Concrete

Introduction

concrete

Constituents

Mixture of Aggregate and Paste

Paste 30 40%

Portland cement 7- 15% by volume

Water 14 to 21% by volume

Aggregate 60 -70%

Coarse aggregates

Fine aggregate sand

Admixtures

concrete

Initially plastic material

Takes shape of mould or formwork

Hardened

Dense

Loadbearing

Lightweight

Thermal insulating

Properties depend on aggregate used

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Concrete

Cements

Ordinary Portland Cement

90% all cement production

Heat limestone and clay
 Clinker
 Add 5% gypsum CaSO4
 Regulates rate of setting

concrete

Cements

Dry powder of very fine particles

Forms paste when mixed with water

Chemical reaction hydration
 Rate which water is absorbed

Paste coats all aggregates together

Hardens to form solid mass

concrete

Aggregates

Cheap fillers

Hard material

Provide volume stability

Reduce volume changes ( shrinkage)

Provide abrasion resistance

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concrete

Aggregates

Most variable material in concrete

Grades affect amount of water required

Fine grade more water

Coarse grade - less water
 Same degree of workability

Sharp edged rough surface

More water than smooth rounded particles
 Same workability

concrete

Aggregates

Sharp edged rough surface

Increase cement content crushed aggregate

 To allow water to be added

Crushed aggregate
 Higher strength
 Same water cement ratio

Max size aggregate cement content

Same workability same water/ cement ratio

Larger surface area to be wetted , smaller aggregate

size

concrete

Aggregates

Proportion fine / coarse aggregate

Obtain required workability
 Minimum water required

Bad proportion
 More water for adequate workability
 Low strength
 Poor durability

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concrete

Water

Needed for 2 purposes

Chemical reaction with cement

Workability

of water needed for chemical reaction

Extra water in holes or pores

Porosity how porous

Ratio of volume of holes to total volume

concrete

Water

Good for preventing

plastic shrinkage

Cracking

Bad for

Permeability

Penetrates substrate filling holes

Strength

durability

concrete

Water

Avoid variation in quality or quantity

Water / cement ratio

Most important for consistent strength

Use minimum necessary for full compaction

Quantity

Absorption by dry / porous aggregates

Free surface water of wet aggregates

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concrete

Admixtures

Added to concrete during mixing

Modify one or more of its properties

Set retarders

Set accelerators

Water reducing / plasticisers

Air Entraining

concrete

Admixture

Set retarders

Decrease rate of set

Dont affect 28 day strength

Extend workable life of ready mix to 36 hrs

Phosphates

Hydroxycarboxyic acid

concrete

Admixtures

Set Accelerators

Increase rate of reaction

Increase rate of set

Advantageous in pre-casting
 Early removal of formwork
 Reduce frost damage

Chlorine free
 Calcium formate
 Chlorine attacks reinforcement

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concrete

Admixtures

Water reducing plasticisers

Increase workability

Easier placing and compaction

Used to reduce water / cement ratio

 15% strength increase

 Increase in durability

Lignosulfonates

Hydroxylated polymers

concrete

Admixtures

Air- Entrained

Stabilise air bubbles

Bubbles improve workability

Reduce segregation

Enhance frost resistance

Decreases crushing strength

 6% for 1% air entrained

Wood resins

Synthetic surfactants
 Fairy liquid

concrete

Concrete mixes

Essential properties of hardened concrete

Durability

Strength

Both affected by voids

Complete compaction

Excessive water

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 concrete

Concrete mixes

cement water/cement ratio

More durable

Greater strength

Mechanical compaction

Drier

Stronger

More durable

Mixes can be designed to reach full strength

concrete

Concrete classifications

Designed mixes

Strength main criterion

Strength tested

Cement content specified for durability

Supplier responsible

Prescribed mix

Cement content / mix proportions given

Specifier responsible

Lowest grade for compliance with appropriate use

Grade Strength N/mm2

7 7.0 Plain concrete

10 10.0 Plain concrete
15 15.0 Reinforced concrete lightweight aggregate

20 20.0 Reinforced concrete dense aggregate

25 25.0 Reinforced concrete dense aggregate

30 30.0 Concrete with post tensioned tenons

40 40.0 Concrete with pre tensioned tenons

50 50.0 Concrete with pre tensioned tenons

60 60.0 Concrete with pre tensioned tenons

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concrete

Control of Quality

Fresh concrete

Workability

Ease of placement

Resistance to segregation

Homogeneous mass

Consistency

Ability to flow

concrete

Control of Quality

Fresh concrete

Slump test

Vebe consistomer test

Hardened Concrete

Cube crushing test at 7 and 28 days

concrete

Concrete properties

Strength

Increases with age -hydration drying out

Compressive strength

Possible most important

Good in compression

High strength
 Nature of aggregate important
 Good control of operations

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concrete

Concrete properties

Resistance to weather and chemical attack

Durability permeability

concrete

Practical Concreting

Batching

Measure proportions of materials correctly

Extremely important

Mixing (Mechanical preferred)

Thoroughly

Uniform colour and consistency

 Coarse aggregate
 Cement
 Fine aggregate
 Water

Low workability extend mix time

concrete

Practical Concreting

Transporting Placing Compacting

Dont cause delay or segregation

Prevent rain increasing water content

Formwork treated release agent

Remove foreign matter before placing concrete

 Wood shavings, nails dirt water

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Concrete Transporting
HORIZONTAL MOVEMENT

Barrows Used for small quantities transported over short distances.

