Concrete Technology Manual

CTM Manual (PDF) Open with Google Chrome

Table of Contents

• Preface
• Chapter 1 Structure Concrete Characteristics
• Structure Concrete Characteristics
• Workability and Consistency
  • Consolidation
  • Bleed Water
• The Hardening Process
  • Initial Set
  • False Set
  • Final Set
  • Heat of Hydration 
• Strength Development
  • Compressive Strength
• Effect of Water-Cement Ratio on Concrete Strength
  • Curing
  • Strength of Concrete in Existing Structures
• Volume Changes and Deformations
  • Creep
  • Dry Shrinkage
  • Shrinkage and Swelling Due to Moisture Change
  • Thermal Expansion and Contraction
• Durability
  • Carbonation
  • Sulfates
  • Chlorides
  • Resistance to Freezing and Thawing
  • Alkali Aggregate Reaction
  • Delayed Ettringite Formation
  • Abrasion
• References
• Chapter 2 Concrete Construction Materials
• Concrete Construction Materials
• Cementitious Materials
  • Portland Cement
  • Portland Cement Types
  • Blended Portland Cements
  • Portland Cement Manufacturing Process
  • Particle Size and Appearance
  • Specific Gravity
  • Hot Cement
  • Supplementary Cementitious Materials
  • Fly Ash
  • Metakaolin
  • Ground Granulated Blast Furnace Slag
  • Silica Fume
  • Rice Hull Ash
  • Specialty Cementitious Materials
  • Type I, Type II or Type III (White) Portland Cement
  • Magnesium Phosphate Cements 
  • Calcium Aluminate Cements
  • Aggregate
  • Contamination
  • Moisture
  • Shape and Texture
  • Gradation
  • Alkali-Silica Reactivity
  • Water
  • Concrete Admixtures
  • Type AE, Air-Entraining Admixtures
  • Air-Entrainment Advantages
  • Air-Entrainment Disadvantages
  • The Air-Entrainment Process
  • Dosage
  • Water Content
  • Aggregate
  • Other Admixtures
  • Mixing
  • Concrete Temperature
  • Vibration
  • Type A – Water Reducing Admixtures
  • Type B – Retarding and Type D – Water Reducing and Retarding Admixtures
  • Type C – Accelerating and Type E – Water Reducing and Accelerating Admixtures
  • Type F – High Range Water Reducers and Type G – High-Range Water Reducer and Set Retarder
  • Type S – Specific Performance Admixtures
• Chapter 3 Review of Concrete Mix Designs
• Introduction
• Design of Concrete Mixes
• Definitions
• Supplementary Cementitious Materials
• Aggregate
• Grading Limits
• Maximum Density and Balanced Grading
  • General Information
• Workability and Gradation
• Particle Shape and Surface Texture
• Water
  • Admixtures
• Mix Design Procedure (Absolute Volume Method)
• Review of Concrete Mix Designs
  • Initial Submittal Review
• Checking Submitted Cementitious Material Requirements and Proportioning
• Checking Submitted Aggregate Gradations
• Checking Amount of Water and Penetration 
• Checking Submitted Chemical or Air-Entraining Admixtures
• Minor Concrete Binary Mix
• References
• Chapter 4 Proportioning, Mixing and Transporting
• Introduction
• Proportioning
  • Aggregate Storage and Handling
  • Cementitious Material Storage and Handling
  • Weighing and Measuring Equipment
  • Manual and Automatic Batching
  • Moisture Meters
  • Chemical Admixtures
  • Controlling Batch Temperature
  • Cooling Concrete
  • Heating Concrete
• Mixing and Transportation
  • Ready-Mixed Concrete
  • Central-Mixed Concrete
  • Transit-Mixed Concrete
  • Inspection of Mixing Equipment
  • Transporting Mixed Concrete
  • Time or Amount of Mixing
  • On-Site Mixing
• References
• Chapter 5 Concrete Construction
• Concrete Construction
• Quality Assurance: Pre-Construction Review
  • Specifications
  • Standard Plans
  • Other Reference Documents
  • Technical Resources
  • Specific Pre-Construction Practices
  • Bridge Construction Surveying
• Concrete Forms
  • Specifications
  • Forming System
  • Form Fasteners
  • Form Liners
  • Miscellaneous Form Types
  • Steel Forms
  • Fiber Form Tubes
  • Metal Decking
  • Pre-Fabricated Forms
  • Form Workmanship.
