Concrete Works
What is Concrete?
Concrete is a construction material composed of
cement (commonly Portland cement) as well as
other cementitious materials such as fly ash and
slag cement, aggregate (generally a coarse
aggregate such as gravel, limestone, or granite,
plus a fine aggregate such as sand), water, and
chemical admixtures. Concrete is strong in
COMPRESSION, as the aggregate efficiently carries
the compression load.
What is Concrete?
Concrete is strong in
COMPRESSION, as the aggregate efficiently carries
the compression load.
What is Concrete?
Concrete is an artificial conglomerate stone made essentially of
Portland cement, water, and aggregates. When first mixed the water
and cement constitute a paste which surrounds all the individual
pieces of aggregate to make a plastic mixture. A chemical reaction
called hydration takes place between the water and cement, and
concrete normally changes from a plastic to a solid state in about 2
hours. Thereafter the concrete continues to gain strength as it cures.
A typical strength-gain curve is shown in Figure 1. The industry has
adopted the 28-day strength as a reference point, and specifications
often refer to compression tests of cylinders of concrete which are
crushed 28 days after they are made. The resulting strength is given
the designation f'c
Curing
During the first week to 10 days of curing it is important
that the concrete not be permitted to freeze or dry out
because either of these, occurrences would be very
detrimental to the strength development of the concrete.
Theoretically, if kept in a moist environment, concrete
will gain strength forever, however, in practical terms,
about 90% of its strength is gained in the first 28 days.
Curing
Concrete has almost no tensile strength (usually measured to
be about 10 to 15% of its compressive strength), and for this
reason it is almost never used without some form of reinforcing.
Its compressive strength depends upon many factors, including
the quality and proportions of the ingredients and the curing
environment. The single most important indicator of strength is
the ratio of the water used compared to the amount of cement.
Basically, the lower this ratio is, the higher the final concrete
strength will be. (This concept was developed by Duff Abrams
of The Portland Cement Association in the early 1920s and is
in worldwide use today.) A minimum w/c ratio (water-to-cement
ratio) of about 0.3 by weight is necessary to ensure that the
water comes into contact with all cement particles (thus
assuring complete hydration). In practical terms, typical values
are in the 0.4 to 0.6 range in order to achieve a workable
consistency so that fresh concrete can be placed in the forms
and around closely spaced reinforcing bars.
What are the main components
of Concrete?
Cement. Portland cement is the most common
type of cement in general usage. It shall conform
to PNS 07, type 1. Cement for exposed concrete
surfaces shall be from the same mill.
Fine aggregates. Shall be clean, hard natural sand
or manufactured sand or a combination of both,
and conforming to PNS 18, type 1.
Coarse aggregates shall be hard, durable,
uncoated gravel, crushed gravel, or a
combination thereof conforming to PNS 18, type 2.
What are the main components
of Concrete?
Water. Mixing water for concrete shall be fresh,
clean and potable.
Chemical 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. In normal
use, admixture dosages are less than 5% by
mass of cement, and are added to the
concrete at the time of batching/mixing. The
most common types of admixtures are
accelerator, acrylic retarder, air entrainments,
plasticizers, pigments and corrosion inhibitors.
Working Agents
Workability agents, which include water-reducing agents and
plasticizers, serve to reduce the tendency of cement particles to
bind together in flocs and thus escape complete hydration. Fly
ash, a by-product of the burning of coal that has some
cementitious properties, is often used to accomplish a similar
purpose. Superplasticizers are relatively new admixtures which
when added to a mixture serve to increase the slump greatly,
making the mixture very soupy for a short time and enabling a
low-water-content or otherwise very stiff) concrete to be easily
placed. Superplasticizers are responsible for the recent
development of very high strength concretes, some in excess of
15,000 psi because they greatly reduce the need for excess water
for workability.
Retarders
Retarders are used to slow the set of concrete when large
masses must be placed and the concrete must remain plastic
for a long period of time to prevent the formation of "cold
joints" between one batch of concrete and the next batch.
Accelerators serve to increase the rate of strength gain and to
decrease the initial setting time. This can be beneficial when
concrete must be placed on a steep slope with a single form or
when it is desirable to reduce the time period in which
concrete must be protected from freezing. The best known
accelerator is calcium chloride, which acts to increase the heat
of hydration, thereby causing the concrete to set up faster.
Classes of Concrete
Concrete of the various classes, if not indicated in the
drawings and as specified under sections, shall be
proportioned and mixed for the following strengths:
STRENGTH REQUIREMENTS
Classes Specified Specified
compressive compressive
strength 28 days strength 28 days
(Psi) (mpa)
AA 4000 27.57
A 3000 20.68
B 2500 17.23
C 2000 13.78
P 600 4.136
Concrete Usage
Class AA concrete: For water tank, septic tank,
and other work as indicated.
