CRACK ANALYSIS, REPAIR

AND CONTROL IN
MASS CONRETE
DR. FLORANTE D. POSO, JR.
CONCRETE OVERVIEW
DR. FLORANTE D. POSO, JR.
CONCRETE :
COMPONENTS
CONCRETE
Concrete, usually Portland cement concrete is
a composite material composed of fine and
coarse aggregate bonded together with a
fluid cement (cement paste) that hardens over time — most
frequently in the past a lime-based cement binder, such as lime
putty, but sometimes with other hydraulic cements, such as
a calcium aluminate cement or Portland cement.
Admixtures – added to improve the properties of concrete
CEMENT

When mix with water, serves as binding agent of

concrete (paste)
MANUFACTURING OF CEMENT
MANUFACTURING OF CEMENT
QUARRYING
CRUSHING
STORAGE AND HOMOGENISATION
DRYING AND GRINDING
 The burning of the raw meal at
BURNING approx. 1,450°C is carried out
in preheater kilns that work by
varying methods, the
main difference being in the
preparation and preheating of
the kiln feed. By chemical
conversion, a process known as
sintering, a new product is
formed: clinker.
 After burning, the clinker is
CEMENT GRINDING cooled down and stored in
clinker silos. From there the
clinker is conveyed to ball mills
or roller presses, in which it is
ground down to very fine
cement, with the addition of
gypsum and anhydrite, as well as
other additives, depending on the
use to which the cement is to be
put.
 The finished cement is stored in
separate silos, depending on type
LOADING AND SHIPPING and strength class. From there it
mainly loaded in bulk form from
terminals onto rail or road vehic
as well as onto ships. Only a sma
proportion of the cement reach
the customer in the form of bag
that have been filled by rotary
packers and stacked by automat
palletising systems.
BASIC RAW MATERIALS
CLINCKER COMPOSITION
PROPERTIES OF CEMENT COMPOUNDS

Tricalcium aluminate
 It liberates a lot of heat during the early stage of hydration
 Has little strength contribution
 Gypsum slows down the hydration rate of this
Tricalcium silicate
 Responsible for initial set and early strength gain
 Hydrates and hardens rapidly
PROPERTIES OF CEMENT COMPOUNDS

Dicalcium silicate
 Responsible for strength gain after one week
 Hydrates and hardens slowly

Ferrite
 Fluxing agent that reduces melting temperature of materials
 Hydrates rapidly
 Do not contribute much in strength
PROPERTIES OF CEMENT
Setting time
 Time required to stiffened and hardened
 Initial set – occurs when the paste begins to stiffen
considerably
 Final set - Occurs when the cement has hardened to the
point at which it can sustain some load
 Influenced by : cement fineness, water-cement ratio,
chemical content, admixtures
TEST FOR CONSISTENCY OF CEMENT (SETTING TIME)
PROPERTIES OF CEMENT

Soundness
 Volume stability of cement paste
 Ability of hardened cement paste to retain its volume after
setting without delayed expansion
 Free lime or magnesia can cause expansion of cement paste
after setting
 Le Chatelier Test
Le Chatelier Test
 PROPERTIES OF CEMENT
Fineness
 The finer the cement particles are, the larger the total surface area is and
the bigger the area contacting with water is. Thus, the hydration will be
quick, the setting and hardening will be accelerated correspondingly, and
the early strength will be high.
 If the cement is too fine, its shrinkage is large in the hardening process
 In course particles, hydration starts on surface. Thus it may not be
completely hydrated resulting to low strength and durability
lcium aluminate (C3A) is mostly related to the heat of hydration.
CONCRETE : MIXTURE
MIX DESIGN GENERAL NOTES

• Any mix design procedure will provide a

first approximation of the proportions and
must be checked by trial batches.
• Local characteristics in materials
should be considered
CONCRETE MIX
WATER/CEMENT RATIO (W/C)

• Water/cement ratio theory states that for a

given combination of materials and as long as
workable consistency is obtained, the strength of
concrete at a given age depends on the w/c ratio.
• The lower the w/c ratio, the higher the
concrete strength.
AIR-ENTRAINED CONCRETE
• With improved resistance to freezing when
exposed to water and deicing chemicals
• Contains billions of microscopic air cells that
relieve internal pressure by providing tiny
chambers for the expansion of water when it
freezes.
 IDEAL DURABLE CONCRETE

