4 Working Instructions PDF

Foundation frame castings for No.
44926674-00-4 en
_ LOESEHE,T LOESCHE mills

Work lnstructions
Rev. A
Created: Checked and pproved:

on:2012-08-09 on:2012-08
by: Grubing by: Mors
The æpyrighl for thìs dæument and all append¡ces is reserued by Loesche GmbH
F¡le WlDept\Design\Docs\Q-Dokumente\Allg O-Dokument\A4926674404EN RevA docx
Foundation frame castings for No. AA926674-00-4 en
Rev. A
LOESCHE mills
Work Instructions
1 Purpose
In order to form a single unit between the foundation and the mill, using the correct
and proper casting method between the reinforced concrete and the mill's frame is
especially important for the function of the mill. In the following text, basic
considerations are discussed that are especially important when it comes to casting
works and compliance with instructions is mandatory.
The work instructions contain recommendations by Loesche GmbH that have been
tried and tested successfully in the past. All concrete work is outside Loesche's
responsibility, and therefore, the company cannot provide any warranties. These
specifications do not release the contracting firm from rendering proper warranty for
all work to be executed.
For the casting work to be successful, four individual criteria were compiled.
All are of equal importance and are listed below
● Concrete composition
● Concrete preparatory work
● Concrete pouring
● Post-treatment
Only compliance with all four criteria can guarantee successful casting work.
2 Scope of applicability
Definition of these work instructions applies to all Loesche departments. Any
departure from these instructions requires the written approval and must be
documented by the Order processing/Project department or the Technical Field
Services.
3 Definition of terms
-
4 Responsibility
The contracting firm shall be responsible for the execution of these work
instructions.
Page 2 / 13
The copyright for this document and all appendices is reserved by Loesche GmbH.
File: W:\Dept\Design\Docs\Q-Dokumente\Allg. Q-Dokument\AA926674-00-4EN_RevA.docx
Rev. A
LOESCHE mills
Work Instructions
5 Executions
5.1 Concrete composition

5.1.1 Cement
When using reinforced concrete, a cement generating low heat shall be used.
These requirements are met if using cement CEM III/B 32.5-NW, in compliance with
DIN EN 197-1.
CEM III Blast furnace cement

B 32.5 Blast furnace cement with reduced amount of Portland cement (20%
to 34%) and increased portion of blast furnace slag (66% to 80%). The
percentages refer to the fractions of mass. 32.5 is the minimum
standard strength of 32.5 N/mm² after 28 days.
NW Cement generating low heat
The maximum cement content must not exceed 300 kg/m³. A higher cement content
will increase the final shrinkage value and with that, raises the risk of crack
formation.
5.1.2 Aggregates
The shape of the rock particles should be as compact as possible. At a minimum
joint thickness of 75 mm, the largest aggregate can be 16 mm in size. For
aggregates up to 40 mm, the largest aggregate can be 8 mm in size. The joint
thickness and the largest aggregate size should be selected depending on the width
of the frame support.
In order to achieve a dense structure, the grain distribution for 8 mm largest

aggregate is listed in Appendix 1, and the grain distribution for 16 mm largest
aggregate is listed in Appendix 2.
5.1.3 Water
Any naturally occurring water can be used as mixing water. Ensure that the water
does not contain substances (e.g., chlorine) that may damage the concrete's
reinforcing components. Thus, corrosion protection could not be guaranteed. When
using sulphite-containing water, so-called HS-cements with a high resistance to
sulphite must be used. Otherwise, however, this water must comply with the above-
mentioned requirements.
5.1.4 Water/cement ratio
The water/cement ratio greatly affects the final shrinkage value of the concrete. The
max. water/cement ratio must be maintained and must not be exceeded. The ratio
water to cement refers to the fractions of mass. When determining the required
amount of water, the water clinging to the surface of the aggregates must also be
considered. In order to improve the workability of the concrete, a superplasticizer
can be used (see Section 5.1.5 Add-ons)
5.1.5 Add-ons
In order to improve the workability of the fresh concrete, superplasticizers can be
added shortly before pouring the concrete. Compliance with the manufacturer's
specifications is mandatory. Using the incorrect doses may lead to strength
Page 3 / 13
Rev. A
LOESCHE mills
Work Instructions
reductions, introduction of air pores, and increased shrinkage. This must be

