CEE 306 - Lecture 08 - Sequence - Special Concrete

PORTLAND CEMENT CONCRETE:
ORDER OF OPERATIONS FOR CONCRETE

&
ALTERNATIVE CONCRETE
CEE 306
CIVIL ENGINEERING MATERIALS
CHANG-SEON SHON, PH.D., ASSISTANT PROFESSOR

DEPARTMENT OF CIVIL & ENVIRONMENTAL ENGINEERING
NAZARBAYEV UNIVERSITY
Lecture 08
1
CEE 306: Civil Engineering Materials
ORDER OF OPERATIONS FOR

CONCRETE
Lecture 08 2
1
ORDER OF OPERATIONS FOR
CONCRETE
SPECIFIC OPERATIONS MUST BE PERFORMED IN A CERTAIN ORDER
• FINAL QUALITY IS INFLUENCED BY EVERY STEP
I. mix design (proportioning)
II. trial mixes & testing
III. batching Complete
------------------------------------------------------------start the clock
IV.mixing
V. transporting
VI. pouring (placing)
VII. vibrating (consolidating)
-------------------------------------------------------------initial set here
VIII. finishing
-------------------------------------------------------------final set here
IX. curing
X.maintenance
Lecture 08
3
MIXING, PLACING, & HANDLING OF PCC

• BATCHING
– Measuring correct proportions of components and placing in
the mixer
– By weight is more convenient & accurate because air voids
don't matter (Convert Vol. to weight)
• MIXING
– Until uniform appearance
– Usually batch mixers (one at a time), but sometimes
continuous (conveyors automatically feed components into
mixer)
– Usually start with 10% of the water in the mixer, then solids
with 80% of the water, and then remaining water
Lecture 08 4
2
(CONT’D)
• CENTRAL BATCH CONCRETE PLANT
– Mix ingredients in predetermined proportions
– Place concrete in
trucks
Lecture 08
5

(CONT’D)
• READY MIX CONCRETE PLANT
Lecture 08 6
3
(CONT’D)
• SLIPFORM PAVER
Lecture 08
7

(CONT’D)
• MOBILE PLANT
– Batcher
– batcher mixer at (or
near) the jobsite
Lecture 08 8
4
MIXING
• STATIONARY MIXING • SPECS. LIMIT THE REVS. OF THE
– On-site or central mix TRUCK BARREL TO AVOID
SEGREGATION
• READY MIXED CONCRETE
– Central-mixed • MAX. 90 MINUTES FROM
• Mixed completely in a plant START OF MIXING TO
and delivered in an agitator DISCHARGE, EVEN WITH
truck (2 - 6 rpm) RETARDERS
– Shrink-mixed
• Partially mixed in plant and
delivered in a mixer truck (4 -
16 rpm)
– Truck-mixed
• Mixed completely in a mixer
truck (4 - 16 rpm)
Lecture 08
9

III. batching
------------------------------------------------------------start the clock
IV. mixing
Complete
V. transporting
VII. vibrating (consolidating) Sampling and testing
-------------------------------------------------------------initial set here
VIII. finishing
-------------------------------------------------------------final set here
IX. curing
X.maintenance
Lecture 08 10
5
SAMPLING AND TESTING
• PULL SAMPLES AT THE JOB SITE
• TEST ON SITE
– Slump
– Air content
– Unit weight
• PREPARE SAMPLES FOR LATER TESTING
– Cylinders
– Beams
Lecture 08
11
REMIXING CONCRETE
• ASTM C 94 (AASHTO M 157) ALLOWS WATER TO BE ADDED TO
REMIX CONCRETE WHEN THE TRUCK ARRIVES ON THE JOBSITE AND
THE SLUMP IS LESS THAN SPECIFIED PROVIDING THE FOLLOWING
CONDITIONS ARE MET:
– Maximum allowable water-cement ratio is not exceeded as
calculated including surface water on aggregates as well as batch
water and water added on site
– Maximum allowable slump is not exceeded
– Maximum allowable mixing and agitating time (or drum
revolutions) are not exceeded
– Concrete is remixed for a minimum of 30 revolutions at mixing
speed or until the uniformity of the concrete is within the limits
described in ASTMC94 (AASHTOM 157)
Lecture 08 12
6
PLACING CONCRETE
TRANSFER FROM TRUCK….
Chute Conveyor
Lecture 08
13
PLACING CONCRETE
TRANSFER FROM TRUCK….
Lecture 08 14
7
PLACING ISSUES
• MOVEMENT TO CONCRETE’S FINAL POSITION WITH A NEAR
VERTICAL DROP TO PREVENT SEGREGATION
• IF SEGREGATION DOES OCCUR, SHOVEL AGGREGATE INTO
CONCRETE. DO NOT SHOVEL CONCRETE ON SEGREGATED
AGGREGATE
• DROP HEIGHT
– < 3 ft (0.9 m)
• HORIZONTAL MOVEMENT
– Limit to prevent segregation
• PUMPING
– Adjust mix design
Lecture 08
15
PLACING ISSUES (CONT’D)
Correct placement of concrete
Incorrect placement of concrete
Lecture 08 16
8
VIBRATION OF CONCRETE
• VIBRATION CAUSES TEMPORARY LIQUEFACTION SO THAT AIR

