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civil techniques

Concrete Manufacturing Process

abbu riyaz 1 May, 2023

Concrete Manufacturing Process consists of many stages. The Concrete mix for delivery from a plant instead of mixing on the job site. The concrete mixes, transports and delivers to a construction site to place in formworks for construction. And to form various structures, like a column, beam, slab, etc.

Concrete Manufacturing Process

The main Concrete Manufacturing Process is as follows

Batching
Mixing
Transporting
Placing
Compacting
Curing

1. Batching

It is the main thing in the Concrete Manufacturing Process. The measurement of materials like aggregates, cement, water necessary for preparing different grades of concrete is Batching. It is by two processes. One is volume and other is weight batching. The volume batching is by mixing materials with its volume. And weight batching is by the self-weight ratio of materials. It has ratios according to standard codes. Some of the different grades of concrete are M10, M20, M25, M30.

2. Mixing

Mixing is to produce uniform, high-quality concrete. The mixing equipment is capable of effective concrete material. Separate paste mix shows the mixing of cement and water into a paste before combines with aggregates. This increase the compressive strength of concrete. This paste mix in high-speed, shear-type mixer at a water-cement ratio of 0.30 to 0.45 by mass. The premix paste blends with aggregates. The remaining batch water and final mix complete in a rotating concrete mixing equipment.

3. Transporting

Transporting concrete require great care. After mixing, the concrete transports to site. The mixing carries near the construction site. A bucket, ropeway, belt conveyor use to transport concrete. Readymix conveyor trucks use mostly in the modern construction times. The concrete transporting by conveyor truck has time limits. The concrete transporting by trucks reach the construction plant early.

4. Placing

Concrete to place in a good manner. It places without segregation to reach maximum efficiency. The concrete not to pour over a height of 1.5m. As the height of pouring concrete increases, it leads to separation of aggregates and cement paste. It causes segregation of concrete and causes honeycomb. Many concrete placing equipment use in modern construction times. some of the equipment are concrete pumps and boom lifts. Concrete pumps are normal pumps with joints to connect and remove according to needs.

Boom lifts are concrete pumps with movable arms. With the help of movable arm, a concrete place easily at heights and corners which is difficult with the normal pump.

5. Curing

Curing is to provide best strength and hardness to concrete. It is the next step after placing of concrete. Curing helps concrete to gain strength early. The concrete requires a moist and wet environment to gain full strength. Proper curing of concrete leads to increase the strength of concrete. And prevent cracking at surface dries. Avoid freezing and overheating of concrete to gain its full strength.

civil techniques

Concrete in construction Field

abbu riyaz 1 May, 2023

Concrete in construction Field is a mixture of paste and aggregates. It composes of fly ash, fine and coarse aggregate, water and chemicals. The fine aggregates are sand and coarse aggregates are gravel. By hydration, the paste hardens and gains strength to form the concrete.

Concrete in construction Field

Concrete is soft in newly mix, strong at hardens. Hence concrete uses to build bridges, superhighways, houses, and dams.

There are some important factors involve in the manufacturing process of concrete. They are

Proportioning
water-cement ratio
Ingredients
Hydration
Placement
Curing and
Special techniques

1. Proportioning

Proportioning and mixing are the main things in making a strong concrete. so choose the materials carefully. The mixture that does not have enough paste to fill the gaps between the aggregates is difficult to place. And produce rough surfaces. A mixture of a high cement paste is easy to place. And produce a smooth surface.

2. water-cement ratio

The quality of the paste determines the character of the concrete. The strength of the paste depends on the ratio of water to cement. It is the weight of the mixing water divided by the weight of the cement. High-quality concrete produces by lowering the water-cement ratio without losing the workability of fresh concrete. And allowing it to properly place and cure.

A properly design mixture possesses desire workability for the fresh concrete and the long-life and strength of the concrete.

3. Ingredients

Natural water drinkable and has no bad taste or smell used as mixing water for concrete. Impurities in mixing water affect setting time and strength. It causes efflorescence, staining, corrosion of reinforcement, and reduce lifetime. Drinking water suitable for mixing concrete and aggregates are to choose properly.

The aggregates to be clean and free from matter that affects the quality of the concrete.

4. Hydration

Aggregates, water, and the cement combine, the mixture hardens. By hydration, the paste hardens and get the strength to form concrete. During this reaction, a node forms on the surface of each cement particle. The node grows and expands until it links up with nodes from other cement particles.

5. Placement

The concrete thoroughly mixes and workable is places in forms before the mixture becomes too stiff. At placement, the concrete compact within the forms to reduce honeycombs.

For slabs, concrete makes ideal to stand until the surface moisture film disappears. A wood or metal hand float uses to smooth off the concrete. Floating produces an even, but slightly rough, texture that has good slip resistance. And use as a final finish for exterior slabs. If smooth, hard, dense surface requires, floating follows by steel trowels.