prevented by all means.
5.1.6 Properties of hardened concrete
Compliance with the above-mentioned individual criteria ensures a concrete with
little shrinkage and a concrete that meets the high requirements. This guarantees a
solid connection between the mill's frame and its foundation. In order to minimise
the shrinkage of the hardened concrete, a cement of a lower strength category and
low heat generation was selected. However, when using a water/cement ratio of
0.45, a concrete compression strength of 35.0 N/mm² is achievable. This equates at
least a concrete compression strength grade of C30/37 after 28 days. A
water/cement ratio of any higher value will decrease the final compression strength
of the concrete. As guidelines for the development of the compression strength, at a
temperature of 20°C, the following values can be used:
– after 3 days 30% to 40% of final compression strength

Lower temperatures will slow down the development of the compression strength
accordingly. If assuming an outside temperature of 5°C, the following guidelines
apply:

5.2 Concrete-pouring procedures

Before pouring the concrete, preparation of the concrete surface is of particular
importance. In order to achieve an internal bond between the prepared foundation
and the concrete, the following work steps are mandatory:
– Cleaning and roughing the concrete surface

– Removing loose concrete parts such as cement paste, additives, etc.
– Cleaning the anchor holes and concrete openings
– Wetting the anchor holes and concrete surfaces
– Ensure to prevent water accumulating inside the anchor holes. If necessary,
water must be extracted immediately after completing the concrete work.
– Ensure to prevent puddles of water accumulating on the foundation surface. If
necessary, water must be extracted immediately after completing the concrete
work
– When pouring the concrete, the temperature of the fresh concrete and the
component must be at least 10°C.
– During high outside temperature, the areas in which the concrete is being poured
must be protected from direct sunlight.
– The number and the layout of the concrete openings must be selected such as
to ensure a rapid and controllable pouring of the concrete.
Page 4 / 13
Rev. A
LOESCHE mills
Work Instructions
5.3 Concrete pouring

Immediately before pouring the concrete, the work steps mentioned in Section 5.2
must be completed. During extended periods of concrete work, particularly in a hot
climate, sufficient wetting of the surfaces must be ensured. If necessary, the surface
must be watered afterwards. If possible, concrete pouring must proceed rapidly and
without interruption. The anchor holes may be poured in advance, regardless when
the general concrete pouring work occurs. Internal vibrators may be used to ensure
sufficient consolidation. Concrete pouring and consolidation processes must be
performed in a manner to ensure that all steel frame components are covered
completely by concrete. Pores and/or air bubbles are not permitted. During this
process, the bottle of the vibrator must not contact the foundation frame.
If procedural aspects prevent pouring of the concrete in a single work step, the
following requirements must be considered:
– If at all possible, the work must be continued during the same day, i.e. within 8
hours following the work interruption. Otherwise, the work should only be
continued after the third day or later.
– If the work is interrupted for more than 8 hours, post-treatment of the fresh
concrete according to Section 5.5 must be performed. Before continuation,
preparatory measures according to Section 5.2 must be repeated.
– Joints must be laid out to ensure a continuous bond between the concrete and
the foundation frame.
All concrete work must be documented. This report must contain the following
information:
– Calculated amount of concrete

– Amount of concrete poured and concrete composition
– Weather - rain, sunshine, wind
– Preparatory procedures
– Post-treatment of the concrete
– Number of work steps during the concrete pouring process.
5.4 Post-treatment of the concrete

In order to prevent drying of the fresh concrete just supplied to the site and to
ensure sufficient hardening, even in areas nearest the surface, post-treatment of the
concrete is mandatory. Until the freshly poured concrete is cured, it must be
protected to avoid:
– Premature drying
– Extreme temperatures
– Abrupt temperature changes
Mechanical impacts
– Chemical impacts
– Damaging vibrations
Page 5 / 13
Rev. A
LOESCHE mills
Work Instructions
The following precautions are to be considered:
– Leaving the formwork in place