BUBBLES COME ON TO THE TOP AND EXPELLED ULTIMATELY
• CONSOLIDATION (COMPACTION) COMPLETE BEFORE INITIAL SET
• HAND COMPACTION
– Hand compaction is used for ordinary and unimportant
structures
– Workability should be decided in such a way that the
chances of honeycombing should be minimum.
– Type of hand compaction
• Rodding
• Ramming
• Tamping
Lecture 08
17
VIBRATION OF CONCRETE (CONT’D)
• HAND COMPACTION
– Rodding: It is a method of poking with 2m
long, 16 mm dia. rod at sharp corners and
edges. The thickness of layers for rodding
should be 15 to 20 cm.
– Ramming: It is generally used for compaction
on ground in plain concrete. It is not used
either in RCC or on upper floors.
– Tamping: It is a method in which the top
surface is beaten by wooden cross beam of
cross section 10 cm x 10 cm. Both
compaction and leveling are achieved
simultaneously. It is mainly used for roof
slabs and road pavements.
Lecture 08 18
9
• MECHANICALLY USING VIBRATORS
• CONSOLIDATE EACH LAYER BEFORE NEXT IS
PLACED
– Internal vibrator (poker)
• Dia. (20-75 mm), length (25-90 cm)
• 5 sec to 2 min in one spot
• <10 sec. typical
• Avoid segregation
• Through entire depth
• Penetrate layer below if still plastic
Lecture 08
19
• CORRECT
– Start placing at bottom of slope so
that compaction is increased by
weight of newly added concrete.
Vibration consolidates the concrete
• INCORRECT
– When placing is begun at top of slope
the upper concrete tends to pull apart
especially when vibrated below as this
starts flow and removes from
concrete above
Lecture 08 20
10
• MECHANICALLY USING VIBRATORS
– External vibrator
• Adopted where internal vibration can’t be used
due to either thin sections or heavy reinforcement
• Less effective and it consumes more power as
compared to the internal vibration
• The formwork must be designed to take load
imposed by vibrator
– Table vibrator: Used for laboratory
– Screed vibrator: roof slabs, road pavement
Lecture 08
21
• INADEQUATE CONSOLIDATION CAN RESULT IN:

– Honeycomb
– Excessive amount of entrapped air voids
(bugholes)
– Sand streaks
– Placement lines (Cold joints)
– Subsidence cracking
Lecture 08 22
11
III. batching
------------------------------------------------------------start the clock
IV. mixing
V. transporting
VII. vibrating (consolidating) Complete
-------------------------------------------------------------initial set here
VIII. finishing
-------------------------------------------------------------final set here
IX. curing
X.maintenance
Lecture 08
23
FINISHING CONCRETE
• SMOOTHING AND IMPRINTING THE SURFACE OF THE CONCRETE
WITH THE DESIRED TEXTURE
• MUST BE COMPLETED BEFORE FINAL SET
• MANY TYPES OF COLORS AND TEXTURES AVAILABLE THESE DAYS
– Stamped concrete uses rubber stamps to create the look of
stone, tile, etc.
Lecture 08 24
12
FINISHING CONCRETE
Screeding (strike-off) : strike

concrete off to desired level
Bullfloating: Eliminating high and low

spots and embeding large aggregate
Brooming: providing a slip-resistant surface particles immediately after strike-off.
Lecture 08
25

