Important Indian Standard Codes: Civil Booster (Civil Ki Goli Publication 9255624029)
Important Indian Standard Codes: Civil Booster (Civil Ki Goli Publication 9255624029)
Important Indian Standard Codes: Civil Booster (Civil Ki Goli Publication 9255624029)
Important Indian
Standard Codes 1
456 Plain and reinforced concrete
269 Specification of OPC 33 grade
8112 Specification of OPC 43 grade
12269 Specification of OPC 53 grade
8041 Rapid hardening Portland cement
8042 White Portland cement
8043 Hydrophobic Portland cement
IS:6452 High alumina cement
IS:1489 Part-I Portland Pozzolana cement (fly ash based)
IS:1489 Part-II Portland Pozzolana cement (Calcined clay based)
383 Coarse & fine aggregates from natural sources
516 Strength of concrete tests
650 Specification for standard sand for testing
2386 Test for Aggregate (1–8 Parts)
2430 Sampling of aggregate for concrete
5816 Splitting tensile strength of concrete
6461 Glossary of terms related to cement concrete (Part 1–12)
7320 Specification of concrete slum test apparatus
10262 Guidelines for concrete mixed design
13311 Part –1 Ultrasonic pulse velocity test Non-Destructive
Part – 2 Rebound hammer testing of concrete
875 Design loads (other than earthquakes) for building & structures
Part I : Dead load. Part II: Live load
Part III : Wind load, Part IV : Snow load
Part V : Special loads & load combinations
1893 Earthquake resistant design for structures
Note: The new code for all OPC 33, 43 & 53 grade is IS 269:2015
Building Material Construction 3
Cement 2
Cement is a material which has cohesive & adhesive properties in the
presence of water
Cement was invented by Joseph Aspdin of UK in 1824.
John Smeaton is considered as the father of civil engineering.
Basic
Standard density = 1440 kg/m3
Weight of 1 bag of cement = 50 kg
50
Volume =
1440
= 0.0347 m3
The tolerance in measurement of cement, is 2%
Material Unit weight (kN/m3)
Brick Masonary 19 – 20
Plain cement concrete 22–24
Reinforced cement concrete 24–25
Cement mortar 20–21
Steel 78–80
Cement 14.4
Types
Hydraulic Non-hydraulic
Sets & hardens in Derived from calcination
presence of water & of gypsum or limestone
results in water-resistant because their products of
product which is stable hydration are not water resistant
Ex:- Portland cement Ex:- Plaster of Paris
4 Civil Booster (Civil Ki Goli Publication 9255624029)
Raw materials in cement manufacture
Argillaceous Calcareous
Blast Furnace slag Lime stone
Cement Rock Chalk
Marl Marine Shells
Shale and Clay
CIVIL Ki Goli
Silica Iron oxide
Loss esa gSA I M S
Sulphur Trioxide
Lime Alumina Magnesia
Cement Storage
Floor area occupied by a cement bag in warehouse is 0.3 m2 & Height is
0.18 m.
The length of one bag of cement is 0.70m
The width of one bag of cement is 0.42m
Cement must be kept above from the ground level about 45 cm
The distance of cement bags from the wall should be 30 cm
As per IS 4082 : 1996, the stacking & storage of cement shall be done as
follows:
Cement shall be stored at the worksite in building or a shed which is dry,
leakproof & moisture proof as possible.
Building Material Construction 5
Cement bags shall be staked off the floor on the wooden piles in sush a
way as to keep about 150 mm to 200 mm clear above the floor.
A space of 600 mm minimum shall be left around between the exterior
walls & the stack.
The height of stack shall not be more than 10 bags to prevent the
possibility of lumping up under pressure.
The width of stack shall not be more than four bags length or 3 meters.
In stacks more than 8 bags high the cement bags shall be arranged
alternately lengthwise & crosswise so as to tie the stack together &
minimize the danger of toppling over.
Cement bags shall be stacked in manner to facilitate their removal & use
in order in which they are received, a label showing date of receipt of
cement shall be put on each stack to know the age of cement.
