
kg/cm2
(100
to
150
p.s.i.)
head rubble
concrete
can
be
safely
rated
as
impervious
requiring
no
post-construc-
tion treatment.
4.5 Strength
and
Homogeneity
After
the
density
and
percolation
tests,
several of
these
0.9 m
(3
f0 diameter
cores
were tested
in
com-
pression
at
Hirakud.
Simultaneously
companion
matrix
concrete
cylinders 15
cm
x
30
cm
(6
in.
x
12
in.)
were
also
crushed. Observations made during
crushing
of
rubble concrete
cores
revealed that
invari-
ably
the development
of
the
first
crack
had
been
instantaneous
as
well
as
simultaneous both
in
the
rubble
and
the
concrete
indicating
the
homogeneity
of the
combined
mass.
lt
is
probable
that
the internal
compressive
stresses
built
up within
the
rock
mass
could
be
2-3 times
more
than
that of the
matrix
con-
crete
when it
is
presumed
that rubble
concrete
as
a
mass
would
have
uniform
deformation; this
assump-
tion is
based
on
the
relative
differences in the
modulus
of elasticity
of
the
two
components.
The
surface
of
the
cores
indicate a fullycompacted mass
and absence
of air
voids
or segregated
zone indicate
good
bond
between
the concrete
and the
rubble
(Photos
4.3
and
4.4).
The
large size
cores
yielded
strength
of
over
210
kg/sq
cm
(3,000 p.s.i.)
at ages
of
90
days
and
over
(Table
lV.4) even
when
the
cement
content
of
the matrix
poncrete
was
270 kg/cu
m
(450
pcy)
[280
pcy
or
168
kg/cu
m
in
rubble
concretel
or 24O
kglcu
h
i+OO
pcy)
[240
pcy
or
144 kg/cu m in
rubble con-
crete].
The strength
data
of
the
companion
15
cm
x
30
cm
(6
in. x
12 in.) cylinders
when
corrected
for
the
sizsand
Li
D
ratio to
equate
with
the
large size
core,
by
applying
the standard
factors
revealed
that
the
strength
of the
rubble
concrete
is
reflected
to a
large
extent
directly
by
the strength of
the
matrix
concrete
in
it. For design
and
control
purposes,
tests
on standard
15 cm
x 30
cm
(6
in. x
12 in.\
cylinders
of
matrix
concrete
can
by
proper
interpretation,
indi-
cate
the
potentia!
strength
of
rubble
concrete.
4.6 Field
Performance
A
lava
flow
free
from
secondary deposits of
zeolites,
chalcedony,
etc.,
was selected for
the
quarry,
at a
minimum
tead
of
about
0.8 km to 1.2 km
$
mite to
f
mile)
at
an elevation
above
FRL
The
properties
of
the
quarry
rock
are
tabulated
irr Table IV.4
(a).
An
idea
of
uniformity
in
the
gradation
of the
aggregates
produced
from
season
to season
can
be
had
from
lable
tV.4
(.b).
Two
rodmills each
of
45
tons
capacity
per
hour
produce by
wet
process
the
required
grade
of
sand.
Afcer
eliminating
the
excessive fines through the
static
cone
arrangement,
by
continuous trials and
testing,
a
good
measure
of success was
achieved in
producing well-graded
sand
meeting
the
general
requirementsof
the
work.
The
average
grading
of
the
sand
produced
is
given
in Table
tV.4
(c).
Jo,
place
_c_oncrete
at
65' F
or less
the
aggregates
and
the
rubble
are
precooled
with
chilled waier
white
as
the
rubble were
conveyed
by
silo buses
to
load
the
4.56 cu
m
(6
cu
yd)
buckets
of two cable
cranes
[span
731.5
m
(2400
ft)] 15
T. hook load Tabte
rv.4
(d).
Mix No.
1 was
usod
hardly
for abour
0.035
M
(19
M
cu
ft) up
to
El.
2150-60
was
placed
with
270
kg/cu m
(450
pcy)
concrete.
lnvarlably
above
El. 2,150
the
240
kg/cu
m
(400
pcy)
concrete was
used. Though
the preliminary
evaluation
of rubble
concrete
had
shown
that as
far as
strength-curn-
permeability
was
considered
even
240 kg/cu
m
(400
pcy)
concrete
could
have
been
adopted
over
elevation
1900.
Since
the rubble
concrete
construction is
being
practised
in
India
for
the first
time, the reduc-
tion in
cement
content
was
made continuously
and
gradually.
Water-cement
ratio
for the interior
con-
crete
with
270
kg/cu
m
(450
pcy)
matrix
concrere
is
0.69 weight
and
with
240 kg/cu
m
(400
pcy)
matrix
concrete it
is 0.75.
For
the upstream 1.8
m
(6
fr) instead of
the
rubble-
concrete
a richer
and
conventional concrete with
7.5
cm
(3
in.) maximum
size
was used
which
had
269
kg/cu
m
(445
pcy)
cement
and
156
kg/cu
m
(260
pcy)
water; similar
concrete was
placed
in the
downstream
in
the
overflow
monoliths.
The
placement
of
rubble
concrete consisted
of
spreading the
plastic
air-entrained
matrix concrete
to
23
cm
(9
in.) thick
layer
and
closely
packing
the
rubble
over
this and vibrating
the whole layer with
l0 cm
(4
in.)
dia.
electrical vibrators
(frequency
of
7000-
9000
vibrations
per
minute)
held
by
two men
standing
on
the rubble.
ln
each
cycle
a strip of 6
to 8
m
(20-
25 ft)
parallel
to
axis
was
taken
(Photo
4.5).
Rubble
after it
was
unloaded
as a
dump
over
the
plastic
concrete
was
spread
manually.
Trials
made
to
spread
the
concrete and
then
the rqbble
by
a small
dozer
revealed
that
the
concrete
got partially
compac-
ted
and
that much
less
quantity
of
rubble
got
sunk
with
all
the best
of efforts
in vibration.
The
prepara-
tion of the
surface
of rubble concrete
for
the
next
a
---
ql.'|dta,ft{2
133