About cement history , chemical & physical parameters , application , Concrete & their test

1. WELCOMES
By – Devendra Singh Nischal
9630313333

2. GENERAL
CONSTRUCTION
PRACTICES

3. TYPES OF
STRUCTURE
• LOAD BEARING WALL STRUCTURE
• FRAMED STRUCTURE ( R.C.C.)

4. STAGES OF CONSTRUCTION
EXCAVATION
FOUNDATION
D.P.C.
COLUMN
BEAM
SLAB
BRICKWORK
PLASTERING
FLOORING

5. Break Up of Cost of a Building Excluding
Sanitary and Electrical Works - Guidelines
 Earthwork in excavation and filling = 0.5%
 Concreting in foundation = 5%
 Damp proof course = 1%
 Brickwork = 34%
 Roofing = 20%
 Flooring = 6%
 Doors and windows = 16%
 Plastering and pointing = 10%
 White washing, colour washing and painting etc. = 2%
 Miscellaneous = 5.5%
 TOTAL = 100%
 Individual cost may vary depending upon various local
parameters and fancy items)

6. Building Material Required
For Construction
Cement
Fine Aggregate (Sand)
Coarse Aggregate (Stone Chips)
Reinforcement (Steel Bars)
Water

7.  1756 – British Engineer, John Smeaton
invented first modern concrete by adding
pebbles, lime & brick powder.
 1824 – Joseph Aspidin a mason at Leeds,
England invented Portland Cement.
 1828 – Joseph Aspidin established first
cement Plant at Wakefield.
 1849 – Joseph Monier invented R.C.C.
 1885 – British Engineer F. Ransome
patented slightly tilted horizontal rotary
Kiln.
CEMENT HISTORY

8. INDIAN CEMENT INDUSTRY – OVERVIEW
 1914 – First Cement Plant in India at
Porbandar.
 India ranked second Largest Producer.
 Installed Capacity of 159.33 MTPA.
 54 – Major Companies in India
 125 – Large Plants.
 300 – Mini Plants.
 94%- Contributed by Large Plant.
 36% - Manufacturing of OPC
 64% - Manufacturing of Blended Cement.
 6% - Contribution in world production.

9. What Is Cement?
Portland cement is made by heating a mixture
of limestone and clay up to a temperature of
about 1350-14000c. partial fusion occurs &
nodules of clinker are produced. The clinker
is mixed with a few percentage of gypsum and
finely ground to make the cement.
The gypsum controls the rate of set of cement.

10. FOLLOWING ARE THE
MINERALS USED TO PRODUCE
THE CEMENT-
 Limestone
 Laterite
 Coal
 Gypsum
 High reactive silica (for PPC)

11. BASIC RAW MATERIAL
REACTANT RANGE SOURCE
LIME 60 – 67 % LIME STONE
SILICA 17 – 25% SAND/ SHALE
ALUMINA 03 - 08% CLAY / SHALE
IRONE OXIDE 01 - 04% CLAY / SHALE
MAGNESIA 01 - 05% IMPURITIES IN
RAW MATERIAL

12. CEMENT
MANUFACTURING
PROCESS

13. Limestone
quarry Crusher LS Stock Pile
Raw Mill
Raw meal
Silo
Rly. Wagon
Truck
Coal Crusher Coal Hopper
Coal Mill Fine Coal bin
P.H.
Kiln Cooler Clinker
SILO Cement Mill
Cement Silos
Packing
Plant Despatch Truck
Wagon
Bulk Loading
ROLLER
PRESS
FLYASH GYP.

14. SALIENT FEATURES
OF
WONDER CEMENT PLANT

15. Special Feature Of Wonder Cement Plant
 1st plant in North India with Robotic Technology
 Six Stage Low Pressure drop Pre-Heater.
 Double Grinding system to ensure better fineness.
 On-Line computerized quality control to ensure consistency from
the raw meal to the final product.
 Fuzzy logic control for kiln and cement for instantaneous
response for corrective action.
 Three electronic packers capable of packing 280 mt per hour.
 Twelve truck loaders each capable of loading one truck of 15 MT
in 10 minutes.
 Advanced Auto Packing & Auto Loading Technology First Time
in India
 Self reliance in total Power requirement.

