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Lecture one
concrete is a mixture of cement, water, fine aggregate, coarse aggregate.Cement and water makes up paste at 1:0.5 ratio. Add in fine aggregate to make mortar at two ratio and concrete coarse aggregate at three ratio.
Making Cement:Water:Fine Aggregate: Course Aggregate = 1:0.5:2:3
add in 2% steel Rebar
Cost: £28-£48 per tonne, £70-100 per metre cubed
Usual density: 25kNm^-3
Usual strength: 20 to 80 Nmm^-2
Aggregates:
- Fine
- Natural Sand
- Crushed Limestone
- Course
- Gravel
- Crushed Limestone
- Crusted Granite
All 300-400Nmm^-2
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Lecture two: Manufacture, Chemistry & Properties
Manufacture
- Minging
- Explosives are used to collect limestones
- Higher up you get more impure wiht silica, iron and aluminium oxide
- Transport
- Transported in 50t trucks to the processing plant
- Primary crushing
- Softball size
- Water is sprayed to stop dust leaving
- Secondary crushing
- Golfball size
- Storage and mixing of high and low purity
- Tripper makes piles of correct proportion
- These piles are raw mix.
- Raw mix grinding
- Ground in a roller mill
- Blending and storage
- Minerals addrd
- Silica
- Iron
- Aluminium oxide
- Called raw meal.
- Pre heater
- Bonds minerals for hardening
- uses heat from rotery kiln via heat exchanger
- Removes carbon via flash calcinator
- CaCO_3 --> CaO + CO_2
- 800 degrees C
- Rotary Kiln
- 49 -80 meters long
- 1500-1700 degrees C
- Powder fuses into marble size
- Clinker
- Cooled quickly to 80 degrees C with large fans
- Finish Grinding
- Gypsum added here
- Used so that the cement retains workability for up to 2 hours before hardening
- Ball mills
- Uses little iron balls of different size to grind
Electrostatic Precipitator used to take dust away (fires charged electrons at the dust which contact then move to positvely charged plates which get banged to let the dust fall)
Packed into 25kg bags.
The kiln fuel is a mixture of coal and tyres
200kg of coal makes 1 tonne of cement
100kg of rubber tyres makes 1 tonne of cement
Packed into 25kg bags.
The kiln fuel is a mixture of coal and tyres
200kg of coal makes 1 tonne of cement
100kg of rubber tyres makes 1 tonne of cement
Chemsitry
C3A - 10.8
C3S - 54.1
C2S - 16.6
C4AF - 9.1
This makes up 93-95% and the rest are minor compounds like magnesium,, potassium and sodium.
C = CaO
S = SiO2
A = Al2O3
F = Fe2O3
Properties
Can be changedto suit wants and needs
OPC - Ordinary portland cement C3S+C2S>67%
RHPC - Rapid hardening portland cement C3S is greated but still <70% (C2S is lower)
SRPC - Sulphate resistant portland cement C3A+SO4+H2O and C3A <3.5%
White - White portland cement C4AF<1%
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Lecture 3: Aggregates
Why?
- Paste has
- Low modulus of elasticity
- High creep and shrinkage
This means that it has a high dimentional changes
The maximum aggregate size is preferablefor strength.
Source?
- Primary
- Made for concrete
- Secondary
- By-product from another process (e.g. metal mining)
- Recycled
- Recycled from demolition sites etc.
Extraction
- Crushed Rock
- Drilling/blasting
- Crushing
- Screening
- Blending
- Stockpiling
- Sea dredged
- 15% of uk sand and gravels
- Good quality
- Smooth
- Fine aggregates
- Size <4mm
- Lighweight aggregates
- obtained from air voids
- density < 200kgm^-3
- f_c>15MPa
- Pumis, Ligtag, Perlite
Grading
- Use a seive
- Find the % passing
- Draw grading curve
- compare to EN12620 table 2,
Particle Size
- Take account of shape unlike sieve & grading
- influences void size (smooth packs down better
- Tyoes
- Flaky, elongated, round, angular, irregular
- Angularity Index
A=67-(100G)/(Vwγ)=67-100(Vagg/Vw)
Vw = Volume of water to fill the voids in a control vessell
γ = Specific gravity of aggregate
67 = % volume occupied by perfect spheres
G= weight of aggregate in vessel
γ = Specific gravity of aggregate
67 = % volume occupied by perfect spheres
G= weight of aggregate in vessel
Strength
- Concrete strength < Crushed aggregate strength
- Stength of parent rock not necessarily the strength of the crushed aggregate
Graph of Parent rock strength vs. 10% fine crushed value
One tested in cube test, the other tested by crushing in a vessell and stop when 10% of the sample is <2mm in size.
