtures.
Eswar/ BTech2yr/ BMCT/ Unit5
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Quality Concrete
QUALITY CONCRETE
Most of the properties of the hardened concrete
depend on the Care exercised at Every Stage of
Mfg.
A Rational Proportioning of the ingredients of
concrete is the essence of the Mix Design.
However, it may not guarantee of having achieved
the objective of the quality concrete work.
The AIM of QC is to ensure the production of
concrete of Uniform Strength from Batch to Batch.
This requires some Rules to be followed in various
stages of Concrete Production
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BATCHING
Ensuring Proper and Accurate Quantity of all
ingredients to achieve Good Quality Concrete
Accuracy of Batching.
Aggregates, Cement and Water. 3%
Admixtures. 5%
2 Methods of batching
Volume batching
Weigh batching.
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VOLUME BATCHING
VOLUME BATCHING
for Small Jobs only.
Amount of each Solid Ingredient is measured by Loose
Volume; using standard box known as Gauge Box (Fig.
10.1). Gauge Box Vol = 0.035m3
Cement
is always measured by Weight, irrespective of the method of
batching.
Volume of a Bag of Cement (50 kg) = 0.035 m3.
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WEIGH BATCHING
MANUAL BATCHING.
WEIGH BUCKETS.
For Large size wks.
Weigh Buckets are fed from Hoppers and these discharge
the ingredients by Gravity, straight into the Mixer.
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WEIGH BATCHING
Adding Water
Water is NOT added by Graduated Buckets, as the
Water may spill over during its addition.
A Horizontal or Vertical Tank is fitted to the Mixer.
The Fitting is so designed to have a Control to
admit any desired Qty of Water
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MIXING
The Object of Mixing is
to make the Concrete Mass
Homogeneous and Uniform
in Colour and Consistency.
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HAND MIXING
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MACHINE MIXING
For Quality Wks
Mixers can be broadly classified as
Batch Mixers
Continuous Mixers.
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MACHINE MIXING
CONTINUOUS MIXERS
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TILTING MIXERS
The Tilting Mixers may be
Hand Fed or
Loader (Skip) Fed.
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NON-TILTING MIXER
It consists of a
Non-tilting Cylindrical Drum with Blades inside
2 Circular Openings at the 2 ends.
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TRANSIT MIXER
Truck mounted mixers also know as Transit Mixers
(Fig. 10.7(a)) are very popular and have replaced
the Dumpers and Agitator Cars used earlier to
transport fresh concrete from the batching plant
to the site.
Transit mixers of capacity 4 to 12 Cu M mounted
on Truck Chassis are available.
Initially, these Mixers were NOT very efficient
and needed long Mixing Duration depending on
the extent of Dryness in the Mix.
Their Main Function is to keep the mix in an
agitated condition.
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MIXING TIME
Counted from the instant Complete Water is fed into
the mixer.
Time of mixing also depends on Capacity of Mixer and
is given in Table 10.3
If the Mixing Time is Reduced A Poor Quality of
Concrete is obtained
On the other hand if the Mixing Time is Increased
it is Uneconomical.
may cause Segregation.
Water may get Absorbed by the Aggregates or Evaporate
resulting in LOSS of Workability and Str.
However, it is found that
if the Mixing Time is increased to 2 minutes the Compressive
Str of Concrete produced is enhanced.
BUT, beyond this time the improvement in Compressive Str is
insignificant
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Time of Mixing
Ser
No
Capacity of
Mixer
(Cu M)
1
2
3
>= 3
2
<=1
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TRANSPORTING
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TRANSPORTING
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MORTAR PAN
WHELL BARROW
CHUTES
DUMPER
BUCKET AND ROPE WAY
CONVEYOR BELT
SKIP AND HOIST
PUMPING
Eswar/ BTech2yr/ BMCT/ Unit5
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WHEEL BARROW
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PLACING
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The Rft
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MASS CONCRETING
When the concrete is to be laid in Mass as for
Raft Foundation
Dam
Bridge,
Pier etc.,
LIFTS
Concrete is placed in layers of 350450 mm th. Several such
layers placed in quick succession form a LIFT
Before placing the Concrete in the next LIFT, the Surface of
Previous Lift is Cleaned thoroughly with Water Jets and
Scrubbed with Wire Brush.
In case of Dams, Sand Blasting is done.
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COMPACTION
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COMPACTION
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COMPACTION
Voids, Permeability, Rusting, Str
Voids effect Str
5 % Voids in Hardened Concrete REDUCE the Str by 30%
10 % Voids REDUCE the Str by 50%.
Therefore, the Density and consequently the Str and
Durability of Concrete largely depend upon the Degree
of Compaction.
For Max Str Driest possible concrete should be
compacted 100%.
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COMPACTION (Contd)
Easy entry of Sulphates from the environment causes
Expansive Reaction with the C3A present in Cement.
This causes Disintegration of Concrete and Loss of Durability.
Voids also
REDUCE the Contact between embedded Steel and Concrete. This
results in Loss of Bond Strength of Reinforced Concrete member and
thus the member loses Str.