– Covering the area with vapour-proof plastic foils
– Installing water-retaining covers
– During low temperatures, heat insulation in addition to the water-retaining covers
must be provided.
As a rule, under normal boundary conditions and 36 hours after pouring the
concrete, it must not be subjected to the above-mentioned loads. Appendix 3 lists
the post-treatment processes for concrete subject to surface/air temperature.
Appendix 4 shows the minimum duration of the post treatment. Appendix 5 lists the
drying behaviour of the concrete, subject to wind velocity, humidity, and concrete
temperature.
5.5 Summary
In order to achieve a concrete with very little shrinkage, all above-mentioned work
steps must be considered to be of equal importance. Only if all conditions were
applied successfully, a concrete that is almost free of any cracks is possible.
A water/cement ratio of 0.45 and a cement content of max. 300 kg/m³ guarantee a
final shrinkage value of approximately 0.27‰.
The procedures applied before pouring the concrete ensure that the curing
foundation does not remove moisture from the concrete thus, adversely affecting the
pouring and workability significantly. On one hand, water abstraction may force the
water/cement ration below 0.40, resulting in an insufficient amount of water that is
necessary for the curing process of the cement. On the other hand, it may not be
possible to provide a solid enclosure around the foundation frame.
Page 6 / 13
Rev. A
LOESCHE mills
Work Instructions
5.6 Applicable literature (the bulletins listed below are available in the German
language only)
1 Concrete calendar, Ernst & Sohn, 2001, Part 1
2 Bulletins of the German cement industry
– Bulletin B1: Cements and their production (1-2006)
– Bulletin B2: Aggregates for standard concrete (1-2012)
– Bulletin B3: Concrete additives (9-2005)
– Bulletin B7: Preparation and processing concrete (3-2011)
– Bulletin B8: Post-treatment of concrete (3-2011)
The diagrams and illustrations shown in the appendices were extracted from the
above-mentioned literature.
5.7 Appendices
Appendix 1 Grain composition curve; aggregates up to 8 mm
Appendix 2 Grain composition curve; aggregates up to 16 mm
Appendix 3 Post-treatment procedures
Appendix 4 Post-treatment duration
Appendix 5 Drying-out behaviour of concrete; depending on wind velocity,
humidity, and temperature of concrete.
Appendix 6 Hand-over documentation of concrete work
6 Amendment Service
The Customer Service department is responsible for amending these work
instructions. A responsible member of the Customer Service department checks and
approves the instructions. The Quality Management department publishes the work
instruction on the network.
Only the version saved on the network is valid; this is subject to the amendment
service. All printed copies are not subject to the amendment service and are
considered non-binding. They must not be used in the context of the performance of
quality-related activities.
7 Further applicable documents

– The appendices mentioned in Section 5.7 are part of these work instructions
– DIN 1045-2
– DIN EN 206-1
Page 7 / 13
Appendix 1 to "AA926674-00-4, Foundation frame castings for
Loesche mills“
6 %
8 10
9 11
Fig. 1: Grading curve for aggregate of 8 mm (from DIN 1045-2, pg. 57)
Key
1 Coarse aggregate 6 Per cent by volume 11 Square hole sieve
2 Rejected aggregate 7 Screening
3 coarse to medium size 8 Mesh size
aggregate
4 medium to fine size aggregate 9 Mesh sieves
5 fine size aggregate 10 Hole width
Page 8 / 13
Loesche mills“
6 %
8 10
9 11
Fig. 2: Grading curve for aggregate of 16 mm (from DIN 1045-2, pg. 57)
Key
1 Coarse aggregate 6 Per cent by volume 11 Square hole sieve
2 Rejected aggregate 7 Screening
3 coarse to medium size 8 Mesh size
aggregate
4 medium to fine size aggregate 9 Mesh sieves
5 fine size aggregate 10 Hole width
Page 9 / 13
Loesche mills“
Type Measures Surface/air temperature
Line
above
below to to to to
Cover or spray/
wet with layer of water
+ Sprinkle with water in addition:
-spray wooden shuttering
with water
Cover with water vapour-tight foil/spray with post-treatment agent
-protect steel shuttering

