Concrete and Concrete Products: Group 3 // Bsar - 1B
Concrete and Concrete Products: Group 3 // Bsar - 1B
Concrete
- An artificial, stone-like building material made by mixing cement and various mineral
aggregates with sufficient water to cause the cement to set and bind the entire mass
- Widely used for construction for centuries because of reasonable cost and
convenience.
- Structures that use concrete are durable and are designed to face earthquakes,
hurricanes, and typhoons.
Cement
- A binding agent that sets and hardens to adhere to building units such as stones, bricks,
and tiles.
- Fine powdery substance
Aggregates
- Raw materials that are produced from natural sources and extracted from pits and
quarries, including gravel, crushed stone, and sand.
Admixtures
- These are chemicals or additives in concrete other than cement, water, and aggregates
- Used to enhance specific properties of the fresh or hardened concrete
Sieve
- Are used at construction sites to separate pebbles and stones from sand. These are also
used to separate fine particles from bigger impurities.
Setting
- Is the stiffening of the cement paste, where the concrete becomes sufficiently rigid to
withstand a certain amount of pressure but still contains moisture within the mixture
- Transformation from liquid to plastic state and solid state of the cement
Hardening
- Happens after the setting state
- Where the mixture gains strength
Curing
- Involves maintenance of desired moisture and temperature conditions, both at depth and
near the surface
- Properly cured concrete has an adequate amount of moisture for continued hydration and
development of strength
Harmful Impacts
BUILDING TECHNOLOGY I MODULE 4
MATERIALS OF CONSTRUCTION CONCRETE AND CONCRETE PRODUCTS
- Since the cement industry is one of the main producers of carbon dioxide. The
production process for cement produces large volumes of greenhouse gas emissions
- Other concerns include widespread illegal sand mining which causes urban heat effects
and several health implications. Because of this significant research and development is being done to
try to reduce the emissions.
Cultures across the globe have used concrete and concrete-like substances to build, since the
material has changed over the years.
The earliest uses of concrete in construction are the following:
Buildings
Floors
Bridges
Roads
Sculptural structures
The time period during which concrete was first invented depends on how one interprets the
term “concrete.” This timeline shows how cultures have used concrete throughout the years;
6500 B.C.
o Nabatea traders, or Bedouins, created these historical concrete structures in modern-
day Syria and Jordan. They created concrete floors, housing structures, and
underground cisterns.
3000 B.C.
o Egyptians used mud mixed with straw to bind dried bricks. They used a concrete-
like material in the construction of the pyramids.
o Chinese invented their own “concrete” using sticky rice. They produced another
form of “mortar” to build the Great Wall of China.
600 B.C.
o Ancient Romans weren’t the first to create concrete, they were first to utilize this
material widespread. By 200 BC, the Romans successfully implemented the use of
concrete in most of their construction.
o The Pantheon has the largest unreinforced concrete dome ever built.
1300 B.C.
o Middle Eastern builders used a thin damp layer of burned limestone as a coating on
pounded-clay home walls. This coating formed a hard-protective layer.
TECHNOLOGICAL MILESTONES:
1414
o The collapse of the Roman Empire made the interest in concrete dormant until
manuscripts explaining the substance resurfaced during this year. Then came a new
appreciation for the building material.
1793
o The technology took a big leap forward when John Smeaton discovered a more
modern method for producing hydraulic lime for cement. It is used in historic
rebuilding of the Eddystone Lighthouse in Cornwall, England.
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1824
o Joseph Aspdin invented Portland cement by burning finely ground chalk and clay
until the carbon dioxide was removed. His goal is to create a better alternative to the
Romans’ building material.
19th Century
o For industrial buildings, concrete was typically used.
o Between 1850 and 1880, Francois Coignet used Portland cement extensively for the
first time in the construction of homes in England and France. He added steel rods to
stop the external walls from expanding.