ECONOMY  Optimal automated plant

operation
 Large maximum aggregate
size  Admixture and entrained air
 Efficient grading  Quality assurance and
control
 Minimum slump
 Minimum cement content
 IDEAL DURABLE CONCRETE

STRENGTH Sound aggregate,

Good quality of paste grading, and vibration
Low w/c Low air content
Optimal cement
content
 IDEAL DURABLE CONCRETE

RESISTANCE TO WEAR DETERIORATION

Low w/c ratio
Proper curing
Dense, homogeneous concrete
High strength
Wear-resisting aggregates
Good surface texture
 IDEAL DURABLE CONCRETE
RESISTANCE TO WEATHERING AND CHEMICALS
Appropriate cement type
Low w/c ratio
Proper curing
Alkali-resistance aggregate
Suitable admixture
Air entrainment
 BASIC CONSIDERATIONS FOR MIX DESIGN

ECONOMY
Relative costs of different mixes are dependent
on material cost
Labor and equipment costs, except for special
concretes, are generally independent for the mix
design
 BASIC CONSIDERATIONS FOR MIX DESIGN

ECONOMY
Cement is expensive, thus it should be minimized
• Use lowest slump that permit handling
• Good ratio of coarse and fine aggregate
• Possible use of admixtures
 BASIC CONSIDERATIONS FOR MIX DESIGN

WORKABILITY
Capability of being placed and compacted, with
minimal bleeding and segregation, and be finished
Should be improved by redesigning of mortar
rather than simply adding more water
 BASIC CONSIDERATIONS FOR MIX DESIGN

STRENGTH AND DURABILITY

Minimum compressive strength and a range of
w/c ratios are specified
Balance strength and workability
 SLUMP
• Measure of the degree of consistency and extent of
workability.
• Slump Test – ASTM C-143
• Concrete is formed into a conical metal mold. Then the
mold is lifted, and the concrete spread or drop in
height.
MIX DESIGN PROCEDURE

1. REQUIRED MATERIAL INFORMATION

Gradation, unit weight, specific gravities,
and absorption capacities of aggregates
2. CHOICE OF SLUMP
Specified by a particular job. If not given,
refer to the table of slumps.
MIX DESIGN PROCEDURE
MIX DESIGN PROCEDURE

3. MAXIMUM AGGREGATE SIZE

Should not be larger than:
• 1/5 of minimum dimension of structural
members
• 1/3 thickness of slab
• ¾ the clearance of reinforcing bars and forms
MIX DESIGN PROCEDURE

3. MAXIMUM AGGREGATE SIZE

 Current thought suggests that a reduced
maximum aggregate size for a given w/c ratio
can achieve higher strengths. Also, in many
areas, the largest available sizes are 3/4 in.
to 1 in
MIX DESIGN PROCEDURE

3. MAXIMUM AGGREGATE SIZE

 Current thought suggests that a reduced
maximum aggregate size for a given w/c ratio
can achieve higher strengths. Also, in many
areas, the largest available sizes are 3/4 in.
to 1 in
MIX DESIGN PROCEDURE

4. ESTIMATION OF MIXING WATER AND AIR CONTENT

MIX DESIGN PROCEDURE

4. ESTIMATION OF MIXING WATER AND AIR CONTENT

MIX DESIGN PROCEDURE

5. WATER CEMENT RATIO

MIX DESIGN PROCEDURE

6. CALCULATION OF CEMENT CONTENT

MIX DESIGN PROCEDURE

7. ESTIMATION OF COARSE AGGREGATE CONTENT

MIX DESIGN PROCEDURE

7. ESTIMATION OF COARSE AGGREGATE CONTENT

MIX DESIGN PROCEDURE

8. ESTIMATION OF FINE AGGREGATE CONTENT

MIX DESIGN PROCEDURE

8. ESTIMATION OF FINE AGGREGATE CONTENT

MIX DESIGN PROCEDURE

9. ADJUSTMENT OF MOISTURE IN THE AGGREGATE

MIX DESIGN PROCEDURE

10. TRIAL BATCH

Using the proportion developed in the preceding steps, mix a
trial batch of concrete using only as much water as is needed to
reach the desired slump (but not exceeding the w/c ratio)
CONCRETE MIX
DESIGN
CONCRETE :
MANUFACTURING, TEST, AND
PLACING
 CONCRETE MANUFACTURING AND POURING

