A Course Material on Construction Materials By Mr. R.Arthanareswaran LECTURER DEPARTMENT OF CIVIL ENGINEERING SASURIE COLLEGE OF ENGINEERING VIJAYAMANGALAM – 638 056 QUALITY CERTIFICATE This is to certify that the e-course material Subject Code : CE6401 Scubject : Construction Materials Class : II Year CIVIL being prepared by me and it meets the knowledge requirement of the university curriculum. Signature of the Author Name: R.Arthanareswaaran Designation: Lecturer This is to certify that the course material being prepared by Mr.R.Arthanareswaran is of adequate quality. He has referred more than five books amont them minimum one is from aborad author. Signature of HD Name: N.Sathish Kumar SEAL Table of Contents Chapter No Title Page No 1 Stones – Bricks – Concrete Blocks 1.1 Characteristics Of Good Building Stone 1 1.2 Testing of Stones 2 1.3 Deterioration Of Stones 8 1.4 Durability of Stones 9 1.5 Preservation of Stones 9 1.6 Selection of Stones 10 1.7 Bricks 10 1.8 Classification of bricks 11 1.9 Manufacturing Of Bricks 13 1.10 Testing of Bricks 19 1.11Fire-Clay Bricks Or Refractory Bricks 22 2 Lime – Cement – Aggregates – Mortar 2.1 Lime Mortar 24 2.2 Composition Of Cement Clinker 25 2.3 Hydration Of Cement 28 2.4 Rate Of Hydration 29 2.5 Manufacture Of Cement 29 2.6 Testing of Cement 32 2.7 Types Of Cement 45 2.8 Testing Of Aggregates 50 3 Concrete 3.1 Concrete 59 3.2 Ingredients 59 3.3 Manufacturing Process 59 3.4 Ready Mixed Concrete (RMC) 66 3.5 Properties of Fresh Concrete: 68 3.6 Properties Of Hardened Concrete 69 3.7 Mix Design 70 3.8 High Strength Concrete 71 3.9 High Performance Concrete 71 3.10 Self Compacting Concrete 72 3.11 Durability of Concrete 72 4 Timber And Other Materials 4.1 Timber 75 4.2 Market Forms of Timber 75 4.3 Plywood 75 4.3.1 Types 75 4.3.2 Grades 76 4.3.3 Applications 76 4.4 Veneer 79 4.4.1 Types of Veneer 80 4.4.2 Advantages of using veneers 80 4.5 Thermocol 81 4.6 Panels of Laminates 81 4.6.1 Types 81 4.6.2 Sizes 81 4.6.3 Applications 81 4.7 Steel 82 4.7.1 Manufacturing Methods 82 4.7.2 Properties and Uses 83 4.7.3 Properties of Steel 83 4.8 Aluminum 87 4.8.1 Applications 90 4.8.2 Other names 91 4.8.3 The selective use of ACP 91 4.9 Composition 92 4.10 Characteristics Of An Ideal Pain 96 4.10.1 Preparation Of Paint 96 5 Modern Materials 5.1 Glass 98 5.1.1 Constituents 98 5.1.2 Manufacture 99 5.1.3 Classification 101 5.1.4 Commercial Forms 101 5.2 Ceramic 103 5.3 Fibre glass reinforced plastic 103 5.4 Clay products 104 5.4.1 Clay And Its Classifications 104 5.4.2 Physical Properties Of Clays 105 5.5 Fire-Clay Or Refractory Clay 106 5.6 Composite materials 107 5.7 Applications of laminar composites 109 5.8 Fibre textiles 109 5.9 Reinforced Earth 109 CE 6401 Construction Materials CE6401 CONSTRUCTION MATERIALS L T P C 3 0 0 3 OBJECTIVES: To introduce students to various materials commonly used in civil engineering construction and their properties. UNIT I STONES – BRICKS – CONCRETE BLOCKS 9 Stone as building material – Criteria for selection – Tests on stones – Deterioration and Preservation of stone work – Bricks – Classification – Manufacturing of clay bricks – Tests on bricks – Compressive Strength – Water Absorption – Efflorescence – Bricks for special use –Refractory bricks – Cement, Concrete blocks – Light weight concrete blocks. UNIT II LIME – CEMENT – AGGREGATES – MORTAR 9 Lime – Preparation of lime mortar – Cement – Ingredients – Manufacturing process – Types and Grades – Properties of cement and Cement mortar – Hydration – Compressive strength – Tensile strength – Fineness– Soundness and consistency – Setting time – Industrial byproducts – Fly ash –Aggregates – Natural stone aggregates – Crushing strength – Impact strength – Flakiness Index – Elongation Index – Abrasion Resistance – Grading – Sand Bulking. UNIT III CONCRETE 9 Concrete – Ingredients – Manufacturing Process – Batching plants – RMC – Properties of fresh concrete – Slump – Flow and compaction Factor – Properties of hardened concrete –Compressive, Tensile and shear strength – Modulus of rupture – Tests – Mix specification – Mix proportioning – BIS method – High Strength Concrete and HPC – Self compacting Concrete –Other types of Concrete – Durability of Concrete. UNIT IV TIMBER AND OTHER MATERIALS 9 Timber – Market forms – Industrial timber– Plywood – Veneer – Thermacole – Panels of laminates –Steel – Aluminum and Other Metallic Materials – Composition – Aluminium composite panel –Uses – Market forms – Mechanical treatment – Paints – Varnishes – Distempers – Bitumens. UNIT V MODERN MATERIALS 9 Glass – Ceramics – Sealants for joints – Fibre glass reinforced plastic – Clay products –Refractories – Composite materials – Types – Applications of laminar composites – Fibre textiles– Geomembranes and Geotextiles for earth reinforcement. TOTAL: 45 PERIODS OUTCOMES: On completion of this course the students will be able to compare the properties of most common and advanced building materials. understand the typical and potential applications of these materials understand the relationship between material properties and structural form understand the importance of experimental verification of material properties. TEXT BOOKS: 1. Varghese.P.C, "Building Materials", PHI Learning Pvt. Ltd, New Delhi, 2012. 