Multicolour Illustrative Edition TIIEOIW nunPnncrlci M.S. SH ETTY BE, ME, FICI, FIIBE,FIE, MACCE Technical Advisor, MC Bauchemie (Ind) Pvl. Lld. Principal Technical Consultant, Grasim Industries, Ltd. Consullanl lo IMCC Delhi Metro Corporation Formerly Senior Prof. and Head of Deparlmenl of Conslruclion Engineering College of Military Engineering (CME), Pune Ministry of Defence -0V "'V" S. CHAND & COMPANY (An ISO 9001 : 2000 Company) Ram Nagar, New Delhi - 110 055 LTD. _._ S.CHAND & COMPANY LTD. 4%,. (AnISO9001: 2000Company) -§f Head Ofce : 7361,RAM NAGAR, NEWDELHI 110 055 'V" Phones : 236720808182; Fox: 91-1123677446 Shop 01'! schandgroup.com Emoi|: Branches schand@vsnl.com : '' 1sr Floor, Heritage, Neor Gujoroi Vidhyopeeih, Ashram Rood, Ahmedabad-380 014. Ph. 27541965, 27542369 ° No.6, Ahujo Chambers, 1st Cross, Kumoro Krupo Rood, BangaIore560 001. Ph : 22268048, 22354008 ° 152, Anna Soloi, Chennai-600 002. Ph : 28460026 ° S.C.O. 6, 7 & 8, Sector 9D, Chc1ndigc1rh160017,Ph2749376, 2749377 0 1sr Floor, Bhorrio Tower, Bodombodi, Cuack753 009, Ph2332580; 2332581 ° 1st Floor, 52-A, Rojpur Rood, Dehradun-248 011. Ph : 2740889, 2740861 Pan Bozor, Guwahati-781 001. Ph : 2522155 Sultan Bozor, Hyderabad500 195. Ph : 24651135, 24744815 Moi Hiron Gore,Jc1landhar- 144008 . Ph. 2401630 613-7, MG. Road, Ernokulom, Kochi682 035. Ph : 2381740 285/J, Bipin Bihc1riGcIngu|iSrreer, Kolkata-700 012. Ph : 22367459, 22373914 Mohobeer Market, 25 Gwynne Rood, Aminobod, Lucknow226 018. Ph : 2626801, 2284815 Blockie House, 103/5, Wolchond Hirochond Morg, Opp. G.P.O., Mumbai400 001. Ph : 22690881, 22610885 ° 3, Gandhi Sogor East, Nagpur440 002. Ph : 2723901 ° 104, Citicentre Ashok, Govind Mitro Rood, Patna-800 004. Ph : 2300489, 2302100 >238:A 1v1_p. Ngxgqrg 1zohe.1t 03n6pq1,e4<:2[1o1~, _Ph:.52747f23 3 , V_ L 1 V , 4e.J.oIrf1,1qIS1iore Shop gC p1e;g,.u.g1veis1ygmgrgr Hopi} 'Nc1gq qipggur so ,015,[ iéhoynei;I0141-2709153: 223 _ © 1982, M.S. Shetty All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the Publisher. First Edition 1982 Subsequent Editions and Reprints 1986, 88, 89, 91, 94, 95, 96, 97, 98, 99 2000, 2001, 2002, 2003, 2004 Reprint with Corrections 2005 Firs1MuI1icoIour Illustrative Revised Edition 2005 ISBN : 81 -21 900034 PRINTED IN INDIA By Rdjendro Rdvindrd Printers (Pvt.) Ltd., 7361, Ram Nogor, New DeIhi1 10 055 and published by S. Chond & Company Ltd. 7361, Ram Nogor, New DeIhi1 10 055 Dedicated To MyBeloved Father V. VENKAPPA (iii) SHETTY (iv) FOREWORD s one who has cbsely watched the author's interest and involvement in concrete technobgyforthe past severalyears, Ihave greatpleasure in writting this foreword. te is by far the most w idely used construction material today. The versatility and moug ofthis materialitshgh compressive strength,andthediscovery of the and prestressingtechniqueswhich helped to makeup for its bw tensile strength have contributed largely to its widespread use. We can rrghtly say thatwe are in the age ofconcrete. It is easy to make concrete. cement make good concrete. There is an okl saying that broken But the same proportion of broken stone, sand, and stone, sand and cement also make bad concrete. This ismainly because the quality ofthe endproduct depends as much, and perhaps more, on the man on the job as on the constituent materials. The difference between good concrete and bad concrete lies in quality control Extensive research workwas, therefore, carried out alrnostfrom the beginning ofthis century not only on the materials but also on the methods used for concrete making. Sti, notmany men on thejob seem to make use ofthe known techniquesfor making good concrete which isnecessaryforachieving strong, durable, and economical construction. This textbook by Prof M.S Shetty will, therefore, help to generate a betterawareness ofthe potential ofconcrete. The book deals with several aspects ofconcrete technobgy and also covers the latest devebpments that have taken place in India and abroad. The coverage is comprehensive and complete. The properties ofthe constituent materials ofconcrete have been explained very lucidly in the text. The information on admixtures and on special concrete, engaged concretes, such as air-entrained concrete, vacuum concrete, light-weight andgap-graded concrete, wibe very useilto concrete engineersand those in precast concrete construction. At many places in the text, the