III. batching
------------------------------------------------------------start the clock
IV. mixing
V. transporting
VII. vibrating (consolidating)
-------------------------------------------------------------initial set here
VIII. finishing Complete
-------------------------------------------------------------final set here
IX. curing
X.maintenance
Lecture 08 26
13
CURING CONCRETE
• MAINTAIN MOISTURE AND TEMPERATURE IN THE CONCRETE TO
PROMOTE CONTINUED HYDRATION AND STRENGTH GAIN (TIME)
• HYDRATION WILL RESUME IF CURING IS STOPPED AND RESUMED
• CURING APPROACHES
– Maintaining presence of water in the concrete
– Seal the surface so mix water can’t escape
– Heat & additional moisture
• CURING AFFECTS:
– Durability – Abrasion resistance
– Strength – Volumetric stability
– Water-tightness – Resistance to freezing and thawing
Lecture 08
27
CURING CONCRETE (CONT’D)

• EFFECT OF MOISTURE CURING AND CURING TEMPERATURE ON
STRENGTH
Effect of moisture curing Effect of curing temperature
Lecture 08 28
14
Spraying
• APPROACH 1. MAINTAINING
PRESENCE OF WATER
– Must water periodically
– Also provides cooling
Wet covering Fogging
– Methods
• Ponding: smaller jobs flat-
work (floors and pavement)
and laboratory
• Spraying or fogging: expensive
and a lot of water
• Wet coverings: burlap, cotton,
rugs, etc.
Lecture 08
29

• APPROACH 2. SEAL THE SURFACESpraying
– Reducing the loss of mixing water
from the surface of the concrete:
– Impervious paper or plastic sheets
– Membrane forming compounds
Plastic Sheets
– Leave forms in place
Membrane forming compound
Lecture 08 30
15
Spraying
• APPROACH 3. HEAT
– Accelerating strength gain
– Insulate
– Steam
• Good for early strength gain and in
Steam curing
freezing weather
– Heating coils, electrically heated
forms or pads
• Usually in precast plants only
Heated blankets
Lecture 08
31
CURING CONCRETE
• CONSIDERATIONS: • CURING : IMMEDIATELY AFTER

– Availability of curing FINAL SET TO AVOID SURFACE
materials DAMAGE
– Size and shape of structure • CURING PERIOD
– Production facilities (in- – Minimum 7 days
place or precast) – 70% of f’c (3 days for
– Aesthetic appearance high early strength)
– Economics – Other job requirements
Lecture 08 32
16
COLD WEATHER CONCRETING
• MATERIALS AND PROPORTIONS (INDIRECT WAY)

– Use of set accelerators, Type III cement, HRWR
– Use more cement (more heat generation)
– AE admixture
• MIX TEMPERATURE
– Heat aggregates
– Replace some of the mixing water with hot water
• COMMON PRACTICE
– Insulating formwork (keep heat inside)
– Keep formwork for a longer period of time
– Prevent F&T damage
Formwork
Lecture 08
33
HOT WEATHER CONCRETING
• MATERIALS AND PROPORTIONS (INDIRECT WAY)

– Use cooling the mixing water and/or aggregates before
mixing
– Use Type IV cement
– Add a retarder
• COMMON PRACTICE Cool concrete with liquid nitrogen injection
– Reduce the maximum time before discharge of ready-mixed

concrete from the normal 1 and 1/2 h to 1 h or less
– Use of shades or covers to control the temperature of
concrete after placement
– Start moist curing immediately after finishing and continue
for at least 24 h
Lecture 08 34
17
ALTERNATIVES TO CONVENTIONAL
CONCRETE
Lecture 08
35
TYPES OF CONCRETES:
NORMAL-WEIGHT CONCRETE
• UNIT WEIGHT
– 2,243 to 2,563 kg/m3 (140 to 160 lb/ft3)
– A unit weight of 2403 kg/m3 (150 lb/ft3) is usually assumed
for design purposes
• 28-d COMPRESSIVE STRENGTH (f’c)
– 13.79 to 27.58 MPa (2000 to 4000 psi)
Lecture 08 36
18
STRUCTURAL LIGHTWEIGHT CONCRETE
Rotary kiln expanded
• UNIT WEIGHT clays
– Less than 1,922 kg/m3 (120 lb/ft3)

