Scribd Logo
Upload

Welcome to Scribd!

  • Bonded-Concrete-Toppings CHR 2004

    Uploaded by

    Tracy
    21 views6 pages
    Construction

    Original Title

    Bonded-concrete-toppings_chr_2004

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Report this Document
    Construction

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    21 views6 pages

    Bonded-Concrete-Toppings CHR 2004

    Uploaded by

    Tracy
    Construction

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 6
    2 Bonded concrete toppings ince the inception of precast concrete products, concrete topping slabs from 2 to 4 ‘The writers are aware of major projects ‘where spcifed topping slab composite systems failed to develop the required long-term | bonding, resulting in systemic disbonding throughout the project. The topping slab bond failures — on a parking garage, two stadiums, and a penal facility — required expensive reme. dial work to remove and replace the topping slab and could have been avoided ifthe design sand contractors had increased knowledge ‘on factors inuencing topping sb bonding. Topping slab disbonding, when it occurs it 's often the result of generalized specifications, drawing notes and plan detils that do not clearly define a “composite” condition; lack of, specific requirements for the precast concrete member (or substrate) top surface finish; inad- equate of omitted topping slab pre placement procedures; incomplete material specifications for the topping slab concrete; and insufficient ‘or omitted prescriptive step-by-step methods for placing the planned composite topping slab, Also, bonding failures can result from contractors not following specifications andor using poor consirucion practices. An inches thick have been used with structural precast concrete members. Typically, the intended purpose of the additional concrete is to produce composite behavior of the topping slab with the precast member. The most common composite topping. slab systems are constructed with precast concrete members, such as hollowcore, solid planks, and tees, and rely on bond only. Unfortunately, planned composite topping slabs are not always successful where bonding is the sole means used to structurally connect the topping slab to the precast concrete component. additional problem facing the bonded-topping- slab-precast-concrete system isthe common use of divided design responsibilty. The actual designer of the composite stem is typically not the project architect or structural engineer Dut rather is the precast concrete supplier engineer, who has no control over any of the concrete topping slab requirements or inte sation ofthe topping slab and precast concrete units with other aspects of the planned construction. ll of these various events t00 ‘often result in the construction of a bonded topping slab system being an uncontrolled activity and will be discussed below Bonded systems Bonded topping slabs are used for both struc tural and functional reasons. Figure 1 illustrates bonded composite conditions. One strucural reason for havinga bonded sjsem isto make the topping slab a par of the structural coss-section {dough composite behavior. By using a bonded composite system, additional superimposed Joaul capacity can be developed without needing larger precast concrete members or additional <| Tips for bonding topping slabs with precast concrete construction By Charles H. Raths, S.E., and Kurt R. Hoigard, P.E. reinforcement. An added benefit of the composite sytem is an increase in flexural siffoess, which reduces shor and long-term ‘deflections, and undesirable vibration responses. In addition, « bonded topping slab assists in istrbuting. concentrated loads on a. given precast concrete member to adjacent members Another important use ofa bonded concrete floor of roof system is to act as a structural ciaphragm. The topping slab, acting together with the precast concrete units, produces a sit ssructural diaphragm that tansmits in-plane lateral loads to shear walls or moment frames, Bonding of the topping slab diaphragm prevents localized topping slab upward buck ling displacement asa result of compression or shear loading, In-situ application of the topping sab provides a convenient means to rake connections between the diaphragm and load resisting Commonly; insen are cast into the lateral load resisting clement into which coarsely threaded. rods are placed and then encased in the topping slab concrete Sometimes projecting rebars, instead of inserts and coarsely threaded rods, ate employed forte load transfer