author touches upon some important, down-to-earth problems andgivesspecic datwns based on hisown knowledge and vastexperience. The chapteron gives simple and scwntific concrete technobgists. One ofthe welcome procedures features ofthis for the benet ofpractising book is the inclusion recommenmix design engineers ofdetaikd and information on recent devebpments relating to fibre-reinforced concrete, sulphur-impregnated concrete, and different types ofpolymer concrete. The author has hghlighted the potentialofthese new materials and has laidemphasison the needforfurtherresearch. The text has been written in simple language and is supplemented by numerous iustrative examples, charts, and tables. The authorhas succeeded inpresenting allthe relevant information on concrete technobgy in a very effective manner. book wi be we received by students ofconcrete technobgy as we engineers and research workers. Iam sure the as practising M. RAMAIAH Director 6lructurulE}zgv'zee Iksearch Centre 11/adras (Vi) A ACKNOWLEDGMENTS I ihatmademeinterestedin concretetechnobgywasmyassociation with Shri M.R Vinayaka ofAssociated CementCompany, whenhe wasworkingat fl Kryna Dam ConcreteResearchIaboratory. My interestwas further en. iedlwhlle teachingthis fascinatingsubjectto the graduate and postgraduate H studentsat the Coege ofMilitaryEngineering.Iam gratefulto them. Igratefully acknowledge thefoowing institutwnsand societiesin thereproduction ofcertain tables, charts and information The American Cementand Concrete Institute, Concrete Association, in my book: the American the Portland Socwtyfor7esting CementAssociation, and Mate rials, the the Institute ofCivll Engineers, Iondon, Department ofMines, Ottawa, Canada, the Concrete Association oflhdia, the CementResearch Institute oflhdia, the CentralBul7ding Research Institute, Roorkee, the Structural Engineering Research Centre, Madras, the Central Road Research Institute, Delhi, and the Bureau oflhdian Standards. A book of this nature cannot be written without the tremendous background information made available by vario usresearch workers, authorsofexceentbooksand artwkswhich have been referred to and listed at the end ofthe chaptersand at the end ofthis book Ialso Engineering this book. Iam thankful to them. wish to express my sincere thanks to the Commandant, forextending afacllities My specialgrateilness going through Coege and words ofencouragementwhik is due to Srnt. Brinda Balu and Dr. Balasubramanian the manuscript with such diligence as to bring it into the present My special thanks are due to Dr. M. Ramaiah, Director; Structural Research Centre, Madras, who obliged with aforeword to this book. Iastly Iam grateful publishing this book. Pkzce:Pune, ofMllitary working to M/s S Chand and Co., Itd., 1982 (vii) for state. Engineering for taking the responsibility M.S. on SHETFY of (viii) PREFACEjTO THE SIXTH J iivesme immense pleasure thatthe bookrstpublished EDITION in 1982, has seen more than 25 reprints. The popularityofthis bookamongststudentsandpracticmgengineershasgivenmethe encouragement revise thisbooktomakeitmoreusetlto them.Theproposalandencouragementgiven byofficers Chand& Company to bringthisSixthEditionin multicoburshouhlmakethebookmoreusefuland [attractive V Concrete technology is becoming a majorbranch ofcivilengineering.1tis becoming the backbone ofm/rastructural developments ofe very country. E has made tremendous advancement in the western and the eastern world. Tho ugh Indiaislagging behind, we are catching up fastwith the restofthe world. E can be recalled that in the preface to the fast edition (1982) Ihad mentioned that the cement production in India w as 22 miion tons. This was abo ute ght decades aerwe first started manufacturing Portland Cement (1904). Eisheartwarmmg to note thatin the subsequent two decades aer 1982 ie. in2004, the productionofcementhascrossed120 miion tons. Tbdaywe are the second hrrgestproducer ofcement in the world, only behind China. The quantity ofconcrete and othercementproducts made, utising over120 million tons ofcement to caterforthe tre mendo us inastructural de velopment that is taking place in the country, is making the concrete industry one ofthe bggestm monetary terms. Western and Eastern co untrieshave been making concrete ofstrength M40, M80, M100 and o ver. In the rece ntpast, we in India have started using concrete ofstrength