16. TYPES OF CEMENT AND ITS APPLICATION
CEMENT TYPE BIS NO. MAJOR
 OPC – 33 Grade 269:1989 Mass Concreting.
 OPC – 43 Grade 8112:1989 RCC work – M15,M20.
 OPC – 53 Grade 12269:1987 High Strength – All type of
RCC WORKS.
 PPC ( Part –1 ) 1489:1991 Mass Conc./Dam/Marine/
RCC WORKS.
 PSC 455:1975 Mass Conc./Dam/Marine/
RCC WORKS.
 White cement 8042:1975 Decorative work / Marble/
Tiles WORKS.
 OPC – SRC 12330:1988 Marine/Underground.
 Rapid Hardening 8041:1978 Under water Structures.
Cement
 High Alumina 6052:1972 High Initial Strength –1day /
Cement 3days

17. ROLE OF CHEMICAL COMPOUND IN
CEMENT QUALITY
REACTANT CONTRIBUTION IN QUALITY
C3S EARLY STRENGTH /
FINAL STRENGTH
C2S LATER STRENGTH
(AFTER 14 DAYS ) TO
ULTIMATE STRENGTH.
C3A ENHANCE
DURABILITY
C4AF MAJOR CONTRIBUTION
IN PROCESS

18. JELLIFICATION IN OPC
2C3S (OPC)+ 6H20 = C-S-H Gels +3Ca(OH)2
2C2S (OPC)+ 4H20 = C-S-H Gels +Ca(OH)2

19. OPC
CONCRETE
MICRO CRACKS & POROUSITY
EFFECTS OF HUMIDITY & TEMPERATURE GRADIENTS,
CHEMICALATTACKS & LEACHING OF LIME,
HIGH PERMEABILITY
WATER & O2,
CO2 CHLORIDES
CORROSION OF
EMBEDDED STEEL
GROWTH
IN CRACKS

20. PRIMARY JELLIFICATION
SECONDARY JELLIFICATION
POZZOLANA (SiO2) + Ca(OH)2 + H2O =
(PPC)
2C3S + 6H20 = C-S-H Gels +3Ca(OH)2
2C2S + 4H20 = C-S-H Gels +Ca(OH)2
C-S-H Gels
JELLIFICATION IN PPC

21. WONDER CEMENT
PRODUCTS
43 grade
53 grade
PPC

23. Strength
BIS Recommendation – ( Compressive Strength in Mpa)
Days 33 G 43 G 53 G PPC
3 days 16 23 27 16
7 days 22 33 37 22
28 days 33 43 53 33

24. S.NO PARTICULERS 43 GRADE PPC
IS:8112 WONDER IS:1489 (PART-
1) 1991
WONDER
1 COMPRESIVE STRENGTH
a. 3 DAYS 23 MPa Min 32 MPa 16 MPa Min 32 Mpa
b. 7 DAYS 33 MPa Min 44 MPa 22 MPa Min 42 Mpa
c. 28 DAYS 43 MPa Min
, 58 MPa
max
57 MPa 33 MPa Min 61 Mpa
2 SETTING TIME
a. Initial 30 Min 120 30 Min 140
b. Final 600 Max 160 600 Max 220
3 Fineness (m2/kg) 225 Min 300 300 Min 360

25. MAIN FEATURES
OF
WONDER CEMENT (PPC)

26. LOW HEAT OF HYDRATION.
LOW LEACHING OF LIME
DOUBLE REACTION
HIGHER FINENESS.
HIGHER WORKABILITY.
LOW PERMEABILITY.
SAFEGUARD STEEL FROM CORROSION.
BETTER RESISTANCE TO CHLORIDE &
SULPHATE.
HIGH COMPRESSIVE STRENGTH.
LONG TERM DURABILITY.
CONSISTENT QUALITY

27. DOUBLE CHEMICAL REACTION
 FIRST STAGE REACTION:
Cement part of Clinker + water C –S – H + Ca(OH)2
(Cement Gel)
 SECOND STAGE REACTION:
Ca(OH)2 + Fly Ash C – S – H (Additional Gel)

28. Wonder Cement (PPC)–
MULTI PURPOSE CEMENT
RCC Work, in all types of building
construction.
Mass concrete project Dams, Spillways
Canals
Bridge,Culverts & Drainage work.
Effluent & sewage treatment plants.
Marine works
Plastering,Brick Work
Cement Based Product

29. Fine Aggregate (Sand)
 clear, angular and hard
 free from clay, mica and soft, flaky material
 graded, which means it should be a mix of fine,
medium and coarse sand
 free from contaminants like sea salt
 consistent in moisture (water) content which
should not exceed 7%. When mixing concrete the
moisture content must be taken into consideration

30. Coarse Aggregates
(Stone Chips)
 Stone chips should be angular or round, not flat or
flaky
 They should not contain marks or layers of any
other colour
 They should be free from mud and other
impurities, which are harmful for concreting. It is
advisable to wash the stone chips before mixing to
make it free from dust, dirt and mud.

31. Reinforcing steel
 Make sure the steel you use is:
 Steel bars/rods should be reasonably clean and
free of rust
 Bars that cannot be easily bent manually or
mechanically should be rejected
 Optimum length bars must be chosen to reduce
wastage in cutting
 To avoid laps, shorter bars must not be accepted
 Welded lengths of bars should not be accepted.

