Advanced Construction Techniques: CM 510-Course Description

Advanced Construction Techniques
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Professor Kamran M. Nemati
Fall Quarter 2013 1
1
CM 510
Advanced
Construction
Techniques
Fall Quarter 2013
2
CM 510- Course Description
The course will introduce unique construction
methods involved with several types of
complex construction projects. The
construction process will be discussed as a
system to provide a background for examining
various types of projects including modern
concretes and infrastructure, high-rise
construction, deep foundations, dams and
bridges, tunneling and shotcretes, and other
complex construction issues.
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Fall Quarter 2013 2
3
CM 510- Text
P.K. Mehta and P.J .M. Monteiro Concrete :
Microstructure, Properties, and Materials, Third
Edition, MacGraw Hill, 2006 (reserved at both
Engineering and Architecture Libraries).
Handouts and other reference materials will be
distributed in class.
Class presentations and notes will be available
through the course web site at:
http://courses.washington.edu/cm510/
4
Faculty Office Hours:
Thursdays 5-6 PM or by appointment, 130J Architecture
Hall. Voice-mail: 685-4439, Email: nemati@uw.edu
Assignments:
There will be three homework assignments in this class.
All assignments are due at the beginning of the class on
the date due. 20% will be deducted for each day late.
Exams:
One midterm tests will be given on Thursday, November
14th.
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Term Project:
Each student will work on a term project that is
pre-approved by the instructor. The term
project should involve an analysis of an
innovative technique or the use of an innovative
building material in a construction project.
Students are required to submit a one-page
description of the project to the instructor by
October 10th. The project is due on Thursday,
December 5th at the beginning of the class.
Students are expected to work individually.
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Sample Projects in the Past
Floating bridge construction processes and
techniques
Construction process in Experience Music Project
Micro-tunneling
Mast climbing construction system
The use of robots in the construction industry
Mechanically stabilized earth retaining wall
Precast Seismic Structural Systems (PRESSS)
Mobile Bridges
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Grading:
Homework 20%
Midterm 25%
Term Project 25%
Term Project Presentation 20%
Class Participation 10%
Participation: Students are expected to maintain
an active role in class discussions. By completing
assignments on time and being prepared for class
you demonstrate your interest in the class.
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CM 510 - Lecture Topics
September 26 Introduction to Concrete as a
Construction Material
October 3 Alaskan Way Viaduct Replacement project;
Progress in Concrete Technology
October 10 Site Improvement and Deep Foundations;
Ground Freezing; Bridge Construction
October 17 Field Trip to Spokane Street Swing Bridge
October 24 Dams; Cofferdams; Construction
Dewatering; Shotcrete
October 31 High-rise Construction
November 7 Tunneling
November 14 Pavement Construction / Midterm
November 21 IDX Tower, Presentations
November 28 Thanksgiving Holiday
December 5 Presentations
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Fall Quarter 2013 5
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CM 510
HYDRAULIC CEMENTS
AND THEIR PROPERTIES
10
Definitions
Cement Powder
Cement + Water Cement Paste
Cement Paste + Fine Aggregate (FA) Mortar
Mortar + Coarse Aggregate (CA) Concrete
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Concrete is initially plastic, allows
one to mold into desired shape.
Chemical reaction (hydration) and
paste set of concrete - producing
strength and stiffness.
Definitions
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Cement
Cement is a pulverized material that
develops binding forces due to a reaction
with water
Hydraulic Cement Stable under water
Nonhydraulic Cement
Products of
hydration are not resistant to water (i.e.
limestone)
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Cements that harden by reaction with
water and form a water-resistant product.
Portland Cement (P.C.)
Portland cement is a hydraulic cement
capable of setting, hardening and
remains stable under water. It is
composed of calcium silicates and some
amount of gypsum.