M30, M50 and even M75. We have a bng way to go to learn andpractice the artand science ofmakmg Hgh Performance Concrete (HPC)yet. The recentrevision ofB456, code ofpractice forplain and reinforced concrete isguidmg concrete technologists to make strong and durable concrete. Ihave grown olderby twenty three years since Iwrote the first edition. During these 23 years and especiay in the last15years, Ihave had opportunitiesto delive rnumero uslecture s, training site engineers, co nductmg trials at large project sites, througho ut the co untry which has made me once again a student ofconcrete technology and motivated me to revise this book. Majorrevision has been carried out in Fifth and Sixth Edition. Tbpics, such as blended cements, use ofadmixtures and theiruse, field trials to nd outtheb'suitability, compatrbity and dosage, RMe, pumping of concrete, latest methods mix design step by step, and extensive unconventional deliberation on durability, have been included. Another specialfeature of this &xth Edition is the inclusion of»%IF COMPACTWG CONCRETE a revolutionary method ofconcrete construction. This innovative method which isfound only injoumals and seminarproceedings is rarely incorporated in text books. &'miIarly, other latest research information on Bacteria Concrete Geopolymer Concrete and Basaltbre concrete are also included. The book incorporates rele vant information on numero us Indian standard specications and code of practices relating to cement and concrete, including the hrtest revision ofE456' of2000 in respect of section 2 on materials, workmanship, inspection, testing and acceptance criteria. The book should serve as a vehicle to disseminate the information to all those who are mterested in concrete construction. Iam sure thatthismulticolournevisededitionwzllprove to be very usetlto students ofengmeering, architects, practicing engineers and teachersin allengineering coeges. Kthis book helps to enthuse the readers and enable them to make betterconcrete atourconstruction sites, Iwouldfeelthat my efforts are wellrewarded. Iwould like to express my sincere thanks to Sari Samir Surlaker, an authority on admixtures and construction chemicals in India, forhehring me to enhance the technicalcontent ofthis book. Iam also thankfulto the o/cersand sta"ofM/s S Chand &Co mpanyltd. w ho were extremely amicable and hekril to bringing out this sixth edition in Multicolour. Place: Purle May 2005 M.S. (ix) SHETTY PREFACE TO_ THE FIRST EDITION- » ement mortar and concrete are the most widely used construction materials. It is T to point out another materialof constructionwhich is as versatikas concrete.It is the materialof choice where strength,permanence,durability, irnpermeability, fire resistance and abrasion resistance are required. associated now with every human activity that it touches every human It is so cbsely being in his day g to daylliving. I Tiii"Cementconcreteisoneofthe seeminglysimplebut actuay complexmaterials. Many ofits complex behaviours andeconomicay. are yet to be identified The behavio urofconcrete to empby this materialadvantageously with respectto bng-term drying shrinkage, creep, fatgue, morphobgy ofgel structure, bond, fracture mechanism and polymer modified concrete, brous concrete are some ofthe areas ofactive research in orderto have a deeper understanding ofthe complex behaviour ofthese materials. In any country, construction acco unts forabout 60 percent ofthe plan outlay. Out ofthis, cementand cementproduct woukl accountformore than 50 percent. Today in India the annualconsumption ofcementis in the orderof22 million tonnes. Eisestimated that the cost ofmortar and concrete made from 22 miion tons ofcement woukl work out to aboutRs. 