Period of Storage % Strength at 28 days concrete
Fresh 100
3 Month 80
6 Month 70
12 Month 60
60 Month 50
Bogue’s Compound
When these raw materials are put in kiln. Then it fuses & following four
major Compounds are formed:-
CIVIL Ki GOLI
Belite Felite
A B C fraud vkneh gS
Alite Celite
6 Civil Booster (Civil Ki Goli Publication 9255624029)
Special Point:- It is found that OPC achieves 70% of its final strength in
28 days & about 90% in one year.
Flash set is the stiffening of cement paste without strength development
with heat evolution (premature hardening). It is cause by (C3A), Gypsum,
Alkali etc.
Tri calcium Aluminate (C3A) reacts immediately with water & is
responsible for flash set.
Gypsum is added to cement to reduce flash setting.
After flash set, mixing is not allowed because no gain in strength
development after mixing.
Gypsum retards setting time of cement
Gypsum is usually mixed with clinker before final grinding
Excess gypusm makes cement unsound. So Gypsum added to clinker
should not be greater than 2.5-3%
False set
Rapid stiffening/Hardening (with no appreciable evolution of heat) in
freshly mixed P.C. paste, mortar or concrete.
Remixing the cement paste without addition of water, plasticity of paste
restores again. It is cause by Grinding to hot clinker low C3A + high
Gypsum
Water Requirement for hydration
Hydration of cement is exothermic reaction.
Bound water = 23% by weight of cement.
Gel water = 15% by weight of cement
Total minimum = 38%,
Rate of hydration C4 AF > C3 A > C3S > C2S
Rate of Heat evolution C3A > C3S > C4AF > C2S
Food inlet
To air separator
Tube mill
Building Material Construction 7
Outer casing
Curved steel
plate
Sieve
Hardened
steel balls
Outer funnel
Ball Mill
Types of Cement
1. Portland cement: Classified on the basis of manufacturing as 33 grade,
43 grade & 53 grade.
OPC
(i) OPC-33 (IS : 269-2015)
(ii) OPC-43 (IS : 8112-1989)
(iii) OPC-53 (IS : 12269-1987)
Initial Setting Time (IST) – 30 minute & final Setting Time (FST) – 600
minute
2. Rapid hardening cement (IS:8041): More C3S & less C2S as
compared to OPC
Not-used in mass concrete & it produce Large Shrinkage
RHC attains same strength in 1 day which an OPC attains in 3 days
with same w/c.
It is suitable for repair of roads, bridges etc.
3. Extra Rapid hardening cement: Rapid hardening cement + 2% CaCl2
(also called calcium chloride cement)
Especially used in cold weather but also give Excessive Shrinkages
8 Civil Booster (Civil Ki Goli Publication 9255624029)
Fly Ash
It is residue from the combustion of pulverized coal collected by
Mechanical or electrostatic separaters from the flue gases or power plants.
It is about 75% of total ash produced.
It descrease segregation & bleeding
It also lowers the early strength of conerete mixture
It reduces the permeability of concrete
Special Points:
Main function of Surkhi is to give strength & Hydraulic properties to
morter
Blast farnace slag is a by product obtained while smelting Iron - ore
in Blast furnance.
10. Quick setting cement: Fine grounded OPC with reduced Gypsum
content.
IST = 5 minutes & FST = 30 minutes
Used in under water concreting.
11. Air Entraining cement: OPC + Vinsol resin or vegetable fats of oils
or fatty acids.
Small amount (0.1%) by weight of an air entraining agent.
12. White and Coloured Portland cement (IS: 8042) : From Pure white
chalk & china clay
Nil Iron Oxide
These are used for making Terrazzo flooring, ornamental works &
casting stones.
Hunter scale is use for checking the whiteness of cements
5–10% Colouring pigment before grinding
13. Water Repellent or Hydrophobic cement: OPC + fractions of olic
acid, Stearic acid or pentachlorophenol.
Suitable for basement & making water tight structures.
Minimum Specified Strength in N/mm2
Type/days 1 day 3days 7 days 28 days
OPC (33 grade) – 16.0 22.0 33.0
Portland Pozzolana – – 22.0 33.0
Low heat Portland – 10.0 16.0 35.0
Testing of cement: It should be taken from 12 points from heap or from
12 different bags or packages. Weight of sample collected should be atleast
5 kg.
