The document discusses lightweight concrete, including its production, properties, and applications. Lightweight concrete has a density ranging from 300kg/m3 to 1850kg/m3, which is achieved through the inclusion of air into its composition. This can be done by replacing normal aggregate with hollow, cellular, or porous aggregate that contains voids. Lightweight concrete offers benefits like reduced self-weight, increased productivity, better thermal insulation, seismic resistance, and fire protection compared to normal concrete. It can be classified based on its intended use, such as structural, non-load bearing walls, or insulation purposes.

1. Staff De
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6. Fast track concrete technology
Prof. A.R.Santhakumar
Emeritus Professor of Civil Engineering
IIT (Madras),600 036 India
Email: santhaar@gmail.com.
Abstract
Construction is the ultimate objective of design and machines
make accomplishment of that task possible. The efforts of the
engineer who designs a project , and the constructor, who
builds the project are directed towards the same goal: creation
of some infrastructure that will improve the quality of life for
mankind and serve the purpose for which it is built in a
satisfactory manner. Construction is the ultimate objective and
machines and methods make accomplishment of that objective
possible. The constructor must select the proper equipment to
process materials and build the structure economically.
Whereas most manufacturing companies have a permanent
factory a construction company carries its factory with it from
site to site depending on job requirement.
1. INTRODUCTION
In order to supply the required land for accommodating the huge
population, and to provide ample infrastructure and community
facilities to substantiate an acceptable standard of living, commercial
operations and other necessary developments, many critical locations
which may be unsuitable for development to most international
yardsticks, are built with very large sized and high-rise buildings. The
following situations are some of these examples.

7. FIBER REINFORCED CONCRETE FOR RETROFITTING
Dr. C.Antony Jeyasehar R.Balamuralikrishnan
Professor and Head, Sr.Lecturer
E-mail: auhdse@sify.com E-mail:bmk_gaya@rediffmail.com
Dept. of Civil and Structural Engineering
Annamalai University, Annamalainagar- 608 002
Tamilnadu, India
Telephone No: 91-4144-239732
Fax No: 91-4144-239732
1. Introduction
The use of randomly oriented, short fibers to improve the physical properties of a matrix is
an age – old concept. For example, fibers made of straw or horsehair have been used to
improve the properties of bricks for thousand of years. In modern times, fiber – reinforced
composites are being used for a large variety of applications. The composite could be a clay
brick reinforced with natural fibers or a high – strength, fiber – reinforced ceramic
component used in space shuttle. The fiber reinforced composites made with the primarily
Portland cement – based matrices. The matrices can consist of any of the following:
1. Plain Portland cement
2. Cement with additives such as fly ash or condensed silica fume
3. Cement mortar containing cement and fine aggregate
4. Concrete containing cement, fine and coarse aggregates.
The presence of micro cracks at the mortar-aggregate interface is responsible for the inherent
weakness of plain concrete. The weakness can be removed by inclusion of fibers in the
matrix. The fibers help to transfer loads at internal micro cracks. Such a concrete is called
fiber reinforced concrete. Thus the fiber-reinforced concrete is a composite material
essentially consisting of conventional concrete or mortar reinforced by fine fibers.
The fibers can be broadly classified as
1. Metallic fibers
2. Polymeric fibers
3. Mineral fibers
4. Naturally occurring fibers
Metallic fibers are made of either steel or stainless steel. The polymeric fibers in use include
acrylic, carbon, nylon, polyester, polyethylene and polypropylene fibers. Glass fiber is the
predominantly used mineral fiber. Various types of organic and inorganic naturally occurring
fibers such as cellulose are being used to reinforce the cement matrix.
Fiber reinforced concrete (FRC) has been used since the 1960’s (ACI 544.1, 1996), although
use was generally limited to warehouse floor or pavement overlays. Steel, glass, carbon and