4,000 crores which isabout1/5 ofthe plan outlayforthe year198283. It is in this context that the knowledge ofconcrete technobgy assumes importance. Concrete isa site -made mate rialunlike othermaterials ofconstruction and as such can vary to a very greatextent in its quality, properties andperformance owing to the use of naturalmaterialsexceptcement. From materials ofvarying properties, to make concrete ofstipulated qualitites, an intimate knowledge ofthe interaction ofvarious ingredients thatgo into the making ofconcrete isrequired to be known, both in the plastic condition and in the hardened condition. This knowledge is necessary forconcrete technobgists as well as forsite engineers. This book is written students ofengineering Approach mainly to give practical bias into concrete-making practices to and site engineers. Practical bias needs good theoretical base. to practwalsolution should be made on the basis ofso und theoretwalconcept. Sometimes, theory, howevergood, may not be applicable on many practwalsituations. This is to say, thatparticularly in concrete-making practices both theory and practice go hand in hand more cbsely than in many otherbranches ofEngineering mainly because it is a site made material. There are many good books written on this subject. But there are only afew books dealing w ith condit&)ns,practice and equwmentavaihzble in thiscountry. Moreover; most ofthe books refer to only British and American standards. It has been the endeavour of the author standard readerto to give as much information as possible about the Indian practice, Indian specifkations and code ofpractices forconcrete making. Ethis book helps the make betterconcrete in the field, my efforts, Ifeel are rewarded. Pk/ice: Pune M. S. SHETTY CONTENTS C/1azpter 1. No. Page CEMENT No. 1-26 General 1 Early History ofModem Cement Manufacture ofPortland Wet Process 2 Cement 5 6 Dry Process 2. 9 Chemical Composition 14 Hydration of Ceme nt 17 Heat ofHydration 18 Cakium Silicate Hydrates 19 Calcium Hydroxide 20 Cakium Aluminate Hydrates 21 Sructure ofHydrated Transition Zone Cement 22 22 WaterRequirements forHydration 25 TYPES OF CEMENT AND TESTING OF CEMENT 27-65 Iypesofcement ASYM Chzssication 28 28 Ordmary Portland Cement 29 Rapid Hardenmg Cement Extra Rapid Harde nmg Cement 30 30 Sulphate Resisting Cement Portland Sag Cement 31 31 Application ofGGBSConcrete Quick Settmg Cement 33 33 Super Sulphated Cement low Heat Cement 34 34 Portland Pozzolana Cement 35 Advantages ofPPC 36 Grading ofPPC Application Air-Entrafning Cement Coloured Cement 37 37 37 38 Hydrophobic 39 Cement Masonry Cement 39 Expansive Cement 40 R9740 recial Grade Cement O11-WellCement 40 41 Rediset Cement 41 (xi) Properties ofRediset Applications Hgh Alumina Cement Hydration ofH@h Alumina Cement Hgh Alumma Cement Concrete Re/ractory Concrete Very Hgh Srength Cement Macro-defectee Cement Densely Packed System Pressure Densication and Warm Pressing Hgh Early Srength Cement Iyrament Cement Magnesium Phosphate Cement Testing ofcement Field Testmg Fme ness Test Seve Test A1'rPermeabilz'ty Method &andard Consistency Test Setting Time Test 1nz'tr'alSettz'ng Time FinalSetting Time Srength Test Soundness Test Heat ofHydration Chemical Composition Test Test Certicate 3. AGGREGATES AND TESTING OF AGGREGATES General Classication Source 41 Aggregates from Igneous Rocks Aggregates from Sedftnentary Rocks Aggregates from Metamorphic Rocks &'ze »9Lape 42 recic Gravity Absorption and Moisture Content 78 78 Bulking ofAggregate Measurement ofMoisture Content ofAggregates 80 81 Drying Method 82 Displacement Method Calcium Carbide Method 82 82 Ekctrical Meter Me thod 82 Automatic Measurement 82 Cleanliness 83 Soundness ofAggregate 85 Alkali-Aggregate Reaction 85 Factors Promo ting Alkali-Aggregate Reaction 86 Hgh Alkali Contentin Cement 88 Availability ofMo isture Temperature Condition 89 89 Mechanism ofDeterioration ofConcrete 89 ControlofAlkaIi Aggregate Reaction 89 ThermalPnoperties 90 Grading ofAggregates Seve Analysis 91 93 Combming Aggregates to obtain recied Gradings 94 recic Surface and Surface Index Sandard Gradmg Curve Crushed Sand 96 100 105 Gap Gradmg 107 Testing ofAggregates 107 TestforDetermination ofFhrkiness1ndex TestforDetermination ofEbngation Index 107 109 TestforDetermination ofChry and Fine Slt 110 TestforDetermination ofOrganic Impurities 111 TestforDetermination ofrecic TestforBulkDensity and Voids 112 112 Gravity MechanicalPropertiesofAggregates 4. 