C. CHARACTERISTICS/PROPERTIES
BINDING MATERIAL
o Cement - is a fine gray powder that is mixed with water and other substances
to make mortar or concrete. It is a key binding material used in both
residential and commercial construction work.
Types of Cement
Type I – (Portland cement)
o It is the most common cement and is a binding material in the form of a finely
ground powder, usually gray, that is manufactured by burning and grinding a
mixture of limestone and clay or limestone and shale.
Type II – (Moderate Sulphate Resistance Portland Cement)
o This type of cement is used where precaution against moderate sulphate attack is
important.
Type III – (Rapid Hardening Portland Cement)
o It is used where formwork is to be removed quickly or sufficient strength for
further construction is required. It has high heat of hydration and achieves its
design strength in 7 days or less.
Type IV- (Low Heat Portland Cement)
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oThis type of cement is used in mass concreting because it generates less heat,
though sets slowly but becomes much stronger after curing. Its design strength is
90 days.
Type V - (High Sulphate Resisting Portland Cement)
o When concrete is exposed to highly alkaline soil or water having high sulphate
content then this type is used. This cement has a low C3A content to avoid
sulphate attack from outside the concrete.
AGGREGATES
o These are raw materials that are produced from natural sources and extracted
from pits and quarries, including gravel, crushed stone, and sand.
Classifications of aggregates
- Coarse aggregates
o Crushed stone, crushed gravel or natural gravel
o Particles retained on a 4.75mm sieve
- Fine aggregates
o Crushed stone, crushed gravel, sand or natural sand
o Particles pass through 4.75mm sieve
WATER
o Needed to chemically react with the cement (hydration) and to provide
workability with the concrete. The amount of water in the mix in pounds
compared with the amount of cement is called the water/cement ratio. The
lower the w/c ratio, the stronger the concrete. (higher strength, less
permeability)
Concrete mix ratios are the proportions of concrete components such as cement, sand,
aggregates and water. These mix ratios are decided based on the type of construction and mix designs.
o Offer simplicity and under normal circumstances, have a margin of strength above
that specified.
o 1:2:4 for M15 (1-part cement, 2 parts sand, and 4 parts aggregates)
- Standard Mixes
o Nominal mixes of fixed cement-aggregate ratio vary widely in strength and may
result in under or over-rich mixes. Because of this, the minimum compressive strength has
been included in many specifications.
- Designed Mix of Ratio
o Specified by the designer but the mix proportions are determined by the producer
of concrete.
o Most rational approach to the selection of mix proportions with specific materials
in mind possessing more or less unique characteristics
o Does not serve as a guide since this does not guarantee the correct mix proportions
for the prescribed performance
Water proportions
The strength properties of the concrete are inversely proportional to the water-cement ratio.
More water in concrete mix proportions, the weaker the cement’s strength and adhesive strength.
Ideally, the least amount of water possible is the best if strong adhesion is a high priority. But there
are times where workability is a higher priority than structural integrity and water is the secret to
workability.
c. Concrete strength
Concrete is the foundation of modern construction. It may be the ability of the concrete to
respond to circumstances it may be put up with. Although compressive strength is the prominent
concrete specification, tensile, flexural, and other properties can play a significant role in modern
designs.
- Compressive Strength Compressive
o the most common and well-accepted measurement of concrete strength.
o It is the main criteria used to determine if a given concrete mixture can
withstand the structural forces being applied. Compressive strength is the
"nameplate" concrete rating. It is the most common attribute cited in construction
specifications.
- Tensile Strength
o defines concrete’s ability to resist breaking or cracking under tension. It
affects crack formation and the ability of certain members, such as horizontal
beams, to withstand transverse loading and the resultant "pulling" forces that
effectively act to pry open the concrete transition zones (which consist of the
cement/binder that holds aggregates in the matrix). Cracks occur when tensile
forces exceed the tensile strength, which is measured in psi.
