Lecture 3, 4 &5
Lecture 3, 4 &5
COMPACTED CONCRETE
Lecture 3
Mass Concrete
• Mass concrete is defined by the American Concrete Institute as: “any volume of
concrete in which a combination of dimensions of the member being cast, the boundary
conditions, the characteristics of the concrete mixture, and the ambient conditions can
lead to undesirable thermal stresses, cracking, deleterious chemical reactions, or
reduction in the long-term strength as a result of elevated concrete temperature due to
heat from hydration.”
• Structural elements which require the use of large amounts of concrete:
Abutments
Shear walls
Tanks
Mat foundations
Large-diameter drilled shafts
Footings,
Transfer girders, and
Dams.
Mass Concrete
• The biggest concerns with mass concrete are the maximum temperatures
generated and the maximum temperature differentials.
Using internal pipes to cool the concrete itself after placement, and;
• Pours with a large volume: surface area ratio are more susceptible to thermal cracking!
• Research has been performed to produce more accurate dimensions for when temperature
rise should be considered.
• Cement Composition
• Cements used for Mass Concrete should have a low C3S and C3A content to reduce
excessive heat during hydration.
• Most Mass Concrete structure do not require early strength, so slower hydration is usually
not harmful to construction
Mass Concrete
Mass Concrete
• Materials
• As is the case with other concrete, mass concrete is composed of cement, aggregates,
and water, and frequently pozzolans and admixtures.
• The following types of hydraulic cement are suitable for use in mass concrete
construction:
ASTM C 150. Type II portland cement is suitable for mass concrete construction
because it has a moderate heat of hydration important to the control of cracking
Blended cement: Types P, IP, S, IS, I(PM), and I(SM) as covered by ASTM C 595.
Mass Concrete
• Chemical admixtures
• The chemical admixtures that are important to mass concrete are classified as follows:
(1) air-entraining;
(3) set-controlling.
• Accelerating admixtures are not used in mass concrete because high early strength is
not necessary in such work and because accelerators contribute to undesirable heat
development in the concrete mass.
Mass Concrete
Mass Concrete
Mass Concrete
• Coarse aggregate is defined as gravel, crushed gravel, or crushed rock, or a
mixture of these nominally larger than the No. 4 (4.75 mm) and smaller than the
6 in. (150 mm) sizes for large structures.
• This is best accomplished with large tilting mixers in stationary central plants.
• Specifications for mixing time range from a minimum of 1 min for the first
cubic yard plus 15 sec for each additional cubic yard (80 sec for first m3 plus
20 sec for each additional m3) of mixer capacity
Mass Concrete
Mass Concrete
Roller Compacted Concrete (RCC)
• What is RCC?
• RCC is concrete that has a consistency that allows it to be compacted with a
vibratory roller.
• Usually a 10-ton vibratory roller intended for compaction of asphalt and
granular base is used because of its high compactive energy with high
frequency and low-amplitude vibration.
• RCC is often mixed in a continuous
process rather than in batches.
RCC
• Freshly mixed uncompacted RCC generally looks like damp gravel that might be
used for a road base, although some mixtures that have a wetter consistency look
more like a conventional no-slump concrete.
• Not until the cement has reached a point near final setting or until the hydrated
interior is exposed does RCC have the visual appearance of normal concrete.
• Portland cement is normally the primary cementing medium, although fly ash or
natural pozzolan is often used for a major portion of the cementing
RCC
• RCC can use a broader range of materials than conventional concrete, and
derives its strength and durability from a mixture philosophy that relies on using
just enough paste volume to fill the aggregate voids and no more water content
than what is needed for
proper workability
RCC
• Advantages and Disadvantages
• The main advantages are reduced cost, time of construction, and lower spillway costs.
Rapid implementation
• Disadvantages
• RCC may not be appropriate when aggregate material is not reasonably available, the
foundation rock is of poor quality or not close to the surface, or where foundation conditions
can lead to excessive differential settlement
RCC
RCC
RCC
• Mixture proportioning considerations
• Is measured on a vibratory table with a Vebe apparatus in accordance with ASTM C1170.
• This test produces a Vebe time for the specific mixture and is used similar to the slump test
for conventional concrete.
• RCC mixtures with Vebe consistency of 10 to 45 s have a workability sufficient for ease of
compaction, uniform density from top to bottom of the lift, bonding with previously placed
lifts, and for support of compaction equipment.
