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R.C.C & Steel Structures
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Syllabus R.C.C & Steel Structures
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Syllabus for R.C.C
Concrete Technology- properties of concrete, basics of mix design. Concrete design- basic working stress
and limit state design concepts, analysis of ultimate load capacity and design of members subjected to
flexure, shear, compression and torsion by limit state methods. Basic elements of pre-stressed concrete,
analysis of beam sections at transfer and service loads.
Syllabus for Steel Structures
Analysis and design of tension and compression members, beams and beam- columns, column bases.
Connections- simple and eccentric, beams column connections, plate girders and trusses. Plastic analysis
of beams and frames.
Analysis of GATE Papers
(R.C.C & Steel Structures)
Year Percentage of marks Overall Percentage
2013 5.00
13.26%
2012 11.00
2011 12.00
2010 9.00
2009 12.00
2008 11.33
2007 12.00
2006 11.33
2005 15.33
2004 16.00
2003 15.3
2002 24.66
2001 17.33
2000 13.33
Contents R.C.C& Steel Structures
THE GATE ACADEMY PVT.LTD. H.O.: #74, KeshavaKrupa (third Floor), 30
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CONTENTS
Chapter Page No.
R.C.C
#1 Concrete Technlogy 1-18
 Properties of Concrete 1
 Classification of Cements 1 – 3
 Specifications for Portland Cement 3 – 4
 Specification of Aggregates 5
 Measurement of Materials 5 – 7
 Solved Examples 8 – 9
 Assignment 1 10
 Assignment 2 11 – 13
 Answer Keys & Explanations 14 – 18
#2 Basic of Mix Design 19 – 30
 Methods of Proportioning of Concrete Mixes 19 – 20
 Grades of Concretes (IS 456:2000) 21 – 24
 Mixing Compacting and Curing of Concrete 24 – 25
 Assignment 1 26 – 27
 Assignment 2 27 – 28
 Answer Keys & Explanations 29 – 30
#3 Design of RCC Structures 31 – 40
 Methods of Analysis and Design of RCC Structure 31 – 32
 Limit State Design Concepts 32 – 33
 Recommendations of Indian Standard Codes 34
 Assignment 1 35 –36
 Assignment 2 36– 38
 Answer Keys & Explanations 39 – 40
#4 Analysis of Ultimate Load Capacity 41 – 93
 Modes of Failure: Flexure 41 – 48
 Limit State of Collapse – Shear 48 – 50
 Vertical Stirrups 50 – 52
 Limit State of Serviceability, Deflection & Cracking 52 – 54
Contents R.C.C& Steel Structures
THE GATE ACADEMY PVT.LTD. H.O.: #74, KeshavaKrupa (third Floor), 30
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 Coefficient for Moment & Shear Force Calculations in Beams &
Slabs
54 – 56
 Columns 57 – 62
 Tensile Reinforcement 62 – 63
 Solved Examples 63 – 87
 Assignment 1 88 – 89
 Assignment 2 89 – 91
 Answer Keys & Explanations 92 – 93
#5 Basic Elements of Pre-stressed Concrete 94 – 107
 Disadvantages of Simple Reinforced Concrete 94
 IS Code Provision (IS: 1343 – 1980) 94 – 95
 Permissible Stress in High Tension Steel 95 – 96
 Losses of Pre-stress 96 – 98
 Solved Examples 99 – 104
 Assignment 1 105 – 106
 Assignment 2 106
 Answer Keys & Explanations 107
#6 Design of Pre-Stressed Concrete Beams 108 – 125
 Design of a Rectangular Beam 108– 110
 Design of an I – Section Beam 110 – 111
 Deflection of Pre-stressed Concrete Member 111 – 113
 Analysis of Pre-stress Concrete 113 – 117
 Solved Examples 117 – 122
 Assignment 1 123 – 124
 Assignment 2 124
 Answer Keys & Explanations 125
Steel Structures
#7 Introduction 126 – 145
 Types of Steels 126 – 128
 Bolted Connections 128 – 130
 Terminology 130–133
 Solved Examples 134 – 139
 Assignment 1 140
Contents R.C.C& Steel Structures
THE GATE ACADEMY PVT.LTD. H.O.: #74, KeshavaKrupa (third Floor), 30
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 Assignment 2 141 – 143
 Answer Keys & Explanations 144 – 145
#8 Plastic Analysis 146 –166
 Classification of Structural Analysis 146 – 147
 Plastic Section Modulus 147 – 148
 Shape Factor 148 – 150
 Characteristics of Plastic Hinge 150 – 151
 Methods of Analysis 151 – 153
 Solved Examples 154 – 161