• 28-d f’c COMPRESSIVE STRENGTH (f’c)
– Greater than 17.2MPa (2500 psi)
• ITS LIGHTWEIGHT IS OBTAINED BY USING
LIGHTWEIGHT AGGREGATES
– Rotary kiln expanded clays, shales, slates,
and slag
– Sintering grate expanded shales and slates
– Pelletized or extruded fly ash
– Expanded slags
Lecture 08
37
LIGHTWEIGHT INSULATING CONCRETE
• UNIT WEIGHT
– 240 to 1,442 kg/m3 (15 to 90 lb/ft3)
• 28-d compressive strength (f’c)
– 690 to 6,895 kPa (100 to 1000 psi)
• PRIMARILY UTILIZED FOR ITS THERMAL INSULATING PROPERTIES
– Use lightweight aggregates
• Perlite, vermiculite, expanded polystyrene wastes
• Aggregate manufactured by expanding, calcining, or sintering such
as slag, clay, diatomite, fly ash, shale, slate
• Processing natural materials such as pumice, scoria, tuff
– In some cases, air voids introduced into the concrete mix in
foam replace some or all of the aggregate particles (25-35%)
Lecture 08 38
19
(CONT’D)
Lecture 08
39

(CONT'D)
Lecture 08 40
20
CELLULAR/AERATED CONCRETE
• LIGHTWEIGHT CONCRETE
• MORTAR + FORMING ADMIXTURE (FOAMED-IN-PLACE FOAM)
• CEMENT + SILICA RICH MATERIALS
(SAND, FLY ASH, ETC) + ALUMINUM
POWDER + WATER
Cellular concrete
Lecture 08
41
CELLULAR/AERATED CONCRETE
• PRESSURE STEAM CURED (AUTOCLAVED)

→ AUTOCLAVED AERATED CONCRETE
USING A TEMPERATURE OF 190oC AND A
PRESSURE OF 1.2 MPa.
• BLOCK OR PANEL FORM
• DENSITY
– 300 to 1000 kg/m3 (19 to 63 lb/ft3)
• 28-d compressive strength (f’c)
– 2,500 to 10,000 kPa (300 to 1,500 psi)
• AIR-VOIDS UP TO 80% BY VOLUME
Lecture 08 42
21
LIGHTWEIGHT CONCRETE CANOE
• FLOATING CONCRETE (ASCE CONCRETE CANOE)
http://www.engineering.utoronto.ca/Assets/AppSci+Digital+Assets/images/Newsletter+Images/C
Lecture 08
43
CEE 306: Civil Engineeringoncrete+Canoe+02.jpg
Materials
HEAVYWEIGHT CONCRETE
• MADE WITH HEAVY AGGREGATES SUCH AS BARITE, MAGNETITE,

