Concrete Construction

5/21/2018 Concrete Construction

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BLDG2101 Construction Science 1Foundations and Structures

Cast-in-Place Concrete


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BLDG2101Construction Science 1Foundations and Structures

Concrete Construction - Options

Cast off Site (Precast) Construct components prior to installation

Transport components to the project (if cast off site)

Assemble / Erect the concrete elements

Cast on Site (Site Cast) Labor, Material, & Equip. brought to the site, and

Concrete elements constructed in-place

Combination


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Types of Concrete Elements That Must

be Cast on Site

Caissons & Pile Caps

Footings (Spread& Strip)

Slab-on-Grade Slab Toppings

Elements too large or heavy to Transport

Irregular or Special Elements (typically)

Structures Requiring Full Structural

Continuity


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Concrete Frame Construction

Major Cost Components (Labor, Material, &Equipment)

Formwork, Reinforcing, Concrete


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Types of Concrete Elements

Slab-on-Grade

Columns

Walls

Floors & Roofs

Other (stairs, panels, etc.)


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Slab-on-Grade (SOG)

Level surface of concrete supported on the ground


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Slab-on-Grade (SOG)

Loading; Carries little or no structural stress except,

Transmission of superimposed loads

Thickness & Reinforcing determined by: Capacity & consistency of the soil

Loads imposed(People, cars, airplanes, equipment, etc.??)

Thickness; 75 mm to 450 mm +

Reinforcing Options; none, WWF, rebar


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Casting a SOG

Strip Topsoil

Cut/Fill/Compact Subsoil (Subgrade)

Install Underground Utilities (if reqd)


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Casting a SOG (cont.)

Installation of Crushed Stone

SOG inside of Buildings - typical

Sidewalks (rarely)

Paving (depends)

Primary Purpose:

Drainage

Structural Fill


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Install Formwork

Edge Forms

Construction Joints

Formed Control Joints

Expansion joints


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Expansion Joint


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Apply termite protection

Install moisture barrier


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BLDG2101 Construction Science 1Foundations and StructuresPlacing Termite Protection


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Install Reinforcing

Lightly loaded - Light gauge WWF

Heavily loaded - heavy gauge or

reinforcing

i f i ki f


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Reinforcing Purpose - Prevent cracking from

Shrinkage,

Temperature stresses

Concentrated loads,

Frost heaving

Ground Settlement

Slab-on-Grade with Vapor Barrier & WWF

(Note lapping of WWF)


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Place Concrete

Chute, Wheelbarrows & Buggies

Concrete Bucket, Conveyor Belt, Pump


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Placement with a Pump


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Laser-screedOften used for superflat floors


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Consolidate & Finish

Straightedge (Strike off)

Float Finish

Hard Trowel Finish

Broom Finish


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FinishingRotary Power Trowel

(Rider - Double Blade)

Finishing

Rotary Power Trowel(Walk behind)


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Application of Curing Compound


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Control Joint

(tooled)

Control Joint

(sawed)

Joints

Note the Broom Finish


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Casting a Concrete Wall

Footing (Wall Support)

Size determined by Engineer

Keyways

A grove-often formed by 2x lumber

Forms a mechanical connection

Waterstop (depends)

Reinforcing Dowels Structural connection

Transfers stresses to Foundation


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Footingexcavated and reinforced


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Waterstop, Keyway, & Wall Reinforcing Dowels


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Casting a Concrete WallFormwork Components

Form FacingMaterialSpans between Support System

Provides Surface/ Appearance

Can be faced w/ Liner

Form Support SystemIntermediate Supports (Studs)

Primary Supports (Walers)

Form TiesHold the 2 faces together

Bracing(Positions/Aligns Form)


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Support System Spanning Horizontal


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Materials Stick Built of Lumber & Plywood

Standardized prefabricated panels

Prefabricated steel, fiberglass

Insulated Concrete Forms

Choice Depends on:

Number of uses, Irregularity of wall Wall finish & tie spacing,

Availability & Cost


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Stick Built Formwork

Built in-Place

From Stock Matl

Panelized sections

Materials: (often)

Plywood2x Lumber

Light tie

Tie Spacing

Close - regular

Uses

Limited Reuses

Smaller projects

Irregular shapes


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Panelized Systems

Built in-Place with:

Panelized Sections

Multiple Sizes

Rent or Buy

Materials: (often)Higher Quality Facing Matl

Metal support system

Ties appropriate for the

system

Tie Spacing

Spaced @ or > Stick built

Uses

Multiple Reuses, Regular

shapes


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Panelized System with its Own TiresPanelized System


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Metal & Fiberglass

Often Built:

Specifically for a project

Examples:

Multi-level Shear Walls

Exposed /ArchitecturalMaterials: (often)

