![]() |
| CONCRETE |
![]() |
| CONCRETE PUMP BOOM PLACER CHUTE |
![]() |
| CONCRETE |
![]() |
| CONCRETE PUMP BOOM PLACER CHUTE |
Construction of any roof slab comprises of these following steps..
1.Staging:-After completion of Columns upto Roof Beam Bottom Construction of Roof Slab is stats. The First stage is Staging. Staging is noting but erection of staging forms on which shuttering of Roof Slab or Beam will rest. Staging can be made of different type of materials starting wooden to metal parts, which hold is shuttering. Staging should be stable and firm to hold the load of the slab.It should be firm enough so that during concreting it should properly hold the concrete & shuttering so that shuttering do not bulge of settle.
2.Shuttering:- Shuttering is started after completion of staging. Plywood or metal any type of shuttering are used base on the load of slab. During shuttering proper alignment and level of shuttering is checked. Shuttering is properly sealed to avoid slurry lickage which will lead to honeycomb structure or segregation of concrete. Demolding agent are used in shuttering for smooth finishing of concrete surfaces and easy stripping of shuttering boards.
3. Reinforcement:- Reinforcement the third step is construction of roof slab. It can be started after completion of shuttering or it can be done together with shuttering for beams also. Reinforcement placement to be properly checked according to the BBS or Approved Bad Bending Schedule. Diameter of rods, length, spacing, lap length, no of chairs and location of rods to be properly checked before concreting.
4.Concreting:- After completion of Shuttering, Reinforcement Concreting of Slab is started. Concreting is to be properly done as per design with proper vibration (Surface & Needle Vibrator) for avoiding segregation. Extra care to be given for maintaining proper slump during concreting. No bleeding and creep should be there. After concreting Surface of Slab is finished by manual or mechanical means.
5. Curing:- Curing to be done by making ponds/ carry over the slab. Slab to be cured for 21 days.
6. De-shuttering:- De-shuttering is to be done after slab reaches its design strength ie. after 21 days. If quick setting cement or admixture is used during concreting shuttering can be removed earlier as per the specification of the chemical.
Creep of concrete is the continued deformation with time under applied load. Sometimes it is defined as increase in strain in concrete with time under sustained stress. This is also known as plastic flow or time yield. The rate of creep decrease with time and the creep strains at five years are taken as terminal values. Creep increases rapidly with the stress, loading at an early age of concrete, broken ballast, soft and porous aggregate, poorly graded and improperly compacted concrete. The deformation of hardened concrete is shown in Fig. below.
The Causes of Creep are.
Closer of internal voids of Concrete
Viscous flow of the cement paste inside concrete
Flow of water out of the cement gel inside concrete.
In reinforced concrete structures it is of advantage since it causes better distribution of stresses. For example in a R.C.C. column there is a reduction of stress in concrete and a corresponding increase of stress in steel due to creep. As another example creep relieves the high stressed portions of concrete in a continuous beam and increases the stress in the adjacent less stressed portion. Creep causes large deformations and deflections and is undesirable.
Cement is one of the most important base products of construction industry and Ordinary Portland cement or OPC is by far the most important type of cement. Prior to 1987, there was only one grade of OPC [which was governed by IS 269-1976]. After 1987 higher grade cements were introduced. The OPC was classified into three grades, namely..
These classifications are based on the strength of the cement at 28 days when tested as per IS 4031- 1988. If the 28 days strength is not less than 33N/mm2, it is called 33 grade cement, if the strength is not less than 43N/mm2, it is called 43 grade cement, and if the strength is not less then 53 N/mm2, it is called 53 grade cement. But the actual strength obtained by these cements at the factory are much higher than the BIS specifications.
The physical and chemical properties of different types of OPC are shown in Table below.
It has been possible to upgrade the qualities of cement by using high quality limestone, modern equipments, closer on line control of constituents, maintaining better particle size distribution, finer grinding and better packing. Generally use of high grade cements offer many advantages for making stronger concrete. Although they are little costlier than low grade cement, they offer 10-20% savings in cement consumption and also they offer many other hidden benefits. One of the most important benefits is the faster rate of development of strength. In the modern construction activities, higher grade cements have become so popular that 33 grade cement is almost out of the market. Table shows the grades of cement manufactured in various countries of the world.