113 TestforAggregate Crushing Value 113 TestforTenpercentFinesValue 114 TestforAggregate Impact Value TestforAggregate Abrasion Value 114 115 WATER 1 19-123 QualitiesofWater 119 Use ofSea WaterforMixmg 5. ADMIXTURES AND Concrete CONSTRUCTION 122 CHEMICALS 124-217 General 124 Admimxtures 125 Construction Chemicals 126 Plasticizers(WaterReducers) 126 (xiii) Action ofPlasticizers Dispersion Retardmg Efect Superphzsticizers (Hgh Range WaterReduce rs) 12 Chzsszcation ofSuperplasticizer Hfect ofSuperplasticizers on Fresh Concrete Co mpatibity Factors Efecting ofSuperplasticizers and Cement Wo rkability Type ofSuperplasticizers Dosage Mix Composition Var1'abz'l1ty in Cement Composition Mixing Procedure E'quipment Ste Problems in the use ofSuperplasticizers Sump Ioss 140 &epsforReducing Sump Ioss 0therPotentialProblems Hfect ofSuperplasticizers on the Properties ofHardened New Generation Superphzsticizers Concrete Carboxylated Acrylic Ester (CAE) Multicarboxylate ther (MCE) Retarders Retarding Plasticize rs Accelerators Accelerating Plasticize rs Air-e ntrainmg Admixtures Air-entraming Agents Factors Affecting Amo unt ofAir-e ntrainme nt The Effect ofAb'-entrainment on the Properties ofConcrete Resistance to Freezmg and Thaw ing Hfect on Workability meet on &re ngth meet on Segregation and Bleeding Efect on Permeabilzty meet on ChemicalResistance meet on Sand, Waterand Cement Content Unit Weight AlkaliAggregate Reaction Modulus ofE7asticzty Abrasion Iksistance Optimum Air Content in Concrete Measurement ofAb' Content Gravime tric Method Volumetric Method Pressure Method 12 Pozzo lanic Materials NaturalPozzo lans ArticialPozzo lans Fly Ash Efect ofFly Ash on Fresh Concrete Efect ofFly Ash on Hardened Concrete Durability ofConcrete Hgh Volume FlyAsh Concrete (HVFA) Properties of(HVFA) Fresh Concrete Bleedmg and Settmg Time Heat ofHydration Curing of(HVFA) Concrete Mechanical Prope rties of(HVFA) Concrete Durability of(HVFA) Concrete Use ofH@h Volume FlyAsh &'lica Fume Indian Scenario Available Forms Pozzo lanic Action Inuence on Fresh Concrete Inuence on Hardened Concrete Mixing Curing lce Husk Ash Surkhi Metakaolin Ground Granulated Blast Furnace Sag (GGB69 Performance ofGGBSin Fresh Concrete Concrete Hardened Concrete Damp-Proong and Wate r-Proong Admixtures Gas Formmg Agents Air-De training Agents AlkaliAggregate Expansion Inhibitors Workabrlity Agents Grouting Agents Corrosion Inhibitmg Agents Bondmg Admixtures Fungicidal, Germicidal and 1nsecticidalAdmixtures Colouring Agents Miscellaneous Admixtures Damp-proofers Construction Chemicals Membrane Forming Curing Compounds Drymg Behaviour Types ofCuring Compounds 1 WaterRetention Test 203 PolymerBonding Agents PolymerMod1ed Mo rtar forlkpair 204 204 and Maintenance Mo uhil Releasmg Agents Installation Aids 205 205 FloorHardners 206 and Dust Proofers Non-Szrink Hgh Strength Grout 207 Surface Retarders 207 BondAidforPlastering Ready to use Phzster 208 208 Guniting Aid 208 Construction Chemicals for Waterproofmg 209 Integral Waterproong Compound 210 Acrylic Based Polymer Coatings Mme ral Based Polymer Mo die d Coatmgs 210 21 1 Protective and Decorative Coatmgs ChemicalDPC 212 212 Waterproofmg AdhesivesforTiIe, Marble and Granite &'licone based Waterliepeant Materials 213 214 Injection Groutfor ebint Seahznts 214 215 Cracks Concrete Repair Systems &agesforRepafr Works 6. FRESH 215 215 CONCRETE 218-297 Wo rkability 219 Factors A/fectmg Wo rkability Water Content 220 220 Mix Proportions 220 &'ze ofAggregate 221 »9LapeofAggregate Surface Texture 221 221 Grading ofAggregate Use ofAdmixture 221 221 Measurement ofWorkabI1ity 222 Sump Test 222 K-Sump Tester Remarks 224 227 Compacting Factor Test Flow Test 227 228 Flow Table Apparatus 229 Accessory Procedure 230 Kelly Ball Test Vee Bee Consistometer Test 231 232 Segregation 233 Bkedmg Method ofTestforBleeding 234 236 (xvi) Setting Time ofConcrete ProcessofManufacture ofCo ncrete Batchmg Volume Batching Wegh Batching Measurement ofWater Mixing Hand Mixmg Machme Mixing Mixmg Time Retempering Maintenance ofMi'xer Thansportfng Mortar Pan WheelBar1ow Crane Bucket and Rope way Truck Mixer and Dumper Belt Conveyors Chute Skip and Hoist TransitMixer Pumps and Pipeline Devebpment ofConcrete Pump Concrete Pumps Types ofvalve Pipelme and Couplmgs laying the Pipeline Capabilities ofConcrete Pump Pumpable Concrete Design Consideration Choosing Correct Pump Common Problems Clearing Bbckages Placing Concrete Form Work Sripping Time Under Water Concreting Compaction ofConcrete Hand Compaction Compaction by Vibration Ihtemal Vibrator Formwork Vibrator Table Vibrator Platform Vibrator Surface Vibrator Compaction by Pressure and ebbting Compaction by zinning Vibratory Roller (xvii) 2 GeneralPoints on Using Vibrators 270 Further Instructions on use ofVibrators 270 HeightofConcrete 271 layer Depth oflrnmersion ofVibrator racing and Number oflhsertion 271 272 Positions reed oflhsertion Duration ofVrbration 