HINDUSTAN CONSTRUCTION CO. LTD.

PROPERTIES OF FRESH AND HARDENED CONCRETE

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DISCLAIMER

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.
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Properties of concrete

Overview

1. Properties of fresh concrete

Workability Segregation Bleeding Heat of Hydration

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Overview

2. Properties of Hardened concrete

Strength Creep Shrinkage Sulphate & chloride attacks

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Concrete
Concrete is a mix of cement, fine aggregate, coarse aggregate, water, chemical admixtures and sometimes supplementary cementitious materials like Fly Ash, GGBS, Silica Fume etc. which, when placed in the skeleton of forms, allowed to hydrate and cured form a hardened mass with very high compressive strength

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Mixing of concrete
It is essential that the mix ingredients are mixed properly so as to produce fresh concrete in which all the aggregate particles is coated with cement paste and therefore possessing uniform properties Types of mixers: Pan mixers Twin shaft mixers Gravity mixers (tilting & non-tilting)
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Mixing of concrete (contd.)

Mixing time is specified by the manufacturer depending upon the type of mixer and its size Mixing time for producing a good mix in a batching plant generally varies between 30 to 90 secs Lesser mixing time than recommended will not produce a uniform mix, but prolonged mixing time than required will have no significant improvement
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Workability Requirements
Generally implies the ease with which a concrete mix can be handled from mixer to its finally compacted shape
Consistency - fluidity

Mobility ease of flow

Compactibility ease of compaction

Internal work required to produce full compaction

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Tests to measure workability

Four widely used tests
Slump test Compacting factor test Vebe test Flow test

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Slump Test
Requirement
Slump Cone Tamping Rod

Ruler
Suitable for normal mixes of medium to high workability

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Slump Test (cont.)

Method
Concrete put in cone in 4 layer, each layer tamped 25 times Top struck off and cone carefully lifted off Slump measured

Not suitable for dry mixes

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Compacting Factor Test

Considered more sensitive Suitable for all mixes Method
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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Other Tests
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 Flow Test the measured spread in mm of a standard cone on a dropping table (40mm, 15 times) Neither of these are popular at site
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Other Tests (contd.)

Vebe Consistometer
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Flow Table
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Effect of time and temp. on workability

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Workability Requirements
Slump (mm) Concrete Construction Maximum Reinforced foundation walls and footings Plain footings, caissons and substructure walls Beams and reinforced walls 75 75 100 Minimum 25 25 25

Building columns Pavements and slabs

Mass Concrete

100 75
50

25 25
25

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Segregation
Segregation is defined as separation of the constituents of a heterogeneous mixture so that their distribution is no longer uniform It is a tendency for
sand-cement mortar to separate from coarse aggregates

Cement mortar to separate from fine aggregate

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Segregation (contd.)
Caused by
Excessive vibrations Dropping fresh concrete from a height Poor grading High workability Mixes with no air entrainment

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Bleeding
Tendency of water to rise to the surface
This will cause weakness or dustiness of the surface of finished concrete or a line of weakness between pours

Bleeding is affected largely by the properties of cement. It can be avoided by

A finer cement Reducing water cement ratio Increasing proportion of minus 300m in the mix Using air-entraining admixture
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Grading of aggregates
Proper grading of aggregates is required to get desired workability Though it is not affecting strength, it is required for proper compaction of concrete, which subsequently gives good strength Main factors governing desired grading are:
Surface area of aggregates which determine the amount of water necessary to wet all the solids
Relative volume occupied by the aggregates Workability of mix and tendency to segregation
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Grading of aggregates (contd.)

Grading curve for pumping concrete
100 80 60 40 20 0

% passing

m 13 m
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10 m

0. 3m

0. 07 5m

0. 15 m

0. 6m

1. 18 m

2. 36 m

Sieve size
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4. 75 m

20 m

Vibration of concrete
The purpose of compaction of concrete is to achieve highest possible density of concrete Types of vibrators Internal vibrators External vibrators Vibrating tables

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Heat of Hydration
The exothermic reaction during setting can cause a significant temperature rise in large concrete pours This causes expansion, then setting, then contraction If the pour is restrained, or has a temperature differential, cracking may occur

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Heat of Hydration (contd.)