High Quality Facing Matl

Higher quality / strength Ties

Tie Spacing

Larger spacing

Uses

Multiple Reuses

Irregular or Regular shapes


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Gang Forms

Assemble formwork into large sectionsStick built, Panels, or any other system

Minimizes labor, increases equipment requirements,

Increases speed of construction

Generally used only for large, similar & repeated wallelements


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Gang Forms


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Gang Forms


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Insulating Concrete Forms


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Casting A Concrete Wall

Layout, Install one side, anchor, & brace

Coat w/ Form Release


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Wall Braced

Reinforcing Installed


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Reinforcing Installed


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BLDG2101 Construction Science 1Foundations and StructuresReinforcing Installed


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Install Form Ties Small diameter metal rods which hold the forms

together (generally remain in the wall)

Snap Tie


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Install Embedments (if required)

Install Bulkheads

Inspect

Erect second side

Plumb& Brace

Establish Pour Height


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Pour Wall (Place, consolidate,

smooth/level top of wall)

Cure (including after stripping)

Strip, break ties, point & patch if

required

R l i hi B


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Relationship BetweenFormwork Design and Concrete Placement Rate

Faster Pour Rate = Higher Stress on the Formwork

Facing material

Form support system

Form Ties Hydration Process starts:

Upon initial mixing of ingredients

Tall Walls

Poured in lifts Take advantage of set

Minimize form design loads

Liquid

Head


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Form

Buckled


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BLDG2101 Construction Science 1Foundations and StructuresFormwork Failure


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BLDG2101 Construction Science 1Foundations and StructuresFormwork Failure


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Casting a Concrete Column

Column Footing

Usually not a strip footing

Column footing, pile cap, or caisson


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Layout /Establish

Column Location

Fabricate &

Install Reinforcing


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Reinforcing for a Round Column


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Offset Reinforcing at the Top


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Install column form, plumb & brace

Place & Cure Concrete (similar to

wall)

Strip (& cure)


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Pouring a Concrete Column

(Workers Tied off)


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Column Forms

Material

Wood

Field fabricated or

Standardized panels

Steel

Plastic or Fiberglass

Waxed cardboard

Typically - Ties not required

(Column Clamps)


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Column Form Materials


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Panelized Formwork

Formed and Braced


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Formed and Braced


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SonotubeWaxed Cardboard

Column Form Material


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Stripped ColumnNote the spiral formwork markings


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Elevated Framing Systems

One-Way System

Spans across parallellines of support

furnished by wallsand/or beams

Two-Way SystemSpans supports running

in both directions


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One Way Elevated Framing Systems

One-Way Flat-Slab

Limited Depth

Limited Spans

Shorter Story

Heights

Underside oftenexposed


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One-Way Joist System

Span Greater Distances, Less Dead Load

Spaced ribs or joists w/ a thin top slab

Utilizes pans (metal, plastic, fiberglass)


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Wide-Module or Skip-Joist System

One-Way Slab & Beam


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One-Way Slab & Beam


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Two-Way Framing Systems

Often more economical than One-Way if:

Bay spacing (columns) square

Can be accomplished with a flat slab,

joists, beams, etc.

Often associated with higher loadings


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Two-Way Flat Slab

Flat slab w/ reinforcing beams

With, or w/o Capitals or drop panels

Drop Panel

Drop Panel w/

Capital

Flat

Plate


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Two-Way Waffle Slab


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Factors to Consider

Bay Spacing - Square or Irregular

Span Length

Loading

Ceiling Treatment

Lateral Stability


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BLDG2101

Construction Science 1Foundations and Structures

Elevated Slab Preparation

Prior to Formwork Construction

Prepare, submit, & approve EngineeredShop Drawings

FRPS supporting walls/columns


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Elevated Slab Sequence

Set Beam Bottoms (if required)

Erect Beam Sides

Form Slab


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Beam Formwork

Form Beam Bottoms & Sides


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Install Deck formwork

Install MPE sleeves, block outs, Cast in

electrical rough-in

Clean Deck &

Apply form release


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Elevated Slab Sequence (cont.)

Place Reinforcing

Beam reinforcing

Slab bottom &

Then top reinforcing

Elevated Slab Sequence (cont )


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Elevated Slab Sequence (cont.)

Place, Consolidate, & Finish

and Cure



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(cont.)

Allow Concrete to Achieve Stripping

Strength

Often 75% of design strength

Often use high-early cementTime of the

essence

Verify reqd strength prior to stripping

Test to destruction one or more test cylinders



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(cont.)

Strip Formwork & Re-shore

Re-shore(May Extend 3-4 FloorsBelow)

Re-shore Purpose -Support

Construction Load

Weight of the next Floor

El d Sl b S


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The following group of photos shows

the sequence for installation of a one-

way elevated slab.

