Concrete – EIRI – eBooks and Project Reports

CONCRETE PLASTICIZER

EIRI Team — Thu, 01 Dec 2016 09:47:59 +0000

Superplasticizers (SPs) are recognized as important admixtures for their applications in modern concrete technology. Efforts have long been made by scientists and technologists to keep fresh concrete fluid to provide homogeneous transport of all particles in the building industry. Traditional techniques which use the superplasticizers such as sulfonated melamine formaldehyde condensate (SMF) and sulfonated naphthalene formaldehyde condensate play a positive role in maintaining high fluiding concrete. The superplasticizers interact with the surface of cement particles and involve dispersion and decreasing of the natural tendency to coagulate in concrete. Polycarboxylates (PC) are recently commonly used as superplasticizers to disperse cement particles in concrete and mortar. However, it has been known that the dispersing force of PC for cement and its time variation are significantly affected by even slight differences in concrete components or mixing conditions. Such instability of the dispersing force is explained by the incompatibility between cement and PC. Moreover, the side chain of the copolymer-type PC is composed of polyethylene oxide units. The methyl oxide bonds are easy to break under heat and oxygen. Furthermore, as a new generation water-reducing agent, the PC water-reducing agent would face the problem of short resources in the near future for nonregenerate ability of crylic acid derived from petroleum, so melamine superplasticizer has shown great advantage. Melamine superplasticizer is one of the most commonly employed due to its colorless, nontoxic, and good thermal stability. However, the application of traditional melamine water reducing agent is becoming less and less due to the complex production process, high cost, and relatively inferior slump loss. Along with the architecture industrial development and on the concrete performance requirements to improve, the development of high performance superplasticizer is imperative.
Water-reducing admixtures or plasticizers are all hydrophilic surfactants which, when dissolved in water, deflocculate and disperse particles of cement. By preventing the formation of conglomerates of cement particles in suspension, less water is required to produce a paste of a given consistency or concrete of particular workability. Maintaining low water contents whilst achieving an acceptable level of workability results in higher strengths for given cement content as well as lower permeability and reduced shrinkage. An important consequence of the reduction in the permeability is a major enhancement of its durability. The permeability of concrete to gases (oxygen, CO2), and water (carrying chlorides, sulfates, acids and carbonates) is of major importance with respect to its durability.
Retarding admixtures, which extend the hydration induction period and thereby lengthening the setting times, are often treated together with plasticizing admixtures as the main components used for retarding mixtures are also present in water-reducing admixtures. As a result, many retarders tend to reduce mixing water and many water reducers tend to retard the setting of concrete.
A much greater reduction in the volume of mixing water can be achieved using socalled superplasticizers or high-range water-reducing admixtures in case of concretes of normal workability. Normal water reducers are capable of reducing water requirement by about 10-15%. Further reductions can be obtained at higher dosages but this may result in undesirable effect on setting, air content, bleeding, segregation and hardening characteristics of concrete. Superplasticizers are capable of reducing water contents by about 30%.
Plasticizers (UK: plasticisers) or dispersants are additives that increase the plasticity or viscosity of a material. The dominant applications are for plastics, especially polyvinyl chloride (PVC). The properties of other materials are also improved when blended with plasticizers including concrete, clays, and related products. According to 2014 data, the total global market for plasticizers was 8.4 million metric tons.
Plasticizers or water reducers, and superplasticizer or high range water reducers, are chemical admixtures that can be added to concrete mixtures to improve workability. Unless the mix is "starved" of water, the strength of concrete is inversely proportional to the amount of water added or water-cement (w/c) ratio. In order to produce stronger concrete, less water is added (without "starving" the mix), which makes the concrete mixture less workable and difficult to mix, necessitating the use of plasticizers, water reducers, superplasticizers or dispersants.
Plasticizers are also often used when pozzolanic ash is added to concrete to improve strength. This method of mix proportioning is especially popular when producing high-strength concrete and fiber-reinforced concrete.
Adding 1-2% plasticizer per unit weight of cement is usually sufficient. Adding an excessive amount of plasticizer will result in excessive segregation of concrete and is not advisable. Depending on the particular chemical used, use of too much plasticizer may result in a retarding effect.
Plasticizers are commonly manufactured from pop lignosulfonates, a by-product from the paper industry. Superplasticizers have generally been manufactured from sulfonated naphthalene condensate or sulfonated melamine formaldehyde, although newer products based on polycarboxylic ethers are now available. Traditional lignosulfonate-based plasticisers, naphthalene and melamine sulfonate-based superplasticisers disperse the flocculated cement particles through a mechanism of electrostatic repulsion (see colloid). In normal plasticisers, the active substances are adsorbed on to the cement particles, giving them a negative charge, which leads to repulsion between particles. Lignin, naphthalene and melamine sulfonate superplasticisers are organic polymers. The long molecules wrap themselves around the cement particles, giving them a highly negative charge so that they repel each other.
Polycarboxylate ether superplasticizer (PCE) or just polycarboxylate (PC), work differently from sulfonate-based superplasticizers, giving cement dispersion by steric stabilisation, instead of electrostatic repulsion. This form of dispersion is more powerful in its effect and gives improved workability retention to the cementitious mix.

