Beruflich Dokumente
Kultur Dokumente
1.01 LIME
One of the oldest manufactured building materials used as a mortar and plaster by
all the early civilizations:
Romans developed a mixture of lime putty and volcanic ash for the first real
cement.
Before quicklime can be used, it must first be mixed with water in the process
called slaking or hydration.
The lime has now become calcium hydroxide (Ca(OH)2), known as slaked
lime or hydrated lime.
Hydrated lime mixed with water to make lime putty, is used as an ingredient of
hard-finish coat for two-and three-coat Portland cement plasters. It is also used for
mixing with cement mortar or concrete to:
A type of lime which will set under water is hydraulic lime, used only where
slow underwater setting is required.
1.02 GYPSUM
Gypsum, like lime, was used as a plaster by the Egyptians, Greeks and
Romans.
Plaster from the Greek word for both the raw material and calcined
product. In architectural terminology the words Plaster and gypsum are
often used interchangeably.
1.03 CEMENT
With the fall of the Roman Empire the art of cement-making was lost and for
several centuries.
Today, the word cement generally refers to Portland cement which is the
principal type of cement in use.
slow-setting cement
sulfate-resisting cement for applications where alkaline water and soils occur
2. STORAGE OF CEMENT
Cement should be protected at the building site from injury through contact with
dampness.
They should be stored in shed with a wood floor raised about 300mm (12)
from the ground.
Cement should be used as soon as possible after delivery.
Piles should be limited to twelve sacks in height.
Warehouse set - when the cement is stored in high piles for long periods, there
is a tendency for the lower layers to harden caused by the pressure above.
3. CONCRETE
Concrete is:
when mixed with water and a fine aggregate of less than 6mm () is known
as mortar, stucco or cement plaster.
when mixed with water, fine aggregate and a large aggregate of more than
6mm () in size produces concrete.
Strong ,
correct proportioning
thorough mixing
3.03
MATERIALS OF CONCRETE
a. Cement
time of setting
fineness
tensile strength
Each bag of cement is equivalent to approximately 1 cu. ft. and weighs 94 lbs.
b. Aggregates are:
inert mineral fillers used with cement and water in making concrete, should
be particles that are durable strong, clean, hard and uncoated, and which are
free from injurious amount of dusts, lumps, soft and flaky particles, shale,
alkali, organic matter loam or other deleterious substances.
c. Water
The water-cement ratio is the amount of water used per bag of cement.
This usually varies from 5 to 7 gallons, with 6.5 gallons as average for
ordinary job conditions. The less water used in mixing, the better the quality of
concrete.
-
Maximum water-cement
ratio
Pounds of water
per 100 lbs. of
cement
2,000
7.00
62.0
2,500
6.50
57.5
3,000
5.75
51.0
3,750
5.00
44.5
In this
a mix
or
height
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m
p
test the
tendency of
to slump,
reduce its
due to
gravity
action, is
measured. The apparatus consist of metal cone, the bottom opening being
200mm (8) in diameter, the top opening being 100mm (4), and the height
exactly 300mm (12).
The following table gives the permissible slump for various types of concrete in
relation to their uses:
CONSISTENCY (SLUMP)
Maximum
Minimum
125mm (5)
50mm (2)
100mm (4)
25mm (1)
150mm (6)
75mm (3)
25mm (1)
75mm (3)
25mm (1)
75mm (3)
b.
c. Determine the consistency of the mix using the slump test using as
dry a mix as practicable.
a.
a.
b.
c.
Proportioning concrete by the arbitrary selection of the proportions is the oldest, the
most commonly used, the most convenient and the least scientific method.
f
o
o
t
f
o
o
t
In this method, the aggregates are measured by loose volume, that is, its volume as
1
it is thrown into a measuring box.
f
o
o cement to fine aggregate to
Common mixes expressed in proportions by volumes of
t
coarse aggregate are as follows
CONCRETE PROPORTIONS
Class AA
1 : 1.5 : 3
Class A
1: 2
:4
Class B
1 : 2.5 : 5
Class C
1:
Class D
1 : 3.5 : 7
3 :6
b.