The temp. of concrete has to be lowered so that the temp. differential between surface and core of concrete is not high Methods to cool concrete

Use of chilled water

Use of ice

Cooling aggregates
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Heat of Hydration (contd.)

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Air content in Fresh Concrete

Mixing and handling can significantly alter the air content of fresh concrete Various test methods:
Pressure Method
Volumetric Method Gravimetric Method

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Pressure Method
It is the most widely used method It is based on the relation between the volume of air and applied pressure

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Setting time of concrete

Initial Setting Time is the time elapsed after initial contact of cement & water required for mortar (sieved from concrete) to reach a penetration resistance of 3.43 N/mm2 Final Setting Time is the time elapsed after initial contact of cement & water required for mortar (sieved from concrete) to reach a penetration resistance of 26.97 N/mm2
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Setting time of concrete (contd.)

Initial Setting Time indicates that the concrete has become too stiff to be made mobile by vibration Final Setting Time indicates that the compressive strength of concrete measured on a standard cylinder is about 0.7 MPa

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Setting time of concrete (contd.)

The required force is calculated as the area of the needle used and the actual force is measured for a penetration of 25mm. For 0.16 cm2 needle F = 0.16 x 100 x 26.97/10 = 43.15 kg
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Curing
If left in contact with water, concrete will continue to gain strength for many months Otherwise all free water evaporates or is used up in the hydration process and no further hydration can continue Curing ensures that water for hydration is available as long as possible

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Curing (contd.)
Methods of curing Water curing (Immersion, Ponding, Spraying or fogging, wet covering) Membrane curing using curing compound Application of electrical curing) heat (steam curing,

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Properties of Hardened concrete

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Compressive Strength of concrete

Size of cube 15x15x15 cm Size of cylinder 15dia. x 30ht. cm Rate of loading 140 kg/sq.cm/min

Comp. Strength depends on the W/C Ratio

Strength is affected by the amount of pores in the concrete

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Split Tensile Test

Compressive load is applied along vertical diameter until failure Failure occurs along vertical dia. in tension T = 2P/LD
T= Tensile Strength P= Load at failure

L= Length of specimen
D= Diameter of specimen
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Flexural Strength Test

Standard size of specimen 15x15x70 cm For aggregate size less than, 20mm size of specimen 10x10x50 cm Rate of loading 400 kg/min for 15cm specimen

Rate of loading 180 kg/min for 10cm specimen fb=pl/bd2 fb=3pa/bd2

b= measured width of specimen d= depth of specimen l= length of specimen
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p= maximum load applied

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a<20cm but greater than 17cm for 15cm specimen or less than 13.3cm but greater than 11cm for 10cm specimen
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Creep
Creep is defined as the gradual increase in strain under sustained load

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Creep (contd.)
The magnitude of creep is affected by

More cement in mix more creep Higher w/c ratio more creep Higher relative humidity lower creep
Greater age lower creep

Rapid hardening lower creep

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Permeability and porosity

Permeability and porosity, though both relating to pore space in the concrete, are not necessarily related Both cement paste and aggregates contain pores, and in addition there may be voids due to incomplete compaction Cement paste is made up of gel and cement particles. The gel has about 28% pores in it, but a permeability of only about 7 x 10-6 m/s. also the cement paste has about 0 to 40% interconnected capillary pores, but the permeability is 20 to 100 times higher than the gel
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Permeability and porosity (contd.)

Effect of water cement ratio
140

m/s)
-14

120 100 80 60 40 20 0 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Perm. (10

w/c ratio
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Permeability and porosity (contd.)