AND STEEL PUNCHING
• USED PRIMARILY FOR NUCLEAR RADIATION SHIELDING
• UNIT WEIGHTS: 2884 TO 6408 kg/m3 (180 TO 400 lb/ft3)
Lecture 08 44
22
HIGH PERFORMANCE CONCRETE
• HIGH STRENGTH SACRIFICES OTHER PROPERTIES
• BY USING SPECIAL AGGREGATE GRADATION, ADMIXTURES, AND
TECHNIQUES WE CAN IMPROVE SEVERAL PROPERTIES AT ONCE
(WORKABILITY, STRENGTH, TOUGHNESS, VOLUME STABILITY,
AND EXPOSURE RESISTANCE)
– High strength – Resistance to chemical attack
– High early strength – High resistance to frost and
– High modulus of elasticity deicer scaling damage
– High abrasion resistance – Toughness and impact
resistance
– High durability and long life
– Volume stability
– Low permeability and diffusion
– Ease of placement
Lecture 08
45
HIGH-EARLY-STRENGTH CONCRETE /
HIGH-STRENGTH CONCRETE
• HIGH-EARLY-STRENGTH CONCRETE
– High-early compressive strength (ASTM C 39)
• 20 to 28 MPa (3000 to 4000 psi) /at 3 to 12 hrs or 1 to 3 days
– High-early flexural strength (ASTM C 78)
• 2 to 4 MPa (300 to 600 psi) / at 3 to 12 hrs or 1 to 3 days
• HIGH-STRENGTH CONCRETE
– At least 42 MPa (6,000 psi) strength with normal weight
aggregates → 55 MPa (8000 psi) ACI Committee 363
– Very low w/c with superplasticizers up to 138 MPa (20,000
psi)
Lecture 08 46
23
HIGH-EARLY-STRENGTH CONCRETE /
HIGH-STRENGTH CONCRETE (CONT’D)
• MAY BE ACHIEVED BY
– Type III
– High cement content: 400 to 600 kg/m3 (675 to 1000 lb/yd3)
– Special rapid hardening cements
– Low water-cementing materials ratio (0.20 to 0.45 by mass)
– Higher freshly mixed concrete temperature
– Higher curing temperature
– Chemical admixtures
– Silica fume (or other supplementary cementing materials)
– Steam or autoclave curing
– Insulation to retain heat of hydration
Lecture 08
47
SELF-CONSOLIDATING CONCRETE
• ALSO REFERRED TO AS SELF-
COMPACTING CONCRETE
• IS ABLE TO FLOW AND CONSOLIDATE
UNDER ITS OWN WEIGHT (1980S JAPAN)
→ CAN SPREAD INTO PLACE, FILL THE
FORMWORK, AND ENCAPSULATE THE
REINFORCEMENT, WITHOUT ANY
MECHANICAL CONSOLIDATION
• IS COHESIVE ENOUGH TO FILL SPACES OF
ALMOST ANY SIZE AND SHAPE WITHOUT
SEGREGATION OR BLEEDING.
Lecture 08 48
24
(CONT’D)
• THIS MAKES SCC PARTICULARLY USEFUL WHEREVER PLACING IS
DIFFICULT, SUCH AS IN HEAVILY REINFORCED CONCRETE MEMBERS
OR IN COMPLICATED FORMWORK (HIGH FLOWABILITY).
• THIS TECHNOLOGY IS BASED ON INCREASING THE AMOUNT OF
FINE MATERIAL WITHOUT CHANGING THE WATER CONTENT. THIS
CHANGES THE RHEOLOGICAL BEHAVIOR OF THE CONCRETE.
• A LOW WATER CONTENT
ENSURES HIGH VISCOSITY, SO
THE COARSE AGGREGATE CAN
FLOAT IN THE MORTAR
WITHOUT SEGREGATING.
Lecture 08
49
(CONT’D)
• STRENGTH AND DURABILITY OF WELL-DESIGNED SCC ARE ALMOST
SIMILAR TO CONVENTIONAL CONCRETE.
• THE USE OF FLY ASH AS A FILLER COMPARED TO LIMESTONE AS A
FILLER SEEMS TO BE ADVANTAGEOUS → IT RESULTS IN HIGHER
STRENGTH AND HIGHER CHLORIDE RESISTANCE.
Lecture 08 50
25
(CONT’D)
• ADVANTAGE OF SELF-CONSOLIDATING CONCRETE
– Reduction in site manpower
– Reduction problems caused by vibration
– Easy to place
– Fast construction
– Better surface finish
– Improvement of durability due to better compaction and
homogeneity of concrete
Lecture 08
51
(CONT’D)
• DISADVANTAGE OF SELF-CONSOLIDATING CONCRETE
– Higher paste volume results in greater shrinkage and creep
without proper curing
– The mix design and procedure adopted is too complicated for
practical implementation
– It requires more trial batches
– More Costly than conventional concrete based on materials
except placement cost
Lecture 08 52
26
FLOWABLE FILL
• CALLED ‘CONTROLLED LOW STRENGTH MATERIALS’
• SELF-LEVELING AND SELF-COMPACTING, CEMENTITIOUS
MATERIAL WITH LOW UNCONFINED COMPRESSIVE STRENGTH
• USED AS BACKFILL MATERIAL IN LIEU OF COMPACTED GRANULAR
FILL
• WORK AT TRENCH WORKS
Lecture 08
53
SHOTCRETE (“GUNITE” OR
“SPRAYED CONCRETE”)
• MORTAR OR SMALL-AGGREGATE CONCRETE THAT IS SPRAYED AT
HIGH VELOCITY ONTO A SURFACE
Foundation
Tunneling
Bridge repair
Lecture 08 54
27
SHOTCRETE (CONT’D)
• EQUIPMENT
– Gun
– Pump
– Compressor
– Mixer
– Nozzles
– Hoses
Lecture 08
55
• DRY-MIX PROCESS VS. WET-MIX PROCESS
Lecture 08 56
28
Lecture 08
57
• CRITICAL PARAMETERS TO REDUCE REBOUND OF SHOTCRETE IN