 Assignment 1 162 – 163
 Assignment 2 164
 Answer Keys & Explanations 165 – 166
#9 Welded Connections 167 – 176
 Types of Welding Process 167 – 169
 Design Stresses in Welds 169 – 170
 Solved Examples 170 – 172
 Assignment 1 173 – 174
 Assignment 2 174
 Answer Keys & Explanations 175 – 176
#10 Design of Tension Member 177– 185
 Types of Permissible Stress 177 – 178
 Lug Angle 178 – 179
 Solved Examples 180 – 183
 Assignment 1 184
 Assignment 2 184
 Answer Keys & Explanations 185
#11 Compression Member 186 – 207
 Compression Member 186
 Construction Details 186 – 189
 Behaviour of Compression Member 189 – 192
 Design of Compression Members 192 – 196
 Solved Examples 197 – 202
Contents R.C.C& Steel Structures
THE GATE ACADEMY PVT.LTD. H.O.: #74, KeshavaKrupa (third Floor), 30
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Cross, 10
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 Assignment 1 203 – 204
 Assignment 2 204 – 205
 Answer Keys & Explanations 206 – 207
#12 Beams 208 – 230
 Classification of Beams 208 – 210
 Design for Shear 210 – 211
 Web Buckling and Web Crippling 212
 Design Procedure for Channel / I – Section Purlins 212 – 215
 Solved Examples 216 – 226
 Assignment 1 227
 Assignment 2 227 – 228
 Answer Keys & Explanations 229 – 230
Module Test 231 – 243
 Test Questions 231 – 238
 Answer Keys & Explanations 239 – 243
Reference Books 244
Chapter 1 R.C.C
THE GATE ACADEMY PVT.LTD. H.O.: #74, KeshavaKrupa (third Floor), 30
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Chapter 1
Concrete Technology
Properties of Concrete
Cement Concrete
It is the construction material, which is obtained by hardening of mixture of cement, sand, gravel
and water in a predetermined proportions, this mixture is used by pouring it into suitable
moulds and allowed to harden and then cured.
Characteristics of Concrete
1) It has good compressive strength but weak for taking tensile loads.
2) It shows resistance to corrosion & fire.
3) The process of hardening of concrete is time varying and it gains strength with time.
4) Concrete structures are much more economical then steel.
5) Concrete can form hard surface and thus resist the abrasion.
6) Its strength depends upon quality of material and handing condition.
7) It shows the tendency of shrinking initially, because of loss of water. It also shrinks as the
process of hardening goes on.
8) It can be blended with steel bars to far R.C.C
Cement & its Setting Time
a) Initial setting time of concrete:(30 to 60 minutes)this is the time phase in which mixed
proportion attains the pronounce resistance to flow and plasticity is decreased. As per the
IS code it should be more than 30minutes, so that during this phase concrete can be mixed,
transported and used at required place.
b) Final Setting time of Concrete: (5 to 6 Hours). This is the second time phase during which
concrete remains relatively soft solid with no surface hardness. In this time concrete
starts gaining the strength. As per IS codes, it should not be more than 10 hours.
c) Progressive Hardening and Increase in Strength:This is the third time phase during which
concrete almost attains most of its strength during initial stage, this process is quite rapid.
It is generally one month after mixing.
A small quantity of Gypsum is added in the cement. The initial setting time is controlled by
the quantity of Gypsum added. More is the quantity of Gypsum, more will be initial setting
time.
Classification of Cements
1) Portland Cement
The main constituents of Portland cements are
Lime (CaO) 60 to 67%
Silica (SiO2) 17 to 25%
Alumina (Al2O3) 3 to 8%
Calcium Sulphate (CaSO4) 3 to 6%
Iron Oxide (Fe2O3) 0.5 to 6%
Magnesia (MgO) 0.1 to 4%
Chapter 1 R.C.C
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Sulphur trioxide (SO3) 1 to 3%
Alkalies 0.5 to 1.3%
 Argillaceous Material in form of clays and shade and calcareous material in the form
of lime, stone, chalk are used as Raw Materials in the ratio of 1:2.
