Complete Technology Handbook on Ready Mixed Concrete and Construction Chemicals with Detailed Manufacturing Process and Formulations with Project Profiles

Complete Technology Handbook on Ready Mixed Concrete and Construction Chemicals with Detailed Manufacturing Process and Formulations with  Project Profiles

ISBN: 9788189765804

Brand: EIRI

Are you ready to embark on a fascinating journey into the world of concrete technology and construction chemicals?

In this book "Complete Technology Handbook on Ready Mixed Concrete and Construction Chemicals with Detailed Manufacturing Process and Formulations with  Project Profiles," you will discover a wealth of knowledge that will revolutionize your understanding of the construction industry.

Chapter by chapter, you will explore the intricacies of ready-mix concrete, from its international context to its advantages and disadvantages. Delve into the fascinating realm of concrete materials technology, where you will uncover the secrets behind various concrete types, their properties, and the manufacturing process that brings them to life.

But that's just the beginning! You'll also dive deep into the properties of fresh and hardened concrete, gaining insights into strength, durability, and more. Discover the world of aggregates, the backbone of concrete, and learn about the tests that ensure their quality.

Specifications and compliance procedures are laid out meticulously, providing a roadmap for ensuring the highest standards in your construction projects. Mix design and quality control are unveiled, guiding you towards the perfect concrete mixture for any application.

Strength, elasticity, creep, and shrinkage—all these essential factors are explored in detail, providing you with a comprehensive understanding of concrete behavior over time.

The journey continues with an exploration of durability, with a focus on the many factors that can affect a concrete structure's lifespan. From chloride attack to carbonation, you'll become an expert on safeguarding your concrete creations.

The book then transitions into the world of construction chemicals, revealing their role in enhancing and protecting concrete structures. From waterproofing to epoxy coatings, you'll learn about the various types and their applications.

Transportation and placing methods are also discussed, providing you with insights into the practical aspects of working with concrete on-site. And to round out your knowledge, you'll delve into the economics of ready-mixed concrete, understanding market dynamics and the technology behind it.

In the final chapters, you'll discover the formulation and manufacturing processes of essential construction materials, from cement admixtures to sealants, coatings, and more.

Whether you're a seasoned professional looking to expand your expertise or someone new to the world of construction, this handbook is your ultimate guide. With its detailed content and practical insights, it's a valuable resource for anyone involved in the construction industry.

So, are you ready to embark on this exciting journey of discovery? Turn the page, and let the adventure begin!

Contents-cum-Index

Chapter 1

Introduction

• Process of Ready-mix concrete
• International Scenario
• Status in India
• Advantages of ready-mix concrete
• Disadvantages of ready-mix concrete
• Plasticizing Chemical Admixtures for RMC
• Mechanism of Plasticizing Chemical Admixtures
• Chemical Structure and Mechanism of Poly carboxylate Based Dispersing Admixtures
• Ideal for Many Jobs

Chapter 2

Concrete Materials Technology

• Raw Materials
• The Manufacturing Process
• Preparing Portland cement
• Mixing
• Transport to work site
• Curing
• Advantages of Concrete
• Disadvantages of Concrete
• Limitations of Concrete
• Types of Concrete Mixs
• Normal Strength Concrete
• Plain Concrete
• Reinforced Concrete
• Prestressed Concrete
• Precast Concrete
• Lightweight Concrete
• High-Density Concrete
• Air Entrained Concrete
• Ready Mix Concrete
• Polymer Concrete
• High-Strength Concrete
• High-Performance Concrete
• Self-Consolidated (compacted) Concrete
• Shotcrete Concrete
• Pervious Concrete
• Vacuum Concrete
• Pumped Concrete
• Limecrete
• Asphalt Concrete
• Roller Compacted Concrete
• Rapid Strength Concrete
• Glass Concrete
• Designation of Concrete
• Classification
• Based on Size
• Based on Density:
• Based on Mineralogical Composition:
• Properties of Aggregates
• Mechanical Properties
• Physical Properties
• Bulking of Sand
• Cement - Manufacturing of Cement, Compound Composition of Portland Cement, Structure and Reactivity of Compounds
• Manufacture of Portland Cement
• Compound Composition of Portland cement
• Bogue’s Compounds
• Microstructure
• Calcium Silicates
• Calcium aluminate and ferroaluminate
• Magnesium Oxide and Calcium Oxide
• Alkali and Sulphate Compounds
• Chemical Reactions when mixed with Water
• Hydration of Silicates
• Introduction to Special Types of Cement
• Rapid Hardening Cement
• Quick Setting Cement (QSC)
• Portland Pozzolana Cement (PPC)
• Coloured Cement
• White Cement
• Sulphate Resisting Cement
• Portland Blast Furnace Slag Cement
• Low Heat Cement
• Alumina Cement
• Use of Water in Concrete
• Requirements of Mixing Water
• Test of Water
• Admixtures
• Chemical Admixtures/Chemical Plasticizers
• Plasticizers (Water-reducing Admixtures)
• Mechanism of Action
• Super Plasticizers
• Increased Fluidity:
• Reduced W/C ratio:
• Accelerators
• Set Retarders
• Mineral Admixtures
• Cementitious
• Pozzolanic
• Fly Ash
• Silica Fume
• By-product of semiconductor industry
• Rice Husk Ash