8. Polymer Modified Concrete for Retrofitting
Dr. C.Antony Jeyasehar R.Balamuralikrishnan
Professor and Head, Sr.Lecturer
E-mail: auhdse@sify.com E-mail:bmk_gaya@rediffmail.com
Dept. of Civil and Structural Engineering
Annamalai University, Annamalainagar- 608 002
Tamilnadu, Tel. No: 91-4144-239732, Fax No: 91-4144-239732
1. Introduction
In virtually all cases of concrete deterioration, the problem is associated with corrosion of
steel reinforcement. It is well established that steel reinforcement well embedded in good
quality concrete is protected from corrosion by the passivating nature of the highly alkaline
cement matrix. Therefore, whenever, possible, it is desirable from both technical and
economic considerations deteriorated reinforced concrete should be repaired with
impermeable highly alkaline cement based materials closely matched in properties to the
parent concrete. However there are many instances where repair composition containing
polymers, either as admixtures for cementation systems or as high strength binders (for
adhesive mortars and grouts) are the most appropriate. Over the past twenty years, many
different polymers have been used in a range of applications in the repair and maintenance of
building and other structures. With out the unique properties of some of the polymer systems,
many of the repairs undertaken would, with out doubt, have been much more costly and have
taken much longer to carry out.
To realistically appraise the position of concrete repair technology and the complex fabric of
problems it faces today, we must pause periodically to review where we are and where we
might be going. The majority of the faults and problems are caused by lack of attention to
design details, specifications and poor in-site workmanship. Material, although important, is
less of an evil. Material, per se, does not problem; the end product made from a material - the
repaired structure - performance. The concern should not be solely with repair, material
themselves, but with the uses to which they are being put, with the gray area of overlap
between material properties, and the end engineering product - the repaired structure.
Experience world-wide now confirms that even when specific national code requirements of
durability in terms of concrete cover and concrete quality are achieved in practice, there is an
unacceptable high risk of premature deterioration of concrete structures exposed to
aggressive conditions. Deterioration of concrete and corrosion of reinforcement have thus
become the major causes of loss of serviceability and safety of reinforced and prestessed

9. LIGHTWEIGHT CONCRETE:
MATERIALS, PRODUCTION CHARACTERISTICS,
PROPERTIES AND APPLICATIONS
Kunhanandan Nambiar E K1
ABSTRACT: In concrete construction, self-weight usually represents a large proportion of the total load in the
structure and hence, any attempt to reduce the self-weight of the structure is undoubtedly considered as an
advantage. In addition to reducing stresses through the life time of the structure, the total weight of material to
be handled during construction is also reduced, which consequently increases the productivity. Further more,
lightweight concrete offers better thermal insulation, seismic resistance and fire protection than ordinary
concrete.
INTRODUCTION Lightweight concrete can also be classified
according to the purpose for which it is to be used:
Practical range of densities of lightweight we distinguish between structural lightweight
concrete (LWC) varies between 300kg/m3 and 1850 concrete (ASTM C 330-89) and concrete used in
kg/m3. Basically there is only one way of making non-load bearing walls (concrete used in masonry
concrete lighter – the inclusion of air in its units, ASTM C 331-89) , for insulation purposes
composition. However this air-entrainment can be (ASTM C 332-87), and the like. The strength and
achieved by three different ways viz. ; (i) by density ranges of these concretes are given in Table
replacing the ordinary aggregate with a hollow 1. The essential feature of insulating concrete is its
cellular or porous aggregate that includes voids coefficient of thermal conductivity which should be
within its body, this is termed ‘lightweight aggregate below about 0.3 J/m2s oC/m (Neville, 1995)
concrete’; (ii) by omitting finer sizes from the
aggregate grading thereby creating ‘no fines . Table 1 Classification based on use
concrete’; (iii) by introducing gas/air bubbles in the
plastic mix of cement/ cement-filler slurry (aerated Type of
concrete) or by introducing pores due to excessive Insulating Masonry Structural
LWC
water proportion in the mortar (microporites), both
after setting leaves a cellular structure, termed as
Density 1400-
‘cellular concrete’ (Shrivastava, 1977). A general <800 500-800
range, kg/m3 1800
classification of lightweight concrete is presented in
Fig. 1.1. Out of these, lightweight aggregate concrete
and aerated concrete are the most popular classes. Strength
0.7-7 7-14 ≥17
range, MPa
Lightweight concrete
Also, classification based on strength is given in
Table 2.
Lightweight Cellular No-fines
aggregate concrete concrete
concrete
Table 2 Classification based on strength
Aerated Microporites Moderate
Type of Insulating Structural
concrete strength
LWC concrete concrete
concrete
Gas concrete Strength
Foam concrete range, 0.7-7 7-17 17- 41
MPa
Fig. 1 Classification of lightweight concrete Density
range, 250-800 800-1350 1350-1850
1
kg/m3
Assistant Professor, N S S College of Engineering,
Palakkad, 678 008

