Plain Cement Concrete (PCC) in Construction : Comprehensive guide

Plain cement concrete (PCC) is a basic yet vital material in construction. Plain Cement Concrete (PCC) is without reinforcement steel. PCC is high in compression and very low in tension. Builders use PCC in foundations, flooring, and pavements because it offers strength and durability. It combines cement, sand, aggregates, and water in specific PCC ratios. As a result, PCC concrete creates a solid base for structures. Moreover, PCC in construction is cost-effective and easy to mix. Many choose Plain cement concrete for its simple application and reliable performance. Additionally, understanding PCC specification, grades, and mixing methods ensures quality work. While PCC has advantages, it also has some disadvantages compared to RCC. Even so, PCC applications remain popular in both small and large projects. Therefore, knowing the uses, cost, and properties of plain cement concrete helps you make informed choices.

Plain cement concrete is commonly used over the ground to keep footing reinforcement from coming into direct contact with the soil. The design mixes commonly used for Plain Cement Concrete (PCC) are 1:4:8, 1:3:5, 1:2:4, M7.5, M10 etc. PCC can also be used for grade slabs (floors) and concrete roads where the only load is compressive.

What is PCC Concrete or Plain cement Concrete in construction?

Plain Cement Concrete (PCC) is a fundamental building material in construction, made by mixing cement, sand, coarse aggregates, and water without any steel reinforcement. Builders mainly use PCC in construction to provide a strong, stable, and level base for foundations, floors, and pavements. Since PCC concrete does not resist tensile stresses well, engineers choose it for areas where compressive strength is crucial but reinforcement is not needed. It also acts as a protective layer, reducing moisture and chemical attack on structural elements. Easy to mix and cost-effective, PCC concrete ensures durability and reliability for a wide range of construction applications.

Properties of Plain Cement Concrete or PCC concrete

Plain cement Concrete (PCC) has compressive strengths ranging from 200 kg/cm2 to 500 kg/cm2. Likewise, tensile strength of PCC ranges from 50 kg/cm2 to 100 kg/cm2, and density ranges from 2200 kg to 2500 kg, depending on the grade of concrete and aggregates used.

Ingredients of Plain Cement Concrete or PCC Concrete

Basically, PCC is made from cement, coarse aggregate, and fine aggregate. Ordinary Portland cement is used as the binding material. Accordingly, as coarse aggregate, broken or crushed stone or brickbats must be used. However, fine aggregate must consist of coarse sand. Finally, these ingredients are combined in the appropriate proportions with potable water to make PCC.

PCC Mix Design and Grades

The PCC ratio defines the proportion of cement, sand, and coarse aggregate in the mix. Common PCC ratios include 1:2:4 (one part cement, two parts sand, four parts aggregate), 1:3:6, and 1:4:8.Builders widely use the 1:2:4 mix for general construction because it balances strength and workability. They choose 1:3:6 and 1:4:8 mixes for less critical, low-strength applications like flooring or leveling bases.

Selecting the Right Grade for Your Project

Selecting the right PCC grade depends on the required compressive strength and the application. Grades such as M5 (1:5:10), M7.5 (1:4:8), M10 (1:3:6), and M15 (1:2:4) indicate increasing strength, with the number representing strength in MPa.Engineers use lower grades like M5 or M7.5 for simple foundations and leveling. They select M10 and M15 for flooring and structural bases. For heavy-duty or load-bearing works, they prefer higher grades like M20 or M25. Always match the PCC grade and ratio to the structural demands and durability requirements of your project to ensure safety and performance

Production of Plain Cement Concrete (PCC) in Construction

PCC can be manufactured in batching plants, mixer machines, or manually mixing. Generally, the thickness of PCC can range from 50 mm to 300 mm or more, depending on the design parameters.

Types of concrete in construction

The following are the main types of concrete used in construction

• PLAIN CEMENT CONCRETE (PCC)
• REINFORCED CEMENT CONCRETE (RCC)
• PRESTRESSED CONCRETE
• PRECAST CONCRETE
• SELF COMPACTED CONCRETE

How to Decide On A Concrete Type

The type of concrete to be used on a particular work is decided based on following conditions.

Material Availability

Normally, the raw material (aggregate, sand, cement etc) availability decides the type of concrete to be used.

Strength Required

The concrete requires different strengths for different structures. However, the strength required for the particular structure decides the type of concrete to be used.

Construction methodology to be adopted

The construction technique to be adopted for a structure decides the type of concrete. Example Pre-stressed concrete etc.

Type of structure

Most of times the type of the structure decides the type of concrete to be used.

SELF COMPACTED CONCRETE (SCC) is preferred in structures where normal pouring is restricted due to rebar congestion or access restricted pouring area. SCC, when pumped from a single point, can fill every part of the structure. 

Area of application

The type of concrete shall be decided by the area where it has to be used. In some structures, the reinforcement is so dense that concrete may not pass through it. Mostly, In those cases, specially designed concrete with small-size aggregates or Self compacted concrete (SCC) may be used.

Climate and pouring conditions

The areas where there is extreme weather conditions like heavy rain , extreme cold, extreme hot specially designed quick setting concrete will be used.