Hydraulic Cements
14
Cement Chemistry
Short Hand Notation
C (CaO, calcium oxide)
A(Al
2
O
3
, alumina)
S (SiO
2
, silica)
S (SO
3
, sulfate)
H(H
2
0, water)
Reactive Compounds
C
3
S (tricalcium silicate)
C
2
S (dicalcium silicate)
C
3
A(tricalcium aluminate)
CSH
2
(gypsm)
C
4
AF (tetra-calcium
alumino ferrite)
In cement chemistry, the individual oxides and clinker
compounds are expressed by their abbreviations
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C
3
S 3CaO . SiO
2
C
2
S 2CaO . SiO
2
C
3
A 3CaO . Al
2
O
3
C
4
AF 4CaO.Al
2
O
3
.Fe
2
O
3
C
4
A
3
S 4CaO.3Al
2
O
3
.SO
3
=
=
=
=
ferrite aluminate m Tetracaciu AF C
aluminate Tricalcium A C
Silicate Dicalcium S C
Silicate Tricalcium S C
4
3
2
3
Compounds of Portland Cement
16
Hydration Reactions
2C
3
S + 6H => C-S-H + 3CH (120 cal/g)
2C
2
S + 4H => C-S-H + CH (62 cal/g)
C
3
A + 3CSH
2
+26H => C
6
AS
3
H
32
(300 cal/g)
2C
3
A + C
6
AS
3
H
32
+ 4H => 3C
4
ASH
12
C
4
AF + 10H + 2CH => C
6
AFH
12
C
3
S
2
H
3
(C-S-H gel)
CH (calcium hydroxide)
C
6
AS
3
H
32
(ettringite)
C
4
ASH
12
(monosulfate)
Cement Chemistry
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Hydration of Portland Cement
Cal/g 120 3CH H S C 6H S 2C
3
+ + +
Cal/g 2 6 CH H S C 4H S 2C
2
+ + +
e) (Ettringit H S A C H S C AF, C A, C
4 3

Compound Composition Morphology Amount (% Vol.)
C-S-H
Variable
C/S ~ 1.5 to 2
Poorly crystalline
High surface area: higher
bonding energy
50 60%
CH
Ca(OH)
2
Large hexagonal crystals,
low surface area, and poor
bonding energy
20 25%
C-A-S-H
C
6
AS
3
H
32
Ettringite
C
4
ASH
12-18
Monosulfate
Long, well crystallized
needles
Hexagonal small
crystals
15 20%
Hydration: Reaction with water
18
Calcium silicates are the primary constituents
of portland cement.
Raw material for P.C. Calcium Silica
Calcium: Limestone, chalk, etc (CaO+CO
2
)
Silica: Clays and shales (SiO
2
+Al
2
O
3
+Fe
2
O
3
+H
2
O)
Clay 1/3
Calcium 2/3
ment heat treat

the before d homogenize
well be should mix Raw
Manufacturing Process
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Aerial Photo of a Cement Manufacturing Plant
(Colorado)
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Raw Mill Feed
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Kiln Line Overview
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T =1400C
Raw
(Limestone
+Clay)
Clinker+Gypsum
Grind
Portland Cement
Grind Mill
( )
( )
( )
( ) AF C
A C
S C
S C
O .Fe O 4CaO.Al
O 3CaO.Al
2CaO.SiO
3CaO.SiO
O H O Fe O Al SiO Clay
CO CaO Limestone
4
3
2
3
3 2 3 2
3 2
2
2
2 3 2 3 2 2
2
)
`
+ + +
+
Rotary Kiln
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Reactivity of cement with water
is a function of its fineness.
Generally, the finer a cement,
the more rapidly it will react, and
the strength development will be
enhanced (expensive).
Fineness
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Types of Portland Cement
ASTM C 150, Standard Specifications for
Portland Cement
Type I : General purpose. For use when the special
properties specified for any other types are not required.
Type I I : For general use, more specially when moderate
sulfate resistance or moderate heat of hydration is desired.
Type I I I: For use when high early strength is desired.
(limit the C
3
A content of the cement to maximum 15%)
Type I V: For use when low heat of hydration is desired.
Type V: For use when high sulfate resistance is desired.
(Maximum limit of 5% on C
3
A)
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In classic research from over fifty years ago
Bouge and Lerch* found that of the four
portland cement phases only C
3
S and C
2
S
developed appreciable compressive strength
when pure samples of each were hydrated.
The compressive strength found by Bogue and
Lerch** are plotted in the next Fig. as a
function of age. Compressive strengths of C
3
A
and C
4
AF, hydrated alone A and have not
been plotted explicitly.
Effects of Chemical Composition of
Portland Cements of Strength
* T.C. Powers, The Non-Evaporable Water Content of Portland Cement Paste: Its Significance for
Concrete Research and Its Method of Determination, ASTM Bul., No. 158, (May 1949) pp. 68-76.
** R H Bouge and W Lerch Industrial Engineering, Chem. 26 873 (1934)
The compressive strength found by Bouge and Lerch** for hydrated samples of the
pure cement phases C
3
S and C
2
S are plotted as a function of age. The compressive
strengths of C
3
A and C
4
AF, hydrated along and with gypsum, fall within the cross-
hatched region labeled A and have not been plotted explicitly. The time scale is
linear. The time scale is logarithmic, which has the effect of expanding the early
ages, and this shows the differences between strength gain of C
3
S and C
2
S pastes.