- Flexural Strength
o is an indirect measure of tensile strength. Flexural strength defines an
unreinforced concrete slab or beam’s ability to resist failure in bending. As
concrete bends, it incurs tensile stresses that eventually result in failure
(cracking).
d. Concrete tests
BUILDING TECHNOLOGY I MODULE 4
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Slump test
o To determine the workability of concrete
o After batching the concrete, a sample of fresh concrete shall be taken to test for slump
tests and the samples for compressive strength test be taken too. This is to make sure
that the batched concrete is complying with the mix design before it’s released from
the batching plant.
Compressive strength test
o Performed by breaking cylindrical concrete specimens in a compression-testing
machine
o Three samples of cubes or cylinders shall be taken for compressive strength test, but
it is not commonly three samples, sometimes it is two depending on the specification.
o This one sample extra shall be tested “if” The two cubes or cylinders samples are
tested from the three and if it is failed and the remaining sample is passed. If the
consultant is not satisfied with the result and he wishes to test the extra one. It shall
be tested in 60 days.
Water Permeability test
o To determine the durability of concrete
o Three cubes shall be taken from fresh concrete and tested in accordance with the
German Standard DIN 1048 at 28 days age.
o This kind of test shall be taken from substructures concrete elements like foundations,
concrete water tank, retaining wall, etc.
Rapid Chloride Ion Penetration Test
o Used to evaluate the resistance to penetration of concrete to chloride ions
o Like water permeability test, this is also one of the tests to determine the durability of
concrete. Three cubes shall be taken from fresh concrete delivered on site and tested
at 28 days age. The test shall be done in accordance with ASTM C1202-97.
Water Absorption Test
o Here is the other test that would determine the durability of concrete. The three cube
samples shall be taken from the delivered fresh concrete and kept it in the curing tank
for 28 days or after 24 hours the concrete sample would be demolded and it will be
sent directly to the approved third-party laboratory to ensure its curing. The size of
the cube sample is 150 mm and tested in accordance with BS 1881-122.
e. Concrete additives/admixtures
Set-Retarding Admixture
o Used to delay the chemical reaction that takes place when the concrete starts the
setting process. These types of concrete admixtures are commonly used to reduce the
effect of high temperatures that could produce a faster initial setting of concrete.
Air Entraining Admixture
o Used to improve workability, ease of placing, increased durability, better resistance to
frost action and reduction in bleeding
Accelerating Admixtures
o Accelerating concrete admixtures are used to increase the rate of concrete strength
development or to reduce concrete setting time.
o It provides higher early strength development in freshly cast concrete.
BUILDING TECHNOLOGY I MODULE 4
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D. CONSTRUCTION USES
Classification of aggregates
a) Natural aggregates - found in the natural sources like river basin, sea bed, slope deposits
b) Manufactured aggregate - formed by crushing the various rocks obtained from quarries
c) Artificial aggregate - made up of various waste materials. Examples are burnt clays, artificial
cinders, steel rivet, iron ore etc.
d) Recycled Aggregate - is manufactured by crushing inert construction and demolition waste
Aggregate Tests
Impact Test
o Used to measure the toughness of aggregates which is nothing but the ability of
aggregates to resist the sudden loading or impact loading.
Crushing Test
o It is to test the aggregates’ crushing value.
o Aggregate crushing value is a relative resistance of aggregates to crushing under
gradually applied compressive load.
Abrasion Test
o It is to measure of aggregate’s toughness and abrasion resistance such as crushing,
degradation and disintegration.
Soundness Test
Specific Gravity and Water Absorption
o These two parameters or properties of aggregate play an important role in the mix
design of concrete.
o Specific Gravity is defined as the ratio of the weight of a given volume of aggregate
to the weight of an equal volume of water. It is usually used for the identification of
stones or aggregates.
o Water absorption of aggregates is the water absorbed by an air-dried aggregate when
immersed in water for 24 hours.
b. Mixing of concrete
Concrete mixing is a process of mixing the ingredient of concrete such as cement,
sand, aggregate, water, and admixture together to make concrete of suitable grade.