from direct sunlight
-cover unprotected
concrete surfaces of the
shuttering and spray
with water
Cover or spray with

a thin layer of water
if necessary, additional
measures as mentioned
in line 1
Cover or spray/wet with

a thin layer of water and
cover with heat insulation.
Using heat-insulating
shuttering (e.g. timber)
is recommended;
cover steel shuttering
with insulating sheets
+ Heat insulation
Cover and put down

heat insulation sheet1);
Provide enclosure of the
construction site (e.g., tent),
if necessary, use heaters
(e.g. radiant heaters).
In addition:
Maintain a concrete
temperature of ≥ +10°C
for at least 3 days.
Sprinkle/ Maintain a constant thin

flood layer of water on the
with concrete surface
water
Fig. 3: Post-treatment procedures (Cement bulletin B8, 3. 2011, pg. 3)

1)
do not wet; keep condensate and rain water away
2)
advisable in unfavourable conditions (e.g., strong winds) and concrete exposition
classes XM, XD, XF, XS
Page 10 / 13
Loesche mills“
Minimum duration of post-treatment [in days]
Surface Strength development of concrete
temperature
fast medium slow very slow
Fig. 4: Post-treatment duration (Cement bulletin B8, 3. 2011, pg. 4)

1)
Interim values may be switched on
2)
Instead of the concrete's surface temperature, the air temperature in the morning
may be set.
3)
Very slow curing concretes are not common in Germany.
Page 11 / 13
Loesche mills“
1
2
4
3
Fig. 5: Drying behaviour of the concrete, subject to wind velocity, humidity, and concrete temperature (Cement bulletin B8, 3. 2011,
pg.1)
Key
1 Relative air humidity 4 Wind velocity
2 Concrete temperature 5 Evaporated water volume
3 Air temperature
Page 12 / 13
Loesche mills“
Hand-over documentation of concrete work
Mill type LM _____

Location
Day of installation
Weather condition sun cloudy rainy rain strong wind
wind none moderate strong very strong
calculated volume of concrete m³ The volume of the steel frame must be subtracted from the
calculation.
volume of poured concrete m³
Concrete
Aggregate composition
Cement quality
Cement CEM/B III 32.5 - NW other type of cement
Volume kg/m³
Water
Volume kg/m³
Water/cement ratio
Add-ons Type and manufacturer
added amount ml/kg cement
Description of measures taken before pouring the concrete
Description of post-treatment
Duration of post-treatment ______days
contracting firm Date of hand-over __________
Signature of responsible construction site manager
Note
Concrete pouring works are not the responsibility of LOESCHE GmbH. With the signing of this document, the
contractor confirms the proper installation.
This hand-over documentation does not release the contracting firm from rendering proper warranty for all
work to be executed.
Page 13 / 13

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Foundation frame castings for No.

_ LOESEHE,T LOESCHE mills

Created: Checked and pproved:

All are of equal importance and are listed below

5.1 Concrete composition

CEM III Blast furnace cement

In order to achieve a dense structure, the grain distribution for 8 mm largest

reductions, introduction of air pores, and increased shrinkage. This must be

– after 3 days 30% to 40% of final compression strength

– after 3 days 10% to 20% of final compression strength

5.2 Concrete-pouring procedures

– Cleaning and roughing the concrete surface

5.3 Concrete pouring

– Calculated amount of concrete

5.4 Post-treatment of the concrete

The following precautions are to be considered:

– Leaving the formwork in place

7 Further applicable documents

-protect steel shuttering

Cover or spray with

Cover or spray/wet with

Cover and put down

Sprinkle/ Maintain a constant thin

Fig. 3: Post-treatment procedures (Cement bulletin B8, 3. 2011, pg. 3)

Fig. 4: Post-treatment duration (Cement bulletin B8, 3. 2011, pg. 4)

Hand-over documentation of concrete work

Mill type LM _____

Description of measures taken before pouring the concrete

Duration of post-treatment ______days

contracting firm Date of hand-over __________

Signature of responsible construction site manager

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