INTRODUCTION
CHEMISTRY OF SUPER PLASTICIZER FOR CONCRETE
ADMIXTURE FOR CONCRETE
CLASSIFICATION OF CONCRETE ADMIXTURE
PLASTICIZERS FOR CONCRETE
MARKET SURVEY
PRESENT MANUFACTURERS OF CONCRETE PLASTICIZER
CHARACTERISTICS OF PLASTICIZER FOR CONCRETE
PROPERTIES AND SPECIFICATION OF CONCRETE ADMIXTURE
USES AND APPLICATION
COMMON PLASTICIZER BY TYPES
ADDITIVES FOR CONCRETE PLASTICIZER
WATER REDUCING/PLASTICIZING ADMIXTURE AND ITS MECHANISM
SPECIFICATION OF SULFONATED NAPHTHALENE FORMALDEHYDE (SNF)
FORMULATION OF CONCRETE PLASTICIZER
(SULFONATED MELAMINE FORMALDEHYDE)
MANUFACTURING PROCESS OF CONCRETE PLASTICIZER
(SULFONATED MELAMINE FORMALDEHYDE)
PROCESS FLOW DIAGRAM
MANUFACTURING PROCESS OF SULPHONATED
NAPHTHALENE FORMALDEHYDE
BENEFITS OF CONCRETE PLASTICIZER
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND MACHINERY

APPENDIX – A :

1.     COST OF PLANT ECONOMICS
2.     LAND & BUILDING
3.     PLANT AND MACHINERY
4.     FIXED CAPITAL INVESTMENT
5.     RAW MATERIAL
6.     SALARY AND WAGES
7.     UTILITIES AND OVERHEADS
8.     TOTAL WORKING CAPITAL
9.     COST OF PRODUCTION
10.     PROFITABILITY ANALYSIS
11.     BREAK EVEN POINT
12.     RESOURCES OF FINANCE
13.     INTEREST CHART
14.     DEPRECIATION CHART
15.     CASH FLOW STATEMENT

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DRY MORTAR MIX

EIRI Team — Wed, 21 Jan 2015 10:00:12 +0000

Dry Mortar Mix is gaining eminence in modern times owing to its versatile superiority in regard to characteristics over the conventional in-situ mortars viz. better performance easy to uses easy to set and the quality of leaving no crakes and voiels. Besides it has preferably better and wider field of application as patching & repairing materials for plasting purposes and other construction works viz. internal/external plastering masonry work etc. It is a very good substitute for conventional in-situ mortars.