 When raw material containing above constituents undergo burning & fusion, the
chemical reaction takes place and following compounds are formed called (Bogue
Compounds).
1. Tricalcium silicate (3CaO.SiO2): C3S
2. Dicalcium silicate (2CaO. SiO2): C2S
3. TricalciumAlluminate (3CaO.SiO2): C3A
4. TetracalciumAluminoFerrite (4CaO.Al2O3.FeO3): C4AF
 C3S and C2S contributes to most of eventual strength, However, initial setting is due to
C3A.
 C3S quickly hydrates and contributes initial strength. Contribution of C2S is after 7
days of mixing and extends upto 1 year the strength in first 24 hours are imparted by
C3A. All the four compounds looses heat when mixed with water. C2S generate
minimum heat whereas C3Agenerate maximum. Therefore C3 A is responsible for
undesirable properties of concrete cement having lower C3A content will have higher
ultimate strength, less generation of heat and less cracking.
Types of Portland Cement
a. Ordinary Portland cement(IS:269):[OPC]
It is manufactured generally in larger quantities than others. It is generally suitable in
concrete construction where there is no exposure to sulphates in soil or ground water.
b. Rapid Hardening Portland Cement (IS: 8041)
Also known as high early strength cement. It is ground finer, contains lesser C2S and more
C3S compared to OPC. Strength developed in 3 days in rapid hardening Portland cement is
nearly equal to strength developed in 7 days in OPC but shuttering may be removed
earlier, thus saving time and expanses. Similarly in concrete product industry, moulds can
be released early. Also used in road construction when any delay has to be avoided.
c. Extra Rapid Hardening Cement
Obtained by Inter grinding CaCl2 with rapid hardening cement. It imparts quick setting
properties also.
d. Low Heat Portland Cement (IS: 12600)
It has low percentage of C3A and C3S and higher percentage of C2S it has low rate of gaining
strength but practically equal ultimate strength This is achieved by limiting amount of
calcium and increasing silicates in raw materials.
This is used where the rate at which heat can be lost at the surface is lower than at which
heat is being generated initially.
Examples: Abutments, Retaining walls, dams etc.,
e. Portland Blast Furnace Cement (Is: 455)
It is manufactured inter grinding of Portland cement clinker with blast furnace slag. It has
comparatively low heat of hydration and can be used in replacement to ordinary Portland
cement. Proportion of slag vary from 25% to 65% by weight of cement. Gypsum is added
to regulate the setting time of cement.
Chapter 1 R.C.C
THE GATE ACADEMY PVT.LTD. H.O.: #74, KeshavaKrupa (third Floor), 30
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f. Portland Pozzolana Cement (IS: 1489):- [PPC]
It is manufactured by inter grinding Portland cement clinker and pozzolana (burnt clay,
shale or fly Ash etc.) or by blending instead of inter grinding. 10% to 25% of pozzolana
can be used. Pozzolana have no cementing value but combine with free lime. This cement
has more resistance to chemical and sea water attack. It also have low heat evolution.
g. Sulphate Resisting Cement (IS: 12330)
In these cement the quanity of C3A is strictly limited. And these are normally ground finer
than OPC. Resistant skin formed through carbonation by action of atmospheric CO2. This
cement should be allowed to harden in air for as long as possible.
h. White and coloured Portland Cement
Raw materials like chalk and lime stone having low percentage of iron are used the
percentage of iron oxide is limited to 1% sodium aluminium fluoride (Cryolite) is added to
act as flux in absence of Fe2O3. Oil fuels are used instead of coal fuel to avoid contamination
by coal ash. Colour is obtained by adding pigments in OPC or white cement. Pigment
should be permanent & chemically inert.
2) High Alumina Cement
Raw materials in manufacturing are of extremely high alumina content (chalk and
Bauxite). It has dark colour, high early strength even than rapid hardening cement, high
heat of hydration and more resistance to chemical attack. Rapid hardening proper arise
from monocalcium Aluminate (Al2O3.CaO). It has free hydrated lime as in case of OPC.
Manufacture is more expensive than OPC.