connection. In addition to the structural. benefits, concrete topping slabs ae frequently used for functional benefits such asin exterior structures exposed to the elements where the topping provides both drainage profiles and water proofing. The use of topping slabs for water proofing requires complete assurance that the topping slab will be composite, since dishonding would provide water with a path= ‘way between the topping slab and the top sur face ofthe precast concrete substrate. Moreove, if topping slab disbonding occurs, it typically leads 10 the development of excessive crack in the topping slab, allowing additional water to penetrate into the open interface atthe precast concrete top surface. Precast concrete substate members are most likely 10 be prestressed Prestressing causes camber that can influence the drainage profile, and it may equite some of the topping slab to havea greater thickness than, the nominal design value ‘other lateral elements 44 or cus 0 Slab disbonding Dishonding of the topping slab fiom the precast concrete member can lead toavaiety of "unwanted problems, which can creat the need for expensive and inconvenient remedial wotk. Some of the problems resuling from Aisonding include the following «Jos of flexural capacity due othe decrease in the cross-section depth + creation of hollow sounds ftom footsteps or trafic from the interface gap between the topping slab and the precast concrete: ‘development of excessive. topping. slab shrinkage cracks + curling o the topping slab a racks (particu lly at crack locations above precaseto-pre «cast member joins) + development of reflective racks in flooring materials that ae adhered othe topping lab; + loss of rebar or mesh engagement within the topping slab where the reinforcement has Fie oF no concrete cover at the topping slab bottom (panicularly where reinforcement is placed too close to ot ditecly upon the precast concrete unit top surface); ‘leakage through the topping slab cracks, which permits water migration. via. the disonded interface to areas below the floor or roof system; ‘corrosion of topping slab reinforcement (esting from improper cower at the topping slab ottom and wate leakage); + comosion of precast concrete embeds (when water is present in the isbonded interface); and + damage rom freeze-thaw tothe topping sab bottom and the precast concrete top surface (which can occur when water is within the disbonded interface). This is a serious problem for non-ientained topping slab and precast concrete members. Substrate surfaces Surfaces of the bonded! topping slab sub- strate can be made smooth or have a purposely roughened profile, Smooth surfaces are most ‘often produced by a precast concrete fabricator as part of ts normal finishing methods. In fat, the extruded manufacturing process for most hollowcore slab units results in a smooth su. face, Smooth finishes fr other precast concrete _members are typically created by screeding and floating the precast concrete’ top surface atthe ‘ime ofits production. A roughened top finish can be fashioned by mechanically raking the sutface during fabrication, scoring or grooving the precast concrete member top surface atthe time of extn: sion, oF sometime later by mechanical ly searifying the already hardened top surface, Photo 1 illus: trates the smooth top surface of an extruded precast. prestressed concrete hollowcore member. Usually precast con- ‘rete members with smooth surfaces do ; not have open pores since the surface is closed by the cement past laitance. A purposely roughened surfaces Figure ¢ Common precast concrete construction wth slab topping. shown in Photo 2 ‘This surface was produced with a common stel garden rake after the surface was slightly sift ened, but before the concrete hardened, The roughened surface shown in Photo 2 is similar to that produced for specimen testing of bond strength (see “Bonded surface testing” on page 46 for more information on testing proce- dures), except for the depth of the grooves, hich is approximately 5/8-inch peak-tovalley maximum, Cites ofthe purposely roughened, surface argue that some of the aggregate and paste projections will come lose and lessen the ygslab bond. Akey aspectof the ATURE: CONCRETE roughened substrate surface i that it allows the topping slab concrete to mechanically interlock with the substrate to prevent disbonding, Also, the interlock negates the loose surface particle effect. Roughening the substrate as shown in Photo 2 increases the rea ofthe topping slab contact surface by about one-half Scarfying a