272 273 Vibrating Concrete at Jmctions 273 Vibrating Reinforced Concrete Vibratmg Near the Form Work 273 273 Vibratmg Hgh Walls and Columns OverVibration 276 276 Outputoflmmersion Revrbration 276 276 Vibrations Vibration oflight-weight Concrete 277 Curing ofConcrete Curing methods 277 279 Water curing 279 Membrane curing 280 Application ofHeat &eam curing 281 282 Hgh Pressure Seam curing 287 Curing by In/ra-red Rrdiation 288 Electricalcuring Miscellaneous Methods ofCuring 289 289 When to &art Curing 289 Ffnishing Formwork Finishes 291 291 Surface Tieatment 292 Exposed Aggregate Finish Bush Hamme ring 293 293 Applied Finish Miscellaneous Finish 293 294 WearResistant Floor Finish 294 Requirement ofa Good Finish 295 Grinding and Polishing Craziness 295 295 Whisper Concrete Finish STRENGTH OF 296 CONCRETE 298-324 General 298 Water / Cement Ratio 299 Gel / race 301 Ratio Gain of&rength with Age 303 Accelerated Curing Test 306 Maturity Concept ofConcrete 306 Efect ofMaxftnum 311 Size ofAggregate (xviii) Rehztion between Compressive and Tensile Srength 311 Centre Point and Third Point loading 314 Bond Srength 315 Aggregate Cement Bond Strength 316 Hgh Srength Concrete 318 Seedmg Revrbration 319 319 Hgh reed Surry Mixing Use ofAdmixture 319 319 Inhibition ofCracks 319 Sulphur Irnpregnation Use ofCementitious Aggregate 319 319 Ultra High &rength Concrete 319 Compaction by Pressure Helical Bindmg 319 320 PolymerConcrete Reactive Powder Concrete 320 320 Hgh-Performance Concrete (HPC) 321 Aggregates forHPC 8. ELASTICITY, 322 CREEP AND SHRINKAGE 325-348 Elastic Properties ofAggregate Rehztion between Modulus ofE7asticity and Srength 325 328 Factors A/fectmg Modulus ofE7asticity 329 Dynamic Modulus ofE7asticity Poisons Ratio 331 332 Creep 332 RheologicalRepresentation ofCreep 333 Macroscopic RheokJgicalApproach 333 Microscopic RheohJgicalApproach Hydration underSustained Ioad 334 335 Measurement ofCreep 336 FactorsA/fectmg Creep Q , .. Inuence ofAggregate Inuence ofMix Proportions 339 Inuence ofAge 339 Efect ofCreep , , Sirinkage 7 » »- PhzsticQirinkage DrymgQirinkage 9. 339 339 P g 339 340 _ 341 CU U 343 Factors A/fectmg Qirinkage Moisture Movement 344 347 Autogeneous Qirinkage Carbonation Sirinkage 347 347 DURABILITY OF CONCRETE 349-419 General 349 &re ngth and Durability Rehztionship 350 (xix) Volume Change in Concrete Defmition ofDurabrlity Sgnicance ofDurabil1ty Irnpact ofW/C Ratio on Durability Permeability Permeabity ofCement Paste Permeability ofConcrete Interaction between Permeability, Volume Change and Cracking Factors Contributing to Cracks in Concrete Plastic Strinkage Cracks Settlement Cracks Bleeding De laye d Curing Co nstructio nal Efe cts Early Frost Damage Unso und Mate rials Szrinkage Drying Sir-inkage Thermal Strinkage Thermal Co nductivity Thermal Di/fusivity re cic He at Coeicient ofTher'malExpansion Mass Concre te Thermal Exp ansio n and Szrinkag Exte nsibity J) ints in Co ncre te Constructio n J) mts e Exp ansio n J) ints Contrac tio n J) mts Isohrtio n J) ints Concrete Subjected to High Temperature Fbe Resistance Freezing and Thaw ing Deicing Efects ofSalts Moisture Movements Transition Zone BiologicalProcess &r'ucturalDes@n De/ciencies ChemicalAction Sulphate Attack Methods ofCo ntrolling Sulphate Attack Use ofSuhrhate Resistmg Cement Quality ofConcrete Use ofAb'-e ntramme nt 3 Alkali-Aggregate 1%action Acid Attack 394 395 Concrete in Sea Water 396 Carbonation Rate ofCarbonation ' Measurement ofDepth ofCarbonation Chloride Attack 400 400 Corrosion of&eel (Chloride Induced) Corrosion Control 402 404 Metallurgical Methods Corrosion Inhibitors 405 405 Coatmgs to Remforcement 406 Fusion Bonded Epoxy Coating 407 Galvanised Reinforcement Cathodic Protection 408 408 Coatings to Concrete 408 Design and Detailing No minal Cover to Reinforceme nt 409 409 Crack Width 411 Deterioration ofConcrete by Abrasion, Erosion and Cavitation 411 Efects ofSome Materials on Durability Action ofMmeralOrls 412 412 Action ofOrganic Acids 412 Vegetables and Animal Oils and Fats 412 Action ofSugaron 413 Concrete Action ofSewage 413 Surface Treatments ofCo ncrete Maxftnum Cement Content 413 415 Concluding Remarks on Durability 1oI 398 398 TESTING OF HARDENED 418 CONCRETE 420-457 Compression Test Moulds 421 422 Compacting 422 Compaction by Hand 423 Compaction by Vibration 423 Cappmg recimens Neat cement 424 424 Cement mortar 424 