3) Super Sulphated Cement (Is – 6909)
It is manufactured from well granulated blast furnace slag (80 to 85%), calcium sulphate
(10 to 15%) and Portland cement (1 to 2%). It ground finer than OPC. It have low heat of
hydration totally and suited for construction of dams and mass concrete work. Concrete
derived from this cement expands if cured in water and shrink if cured in air. It have high
resistance to chemical attack.
4) Natural Cement
There are manufactured from naturally occurring cement rocks with composition similar
to mix of argillaceous and calcareous materials natural cement rocks are burned at
comparatively lower temperature. The properties of these cement depends composition of
cement rock.
5) Masonary Cement
These are manufactured from grinding of Portland Cement linker, lime stone, gypsum &
air-entraining agent. These are ground finer then the high early strength Portland cement.
These are used as mortar for brick masonary. Lime stone & air-entraining agents impart
plasticity and workability shrinkage is fairly low.
Specifications for Portland Cement
ISI has recommended following tests & specifications
1. Chemical Compositions:- (IS: 4032 – 1968)
(A) Ratio of percentage of lime to %
age of silica, alumina and Fe2O3
calculated by following formula
- Not greater than 1.02 but not
less than 0.66
Chapter 1 R.C.C
THE GATE ACADEMY PVT.LTD. H.O.: #74, KeshavaKrupa (third Floor), 30
th
Cross, 10
th
Main, Jayanagar 4
th
Block, Bangalore-11
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CaO − 0.7 SO3
2.8SiO2+1.2 Al2O3 + 0.65Fe2O3
(B) Ratio of % of alumina to that of
Fe2O3
- Not less than 0.66
(C) Weight of insoluble residue - Not more than 2%
(D)Weight of Magnesia - Not more than 6%
(E) Total sulphuric Anhydride (SO3) - Not more than 2.75%
(F) Total loss on ignition - Not more than 4%
2. Fineness:-By Blaine’s air permeability method (IS:4031 – 1968) this is done to check
proper grinding.
Type of Cement Specific Surface
Low heat More than 3200
Rapid Hardening More than 3250
Ordinary More than 2250
3. Soundness:-By ‘Le Chatelier’ method (IS: 4031 – 1968) Rapid hardening & low heat
Portland cement should have expansion less than 10mm.
4. Setting Time:- By Vicat Apparatus
i). Initial setting time for ordinary, Rapid hardening and low heat Portland cements
should be around 30, 30 and 60 minutes respectively.
ii). The final setting time for ordinary, Rapid hardening and low heat cements should be
around 600, 60 and 600 minutes respectively.
5. Compressive Strength:(4031 – 1968) – Cube test.
Compressive strength at the end of 3 days should be more than 11.3 N/mm2 and that at
the end of 7 days should not be less than 17.2 N/mm2
6. Heat of Hydration: (IS 4031 – 1968)
Only for low heat cement heat of hydration after 7 days should not be more than 65
calories per gram and after 28 days should not be more than 75 cal/g.
7. Tensile Strength:
P
5
+ 2.5 at 3 days should not be lesser than 2 N/mm2
P
5
+ 2.5 at 7 days should not be lesser than 2.5 N/mm2.
Where P i standard consistency of cement
Aggregates
a) Coarse Aggregates: (Size > 4.75 mm)
The aggregates which are retained on 4.75 mm size sieve. Maximum size of coarse
aggregates is limited to one third of thickness of concrete section for thin slabs and walls.
b) Fine Aggregates: (Size < 4.75 mm)
The aggregates which are passed through 4.75 mm sieve. Usually natural river sand is
used. Angular grained sand produces good concrete because of interlocking.
Civil Engineering : Rcc & steel structures, THE GATE ACADEMY

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Civil Engineering : Rcc & steel structures, THE GATE ACADEMY

  • 1.