10 Civil Booster (Civil Ki Goli Publication 9255624029)
Types of Cement Tests
Field tests Lab tests
Small quantity of cement thrown in water sinks.
If hand is inserted in cement, Physical tests Chemical
It should feel cool not warm test
Fineness
It should be grey in colour
Consistency
Thin paste of cement feels sticked between fingers Weight of Insoluble residue < 4%
IST & FST
Should be free from lumps Weight of Magnesia < 6%
Soundness
Total loss on ignition < 5%
Strength determination
Heat of hydration
Specific gravity
Air permeability method
Sieve method Wagner turbidimeter
Measures Measures specific surface area
Measures specific surface area
grain size Nurse & Blaine’s apparatus
100 gm cement Manometer-to measure air
used pressure
90 Micron Flow meter to measure Quantity
(9 No.) sieve of air passing
1 mm sq
50
Air
vent 6.4
0.3
5
10
Plunger Enlarged view of needle
Special Point:- The size of concrete cube is 150 × 150 mm
6. Heat of hydration: Measured by Calorimeter.
7. Specific Gravity Test: Measured by Le-chatelier’s flask.
Specific gravity of OPC = 3.15
16 Civil Booster (Civil Ki Goli Publication 9255624029)
Screeding: The process of striking off the excess concrete to bring
the top surface upto proper grade.
Floating: It consist of removing the irregularities on the surface of
concrete & it is generally done by wooden float.
Trowelling: It is final operation of finishing. & it gives a very smooth
finish.
7. Curing: As per IS: 456, curing is the process of preventing the loss of
moisture from the concrete while maintaining a satisfactory
temperature regime.
The test sample should be stored in a place free from vibration, in
moist air of atleast 90% relative humidity & at a Temp. of 27º ±
2ºC for 24 hour ± (1/2) hour from time of addition of water to dry
ingredients.
Curing period for rapid hardening cement is 3 to 7 days, seven
days for OPC.
Combined water: It is chemically combined with hydration
products and it is non evaporable.
Capillary water: It partially occupies the capillary pores that
constitute the space in the cement paste remaining offer accounting
for the volumes of cement gel & unhydrated cement. It is easily
evaporated.
Gel water: It held physically or adsorbed on the surface area of
the cement.
Method of curing Suitability
Shading of concrete work/ For large concrete
Stagnating water surfaces such as
road slab.
Gunny bags For structural concrete
Sprinkling of water For vertical surfaces
Membrance curing At places of scarcity of water
Steam (accelerated) curing For precast concrete work
Special Points: Steam curing is not suitable for high alumina cement
Membrane curing is used for hilly areas
Steam curing increase ultimate strengths & reduced the shear strength
of concrete.
Concrete heated by steam at 93oC either at low or high presture.
More rapid gain of strength can be obtained by with the help of Infra-
red radiation than steam curing.
Building Material Construction 19
CIVIL Ki GOLI
Mild Severe Extreme
M M S Very Entertaining
Moderate Very Severe
Under mild (Normal) condition minimum cover provided is 20mm & in
sever condition the minimum cover provided is 45mm, which is 25 mm
further additional to the cover provided under normal condition.
Strength of Concrete: It is designated in terms of numbers preceded by
the letter ‘M’ where M refer to the ‘Mix’ & number represents the
characteristic strength.
Tensile strength = 10%, of compresive strength
Bending strength = 15%, of compressive strength
Shear Stregnth = 20%, of compressive strength
Probablity density
5%
1.65
fck fm mean
characteristic strength
strength
Characteristic strength is the strength of material below which not more
than 5% of the test result are expected to fall.
f m f ck 1.65
Generally samples are tested for 7 days or 28 days but IS code only
suggest 28 days strength only.
2
7 days strength = of 28 days strength of concrete.
3
Average of 3 values is taken as compressive strength of concrete, provided
the individual variation is not more than ±15% of the average.
28 Civil Booster (Civil Ki Goli Publication 9255624029)
humidity is low or when cement content, Air entrainment, water cement
ratio & temperature are high.
