Professional Documents
Culture Documents
Quality
Definition : Conformance to requirements expressed
& implied.
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Quality
System of causing Quality
DIRFT (DO IT RIGHT FIRST TIME)
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Quality
Measure : The measurement of quality is the Price of
non-conformance.
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Durability
Definition
A durable concrete is one that performs satisfactorily in the
working environment during its anticipated exposure
conditions during service (IS 456-2000)
Durability of concrete is its ability to resist weathering action,
chemical attack, abrasion or any other process of
deterioration (American Concrete Institute).
When exposed to environment durable concrete is
likely to retain its original form, quality and serviceability
during its lifetime.
Durable Concrete envisage limits for maximum water
cement ratio, minimum cement content, cover thickness,
type of cement used and presence of amount of chloride
and sulphates in concrete. ( IS-SP-28)
As Low permeability as possible under situation. (IS-SP-23)
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Consequences of Improper Quality and
Inadequate Durability
Loss of strength of concrete
Concrete liable to be easily affected by deterrents
Corrosion of rebars
Loss of serviceability
Unpleasant appearance
Danger to persons and property
Expensive repair costs
Poor perception of concrete as a material
Poor perception of agencies involved
Reduction of service life
External agencies like weathering, attack by natural or Industrial
liquids, Gases, bacterial Growth etc.
Alkali- aggregate reaction.
Ingression of moisture/air facilitating corrosion of steel and cracking
concrete cover.
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Consequences of
Inadequate Durability
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Consequences of
Inadequate Durability
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Consequences of
Inadequate Durability
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Factors Influencing Durability of
Concrete (IS: 456-2000)
The Environment
Type and quality of constituent materials
Cement content and W/C ratio of concrete
Workmanship especially in compaction curing it is
very important
Cover to embedded steel
Shape and size of the member
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Factors Affecting Durability
Durability depends on two main factors
a) The concrete system &
b) The service environment
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Selection of
Good Quality Materials
(Conforming to relevant IS codes)
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UNSOUND MATERIALS
Cement or aggregate is considered unsound when
they cause unacceptable volume change, hardened
concrete or mortar which causes cracks and affects
durability.
Aggregates containing certain materials such as
shale, clay lumps, coal, iron pyrites etc show
unsoundness later when concrete undergoes wetting
and drying or freezing and thawing.
More moisture absorption in aggregate (CA1 or CA11)
is often used as a rough index for unsoundness
Cement parameters that impact soundness are free
lime, MgO & excess gypsum
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Water - Permissible Limits for Solids. IS 456:2000 Table-1
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PROCESSES
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Workmanship for
Durable Concrete
Batching
Mixing
Transportation
Placing
Compaction
Finishing
Protection
Curing
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Compaction of Concrete
Ensuring suitable workability employing
appropriate placing and compaction
equipment
Adequate compaction without segregation
1% voids reduces strength by 5%
Criticality of Curing
Extremely important if the water-cement ratio
is low & cement content is high.
If the cement has a high rate of strength
development
Ambient temperature during placing is high
and day is windy
If the concrete contains GGBFS or Pulverized
Fly ash (PFA)
Recommended Moist Curing
(IS 456: 2000)
Normal Weather Conditions
* OPC Based Concretes - 7 Days
* Blended Cements based concretes - 10 Days
a) Physical
Temperature, Moisture, alternate wetting and
drying, freezing and thawing
b) Chemical
Acidic, gaseous, alkaline, corrosive
PHYSICAL ENVIRONMENTS
ATTACK AFFECTING DURABILITY
Physical Environment impacts
Temperature
Significantly affects rate of hydration of cement.
Leads to Plastic shrinkage cracks in fresh concrete
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2. Alkali - Aggregate Reaction
Alkali from cement, reacts with reactive silica (of
aggregates) to form alkali-silica gel of unlimited
swelling type.
The continuous growth of silica gel exerts osmotic
pressure within the concrete.
This manifests into cracking and bulging of concrete
Occurrence is due to :
1. High alkali content in
cement (more than 0.6%)
2. Reactive silica in
aggregate
3. Availability of moisture
Alkali - Aggregate Reaction
Alkali-aggregate reaction (AAR) is basically a chemical
reaction between the hydroxyl ions in the pore water
within concrete and certain types of rock minerals
Since reactive silica in the aggregate is involved in this
chemical reaction it is often called alkali-silica-
reaction (ASR).
It is recognized as one of the major causes of cracking
of concrete.
