Before starting any RCC masonry work directly on the excavated soil, the PCC concrete is made to form a flat surface and it is avoided to keep the concrete perpendicular to the soil so that the mixture is mixed with the soil and the water removed by the PCC It can also be weakened to prevent soil.
RCC means Reinforced Cement Concrete in which reinforcement means steel bars are used to give it tensile strength and whereas in PCC, no steel bars are used it.
Plain cement concrete can only be called “cement concrete (CC)” or “binding concrete”. Some people also call it “Mud Mat”.
What Is PCC Concrete?
The term PCC refers to Plain Cement Concrete. PCC is a mixture of cement, fine aggregate(sand), and coarse aggregate without reinforcement. PCC Concrete is spread on the soil surface before concreting maid structure to avoid direct contact of reinforcement of concrete with soil and water.
Concrete has been used for many wonderful things throughout history, either for architecture or infrastructure work, and more. Although concrete is used as construction material nowadays. There are two terms used on any construction site RCC (Reinforced Cement concrete) and PCC Concrete (Plain Cement Concrete) work.
pCC full form in engineering
In engineering, PCC stands for Plain Cement Concrete, which is a basic form of concrete made by mixing cement, water, and aggregates such as sand and gravel. PCC is used in a wide range of construction applications, such as foundations, floors, and pavements.
Read More: What is RCC – Reinforced Cement Concrete
PCC Ratio
PCC ratio stands for Portland cement concrete ratio, which refers to the ratio of Portland cement to the other materials in the concrete mix, such as sand and aggregate. This ratio is crucial in determining the strength and durability of the concrete. A higher PCC ratio results in stronger and more durable concrete, but it also increases the cost.
PCC concrete mix ratio is 1:5:10, which means 1 part of cement, 5 parts of sand, and 10 parts of aggregate. PCC in construction is used to make a level bed for footing.
Importance of PPC concrete
PPC (Portland Pozzolana Cement) concrete is becoming increasingly popular due to its numerous benefits over conventional concrete.
One of the main advantages of PPC concrete is its enhanced strength, which makes it ideal for use in high-rise buildings and structures that require high compressive strength.
Additionally, PPC concrete has a lower carbon footprint compared to traditional concrete, as it uses fly ash as a substitute for some of the Portland cement. This not only reduces the amount of waste generated but also conserves natural resources.
PPC concrete is also more durable and resistant to chemicals, making it an ideal choice for infrastructure projects in harsh environments.
Ingredients of PCC In Construction
The following are the main ingredients of plain cement concrete,
1. Coarse Aggregates
The coarse aggregates used in PCC should be free of hard dust, dirt, and other foreign materials of granite or similar stone. The stone ballast will be 20 mm in size and smaller. All coarse material should be maintained in a 5 mm square mesh and well-graded so that voids do not exceed 42%.
2. Fine Aggregates
The fine set shall consist of coarse sand, consisting of hard, sharp, and angular grains, and shall pass through a 5 mm square mesh screen. The sand shall be of standard specifications, clean, and free from dust, dirt, and organic matter. Sea sand will not be used.
3. Cement
Portland Pozzolana Cement (PPC) is commonly used for plain cement concrete. It should conform to the specifications and have the required tensile and compressive stresses and fineness.
4. Water
The water used will be clean and reasonably free from harmful amounts of harmful materials such as oil, acids, alkalis, salts, and vegetable growth. Generally, potable water shall be used having a pH value of not less than 6. The maximum permissible limits for solids shall be as per IS 456:2000 Clause 5.4, Page No 15.
Making of PCC Concrete
Following is the process of making plain cement concrete (PCC)
- Selection of Ingredients
- Mixing of Ingredients
- Transportation and Placing
- Compaction of concrete
- Finishing and Curing of concrete
Methods for Mixing of Concrete
Concrete production is the process of mixing different ingredients together – water, aggregate, cement, and any additives to produce concrete. Concrete production is time-sensitive.
Once the material is mixed, workers must place the concrete before it hardens. In modern usage, most concrete production occurs in a large type of industrial facility called a concrete plant, or often a batch plant.
When it comes to mixing concrete, the following three mixing methods are used for the production of effective and good-quality concrete.
- Hand Mixing of Concrete (Mixing concrete manually without a mixer machine)
- Machine Mixing of Concrete (Mixing concrete with a mixer machine)
- Ready Mix Concrete (Mixing in automatic or semi-automatic batching plant)
Different constructions require different types of concrete admixture. For efficient results, it is necessary to use the appropriate method of mixing concrete for specific use and application.
Several factors influence the method of concrete mixings, such as
- Location of the construction site with sufficient land for construction activities e.g. highly congested urban areas
- Available space for concrete batching and mixing and storage of aggregates
- The volume of concrete needed
- The construction schedule like the volume of concrete required per hour or per day
- Height at which concrete is to be placed
- Cost
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Uses of PCC Concrete
Plain cement concrete is commonly used for foundations. However, it has other uses:
- As concrete on the bed flooring, under the column footings, and on the walls below the beam.