Non-Destructive Testing
1. On Hardened concrete
(a) Maturity Test
(b) Pull-out Test
(c) Penetration Test
(d) Ultrasonic Pulse Velocity Test
(e) Rebound Hammer Test (Schmidt Hammer Test)
Admixture
Special Points
For making 1 m3 wet concrete requires 1.54 m3 dry concrete.
For making 1 m3 wet mortar require 1.25 m3 dry mortar.
Rebound Hammer test provides useful information for surface layer upto
30 mm depth and is suitable for concrete having compressive strength
20-60 MPa.
Building Material Construction 31
Timber 4
Timber applies to the trees measuring not less than 600 mm in
circumference of the trunk
Timbers are of three types standing timber, dead timber & converted
timber
The tree which is be found in living condition is known as standing
timber
The trunk of tree left after cutting all the branches is known as log
The art of dressing of edges of timber pieces so as to make them straight
& square with the face is called shooting
The timber whose thickness is less than 5cm & the width exceeds 12cm,
is called a board
Screws for wood work are specified by length
The best season for felling of trees for timber production in hilly area is
summer
Types of trees
Endogenous tree Exogeneous tree
Grow inward Grow outward
Bamboo, cane, palm Deodar, Sal, Teak
Conifers Deciduous
(soft wood) (hard wood)
Needle shape leaves Broad shape leaves
Evergreen tree Open tree
Pine, chir, Deodar Oak, Teak, Shishum
Structure of Timber
Heart Wood
Outer Bark
Pith
Sap Wood Inner Bark
Medullary Rays Cambium Layer
Pith
Sapwood
PH SCale
CIVIL Ki GOLI Cambium layer
Heartwood
1. Pith: Innermost central portion consists of cellular tissues & noutrishes
plant at young age.
2. Heart (True) wood: Dead portion of the tree, Dark in colour, Provides
rigidity & durability
3. Sap wood: Light in colour, shows recent growth, sap moves in upward
direction through it & it lie in between heart wood & cambium layer.
4. Cambium layer: Sap which has yet not converted into sap wood.
5. Inner bark: Protection of cambium from injury.
6. Outer bark (cortex): Consists of cells of wood fiber.
7. Medullary ray: Hold the annual rings of heart wood & sap wood.
Special Points: Wood added during early part is different from the wood
added during the late part. Because of this difference between the early
wood & late wood, Growth rings (Annual rings) becomes apparent & use
in age of tree.
Building Material Construction 33
Properties of Timber:
1. Specific gravity of wood = 1.54 & It is orthotropic, shrinks least
along length & maximum along circuferance
2. Tensile strength along the grains is 2–4 times stronger than compressive
strength.
3. Fibre saturation point is % moisture content at which cell walls are
saturated & cell cavity contains no water.
4. Timber has high sound conductivity. nearly 2–17 times greater than
air.
5. Weight of timber should be noted at 12% moisture content
6. Resistance of wood to cutting across the fibers (shear strength) is 3 to
4 times greater than along the fibers
7. Modulus of elasticity is generally (0.5 – 1)× 104 N/mm2 & its ratio of
longitudinal to transverse direction is 1 –2 times.
Sawing of Timber
Saw cuts
Saw cuts
Saw cuts
Bricks 6
Dimensions of Brick
Standard size = 19 cm × 9 cm × 9 cm
Nominal size (with mortar) = 20 cm × 10 cm ×10 cm
Traditional bricks = 9" × 4.5" × 3" (23 cm × 11.4 cm× 7.6 cm)
Frog
Frog (indent in the brick) = 10 cm × 4 cm × 1cm
Frog is provided on top surface and it is useful in key joint between
mortar and brick.
Weight of 1 m3 of brick = 1800 kg
Avg. weight of the brick = 3 kg to 3.5 kg
No. of bricks using 1m3 brick work = 500
The minimum thickness of brick wall is 10cm
The density of bricks should be1600 to 1900 kg/m3
Comparison between Bricks and Stone
1. Brick resist more fire than stones & also resist other atomspheric effects
in a better way.
2. Brick work is cheaper, requires less skilled labour & no complicated
lifting device.
3. In brick work mortar joint are thin, hence more durable.
4. Brick work is less water tight & absorbs more moisture.
5. Stone work is stronger, gives solid appearance, attractive in texture.
6. Thickness of brick wall is 100 – 200 mm but stone wall has minimum
thickness of 300 mm.