PLACING SHOTCRETE
Lecture 08 58
29
• CRITICAL PARAMETERS TO REDUCE REBOUND OF SHOTCRETE IN

PLACING SHOTCRETE
– Choose wet process
– Nozzle should be held at a 90o angle to the surface
– Increase the unit weight of cement, water, and fine
aggregate content in the mixture (W/C = 40~60%)
– Reduce the maximum size of coarse aggregate (MSA =
10~15 mm)
– Reduce nozzle distance from placement surface
• In reinforced area, the nozzle should be held close to the steel to
ensure material flows around the reinforcement
Lecture 08
59
SHRINKAGE COMPENSATING
CONCRETE
• ALUMINA CAUSES A LITTLE EXPANSION TO COMPENSATE FOR
NORMAL SHRINKAGE
• TYPE K CEMENT
Lecture 08 60
30
POLYMER CONCRETE
• VERY QUICK SET (1 HR.) OR SUPER HIGH STRENGTH ( >138
MPa (20,000 psi))
• POLYMER-PC CONCRETE
– Latex is mixed with Portland cement
http://www.kwikbondpolymers.com/wp-
content/gallery/ppc-1121/debruin-w-screed.jpg
Lecture 08
61
FIBER-REINFORCED CONCRETE
• INSTEAD OF REBAR (FOR CORROSION)
– Becoming more common
• FLEXURAL STRENGTH INCREASED BY UP TO 30%
• REDUCES WORKABILITY
• STEEL, PLASTIC, GLASS, ETC.
Lecture 08 62
31
MASS CONCRETE
• AMERICAN CONCRETE INSTITUTE (ACI 207)

– Any volume of concrete in which a combination of
dimensions of the member being cast, the boundary
conditions, the characteristics of the concrete mixture, and
the ambient conditions can lead to undesirable thermal
stresses, cracking, deleterious chemical reactions, or
reduction in the long-term strength as a result of elevated
concrete temperature due to heat from hydration
Lecture 08
63
MASS CONCRETE (CONT’D)
• USED IN A STRUCTURE SUCH AS A DAM IN

WHICH THE WEIGHT OF THE CONCRETE
PROVIDES MOST OF THE STRENGTH OF THE
STRUCTURE
• LITTLE OR NO REINFORCING STEEL IS USED
• UNIT WEIGHT
– Similar to that of regular concrete
Lecture 08 64
32
MASS CONCRETE (CONT’D)
Effect of Concrete-Placing Temperature on

Temperature in Mass Concrete
Potential for Surface Cracking in Mass Concrete
Lecture 08
65
MASS CONCRETE:
METHODS OF TEMPERATURE CONTROL (CONT’D)
• METHODS OF CONTROLLING MASS CONCRETE TEMPERATURES

RANGE FROM RELATIVELY SIMPLE TO COMPLEX, AND FROM
INEXPENSIVE TO COSTLY.
• DEPENDING ON A PARTICULAR SITUATION, IT MAY BE
ADVANTAGEOUS TO USE ONE OR MORE METHODS OVER
ANOTHER.
– Low-heat materials
– Pre cooling of concrete
– Post-cooling of concrete
– Surface insulation
Lecture 08 66
33
MASS CONCRETE:
TEMP. CONTROL: LOW-HEAT MATERIALS (CONT’D)
• SELECT LOW HEAT OF HYDRATION CEMENT OR MIXTURE