32. Water
It is very important to use clean, potable
water in quality concrete production.
Brackish or salty water must never be used.
Contaminated water will produce concrete
and mortars with lower durability, erratic
set characteristics and inconsistent colour

33. Mix
Cement + Water = Paste
Cement + Water + Fine Aggregate =
Mortar
Cement + Water + Fine Aggregate +
Coarse Aggregate = Concrete

34. Types of Concrete
• Plain Cement Concrete
• Reinforcement Cement Concrete

35. Concrete
• By Hand Mix
• By Machine at Site
• Ready Mixed Concrete

36. By Hand Mixing

38. SOME USEFUL TIPS
•Use concrete mix at the earliest. For this purpose prepare
concrete
mix in small batch.
•Don’t pour concrete from a height more than 1 meter.
•Always use potable water for mixing, concreting, curing, etc.
•Always use vibrator in RCC / Concreting, whether it is a
slab/beam/column or any other structure.
•While using brick for masonry purpose, don’t forget to
immerse
brick in water a night before its use.

39. FACTORS AFFECTING
STRENGTH OF CONCRETE
FACTOR VARIATION IMPACT
Stored cement old by 6 months (-) 30 to 40%
Added water Excess by 1 Litre /bag (-) 20 to 25 Kg/Cm2
Temperature less by 1 degree (-) 4 to 8 Kg/Cm2
Compaction Void by 1% (-) 5%
Less curing -- (-) 30 to 50 %

40. Admixtures
• Mineral Admixtures
 Fly Ash
 Silica Fume
 Ground Granulated Blast Furnace Slag
• Chemical Admixtures
 Air –Entrainment
 Water Reducing
 Set –Retarding
 Accelerating
 Super plasticizers

41. Fly Ash
• What is Fly Ash?
• Importance of Fly Ash in
Cement & Concrete

42. Bricks
How do you recognize good bricks?
 They show uniform texture and colour
When broken, they leave no lumps and
grit

43. Bricks Classifications
1st Class Bricks 2nd Class Bricks 3rd Class Bricks Jhama /Over
burnt Bricks
Perfect in size/shape
Red to cherry-red in
colour
Do not break when
dropped from waist
height
Do not absorb more
than 15 to 17% of
their own weight if
kept submerged for 1
hour under water
Suitable for
precision work such as
exposed brickwork
Not so uniform as
1st class bricks in
shape/size/quality of
burning
Do not absorb more
than 25% water of
own weight if kept
submerged under
water for 1 hour
Good for brickwork
wherever subsequent
plastering is to be
done
Much inferior to
2nd class bricks in
terms of shape/size
and burning
Absolutely out of size
and shape, over burnt,
fused with more bricks,
with a honeycomb
texture
Dark red to black in
colour
These bricks are
unsuitable for any kind
of brickwork, and are
only used in broken
pieces for consolidation
of foundation soil and
sub base of floors

44. Curing
For floors and roof slabs
For columns
For beams
For Walls
For Plaster

45. De-shuttering Period
Summer Winter or temp
< 18oC
Walls, Columns & vertical
faces of structural members
24 hr. 48 hr.
Removed of props under
slab Spanning up to 4.5 m
7 days 14 days
Removal of props under
beams & arches spanning
up to 6 m
14 days 28 days
*This holds good under standard conditions of workmanship &
Standard materials used.

46. CEMENT STORING

47. HOW TO STORE CEMENT
Ideally it should be stored at waterproof ware
house.
Stacks should be close together to reduce the air
circulation, max. stack should be of 15 bags.
Stacks should be 30 cm away from the walls and
preferably on wooden plank.
It should be stacked in Staggered manner to
avoid toppling.
Remove them from two or three tiers, rather than
all from one tier. This will prevent toppling.
Due to pressure at the lower bags it tends to
cake, roll the bags before use.
When removing bags for use, do it on a
"first in, first out" system.

48. LOSS OF STRENGTH DUE TO STORING
CEMENT STORED OVER 3 MONTHS
NEED TO BE TESTED IN LAB
BEFORE USE.
 % LOSS OF STRENGTH IN STORING CEMENT
UPTO 3 MONTHS : 20 – 30 %
UPTO 6 MONTHS : 30 – 40%
OVER 6 MONTHS : 40 – 50%

49. COMPLAINTS

50. Major Types Of Complaints
Cracks
Late Setting
Low Initial or Final Strength
Honeycombing
Collapse Of Structure or Failure
Color Variation
Floating

51. HOW TO HANDLE CUSTOMER’S COMPLAINT
 REMEMBER
DO NOT IGNORE COMPLAINT.
 DO NOT STORE COMPLAINT.
 DO NOT ACT AGGRESSIVELY WITH THE CUSTOMER.
 DO NOT TAKE COMPLAINT IN BUSINESS.
 ACTION TO BE TAKEN
• IMMEDIATE SITE VISIT IS REQUIRED BY THE CONCERNED S.O.
• INVESTIGATE THE GENUINENESS OF COMPLAINT.
• COLLECT THE RELEVANT DATA.
• NO ASSURANCE OR COMMITMENT SHOULD BE GIVEN ON SITE.
• CONVEY YOUR COMPLAINT TO THE TECHNICAL PERSON.