Permeability test gives a measure of resistance of concrete against penetration of water exerting pressure Test carried at age of 28 to 35 days as per DIN 1048 Concrete specimen is exposed to a water pressure of 0.5 N/mm2 for 3 days constantly If water penetrates through to the underside of specimen, the specimen is rejected as failed
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Shrinkage
3 principal types of shrinkage
Plastic Shrinkage caused by settlement of solids and loss of free water from plastic concrete Autogenous Shrinkage cement gel has a lower volume than water and cement that makes it. So at a constant water content shrinkage takes place Drying Shrinkage loss of water from cement gel, after loss of water from pores and capillaries
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Carbonation
In presence of moisture CO2 present in air reacts with Ca(OH)2 to form CaCO3 Carbonation causes the reduction in pH of pore water from between 12.6 to 13.5 to about 9 Steel embedded in concrete forms a thin passivity layer of oxide which remains only with high pH As the pH reduces the oxide layer is removed and the corrosion of steel starts, its volume increases and creates tensile stresses in concrete
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Carbonation (contd.)
Equipment Phenolphthalein solution Spray solution on freshly exposed concrete Will turn pink where alkali is present Limitations Phenolphthalein turns pink at pH 9, but depassivation can take place at pH 11 Surface must be freshly exposed
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Sulphate attack
Common sulphates present in soil and ground water are sodium, potassium, magnesium, calcium Sulphates present in solution react with hydrated cement paste Sodium sulphate attacks Ca(OH)2 and gypsum is deposited. Ca(OH)2 can also be completely leached out Magnesium sulphate attacks calcium silicate, calcium aluminate hydrates & also Ca(OH)2
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Sulphate attack (contd.)

Calcium sulphate attacks calcium aluminate hydrate (C3A) forming ettringite Ettringite formed has a higher volume and causes expansion in concrete Preventive measures Use cement with less C3A content i.e, to use sulphate resistant cement Reduce the quantity of Ca(OH)2 by using ash or GGBS
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Fly

Sulphate attack (contd.)

Specimens are stored in solution of sodium or magnesium sulphate and subjected to alternate wetting and drying This accelerates the damage due to crystallization of salts in the pores of concrete The effect of exposure can be estimated by the loss in strength of specimen

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Chloride attack
The primary action in chloride attack is the corrosion of steel and consequently damage to surrounding concrete As long as the oxide film on steel is present, the steel remains intact Chloride ions destroy the film and in presence of water and oxygen corrosion occurs Corrosion does not occur in dry or fully submerged concrete, but occurs in alternate wetting & drying and in relative humidity of 70-80%
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Chloride attack (contd.)

Chlorides can be present in concrete through use of contaminated aggregates, sea water or chlorides in admixture I.S. code states that total chloride content in cement should not be exceed 0.05% by mass of cement I.S. 456-2000 states that total chloride content in concrete should not exceed 0.4 & 0.6 kg/m3 for prestressed and reinforced / plain concrete containing embedded metal respectively
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Alkali-Aggregate Reactivity
Reaction between active silica constituents of aggregates and alkali in cement forms alkalisilicate gels in planes of weakness or either in pores or surface of aggregates

The reaction starts with attack on siliceous minerals in aggregates by alkaline hydroxides in pore water derived from the alkalis (Na2O or K2O) in cement
This gel is of unlimited swelling type, absorbs water and causes increase in volume
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Alkali-Aggregate Reactivity (contd.)

I.S. 2386 Part VII states two tests for determining the potential reactivity of aggregates: Mortar Bar Test Chemical methods

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Estimation of actual structure

Extracting cores from actual structure Visual inspection Testing compressive strength Correlating to corresponding cube strength Schmidt hammer is used to evaluate strength of a structure Ultra sonic pulse velocity meter is used to evaluate the presence of cracks, voids in the interior of concrete.
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Estimation of actual structure

Schmidt Hammer
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Ultra sonic pulse velocity meter

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Thank you

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