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