Chapter 3

Properties of Fresh and Hardened Concrete

• Properties of Fresh Concrete
• Workability
• Consistency
• Cohesiveness
• Hardened Concrete
• Strength
• Compressive Strength of concrete
• Tensile strength of Concrete
• Flexural Strength
• Creep
• Shrinkage
• Dimensional Changes
• Durability
• Impermeability
• Expansion
• Permeability of Concrete

Chapter 4

Aggregates and Testing of Aggregates

• Properties of aggregates
• Types of Tests on Aggregates
• Aggregate Crushing Test
• Aggregate Impact Test
• Aggregate Abrasion Test
• Flakiness Index Test
• Elongation Index Test
• Angularity Test
• Soundness Test
• Specific Gravity and Water Absorption Test
• Stripping Value Test

Chapter 5

Specifications and Compliance Procedures

• Materials Specifications
• State Specifications
• Recommended Specifications for Cement and Concrete Containing Recovered Materials
• Contract Specifications
• Performance Standards
• Mix Design
• Quality Control
• Specifications for Cement and Concrete Containing Cenospheres and Silica Fume
• Referenced Documents
• ASTM Standards
• Other Documents

Chapter 6

Fresh Concrete Technology

• Introduction
• Definition of Workability
• Factors Affecting Workability
• Water Content of the Mix
• Aggregate Properties
• Time and Temperature
• Loss of Workability
• Cement Characteristics
• Admixtures
• Measurement of Workability
• Subjective Assessment
• Slump Test
• Compacting Factor Test
• Flow Table Test
• Remolding Tests
• Vebe Test
• Penetration Test
• Segregation
• Causes of Segregation of Concrete
• Prevention of Concrete Segregation
• Bleeding of Concrete
• Mixing Time
• Compaction of Concrete
• Curing of Concrete
• Significance of Curing of Concrete
• Methods to Cure Concrete

Chapter 7

Strength of Concrete

• Compressive Strength Formula
• The Importance of Strength
• Strength Level Required
• Kinds of strength
• Compressive Strength
• Flexural Strength
• Tensile Strength
• Shear, Torsion and Combined Stresses
• Relationship of Test Strength to the Structure
• Measurement of Strength
• Testing of Hardened Concrete
• Procedure: Compressive Strength Test of Concrete Cubes
• Sampling of Cubes for Test
• Curing of Cubes
• Precautions for Tests
• Procedure for Concrete Cube Test
• Calculations of Compressive Strength
• Reports of Cube Test
• Results of Concrete Cube Test
• Compressive Strength of Concrete at Various Ages
• Compressive Strength of Different Grades of Concrete at 7 and 28 Days
• Some Facts on Concrete Strength Test
• What is compressive strength of commonly used concrete?
• What is compressive strength after 7 days and 14 days?
• Which test is most suitable for concrete strength?
• What is the size of concrete cubes used for testing?
• Which machine is used for concrete strength test?
• What is the rate of loading on compression testing machine?
• Which ACI Code is use for Concrete Strength Test?