52. Attending the complaint – A Technique –
 Up-date your self
 Be confident about your product
 Prepare yourself before attending the complaint
by knowing the data -
 About the party
 Cement batch & grade
 Type of complaint

53. Diagnose the complaint-
- Listen Care fully to the customer dully customer is an
important person
- Be Sympathetic with him
- Try to read his intentions
- Discuss with different people available at site regarding
complaint and work procedure individually like mason,
contractor lobour etc.also
- Do not directly blame their working / mistake
- Do not make hurry to give your decision before you
diagnose the complaint
- Keep calm and do not irritate or anger on harsh
wards of customer remember he is a sufferer

54. Start diagnosing
- Inspect the material available -
Coarse Aggregate
- Quality of aggregate viz. Hardness etc.
- grading of aggregate
- percentage below 4.5 mm
- foreign Material if any

55. Cement
- Packing
- Week no.
- Printing
- Storage condition
- Lumps
- Adulteration if any
- Colour to check adulteration

56. Types of Complaints And Their
Probable Reasoning
Late setting-
- Impurities like clay, silt, chemicals etc. in
sand, coarse aggregate, & water.
- Excess water cement ratio
- Ambient climatic condition (very low temperature)

57. Low Initial / Final Strength-
Use of sub standard building material
Improper mixing
High water cement ratio
Concrete/ mortar mixed on ground
Avoidance of measuring boxes/ pans
High aggregate cement ratio
Improper placing of concrete
Improper or no vibration
Cont.

58. Rain just after or during work execution
Very high or low temperature
Curing
Excess bleeding during concrete
Poor form work
Use of mix after initial setting time
Use of partly set cement

59. Honeycombing-
Poor farm work -resulting bleeding takes
place
Improper vibration
Excess water cement ratio
Improper grading of material
Low cement content

60. Collapse of structure/ failure-
One or some of the above reasons
Design failure
Improper placing & bending of reinforcement
No cover blocks or no proper cover
Movement of props below form work after concreting
Early de shuttering
Settlement of soil below form work props
Improper bearing in case of lintel
Improper anchorage in case of stair landing,
balcony, chhajja etc.
Foundation on loose strata

61. Cracks
 One or some of the above reasons
 No provision for the expansion joint in continuous structure
 During concreting leaving the joint at inappropriate location
at the break time or power failure & restart concrete without
taking proper care
 Superficial crack- due to surface finishing with neat cement
and over troweling
 Naked wall not prepared properly before plastering
 Excess thick coat of plaster
 Corrosion in reinforcement
 Rapid hydration due to high ambient temrature
 Different material combination i.e. R.C.C. & brick wall

62. Color variation-
 Due to comparison with other brand
 Color varies from unit to unit due to different raw material
& process technology
 Varies due to different ratios, and source of gitti, sand in
plastered surface
 Color does not affect the strength & quality of structure

63. Floating-
 It is not a complaint actually it is a phenomena of
PPC
 Floating material is very fine particles of high reactive
silica, which has a major role in developing the strength

64. Investigation of structure -
- Check the hardness of the structure at different places
by hammering. A different ringing sound at different
places shows different workmanship / ratio used at site
- Surface texture to have an idea about workmanship
and ratio used
- Different shades of the surface
- Check the size of measuring boxes / iron pan correlate the no.
told with the volume of cement
- Inspect the the sites where mixing has done either manually
or mechanically
- Ask about the process of mixing, laying, compacting etc
ALSO CHECK -

65. - Reinforcement provided
- Check the strength of different lumps of the structure.
If structure is collapsed-
- Aggregates rough % in debris
- Check if rain on the working day
- Check the possibility of disturbing the props
- strength of other structure made by the same batch cement
- Check whether other brands also used
- Curing – sufficient / insufficient
- Check the minimum / Maximum temp. of the working day

66. Convincing the complainant –
- Prepare of cement balls
- Sample of plaster, masonry, concrete
- If available cubes may be casted
- Draw the samples, minimum -3
- Revisit if required to check the samples prepared
Now conclude and convince the customer
- Brief the customer about mistakes done at his end
by giving some evidence and examples
- Customer should not feel that you are favoring
your company