concrete pervious
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Whats new in Concrete
By Frank A Kozeliski, P.E.Kozeliski Consulting LLC
Gallup, New Mexico
November 12, 2010Track Five
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Pervious ConcreteWhen it rains. . .. . . It d r a i n s !Minimal finesConcrete MixCoarse Agg. Cement and
Water
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Low Impact Development Pervious Concrete Directly Infiltrates Water Through The Pavement
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Conventional Pavement Asphalt (Background)Pervious Concrete (Foreground) - Raining
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Base/Sub-Base ConsiderationsPervious Concrete
Typical Detention Layer = 6 Thickness increases for
storage and to get waterout of pervious for freezethaw
No detention layer requiredwhere you have well
draining native soil
Subgrade compaction95% Standard Proctor90-92% Modified Proctor
40 % voidOr a Detention Layer
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Compaction Methods of pervious
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Pervious placement with a roller screed
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Las Cruces, New Mexico
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Initial Ingredients for aPervious Concrete Mix Design
Cement ------------------------ --500 lbs cu yd to # 8 Aggregate ------- 2600 lbs / cuydNo hot water cold water only 18-21 gal/cuyd
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www.perviouspavement.org
Batching Mixing Transporting Aggregate moisture content prior to batchingZero Near 0 Slump
(Very low W/C Ratio - .27 - .34)
Very sensitive jobsite water additionsTypical Admix (incl. Superplazticizer)
Plus HSA (Hydration Stabilizing extremeretarders) most apps.Plus VMA (Viscosity Modifying) common
AEA Cold climates
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Pervious at work
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Full-Depth Reclamation with Cement
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Examples of Pavement Distress Alligator cracking Rutting Excessive patching
Base failures Potholes Soil stains on surface
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Use of in-place materials Little or no material hauled off and dumped Maintains or improves existing grade Conserves virgin material Saves cost by using in-place
investment Saves energy by reducing
mining and hauls Very sustainable process
Advantages of the FDR Process
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18012
4,500
300
2,700
0
3,000500
1 mile of 24-foot wide, 2-lane road, with a 6-inch base
Sustainable Element of FDR Process
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Pulverize, Shape, Add Cement, Mix In Place,Compact, and Surface
GranularBase
Subgrade
Existingroad
BituminousSurfacing
Subgrade
Pulverized
Pulverizationto desired
depth
Subgrade
Pulverized
Removal ofexcess material(if necessary)and shaping
Subgrade
Stabilized
Addition ofcement, mixing,reshaping, and
compaction
Subgrade
Stabilized
New Surfacing
Final surfaceapplication
FDR Construction Process
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Cement SpreadingCement is spread on top of thepulverized material in ameasured amount in eithera dry or slurry form
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Blending of Materials andMoisture Addition
Cement isblended intopulverized,reclaimedmaterial and, withthe addition ofwater, is brought tooptimum moisture
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Traffic and Surfacing Completed FDR base can be opened
immediately to low-speed local trafficand to construction equipment
Subsequent pavement layers can beplaced at any time
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Whitetopping,
Ultrathin WhitetoppingPavement Rehabilitation
Options
B b l d h
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But concrete can be placed over theexisting asphalt as
WHITETOPPING Avoids asphalt reconstruction problems
Can be placed on pavementsin poor or bad condition
Little or no pre-overlay repair needed
Minimal rain delays
Maintain traffic on existing surface
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Whitetopping
By Definition...- Thicknesses at least 4to 6
- Does not depend on bond tounderlying surface
- Joint spacing is less critical
- Existing asphalt pavementis base
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UTW Design Procedure
New Engineering Bulletin for1998 Conventional Whitetopping
Design Construction Performance
Ultra-thin Whitetopping Design Construction Performance
Crystal, New Mexico, NHA street
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Finished Street
Crystal, New Mexico, NHA
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White toping in Durango, Co.
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Honduras, Central America
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ACI 330R-08Guide for the Design Concrete Parking
Lots and Construction of
CoreyCemex
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ACI has developed recommended design procedurespecifically for parking lots
Recognizes construction integrity of rigidpavement materials. Recommends reduction orelimination of granular base:
ACI 330 recognizes parking lots are different than astreet/roadway.