RCC
• Segregation—A major goal in the proportioning of RCC mixtures is to produce a
cohesive mixture while minimizing the tendency to segregate during transporting,
placing, and spreading.
• Well-graded aggregates with a slightly higher fine aggregate content than conventional
concrete are essential.
• Permeability—Mixtures that have a paste plus fines volume of 18 to 22% by mass will
provide a suitable level of impermeability that is similar to conventional mass concrete
in the unjointed mass of the RCC.
• Others – Factors such as heat generation, durability and construction condition should
also be considered
• Mixture proportioning methods
• Roller-compacted concrete mixture proportions should follow the convention used in
traditional concrete— that is, identifying the mass of each ingredient contained in a
compacted unit volume (cubic yard) of the mixture based on saturated surface dry
(SSD) aggregate conditions.
Construction of prestressed
concrete
Lecture 4
Introduction
• Definition of Prestress:
• Prestress is defined as a method of applying pre-compression to control the
stresses resulting due to external loads below the neutral axis of the beam
tension developed due to external load which is more than the permissible
limits of the plain concrete.
• The pre-compression applied (may be axial or eccentric) will induce the
compressive stress below the neutral axis or as a whole of the beam c/s.
Resulting either no tension or compression.
• Basic Concept
• Prestressed concrete is basically concrete in which internal stresses of a
suitable magnitude and distribution are introduced so that the stresses
resulting from the external loads are counteracted to a desired degree.
Introduction
• Terminology
• Tendon:A stretched element used in a concrete member of structure to impart
prestress to the concrete.
Introduction
• Anchorage: A device generally used to enable the tendon to impart and
maintain prestress in concrete.
Introduction
• Pretensioning: A method of prestressing concrete in which the tendons are
tensioned before the concrete is placed.
• In this method, the concrete is introduced by bond between steel & concrete.
• Post-tensioning: A method of prestressing concrete by tensioning the
tendons against hardened concrete.
• In this method, the prestress is imparted to concrete by bearing.
Introduction
• Materials for prestress concrete members:
• Cement:
• The cement used should be any of the following
• Ordinary Portland cement conforming to IS269
• Portland slag cement conforming to IS455. But the slag content should not be
more than 50%.
• Rapid hardening Portland cement conforming to IS8041.
• High strength ordinary Portland cement conforming to IS8112.
Introduction
• Concrete:
• Prestress concrete requires concrete, which has a high compressive strength
reasonably early age with comparatively higher tensile strength than ordinary
concrete.
• The concrete for the members shall be air-entrained concrete composed of
Portland cement, fine and coarse aggregates, admixtures and water.
• The air-entraining feature may be obtained by the use of either air-entraining
Portland cement or an approved air-entraining admixture.
• The entrained air content shall be not less than 4 percent or more than 6 percent.
• Minimum cement content of 300 to 360 kg/m3 is prescribed for the durability
requirement.
• The water content should be as low as possible.
Introduction
• Steel
• High tensile steel , tendons , strands or cables
• The steel used in prestress shall be any one of the following:-
• Plain hard-drawn steel wire conforming to IS1785 (Part-I & Part-III)
• Cold drawn indented wire conforming to IS6003
• High tensile steel wire bar conforming to IS2090
• Uncoated stress relived strand conforming to IS6006 High strength steel
contains:
0.7 to 0.8% carbons,
0.6% manganese,
0.1% silica
Introduction
• Durability, Fire Resistance & Cover Requirements For P.S.C
Members:-
• According to IS: 1343-1980
• 20 mm cover for pretensioned members
• 30 mm or size of the cable which ever is bigger for post tensioned
members.
• If the prestress members are exposed to an aggressive environment, these
covers are increased by another 10 mm.
Introduction
• Necessity of high grade of concrete & steel:
• Higher the grade of concrete higher the bond strength which is vital in
pretensioned concrete, Also higher bearing strength which is vital in post-
tensioned concrete. Further creep & shrinkage losses are minimum with high-
grade concrete.
• Generally minimum M30 grade concrete is used for post-tensioned & M40 grade
concrete is used for pretensioned members.
• The losses in prestress members due to various reasons are generally in the range
of 250 N/mm2 to 400 N/mm2.
• If mild steel or deformed steel is used the residual stresses after losses is either
zero or negligible.