(Slab & Beam with Reinforcing & Post-

Tensioning)

Columns Placed & Form Support (Scaffolding) Being Erected


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Form Support (Scaffolding) Being Erected


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Decking Support Beams Being Erected


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Plywood Decking Being Erected


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Plywood Decking and Beam Sides Being Erected


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Plywood Decking and Beam Sides Being Erected


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Plywood Decking & Beam Sides Erected


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Plywood Decking and Beam Sides Erected on a Portion


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Construction Science 1Foundations and StructuresDeck Support System (Scaffolding)

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Beam Reinforcing Installation


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Beam Reinforcing Installed


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Beam & Deck Reinforcing Installed


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Post-Tensioning Installation


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Post-Tensioning Installation


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Post-Tensioning Installed


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Post-Tensioning Complete and MPE Sleeves Installed


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Slab Poured & Cured

S i i & P Sh


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Stripping & Post Shores

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Stripping formwork


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Stripping formwork


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Formwork Stripped and Reshores Installed


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es Site Cast Post-tensioning


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Systems

Can be used with any framing system

Reduce member size and/or

Extend span capacity

es Innovations in Site Cast Concrete


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Innovations in Site Cast Concrete

Lightweight Concrete and Admixtures

Formwork Materials & Methods

Lift-Slab

Flying Formwork, Gang forms

Slip Forms

Tilt-Up

Shotcrete

es Lift-Slab


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Lift-Slab

Cast slabs on the ground (Stacked) &Jack into Place, and Anchored

es Lift-slab


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(Note the slab supports at the columns)

es

Flying Formwork


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Floor Tables stacked and

ready for installation

es

Flying Sequence

Jack to Remove the Table Table being slid out


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Jack to Remove the Table

Table placed on the next levelTable being flown to next level

Table being slid out

es Slip Forms


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Slip Forms

USES:

Tall, Repetitive, Walls

ShaftsStairwells

Silos

Ring of formwork steadily pulled upward by jacking offthe vertical reinforcing

es Tilt-Up


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Tilt Up

Walls cast Horizontally & Tilted into Place

Commonly used in Warehouse, Distribution, Retail

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The following group of photos shows the tilt-up

sequence used for construction of a Home Depot

es


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Slab-on-Grade Placed

es


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Formwork for Panels

es


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Edge form & reinforcing installedSlab-on-Grade Placed

ies


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Opening Installed

ies


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Panels formed and reinforced

ies


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Panels Formed and Reinforced

(Note the Inserts)

ies Weld Plate for Joist AttachmentInsert for Brace


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Inserts forPanel Braces,

Steel Framing Anchorage,

& Panel Lifting

Insert for Lifting Bracket

ies


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Panels Poured

ies


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Lifting Inserts Stripped

ies


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Placement of Exterior Footing

Panels

SOG

ies


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Crane for Panel Installation

iesBraces Installed Prior to tilting-up the panels


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Attachment of Lifting Bracket

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Panel being lifted (tilted into place)

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Panel being placed on shims set to proper elevation


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Panels being braced

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Panels braced

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Panel grouted between footing & panel

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Roof support structure anchored to panels

gies


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Subgrade prepared for panel structural connection to Slab-on-Grade

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Slab-on-Grade perimeter poured

to anchor the panel bottom.

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Panels erected

gies Architectural Concrete


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Concrete that is left exposed as finishedinterior or exterior surfaces.

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Exposed Architectural Concrete at the

University of Iowa

gies


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Exposed Architectural Concrete at the

University of Iowa

gies


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Exposed Architectural Concrete

(Note the rough finish )

ogies Architectural Concrete Finishes


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Exposed Aggregate

clean off paste

& expose aggregate

Key

Aggregate choice

Mix Placement

ogies


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Mechanically remove

the paste

Sand BlastBushhammer



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Liners & Form

materials

Multiple # of

Finishes

Form Liner &

Bush-hammer

ogies


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Architectural Concrete with Bushhammered Finish

ogies


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Architectural Concrete with Bushhammered Finish

ogies Simulated Stone Form Liner


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ogies Considerations / Challenges


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Rustication Location

Form Tie Location



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Formwork Joint

Formwork Blemishes

ogies

Considerations / Challenges


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Form Tie Holes

ogies Considerations/ Challenges


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Rusted Bar Supports



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Patching

ogies Designing Economically


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Of three elements - conc., reinf., formworkFormwork is generally the most expensive

element

Formwork - high % of labor

Economies - simplification &standardization

Identical bay spacing

Flat plate - when possible

Standardize column & beam sizes

ogies Site Cast Concrete & Building Codes


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Fire resistant

Assuming adequate re-steel coverage

Most uses - Unlimited Height & Area

Resistance to lateral loading

Rigid joints

ogies QuestionsDiscussions


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Documents

Concrete Construction