Chapter 8

Technology of Elasticity, Creep and Shrinkage

• Shrinkage in Concrete
• Factors Influencing Shrinkage of Concrete
• Influence of Concrete Ingre-dients on Shrinkage
• Effects of Shrinkage in Concrete
• Prevention or Reduction of Shrinkage in Concrete
• Creep in Concrete
• Factors Influencing Creep
• Effects of Creep on Concrete
• Crack-Width in Concrete
• Crack-Width Calculations
• Estimation of Deflection of Concrete Members

Chapter 9

Durability of Concrete

• Factors Affecting Durability of Concrete
• Cement Content
• Aggregate Quality
• Water Quality
• Concrete Compaction
• Curing Period
• Permeability
• Moisture
• Temperature Effects
• Abrasion
• Carbonation
• Durability Tests on Concrete?
• Chloride Attack
• Carbonation
• Sulphate Attack
• Alkali-Silica Reaction
• Water Permeability
• Fineness Test Apparatus
• Vicat Apparatus
• Initial and Final Setting Time of Cement Test
• Soundness Test Apparatus (Le-Chatelier)

Chapter 10

Mix Design and Quality Control

• Introduction
• Consideration of Design
• Design Criteria
• Considerations other Than Strength
• Durability/Permeability
• Chemical attack
• Permeability
• Factors affecting bleeding
• Pumpability
• Shrinkage
• Heat generation
• Quality Control of Concrete
• Quality Control of Concrete Definition
• What is Quality Control of Concrete?
• Quality Control of Concrete Before Concreting
• Quality Test of Concrete Materials
• Cement
• Aggregates (Fine and Coarse)
• Water
• Quality Control of Concrete During Concreting
• Quality Control of Concrete After Concreting (or After Construction of An Element)
• Purpose of Quality Control of Concrete
• Factors Affecting Quality Control of Concrete
• Advantages of Quality Control of Concrete

Chapter 11

Testing of Hardened Concrete

• Compression Test
• Moulds
• Compacting by Hand
• Compacting by Vibration
• Making and Curing test specimen in the field
• Comparison between Cube and Cylinder Strength
• Flexural Strength of Concrete
• Determination of Tensile Strength
• Procedure
• Indirect Tension Test Methods
• Cylinder Splitting Tension Test
• Ring Tension Test
• Double Punch Test
• Test Core
• Strength of Cores
• Non-Destructive Testing Methods
• Surface hardness tests
• Rebound test
• Penetration and Pull out techniques
• Dynamic or vibration tests
• Combined methods
• Radioactive and nuclear methods:
• Magnetic and electrical methods:
• Acoustic emission techniques
• Surfaces Hardness Methods
• Schmidt’s Rebound Hammer
• Limitation

Chapter 12

Concrete Mix Design

• Concrete Mix Design IS Code
• Target Mean Strength
• Water-Cement Ratio
• Water Content Determination
• Cement Content Determination:
• Determining the amount of Course and fine aggregates:
• Determination of Total volume of all the materials
• Taking out the ratio
• Preparation of trial mixes
• Types of concrete mix
• Normal Performance Concrete
• High-Performance Concrete
• Factors affecting concrete mix design

Chapter 13

Special Concrete and Concreting Methods

• Types of Special Concrete
• Ferrocement Concrete
• Fibre Reinforced Concrete
• Steel fibre reinforced concrete
• Glass Fibre Reinforced Concrete
• Polymer Impregnated Concrete
• Polymer Cement Concrete
• Polymer Concrete
• Superplastized concrete
• Ultra-High Strength Concrete
• Sulphur Impregnated Concrete
• Self Compacting Concrete
• Advantages of Special Concrete

Chapter 14

Transportation and Placing Methods

• Methods of Transporting Concrete
• Mortar Pan
• Crane, Bucket, and Ropeway
• Wheel Barrow or Hand Cart
• Belt Conveyor
• Truck Mixer and Dumper
• Skip and Hoist
• Chute
• Transit Mixer
• Pump and Pipe-Line Method