The manufacture of OPC is decreasing all over the world in view of the popularity of blended cement on account of lower energy consumption, environmental pollution, economic and other technical reasons. In advanced western countries the use of OPC has come down to about 40 per cent of the total cement production. In India for the year 1998-99 out of the total cement production i.e., 79 million tons, the production of OPC in 57.00 million tons i.e., 70%. The production of PPC is 16 million tone i.e., 19% and slag cement is 8 million tons i.e., 10%. In the years to come the use of OPC may still come down, but all the same the OPC will remain as an important type for general construction.
Recently a new term has come in the field of concrete technology “High Performance Concrete” or HPC. The properties of HPC are
There is a little controversy between the terms high-strength and high performance concrete. High-performance concrete is also, a high-strength concrete but it has a few more attributes specifically designed as mentioned above. It is, therefore, logical to describe by the more widely embracing term “High Performance Concrete” (HPC).
In normal concrete, relatively low strength and elastic modulus are the result of high heterogeneous nature of structure of the material, particularly the porous and weak transition zone, which exists at the cement paste-aggregate interface. By densification and strengthening of the transition zone, many desirable properties can be improved many fold. A substantial reduction of quantity of mixing water is the fundamental step for making HPC. With reduction of w/c ratio strength concrete will increase. But reduction in w/c ratio to less than 0.3 will greatly improve the qualities of transition zone to give inherent qualities expected in HPC.
Use of silica fume is also found to be necessary to improve the qualities of transition zone.Silica fumes becomes a necessary ingredient for strength above to 80 MPa. The best quality fly ash and GGBS may be used for other nominal benefits. Inspite of the fact that these pozzolanic materials increase the water demand, their benefits will out weigh the disadvantages. The crux of whole problem lies in using very low w/c ratio, consistant with high workability at the time of placing and compacting. Neville opines that the lowest w/c ratio that could be used is 0.227.9
Only with the use of superplasticizer, w/c ratio in the range of 0.25 to 0.3 can be adopted and a high slump is possible to achieve. Therefore, use of appropriate superplasticizer is a key material in making HPC. The associated problem is the selection of superplasticizer and that of cement so that they are compatible and retain the slump and rheological properties for a sufficiently long time till concrete is placed and compacted.
Pumpable concrete is that type of concrete which can be pushed through a pipeline for construction. It is made in such a manner that its friction at the inner wall of the pipeline does not become very high and that it does not wedge while flowing through the pipeline. It is very important to have a clear understanding of what happens to concrete when it is pumped through pipeline to any study of concrete pumping. Pumpable concrete emerging from a pipeline flows in the form of a plug which is separated from the pipe wall by a thin lubricating layer consisting of cement paste. The water in the paste is hydraulically linked with the interparticle water layer in the plug. Fig- 1 below shows the concrete flow under pressure.
The pressure generated by the flow resistance must not be greater than the pump pressure rating for maintaining continuous plug movement. However, if the concrete is too saturated at higher w/c ratio, the concrete at certain pump pressures may be such that water is forced out of the mix, creating an increase in flow resistance and a possible blockage. Fig.2 illustrates such a condition. In other words, a very stiff concrete is not pumpable and also a concrete with high w/c ratio is also not pumpable. It is interesting to note that if a concrete is pumpable, it is implied that it is a good concrete.
As propounded by Duff Abrams many research workers commented on the validity of water/cement ratio law. They have focused on a few of the limitations of the water/ cement ratio law and argued that Abrams water/cement ratio law can only be called a rule and not a law because Abrams’ statement does not include many qualifications necessary for its validity to call it a law. Some of the limitations are that the strength at any water/cement ratio depends on the following things…
1.Degree of hydration
2.Chemical and Physical properties
3.The temperature at which the hydration takes place
4.Air content (in case of air entrained concrete)
5.the change in the effective water/cement ratio and the formation of fissures and cracks due to bleeding or shrinkage
Instead of relating the strength to water/cement ratio, the strength can be more correctly related to the solid products of hydration of cement to the space available for formation of this product. Powers and Brownyard have established the relationship between the strength and gel/space ratio. This ratio is defined as the ratio of the volume of the hydrated cement paste to the sum of volumes of the hydrated cement and of the capillary pores.