  • Structural Adequacy of Formwork
  • Formwork Design
  • Formwork Design Review
  • Deflection
  • Lateral Loading
  • Unit Weight of Concrete
  • Rate of Placement 
  • Other Factors
  • Admixtures
  • Lateral Pressure Values (ACI 347-04)
  • Form Release Agent
  • Formwork Removal
• Concrete Placement
  • Prior to Placing Concrete
  • Concrete Delivery
  • Quality Assurance
  • Forms
  • Mix Consistency and Uniformity
  • Concrete Tickets
  • Concrete Placement Time
  • Transit Mixer Drum Revolution
  • Concrete Temperature
  • Certificates of Compliance
  • Weight Limits
  • Adding Water to Concrete
  • Delivery Rate
  • Conveyance of Concrete
  • Chutes
  • Concrete Buckets
  • Drop Chutes
  • Belt Conveyors
  • Concrete Pumps
  • Slick Line
  • Placing Concrete
  • Depositing Concrete
  • Segregation
  • Prevention of Concrete Defects
  • Protecting Concrete
• Consolidating Concrete
  • Vibrating Concrete
  • Internal Vibrators
  • External Vibrators
  • Consequences of Improper Vibration
  • Revibration
• Finishing Plastic Concrete
  • Bleed Water
  • Strike Off
  • Initial Finishing
  • Machine Finishing: Bridge Deck
  • Other Concrete Finishing Equipment
  • Finishing Air-Entrained Concrete
• Curing Concrete
  • Plastic Shrinkage Cracking
  • Specified Concrete Curing Methods
  • Water Method
  • Plastic Sheets
  • Burlene®
  • Forms-In-Place Method
  • Curing Compound Method
  • Fogging
  • Application
  • Quality Assurance
  • Safety
  • Waterproof Membrane Method
  • Curing Structures
  • Curing Minor Structures
• Surface Finishes
  • Specified Concrete Finishes
  • Ordinary Surface Finish
  • Patching Snap-Tie Holes
  • Repair of Rock Pockets
  • Class 1 Surface Finish
  • Whip Blasting
  • Engineer’s Roles and Responsibilities
  • Unacceptable Class 1 Finishes
  • Class 2 Surface Finish
  • Safety and Environment
  • Working Over Water and Environmentally Sensitive Areas
  • Working Over Traffic
• Special Concrete Construction Practices
  • Specification Requirements
  • Hot Weather Construction
  • Control of Concrete Temperature
  • Mixing and Delivery
  • Placing and Finishing
  • Curing
  • Use Of Admixtures
  • Cold Weather Construction
  • Mixing And Delivery
  • Placing and Finishing
  • Curing
  • Measuring Concrete Temperatures
  • Placing Concrete Under Water
  • Seal Course Concrete
  • Concrete Placement
  • Water and Slurry Displacement Method
• Bridge Construction Practices
  • Foundations
  • Concrete Piles
  • Footings
  • Columns and Walls
  • Bent Caps
  • Superstructure
  • Stem and Soffit-Box Girder
  • Stem/Deck Construction Joint
  • Bridge Decks
  • Barrier Rails
  • Emergency Construction Joints
  • Weight Limits
• Chapter 6 Structure Concrete Repair and Rehabilitation
• Structure Concrete Repair and Rehabilitation
• Concrete Repair Process
  • Assess the Defect and Determine the Cause
  • Surface Imperfections
  • Cracking
  • Scaling
  • Spalling
  • Delamination
  • Surface Wear
  • Determine Limits of Defective Concrete
  • Determine If Repairs are Necessary
  • Choose the Repair Strategy
  • Cementitious Materials
  • Polymeric Materials
  • Thermoplastic/Thermoset
  • High-Molecular-Weight
  • Free Radical Polymerization
  • Key Variables 
  • Methacrylate
  • Polyester Concrete
  • Urethane
  • Epoxy
  • Epoxy Mortar
  • Remove Defective Concrete
  • Place Repair Materials
  • Cure The Repair
• Repairing Minor Construction Defects
  • Dry-Packing
  • Conventional Concrete Patching
  • Shotcrete
  • Commercial Patching Materials
  • Epoxy Mortar Patches
  • Repair Testing
• Large Defect Repair - Concrete Replacement
  • Preparation
  • Placing
• Repairing Defects In New Bridge Decks