10. CHEMICAL ADMIXTURES FOR CONCRETE
G B Vamadev*
FOSROC
Introduction
Concrete is the most widely used construction material in the world. Its consumption is around
20 billion tonnes annually which comes to around two tonnes per every living person. The
reasons for such widespread use of concrete are its adaptability, durability, strength, availability
and economy. Concrete is the only material which can be used everywhere; literally, from
pavements to roofs.
But the most sought after properties of concrete, viz., workability in the fresh state and strength
and durability in the hardened state, cannot always be realised with its regular constituents. In
such cases, chemical admixtures become essential requirements for concrete.
Admixture
An admixture is defined as 'the material added during the mixing process of concrete in a
quantity not exceeding 5% by mass of the cement content of the concrete to modify the
properties of the mix in the fresh and/or hardened state'. Both chemical and mineral admixtures
are widely used. Silica fume and fly ash are the most widely used mineral admixtures.
Chemical Admixtures
As mentioned above, the purpose of using chemical admixtures is to modify certain properties of
concrete. The ACI committee has listed the properties mentioned below.
In the fresh state, admixtures perform the following functions :
1. Increase workability
2. Accelerate or retard the setting time of concrete
3. Reduce or prevent settlement or to create slight expansion
4. Modify the rate and/or capacity for bleeding
5. Reduce segregation
6. Improve pumpability
7. Reduce slump loss
* G B Vamadev – Business Manager –Concrete Industries, Fosroc Chemicals (India) Pvt.
Limited, Bangalore

11. BEHAVIOUR OF CONCRETE EXPOSED TO FIRE
Dr. George Mathew, Reader
School of Engineering
Cochin University of Science and Technology, Kochi-22
The behaviour of various physical properties of concrete that has influence on the overall
behaviour of concrete when exposed to fire has been discussed in this paper. The possible
damage to reinforced concrete structural members when exposed to fire and the method
of reinstatement of fire damaged RCC members are also discussed in this paper.
Concrete is the most widely used 6. Creep Deformation and
material in construction. In general, the 7. Strength
use of concrete in construction can be
grouped in to two, viz. As concrete is made of different
materials, its behaviour with temperature
1. Used as structural concrete- Used depends on several factors and as such a
to construct structural members such general remark can only be made with
as Reinforced Cement Concrete ( respect to the various properties.
RCC) and Pre-Stressed Concrete
(PSC) members and Thermal Expansion of Concrete
2. Used as a protection material to
structural steel against fire – Thermal expansion of materials is one of
Primarily Plain Cement Concrete ( the important properties as far as fire
PCC) safety is concerned. In structures,
members restrained from expansion by
The structural behaviour of a building the surrounding elements or the
subjected to fire depends primarily on development of differential expansion of
the variations developed in the different materials leads to the failure of
properties of individual materials which members in a structure, which may
are exposed to fire. The material ultimately lead to even its
properties which are of importance when collapse.Thermal expansion of concrete
a structure is exposed to fire are: is influenced by different parameters
such as the type of cement
1. Thermal Expansion - type of aggregate
2. Thermal Diffusivity - water content at the time of
3. Modulus of Elasticity temperature change and
4. Poisson’s Ratio - age of concrete
5. Stress-Strain Relationship

12. QUALITY CONTROL OF CONCRETE
George Mathew
Reader, Cochin University
One of the most important requirements in good concrete construction is that the quality
of concrete used in the structure should conform to that specified in the design.
There are several tests that can be made with both plastic and hardened concrete, but the
strength test is widely used in specifying, controlling, and evaluating concrete quality.
Quality concrete must be able to 1)carry loads imposed upon it; 2) resist deterioration;
and 3) be dimensionally stable. Although the strength test is not a direct measure of
concrete durability or dimensional stability, it provides an indication of the water-cement
ratio of the concrete. The water-cement ratio, in turn, directly influences the strength;
durability; wear resistance; dimensional stability; and other desirable properties of
concrete. The strength test is also used to measure the variability of concrete.
VARIABILITY OF CONCRETE
Concrete is subject to numerous factors that affect its strength and other properties. These
may include variations in the manufacturer of cement; preparation of aggregates;
batching, mixing, and curing of concrete; and finally in the preparation, handling, and
testing of the sample specimens. The major sources of variation in the strength test results
are listed in Table 1.
Table 1 – Principal sources of variations in strength test results
Variations in properties of concrete Discrepancies in testing methods
Changes in water-cement ratio Improper sampling procedures
Poor control of water
Excessive variation of moisture in
aggregate
Variations in water requirement Variations due to fabrication techniques
Aggregate grading, absorption, Molding of specimen
particle shape. Poor quality molds
Cement and admixture properties Handling and curing of newly made
Air Content specimen
Delivery time and temperature
Variations in characteristics and Changes in curing
proportions of ingredients Temperature variation
Aggregates Variable moisture
Cement Delays in bringing specimens to
Admixtures the laboratory
Variations in batching, mixing, Poor testing procedures
transporting, placing and compaction Care of specimen, transportation
Improper placement in testing
Variations in temperature and curing machine
Testing machine platens out of
specifications.
Incorrect speed of testing.