Effects of Chemical Composition of
Portland Cements of Strength
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The Structure of Concrete
The type, amount, size, shape & distribution of
phases present in a solid material constitute its
structure.
Concrete Consists of aggregates, paste and voids.
The macrostructure of concrete is shown below:
A polished section
of concrete
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The structure of the aggregates in
concrete is important but it can be
characterized as a macrostructure
which is visible to the human eye.
The limit of resolution of the
unaided human eye is approximately
1/5 millimeter which is 200 microns.
The Microstructure of
Portland Cement Concrete
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The use of both light and electron
microscopes allows the study of the
microstructure of concrete at the
submicron level.
The microstructure of concrete can
be divided into regions:
Cement Paste
Transition Zone between Aggregate
and Cement paste
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Structure of un-damaged Concrete
Macrostructure
Aggregates (CA, FA)
Hydrated cement paste (hcp)
Entrapped air voids
Microstructure
Hydrated cement paste
(Hydration products:C-S-H, ettriginite;
monosulfate; porosity: gel, capillary pores
entrained/ entrapped air voids)
Transition zone (TZ)
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Microstructure of Concrete
(Hydration products)
CH
C-S-H
32
Ettringite
(Hydration products)
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Characteristics of the TZ
Large crystals of Ettringite and
CH with preferred orientation
Porous Structure
(Transition Zone)
34
One way to view cement paste is to consider
the hydration of one grain of cement.
The partial hydration of one grain of cement
is schematically represented in the next
slide.
There are many details in this process that
are not yet understood, but there is
sufficient information available to allow a
consistent mental picture to be considered.
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The hydration products
formed inside and outside
the cement grain are
schematically represented.
The multiple nature of the
cement grain is neglected
and assumed to be a single
phase that shows two types
of products.
P1 refers to the primary
portlandite which appears
early in the originally water-
filled space.
36
The hydration of a number of cement grains
is schematically represented in the next slide
at different degrees of hydration.
The fresh paste (i.e., the initial combination
of water and cement grains) is drawn to
approximately represent the 0.4
water/cement ratio, and thus there are not
enough hydration products to fill the
originally-water-filled space and a capillary
porosity remains in the final microstructure.
Portland Cement Paste
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A schematic representation of the hydration of a number of cement grains. The multiphase
nature the cement grains has been neglected as this is like the hydration of tricalcium silicate
alone. (a) Fresh paste of water-to cement ration of 0.4 is shown cement grains in the
originally water-filled space. (b) After 33% hydration, the cement grains now have inner
hydration regions and outer products which form a columnar zone around each grain. (c)
After 67% hydration, the un-hydrated cores are clearly surrounded by thick rims of inner
hydration products and the columnar zone of outer products is growing on the surface of
each grain. The primary portlandite, P1, is shown with the dendrite morphology. (d) At
100% hydration, the un-hydrated cement has been consumed but the shape of the original
cement grains can be distinguished if the inner product differs from the columnar zone of
outer products. The intergrowth of the columnar zones from two different grains is shown
at several points, but this would be larger at low water/cement rations.
Originally water-filled space =clear, unhydrated cement = , inner hydration products = ,
outer hydration products = , & primary portlandite =P1.
///
Portland Cement Paste
38
The originally-water-filled space within the
cement paste becomes the capillary pores which
act as stress concentrations and reduce the
strength significantly.
The strength of most engineering materials is
increased with a decrease in porosity, and by
controlling the water/ cement ratio the engineer
is assured that the basic porosity of the paste is
also controlled. That is not to say the other
sources of porosity will not occur, but at least
the cement paste will have a given porosity.
Capillary Porosity
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Figure below shows a graphical representation of the
relative volumes of hydration products during hydration.
Graphical representation of the relative volumes of hydration products
during hydration. The initial w/c is 0.5, and one unit of cement is shown to
produce two volumes of hydration products.
Capillary Porosity
40
If cement paste specimens are
prepared with a range of w/c ratios
it is apparent that the density of
high w/c samples is much lower
than low w/c samples.
This is illustrated in the next slide in
a presentation originally given by
T.C. Powers*.
*T.C. Powers, The Non-Evaporaable Water Content of Portland Cement Paste: Its Significance for
Concrete Research and Its Method of Determination, ASTM Bul., No. 158, (May 1949) pp. 68-76.
Capillary Porosity Over a Range of
W/ C Ratios
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Composition of Cement Paste at different stages of hydration. The
percentage indicated applied only to paste with enough water-filled space
to accommodate the products at the degree of hydration indicated.