Load is in the Interior Primary purpose is to store & move vehicles Lot may be a water collector May need to accommodate lighting, islands,
landscaping
Given:
Soil Strength
Concrete Strength
Traffic Demand
Determines:
Thickness
Jointing
Reinforcing (opt.)
Subbase (opt.)
WE RECOMMEND FOLLOWING ACI 330 GUIDELINEFOR DESIGN OF CONCRETE PARKING LOTS
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Major parkingfacilities
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Longitudinal joint
Transverse joint
SubgradeSubbase or base
Surface Texture
Surface smoothnessThickness Design
Dowel bars
Concrete materials
Tiebars
BASIC COMPONENTS OF A CONRETE PAVEMENT
ACI 330 ASSIGNS TRAFFIC TO DESIGN CATEGORIES DEPENDING ON TYPE
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ACI 330 ASSIGNS TRAFFIC TO DESIGN CATEGORIES DEPENDING ON TYPEVEHICLE AND PARKING AREA OF USE
HOW CONCRETE AND ASPHALT PAVEMENTS
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HOW CONCRETE AND ASPHALT PAVEMENTSARE DIFFERENT
Loads are distributed over a large area through slabaction.
Minor deflections. Low subgrade contact pressures. Subgrade uniformity is more important
than strength.
Loads are more concentrated. Deflections are higher Subgrade, base and subbase strength are very important. usually require more layers and greater thickness for
optimally transmitting load to the subgrade
Concretes Rigidity spreads the load over a large area and keeps pressures on the subgrade low
7000 lbs load.
pressure ~3 - 7 psi
7000 lbs load.
pressure~ 15 - 20 psi
Concrete Pavements are rigid Asphalt pavements are flexible
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Parking Area
Entrance/ Exit Lanes
4 to 6
6 to 8
DIFFERENT TRAFFIC AREAS CAN HAVE DIFFERENT THICKNESSES
EQUIVALENT STRUCTURES ARE NECESSARY
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EQUIVALENT STRUCTURES ARE NECESSARYORDER TO COMPARE DESIGNS
5.0 Concrete
6.5 Concrete
8.0
6 Gran. Base
Concrete
2.0
10 Gran. Base
Asphalt
4.0
10 Gran. Base
Asphalt
10 Gran. Base
Asphalt8.0
4.0
6 Gran. Base
Asphalt
6.0
6 Gran. Base
Asphalt
6 Gran. Base
Asphalt10.0
Light TrafficADTT 3 trucks/day,
11,500 ESALs
MediumTraffic
ADTT 100 trucks/day,405,000 ESALs
Heavy TrafficADTT 500 trucks/day,
3,500,00 ESALs
Thin Asphalt Thick AsphaltACI 330 Concrete
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Roller Compacted Concrete
It has the basic ingredients as conventional concreteFresh RCC is stiffer than zero-slump conventional
Concrete. Its stiff enough to remain stable undervibratory rollers.
Placed with asphalt-type paver equippedConstructed without forms, dowels or reinforcementJoints are spaced farther apart than conventional
pavements.
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Log Sort Yards
Vancouver Island, BC, 1978
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Military Facilities
Ft. Lewis, WA,1986
Ft. Drum, NY, 1990
Ft. Carson, CO, 2008
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Intermodal Facilities
Burlington Northern, Denver, CO
Central Station, Detroit, MI
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Parking Areas
134 acre parking facility at Saturn plant,TN (1988-89)
Honda facility, AL (2003)(207 acres; 1.2 mil sy)
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Highway Shoulders
I-285 highway shouldersAtlanta, GA
C P i i h Li h i h
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Concrete Paving with Light weightaggregate make pavements last longer
This is called Internal Curing of concreteLight weight agg. Provides moisture inside the
concrete due to low Water Cementitious ratioCement 451 lb/yd Fly Ash 113 lb/ ydCoarse 1540 lb/yd Light wt 300 lb/ydFine agg 1099 lb/yd Water 242 # 29 galFc = 4500 psi
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ICF -- Insulated Concrete Forms
Picture
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ICF Insulated Concrete Forms
Government push mandates to Maximize energy Design Professionals need to access Energy
efficient material ICF structures require 44% less energy to heat and
32% less energy to cool Resulting in reduced up front capital cost Designing with ICFs proven way to deliver
substantial saving in operating cost and owner ship
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ICF Insulated Concrete Forms
Building energy-efficient is Necessary nolonger a choice
Green buildings are emerging across Americawithin federal agencies
Provide higher structural performance andgreater confort
Help withstand earthquakes, hurricanes andtornados
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ICF Insulated Concrete Forms
Ideal wall system for high-risk geographies Mass wall reduces noise, multi-hour fire
resistance Stable indoor temperatures Well suited to hotels, multi-unit walls theaters
hotels, schools and churches. Resistance to mold mildew and pests
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ICF Insulated Concrete Forms
picture
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Pervious Drive way at a ICF house in Gallup, NewMexico
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Concrete Mix Designs Use Combined Aggregates .