6. Curing

The curing begins after the exposed surfaces of the concrete have hardened sufficiently to resist damage. Curing ensures the continued hydration of the cement. So that the concrete continues to gain strength. Concrete surfaces cure by sprinkling with water fog. Other curing methods prevent evaporation of the water by sealing the surface with special sprays called curing compounds.

7. Special techniques

It uses for curing concrete during cold or hot weather to protect the concrete. The longer the concrete is wet, the stronger it becomes. The rate of hardening depends upon the composition, fineness of the cement, mix proportions, moisture, and temperature. Concrete continues to get stronger as it gets older. Most of the hydration and strength gain take place within the first month of concrete’s life cycle.

Concrete construction chemicals

15 Types of Cement in construction

abbu riyaz 1 May, 2023

There are many types of cement produces to fulfill the needs in construction Industry. By changing compositions and adding substances different types of cement forms.

The Types of Cement

Ordinary Portland Cement
Acid Resistance Cement
Rapid Hardening Cement
Sulpher Resisting Cement
White Cement
Colour Cement
High Strength Cement
High Alumina Cement
Quick Setting Cement
Hydrophobic Cement
Expansive Cement
Masonry Cement
Blast Furnace Cement
Low Heating Cement
Air-entraining Cement
Pozzolana Cement

1. Ordinary Portland cement

It is the most common type of cement use. It produces in different grades. The most common is Grade-53, 43 and 33. It uses for construction of residential, commercial and other constructions. It forms by burning clay and limestone at high temperature. And grinding it with Gypsum.

2. Acid Resistance Cement

It uses for acid-resistance in the chemical industry. It uses for the storage of acids and chemicals in large Tanks. And it prevents white blooming and efflorescence in storage tanks.

3. Rapid Hardening Cement

It uses in the urgent repair works, concreting in cold weather. And it attains high strength quickly. It mainly uses in the field of Marine structures, airfield, highway pavements and in bridge decks.

4. Sulpher Resisting Cement

It uses in the structure affects by sulfate attacks. It uses mainly in the construction of water supply, sewage treatment plant, dams, and Lining of canals.

5. White Cement

It is white in color. And does not contains any coloring chemicals. It uses for architectural decorative purposes and in aerodromes. It is costly.

6. color Cement

This cement contains coloring pigments. The amount of coloring material varies from 5 to 10%. chromium gives green color. Cobalt gives a blue color. And iron oxides give a brown color. It uses in swimming pools, garden parks, tennis courts, and for finishing of floors and external surfaces.

7. Hige Strength Cement

High Strength Cement uses in the construction of special types of work to increase the strength of the structure. It uses for multi-story complex, railway sleepers, prestressed concrete and precast constructions.

8. High Alumina Cement

It contains 32% of alumina in it. Its setting time is more than 3.5 hours. And gives more time for mixing and placing of operations. It generates a large amount of heat mixing with water. So it not affects by frost. It uses in chemical plants and furnace insulations.

9. Quick Setting Cement

It sets quickly. And consist of less amount of gypsum. The initial setting time is 5 minutes. And final setting time is 30 minutes. It mainly uses int the construction of a bridge across river and sea.

10. Hydrophobic Cement

Hydrophobic Cement mainly uses to store cement for a long time in wet climatic conditions. And at aqua constructions.

11. Expansive Cement

On curing cement shrinks normally. But in this type of cement, it expands on curing. It mainly uses for water retaining structures like sumps, dams water tanks and for repairing concrete structures.

12. Masonry Cement

It has high workability, plasticity, and water retaining properties. It uses in preparing of cement mortar and plaster.

13. Blast Furnace Cement

It produces by adding slag obtains from the blast furnace. And consists of alumina, silica, and lime. It gains strength slowly. So it not uses in RCC structures.

14. Low Heating Cement

It uses to reduce the heat produces at setting time of concrete. It has low compressive strength. And uses mainly for mass concrete works.

15. Air-entraining Cement

It is a type of Portland cement. It contains an additive that causes small air bubbles in wet concrete. The bubbles relive internal pressure on concrete by providing tiny chambers. For the expansion of water when it freezes. It gives high resistance to severe frost action.

civil techniques

Cement and uses in Construction

abbu riyaz 1 May, 2023

Cement is an important material in the building construction. It is a fine powder. And use to hold the construction materials together. It is the main component of concrete. And it is an economic material using in construction.

It is an important material in the construction. And replace clay and lime uses in construction from old times. It has an ability to hold the structure together.

And occurs by burning the mixture of limestone and clay at high temperature. And it forms a product clinker. A specific quantity of gypsum adds with it and reduce to fine particles known as Cement. The most popular type is Portland Cement. On setting and hardening, it occurs like sandstone in Portland in England and denotes as Portland Cement.