Sulphur 424 Hard phrster 425 Curing 425 Making and Curing Compression Test recimen in the Field 425 Failure ofCompression recimen 425 Efect ofHeight /Diameterlztio on Srength Comparison between Cube and CylinderStrength 427 428 F7exural&rength ofConcrete Determination ofTensile Strength (xxi) 428 429 Procedure Placing ofrecimen in the Testmg Machine Indirect Tension TestMethods Rmg Tension Test Advantage ofring tension test limitations ofring Double Punch Test tension test Factors Inue ncmg the Strength Results Test Cores &rength ofcores Non-Destructive Testing Methods Schmrdts Rebound Hammer limitation Rebound number and strength ofconcrete Penetration Techniques Pullout test Dynamic or Vibration Method 1%sonant Freque ncy Me tho d Usetlness ofresonantequency Pulse Ve lo city Me tho d method Techniques ofmeasuring pulse velocity through concrete Factors a/fectfng the measurement ofpulse vebcity Snoothness ofcontact surace under test Inuence ofpath length onpulse velocity Temperature ofco ncre te Moisture condition ofconcrete Presence ofreinforvcement Accuracy ofmeasurement Applications Establishmg uniformity ofCo ncrete Establishmg acceptance criteria Determination ofpulse modulus ofclasticzty Estftnation ofstrength ofconcrete Determination ofsetting characteristics ofconcrete &udies on durability ofconcrete Measurement ofdeteriration ofconcrete due to re exposure Relatio nshzp between Pulse Vehrcity and Satic Youngs Modulus ofE7asticity Combined Methods Rrdio activity Methods Nuclear Me tho ds Magnetic Methods Electrical Methods Tests on Composition ofHardened Concrete Determination ofCe ment Content Determination ofOr1'ginalw /c Ratio Physical Method Accelerated Curing Test (xxii) 4 11. CONCRETE MIX DESIGN 458-503 General 458 Concept ofMr'xDesign Variables in Proportioning 459 459 Various Methods ofProportioning 460 &atisticalQuality ControlofConcrete Common Terminologies 460 461 Cakuhztion ofStandard De viation and Coeicient ofVariation Rehztion between Average Design Srength and recied American Concrete hstitute Method ofMr'x Desgn Data to be Colkcted Example:ACICommittee 211.191 Road Note Number4 Method 463 Minftnum Strength 463 466 466 Method 471 473 DOEMethodofConcrete MixDesign Example DOEMethod 474 477 Concrete Mix Design Procedure for Concrete with Fly-Ash 482 Example ofMix De sgn with Fly-Ash with DOEMethod 482 Mix Design forPumpable Concrete 484 Example: Basic Desgn Cakuhrtio ns for a Pumpable Concrete Mix 488 Indian Sandard Recommended Method ofCo ncrete Mix Design llustrative Example ofConcrete Rapid Method 489 Mix Design 495 498 &eps ofMr'xDesign based on rapid method 499 Sampling and Acceptance Criteria 500 Frequency ofsamplmg Test Specimen Test Results 500 501 501 Acceptance Criteria 502 Compressive Strength 1%xural&rength 502 502 Inspection and Testing of&ructures Core Test 502 502 Ioad Testfor1%xuralMember Non-destructive Test 12. SPECIAL CONCRETE 502 503 AND CONCRETING recialconcrete light-weghtconcrete Pumice Diatomite Scoria Volcanic Cinders Saw Dust Rice Husk Brick Bats Cinder, Clinker and Breeze Fo amed Sag Bbated Clay &'ntered Fly Ash METHODS 504-607 504 506 506 507 507 507 507 507 508 508 508 509 509 (xxiii) Exfo liate d Vermiculite Expanded Perlite light-weight Aggregate Concrete &ructuralI1ght-w eight Co ncre te Workability Design oflrght-weightAggregate Mixmg Procedure Aerated Concrete Concrete Mix Proporties No -nes Concrete Mix Proportion Drying Qirinkage Thermal Conductivity Application High Density Concrete Types ofRadi'ation Hazards Siielding Ability ofConcrete Concrete forRadi'ation Siiehiling Sulphur-Inltrated Concrete Application Fibre Remforced Concrete Fibres used Factors Efecting Properties Relative Fibre Matrix &i"ness Volume ofFibres AspectRatio ofFibres Orientation ofFibres Workability &'ze ofcoarse Aggregate Mixmg Application Glass Fibre Remforced Cement Current Development in (HE) High Fibre Volume Micro-Fibre System Surry Inltrated Fibre Concrete Compact Reinforced Composites Polymer Concrete Type ofPolymerConcrete Polymernpregnated Concrete Polymer Cement Concrete Polymer concrete Partially Enpregnated Concrete Properties ofPolymer1rnpregnated Concrete &re ss-&rain Relationship Compressive Strength Tensil Sre ngth Creep Sirinkage due to Polymerisation Durability WaterAbsorption 509 509 5 510 513 Resistanceto Abrasion Wear and Skid Iksistance Fracture ofPolymer1inpregnated