Power’s experiment showed that the strength of concrete bears a specific relationship with the gel/space ratio. He found the relationship to be 240 x3, where x is the gel/space ratio and 240 represents the intrinsic strength of the gel in MPa for the type of cement and specimen used.
The strength calculated by Power’s expression holds good for an ideal case.
The fig. below shows the relationship between strength and gel/space ratio. It is pointed out that the relationship between the strength and water/cement ratio will hold.
Segregation is the separation of the different materials of concrete. A good concrete is one which is homogeneous in nature.If a sample of concrete exhibits a tendency for separation of say, coarse aggregate from the rest of the ingredients, then, that sample is said to be showing the tendency for segregation. Such concrete is not only going to be weak; lack of homogeneity is also going to induce all undesirable properties in the hardened concrete.
There are considerable differences in the sizes and specific gravities of the constituent ingredients of concrete. Therefore, it is natural that the materials show a tendency to fall apart.
Segregation may be of three types — firstly, the coarse aggregate separating out or settling down from the rest of the matrix, secondly, the paste or matrix separating away from coarse aggregate and thirdly, water separating out from the rest of the material being a material of lowest specific gravity. A well made concrete, taking into consideration various parameters such as grading, size, shape and surface texture of aggregate with optimum quantity of waters makes a cohesive mix. Such concrete will not exhibit any tendency for segregation. The cohesive and fatty characteristics of matrix do not allow the aggregate to fall apart, at the same time, the matrix itself is sufficiently contained by the aggregate. Similarly, water also does not find it easy to move out freely from the rest of the ingredients.
The conditions favourable for segregation are, as can be seen from the above para, the badly proportioned mix where sufficient matrix is not there to bind and contain the aggregates. Insufficiently mixed concrete with excess water content shows a higher tendency for segregation. Dropping of concrete from heights as in the case of placing concrete in column concreting will result in segregation. When concrete is discharged from a badly designed mixer, or from a mixer with worn out blades, concrete shows a tendency for segregation. Conveyance of concrete by conveyor belts, wheel barrow, long distance haul by dumper, long lift by skip and hoist are the other situations promoting segregation of concrete.
The most important method of concrete compaction is Vibration. Only comparatively dry mix should be vibrated. When a too wet a mix is excessively vibrated, it is likely to get segregated. Vibration also to be continued just for required time for optimum results. If the vibration is continued for a long time, particularly, in too wet a mix, it is likely to result in segregation of concrete due to settlement of coarse aggregate in matrix.
Concrete is used with very high slump now a days particularly in RMC. The slump value required at the batching point may be in the order of 150 mm and at the pumping point the slump may be around 100 mm. At both these points cubes are cast. One has to take care to compact the cube mould with these high slump concrete. If sufficient care and understanding of concrete is not exercised, the concrete in the cube mould may get segregated and show low strength. Similarly care must be taken in the compaction of such concrete in actual structures to avoid segregation.
In case of floors or pavement finishing, with a view to achieve a smooth surface, masons work too much with the trowel, float or tamping rule immediately on placing concrete. This immediate working on the concrete on placing, without any time interval, is likely to press the coarse aggregate down, which results in the movement of excess of matrix or paste to the surface. Segragation caused on this account, impairs the homogeneity and serviceability of concrete. The excess mortar at the top causes plastic shrinkage cracks.
So it can be concluded that the tendency for segregation can be remedied by correctly proportioning the mix, by proper handling, transporting, placing, compacting and finishing. If segregation is observed, it is advisable to remixing for a short time which would make the concrete again homogeneous. As mentioned earlier, a cohesive mix would reduce the tendency for segregation. For this reason, use of certain workability agents and pozzolanic materials greatly help in reducing segregation. The use of air-entraining agent appreciably reduces segregation.
Segregation is difficult to measure quantitatively, but it can be easily observed at the time of concreting operation. The pattern of subsidence of concrete in slump test or the pattern of spread in the flow test gives a fair idea of the quality of concrete with respect to segregation.