Chapter 15

The Economics of Ready Mixed Concrete

• Ready-Mix Concrete Market Analysis by Application
• Global Ready-Mix Concrete Market Regional Insights
• Ready-Mix Concrete Market Research
• Global Ready-Mix Concrete Market Dynamics
• Ready-Mix Concrete Market Driver
• Ready-Mix Concrete Market Restraint
• Ready Mixed Concrete Entire System
• Tilt Mixer
• Twin shaft mixer
• Pan concrete mixer

Chapter 16

Construction Chemicals: An Introduction

• Introduction
• What is waterproofing?
• What are Construction Chemicals?
• Construction chemicals
• Fly Ash
• Chemical Admixtures
• Waterproofing Admixtures
• Why do we need waterproofing Chemicals?
• Types of waterproofing
• Bitumen waterproofing
• Areas of Application
• Polyurethane Liquid Membrane
• Cementitious Water-proofing
• Plasticizers (Water Reducers)
• Air Entraining Agents
• Waterproofing Admixtures
• Shotcrete Admixtures
• Waterproofing in Construction
• What is meant by waterproofing?
• Types of Construction Chemicals
• Advantage & Disadvantage of Construction Chemicals
• Advantage of Construction Chemicals
• Some of the disadvantage of Construction Chemicals
• Safety Measures & Regulations
• Steps Involved in Waterproofing:

Chapter 17

Cement Water Proofing Powder (Dry Powders)

• Types of Concrete Waterproofing
• Cementitious Waterproofing
• Liquid Waterproofing Membrane
• Bituminous Coating
• Bituminous Membrane
• Admixtures
• Crystalline Admixtures
• Standard Compliances/Specification
• Typical Application
• Features
• Water seepage
• Consistency
• Economics
• Compatibility
• Method of Application
• Embodiment 1
• Embodiment 2
• Embodiment 3
• Embodiment 4
• Hand Mixing
• Machine Mixing
• Precautions & Limitations
• Manufacturing process of cement water proofing compound
• Formulation of Cement Water Proofing Compound

Chapter 18

Epoxy Coating

• Epoxy Coating Uses
• Epoxy Coating Compounds and Paints
• Flooring Applications for Epoxy Coatings
• Process of Manufacture of Sealant (Epoxy Based)
• Formulation of Sealant (Epoxy Based)
• Process Flow Diagram For Sealant (Epoxy Based)

Chapter 19

Leak Sealing Compound

• Function
• Types of sealants
• Common areas of use
• Aerospace sealants
• Comparison with adhesives
• Process Flow Diagram for Leak Sealing Compound
• Leak Sealing Compound

Chapter 20

Tile Adhesive

• Polymer Modified Cementatious Tiles Adhesive Production
• Uses
• Starting formulations for tile adhesives & grouts
• Dispersion Bound Adhesive
• Cement Based Tile Adhesive [Class C1E (EN 12004 [5])] with long adjustability time
• Cement Based Tile Adhesive (economical)
• Cement Based Tile Adhesive [Class C1TES1 (EN 12004 [5], EN 12002 [6])] with high yield
• Cement Based Tile Adhesive [Class C2TE (EN 12004 [5])]
• Cement Based Tile Grout with Fast Setting Properties
• Cement Based Tile Adhesive with Levelling Properties for Floors
• Formulation of Tile Adhesive
• Process of manufacture of tile adhesive
• Process flow diagram
• Adhesive Manufacturing Plant
• Full Automatic Tile Adhesive Manufacturing Plant
• Main Parts of The Automatic Tile Adhesive Manufacturing Machine
• Raw material storage silo
• Batching and weighing system
• Dry mortar mixer
• Packing machine
• Dust collector
• Conveying and lifting structure