  • 2. R.C.C & Steel Structures For Civil Engineering By www.thegateacademy.com
  • 3. Syllabus R.C.C & Steel Structures THE GATE ACADEMY PVT.LTD. H.O.: #74, Keshava Krupa (third Floor), 30 th Cross, 10 th Main, Jayanagar 4 th Block, Bangalore-11 : 080-65700750,  info@thegateacademy.com © Copyright reserved. Web: www.thegateacademy.com Syllabus for R.C.C Concrete Technology- properties of concrete, basics of mix design. Concrete design- basic working stress and limit state design concepts, analysis of ultimate load capacity and design of members subjected to flexure, shear, compression and torsion by limit state methods. Basic elements of pre-stressed concrete, analysis of beam sections at transfer and service loads. Syllabus for Steel Structures Analysis and design of tension and compression members, beams and beam- columns, column bases. Connections- simple and eccentric, beams column connections, plate girders and trusses. Plastic analysis of beams and frames. Analysis of GATE Papers (R.C.C & Steel Structures) Year Percentage of marks Overall Percentage 2013 5.00 13.26% 2012 11.00 2011 12.00 2010 9.00 2009 12.00 2008 11.33 2007 12.00 2006 11.33 2005 15.33 2004 16.00 2003 15.3 2002 24.66 2001 17.33 2000 13.33
  • 4. Contents R.C.C& Steel Structures THE GATE ACADEMY PVT.LTD. H.O.: #74, KeshavaKrupa (third Floor), 30 th Cross, 10 th Main, Jayanagar 4 th Block, Bangalore-11 : 080-65700750,  info@thegateacademy.com © Copyright reserved. Web: www.thegateacademy.com Page i CONTENTS Chapter Page No. R.C.C #1 Concrete Technlogy 1-18  Properties of Concrete 1  Classification of Cements 1 – 3  Specifications for Portland Cement 3 – 4  Specification of Aggregates 5  Measurement of Materials 5 – 7  Solved Examples 8 – 9  Assignment 1 10  Assignment 2 11 – 13  Answer Keys & Explanations 14 – 18 #2 Basic of Mix Design 19 – 30  Methods of Proportioning of Concrete Mixes 19 – 20  Grades of Concretes (IS 456:2000) 21 – 24  Mixing Compacting and Curing of Concrete 24 – 25  Assignment 1 26 – 27  Assignment 2 27 – 28  Answer Keys & Explanations 29 – 30 #3 Design of RCC Structures 31 – 40  Methods of Analysis and Design of RCC Structure 31 – 32  Limit State Design Concepts 32 – 33  Recommendations of Indian Standard Codes 34  Assignment 1 35 –36  Assignment 2 36– 38  Answer Keys & Explanations 39 – 40 #4 Analysis of Ultimate Load Capacity 41 – 93  Modes of Failure: Flexure 41 – 48  Limit State of Collapse – Shear 48 – 50  Vertical Stirrups 50 – 52  Limit State of Serviceability, Deflection & Cracking 52 – 54
  • 5. Contents R.C.C& Steel Structures THE GATE ACADEMY PVT.LTD. H.O.: #74, KeshavaKrupa (third Floor), 30 th Cross, 10 th Main, Jayanagar 4 th Block, Bangalore-11 : 080-65700750,  info@thegateacademy.com © Copyright reserved. Web: www.thegateacademy.com Page ii  Coefficient for Moment & Shear Force Calculations in Beams & Slabs 54 – 56  Columns 57 – 62  Tensile Reinforcement 62 – 63  Solved Examples 63 – 87  Assignment 1 88 – 89  Assignment 2 89 – 91  Answer Keys & Explanations 92 – 93 #5 Basic Elements of Pre-stressed Concrete 94 – 107  Disadvantages of Simple Reinforced Concrete 94  IS Code Provision (IS: 1343 – 1980) 94 – 95  Permissible Stress in High Tension Steel 95 – 96  Losses of Pre-stress 96 – 98  Solved Examples 99 – 104  Assignment 1 105 – 106  Assignment 2 106  Answer Keys & Explanations 107 #6 Design of Pre-Stressed Concrete Beams 108 – 125  Design of a Rectangular Beam 108– 110  Design of an I – Section Beam 110 – 111  Deflection of Pre-stressed Concrete Member 111 – 113  Analysis of Pre-stress Concrete 113 – 117  Solved Examples 117 – 122  Assignment 1 123 – 124  Assignment 2 124  Answer Keys & Explanations 125 Steel Structures #7 Introduction 126 – 145  Types of Steels 126 – 128  Bolted Connections 128 – 130  Terminology 130–133  Solved Examples 134 – 139  Assignment 1 140