Wheelbarrows hold 30 litres or 0.03 m3. Power barrows hold 150 litres
or 0.15 m3 of wet concrete. Runs need to be smooth and well
constructed.
Dumpers Used to transport 0.5 m3 per journey. Care has to be taken when
discharging smooth runs needed to prevent segregation.
Lorry Mounted Hoppers Capacity 2-3 m3 used on large contracts. Hopper uses hydraulic
tipping runs and can be fitted with mixing paddles.
Tipper Trucks Open trucks with tarpaulins to protect concrete from rain or sun.
Ready Mix Lorries Ideal method of transporting concrete from batching plant to point of
discharge. Access roads must be provided.

VERTICAL MOVEMENT

Buckets and Skips Skips and buckets moved by crane with skips discharged from the
bottom and buckets tipped. Capacity from 0.5 m3 to 6 m3.
Conveyor Belts Not used regularly over the past few years. Most likely to be seen
mounted on some truck mixers to allow discharge where chutes are
not long enough (normally 10 m of conveyor).
Hoists Used on tall buildings to transport concrete in containers such as
barrows.
Pumping Pumps are convenient for moving concrete on sites. They can be
static or mobile and have the capacity to move large amounts of
concrete. Normal coverage is 50 m vertically and 100 m horizontally.
Pumps can deliver 30 m3 per hour.

Concrete placing

Practical Concreting

Placing

Compact while placing

Minimise air voids

Less than 1m high
 Avoid segregation

Concrete compacting

Practical Concreting

Compacting

Bonds to reinforcement better

5% air voids vol = 30% reduction compressive strength

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Concrete

Mechanical Vibration

Internal -Poker

A cylindrical vibrator
connected to a motor by
a flexible drive shaft,
diameters ranging from
25-75 mm. Concrete
should be placed in
layers of 300-500 mm
depending on the length
of poker used. Care
must be taken not to
touch reinforcement as
this will result in de-
bonding between the
reinforcement and the
surrounding concrete.

Concrete compacting

Practical Concreting

Mechanical Vibration

External (Clamp On)
Vibrators
 Motors which are
designed to vibrate
are clamped to the
formwork allowing
the formwork to
vibrate the
concrete. Often
used in pre-cast
work. Formwork
must be designed
and constructed to
resist the constant
vibration.

Concrete compacting

Surface

Beam vibrators

Designed for use on
concrete slabs which are
too thick for hand tamping
(over 100 mm), the beam
vibrator is made up of a
metal beam with a clamp
on vibrator fixed to the top.
The need for level side
forms that will not move
when the vibrating beam is
used is essential. The
beam is pulled along the
side forms and will leave a
flat level surface on the
floor slab.

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Concrete curing

Practical Concreting

Curing

Concrete hardens by reaction between cement and

water

Shrinkage occurs internal moisture loss

Minimise cracking

Cover with waterproof sheet

Spray on membrane

Practical Concreting

Curing
METHOD OF CURING WEATHER PROTECTION COMMENTS
Covering concrete with Protects from mild frosts Care must be taken to ensure concrete is
damp sand or hessian and light rainfall dry enough to prevent marking or
contamination when surface is covered
Ponding flooding of the Protects from sun and wind Freezing could cause damage to
surface with water surfaces
Spraying water sprayed None Labour intensive, continual spraying
on surface could cause damage if not carefully
controlled
Sheet polythene retains Protects from all forms of Placed as quickly as possible on a frame
moisture in the concrete weather damage if surface is likely to be damaged. Sheet
weighted at edges preventing wind under
sheet. Tape joints between sheets when
curing slabs
Sprayed compounds Provides protection from Resins have to be applied carefully in
resin sprayed on to rain and wind when dry order to ensure they work properly.
concrete surfaces to form a after application Designed to degrade without effecting
protective skin sealing in concrete after the curing period
moisture

concrete

Pre-cast concrete

Cast

Vertically

Horizontally
 Most common
 Face up
 Face down
 Better quality
control

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concrete

Pre-cast concrete

Moulds

Plywood
 More complex forms
 Modify to non standard units

Steel
 More durable repeated use

Designed for dismantling
 Tight tolerances = quality control

Concrete moulds

concrete

Pre-cast concrete

Moulds

High initial cost
 Limit variations

Fixing and lifting

systems

Incorporated into
units

In conjunction with
reinforcement

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