7. Stone work has higher compressive strength (adopted in piers, docks,
dams) & doesn’t requires any finishing.
Building Material Construction 47
Classification of bricks
Unburnt bricks Burnt bricks
Bricks are dried in sun after
moulding used in temporary
or cheap structures can not be
used at places exposed to First Second Third
heavy rains
class class class
Speical Points:
1. Fourth class bricks: (Jhama)
Over burnt badly distorted.
Used as ballast in foundations & floots in lime concrete.
2. The most common colour of building bricks is red
3. Heavy duty bricks have compressive strength more than 40 N/mm2,
used instructures such as bridges, fondation of industrial buildings
etc. water absorption is limited to 5%.
4. Refractory bricks have following qualities :
These bricks are capable of resisting very high temperature upto
1700ºC without melting or softening.
The water absorption of refractory bricks varies from 4-1%.
These bricks are whitish yellow or light brown in colour.
The minimum average compressive strength of the brick should
be 32.5 MPa.
These bricks are used in furnace lining, hollow files & crucibles
etc.
48 Civil Booster (Civil Ki Goli Publication 9255624029)
Constitute Function
(i) Silica (50-60%) Provide strength, hardness
durbility to brick.
(ii) Alumina (20 –30%) Give plasticity to brick
(iii) Lime (>5%) Causes silica to fuse
during burning & binding
particles together
(iv) Iron oxide (5-6%) Provide red colour &
improves imperme-ability
& durability.
(v) Magnesia (<1%) Give yellow tint
CIVIL Ki Goli
Alumina Iron Oxide
S A L I M
Manufacturing of bricks
Preparation of Brick
Moulding
Drying
Burning
Brick
Flowchart: Preparation of Brick Earth
2. Moulding: Process of giving required shape to the brick earth.
Types of Moulding
Hand moulding Machine moulding
(for soft mud) (for stiff mud)
The Good clay for making Bricks is weathered clay.
The tempering of bricks earth is also known as pugging or kneading
The process of mixing clay, water & other ingredients to make
bricks is known as kneading
The pug mill is used for kneading
Generally wooden moulds are made from shishum
Moulds are made (8–12)% larger in size.
To prevent the moulded bricks from sticking to the side of the mould,
sand is sprinkled on the inner sides of the mould.
3. Drying: Green bricks if burnt can get cracked & distorted.
The percentage of moisture in wet bricks is 7 to 30%
The wet bricks should be dried in an open atmosphere 4 to 5 days
The process of drying of bricks in an open atmosphere is called
hacking
50 Civil Booster (Civil Ki Goli Publication 9255624029)
Drying Types
Natural drying Artificial drying
Hot floor drier Tunnel drier
The Bricks after moulding should be dried in air for (3-8) days but
not in sun.
It is a normal practice to dry moulded bricks to approx moisture content
of (5–7)%. Drying period usually varies from (7–14) days.
4. Burning: Over burnt bricks become brittle while under burnt bricks
will be soft & hence can not carry loads.
Types of Kilns
Intermittent Continous
Testing of bricks
1. Dimension Test (IS 1077): 20 bricks are randomly selected of standard
size (19 × 9 × 9 cm).
Sub Class-A Sub Class-B
Dimension Tolerance Dimension Tolerance
(cm) (mm) (cm) (mm)
Length 380 ±12 380 ± 30
Width 180 ± 6 180 ± 15
Height
(i) 9 cm 180 ± 6 180 ± 15
(ii) 4 cm 80 ± 3 80 ± 6
Building Material Construction 57
Gypsum is a crystalline mineral of hydrated calcium sulphate
(CaSO42H2O)
When gypsum is heated to 120ºC–180ºC, it gets dehydrated to
1
form plaster of Paris (CaSO4. H O).
2 2
It is used to precast & hold parts of omamental plaster work
placed on ceilings.
(ii) Limestone is a sedimentary rock, its major materials are minerals
calcite & aragonite (Crystal forms of CaCO3).
(iii) Kankar is a term usd in India for masses or layers of calcium
carbonate, found in older arrival or stiff clay.