Concrete Application ofPolymer1rnpregnated Concrete Cold Weather Concreting Hfects ofCoh:l Weatheron Concrete Iow Temperature but above 0°C Iow Temperature but behrw 0°C aer Concreting Temperature Below 0°C at the Time ofConcreting Hardened Concrete Subjected to Freezing and Thawing Concreting Methods at Sub-zero Temperature Hot Weather Concreting Precautions Taken 540 Aggregates Water Production and Delivery Prepacked Concrete Vacuum Concrete Rate ofExtraction ofWater Vacuum Dewatered Concrete Gunite or Stotcrete Dry-Mix Process Wet-Mix Process Advantages ofWet and Dry Process General Use of»9Loterete Concluding Remarks on Stotcrete Recent Studies Ferrocement Casting Techniques 540 540 Hand Plastering Semi-Mechanised Process Roller Compacted Concrete Selfcompacting Concrete (KYC) Materialfor KYC Example of&7C Mixes Requirements for self-compactfng concrete Workabrlity Requirementfor the esh SCC Production and Placing Mix Design Test Methods Sump ow Test Jr-ing test V-Funnel Test L-Box test method U-Box Test FullBox Test Orimet test Complexities involved in making SCC Ne w Gene ration Plasticizers Indian Scenario of&7C (xxv) 541 542 590 Experience ofDePLiMetro Project Experience ofMock-up Trials at 72mzpurAtomic PowerProject Use of KYC Kzrga Trials at SEK7 Chennai Sudy at Ho ng K) ng How economicalis SelfCompacting Bacte rial Concrete Concrete Experimental Investigations Zeopolymer Concrete Basaltbre concrete and concre reinforced with basaltbre General List Reference of Indian of Pratices, Subject reinforcements Books standard Related 592 591 Specifications to cement and code and concrete 594 Index 595 597 (xxvi) CONCRETE IN THE UNENDING OF NATION SERVICE BUILDING SARDARSAROVAR DAM : Sclrdar ScrrovcrrProject is an Inter-State Mutti-Purpose project of National Importance. It is one of the Iorgest projects under implementation anywhere In the world. (xxvii 4 THE IDUKKI HYDROELECTRIC PROJECT,KERALA: The reservoir covers nearly 60 square kilometres and has a catchment of 649 square km. Water from the reservoir is taken down to the underground power house at Moolamattom through an underground tunnel, yielding an average gross head of 2182 feet (665 metres). The project has an installed capacity of 780 MW with firm power potential of 230 MW at 100 per cent load factor. > THEBHAKRADAM is a majestic monument across river Sutlej. The construction of this project was started in the year 1948 and was completed in 1963 . It is 740 ft. high above the deepest foundation as straight concrete dam being more than three times the height of Qutab Minar. Bhakra Dam is the highest Concrete Gravity dam in Asia and Second Highest in the world. 4 SAI GANGA approach canal for water supply to Chennai Metro. (xxvi1' i) DELHl METRORailway Station under construction. THE BA:-iA'i HOUSEor WORSHIP known as the LotusTemple, built near New Delhi. Diamond shaped MANI KANCHAN & Jewellery Park at Kolkata. Gem Unconventional building with pleasing architecture. (xxix) TARAPURATOMIC POWERPROJECT: Reactor Building no. 3 8: 4. Fully automatic pavement. construction of concrete A A view of large oval shaped dome under construction over Connaught Place Metro Railway Station. It is going to be a new landmark over Delhi Metro. It will be a modern version of Palika garden A pride feature of Delhi Metro Project. > Sky Bus Metro, Goa my (xxx) Building Heights, m 300 250 l 200 150 100 50 * Reinforcedconcreteframe T Composite concrete/steel frame ** Also includesone experimentalcolumnof 117MPa SOME HIGHRISE BUILDINGS AROUND THE WORLD Paris1889 NewYork NewYork Chicago NewYorkChicago H°"9 K°"9 Dallas H°9 K°"9 K"a'19L9gp"' 1930 1931 1969 1972-1973 1974 1974 1986 1989 ° Eiffel Tower V Chrysler Building Empire State Building John Hancock Building World Trade Center 321m 319m 381 322m 417and415m (xxxi ) Sears Hongkong First Bankof Petronas Tower ansShanhai Interstate China Towers Center Bank Bank BankTower 443m 179m 219m 369m 451m A CHANNEL TUNNELRAIL LINK (UK). Tunnel diameter: 6.84 m and 8.15 m. Number of segments 9+key. Segment thickness : 350 mm. Concrete grade : 60 MPa. Dramix steel fibre reinforcement is used for casting segments without conventional steel. 4 PETRONASTWIN TOWERSin Kuala Lumpur Malaysia : One of the tallest (45lm.) buildings in the world. . . . . and many many more to expand and reshape the world we live in, all in concrete. (xxxii)