• Hence high tensile steel wires are used which varies from 1600 to 2000 N/mm2.
Introduction
• The key elements in prestressed concrete construction are:
• The production of concrete that has stable, predictable properties,,not only of
strength but also of creep, shrinkage, elastic modulus, and durability
• The forming (molding) of concrete into the design shape and within the
specified tolerances
• The incorporation of mild steel reinforcement, accurately placed and held during
concreting
• The placement of high-strength steel wires, strands, or bars to fit the design
profile and the stressing and anchoring and corrosion protection of such
elements
• Installation of the composite structural elements or assemblages described
above, in their final positions, whether they are cast in place or prefabricated
Post-Tensioning Technology
• With post-tensioning, the concrete sections are cast first with all conventional
passive reinforcement, then, after the concrete has gained sufficient strength,
tendons are placed, usually through holes formed by ducts.
• These tendons are stressed so as to react against the concrete and precompress it.
• The concrete must be free to shorten under the precompression.
• The tendons are then anchored, and corrosion protection, such as grout or grease,
is installed.
Post-Tensioning Technology
• Installation of Ducts and Anchorage
• Bearing Plates
• Installing and Stressing Tendons
• Duct, tendons, and anchorages for vertical
prestress of deep webs of long-span bridges
Post-Tensioning Technology
Cont.
Post-Tensioning Technology
• Scaffolding and Falsework for PostTensioned Cast-in-Place Construction
• A great many building and bridge structures are constructed on scaffolding and
falsework.
• After the castin-place concrete has gained strength, the structure is post-
tensioned.
• This prestressing redistributes the dead loads, typically raising the span off of the
central scaffolding and transferring it to the end supports.
Post-Tensioning Technology
• Corrosion Protection of Tendons
• The standard method of providing corrosion protection of tendons is by
injection of cement grout.
• If properly done, this encapsulates the strands and penetrates between the wires
of the strands.
• In the case of ducts no larger than two times the gross area of the tendon,
cement and water are the principal components of the grout.
• Sand or other fines are incorporated only in the rare cases of very large ducts.
Post-Tensioning Technology
Pre-tensioning Technology
• Pretensioning denotes the process by which tensioned high-strength steel wires
or strands are incorporated in a concrete segment.
• The process is relatively simple in concept, economical, and technically
efficient;however, it requires a major plant facility that is able to temporarily
restrain the forces in the tensioned tendons until the concrete cast around them
has gained sufficient strength to effectively bond the tendons and transfer their
force to the concrete.
• In its simplest form, the pretensioning facility consists of a casting slab or bed
on which the segments will be fabricated, reaction frames or stands at the end
to temporarily resist the tendon forces, hydraulic jacks for tensioning,
tarpaulins or hoods to cover the segments during curing, and lifting equipment
to remove the completed segments for storage and shipment.
Pre-tensioning Technology
Pre-tensioning Technology
• Forms
• The forms for concrete segments are typically made of steel.
• Because the forms are standardized members, they minimize the effort and time
required to set them in place and subsequently strip them.
• Concreting
• The concrete mix is designed to gain strength rapidly so the tendons may be
released, transferring their force into the concrete; the segment is then removed
to storage.
• The strength required for release is controlled by two factors:
• (1) adequate bond strength to limit the transfer length at the ends of the
member, and
• (2) adequate strength to minimize the creep under sustained stress.
Pre-tensioning Technology
Pre-tensioning Technology
• Curing
• To gain strength rapidly, accelerated curing is usually applied, which provides
heat and moisture.
• Most commonly, such curing will consist of low-pressure steam.
• Ideally, adequate strength will be gained in 8 to 12 hours, enabling a daily cycle
of production
• Release of Prestress
• After curing is complete, the tendons are released from the stands, transferring
force into the concrete.
• The concrete shortens under compressive stress.
• To ensure behavior as a prestressed concrete member, the shortening must not be
restrained.
Pre-tensioning Technology
• Tendon Profile
• The efficient design of many segments, such as slabs, beams, and girders,
requires that the profile of the tendons follow a path other than a straight line.
• This means that the strands must be deflected
Pre-stressed Concrete Buildings
• Buildings represent perhaps the largest overall use of prestressed concrete and
certainly the most diversified use of precast pretensioned concrete segments.
• Cast-in-place post-tensioned concrete has been widely used for floor slabs,
especially of lift-slab construction and for heavy beams and girders.