15. Cement
• Trends in India
• Special Concrete
• Cement Manufacturing Procedure
• Types of Cement
• Major Compounds in Cement
• Physical Quality Parameters
• Chemical Quality Parameters
• Cement Plants & Products
• Packaging

16. CEMENT
M.A. Joseph
Aditya Birla
• Trends in India
• Manufacturing Procedure
• Special Types of Concrete
• Types of Cement
• Major Compounds in Cement
• Physical Quality Parameters
• Chemical Quality Parameters
• Cement Plants & Products
• Packaging

18. Effect of Supplementary Cementing Materials on Chemical Durability of Concrete.
Nazeer M
Faculty in Civil Engineering
TKM College of Engineering
Kollam – 691 005. Kerala.
ABSTRACT
Increasingly greater attention has been paid in recent years to the problem of structural
durability of plain and reinforced concrete structures. The extensive application of these
building materials and their limited life in various media has necessitated a growing
volume of repair and restoration of reinforced concrete structures. Considering the
difficulties of such repairs, it is imperative to provide an adequate and guaranteed service
life of reinforced concrete right at the time of designing and erecting the building or
structure.
Recently, High Performance Concretes incorporating various mineral admixtures are
used to combat the adverse effects of chemically aggressive environment. The
supplementary cementing materials used for improving the performance of concrete are
silicafume, flyash, ground granulated blast furnace slag, and metakaolin. These materials
are either added as admixtures (mineral admixtures) or as a partial replacement of
cement. A concrete with these materials, prepared from lower w/c ratio and with
chemical admixtures, shows reduced permeability and enhanced strength.
This report discusses the effects of supplementary cementing materials against the
chemical deterioration of concrete.
INTRODUCTION
Durability of hydraulic-cement concrete is defined as its ability to resist weathering action,
chemical attack, abrasion, or any other process of deterioration. Durable concrete will retain its
original form, quality, and serviceability when exposed to its environment. Major causes of
concrete deterioration are freezing and thawing, aggressive chemical exposure, abrasion,
corrosion of metals, and chemical reactions of aggregates.
Freezing and Thawing
When water begins to freeze in a capillary cavity, the increase in volume accompanying the
freezing of water requires a dilation of the cavity equal to 9% of the amount of excess water out
through the boundaries of the specimen or some of both effects. During this process, hydraulic
pressure is generated and the magnitude of that pressure depends on the distance to an escape
boundary, the permeability of the intervening material and the rate at which ice is formed.
Experience shows that disruptive pressures will be developed in an saturated specimen of paste
unless every capillary cavity in the paste is not farther than three or four thousandths of an inch
from the nearest escape boundary. Air entrainment has proved to be an effective means of
reducing the risk of damage to concrete freezing and thawing.
Causes of deterioration of the hardened concrete by freeze-thaw action can be related to the
complex microstructure of the material, and also the specific environmental conditions.

21. Fracture Mechanics of
Concrete Structures
Palivela Subba Rao
Associate Professor
Department of Civil Engineering
JNTU College of Engineering
Kakinada
1
RUDIMENTS OF
FRACTURE MECHANICS
Palivela Subba Rao,
Associate Professor
Department of Civil engineering
JNTU College of engineering
Kakinada, (AP)
1