CEMENT
• USE LOW CEMENT CONTENTS (120 TO 225 kg/m3)
• CLASS F FLY ASH GENERATES ABOUT HALF AS MUCH HEAT AS
THE CEMENT THAT IT REPLACES AND IS OFTEN USED AT A
REPLACEMENT RATE OF 15 TO 25%.
• GROUND GRANULATED BLAST-FURNACE SLAG IS OFTEN USED AT
A REPLACEMENT RATE OF 65 TO 80% TO REDUCE HEAT.
• USE LARGE SIZED AGGREGATES 75-120 mm HIGH AGGREGATE
CONTENTS UP TO 80% OF TOTAL
Lecture 08
67
MASS CONCRETE:
TEMP. CONTROL: PRE COOLING OF CONCRETE
(CONT’D)
• USE OF CHILLED MIX WATER.
• SOME TIMES REPLACEMENT OF MIX WATER BY ICE.
• EFFORTS TO COOL AGGREGATES HAVE THE MOST PRONOUNCED
EFFECTS ON THE CONCRETE TEMPERATURE BECAUSE THEY
REPRESENT 70 TO 85% OF THE WEIGHT OF THE CONCRETE.
• LIQUID NITROGEN CAN ALSO BE USED TO PRECOOL CONCRETE
OR CONCRETE CONSTITUENTS. BUT THIS OPTION CAN
SIGNIFICANTLY INCREASE THE COST OF CONCRETE
Lecture 08 68
34
MASS CONCRETE:
TEMP. CONTROL: POST-COOLING OF CONCRETE
(CONT’D)
• COOLING PIPES IN MASS CONCRETE ARE SOMETIMES USED TO
REDUCE MAXIMUM CONCRETE TEMPERATURES AND TO QUICKLY
REDUCE INTERIOR TEMPERATURES.
• THIS METHOD CAN HAVE HIGH INITIAL AND OPERATING COSTS,
BUT BENEFITS CAN OFTEN.
• IT IS IMPORTANT TO EMPHASIZE AGAIN THAT SIGNIFICANT
INTERNAL AND SURFACE THERMAL CRACKING CAN RESULT IF
POST-COOLING IS IMPROPERLY DESIGNED OR PERFORMED
Lecture 08
69
MASS CONCRETE:
TEMP. CONTROL: SURFACE INSULATION (CONT’D)
• INSULATION OR INSULATED FORMWORK IS OFTEN USED TO

WARM THE CONCRETE SURFACE AND REDUCE THE TEMPERATURE
DIFFERENCE, WHICH IN TURN MINIMIZES THE POTENTIAL FOR
THERMAL CRACKING.
• INSULATION OFTEN HAS TO REMAIN IN PLACE FOR SEVERAL
WEEKS OR LONGER.
• REMOVING IT TOO SOON CAN CAUSE THE SURFACE TO COOL
QUICKLY AND CRACK.
• MANY TYPES OF INSULATION MATERIALS ARE AVAILABLE, AND
INSULATION LEVELS CAN BE OPTIMIZED TO MEET REQUIRED
TEMPERATURE DIFFERENCES AND MAXIMIZE THE RATE OF
70
COOLING
CEE 306: Civil Engineering Materials Lecture 08
35
ROLLER COMPACTED CONCRETE (RCC)
Water control structure
• CALLED NO-SLUMP CONCRETE
• LEAN, ALMOST DRY
• LARGE DAMS, PARKING AREAS
• SLUMP: 2.5 cm (1 in.) OR LESS
• USED IN BEDDING FOR PIPELINES AND
CONCRETE PLACED ON INCLINED
SURFACES
• COMPACTED IN PLACE BY VIBRATORY
ROLLER OR PLATE COMPACTION
EQUIPMENT
RCC in Pavement
Lecture 08
71
REFRACTORY CONCRETE
• SUITABLE FOR HIGH-TEMPERATURE APPLICATIONS SUCH

AS BOILERS AND FURNACES
• MAXIMUM ALLOWABLE TEMPERATURE FOR
REFRACTORY CONCRETE DEPENDS ON THE TYPE OF
REFRACTORY AGGREGATE USED
• BINDERS: PORTLAND CEMENT; SLAG-PORTLAND
CEMENT; HIGH-ALUMINA, ALUMINA, OR PERICLASE
CEMENT; WATER GLASS; AND PHOSPHATE BONDS
• FILLERS: CRUSHED HEAT-RESISTANT OR REFRACTORY
ROCKS, CHIPS OF FIRED HEAT-RESISTANT PRODUCTS,
ETC.
• TEMPERATURE: 1580 oC; 1580-1770 oC; > 1770 oC
Lecture 08 72
36
PRECAST CONCRETE
• A CONSTRUCTION PRODUCT PRODUCED BY CASTING CONCRETE IN A

REUSABLE MOLD OR FORM WHICH IS THEN CURED IN A CONTROLLED
ENVIRONMENT, TRANSPORTED TO THE CONSTRUCTION SITE AND
LIFTED INTO PLACE
• CAST INTO THE DESIRED SHAPE PRIOR TO PLACEMENT
• CERTIFIED BY EITHER THE ARCHITECTURAL PRECAST
ASSOCIATION (APA), NATIONAL PRECAST
CONCRETE ASSOCIATION (NPCA) OR PRECAST
PRESTRESSED CONCRETE INSTITUTE (PCI) FOR A
PRECAST PRODUCER TO SUPPLY THEIR PRODUCT TO A
CONSTRUCTION SITE SPONSORED BY STATE AND A precast concrete
FEDERAL DOTS walled house
Lecture 08
73
ARCHITECTURAL CONCRETE
• ACHIEVE THE DESIRED ARCHITECTURAL