Various types of Ready mix dry mortar comprise internal plaster mortar, external plaster mortar masonry mortar, quick setting mortar high strength mortar repair mortar self leaving flooring mortar pre-mix RCC mortar etc.

INTRODUCTION
USES AND APPLICATION
PROPERTIES AND CHARACTERISTICS
B.I.S. SPECIFICATION
RAW MATERIALS FOR DRY MIX MORTAR
PRODUCTION AND TYPES OF DRY MIX MORTAR
MARKET SURVEY
MARKET POTENTIAL OF DRY MIX MORTOR IN MAHARASHTRA
PRESENT MANUFACTURERS/SUPPLIERS OF DRY MIX MORTAR
FORMULATIONS
FORMULATION OF DRY MIX MORTAR (TILE ADHESIVE)
FORMULATION OF BRICK LAYING MORTAR AND AERATED LIGHT WEIGHT CONCRETE ADHESIVE
FORMULATION OF VOIEL PATCH MIX
PROCESS OF MANUFACTURE OF READY DRY MIX MORTAR
PROCESS IN DETAILS AND EXPERIMENTAL WORK FOR PROPERTY SPECIFICATION
PROCESS FLOW DIAGRAM
DRY MIX MORTOR TECHNOLOGY AND ITS ADVANTAGES
MANUFACTURING OF VARIOUS TYPES OF READY MIX DRY MORTARS IN
THE SAME PLANT
INGREDIENT USED FOR THE MANUFACTURE OF READY MIX DRY
MORTARS
COST ANALYSIS OF VARIOUS TYPES OF MORTORS AND COMPARISON WITH CONVENTIONAL IN-SITU MORTARS
ADVANTAGES OF READY MIX DRY MORTARS OVER THE CONVENTIONAL IN-SITU MORTAR
BUSINESS PRACTICE OF READY MIX MORTAR IN INDIA THEIR
PERFORMANCE IN INDIA NCR READINESS FOR A PRODUCT LIKE
THIS LOOKING AT THE SUCCESS OF THIS PRODUCT IN UK AND USA
CONCEPT OF READY MIX MORTAR AS A SUBSTITUTE FOR THE
CONVENTIONAL IN-SITU (MADE AT SITE) MORTAR
MARKETING/ADVERTISING REQUIRED FOR THIS KIND OF BUSINESS
POSSIBILITY/VIABILITY TO SET UP THE PLANT AT A
DISTANCE OF 500 TO 1000 KMS FROM THE MARKET BEING TARGETED
MARKETING OF THIS PRODUCT READY MIX DRY MORTAR VIS A VIS
RETAIL & BULK (MASS CONSTRUCTION)
GENERAL PUBLIC PERCEPTION OF PRODUCT IN INDIA
RAW MATERIALS CALCULATIONS
SUPPLIERS OF PLANT & MACHINERIES (INDIAN)
SUPPLIERS OF PLANT & MACHINERY (IMPORTED)
SUPPLIERS OF RAW MATERIALS
PORTLAND CEMENT

APPENDIX –A

01.   PLANT ECONOMICS
02.   LAND & BUILDING
03.   PLANT AND MACHINERY
04.   OTHER FIXED ASSESTS
05.   FIXED CAPITAL
06.   RAW MATERIAL
07.   SALARY AND WAGES
08.   UTILITIES AND OVERHEADS
09.   TOTAL WORKING CAPITAL
10.   TOTAL CAPITAL INVESTMENT
11.   COST OF PRODUCTION
12.   TURN OVER/ANNUM
13.   BREAK EVEN POINT
14.   RESOURCES FOR FINANCE
15.   INSTALMENT PAYABLE IN 5 YEARS
16.   DEPRECIATION CHART FOR 5 YEARS
17.   PROFIT ANALYSIS FOR 5 YEARS
18.   PROJECTED BALANCE SHEET FOR (5 YEARS)