22. Rudiments of Fracture Mechanics1
1.1 Introduction
In general, material/ structural component fails either due to any of the following or
their combinations. i) Yielding ii) Buckling iii) Fatigue iv) Impact v) Fracture etc. Therefore
a component is designed so as to avoid the yielding of the maximum loaded point. This is
considered as the basic requirement of design and is taught in all courses on strength of
materials at under graduate level.
Over the ages, man has been under an impression that strength of material is material
property and strength is the criterion for failure of material / structural components under an
influence of external loads. Contrary to this, the incidents that occurred in the past during the
Second World War times taught man lesions: There is some other criterion for failure of
material, beyond strength criterion. Failure of Liberty ships during the world war-II has given
a way to think in a different way from conventional way of understanding of material failure.
Crack occurrence in a structural component either during its construction/
manufacturing or during its life time is inevitable. Performance of a cracked structural
component under mechanical loading is very much different from that of the same
component without crack. The study of performance of a cracked body under the external
loading is called as ‘Fracture Mechanics”. Therefore “Fracture mechanics” is based on the
implicit assumption that there exists a crack in the structural component. The crack may be
man made such as a hole, a notch, a slot, etc.
For a long time man had some idea about the role of a crack or notch. While cutting a
tree, he would make a notch with an axe at its trunk and then pull it down with a rope. While
breaking a stick he would make a small notch with a knife before bending. Leonardo da
Vinci (1452-1519) was the first person to make a set up to measure the strength of a wire. He
found that strength of a wire depends on its length. It was his argument that longer wire was
likely to have more number of cracks.
1.2 Strength of materials Approach (Strength criterion)
The basic assumption in strength of materials approach is that stress is uniform through
out the net cross-sectional area, if there is a hole or crack in structural component. Suppose a
rectangular plate is under a uniform tension as shown in fig.1 If the strength of the plate
is σ y , its width, B and thickness, t ; then the failure load, Py = Btσ y . This is based on the
assumption that stress is uniform through out the width. For example, if the same plate has an
elliptical hole as shown in fig.1, then its failure load, Py = (B − 2a )tσ y , according to strength
of materials criterion. But the actual failure load, from experiments, has been found to be
entirely different from the calculated load, Py = (B − 2a )tσ y , which is much less
than Py = (B − 2a )tσ y . The plate with an elliptical hole under uniform tension is analyzed
Mr. P.Subba Rao, Associate Professor,
Department of Civil Engineering , JNTU College of Engineering, Kakinada, (AP).

23. Repair and Rehabilitation of Concrete Structures
Using Special Materials
Dr. Prasad Varma Thampan C.K.*
Introduction:
Reinforced concrete (RC) is the most extensively used material for construction of
different types of structures such as bridges, tanks, chimneys, dams, buildings, harbors
etc. Maintenance and repair of such structures is presently one of the most significant
challenges facing the concrete building industry. The distress to concrete can be caused
from various sources. The required degree of high standard is not always achieved during
original construction in the case of materials and required degree of quality control is not
achieved in practice and as a result of this the structure is seriously affected which in turn
requires early repair and renovation work. It is reported that the expenses incurred in
Russia on repair and restoration of industrial structure over a normal period of four to five
years reach the total cost of the structure. In USA, the total annual loss due to concrete
deterioration is reported to be 3% of the annual construction expenditure. Even in India,
where the per capita consumption of cement/concrete is much less than global average,
the annual loss due to deterioration of steel and concrete structure is estimated to be of the
order of Rs 300-500 crores. The circumstances leading to inadequate quality control are
worse in our country, where concrete is still a material ‘made at site’ rather than in ready
mix-plants in most of the constructions. In addition to faulty construction and natural
aging, man made explosions as well as natural hazards like earthquake, cyclone, etc. also
can cause serious distress to structures.
The distress in concrete can be observed in the form of cracks. Cracks in concrete are the
manifestation of some disorder; structural, physical, chemical or even biological disorders
in the body of concrete, which shows up as cracks, which further aggravate the
deterioration process of concrete with time. Hence timely analysis of the causes of
distress, correct selection of repair materials and implementation of most suitable repair
methodology are required for an effective, economical and early rehabilitation of the
affected structure.
Assessment of damages in concrete structures:
The distress and damages in concrete shall be examined in detail and be assessed to
determine (1) the cause of damage (2) the type and extent of damage. Table 1 shows the
symptoms of damage as cracks, spalling, discoloration etc and the probable cause of such
*
Assistant Professor of Civil Engineering, N.S.S. College of Engineering, Palakkad-8.

25. constructive solutions
Dr. V. SYAM PRAKASH
Professor
College of Engineering Trivandrum

26. Dr. V. SYAM PRAKASH
Professor
College of Engineering
Trivandrum
READY MIXED CONCRETE FOR
QUALITY CONSTRUCTION
Dr. V. SYAM PRAKASH
Professor
College of Engineering
Trivandrum