surface to provide a roughened top finish is shown in Photo 3. Scarifying increases the topping slab surface bonding area by one-quarter. Sandblasting the scarified surface exposes the surfac’s pores as well as | removes scarifying dust. Open substrate surface Bonded surface testing The American Concrete Instiute’s Building Code Requirements for ‘Swrucural Conerete (ACI 318-02, Chapter 17 - Composite Concrete Flexural Members, provides the references upon whieh the composite ‘design and. contact surfce roughness requirements are based. NW. Hanson's research conducted in 1960, which was detaled in the Portiand Cement Associations Journ! vtled “PrecastPrestressed Concrete Bridges: Horizontal Shear Connections” gives essenal information relative tothe composite contact surface Specialy designed direct shear push-off test specimens were used by Harson to evaluate both rough and smooth bonded plain concrete composite contact surfaces. Push-ff specimen rough contact surfaces were made by scraping the surface ofthe specimen base (the substrate) wih the ede of steel sheet creating depressions and peaks 3/8.nch below and above the average level. wich resulted in an approximate peak-o-depresson height of 3/4 inch. No attempt was made to smooth aggregates into the concrete pase. Hanson’ rough surface is diferent than te intentionally roughened surface define in ACI 318 Chapter 17, which has undulations of I/4 inch, Except for the pealcto-depresion height of 34 inch, Hanson's rough surface i simiar to Figure 2 The smooth surace of the pushoff Specimens was crated by trowelng the base to 2 redatiely smooth condition. Bond, or adhesion, of the test specimens owo parts was achieved by casting the upper part of the specimen to the bases ¢ry hardened surface. Specimen concrete was normal weight and had compressive strengths of 3500 to §,000 pounds per square inch (ps). Ec rough and smooth bonded plan concrete specimens were tested. The ukimate direct shear strength ofthe rough conact surface varied from 350 to 555 pl. Considering these eight ests ab a small sample of a large test popuiaon, che ft percenie rough surfce bonded shear srengi capacity meaning that 95 percent ofthe sample have greater test vale is 300 ps using a studeneT dstribution Tests on eg plain concrete smooth bonded specimens had shear tes timate values raging fom 99 to 230 psi with a stent T dstrbution ff percentile smooth and bonded direct shear capac of 4 ps Hanson te id not conser inherent inplacestrvcwra shear frees acting 2 he concrete bond surace caused by longterm diferent con- crete srikage nor eye temperature diferencesbeoween the concrete These shear forces may excee the smooth bonded sear strength pores enhance topping slab bonding by drawing the topping slab concrete paste tentacles into the pores. Construction practic Many construction factors and procedures can have a’ meaningfal effect upon topping slab-o-substrate bonding induding proper cleaning and preparation of the precast ‘member substrate and placing and curing of the topping slab. For example, substate surface cleaning i eset f topping lab bond isto be achieved All lose debris saw dst and dit require removal. Cleaning canbe accomplished by sweeping and vacuuming followed by the ue of oilfree blown compresed ait. Tn ado, surface contamination resling from spills of constuction mater, grease, il, paints and similar sobetances most be fll removed sing. appropriate chemicals ot abrasie bling Handed topping gatems using hollowcre ‘ype members should have joins | about any. indivi tual slab grouted and the grout should be level with the members. top surface. This decreases the ocut | rence of topping slab racking a each slab heyway jin. | Mesh and other reinforcements embedded inthe | topping slab should be supported on continuous chars or slab bolsers to ensure that the reinforcing will be located atthe planned postions with required. top and bottom concrete cover. Topping slabs should always contain mesh reinforcement at a ‘minimum, to conteol topping slab crack widths above or just adjacent to side and end joints of the precast concrete substrate. Further, properly placed mesh, between the mid-point and tupper.third of the topping slab thicknes, counteracts curling (which can occur at topping slab cracks) by providing moment resistance to the curling deformation. ‘The substrate surfce receiving the topping slab needs to be comectly preavetted prior to placing the slab. This weting should pre-satu rate the concrete and keep it continuously wet for at least 12 hours prior to slab