Arch 23: Building Materials and Construction

CONCRETE and CONCRETE PRODUCTS

Dio, Reynier Loislane R. Osias, Kasmir Lara V.

Arch 23 WFJK November 28, 2012

OUTLINE I. Concrete A. Definition of Types B. Workability of Concrete C. Units of Measurement D. Composition of Concretes 1. Cement 2. Aggregates a. Fine Aggregates b. Coarse Aggregates 3. Water 4. Additives/Admixture E. Proportioning F. Mixing 1. Ready-mixed concrete a. Truck Mixing b. Combination central plant and truck mixing c. Central plant mixing G. Conveying and placing concrete 1. Conveying 2. Placing concrete 3. Vibration 4. Construction joints H. Finishes 1. Floor finishing a. Placing and screeding normal concrete slab or base slab i. Rough finish ii. Non-slip Finish 2. Other finishing a. Rubbed Finish b. Broom finish I. Concrete Testing 1. Slump Test 2. Cylinder/Compression Test J. Curing Materials 1. Polyethylene sheet for curing 2. Waterproof kraft paper 3. Burlap

K. Curing 1. Moist curing 2. Impervious sheet curing 3. Curing periods II. Concrete Products A. Types of Concrete Products (Class) 1. Structural a. Class AA b. Class A 2. Architectural a. Class A b. Class B 3. Masonry a. Class C B. Application of Concrete Products 1. Flooring 2. Roof 3. Walls

I.

CONCRETE A. Definition and Types Concrete is an artificial stone as a result of mixing cement, fine aggregates, coarse aggregates and water. There are two types of concrete: plain concrete and reinforced concrete. Plain concrete is the conglomeration of cement, aggregates and water producing a solid mass. On the other hand, reinforced concrete is a type of concrete with reinforcement embedded in such a manner the two materials act together in resisting forces. B. Workability of Concrete Proper proportion of the said components improves the workability of concrete. A concrete is said to be workable if: a. It is properly proportioned for transport and placed without segregation. b. It is easily molded into desired shapes and completely fills the space it is to occupy. c. It is easily finished. Workability can be also described as: a. Consistency the degree of wetness or slump of concrete mix. b. Plasticity the ease with which fresh concrete can be molded or deformed without segregation. c. Mobility the capacity of concrete for movement or flow, particularly during vibration. C. Units of Measurement These are the units of measurement that are involved in the usage and mixing of concrete: Solid concrete structure - cubic meter (m3) Cement - pounds (lbs) or kilograms (kg) Aggregates - cubic foot (ft3) Water - gallons per bag

D. Composition 1. CEMENT A mixture of alumina, silica, lime, iron oxide and magnesium oxide used as binding element or agency. The following are the different types of cement: Ordinary Portland Cement Rapid Hardening Portland Cement - specified when high early strength is required Portland Blast Furnace Or Sulphate - to resist chemical attack Low Heat Portland Cement - preferred for a massive section to reduce heat of hydration High Alumina Cement Portland Pozzolan Cement- slow hardening concrete 2. AGGREGATES Aggregates are inert materials that when bound together into a conglomerated mass by portland cement and water form concrete, mortar or plaster. There are two types of aggregates: coarse aggregate (gravel) and fine aggregate (sand). Coarse aggregate is the portion of an aggregate that is retained on No 4 (4.76 mm) sieve, which usually come from: a. Natural gravel deposits b. Manufactured by crushing rock, stone, boulder and large cobble stone. 4 Kinds of Coarse Aggregate Materials: a. Limestone or calcium-bearing minerals b. Basalts, granite, related igneous rock c. Sandstone and quartzites d. Rock such as opal and chert, composed mainly of amorphous silicon dioxide.