Chapter 21

Epoxy Resin-based Corrosive Protective Coating

• Introduction
• Various Types of Concrete Protective Coatings
• The Symbiosis
• Failure Mechanism
• Deterioration Mechanism
• Carbonation
• Rate of Carbonation
• Chloride attack
• Sulphate Attack
• Protective Coatings
• Components of Coatings
• Solvent
• Resin
• Pigment
• Coating Types
• Generic Coatings
• Acrylics
• Alkyds
• Bituminous
• Epoxy, Amine
• Epoxy, Polyamide
• Epoxy, Coal Tar
• Epoxy, Fusion-Bonded
• Inorganic Zinc Primers
• Polyurethane
• Urethane
• Coatings that Breathe
• Functional requirements
• Surface Preparation
• Rust
• Grease and oil
• Soluble Salts
• Water
• Chalk
• Deteriorated coatings
• Formulation
• PART - A (PU Resin Based Component)
• Single Component Flexible Water-Proofing Coating
• Process of manufacture of pu resin based components & single components flexible water proofing coating
• Epoxy Resin Based Corrosive Resistant & Protective Coating
• Manufacturing process of epoxy resin based corrosive resistant & protective coating
• Process Flow Diagram
• Process Flow Diagram of epoxy resin based corrosive resistant & protective coating

Chapter 22

PU Resin Based Component

• Spray polyurethane foam system
• Application
• Advantages of insulation with polyurethane foam
• Polyurethane adhesives 
• Characteristics of Polyurethanes
• Application
• Advantages of polyurethane adhesives
• Additives for PU Coatings
• Solvents
• Leveling Agents
• Formulation
• Process Flow Diagram of PU resin based component
• PART - A (PU Resin Based Component)
• Single Component Flexible Water-Proofing Coating

Chapter 23

Single Component Flexible Water Proofing Coating

• Cementitious water proofing
• Spraying Method
• Trowel Method
• Brush Method
• Base surface pretreatment
• Construction method
• Waterproofing Materials
• Cement-based Waterproofing Materials
• Liquid Waterproofing Membrane Materials
• Liquid Bituminous Mem-brane Waterproofing Materials
• Membrane Waterproofing Materials
• Polyurethane Liquid Membrane Waterproofing Materials
• Contribution of Waterproofing Materials to Building Durability
• Waterproofing Methods
• Cementitious Water-proofing
• Applications of Cementitious Waterproofing
• Liquid Waterproofing Membrane
• Bituminous Coating Waterproofing
• Bituminous Membrane Waterproofing
• Polyurethane Liquid Membrane Waterproofing

Chapter 24

Concrete Curing Compound

• Types of Concrete Curing Compounds
• Acrylic Concrete Curing Compound
• Wax Concrete Curing Compound
• Chlorinated Rubber Curing compound
• Properties of Concrete Curing Compound
• Process of Applying Concrete Curing Compound
• Uses of Concrete Curing Compound
• Formulation of Cement Admixture

Chapter 25

Pre-painted Galvanised Iron

• Benefits of Pre-Painted Galvanised Steel Sheets
• Making of Pre-Painted Galvanized Steel Sheet
• Applications of pre-painted galvanized sheet
• Benefits of Pre-painted Galvanized Steel
• Specification of Pre-Painted Galvanised Iron (PPGI)
• Advantages

Chapter 26

Cement Admixture

• Definition of Concrete Admixtures
• Reasons for Using Admixtures
• When Concrete Admixtures Used?
• How to Use Concrete Admixtures?
• Types of Concrete Admixtures (Additives)
• Air Entraining Admixture
• Accelerating Admixtures
• Water Reducing Admixtures
• Why Water Reducing Admixtures are used?
• Effect on durability
• Effect on shrinkage
• Effect on creep
• Detrimental effect
• Applications of Water Reducing Concrete Admixtures
• Retarding Concrete Admixtures
• Why Retarding Concrete Admixtures are used?
• Super Plasticizers or High Range Water-Reducing Admixtures in Concrete
• Chemical type
• Mode of action of Super Plasticizer Admixtures
• Why Super Plasticizer Admixtures are used?
• Advantages of Super Plasticizer Admixtures
• Disadvantage
• Applications of Super Plasticizer Admixtures
• Mineral Admixtures for Concrete
• Classification of Mineral Admixture
• Silica Fume as Concrete Admixture
• Production of Silica Fume
• Types of Alloys Produced in Submerged Arc Electric Furnaces
• Specific Gravity and Specific Surface Area of SF
• Filler and Pozzolanic effects of Silica Fume
• Selection of Concrete Admixtures
• Precautions