placement. Immediately before topping slab placement the substrate should be in a saturated surface Ary condition, with no standing water Bonding ‘ofthe topping slab can be improved by the use of a grout scrub coat. When the topping slab contains mesh reinforcing, use of shotcrete is a ‘mote practical method of applying the grout scrub coat. Regardless ofthe scrub coat applica jon, IIs critical that the scrub coat not be allowed t0 prematurely dry out, which would bit bonding ofthe topping slab ‘The topping slab concrete should have alow vwater-cement ratio to minimize topping-slab- ‘orsubstrate differential shrinkage A low water: cement ratio, in the range of 0.32 0 035, can be best achieved by using high-range water reducers. Also, proper curing of the topping slab minimizes the effects of topping slab-o- substrate dferential shrinkage. The best curing {sto cover the topping slab with a wet burlap- ‘ype material and a moisture retaining cover Wet curing should preferably be maintained for a seven-day period Building code requirements ‘The American Concrete Institutes Building Code Requirements for Structural Concrete (ACI 318-02) and the Intemational Codes Council’ Intemational Building Code (2003 TBC) have specific requirements for composite structural systems, which are not typically adhered in actual practice. Most hollowcore slabs using a composite, bonded only, topping slab do not have an intentionally roughened top surface as required by ACI 318-02. Instead the top surface is smooth, However, a smooth precast concrete member top surface is sanctioned by the Precast/Prestressed Concrete Institute's Design Handbook - Precast and Prestressed Concrete which states, “Experience and tests indicate that normal finishing methods used for precas. concrete structural members will qualify as intentionally roughened.” This conflicts with the writers’ experience and knowledge of can crete topping disbonding, Chapter 17 of the 2008 IBC requires verification and inspection ‘of concrete construction (Table 1704.4) for proper placement of concrete (including topping slabs), however these inspections are ‘not commonly made. In fact, special inspec tions for concrete construction are dictated by the 2003 IBC Sections 1704.1 (Exception 2.) 1704,1.1, and 1704.12 A general summary of the ACL 318-02 requirements for precast concrete structural members having a bonded composite topping slab without reinforcing tes as understood by the authors, include the following ‘The substrate concrete members are requted to have an intentionally roughened compos- ite contact surface. ‘* Elastic section properties forthe centcoid and rroment-o-ineta, should be based upon. the gross composite cross-section for ‘ultimate strength designs ‘The controling ultimate horizontal shear at the contact interface occurs at the point of ‘maximum vertical shea. Use VQ to find the applied ulimate composite horizontal shear stes, where Q isthe static moment of the topping slab area (which i by times the distance between topping slab center, 2, and the composite cross-section centroid), and byis the width of the topping slab acting with the precast concrete: member. The POT orc ca) Tela Structures isthe fist rel parametric 30 modeling software for ‘the concrete industry re-cast febricators and concrete dealers can now enjoy the benefits ofthe unique ‘structural 3D modeling and detailing ‘aos prevcusy available onl for steel designers, engineers and details Toke the opportunity to experience a ig eap in user-tiendlnes, productivity and accuracy. ‘Chele #106 or INTEGRATION Why 30 modeling? Improves Producti and efcleny Better Service to your Client Increases Quaity in Design Decrease in Project Run Trough Tine Prevents Costly Eros Better Project Management ‘Supported by LEAP Software Contact ut at Teka Salesleapsof.com or cal us 3 600.451.5927 2 InloDiect at www.gestructural.com ie Nem siietiy Bde Tey ‘Ckele #106 oF use InloDiect at www.gostructural.com vous aoo Ma 477 ATURE (oe Photo2:Araked surface produces desirable, intentionally rough finish. maximum applied ultimate horizontal shear saress for bond-only composite members is limited to ¢80 psi = 68 psi, where gs 0.85 for shear. * Concrete cover for reinforcement within the topping slab at interior applications is not to be less than 3/4 inch and at exterior cond tions exposed to the weather isnot 10 be less than 1-1/2 inches for #5 bars and smaller. IF the topping slab is exposed to chlorides, the minimum cover is not to be les than 2 inches. A #5 bar in a topping slab exposed to

    You might also like