EFFECT WITH SPECIAL SHAPES, DESIGNS,
OR SURFACE FINISHES
• USE WHITE OR COLORED CEMENT
• SURFACE TEXTURES
– Exposed aggregates, raised patterns
produced by form liners, sandblasted
surfaces, and hammered surfaces
• ARCHITECTURAL CONCRETE PANELS ARE
OFTEN PRECAST AND USED FOR CURTAIN
WALLS AND SCREENS The Warrior located in Beersheba
Lecture 08 74
37
SUMMARY
• ORDER OF OPERATION FOR • SPECIAL CONCRETES
CONCRETE – High performance concrete
– Batching – High (early) strength concrete
– Mixing – Self-consolidating concrete
– Placing – Flowable fill
– Vibrating – Shotcrete
– Finishing – Lightweight concrete
– Curing – Heavy weight concrete
– Shrinkage compensating concr.
– Polymer concrete
– Fiber-reinforced concrete
– Roller compacted concrete
Lecture 08
75
38

CEE 306 - Lecture 08 - Sequence - Special Concrete

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CEE 306 - Lecture 08 - Sequence - Special Concrete

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PORTLAND CEMENT CONCRETE:

ORDER OF OPERATIONS FOR CONCRETE

CHANG-SEON SHON, PH.D., ASSISTANT PROFESSOR

ORDER OF OPERATIONS FOR

MIXING, PLACING, & HANDLING OF PCC

MIXING, PLACING, & HANDLING OF PCC

MIXING, PLACING, & HANDLING OF PCC

ORDER OF OPERATIONS FOR CONCRETE

PLACING ISSUES (CONT’D)

Correct placement of concrete

Incorrect placement of concrete

• VIBRATION CAUSES TEMPORARY LIQUEFACTION SO THAT AIR

VIBRATION OF CONCRETE (CONT’D)

VIBRATION OF CONCRETE (CONT’D)

VIBRATION OF CONCRETE (CONT’D)

• INADEQUATE CONSOLIDATION CAN RESULT IN:

Screeding (strike-off) : strike

Bullfloating: Eliminating high and low

ORDER OF OPERATIONS FOR CONCRETE

CURING CONCRETE (CONT’D)

Effect of moisture curing Effect of curing temperature

CURING CONCRETE (CONT’D)

Membrane forming compound

• CONSIDERATIONS: • CURING : IMMEDIATELY AFTER

• MATERIALS AND PROPORTIONS (INDIRECT WAY)

HOT WEATHER CONCRETING

• MATERIALS AND PROPORTIONS (INDIRECT WAY)

– Reduce the maximum time before discharge of ready-mixed

– Less than 1,922 kg/m3 (120 lb/ft3)

LIGHTWEIGHT INSULATING CONCRETE

LIGHTWEIGHT INSULATING CONCRETE

• PRESSURE STEAM CURED (AUTOCLAVED)

• MADE WITH HEAVY AGGREGATES SUCH AS BARITE, MAGNETITE,

• DRY-MIX PROCESS VS. WET-MIX PROCESS

• CRITICAL PARAMETERS TO REDUCE REBOUND OF SHOTCRETE IN

• CRITICAL PARAMETERS TO REDUCE REBOUND OF SHOTCRETE IN

• AMERICAN CONCRETE INSTITUTE (ACI 207)

MASS CONCRETE (CONT’D)

• USED IN A STRUCTURE SUCH AS A DAM IN

Effect of Concrete-Placing Temperature on

Potential for Surface Cracking in Mass Concrete

• METHODS OF CONTROLLING MASS CONCRETE TEMPERATURES

• SELECT LOW HEAT OF HYDRATION CEMENT OR MIXTURE

• INSULATION OR INSULATED FORMWORK IS OFTEN USED TO

• SUITABLE FOR HIGH-TEMPERATURE APPLICATIONS SUCH

• A CONSTRUCTION PRODUCT PRODUCED BY CASTING CONCRETE IN A

• ACHIEVE THE DESIRED ARCHITECTURAL

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