  • 6. Contents R.C.C& Steel Structures THE GATE ACADEMY PVT.LTD. H.O.: #74, KeshavaKrupa (third Floor), 30 th Cross, 10 th Main, Jayanagar 4 th Block, Bangalore-11 : 080-65700750,  info@thegateacademy.com © Copyright reserved. Web: www.thegateacademy.com Page iii  Assignment 2 141 – 143  Answer Keys & Explanations 144 – 145 #8 Plastic Analysis 146 –166  Classification of Structural Analysis 146 – 147  Plastic Section Modulus 147 – 148  Shape Factor 148 – 150  Characteristics of Plastic Hinge 150 – 151  Methods of Analysis 151 – 153  Solved Examples 154 – 161  Assignment 1 162 – 163  Assignment 2 164  Answer Keys & Explanations 165 – 166 #9 Welded Connections 167 – 176  Types of Welding Process 167 – 169  Design Stresses in Welds 169 – 170  Solved Examples 170 – 172  Assignment 1 173 – 174  Assignment 2 174  Answer Keys & Explanations 175 – 176 #10 Design of Tension Member 177– 185  Types of Permissible Stress 177 – 178  Lug Angle 178 – 179  Solved Examples 180 – 183  Assignment 1 184  Assignment 2 184  Answer Keys & Explanations 185 #11 Compression Member 186 – 207  Compression Member 186  Construction Details 186 – 189  Behaviour of Compression Member 189 – 192  Design of Compression Members 192 – 196  Solved Examples 197 – 202
  • 7. Contents R.C.C& Steel Structures THE GATE ACADEMY PVT.LTD. H.O.: #74, KeshavaKrupa (third Floor), 30 th Cross, 10 th Main, Jayanagar 4 th Block, Bangalore-11 : 080-65700750,  info@thegateacademy.com © Copyright reserved. Web: www.thegateacademy.com Page iv  Assignment 1 203 – 204  Assignment 2 204 – 205  Answer Keys & Explanations 206 – 207 #12 Beams 208 – 230  Classification of Beams 208 – 210  Design for Shear 210 – 211  Web Buckling and Web Crippling 212  Design Procedure for Channel / I – Section Purlins 212 – 215  Solved Examples 216 – 226  Assignment 1 227  Assignment 2 227 – 228  Answer Keys & Explanations 229 – 230 Module Test 231 – 243  Test Questions 231 – 238  Answer Keys & Explanations 239 – 243 Reference Books 244
  • 8. Chapter 1 R.C.C THE GATE ACADEMY PVT.LTD. H.O.: #74, KeshavaKrupa (third Floor), 30 th Cross, 10 th Main, Jayanagar 4 th Block, Bangalore-11 : 080-65700750,  info@thegateacademy.com © Copyright reserved. Web: www.thegateacademy.com Page 1 Chapter 1 Concrete Technology Properties of Concrete Cement Concrete It is the construction material, which is obtained by hardening of mixture of cement, sand, gravel and water in a predetermined proportions, this mixture is used by pouring it into suitable moulds and allowed to harden and then cured. Characteristics of Concrete 1) It has good compressive strength but weak for taking tensile loads. 2) It shows resistance to corrosion & fire. 3) The process of hardening of concrete is time varying and it gains strength with time. 4) Concrete structures are much more economical then steel. 5) Concrete can form hard surface and thus resist the abrasion. 6) Its strength depends upon quality of material and handing condition. 7) It shows the tendency of shrinking initially, because of loss of water. It also shrinks as the process of hardening goes on. 8) It can be blended with steel bars to far R.C.C Cement & its Setting Time a) Initial setting time of concrete:(30 to 60 minutes)this is the time phase in which mixed proportion attains the pronounce resistance to flow and plasticity is decreased. As per the IS code it should be more than 30minutes, so that during this phase concrete can be mixed, transported and used at required place. b) Final Setting time of Concrete: (5 to 6 Hours). This is the second time phase during which concrete remains relatively soft solid with no surface hardness. In this time concrete starts