This method is the same as the second except that the proportions of the fine and
coarse aggregate are determined by the fineness modulus method.
For economy, proportion the fine coarse aggregates so that the largest quantity of
mixed aggregate may be used with a given amount of cement and water to produce
a mix of the desired consistency of slump.
3.06 MIXING OF CONCRETE
Batch mixers into which sufficient materials are placed at one time to make a
convenient size batch of concrete, the whole amount being discharged in
one mass after it is mixed.
Continuous mixers into which the materials are fed constantly and from which the concrete is
discharged in a steady stream.
Concrete mixers may also be classified as:
-
drum mixers
trough mixers
gravity mixers, and
pneumatic mixers.
HAND MIXING
-
cement and fine aggregate shall first be mixed dry until the whole is a
uniform color.
water and coarse aggregate shall then be added and the entire mass turned
at least three times, or until a homogeneous mixture of the required
consistency is obtained.
since initial set of concrete takes place 1 to 3 hours after mixing, a batch may
be used anytime before initial set takes place, provided that the mix is
plastic.
The delivery of the concrete from the mixer to the forms should be
fairly continuous and uninterrupted.
When chutes are used, the slope should not be more than 1 vertical to
2 horizontal or less than 1 vertical to 3 horizontal. The delivery end of
the chutes shall be as close as possible to the point of deposit.
Hardening is a rather slow process in which the cement and water unite to
form compounds that give strength and durability to the concrete. It
continues as long as the temperatures are favorable and moisture is present.
age or time
temperature, and
moisture.
In order that the hardening may proceed favorably, the fresh concrete, for
about 7 days after placing, should be protected from, excessive vibration,
loads, extreme heat or cold, too rapid drying, and contact with impurities
which may interfere with the chemical action.
The strength of the concrete increases with age when the curing conditions
remains favorable.
The increase in strength is rapid during the early ages and continues more
slowly as time goes on. The compressive strength reaches about 60% of its
own maximum value at an age of 28 days and about 80% at an age of 3
months.
Curing consists primarily in keeping the concrete from drying out too rapidly. This
may be done by:
a.
Covering the concrete. Floors shall be covered with paper sacking wetted
down at the edges or with burlap, sand or earth that is kept moist, after the
concrete is hard enough to walk on.
b.
Removal of forms at prescribed time. Forms shall not be removed until
after the time specified.
c.
Sprinkling with water. Beams, columns and walls are sprinkled or sprayed
with water as soon as the forms are removed.
d.
Parts of Structure
FOOTINGS
c. Slab footings
WALLS AND
PLASTERS
COLUMNS
a. Massive walls,
30 cms. thick
or more
e. Up to 2 M. high: 2 days (48 hours. Add 11/2 days (36 hours) for every additional
meter or fraction thereof
c. Cantilever
walls,
buttresses,
counter forts,
diaphragms.
f.
a. Ratio of height
to least
diameter up to
4
b. Ratio of height
to least
diameter from
4 to 15.
SLABS
a. 3 to 7 ft. spans
b. Over 7 ft. span
(672 hours).
BEAMS AND
GIRDERS
a. Sides
c. 3 days
b. Bottoms
ARCHES
a. Spandrel walls
b. Spandrel
arches
c. Main arches
BALUSTRADE
S,
COPINGS,ETC
.
R.C. PILES
and R.C.
POSTS
a. Sides.
b. Bottom
3.10 ADMIXTURES
Substances added to cements, mortars, and concrete for the purpose of
improving or imparting particular properties, such as:
Admixtures come in powder, paste, and liquid form, and are usually patented
and sold under trademark names.
Colored pigments are mainly to used to give color to concrete floors. There
are two types:
Dry-cast, broadcast or dust-on, for surface coloring. They are dusted on,
usually in two coats, after all surface water has disappeared. The surface is
then finished with a steel trowel .