Cement uses

It uses as a basic building material in the construction of structures. Mainly structures like, dams, bridges, apartments, water tanks, cooling towers, and chimneys.

Mortar obtains by mixing it with sand, water and use for masonry works. And mainly plastering of inner faces, outer faces of wall and ceilings.

Quick setting cement prefers for underwater construction and bridges across river and sea.

Expansive cements use to repair damage concrete structures.

It uses in jointing of the concrete pipes.

Cement concrete use for laying roofs, floors, columns, beams, slab, foundation, staircase and more.

White and Rapid hardening cement use for decorative purposes and for quick construction.

To provide color finishes to floors like swimming pools, outer surfaces of building a special type of color cement employs.

It uses in the construction of precast concrete pipes, drainage sewers.

High strength cement uses to repair damage concrete structures. And in the construction of the multi-story complex.

Use in railway platforms, fencing posts and seats in the parks.

It uses to manufacture precast Elements, Pcc and Rcc.

Construction materials

Test For Bricks

abbu riyaz 1 May, 2023

There are many Test For Bricks. Test conduct on bricks to obtain suitability of bricks employing in the construction of various structural elements. These test conduct in site and laboratory at the time of purchasing of materials. And in the time of construction of several structures. It is necessary to conduct the test for bricks to produce a good quality and strong structure.

Test For Bricks

There are several tests for bricks they are,

Compressive or crushing Test
Hardness Test
Durability
Sound Test
Water Absorption Test
Structure and
Presence of chemicals

1. Compressive or crushing Test

The Compressive or crushing Test performs in a compression testing machine. The load applies on the top surface of the brick. The maximum load at which the brick breaks marks. The Compressive or crushing Test calculate by

The compressive or crushing strength of brick = Maximum Load / Surface Area

The Minimum crushing strength of brick is 3.50N/mm². If the Compressive or crushing strength is lesser than 3.50N/mm², the brick fails and not useful for construction.

2. Hardness Test

Hardness Test is a simple test. A good brick is more resistance to abrasion. Sharp object scratches the surface of bricks and if there is no impression on brick then it’s a Hard Brick.

3. Durability

The Durability test is by dropping the brick from a height of one meter on a flat hard surface.

4. Sound Test

Sound Test performs by striking bricks with each other or with a hammer. A clear ringing or a metallic sound hear striking with another brick.

5. Water Absorption Test

In Water Absorption Test the brick weights and soak in water for twenty-four hours. The Difference in weight indicates the amount of water absorbs by brick. The percentage of water Absorption is lesser than twenty percent for a good quality Brick.

6. Structure

It’s a physical test for bricks for its size, shape, and color. Brick possess standard shape, uniform size, plain surfaces and sharp edges. It is rectangular in shape and copper color. The standard size of a good quality Brick is 19cm x 9cm x 9cm. And it tests for voids, cracks, and any other foreign matters present in it.

7. Presence of chemicals

In this test, the brick soaks in water for one day and dry in shade. If the presence of grey or white deposits spots it indicates the presence of chemicals.

Construction materials

Qualities of Good Brick

abbu riyaz 1 May, 2023

There are certain Qualities of Good Brick. A Good Brick has certain physical and chemical properties. Bricks use in new constructions and make renovations right across the world. Brick is a soundproof, fire resisting material. As it posses these characteristics it uses to construct partition walls in Industries. And employes for home extensions, walls of different thickness, other home building projects. It is cheap, hard, durable and easy to handle and to work with. These properties make brick a leading building material.

Qualities of Good Brick

The Qualities of a Good Brick base on its

Size and Shape
Color of Brick
Sound
Strength
Durability
Good Brick Earth
Water absorption
Resistivity

1. Size and Shape

Brick has a standard shape, uniform size, plain surfaces and sharp edges. It is rectangular in shape. The standard size of a good quality Brick is 19cm x 9cm x 9cm.

2. Color of Brick

The natural variations in aggregates vary throughout the globe, so colors of Bricks vary. The normal brick is copper color. The color varies in several classifications of bricks. Low-quality and fourth class bricks are dark in color.

3. Sound

A good quality Brick gives a clear ringing sound struck with another brick. A metallic sound hears clearly striking a brick with a hammer.

4. Strength

A good quality Brick is hard and strong. Scratching on the surface of bricks there are no impressions on faces. It has a relatively high compressive strength.

5. Durability

It has a certain durability. Dropping from a height of one meter on a flat hard surface it never breaks. It is a homogenous and well compact structure free from cracks and voids.

6. Good Brick Earth

It is well burnt in clamps and kilns. And free from earth containing organic matters, foreign materials, and chemical salts.

7. Water Absorption

Water more than twenty percent not absorbs by immersing the brick in cold water for twenty-four hours.

8. Resistivity

A good quality Brick is a soundproof and fire resistant. It is a good abrasion resistant material.