Voids such as Honeycombs and Blowholes on the exposed surface
produce Visual Blemish. Concrete surface is not good to look with all
such blemishes. Concrete with smooth and perfect surface finish not
only Looks good but is also Stronger and more Durable.
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COMPACTION (Contd)
Compaction is achieved by imparting external
Work over the Concrete to overcome the
Internal Friction
between the Particles forming the Concrete,
between Concrete and Rft and
between Concrete and Forms and
by reducing the Air Voids to a Minimum.
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HAND COMPACTION
Used for Small and Unimportant Jobs.
Extremely useful for Thin Elements such as Slabs, and for
members with Congested Rfts.
for Mixes with any Workability except for very fluid or very
plastic Mix.
Hand Compaction is achieved by Rodding, Ramming, or
Tamping.
Rodding is done with the help of 16 mm diameter, 2 m long
Steel Rod to pack the Concrete between the Rft, Sharp Corners
and Edges, continuously during Concreting.
Ramming is permitted only for Unreinforced Concrete
Constructions.
Tamping. Roof and Floor Slabs are usually tamped for achieving
Compaction. Tampers are 100 100 mm in section and about 1
m long. Tamping Bars not only Compact the Concrete but also
Level the Top surface.
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COMPACTION BY VIBRATION
On vibration,
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COMPACTION BY VIBRATION
Vibration
Helps Entrapped Air to escape first from between the CA particles and
later from the Mortar.
When Vibration continues some more Entrapped Air from the mortar
is Driven out.
However, during this Second Phase, Concrete does not show any
movement but it is in this phase that Maximum Entrapped Air is
driven out and that is the time when Most of the Consolidation takes
place.
Plastic mixes need less time of Vibration than Harsh or Dry Mixes.
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Needle,
Formwork,
Table or Platform, and
Surface Vibrators.
Eswar/ BTech2yr/ BMCT/ Unit5
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NEEDLE VIBRATOR
Flexible Shaft
Power Unit. An average Frequency of Vibration is 3,500 to 5,000 CPM
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FORMWK VIBRATOR
These are also known as External or Shutter vibrators.
These are generally used under the following Circumstances:
1. Compaction of Concrete is required to be done in a Very Thin or Very
Densely Congested Reinforced Section.
2. In addition to Internal Vibration, Compaction is required to be done
specially in the Cover Area where at times Needle or Poker Vibrator is
Unable to do satisfactory Compaction.
3. Compaction of Very Stiff Concrete is required to be done because such
Concrete cannot be Compacted by Internal Vibrators.
Formwork Vibrators are used for Concreting
Columns
Thin Walls and
Precast Units.
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Form vibrators if used in addition to Internal vibrators help removing Entrapped Air
along the Concrete Surface giving a much Superior Finish.
Generally, Tapping with a Wooden Mallet on the external face of the formwork
also helps remove Entrapped Air which generally blemishes the concrete surface
inspite of adequate internal vibration.
VIBRATING TABLE.
A Special Case of a Formwork Vibrator used in Labs and Factories is Vibrating
Table.
The Vibrating Table consists of
a rigidly built Steel Platform
mounted on Flexible Springs and
driven by an Electric Motor.
The average Frequency of vibration is 4000 CPM. The Moulds are clamped on the
Platform.
Vibrations are stopped as soon as the Concrete in the moulds develops a Level
Smooth Surface.
Medium Workable Mixes generally require Higher Frequency of Vibration than Stiff
Mixes.
It is observed that increasing the Frequency and decreasing the Amplitude as
vibration progresses improves Consolidation by using this type of Vibrator.
The Vibrating Tables are Very Efficient in compacting Stiff and Harsh Mixes
required for Precast Elements.
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SURFACE VIBRATOR
These are also known as Screed Board
Vibrators.
Surface vibrators are used for Floor and Roof
Slabs and Pavement Surfaces.
These are effective only up to a th of 150 mm
of Concrete but can be used up to 250 mm.
Surface vibrators cause movement of fine
particles to the top and hence aid the
Finishing Op.
The operating Frequency is 4,000 CPM.
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COMPACTION BY SPINNING
This method is also known as Centrifugation
and is used for producing circular elements
such as Pipes.
The Plastic Concrete is SPUN into the
horizontal mould at a Very High Speed.
Water forced out of the mix during spinning
flows out of the Mould.
The initial W-C ratio required for effective
Compaction is 0.35 to 0.4 which after spinning
reduces to 0.3.
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COMPACTION BY JOLTING
In this method of Compaction, the mould
containing Dry Concrete is subjected to Jolt at a
frequency of 100 to 150 JPM.
Jolting
is a Vibrating action of low frequency and high
amplitude.
The mould filled with concrete is raised by about 12
mm and then
allowed to fall under gravity.
This method is used for Precast Units such as
Hollow Blocks
Cavity Blocks etc.
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COMPACTION BY ROLLING
Method of Compaction
the Soft and Plastic Concrete is fed continuously
between Rubber Rollers under Pressure up to 50
atm
This forces out the excess water in concrete.
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