gaining the strength. As per IS codes, it should not be more than 10 hours. c) Progressive Hardening and Increase in Strength:This is the third time phase during which concrete almost attains most of its strength during initial stage, this process is quite rapid. It is generally one month after mixing. A small quantity of Gypsum is added in the cement. The initial setting time is controlled by the quantity of Gypsum added. More is the quantity of Gypsum, more will be initial setting time. Classification of Cements 1) Portland Cement The main constituents of Portland cements are Lime (CaO) 60 to 67% Silica (SiO2) 17 to 25% Alumina (Al2O3) 3 to 8% Calcium Sulphate (CaSO4) 3 to 6% Iron Oxide (Fe2O3) 0.5 to 6% Magnesia (MgO) 0.1 to 4%
  • 9. Chapter 1 R.C.C THE GATE ACADEMY PVT.LTD. H.O.: #74, KeshavaKrupa (third Floor), 30 th Cross, 10 th Main, Jayanagar 4 th Block, Bangalore-11 : 080-65700750,  info@thegateacademy.com © Copyright reserved. Web: www.thegateacademy.com Page 2 Sulphur trioxide (SO3) 1 to 3% Alkalies 0.5 to 1.3%  Argillaceous Material in form of clays and shade and calcareous material in the form of lime, stone, chalk are used as Raw Materials in the ratio of 1:2.  When raw material containing above constituents undergo burning & fusion, the chemical reaction takes place and following compounds are formed called (Bogue Compounds). 1. Tricalcium silicate (3CaO.SiO2): C3S 2. Dicalcium silicate (2CaO. SiO2): C2S 3. TricalciumAlluminate (3CaO.SiO2): C3A 4. TetracalciumAluminoFerrite (4CaO.Al2O3.FeO3): C4AF  C3S and C2S contributes to most of eventual strength, However, initial setting is due to C3A.  C3S quickly hydrates and contributes initial strength. Contribution of C2S is after 7 days of mixing and extends upto 1 year the strength in first 24 hours are imparted by C3A. All the four compounds looses heat when mixed with water. C2S generate minimum heat whereas C3Agenerate maximum. Therefore C3 A is responsible for undesirable properties of concrete cement having lower C3A content will have higher ultimate strength, less generation of heat and less cracking. Types of Portland Cement a. Ordinary Portland cement(IS:269):[OPC] It is manufactured generally in larger quantities than others. It is generally suitable in concrete construction where there is no exposure to sulphates in soil or ground water. b. Rapid Hardening Portland Cement (IS: 8041) Also known as high early strength cement. It is ground finer, contains lesser C2S and more C3S compared to OPC. Strength developed in 3 days in rapid hardening Portland cement is nearly equal to strength developed in 7 days in OPC but shuttering may be removed earlier, thus saving time and expanses. Similarly in concrete product industry, moulds can be released early. Also used in road construction when any delay has to be avoided. c. Extra Rapid Hardening Cement Obtained by Inter grinding CaCl2 with rapid hardening cement. It imparts quick setting properties also. d. Low Heat Portland Cement (IS: 12600) It has low percentage of C3A and C3S and higher percentage of C2S it has low rate of gaining strength but practically equal ultimate strength This is achieved by limiting amount of calcium and increasing silicates in raw materials. This is used where the rate at which heat can be lost at the surface is lower than at which heat is being generated initially. Examples: Abutments, Retaining walls, dams etc., e. Portland Blast Furnace Cement (Is: 455) It is manufactured inter grinding of Portland cement clinker with blast furnace slag. It has comparatively low heat of hydration and can be used in replacement to ordinary Portland cement. Proportion of slag vary from 25% to 65% by weight of cement. Gypsum is added to regulate the setting time of cement.