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Proportion in accordance
with ACI 211.1 Previous field experience Laboratory trial batches
Batch, mix, & deliver byASTM C94 or C685
Concrete Mix Designs Use Combined Aggregates .
WELL GRADED AGGREGATE DISTRIBUTION WILL REDUCE PASTE CONTE
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A mixture of particle sizes is more efficient at fillingvoid space than all particles of any one size
Larger maximum sizes also help graded aggregatesfill volume more effectively
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MIX DESIGN IS A BALANCE BETWEEN ECONOMICS AND PERFORMANC
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What shrinks? Aggregates? - No Paste? - Yes
Cementitous, water Lower paste = lower
shrinkage
Factors affecting pastecontent
Maximum aggregate size Combined aggregate
grading Fineness of sand and
impurities Fineness of cementitious
materials
Limiting Paste Content is Key to reducing Shrinkage
OPTIMIZED AGGREGATE GRADATION
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CAN AFFECT COSTS
$77.42$72.72
Standard Mix Optimized Mix
Est. Contractor Concrete CY Price ($ / CY)
StateMix
OptimizedMix
Cement, Lbs 545 425Water, Lbs 229 230
Air, % 5.0 1.5
W/C Ratio 0.42 0.54
Cyl, 28-day PSI 6,900 6,300
Beam, 28-day PSI 897 895
LOUISIANA TEST RESULTS
$27.25
$21.25
Standard Mix Optimized Mix
Cement Cost ($ / CY)
StandardPaving Mix
(lbs/CY)
Potential OptimizedPaving Mix (lbs/CY)
Cement 500 430
Ty-F Fly-ash 67 67
Sand 1100 1115
Coarse Agg (AASHTO#57)
1885 1485
Coarse Agg 2 (1/4 max) 480
Water, Lbs 254 (28 gals) 220 (26 gals)
W/C Ratio .448 .443
Cement cost = $100 / ton
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Self Consolidating Concrete
Concrete that flows.Measure the spread of the concrete Inches Reduces the man hours for placementReduces the rubbing of the wall.Minimum to no honeycombCan place the concrete qucikerNo water added, keeps the Water Cementitious
ratio low
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Chemical Admixtures
HIGH RANGE WATER REDUCING ADMIXTURES(Super Plasticizers)
Reduces the water content by 12% to 30% whilemaintaining slump.
Produces flowing concrete without the additionof water.
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Chemical Admixtures
HIGH RANGE WATER REDUCING ADMIXTURES
Example:
36 gal / yd x 8.33 lb/gal=300 lb/yd36 gal x 12% = 4.3 gal x 8.33 = 36 lbs36 gal x 30% = 10.8 gal x 8.33 = 90 lbs
This is ASTM Type F (Normal Set)and Type G (Retarding Set).
High range water reducing admixtures
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High range water reducing admixturesadded at the site
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High range ater red cing
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High range water reducingadmixtures added at the site
High range increases the slump 4 with 3gallons in a 10 cuyd load. Normally it would
have taken 40 gallons of water to increasethe slump the same amount or 4 gallons percubic yard.