tep 1 – Preparation and Step 2 – Mixing

torage of materials Step 3 – Transporting to wor
• Aggregates site
• Cement Step 4 – Placing and
• Water compacting
• Admixtures Step 5 - Curing
 PLACING OF CONCRETE
SHOULD:
Started along perimeter at one end
Each batch should be placed against the previously dispatched concrete
SHOULD NOT:
Place concrete in different locations and work them together
Place large amount (pile) of concrete in one location then move
horizontally to final position
COMPACTING OF CONCRETE
 concrete vibrator is used to eliminate honeycomb
(entrapped air)
 Internal Vibrator – placed inside the concrete
form
 External Vibrator – placed outside the concrete
form. Suitable for thin sections when internal
vibrators is not applicable
 FINISHING OF CONCRETE SLAB
• SCREEDING–is the process by cutting off excess
wet concrete to bring the top surface of a slab to the proper
grade and smoothness
• BULLFLOATING –is a tool used to finish a concrete surface
by making it smooth. A float is used after the surface has been
made level using a screed.
• TROWELLING – produces a hard, smooth, dense surface and
should be done immediately after floating
 FINISHING OF CONCRETE SLAB

• SCREEDING OR STRIKE OFF – Use to attain proper grade

of slab by cutting off excess concrete
• BULLFLOATING – Remove low and high points and embed
large aggregate particles after screeding
• TROWELLING – performed if a smooth, hard, and dense
surface is required.
 CONCRETE CURING

• Maintaining enough moisture and temperature at early age

of concrete to attain the required strength.
IMPORTANCE OF CONCRETE CURING

 Predictable strength gain

At high temperature – strength at early age can be
achieved fast but it will reduce strength at later
stage
At low temperature – attaining early strength is
slow that can cause delay
IMPORTANCE OF CONCRETE CURING

 Improved durability
Increase hardness, and surface wear and abrasion
resistance
Improved water tightness that prevents
penetration of moisture and water-borne chemicals
 Better serviceability and appearance
SYSTEM TO KEEP CONCRETE WET
• Burlap or cotton mats and rugs used with a soaker
hose and sprinkler. Should not be dry out to prevent
moisture absorption from concrete
• Straw sprinkled with water regularly
• Sprinkling in continuous basis
• Ponding of water
MOISTURE RETAINING MATERIALS
• Liquid membrane
• Plastic sheets
• Waterproof paper
CONTROL OF TEMPERATURE
 In cold weather
 concrete should not cool faster than 3oC per
hour for the 1st 24 hours
 should not freeze until it reaches compressive
strength of 3.5 Mpa
 use curing methods that retain moisture
CONTROL OF TEMPERATURE
 In hot weather
 concrete should not cool faster than 3oC
per hour for the 1st 24 hours at day and
night extreme temperature
use curing methods that keep concrete wet
TESTING OF CONCRETE
 Destructive Testing
 test until concrete fails
Non-destructive Testing
 test without destroying concrete
DESTRUCTIVE TESTING OF
CONCRETE

 Compressive strength test

 Splitting tensile strength test
 Flexural strength test
NON-DESTRUCTIVE TESTING OF CONCRETE
 Penetration method
 Rebound hammer method
 Pull-out test method
 Ultrasonic pulse velocity method
Radioactive method
PRECAST CONCRETE
 Concrete casted in a place other than
where it will be used
 Mostly casted in factory
 Sometimes casted on-site such as tilt-up
panels
ADVANTAGES OF PRECAST CONCRETE
 Control
 Less expensive
 Easy installation
 Top quality and durability
 Noise reduction
 Fire proof
Aesthetic
ADMIXTURES
 Concrete ingredients other than cement, water,
and aggregates that are added to the mix
immediately before or during mixing
 Classified according to functions such as: air-
entraining, water reducing, retarding, accelerating,
plasticizers, and other specialty function .
ADMIXTURES
 Air-entraining – use to purposely place
microscopic air bubbles for air-entrained
concrete
 Water reducing – use to meet required
slump with reduce water (w/c ratio) thus
resulting to higher strength
ADMIXTURES
 Retarding – it slows down concrete’s
setting rate to balance the accelerating effect
of hot temperature
 Accelerating – increase rate of early
strength development, lessen time for proper
curing and protection for faster operation
ADMIXTURES
 Plasticizers – Making concrete more
workable
 Corrosion inhibiting – specialty
admixture used to slow down corrosion
of steel reinforcement