Class A concrete: For precast concrete items, slabs,
beams, and walls above grade, columns, stairs, lintels,
and for all reinforced work not indicated or specified.
Class B concrete : For slab on grade, tie beams,
footings, and for such concrete work specified or
indicated.
Class C concrete :For all concrete not reinforced
except as otherwise indicated or specified.
Class P concrete : For slab on grade subject to
vehicular load and as indicated or specified.
Hot Weather Concreting
Concrete shall be produced at a temperature such that its
maximum temperature at discharge will not exceed the specified
maximum allowable concrete temperature. Acceptable
production methods to reduce the temperature of the concrete
includes: shading aggregate stockpiles, sprinkling water on coarse
aggregates stockpiles, using chilled water for concrete production,
substituting chipped or shaved iced for portions of the mixing
water, and cooling concrete materials using liquid nitrogen.
Once the approved design strength was obtained, every pouring
which will be scheduled should meet its design strength based on
the number of days specified. Accordingly, every transit mixer or
ready mixed concrete to be eventually delivered at project site
should have approved and consistent design strength.
Actual Trial Mix
Actual Weighing of Aggregates
Mixing of Concrete (Ready-Mixed)
Ready- mixed concrete shall conform to ASTM
C94 modified herein. It is defined as concrete
produced regularly by a commercial
establishment and delivered to the purchaser in
the plastic state. Ready-mixed concrete may be
used provided that the plant has sufficient
capacity and transportation equipment to deliver
the concrete at the rate desired and the plant
meets the requirements specified for equipment
and measurement of materials.
Mixing of Concrete (Ready-Mixed)
Ready mixed concrete shall be mixed and
delivered by means of truck mixers.
Proportioning, Measurement & Mixing
Slump shall be determined in conformance with
ASTM C 143, and shall be within the following limits,
provided the required strength is obtained.
Structural Element Minimum Slump Maximum Slump
Walls, column, 75 mm 100 mm
grade beams,
250mm max.
thickness
Other 50 mm 75 mm
construction
Slump Test
The concrete slump test is in essence a method of
quality control. For a particular mix, the slump should
be consistent. A change in slump height would
demonstrate an undesired change in the ratio of the
concrete ingredients; the proportions of the
ingredients are then adjusted to keep a concrete
batch consistent. This homogeneity improves the
quality and structural integrity of the cured concrete.
At least 3 layers of concrete are placed at the slump
cone with a minimum of 25 blows per layer.
Slump Cone
The slump cone is a mold in the
form of a truncated cone with
handles and foot pieces. The
size of the slump cone is 20 cm
dia. base, 10 cm dia. top and
30 cm height. Foot pieces can
be fixed to the clamps on the
base plate. The base plate has
lifting handle for easy
transportation. One graduated
steel tamping rod 16 mm dia. x
600 mm long rounded at one
20 end graduated in mm.
cm
Actual Slump Test
Placing of Concrete
No concrete shall be placed after there is evidence of
initial set. All concrete placing equipment and methods
shall be subject to approval of the Construction
Architect/Engineer. Concrete placement will not be
permitted when weather conditions prevent proper
placement and consolidation. Before placing concrete
on porous sub-grades, they shall be dampened as
directed by the Construction Architect/Engineer. Forms
shall be clean and free from dirt, construction debris and
water. Concrete shall be deposited in horizontal layers
approximately 31 to 51 cm deep in a manner to preclude
the formation of cold joints between successive layers.
Placing of Concrete
The method of depositing concrete shall be such as to avoid
displacing the reinforcement and segregating the aggregate.
Concrete shall be worked about the reinforcement and
embedded fixtures and avoid overworking which may result in
segregation. On the bottom of slabs, the girders where the
congestion of steel near the forms make placing difficult, a
layer of mortar equal to the approved slump shall be
deposited to cover the surface to a depth of approximately
25 mm before placing the concrete. Water which
accumulates on the surface of the concrete during placing
shall be removed by absorption with porous materials in a
manner that prevents removal of cement. Pumping of
concrete through aluminum pipe shall not be permitted.
How to Compute the Volume
Volume of concrete is usually obtained by
having its “Area” multiply by its height or
thickness. The volume occupied by the
reinforcing bars should be less which is
estimated to be 5% of the total volume.
V = (L x W) ( ht. or thk.)
less 5%
Pouring on Vertical Structures
Column, RC walls and other vertical structures
are usually poured at the standard height of
2.40m which is the typical length of a phenolic
plywood commonly use as forms for this type of
structure.