36 gal x 12% = 4.3 gal x 8.33 = 36 lbs
Flowable t St bl i t
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Flowable - yet Stable mixture
http://localhost/var/www/apps/conversion/tmp/scratch_2/Inverted%20Slump%20Test.MPG -
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High Range Water Reducer
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High Range Water Reducerno Water added
h i C i ?
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What is Concrete Maturity?
Originally developed in thelate 1940s & early 50s
Accidents in the 1970s led tofurther maturity research
Interest increased in the1980s as companies lookedfor ways to accelerateconstruction
Wide spread adoption in theU.S. over the last 10 years
Maturity is a proven, non-destructive, strength estimation technique thatuses time & temperature measurements to determine (in real-time) thestrength gain of in-place concrete.
0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
0 5,000 10,000 15,000 20,000 25,000
Maturity (C-Hours)
Compressive Strength (psi)
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How does Maturity work?
Strength vs. Time
0
1000
2000
3000
4000
5000
6000
7000
0 500 1000 1500
Time, Hours
Strength, PSI
90 F
73
45
What does this tell us?
Strength vs. Maturity
0
1000
2000
3000
4000
5000
6000
7000
0 5000 10000 15000 20000 25000
Maturity, C*H
Strength, PSI
90 F
7345
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0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
0 5,000 10,000 15,000 20,000 25,000
Maturity (C-Hours)
Com
pressive Strength (psi)
Day 1
Day 2
Day 4
Day 7 Day 14
Step 1: Generating a Relationship Curve
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Step 3A: Convert Maturity to Strengthusing Relationship Curve
0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
0 5,000 10,000 15,000 20,000 25,000
Maturity (C-Hours)
Compressive Strength (psi)
3750
4000
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Moisture is critical during the curing process
Detrimental effects of moisture loss
Lowered concrete strength
Shrinkage cracking & curling
Long-term reductions in durability
Moisture has long-term damaging effects
Detrimental effects of moisture retention
Damage to floor covering and adhesives
Promotes mold growth
Structural damage
Measure Slab MoistureintelliRock Humidity Logger
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Ideal for floor moisture applications
(ASTM F 710, ASTM F 2170)
Compliments/Replaces Calcium Chloride testing
Typical threshold of 75% RH for Flooring
Excellent forensic tool for moisture issues
Compatible with the intelliRock Maturity &Temperature logging system
intelliRock Humidity Logger
intelliRock
4 0 %
S l a b
D e p t h
Hole LinerSealed
w/SlilconeUp Walls
Drill Point(Sample Volume)
Open BottomFor Sampling
intelliRock RHSensor
E i f M i d M i
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Equipment for Maturity and Moisture
K S K
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Komponent System K
Shrinkage reducing Cement Add 80 lb bag to a yard of concrete Place as regular concrete Need to wet cure for 7 days Cost about $ 30.00 per cubic yard
No Joints placement 100 x 200
K t S t K
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Komponent System K
H lid I
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Holiday Inn
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R id S t C t
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Rapid Set Concrete
University and Central -- Albuquerque, NM You can open up the concrete in 24 hrs. Asphalt was removed on Friday evening,
Concrete placed and opened on Monday. Added cost about $ 150 / cuyd due to the
overtime and the cement added cost.
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ASTM 1157 Cement
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ASTM 1157 Cement
This is a performance based cement and hasabout 10% inter ground limestone to meet
EPA carbon requirements. You should see it insubmittals this next year. Do not be afraid aslong as you get strength.
Performance Based Mix Designs
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Performance Based Mix Designs
In years to come you will get performancebase mix designs. You order 4000 psi with airand it is the ready mix producers to get thestrength. The engineer will accept the mix and
may not know what was in the mix. (be ready)no more prescription mixes will be in ASTM
Curing Concrete the first 24 hrs on site
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Curing Concrete the first 24 hrs on site.
ASTM No Loss of Moisture Keep cylinders between 60 & 80 Degrees For 6000 psi concrete cure between 68 & 78
deg.
Test Cylinders 4x8
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Test Cylinders 4x8
The new 318.08 Building Code recognizes the 4 x8 inch cylinder molds.
A strength test is the average of 3 4 x 8.
Before the code, recognized 2 6 x12 4 x 8 can be used for trial mixes and acceptance
testing.