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INTERLOCKING CONCRETE BLOCK

EIRI Team — Thu, 15 Jan 2015 09:55:06 +0000

Interlocking Concrete Block Pavement (ICBP) has been extensively used in a number of countries for quite sometime as a specialized problem-solving technique for providing pavement in areas where conventional types of construction are less durable due to many operational and environmental constraints. ICBP technology has been introduced in India in construction, a decade ago, for specific requirement viz. footpaths, parking areas etc. but now being adopted extensively in different uses where the conventional construction of pavement using hot bituminous mix or cement concrete technology is not feasible or desirable. The paper dwells upon material, construction and laying of concrete block pavement as a new approach in construction of pavement using Interlocking Concrete Paver Blocks.

INTRODUCTION
ADVANTAGES AND LIMITATIONS
PHYSICAL REQUIREMENTS
APPLICATION OF ICBP TECHNOLOGY
SHAPES AND CLASSIFICATIONS
MATERIALS
PAVING BLOCKS
BEDDING AND JOINT FILLING SAND
BASE AND SUB BASE MATERIALS
CONSTRUCTION OF INTERLOCKING CONCRETE BLOCK PAVEMENT
SEQUENCING OF OPERATIONS
PAVER PROPERTIES
BIS SPECIFICATION
MARKET POSITION
DESIGN OF PAVNG BLOCK
MANUFACTURING PROCESS
QUALITY CONTROL AND STANDARDS
PROS AND CONS OF WET CAST AND HYDRAULIC PRESS TECHNIQUES
WET CAST PRODUCTION
HYDRAULIC PRESS PRODUCTION
CURING AND PACKING
HOMOGENOUS AND FACE MIX PRODUCTS:
PAVING TEXTURES
NATURAL TEXTURES:
STANDARD TEXTURES:
CONCRETE
CLAY:
SECONDARY PROCESSES:
SECONDARY PROCESSES:
TUMBLING
SHOT BLASTING:
BUSH HAMMERING:
POLISHING:
WASH-TO-EXPOSE:
SPECIFICATIONS FOR ORDINARY CONCRETE
FINE AGGREGATES
COARSE AGGREGATES
PRESCRIBED MIXES FOR ORDINARY STRUCTURAL CONCRETE
FREE WATER:CEMENT RATIO
PROCESS FLOW DIAGRAM
PLANT LAYOUT
SUPPLIERS OF INTERLOCK CONCRETE BLOCK
SUPPLIERS OF PORTLAND CEMENT
SUPPLIERS OF STONE CHIPS
SUPPLIERS OF DG SETS
SUPPLIERS OF WATER PUMP
SUPPLIERS OF PALLETS
SUPPLIERS OF MOULDS
CHINA SUPPLIER OF AUTOMATIC PAVING BLOCK MAKING MACHINE
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT

APPENDIX –A

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RCC HUME PIPES (REINFORCED CONCRETE CEMENT)

EIRI Team — Sat, 31 May 2014 13:22:51 +0000

RCC HUME PIPES (REINFORCED CONCRETE CEMENT)

RCC Hume pipes are made of a mixture of Portland cement, sand and aggregate in the proportion of 1:2:5:2.5 with steel rods and wires as reinforcement material. These pipes are manufactured in diameters ranging from 300 mm to 2200 mm or more. The RCC pipes are suitable for irrigation, culvert construction, sewerage and drainage purposes. Transportation of water, sewerage, effluents or other liquid slurries in these pipes is quite smooth. Seepage or leakage is totally avoided by proper jointing & sealing of two consecutive pieces of the pipe line. Hume pipes have reasonably good load-bearing capacity, and hence, can be laid either underground or over the ground. Carefully made pipes, tested as per IS: 458-1971, are available in a wide range of sizes for use. Well constructed steel wire/rod cage is concentrically placed inside the pipe mould where premixed concrete is charged for pipe casting. The rotating moulds receive the feed material through open ends at both ends.