Standard Height for Column
Bonding of Concrete
In most condition wherein existing or previously
poured concrete must be connected to a new
concrete, a bonding agent or a concrete epoxy is
usually applied at their connection 25-30 minutes
prior to contact of concrete. Concrete epoxy to be
used should be approved by the Construction
Architect /Engineer.
Cleaning Prior to Pouring
Protection
Protection is usually being placed on areas along
the alignment of concrete pipes used during
placing of concrete. These may include plain G.I.
sheets, polyethylene sheet, plywood or any other
protective cover to avoid scattering of concrete
laitance at slab and thus, eliminating honeycomb.
Using Pumpcrete
Using Boom Type
Combination of
Line Pump & Boom Type
Concrete Placing
Vibration
All concrete, except for concrete slabs 100 mm or less in
depth, shall be compacted with high frequency, internal,
mechanical vibrating equipment supplemented by hand
spading and tamping. Concrete slabs 100 mm or less in
depth shall be consolidated by wood tamper, spading
and settling with a heavy leveling straight edge. Vibrator
shall be designated to operate with vibratory element
submerged in the concrete and shall have a frequency
of not less than 6000 impulses per minute when
submerged. The vibrating equipment shall be adequate
at all times. Vibration of forms and reinforcement shall not
be employed except when authorized specifically by the
Construction Architect/Engineer. Vibrators shall not be
used to transport the concrete in the forms. Vibration shall
be discontinued when the concrete has been
compacted thoroughly and ceased to decrease in
volume.
Vibration
A skilled vibrator operator/laborer should be
utilized to obtain consistency of works on concrete.
There is also other form of vibration commonly
used which is the manual vibration. Normally used
for this type is the rubber hammer or the rubber
mallet which is usually approved by the
Construction Architect or Engineer. The types of
structure used for this are column, RC wall and
other vertical structure.
Finishing
Leveling of concrete quickly follows upon
vibrating of concrete. Also, dowels intended for
masonry works are re-aligned and vertically
positioned to their exact location before the
concrete completely settles. In addition to this,
unnecessary concrete or laitance are quickly
removed before it hardens.
Concrete vibrator should always have at least a
spare during concrete placing.
Concrete Vibrator
Sampling
The strengths specified and the design mix shall be
verified during the progress of the work at intervals by
testing standard cylinders of samples taken at the job
site. Eight test cylinders shall be taken for each 50
cubic meter or fraction thereof of each class of
concrete placed, or as directed by the Construction
Architect/ Engineer. Four among the eight cylinders
were considered as spare which were commonly use
if the initial samples failed to meet the required
strength. These are also tested upon the request of
the Construction Architect/Engineer.
Also, with the request and approval of Construction
Architect/Engineer, “coring” on poured slab usually
takes place if the concrete does not meet its required
strength relative to its specified number of days.
Concrete Cylinders and Sampling
Curing of Concrete
Curing is the period of time from consolidation
to the point where the concrete reaches its
design strength. During this period, you must take
certain steps to keep the concrete moist and as near
73°F as practical. The properties of concrete, such as
freeze and thaw resistance, strength, water tightness,
wear resistance, and volume stability, cure or
improve with age as long as you maintain the
moisture and temperature conditions favorable to
continued hydration.
Curing of Concrete
The length of time that you must protect
concrete against moisture loss depends on the
type of cement used, mix proportions, required
strength, size and shape of the concrete
mass, weather, and future exposure conditions.
The period can vary from a few days to a
month or longer. For most structural use, the
curing period for cast-in-place concrete is usually
3 days to 2 weeks. This period depends
on such conditions as temperature,
cement type, mix proportions, and so forth.
Curing Period
When 7-day compression test cylinders,
representative of parts of a structure already
placed, indicate that the 28-day strengths may
be less than 90% of the design strengths, those
parts of the structure shall be given additional
curing, as directed by the Construction
Architect/Engineer.
Curing Material
Burlap, plain or polyethylene-coated burlap is the
most common material used for concrete curing.
It shall be of commercial quality. Burlap is placed
on concrete and continuously watered within
7 days.
Use of Burlap
Cleaning
Upon completion of the work, all concrete floors
shall be cleaned. After sweeping with an
ordinary broom to remove the loose dirt and
concrete, burlap or any other protective cover
should be placed.
SUMT4
SUMT4
NOVO
NOVO
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3. Concrete Epoxy Injection
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5. Carbon Fiber Sika
6. RC Columns Jacketing
7. Concrete inside the Mixer