Test Cylinders 4x8
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Test Cylinders 4 x8
Fill the test cylinder full rod it 25 timeswith a 3/8 rod with a rounded end. Tap the
sides 10 to 15 times to close the voids. Fillthe other half full. Rod the cylinder 25 times
just penetrating the first layer 1. Tap the
sides again. Level the cylinder top.
Test Cylinders 4x8
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Test Cylinders 4 x8
Cap the mold and place in water, coveringthe cylinders with water. Keep between 60 to80F. 24 hrs later take to the laboratory
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32 cylinders in a box cost about $ 2500
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40 cylinders in a thermal II curing box. Cost $ 3500
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Decorative Concrete
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Decorative Concrete
Value added for the Residential ConcreteContractor or for the Home owner
Learn how to do it and do it right if you aregoing to do Decorative Concrete
Decorative Concrete
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Decorative Concrete
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ACI 332-08
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ACI 332 08
Code Requirements for ResidentialConcrete and Commentary
The Concrete Requirements for ResidentialConcrete have changed.
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ACI 332-08
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ACI 332 08
Has established 3 Weathering Probabilities1. Negligible (such as Hawaii)2. Moderate3. Severe (such as Alaska )
Lines defining areas are approximate only.
Severe
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Severe
Moderate
Negligible
Weathering Map for entrained air for Concrete
Severe Weather (Type 3)
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Severe Weather (Type 3)
Drive ways, curbs, walkways,ramps, patios, porches,steps, and stairs exposed toweather and garage floorslabs.
Fc = 4500 psi
Maximum Slump - 5 Slump flow 24 to 28With High Range WRA
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Long Haul Concrete over 2 Hours
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Long Haul Concrete over 2 Hours
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What is the plan cont.
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Why one revolution per mile ????
You are reducing the friction betweenthe cement and aggregate particles Thefriction builds up heat and heats up theconcrete
The stiffer the mix the more friction andheat .
What is the plan (cont.)
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p ( )
The flow-a-ability can be done with DELVO oran overdose of Type B & Type D retarders &water reducing retarder
Go the 120 to 160 miles and get 120 to 160revolutions. Caution in cool weather you canincrease slump if the air is cooler than theconcrete. The concrete gets cooler in transit.
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p ( )
Arrive at the job site and mix for 5 minutes toget the material mixed and then check theslump. If it is a little stiff, use Super Plasticizerto increase the slump to 4 +/ -
This is a method for 50 to 100 cuyd placementper day or one round of mixers. Not for lowslump curb and gutter machines
ontrol Low Strength fill
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ontrol Low Strength fillFlowable Fill Properties
Slump 5 to 8
Plastic Unit Wt 130 pcfC.B.R. 34 to 42Strength 35 psi to 150 psi
Koz-Crete Flowable Fill Mi D i
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Mix Design
Cement 94 lb/cuydFines 3/8 max) 3000 lb/cuyd
Water 50 gals) 416 lb/cuydColor depends)
TOTAL 3510 lb/cuyd
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Cement Burns
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W i !!!!!
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Contact with wet (unhardened) concrete, mortar, cement, orcement mixtures can cause SKIN IRRITATION, SEVERECHEMICAL BURNS (THIRD-DEGREE), or SERIOUS EYE DAMAGEFrequent exposure may be associated with irritant and/or allergic
contact dermatitis. Wear waterproof gloves, a long-sleeved shirt,full-length trousers, and proper eye protection when working withthese materials.
Source: PCA
Warning !!!!!
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If you have to stand in wet concrete, use waterproof boots that are high enough to keep concrete from
flowing into them. Wash wet concrete, mortar, cement,or cement mixtures from your skin immediately. Flusheyes with clean water immediately after contact.
Indirect contact through clothing can be as serious as directcontact, so promptly rinse out wet concrete, mortar, cement,or cement mixtures from clothing. Seek immediate medicalattention if you have persistent or severe discomfort.
Source: PCA
Warning !!!!!
Thank You!
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Thank You!
This concludes the What's new in Concrete
Any Questions?Frank A. Kozeliski, P.E.
Cause-a-Liskey
Consulting EngineerGallup, New Mexico
mailto:fakoz@cnetco.com
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