Classification of mortar
Surkhi mortar Light weight
X-ray shielding
Gauged mortar mortar
Cement mortar
Gypsum mortar
Gunting: Application of mortar or concrete under pneumatic pressure
through cement gun. It is done in layers of 40–50 mm. A thin layer of grout
builds up & acts like a cushion reducing the percentage rebound in the
successive layers. Average unit weight of gunite is 2300 kg/m3.
Grout: Cement mortar of fluid consistency used to fill the voids &
joints in masonry and to repair the cracks water-cement ratio should be kept
as low as possible to increase strength & reduce shrinkage..
60 Civil Booster (Civil Ki Goli Publication 9255624029)
Rocks
Stair Case 11
Pitch line Minimum
head room
Landing At least 2 m
Flight Riser (4 inch-7 inch)
Tread (11 inch minimum)
In public buildings the maximum riser is limited to 15 cm
The height of hand railing above the tread should be generally in between
75 cm to 80 cm
Tread & rise in stairs
R T
Dwelling houses 160 250
Public buildings 150 270
Industrial buildings 190 250
Cinemas 150 270
15. The minimum depth of building foundation on sandy soils is 0.8m to
1m, rocky soils is 0.05m to 0.5 & clay soils is 0.9m to 1.6m
16. The function of coping is to serve as a covering to the wall to throw
off water
17. The portion of wall on which the end of an arch rests in known as
abutment
18. The internal curve of an arch is termed as intrados
19. The depth of arch is the perpendicular distance between the intrados
& extrados
20. The function of cleats in a roof truss is to prevent the purlins from
tilting
Requirement of Part of Building
Plinth: The height of plinth shall not be less than 45 cm from
surroundings ground level.
Kitchen
Size of door for kitchen is 0.9 m × 2.1 m
The area of kitchen shall not be less than 5 m2.
Minimum width of kitchen is 1.8 m.
Habitable room:
The area of habitable room shall not be less than 9.5 sq. m.
For two rooms, area of one shall not be less than 9.5 sq. m & area of
other not less than 7.5 m2.
The minimum width of habitable room shall be 2.4 m.
The height of habitable room shall not be less than 2.75 m.
The minimum clear head room under a beam folded plate or eave
shall be 2.4 m.
Store room:
Area of store room shall not be less than 3 m2.
Height of store room shall not be less than 2.2 m.
Bathroom & water closets:
The size of bathroom shall not be less than 1.8 m2 & with minimum
width is 1.2 m.
The minimum size of water closet shall be 1.1 m2 with minimum
width 0.9 m.
If both are combined the minimum area shall be 2.8 m2 with minimum
size of 1.2 m.
Building Material Construction 81
82 Civil Booster (Civil Ki Goli Publication 9255624029)
Stairway
Residential building (dwelling) upto three story – 0.9 m
Other residential building like flat, hotel etc. = 1.25 m
Residential hotel building = 1.5 m
Educational building like school & college = 1.5 m
Assembly building like auditorium, theatre etc. = 1.5 m
Institutional building like hospital = 2 m
All other buildings = 1.5
Depth of exploration
The term significant depth is used to indicate the depth upto which the
increase in pressure due to structural loading is likely to cause perceptible
settlement or shear failure of foundations.
Depth of exploration
1.50 times the length
1.50 times the base width of 1.50 times the exposed height of face of
wall whichever is greater.
1.50 times the width.
Depth of construction.
1.50 m in general & 3.50 m in black cotton soil.
10 m to 30 m or more with minimum equal to 1.50 times the width of
structure.
Methods of site exploration.
1. Test pits, 2. Sub-surface sounding, 3. Boring, 4. Probing
5. Geo-physical method
Honeycomb: These are hollow spaces and cavities left in concrete mass
on the surface or inside the mass where concrete could not reach. These
look like honey bees nest.
Causes of honeycomb in Concrete:
1. Insufficient compaction to concrete.
2. Improper Workability in concrete.
3. Concrete already set before placing.
4. Less cover to reinforcement bars.
5. High concrete free fall while pouring.
6. Improper placement of bars at column and beam junction.
7. Addition of more water.
8. Steel congestion not allowing concrete flow to all corner.