Fine Aggregate is the product of natural disintegration of silica-bearing or calcium-bearing rock. Fine aggregate are those that passes through No. 4 sieve. It is also manufactured from larger pieces of aggregate by crushing, grinding or rolling. 3. WATER Water that is acceptable for drinking purposes is also satisfactory for use in concrete mixing. 4. ADDITIVES/ADMIXTURE Additives / Admixtures are materials in the form of powder or fluids that are added to the concrete to give it certain characteristics not obtainable with plain concrete mixes. It is a material other than water, aggregate or portland cement that is used as an ingredient in concrete and is added to the batch immediately before or during its mixing. Common Types of Additives: a. Air-entraining admixture - improves the durability of the concrete entraining billions of microscopic air bubbles, which are distributed throughout the matrix of the concrete. Accelerators - speed up the hydration (hardening) of the concrete. Retarders - slow the hydration of concrete and are used in large or difficult pours where partial setting before the pour is complete is undesirable. Bonding agents - are used to create a bond between old and new concrete. Pumping aids - improve pumpability, thicken the paste and reduce separation and bleeding. Plasticizers - increase the workability of plastic or "fresh" concrete, allowing it be placed more easily, with less consolidating effort. Pigments - can be used to change the color of concrete, for aesthetics.

b. c.

d. e. f.

g.

h.

Corrosion inhibitors - are used to minimize the corrosion of steel and steel bars in concrete.

E. Proportioning The right proportioning of the ingredients of concrete provides a balance between the requirements of: 1. Economy 2. Workability 3. Strength 4. Durability 5. Appearance CONCRETE PROPORTION Class of Mixture AA A B C Cement Bag (40kg) 1 1 1 1 Sand cu. ft 1 2 2 3 Sand cu. m .043 .057 .071 .085 Gravel cu. ft 3 4 5 6 Gravel cu. m .085 .113 .142 .170

These are the factors that regulate the strength of concrete: 1. Correct proportion 2. Suitability or quality of the materials 3. Proper methods of mixing 4. Proper placement or depositing of concrete inside the forms 5. Adequate protection of concrete during the period of curing. There are two kinds of concrete mixes: Designed mix is where the contractor is responsible in selecting the mixture proportion to achieve the required strength and workability. Prescribed mix is where the designing engineer specifies the mixture proportion. The contractors responsibility is only to provide a properly mixed concrete containing the right proportion.

F. Mixing is highly recommended to be done using machines for even mixing. Manual mixing is only done when emergencies occur with permission from the architects or engineers. - First thing that is put into the mixer are the aggregates, then the cement and then the water. The aggregates and the cement should be properly mixed first before adding water. Mixing time depends upon the capacity of the mixer (most common truck has the capacity of 8 cubic yards). 1. Ready-mixed concrete this is concrete produced by an establishment then delivered to the purchaser. Concrete is delivered in three ways: a. Truck Mixing Concrete is mixed and delivered using the truck mixer. b. Combination central plant and truck mixing concrete is partially mixed in the stationary mixer in the plant and then completed in a truck mixer. c. Central plant mixing concrete is mixed in the stationary mixer in the plant and then delivered to the site using an agitator or a truck mixer. G. Conveying and placing concrete 1. Conveying concrete should be transferred hastily from the mixer to the forms to avoid separation of aggregates from the mixture and must be poured vertically not higher than 91 cm. - Usage of chute is only allowed when concrete is first transferred into a hopper before pouring into the forms. 2. Placing concrete once there are signs that the concrete has dried up a little, placing of concrete should not be performed; also when the weather is not appropriate for the activity. - The forms should be clean so that there would be no impurity that can weaken the concrete. - Once the concrete is placed and water amasses at the surface, the only way allowed to remove the water is through absorption. 3. Vibration Using a vibrator, the concrete shall be compacted until it doesnt decrease in volume. The vibration helps to remove spaces and bubbles in concrete mixtures. 4. Construction joints joints supporting the structures strength. Although not shown in plans, these are still made but only with the architect and engineers approval - It is reinforced using steel keys and dowels.