Capillary Porosity Over a Range of
W/ C Ratios
Advance Construction Techniques
CM 510 CM 510
42
Admi x t ur es
i n Conc r et e
Lec t ur e 1
Concrete Technology Advanced Construction Techniques CM 510 CM 510
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ADMIXTURES
A material other than water,
aggregates, and hydraulic cements used
as an ingredient of concrete or mortar
and added to the batch immediately
before or during mixing.
Reason:
Improve or modify some or several
properties of portland cement concrete.
Compensate for some deficiencies.
44
A. Chemical Admixtures
Type A: Water-reducing (WR)
Type B: Set retarding (SR)
Type C: Set accelerating (SA)
Type D: WR + SR
Type E: WR + SA
Type F: High-range water-reducing (HRWR)
Type G: HRWR + SR
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B. Mineral Admixtures
Class N: Raw or calcined pozzolans
Class F: Fly ash produced from burning
bituminous coal
Class C: Fly ash normally produced from
burning lignite (subbituminous) coal.
(both pozzolanic and cementatious)
46
1) Admixtures for Durability
Frost action: Air-entraining agents
Sulfate and acidic solutions:
Pozzolans, polymer emulsions
Alkali-aggregate expansion: Pozzolans
Thermal Strains: Pozzolans
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2) Admixtures for Increasing Strength
Water reducing agents
Pozzolans
{
Consistency: Flowability, slump
Workability: High cohesiveness and high consistency
(Advantage of fine particle size Cohesiveness)
To reduce the water content while
maintaining a given consistency
}
48
Chemical Admixtures
Surfactants (Surface-Active Chemicals/ Agents)
Air-entraining surfactants:
At the air-water interface the polar groups are oriented towards the
water phase lowering the surface tension, promoting bubble formation
and counteracting the tendency for the dispersed bubbles to coalesce.
At the solid-water interface where directive forces exist at the cement
surface, the polar groups become bound to the solid with the non-polar
groups oriented towards the water, making the cement surface
hydrophilic so that air can displace water and remain attached to the
solid particles as bubbles.
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Chemical Admixtures
Air-entraining surfactants:
50
Air-Entrained Concrete
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Mechanism of Frost damage in concrete
Only concrete that is
above the critical
saturation is vulnerable
to frost damage.
Critical saturation occurs
when more than 91.7%
of pores in concrete is
filled with water.
Water Expands 9% on
freezing.
52
Mechanism of Frost damage in concrete
If 91.7% of the pores in
concrete are filled with
water prior to freezing,
then all of the pores will be
completely filled upon
freezing.
Water is forced ahead of
the advancing freezing
front.
Internal hydrostatic
pressure can disrupt the
concrete.
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Freeze-Thaw Deterioration
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Mechanism of Protection by AE
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56
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Air Content Specifications
ACI 318 Building Code
ASTM C 94 Specs for Ready-Mixed Concrete
58
Chemical Admixtures
When water is added to cement, a well-dispersed system is not achieved,
because:
The water has high surface tension.
Cement particles tend to cluster together or form flocs.
When a surfactant with a hydrophilic chain is added to the cement-
water system, the polar chain is adsorbed alongside the cement
particle, and thus lowering the surface tension of the water, and
making the cement surface hydrophilic.
Water-Reducing surfactants:
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Chemical Admixtures
Water-Reducing surfactants:
60
Mineral Admixtures
Definition: Mineral Admixtures are
insoluble siliceous materials, used at
relatively large amounts (15-20% by
weight of cement).
Fine particle size, siliceous material
that can slowly react with CH at
normal temperatures, to form
cementitious products.
Aq
Normal Temp.
CH CSH + S
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Mineral Admixtures
Low heat of hydration
Transform large pores to fine pores
Historically, mineral admixtures are
volcanic ashes.
Significance: Durability to thermal
cracking, chemical attack, sulfate
attack, workability.
62
By-Product Mineral Admixtures
Fly Ash (FA) 1-40m Particle Size; Surface Area=0.5 m
2
/g
Blast Furnace Slag (BFS) 1-40m; SA=0.5 m
2
/g
Condensed Silica Fume (SF) 0.1m; SA=20 m
2
/g
Rice Husk Ash (RHA) 10-20m; SA=60 m
2
/g
Internal bleeding is reduced Reduced Microcracking
Effect of Pozzolans:
It will reduce the available space for formation of large crystals
Pozzolans will convert CH into C-S-H
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The Slump Test
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The Slump Test
Consistency of concrete is generally measured by
the slump test (ASTM C143). This test is
performed by measuring the slump (subsidence), in
inches, of concrete after removal of the truncated
cone mold in which the freshly mixed concrete was
placed. Details of the test procedure and the
dimensions of the cone and tamping rod are given
in ASTM C143, and summarized in this figure:

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