Integral colors, for body coloring. Integral color pigments are incorporated
in the mortar topping. They are mixed dry with the cement and aggregate
before water is added. Amount of color pigment required is not more than
10% of the cement by weight, generally 3 to 6 lbs. per bag of cement .
3.11
a.
FORMS
LUMBER FORMS
b.
1-inch thick for floor panels and beam and girder sides
Works best where a smooth surface is required. The plywood should be waterproof,
Grade A and at least 12mm () thick.
c.
STEEL FORMS
Steel forms may be in the form of pans for concrete joist construction or steel
decking or corrugated steel for concrete slabs and slab-and-joist construction. .
d.
PLASTIC FORMS
b.
GUNITE
This is the mixture of sand and cement deposited under high pneumatic pressure
with a machine manufactured under the trade name CEMENT GUN, to which the
required supply of water is added just before the dry constituents emerge from
nozzle.
GUNITE is used for encasing structural steel, when reinforced, for floor and roof
slabs and curtain walls. Ideal for swimming pool construction.
c.
PORETE
d.
HAYDITE
Lightweight plaster has less tendency to crack and its heat resistance makes
it a good material for fireproofing structural steel
Porosity requires changes in the usual formulas for water and slump, and
closer supervision of mixing. Very light aggregates tend to float out of the
mortar and some coarse aggregate concrete mixtures require the addition of
a fine aggregate like sand to prevent harsh working and serious bleeding.
The cost of raw aggregates is higher than for gravel, rock, and sand because
of small production facilities and the additional processing that is sometimes
necessary .
Concrete using lightweight aggregate should not weigh more than 75% of
ordinary concrete. Since the aggregates compromise about 50 percent of the
usual mixes, its weight should not be more than 50 percent of that of rock or
gravel aggregates for the same volume. Grade rock, gravel aggregates weigh
a little less than 100 lbs. per cu. ft. thus a good lightweight aggregate should
weigh less than 50 lbs. per cubic foot.
Perlite is composed of stable silicates, and is inert and thus durable for use
as a lightweight aggregate or for insulation. Its disadvantages are its
friability, small particle size, and extreme lightness. The small particle size
requires more cement, while its lightness, from 8 to 16 lbs. per cu. ft.
increases the tendency to float out of the mortar.
b.
Micaceous minerals
Vermiculite is a micaceous mineral which expands on application of heat to
as much as 30 times its original volume.
Dried ground ore is subjected to about 1,800 degrees heat for 4 to 8 seconds,
after which it weighs only 6 to 12 lbs. per cubic ft.
It is used as an aggregate in concrete fireproofing steel, for floor and roof fill,
and for acoustic and fireproof plaster.
c.
d.
Lightweight aggregates from shales and clays require heating the material in
a kiln to a temperature near its fusion point. The material softens and
coalesces to a sticky mass; escaping gases are trapped, forming cellular
structures and expanding the volume of the material about 50%.
By-product Aggregates
Foamed slag has been used for precast blocks, cast-in-place walls of houses
and for panel filling of steel-framed buildings.
Cinders are composed of the ash components of the coal along with the
various quantities of unburned or partially burned combustible matter.
Cinders containing a minimum amount of combustible material are
satisfactory for use in concrete but are not particularly weight saving.
Lightweight cinders often have unsound physical and chemical properties.
WEIGHT OF AGGREGATE AND CONCRETE BY TYPE OF AGGREGATE
TYPE OF AGGREGATE
Aggregate
Weight per
Cubic Foot
(Lbs.)
Gravel
120
150
Sand
90-100
150
Crushed Stone
100
145
80
110-130
40-60
100-120
Foamed Slag
40-60
90-100
Cinders
40-50
110-115
Pumice
30-60
60-90
Diatomite
28-40
55-70
Perlite
6-16
40-65
Vermiculite
6-10
25-50