H. Finishes 1. Floor finishing a. Rough finish used on all floors b. Non-slip Finish used on ramps for the disabled. 2. Other finishing a. Rubbed Finish Surfaces are rubbed with carborundum or abrasives to smoother appearance. b. Broom finish usually used in parking lots. I. Concrete Testing 1. Slump Test Procedures: a. Place the freshly mixed concrete inside the mould in 3 layers each roded separately by 16mm rod 25 times. b. Level the mould and lift at once. c. Measure the slump action immediately by getting the difference in height between the height of the mould and the top of the slumped concrete. d. If the slump measure 10 cm, it is said to be a 10 cm slump. Types of construction Reinforced foundation wall and footing Plain footing, caissons and substructure walls Slabs, beams and reinforced walls Building columns Pavement Heavy mass construction Maximum cm 13 10 15 15 7 7 Minimum cm 5 2.5 7.5 7.5 5 2.5

2. Cylinder Test a. For a coarse aggregate not more than 5 cm diameter, prepare a cylindrical specimen 15 cm diameter and 30 cm long. b. For a coarse aggregate more than 5 cm diameter, prepare a cylindrical specimen with a diameter 3 times the maximum size of the aggregate and a height double its diameter.

c.

The mould should be made of metal placed on a plane surface preferably 6 to 12 m plate. d. Place the fresh concrete inside the mould in 3 separate equal layers rodded separately with 16mm rod 25 strokes. e. Level the surface with trowel and cover with a glass or plane steel. f. After 4 hours, cover the specimen with a thin layer of cement paste and cover again with the planed metal or glass. g. After 24 hours, curing shall be made in a moist atmosphere at 21 h. Test should be done at 7 and 28 days period. i. Ascertain that both ends of the specimen are perfectly levelled. j. Specimen is placed under a testing machine; then a compressive load is applied until the specimen fails. The load that makes the specimen fail is recorded. k. The recorded load divided by the cross sectional area of the cylinder gives the ultimate compressive unit stress of the sample. J. Curing Materials 1. Polyethylene film and sheet is a very strong plastic film used for weatherproofing exterior walls. Sometimes takes the form of a sheet. 2. Waterproof kraft paper - polyethylene-coated waterproof paper used in curing to achieve high quality. 3. Burlap - absorbent fabric saturated with water used in moist curing. L. Curing 1. Moist curing - keeping the concrete wet or moist by covering it with burlap. - If forms are removed early, continue moist curing on exposed unformed parts. 2. Impervious sheet convenient because it blocks moisture loss once the surface is saturated. Apply the impervious paper after the cement has hardened enough and you have thoroughly saturated the concrete. Weigh down the sheets so they remain in contact with the concrete surface throughout the curing process. 3. Curing periods within 7 until 10 days if compression test cylinders indicate 28 day strength less than 90%, additional curing shall be given.

II.

CONCRETE PRODUCTS A. Types of Concrete Products 1. Structural used for heavy mass structures a. Class AA storage tanks, septic tanks b. Class A pre-cast concrete items 2. Architectural used for supporting a. Class A pre-cast concrete items b. Class B slabs & grade, grade & tie beams 3. Masonry used for construction of walls a. Class C not reinforced B. Strength of Concrete CLASS Class AA Class A Class B Class C SPECIFIED COMPRESSIVE STRENGTH IN 28 DAYS 4,000 psi 3,000 psi 2,500 psi 2,000 psi

C. Application of Concrete Products 5. Flooring Slabs, slab-on-fill, pavements, driveways 6. Roof Joists, suspended slab, beams 7. Walls Columns (reinforced), concrete hollow block (CHB), screen blocks

Bibliography: Fajardo, Max B. Simplified Methods on Building Construction. 2nd Edition. Quezon City: 5138 Merchandising, 1993. Print. Fajardo, Max B. Simplified Construction Estimate. 2nd Edition. Quezon City: 5138 Merchandising, 1988. Print. Sajorda, Quin A. Construction Master Specifications. 2nd Edition. Quezon City: The Elastomark Corporation, 1999. Print.