  • Filling Shallow Voids
  • Filling Deep Voids
  • Bonding Agents
  • Small Area Repair (< Two Inches Deep)
  • Large Area Repair (> Two Inches Deep)
  • Filling Cracks by Epoxy Injection
• Bridge Deck Rehabilitation
  • Surface Preparation
  • Low-Slump Portland Concrete Overlays
  • Latex-Modified Concrete Overlays
  • Conventional Portland Cement Concrete Overlays
  • Methacrylate Overlays
  • Polyester Concrete Overlays
• Chapter 7 Caltrans Advancements/High Performance Concrete
• Introduction
• High Performance Concrete
  • High Early Strength
  • High Strength Concrete
  • Self-Consolidating Concrete
  • Mass Concrete
  • The Basics of Mass Concrete
  • Thermal Control Measures
  • Identifying Mass Concrete
  • Passive Control by Prescriptive Specifications, Caltrans Practice Prior to the 21st Century
  • Performance Based Requirements
  • The Use of Active Thermal Control by Caltrans
  • Noyo River Bridge
  • San Francisco-Oakland Bay Bridge East Spans
  • Benicia-Martinez Bridge Substructure and Foundation
  • Cast-in-Place Segmental Bridge Construction
  • Lightweight Concrete Segments and Mass Concrete in Elements with Dimensions as Small as 10 inches
  • Devil’s Slide / Confusion Hill: A Laconic Approach to Mass Concrete Specifications
  • Acceptance of Active Controls And Return to Passive Control
  • Back to Prescriptive Passive Control Specifications & Mass Concrete for Concrete Piles
  • Mass Concrete Conclusions
  • Lightweight Concrete
  • Shrinkage Compensating Concrete
  • Durability
  • Fiber Reinforced Concrete
  • Reactive Powder Concrete
• Chapter 8 Material Sampling and Testing
• Introduction
• Test Types
  • Initial Samples And Tests
  • Acceptance Tests
  • Independent Assurance Tests
  • FHWA Samples And Tests
  • Test Frequency
• Sample Identification
• Acceptance Testing and Sampling
  • Certification of Project Personnel
• Sampling and Testing Aggregate
  • Test Methods for Aggregates
  • Sieve Analysis (California Test 202)
  • Percentage of Crushed Particles (California Test 205)
  • Resistance to Abrasion Loss (California Test 211)
• Soundness and Durability (California Tests 214 and 229)
• Sand Equivalent (California Test 217)
• Surface Moisture (California Test 223)
• Specific Gravity of Coarse Aggregate (California Test 224)
• Specific Gravity of Fine Aggregate (California Test 225)
• Moisture Content by Oven Drying (California Test 226)
• Cleanness of Coarse Aggregate (California Test 227)
• Alkali Reactivity of Aggregates
  • Short Method, ASTM C 1260
  • Long Method, ASTM C 1293
• Material Sampling
  • Sampling Cementitious Materials
• Sampling Water
• Sampling Admixtures
• Sampling for Polyester Concrete
• Chapter 9 Job Control Sampling and Testing
• Introduction
• Sampling Procedure
• Field Control Tests
• Ball Penetration Test (California Test 533)
  • Lightweight Concrete
  • Calibration
• Test Procedure
• Density Of Fresh Concrete (California Test 518)
• Air Content by Pressure Method (California Test 504)
• Air Content by Volumetric Method (California Test 543)
• Proportion of Coarse Aggregate (California Test 529)
• Tests for Compressive Strength (California Test 521)
  • Number of Test Cylinders
  • Frequency of Sampling
• Making and Handling Test Specimens (California Test 540)
  • Identification of Test Cylinders
  • Shipping Test Cylinders
  • Reporting Test Results
  • Safety
  • Concrete Pour Records
  • Trial Batches
  • Concrete Compressive Strength by Maturity Method
  • Sampling and Testing of Self-Consolidating Concrete
  • Slump-Flow Test (ASTM C1611)
  • Static Segregation Test (ASTM C1610)
  • Passing Ability Test (J-Ring, ASTM C1621)
• References