Concrete Construction Engineering Handbook Second Edition Concrete Construction Engineering Handbook Second Edition Editor-in-Chief Dr. Edward G. Nawy, P.E., C.Eng. Distinguished Professor Rutgers—The State University of New Jersey New Brunswick, New Jersey Boca Raton London New York CRC Press is an imprint of the Taylor & Francis Group, an informa business Cover Image: Veterans’ 1-280 Glass City Skyway, Toledo, Ohio, 612-ft twin cable-stayed spans with 403-ft pylon. The top 196 ft of the pylon features four sides of glass enveloping LED light fixtures that allow an array of as many as 16.7 million color combinations at night. The bridge construction involved 185,000 cubic yards of concrete, 1.9 million lb of post-ten- sioning strands, and 32.6 million lb of mild steel reinforcement. The bridge was opened in June 2007. (Photos courtesy of Ms. Linda Figg, President and CEO, FIGG, Tallahassee, Florida. Owner: Ohio Department of Transportation. Designer: FIGG. Contractor: Fru-Con.) 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Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Library of Congress Cataloging‑in‑Publication Data Concrete construction engineering handbook / editor, Edward G. Nawy. -- 2nd ed. p. cm. Includes bibliographical references and index. ISBN 978-0-8493-7492-0 (hardback : alk. paper) 1. Concrete construction--Handbooks, manuals, etc. I. Nawy, Edward G. II. Title. TA681.C743 2008 624.1’834--dc22 2008013027 Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com Contents Preface......................................................................................................................................................................xiii Acknowledgments....................................................................................................................................................xv Editor-in-Chief.......................................................................................................................................................xvii Contributors............................................................................................................................................................xix 1 Concrete Constituent Materials Sidney Mindess...........................................................................1-1 1.1 Introduction...................................................................................................................................1-1 1.2 Portland Cement............................................................................................................................1-2 1.3 Modified Portland Cements..........................................................................................................1-9 1.4 High-Alumina Cement................................................................................................................1-10 1.5 “Green” Cements.........................................................................................................................1-11 1.6 Performance of Different Cements in Concrete........................................................................1-11 1.7 Water.............................................................................................................................................1-12 1.8 Water/Cement Ratio....................................................................................................................1-12 1.9 Aggregates.....................................................................................................................................1-14 1.10 Reinforcement..............................................................................................................................1-21 1.11 Durability Considerations...........................................................................................................1-23 References................................................................................................................................................1-26 2 Mineral Admixtures V.M. Malhotra.................................................................................................2-1 2.1 Fly Ash............................................................................................................................................2-1 2.2 Blast-Furnace Slag........................................................................................................................2-18 2.3 Silica Fume...................................................................................................................................2-29 2.4 Highly Reactive Metakaolin........................................................................................................2-38 References................................................................................................................................................2-42 3 Chemical Admixtures David P. Whitney..........................................................................................3-1 3.1 Introduction to Chemical Admixtures.........................................................................................3-1 3.2 Retarding Admixtures....................................................................................................................3-2 3.3 Water-Reducing Admixtures.........................................................................................................3-3 3.4 High-Range, Water-Reducing Admixtures...................................................................................3-5 3.5 Accelerating Admixtures................................................................................................................3-7 3.6 Air-Entraining Admixtures.........................................................................................................3-10 3.7 Antifreezing Admixtures.............................................................................................................3-12 3.8 Antiwashout Admixtures.............................................................................................................3-13 3.9 Shrinkage-Reducing Admixtures................................................................................................3-14 3.10 Polymer Modifier Admixtures....................................................................................................3-14 3.11 Alkali–Silica Reaction Prevention Admixtures..........................................................................3-18 3.12 Conclusion...................................................................................................................................3-18 References................................................................................................................................................3-18 4 Long-Term Effects and Serviceability Edward G. Nawy and Hani Nassif...................................4-1 4.1 Creep and Shrinkage Deformations in Concrete........................................................................4-1 4.2 Creep Deformations in Concrete.................................................................................................4-2 4.3 Creep Prediction............................................................................................................................4-6 4.4 Shrinkage in Concrete.................................................................................................................4-10 4.5 Strength and Elastic Properties of Concrete vs. Time..............................................................4-16 4.6 Serviceability Long-Term Considerations..................................................................................4-18 v vi Concrete Construction Engineering Handbook 4.7 Long-Term Shrinkage and Temperature Reinforcement Controlling Cracking between Joints in Walls and Slabs of Liquid-Retaining Structures.........................4-34 4.8 Autogenous Shrinkage in Early-Age Concrete..........................................................................4-35 Acknowledgments...................................................................................................................................4-35 References................................................................................................................................................4-37 5 Properties and Performance of Normal-Strength and High-Strength Concrete Steven H. Kosmatka.........................................................................5-1 5.1 Introduction...................................................................................................................................5-2 5.2 Workability, Bleeding, and Consolidation...................................................................................5-2 5.3 Mixing, Transporting, and Placing Concrete...............................................................................5-6 5.4 Permeability..................................................................................................................................5-10 5.5 Carbonation.................................................................................................................................5-10 5.6 Early-Age Characteristics and Strength......................................................................................5-12 5.7 Density..........................................................................................................................................5-16 5.8 Abrasion Resistance.....................................................................................................................5-17 5.9 Volume Change and Crack Control...........................................................................................5-20 