Chapter 27

Hardening Agent for Cement

• Maintaining mixing water in concrete during the early hardening process
• Ponding and immersion
• Spraying and fogging
• Saturated wet coverings
• Left in Place Forms
• Reducing the loss of mixing water from the surface of the concrete
• Covering concrete with impervious paper or plastic sheets
• Applying membrane-forming curing compounds
• Accelerating strength gain using heat and additional moisture
• Live steam
• Heating coils
• Electrical heated forms or pads
• Concrete blankets
• Curing Concrete Test Specimens

Chapter 28

Metallic Waterproofing Compound

• Metallic Floor Hardener
• Non-Oxidized heavy-duty metallic floor hardener
• Non-Metallic floor hardener:
• Polysulphide Sealants

Chapter 29

Polyvinyl Chloride

• Polyvinyl Chloride Origin
• Properties of PVC
• Applications
• Uses & Benefits
• Building and Construction
• Packaging
• Healthcare
• Household Products
• Safety Information
• Tested, Effective, Affordable

Chapter 30

Ready Mix Plaster

• Advantages
• Technical Data
• Technical Data Sheet
• Quality Requirement of good plastering
• Features and benefits
• High Strength
• Consistency
• Saves Time
• Hassle Free
• Easy Application
• Minimum Wastage
• Minimum Cracks
• Storage
• Higher Coverage
• Finish
• Economical
• Availability
• Premixed
• Product characteristics

Chapter 31

Mould Releasing Agent

• Types of Mold Release Agents
• Semi-Permanent Mold Release Agents
• Sacrificial Mold Release Agents
• Mold Release Agent Applications
• Composite
• Rubber
• Industrial Applications of Mold Release Agents
• Boat Building Industry
• Rubber Goods Industry
• How Release agent works
• Release Agent Uses
• Benefits of Various Mold Release Applications
• Mold Release Agent Manufacturing Process

Chapter 32

Protective and Decorative Coating

• Types of decorative wall painting
• Latex paint or plastic
• Synthetic enamel paints
• Paint in acrylic enamel
• Paint Primers
• Varnishes
• Silicate Paint
• Benefits of ornamental painting on walls
• Plaster of Paris
• Acoustic Plastering
• Barium Plaster
• Granite Silicon Plaster
• Asbestos Marble Plaster
• Keene’s Cement
• Parian Cement
• Snow-crete and colour crete cements
• Plaster’s Putty
• Sira Bite
• Scagliola
• Thistle Hard Wall

Chapter 33

Bisophenol A

• Epoxy Resins
• Bisphenol A

Chapter 34

Plant Economics of Cement Waterproofing Compound (SBR Latex Chemicals)

• Plant Economics
• Land & Building
• Plant & Machinery
• Fixed Capital
• Working Capital Requirement/Month
• Turn Over/Annum

Chapter 35

Plant Economics of Construction Chemicals [Cement Water Proofing Powder (Dry Powders), Epoxy Sealant, Leak Sealing Compound, Tile Adhesive, Epoxy Resin-based Corrosive Protective Coating, PU Resin Based Component, Single Component Flexible Water Proofing Coating]

• Plant Economics
• Land & Building
• Plant & Machinery
• Fixed Capital
• Working Capital Requirement/Month
• Total Capital Investment
• Turn Over/Annum

Chapter 36

Plant Economics of Dry Mix Mortar (DMM) [Dry Mix Plant - Ready Mix Plaster, Thin Bed Mortar, Tile Adhesives (Floor And Wall Tiles) & Tile Grouts]

• Plant Economics
• Land & Building
• Plant & Machinery
• Fixed Capital
• Working Capital Requirement/Month
• Total Capital Investment
• Turn Over/Annum

Chapter 37

Plant Economics of Sand-Cement Based Ready Mix Mortars

• Plant Economics
• Land & Building
• Plant & Machinery
• Fixed Capital
• Working Capital Requirement/Month
• Total Capital Investment
• Turn Over/Annum

Chapter 38

Plant Economics of Wall Putty and Construction Chemicals

• Plant Economics
• Land & Building
• Plant & Machinery
• Fixed Capital
• Working Capital Requirement/Month
• Total Capital Investment
• Turn Over/Annum