Production of good quality and bad quality concrete includes the same material, but the
proportion and mixing method can be a differentiating factor. It requires proper care and knowledge
for making good quality concrete.
Mixing Time
From the results obtained & following observations it was concluded that the workability,
compressive strength of concrete is higher when the mixing time is within 4 to 7 minutes.
c. Placing of concrete
d. Setting of concrete
Setting is the process a concrete mixture goes through being a liquid mixture to gaining a
certain stiffness.
Hardening Process
When the properties of concrete (cement, aggregate and water) are brought together, the
cement and water chemically react and eventually set to form a hard mass which adheres to and binds
together the aggregates to form concrete. Setting takes time, approximately two hours after which the
hardening process (strength development) can be irrecoverably damaged by re-working.
Generally speaking, concrete will reach a useful strength in about 3 days although this does
depend on the mix design and constituent materials. The majority of strength is gained within a
month. It is important to remember that concrete will reach its maximum strength only if moisture is
present during the hardening process.
The hardening process is therefore not dependent on the concrete ‘drying out’, and it is
normally important that the concrete is properly ‘cured’ to maintain the moisture in the concrete
(especially at vulnerable surfaces) while the cement water reaction is active. Early loss of moisture
will cause a reduction in strength and lead to poorer durability.
Curing Process
o is the process of maintaining satisfactory temperature and moisture conditions in concrete
long enough for hydration to develop the desired concrete properties.
o Plays an important role on strength development and durability of concrete.
Curing takes place immediately after concrete placing and finishing, and involves maintenance of
desired moisture and temperature conditions, both at depth and near the surface, for extended periods
of time. Properly cured concrete has an adequate amount of moisture for continued hydration and
development of strength, volume stability, resistance to freezing and thawing, and abrasion and
scaling resistance.
Hydration of cement takes time—days and even weeks rather than hours—and curing must
be done for a reasonable period of time if the concrete is to achieve its maximum potential strength
and durability.
It is also important to cover the slab with a waterproof membrane before backfilling to
prevent moisture loss and to have extra protection against any chemicals in the soil.
Sealers are recommended to be applied since they help prevent water intrusion, improve
weathering resistance, reduce surface dusting, and minimize ultraviolet ray degradation.
Types of sealers
a) Water-based sealer
o Has the benefit of water dilution and clean up, good durability, low odor (VOCs) with
improved hardness and flexibility.
o The polymer particles are dispersed in water. When the sealer is applied to concrete,
the water evaporates and the polymer particles move closer together. As the
evaporation of water continues, the polymer particles begin to deform and fuse
together, eventually forming a continuous, clear coating.
b) Solvent-based sealer
o Protects and enhances the surface and color of your concrete whilst providing
protection from the elements.
BUILDING TECHNOLOGY I MODULE 4
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o The polymers are not present as separate particles. Instead, the polymer and solvent
form a continuous, clear polymer solution. When solvent evaporates from a solvent-
based sealer, the polymer chains are drawn closer together and eventually entangle.
For both water- and solvent-based sealers, the polymer remains on the concrete
surface. This is why a sealed concrete surface often appears glossy.
o This kind of sealer is the most popular sealer used on concrete driveways, paths, patio
areas and pool surrounds.
c) Superior-grade sealer
o Can be used on all surfaces—from domestic applications, such as driveways, internal
flooring and garage floors, to industrial projects.
d) Penetrating concrete sealers
o Penetrates deeply into the surface and protects against water absorption.
o It helps repel oil and organic-based stains, and will not change the appearance of the
surface, leaving it with a natural look.
A concrete expansion joint – or control joint – is a gap which allows the concrete to expand
and contract as/when the temperature changes. It forms a break between the concrete and other parts
of a structure to allow movement without causing stress, which can lead to cracking.
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MATERIALS OF CONSTRUCTION CONCRETE AND CONCRETE PRODUCTS
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BUILDING TECHNOLOGY I MODULE 4
MATERIALS OF CONSTRUCTION CONCRETE AND CONCRETE PRODUCTS
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