The reaction produces what is called alkali-silica gel
of unlimited swelling type under favorable conditions
of moisture and temperature.
The crack width can range from 0.1mm to as much as
10mm.
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Alkali - Aggregate Reaction
Alkali content (K2O and Na2O) or what is called soda
equivalent.
This is calculated as the actual Na2O content plus
0.658 times the K2O content of the clinker.
It should be less than 0.6 percent by mass of
cement.
Alkalis from all these sources must be included in
finding the total alkalis.
British standard 5328 : part 1 : 1091 specifies a
maximum of 3.0 kg of alkalis (expressed as soda
equivalent) in 1 m3 of concrete in case of alkali
reactive aggregates are used.
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Alkali - Aggregate Reaction
Remedial Measures:
1. Use non-reactive
aggregates from alternate
sources
2. Use low-alkali cement
3. Reduce cement content in
concrete
At the anode, steel releases electron and takes the ionic form
Fe 2e- + Fe2+
Fe++ + 2(OH)- 2H
2Fe(OH)
O+O24e 2
-=4Iron
(OHHydroxide
-) (Rust)
Example of Delamination
of Concrete cover
Corrosion
Crack formed due to bursting pressure on
account of rusting of reinforcements
Methods of
Controlling Corrosion
Limit the chlorides in water, cement, superplastizers,
etc to acceptable levels
Provide proper cover as per IS norms
Cover blocks also need to be of good quality
Concrete should be properly compacted
Make dense, impermeable / waterproof concrete
Have protective coatings wherever suitable
Ensure proper & timely maintenance of structures
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4. Carbonation of Concrete
Mechanism : Carbon dioxide from the air reacts
with calcium hydroxide to form calcium carbonates
In the presence of moisture, carbonic acid is
formed which reduces the alkalinity of concrete
pH value of concrete reduces from 12.5 to 9, thus
destroying the protective layer and exposing the
steel to corrosion
Rate of Carbonation depends upon relative
humidity, grade of concrete, permeability of
concrete, depth of cover and time
Nearly 1 mm carbonation is reported per year in
normal M-20 grade of concrete
Measurement of
Depth of Carbonation
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Steel in Passivity condition
Concrete is under continuous attack by aggressive
environmental agencies.
Good concrete and sufficient cover is the answer
for durability
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Acid attack
But the attack is severe only at a pH value below 5.5.
At a pH value below 4.5, the attack is very severe.
Cement compounds are eventually broken down and
leached away.
If acids are able to reach the reinforcing steel
through cracks corrosion can occur leading to further
cracking
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COVER TO REINFORCEMENT
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Cover to Reinforcement
(IS 456 2000)
Exposure Min Nominal
Condition cover (mm)
Mild 20
Moderate 30
Severe 45
Very Severe 50
Extreme 75
Note :
1) For main reinforcement upto 12 mm dia bar for mild exposures,
the nominal cover may be reduced by 5 mm
2) Unless specified otherwise, actual concrete cover should not
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deviate from the required nominal cover by +10mm or 0mm
Effect of Other materials
Mineral Oil usually effects only fresh concrete in their
hardening process (petrol, petroleum distillates etc)
Organic Acid have corrosive effect
Vegetable & Animal oils & Fats causes deterioration of
concrete surfaces due to their corrosive action
Action of Sugar has retarding effect on fresh concrete;
has gradual corrosive effect on hardened concrete
Action of Sewage concrete sewers running full remain
unaffected; but in partially filled sewers where hydrogen
sulphide gas is evolved & sulphuric acid is formed, concrete
above sewage level gets affected due to corrosive action of
such acids
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Fire Resistance
The fire resistance is not only dependent upon the
type of concrete but also on the thickness of cover to
reinforcement.
Effect of temperature on the strength of concrete is
not much upto a temperature of about 250oC
Above 300oC definite loss of strength takes place.
Portland blast furnance slag cement is found to be
more resistant to the action of fire.
Light weight concrete stand up better to fire than
ordinary concrete.
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Fire Resistance
Best fire resistant aggregates amongst the igneous
rocks are, the basalts and dolerites less amount of
silica.
Since then decomposition takes place only at a very
high temperature of 900oC , Limestone is considered
as a good fire resistant aggregate.
Serious reduction in strength occurs at a
temperature of about 600oC.
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Constraints/Issues for Concrete in
Aggressive Environment
I am CSO I am COM
After
construction &
commissioning
Construction Process Analysis
What it should be
What we think it is