- As a solid to get a hard and uniform surface on the surface of the window and ventilator.
- To counter concrete on parapets and composite walls.
- To flag the area around the buildings.
- Pavement Making.
- For making tennis courts, basketball courts, etc.
- Plinth protection
- Storm/sewer on drains, small retaining walls.
PCC Concrete Grades
Regular grades of concrete are M15, M20, M25, etc. For PCC concrete works, generally, M15 is used. For reinforced concrete construction minimum M20 grade of concrete is used.
The concrete admixture ratio is the ratio of its components such as cement, sand, aggregate, and water. These mix ratios are defined based on the type of construction and the power required.
Although IS code gives nominal and standard PCC concrete mix ratios for various construction tasks based on experience and testing.
Concrete Mixing Type
- Nominal concrete admixture
- Ready mix concrete mixture
- Nominal mixture
1. Nominal Concrete Admixture
Nominal concrete mixtures can be used for concrete grades M5, M10, M15, and M20. The ratio of its components is given below:
The penalty ratio for coarse aggregates should be adjusted from the upper limit to the progressively lower limit, as the grading of the fine aggregate becomes finer and the maximum size of the coarse aggregate becomes larger. Graded coarse aggregate should be used.
2. Ready Mix Concrete Mixture
In designed concrete mixtures, the ratio of the ingredients of the concrete is determined to achieve concrete of specified properties with the overall economy. Concrete is classified according to its compressive strength given in the table below: –
Read More: What is Batching of Concrete? & Types of Batching of Concrete Methods
Different Grades of Concrete
1. Normal Grade Concrete
| Concrete Grade | Mix Ratio | Compressive Strength | |
| MPa (N/mm2) | psi | ||
| Normal Grade of Concrete | |||
| M 5 | 1: 5: 10 | 5 MPa | 725 psi |
| M 7.5 | 1: 4: 8 | 7.5 MPa | 1087 psi |
| M 10 | 1 : 3 : 6 | 10 MPa | 1450 psi |
| M 15 | 1 : 2 : 4 | 15 MPa | 2175 psi |
| M 20 | 1 : 1.5 : 3 | 20 MPa | 2900 psi |
Generally, M5, M10, and M15 grades of concrete are used for PCC (plane cement concrete) work like leveling courses, bed footing, etc.
The unit weight of plain cement concrete (PCC) is 2400 kg/m3 or 24 24 KN/m3.
The unit weight of reinforced cement concrete (RCC) is 2500 kg/m3 or 25 KN/m3.
M 20 is used for RCC (reinforced cement concrete) work such as slabs, beams, columns, footings, etc. (for light exposure).
| Concrete Grade | Mix Ratio | Compressive Strength | |
| MPa (N/mm2) | psi | ||
| Normal Grade of Concrete | |||
| M 5 | 1: 5: 10 | 5 MPa | 725 psi |
| M 7.5 | 1: 4: 8 | 7.5 MPa | 1087 psi |
| M 10 | 1 : 3 : 6 | 10 MPa | 1450 psi |
| M 15 | 1 : 2 : 4 | 15 MPa | 2175 psi |
| M 20 | 1 : 1.5 : 3 | 20 MPa | 2900 psi |
2. Standard Grade Concrete
Concrete Grades M 25, M 30, and M 35 are used for RCC (reinforced cement concrete) such as foundations, footing columns, beams, slabs, etc.
M-40 grade is used for prestressed concrete work, slabs, beams, columns, footings, etc.
M-45 and M-50 grades are used for RCC, runway, concrete road (POQ) prestressed concrete girders, RCC columns, prestressed beams, etc.
M-55 grade is used for prestressed concrete girders and piers etc.
3. High Strength Concrete
| Concrete Grade | Mix Ratio | Compressive Strength | |
| MPa (N/mm2) | psi | ||
| High Strength Concrete Grades | |||
| M 50 | Design Mix | 50 MPa | 7250 psi |
| M 55 | Design Mix | 55 MPa | 7975 psi |
| M 60 | Design Mix | 60 MPa | 8700 psi |
| M 65 | Design Mix | 65 MPa | 9425 psi |
| M 70 | Design Mix | 70 MPa | 10150 psi |
M-60, M-65, and M-80 are used for RCC work where high compression power is required such as high-rise buildings, long-span bridges, ultra-thin white toppings and dispersal of dams, coastal Construction, etc.
Applications of PPC Concrete
PPC (Portland Pozzolana Cement) concrete has a wide range of applications in the construction industry due to its various advantages. Here are 10 common applications of PPC concrete:
- High-rise buildings and skyscrapers
- Bridges, flyovers, and viaducts
- Dams, canals, and water storage structures
- Marine structures, such as ports and harbors
- Nuclear power plants and other industrial structures
- Roadways, pavements, and airport runways
- Underground structures, such as tunnels and subways
- Pre-cast concrete products, such as pipes and slabs
- Concrete blocks and bricks for masonry work
- Decorative concrete, such as stamped concrete and exposed aggregate concrete.
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