2. Rajput. R.K., "Engineering Materials", S. Chand and Company Ltd., 2008. 3. Shetty.M.S., "Concrete Technology (Theory and Practice)", S. Chand and Company Ltd.,2008. 4. Gambhir.M.L., "Concrete Technology", 3rd Edition, Tata McGraw Hill Education, 2004 5. Duggal.S.K., "Building Materials", 4th Edition, New Age International , 2008. SCE Dept of Civil CE 6401 Construction Materials REFERENCES: 1. Jagadish.K.S, "Alternative Building Materials Technology", New Age International, 2007. 2. Gambhir. M.L., & Neha Jamwal., "Building Materials, products, properties and systems", Tata McGraw Hill Educations Pvt. Ltd, New Delhi, 2012. 3. IS456 – 2000: Indian Standard specification for plain and reinforced concrete, 2011 4. IS4926–2003 : Indian Standard specification for ready–mixed concrete, 2012 5. IS383–1970: Indian Standard specification for coarse and fine aggregate from natural Sources for concrete, 2011 6. IS1542–1992: Indian standard specification for sand for plaster, 2009 SCE Dept of Civil CE 6401 Construction Materials Chapter 1 Stones – Bricks – Concrete Blocks Stone as building material – Criteria for selection – Tests on stones – Deterioration and Preservation of stone work – Bricks – Classification – Manufacturing of clay bricks – Tests on bricks – Compressive Strength – Water Absorption – Efflorescence – Bricks for special use –Refractory bricks – Cement, Concrete blocks – Light weight concrete blocks. 1.1 Characteristics Of Good Building Stone A good building stone should have the following qualities. Appearance: For face work it should have fine, compact texture; light-coloured stone is preferred as dark colours are likely to fade out in due course of time. Structure: A broken stone should not be dull in appearance and should have uniform texture free from cavities, cracks, and patches of loose or soft material. Stratifications should not be visible to naked eye. Strength: A stone should be strong and durable to withstand the disintegrating action of weather. Compressive strength of building stones in practice range between 60 to 200 N/mm2. Weight: It is an indication of the porosity and density. For stability of structures such as dams. retaining walls, etc. heavier stones are reauired, whereas for arches, vaults, domes, etc. light stones may be the choice. Hardness: This property is important for floors, pavements, aprons of bridges, etc. The hardness is determined by the Mohs scale Toughness: The measure of impact that a stone can withstand is defined as toughness. The stone used should be tough when vibratory or moving loads are anticipated. Porosity and Absorption: Porosity depends on the mineral constituents, cooling time and structural formation. A porous stone disintegrates as the absorbed rain water freezes, expands, and causes cracking. Permissible water absorption for some of the stones is given in Table 1 Table 1 24-Hours Water Absorption of Stones by Volume Water absorption (% S.No. Types of Stone not greater than) 1. Sandstone 10 2. Limestone 10 3. Granite 1 4. Trap 6 5. Shale 10 6. Gneiss 1 7. Slate 1 8. Quartzite 3 Seasoning: The stone should be well seasoned. Weathering: The resistance of stone against the wear and tear due to natural agencies should be high. Workability: Stone should be workable so that cutting, dressing and bringing it out in the required shape and size may not be uneconomical. Fire Resistance: Stones should be free from calcium corbonate, oxides of iron, and minerals having different coefficients of thermal expansion. Igneous rock show marked disintegration principally because of quartz which disintegrates into small particles at a temperature of about 575°C. Limestone, however, can withstand a little higher temperature; i.e. up to 800°C after which they disintegrate. Specific Gravity: The specific gravity of most of the stones lies between 2.3 to 2.5. Thermal Movement: Thermal movements alone are usually not trouble-some. However, joints in SCE 1 Dept of Civil CE 6401 Construction Materials coping and parapets open-out inletting the rain water causing trouble. Marble slabs show a distinct distortion when subjected to heat. An exposure of one side of marble slab to heat may cause that side to expand and the slab warps. On cooling, the slab does not go back to its original shape. 1.2 Testing Of Stones Building stones are available in large quantity in various parts of the country and to choose and utilize them for their satisfactory performance, it is necessary to test the stone for its strength properties, durability and quality. Durability Test: Some of the tests to check the durability of stone are as follows.