Applications of Plain cement Concrete

Plain cement concrete (PCC) serves a wide range of construction needs due to its versatility, durability, and cost-effectiveness. It is especially valued for providing stable, level, and protective surfaces in various structural applications.

PCC in Foundations and Flooring

• PCC is widely used as a base layer for foundations, ensuring a level and stable surface for footings, columns, and walls.
• It acts as a barrier, protecting reinforcement steel from direct soil contact and reducing the risk of corrosion and moisture ingress.
• In flooring, PCC provides a smooth, hard-wearing surface suitable for residential, commercial, and industrial spaces.
• It simplifies further construction by creating a uniform base for tiles, screeds, or other finishes.
• PCC is also used beneath slabs and as a blinding layer before placing reinforced concrete, preventing contamination from the soil.

PCC for Pavements and Damp-Proof Courses

• PCC is used in the construction of rigid pavements, driveways, walkways, and sports courts, offering a durable surface that withstands regular loads.
• It is applied as a damp-proof course at plinth level, preventing moisture from rising into the superstructure and protecting against dampness.
• PCC is also suitable for small-scale canals, retaining walls, and as a base for precast elements, making it a fundamental material in diverse construction projects.

Advantages and disadvantages of Plain cement Concrete

Plain cement concrete (PCC) in construction offers several benefits, but it also comes with some limitations. Understanding PCC advantages and disadvantages helps in selecting the right material for specific applications.

Advantages of PCC in Construction	Disadvantages of PCC in Construction
Cost-effective and affordable	Lacks tensile strength; unsuitable for tension
Easy to mix and place	Brittle and prone to cracking
Provides a stable, level base	Heavy weight may limit use in some projects
Acts as a moisture barrier	Limited to non-reinforced, compressive uses
Durable and low maintenance	Environmental impact due to cement production
Increases construction speed	Not suitable for heavy-load or high-stress areas
Protects reinforcement from soil contact	Susceptible to shrinkage cracks if not cured properly

Placing of Plain Cement Concrete (PCC)

The following steps are followed while placing Plain Cement Concrete (PCC)

Level marking and dressing for PCC concrete

After completing the excavation, workers mark the bottom level of the PCC on the ground using a level machine. They transfer the center line from the survey pillars to the ground where they need to lay the PCC. Next, they manually dress the surface to remove loose soil and level it, preparing the area to receive the PCC.

Surface Preparation and shuttering

First, workers neatly dress the surface to prepare it for PCC work. They then place supports around the area using wooden battens, ensuring the battens match the size of the PCC as closely as possible. To keep the battens stable, they use proper supports, such as scrap steel, for reinforcement. Before pouring the concrete, they sprinkle water on the dressed surface to prevent the soil from absorbing water from the concrete mix. This careful preparation helps maintain the quality and strength of the PCC by ensuring proper shape and preventing water loss during curing.

Placing and Finishing of PCC Concrete

Concrete must be poured from one end to the other. For leveling purposes, level pillars at 2 metre intervals must be provided. The concrete must be leveled and rammed in accordance with the level pillars and end supports. The slump for PCC should be approximately 75 mm. Concrete must be poured within 30-45 minutes.

Precautions while doing Plain Cement Concrete (PCC)

• Excavate only to the required levels and avoid over-excavation.
• If you exceed the required depth, do not backfill with loose earth; instead, place PCC at the required level using plum concrete.
• Compact the soil with plate compactors, walk-behind rollers, or Vibro rollers, as appropriate.
• Before starting excavation, transfer the PCC level to different locations.
• Mark the centerline and PCC dimensions on the ground before fine dressing with lime powder to prevent rework.
• Sprinkle water on the surface before laying PCC.
• Sometimes, apply anti-termite chemical or use LDPE sheets before placing PCC, but always get confirmation from clients or customers first.
• Restrict the free-falling height of concrete to 1.5 meters to prevent segregation.

Key Takeaways

Plain cement concrete (PCC) is a vital material in construction, offering cost-effective, durable, and versatile solutions for foundations, flooring, and pavements. Common PCC ratios like 1:2:4 and 1:3:6 ensure the right balance of strength and workability for various PCC applications. PCC in construction provides a stable base, acts as a moisture barrier, and simplifies further building processes. However, PCC concrete lacks tensile strength and is best suited for compressive uses. Selecting the appropriate PCC grade and understanding PCC advantages and disadvantages are essential for successful project outcomes. PCC remains a popular choice for both small and large-scale construction due to its reliability and simplicity.

Conclusion

In summary, plain cement concrete (PCC) continues to play a crucial role in modern construction. Its ease of mixing, cost-effectiveness, and durability make it ideal for a wide range of PCC uses, especially in foundations and flooring. While PCC in construction has some disadvantages, such as limited tensile strength, its benefits often outweigh these drawbacks for non-reinforced applications. By carefully selecting the right PCC ratio and grade, builders can ensure long-lasting and high-quality results. Understanding the properties, applications, and limitations of PCC concrete helps in making informed decisions for any construction project.