Concrete Technology Manual
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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