• Posttensioning permits the full integration of slabs, beams, and girders. Similar
monolithic construction is attained with precast pretensioned construction by
jointing and cast-in-place infill and topping.
Pre-stressed Concrete Buildings
• Pretension: The most widely employed pre concrete segment are the
double-tee and the hollow core slab
Pre-stressed Concrete Buildings
Pre-stressed Concrete Buildings
Pre-stressed Concrete Buildings
Pre-stressed Concrete Bridges
• Prestressed concrete has been quite successfully used in the field of bridges,
ranging from low- to medium span precast pretensioned bridges to post-
tensioned girder spans 250 m in length and, beyond that, to cable-stayed
concrete bridges 600 m long.
Pre-stressed Concrete Bridges
Pre-stressed Concrete Bridges
• When bridge girders are erected, they are initially vulnerable to tipping.
• Tipping may be caused by girders being set on a super elevation, by wind, or by
contact with a line from a second girder while it is being lifted.
• Long and deep I-beam girders should be braced as soon as they are set.
• Cast in-place decks are designed to act compositely with the precast girders.
• To ensure full transfer of horizontal and vertical shear across the joint, the top flange
of the precast girder is roughened and multiple stirrups are employed to tie the
girder and deck together.
• Transverse diaphragms are cast between the end blocks of the girders and sometimes
at intermediate locations
Pre-stressed Concrete Bridges
Pre-stressed Concrete Bridges
• Post-Tensioned Girders, Cast-in-Place on Falsework
• This is a widespread application of prestressed concrete.
• Falsework shoring is set up, is adequately supported on the ground (or on the
new foundations or on piling), and is capable of resisting the dead load of the
concrete with minimal deflection.
• For continuous structures, the concrete is usually cast in progression from the
center of the span to each end, so as to reach its deflected profile prior to
casting the concrete over the piers, thus preventing cracking in the negative
moment zone.
• As the cast-in-place sections are prepared, the ducts are placed to the required
profile and alignment.
Pre-stressed Concrete Bridges
• Post-Tensioned Precast Segmental Bridges
• The concept here is that short segments of the full crosssection of the bridge
are cast in a prefabrication site or casting yard.
• These segments are then transported to the site and erected on falsework.
• Because the segments are cast as relatively small, discrete units, it is possible
to obtain close tolerances for reinforcing and duct placement, as well as for
finished concrete dimensions.
Pre-stressed Concrete Bridges
Pre-stressed Concrete Bridges
• Cast-in-Place Cantilever Segmental Bridge
• Construction
• This process has been successfully employed on spans up to 200 m and more. With
cable-stayed concrete segmental bridges that employ the external tendon principle,
much longer spans—500 m and longer—have been attained.
• The casting is followed by prestressing the segments over the pier to resist the
negative moment in cantilever.
Lecture 5
“Ready mix concrete is concrete whose components are
proportioned away from the construction site for delivery to the
construction site by the truck in a ready-to-use-condition.”
RMC is a ready-to-use material, with predetermined mixture of
cement, sand, aggregates and water. RMC is a type of concrete
manufactured in a factory according to a set recipe or as per
specifications of the customer, at a entrally located batching plant.
It is delivered to a worksite, often in truck mixers capable of mixing
the ingredients of the concrete on route or just before delivery of the
batch.
This results in a precise mixture, allowing specialty concrete
mixtures to be developed and implemented on construction sites.
RMC is preferred to on-site concrete mixing because of the precision
of the mixture and reduced worksite confusion. It facilitates speedy
construction through programmed delivery at site and mechanized
operation with consequent economy.
It also decreases labour, site supervising cost and project
time, resulting in savings. Proper control and economy in use
of raw material results in saving of natural resources. It
assures consistent quality through accurate computerized
control of aggregates and water as per mix designs. It
minimizes cement wastage due to bulk handling and there is
no dust problem and therefore, pollution-free.
In 1909, the residents of Sneridan, Wyoming
1926.
Transit Mixer in late 1950’s
In 1931, a RMC plant was set up for the
SITE RESTRICTION
roads, and site access have to be able to carry the weight of the
truck and load.
A centralized concrete batching plant can serve a wide
securely in place.
Concrete should be deposited continuously as near as possible
Mechanical methods.
External vibrators.
Honeycomb: spaces between coarse aggregate particles do not
become filled with mortar .