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Lecture 4: Properties of Fresh Concrete
Mixing
- 50-80 seconds - Drum Mixer
- 40-70 seconds - paddle/blade mixer
- 30-50 seconds - Superplasticiser
All running at 15-20rpm
Delivery
- 12m^3 (50% water added on site)
- or add all water on site
- Take consistency sample 15 mins after mixing
Placement
- Use a laser screed to level
- bleed water on the surface must be vacuumed off
Properties
- Fresh
- Workability - Enables mixing/transport/compacting without segregation of aggregate and paste and without bleed water on surface
- Hardened
- Strength
- Durability
Test
- Slump
- Pour cement into a container
- poker to make sure air is out
- Lift container
- Measure from top of container to top of concrete
- This is the slump
- High workability (100-175)
- Low workability (0-25)
- Compacting factor
- w_1 = Weight of uncompacted concrete
- w_2 = Weight of compacted concrete
C.F.=w_1/w_2
- RC mix is usually 0.8 - 0.9
- V-B time
- Vebe consistometer
- make slump test in a circular container
- time to get a level surface in larger container after slump container removed and vibrator switched on.
Compaction
- Poker vibrator
- Stop when water/cement slurry rises to surface
- Better than hand compaction
- Hand compactor
- Pour concrete in layers
- Look at graph in notes showing concrete strength with compaction vs. water/cement ratio
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Lecture 5: Properties of Hardened Concrete
For sutrctures
- Compressive strength
- fck=20-50 Nmm-2
- Tensile strength in flexure
- fctm=2.5-4.5 Nmm-2
- Direct Tensile Strength
- fctd=1.5-3.0 Nmm-2
- Young's modulus
- Ecm=30-38 kNmm-2
- Poisson's ratio
- 0.15-0.25
- Zero when cracked
For building services
- Thermal movement
- α=11x10^-4
- Shrinkage
- 300x10^-6 strain (0.3%)
- Curing can be used to stop this, continually supply water to the concrete for the first few days.
- Vibration
- Acoustic
- Fire
Tests
- Compressive Strength
- Cylinder test
- L/d=2
- fck=P_max/area
- Cube test
- fcu=P_max/area
- fck=fcux1.2
- Tensile Strength due to Flexure
- Flexure Bending Test
- Splitting tensile Strength
fctm,fl=M/Z
M=Pa/2
Z=a^3/6
fctd=(0.7xfctm,fl)/1.5
fctm,sp=(2P)/(pi x LD)
fctd=(0.9xfctm,fl)/1.5
- PUNDIT
- Time for ultrasonic pulse to pass through prism
- Velocity calculated from this
- long equation here (can't be bothered to type out!
- ERUDITE
- Finds the first natural frequency of the concrete prism
Ec(t)=4 x 10^-15 x n^2 x L^2 x density
n=frequency
Ecm=Ec(t)/1.05
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Going for a run now, then I will try and get to the end of at least Lecture 7 before bed.
Lecture 6: Concrete mix design
A short lecture, it goes through the basic steps for mix design, this is not necessary for the moment, I will go over it before the exam.
Statistics are used - this is because of a lot of samples.
Aim to make 30Nmm^-2
Look for 95% characteristic strength.
This margin is = ks where k is a constant and s is the standard deviation.
fm=fk+ks
where fm is the mean strength and fk is the 95% characteristic strength
Statistics are used - this is because of a lot of samples.
Aim to make 30Nmm^-2
Look for 95% characteristic strength.
This margin is = ks where k is a constant and s is the standard deviation.
fm=fk+ks
where fm is the mean strength and fk is the 95% characteristic strength
The rest of the lecture is the mix design.
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Lecture 7: RC Intro
Limit states design
- Limit state design makes sure the structure is safe under worst loads
- It also makes sure there are no extreme deformations whilst under working loads that can effect:
- appearance
- durability
- performance
Partial Safety Factors
- γf
- Partial Safety Factor for loads.
- Dead = 1.35
- Live = 1.5
- γm
- Partial Safety Factor for materials
- Concrete = 1.5
- Rebar = 1.15
- Design Strength fcd = [Characteristic Strength (fck)] / [PSF γm]
- Design Load = [Characteristic Load] x [γf]
On your beam, find the largest possible bending moments:
Load our beam with different cases combine choose greatest from each section (hogging & sagging) This generates the Bending Moment Envelope.
Typical Cross Section
Usually h / b = 1.5 - 3.0
As is the area of steel, usually between 1-4% for main bars and 0.13-1% secondary bars
Generally the distance between rebar pieces is > the size of aggregate + 5mm or 20mm. whichever is bigger.
All rebar must have links turning 90o around them at some point.
That's it for tonight, I will continue on Dissertation all tomorrow and probably geotechnics the day after.
That's it for tonight, I will continue on Dissertation all tomorrow and probably geotechnics the day after.