  • 10. Chapter 1 R.C.C THE GATE ACADEMY PVT.LTD. H.O.: #74, KeshavaKrupa (third Floor), 30 th Cross, 10 th Main, Jayanagar 4 th Block, Bangalore-11 : 080-65700750,  info@thegateacademy.com © Copyright reserved. Web: www.thegateacademy.com Page 3 f. Portland Pozzolana Cement (IS: 1489):- [PPC] It is manufactured by inter grinding Portland cement clinker and pozzolana (burnt clay, shale or fly Ash etc.) or by blending instead of inter grinding. 10% to 25% of pozzolana can be used. Pozzolana have no cementing value but combine with free lime. This cement has more resistance to chemical and sea water attack. It also have low heat evolution. g. Sulphate Resisting Cement (IS: 12330) In these cement the quanity of C3A is strictly limited. And these are normally ground finer than OPC. Resistant skin formed through carbonation by action of atmospheric CO2. This cement should be allowed to harden in air for as long as possible. h. White and coloured Portland Cement Raw materials like chalk and lime stone having low percentage of iron are used the percentage of iron oxide is limited to 1% sodium aluminium fluoride (Cryolite) is added to act as flux in absence of Fe2O3. Oil fuels are used instead of coal fuel to avoid contamination by coal ash. Colour is obtained by adding pigments in OPC or white cement. Pigment should be permanent & chemically inert. 2) High Alumina Cement Raw materials in manufacturing are of extremely high alumina content (chalk and Bauxite). It has dark colour, high early strength even than rapid hardening cement, high heat of hydration and more resistance to chemical attack. Rapid hardening proper arise from monocalcium Aluminate (Al2O3.CaO). It has free hydrated lime as in case of OPC. Manufacture is more expensive than OPC. 3) Super Sulphated Cement (Is – 6909) It is manufactured from well granulated blast furnace slag (80 to 85%), calcium sulphate (10 to 15%) and Portland cement (1 to 2%). It ground finer than OPC. It have low heat of hydration totally and suited for construction of dams and mass concrete work. Concrete derived from this cement expands if cured in water and shrink if cured in air. It have high resistance to chemical attack. 4) Natural Cement There are manufactured from naturally occurring cement rocks with composition similar to mix of argillaceous and calcareous materials natural cement rocks are burned at comparatively lower temperature. The properties of these cement depends composition of cement rock. 5) Masonary Cement These are manufactured from grinding of Portland Cement linker, lime stone, gypsum & air-entraining agent. These are ground finer then the high early strength Portland cement. These are used as mortar for brick masonary. Lime stone & air-entraining agents impart plasticity and workability shrinkage is fairly low. Specifications for Portland Cement ISI has recommended following tests & specifications 1. Chemical Compositions:- (IS: 4032 – 1968) (A) Ratio of percentage of lime to % age of silica, alumina and Fe2O3 calculated by following formula - Not greater than 1.02 but not less than 0.66
  • 11. Chapter 1 R.C.C THE GATE ACADEMY PVT.LTD. H.O.: #74, KeshavaKrupa (third Floor), 30 th Cross, 10 th Main, Jayanagar 4 th Block, Bangalore-11 : 080-65700750,  info@thegateacademy.com © Copyright reserved. Web: www.thegateacademy.com Page 4 CaO − 0.7 SO3 2.8SiO2+1.2 Al2O3 + 0.65Fe2O3 (B) Ratio of % of alumina to that of Fe2O3 - Not less than 0.66 (C) Weight of insoluble residue - Not more than 2% (D)Weight of Magnesia - Not more than 6% (E) Total sulphuric Anhydride (SO3) - Not more than 2.75% (F) Total loss on ignition - Not more than 4% 2. Fineness:-By Blaine’s air permeability method (IS:4031 – 1968) this is done to check proper grinding. Type of Cement Specific Surface Low heat More than 3200 Rapid Hardening More than 3250 Ordinary More than 2250 3. Soundness:-By ‘Le Chatelier’ method (IS: 4031 – 1968) Rapid hardening & low heat Portland cement should have expansion less than 10mm. 4. Setting Time:- By Vicat Apparatus i). Initial setting time for ordinary, Rapid hardening and low heat Portland cements should be around 30, 30 and 60 minutes respectively. ii). The final setting time for ordinary, Rapid hardening and low heat cements should be around 600, 60 and 600 minutes respectively. 5. Compressive Strength:(4031 – 1968) – Cube test. Compressive strength at the end of 3 days should be more than 11.3 N/mm2 and that at the end of 7 days should not be less than 17.2 N/mm2 6. Heat of Hydration: (IS 4031 – 1968) Only for low heat cement heat of hydration after 7 days should not be more than 65 calories per gram and after 28 days should not be more than 75 cal/g. 7. Tensile Strength: P 5 + 2.5 at 3 days should not be lesser than 2 N/mm2 P 5 + 2.5 at 7 days should not be lesser than 2.5 N/mm2. Where P i standard consistency of cement Aggregates a) Coarse Aggregates: (Size > 4.75 mm) The aggregates which are retained on 4.75 mm size sieve. Maximum size of coarse aggregates is limited to one third of thickness of concrete section for thin slabs and walls. b) Fine Aggregates: (Size < 4.75 mm) The aggregates which are passed through 4.75 mm sieve. Usually natural river sand is used. Angular grained sand produces good concrete because of interlocking.