PROJECT REPORT COVERS:

Introduction
Uses and Applications
Properties
Market Survey with future aspects
Present Manufacturers
B.I.S. Specifications
Manufacturing Process with Formulae
Cost Economics with Profitability Analysis
Capacity
Land & Building Requirements with Rates
List & Details of Plant and Machinery with their Costs
Raw Materials
Details/List and Costs
Power & Water Requirements
Labour/Staff Requirements
Utilities and Overheads
Total Capital Investment
Turnover
Cost of Production
Break Even Point
Profitability
Land Man Ratio
Suppliers of Plant & Machineries and Raw Materials.

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Prestressed Concrete Electric Poles

EIRI Team — Thu, 23 Jan 2014 06:37:40 +0000

P.C.C.Poles are essentially made of concrete which are inevitably less costly and more economically maintainable than the conventional steel poles. They are of two types depending upon the end use of the pole-Low tensile and High Tensile Line. The latter is primarily used for transmission of electricity.

Project Reports Cover:

Introduction
Uses and Applications
Properties
Market Survey with future aspects
Present Manufacturers
B.I.S. Specifications
Manufacturing Process with Formulae
Cost Economics with Profitability Analysis
Capacity
Land & Building Requirements with Rates
List & Details of Plant and Machinery with their Costs
Raw Materials
Details/List and Costs
Power & Water Requirements
Labour/Staff Requirements
Utilities and Overheads
Total Capital Investment
Turnover
Cost of Production
Break Even Point
Profitability
Land Man Ratio
Suppliers of Plant & Machineries and Raw Materials.

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Autoclaved Aerated Concrete Blocks

EIRI Team — Wed, 22 Jan 2014 12:56:05 +0000

Concrete blocks for building houses were first made in Europe around 1850. The mass-production of concrete blocks underwent in step with the development of the cement industry chiefly in Western Countries around 1918.

In the United States, the concrete blocks industry recorded a major development after the introduction of the vibration process as a new method of compaction around 1930.

During the World War - II, the concrete block industry developed significantly in European countries and the United States.

Japan introduced the latest type of block making machine in the past war era. Cavity type or Hollow blocks are mainly made of materials like sand, gravel, and cement. These are used to construct walls of houses and other structures with embeded steel re-enforcement. They are safe & have good durability in earthquake & fire prone areas.

Project Reports Cover:

Introduction
Uses and Applications
Properties
Market Survey with future aspects
Present Manufacturers
B.I.S. Specifications
Manufacturing Process with Formulae
Cost Economics with Profitability Analysis
Capacity
Land & Building Requirements with Rates
List & Details of Plant and Machinery with their Costs
Raw Materials
Details/List and Costs
Power & Water Requirements
Labour/Staff Requirements
Utilities and Overheads
Total Capital Investment
Turnover
Cost of Production
Break Even Point
Profitability
Land Man Ratio
Suppliers of Plant & Machineries and Raw Materials.

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Prestressed Concrete Electric Rectangular Poles

EIRI Team — Wed, 22 Jan 2014 12:43:07 +0000

P.C.C.Poles are essentially made of concrete which are
inevitably less costly and more economically maintainable than
the conventional steel poles. They are of two types depending
upon the end use of the pole-Low tensile and High Tensile Line.
The latter is primarily used for transmission of electricity.

Project Reports Cover:

Introduction
Uses and Applications
Properties
Market Survey with future aspects
Present Manufacturers
B.I.S. Specifications
Manufacturing Process with Formulae
Cost Economics with Profitability Analysis
Capacity
Land & Building Requirements with Rates
List & Details of Plant and Machinery with their Costs
Raw Materials
Details/List and Costs
Power & Water Requirements
Labour/Staff Requirements
Utilities and Overheads
Total Capital Investment
Turnover
Cost of Production
Break Even Point
Profitability
Land Man Ratio
Suppliers of Plant & Machineries and Raw Materials.

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