5.10 Deformation and Creep..............................................................................................................5-21 5.11 Concrete Ingredients...................................................................................................................5-22 5.12 Proportioning of Concrete Mixtures..........................................................................................5-31 5.13 Hot and Cold Weather Concreting............................................................................................5-32 5.14 Control Tests................................................................................................................................5-33 5.15 Freeze–Thaw and Deicer Scaling Resistance..............................................................................5-34 5.16 Sulfate-Resistant Concrete...........................................................................................................5-35 5.17 Corrosion Protection...................................................................................................................5-37 5.18 Alkali–Silica Reaction..................................................................................................................5-39 5.19 Heat-Induced Delayed Expansion..............................................................................................5-42 5.20 Self-Consolidating Concrete.......................................................................................................5-43 5.21 Related ASTM Standards.............................................................................................................5-43 References................................................................................................................................................5-44 6 Design and Placement of Concrete Mixtures.................................................................................6-1 Part A. Design of Concrete Mixtures Edward G. Nawy......................................................................6-2 6.1 General............................................................................................................................................6-2 6.2 Selection of Constituent Materials...............................................................................................6-2 6.3 Mixture Proportioning for High-Performance, Normal-Strength Concrete (Cylinder Compressive Strength Limit 6000 psi)........................................................................6-9 6.4 Mixture Proportioning for High-Performance, High-Strength Concrete (Cylinder Compressive Strength Exceeding 6000 psi)..............................................................6-18 Part B. Applications and Constructability Jaime Moreno and John Albinger...................................6-30 6.5 Applications and Constructability with an Emphasis on High-Strength, High-Performance Concrete.......................................................................6-30 6.6 Job-Site Control...........................................................................................................................6-41 6.7 Testing...........................................................................................................................................6-41 Acknowledgments...................................................................................................................................6-43 References................................................................................................................................................6-43 7 Design and Construction of Concrete Formwork David W. Johnston.....................................7-1 7.1 Introduction...................................................................................................................................7-2 7.2 Types of Formwork........................................................................................................................7-5 7.3 Formwork Standards and Recommended Practices..................................................................7-17 7.4 Loads and Pressures on Formwork............................................................................................7-23 7.5 Formwork Design Criteria..........................................................................................................7-27 7.6 Formwork Design........................................................................................................................7-35 7.7 Slab-Form Design Example........................................................................................................7-38 7.8 Wall-Form Design Example........................................................................................................7-43 References................................................................................................................................................7-49 Contents vii 8 Construction Loading in High-Rise Buildings S.K. Ghosh........................................................8-1 8.1 Introduction...................................................................................................................................8-1 8.2 Construction Loads.......................................................................................................................8-1 8.3 Properties of Concrete at Early Ages..........................................................................................8-19 8.4 Strength Consequences of Construction Loads........................................................................8-37 8.5 Serviceability Consequences of Construction Loads................................................................8-47 8.6 Codes and Standards...................................................................................................................8-55 References................................................................................................................................................8-58 9 Deflection of Concrete Members Russell S. Fling and Andrew Scanlon.......................................9-1 9.1 Introduction...................................................................................................................................9-1 9.2 Elastic Calculation Methods.........................................................................................................9-2 9.3 Other Calculation Considerations................................................................................................9-6 9.4 Factors Affecting Deflection........................................................................................................9-10 9.5 Reducing Deflection of Concrete Members..............................................................................9-16 9.6 Allowable Deflections..................................................................................................................9-20 References................................................................................................................................................9-22 10 Structural Concrete Systems Scott W. McConnell.........................................................................10-1 10.1 Overview.......................................................................................................................................10-2 10.2 Building Loads.............................................................................................................................10-3 10.3 Composite Steel–Concrete Construction...................................................................................10-7 10.4 Foundations................................................................................................................................10-10 10.5 Structural Frames......................................................................................................................10-14 10.6 Concrete Slab and Plate Systems..............................................................................................10-17 10.7 Liquid-Containing Structures...................................................................................................10-23 10.8 Mass Concrete............................................................................................................................10-26 10.9 On-Site Precasting and Tilt-Up Construction.........................................................................10-28 10.10 Lift-Slab Construction...............................................................................................................10-30 10.11 Slip-Form Construction............................................................................................................10-33 10.12 Prestressed Concrete..................................................................................................................10-37 Acknowledgments.................................................................................................................................10-40 References..............................................................................................................................................10-40 11 Construction of Prestressed Concrete Ben C. Gerwick, Jr.........................................................11-1 11.1 Introduction.................................................................................................................................11-2 11.2 Concrete and Its Components....................................................................................................11-4 11.3 Reinforcement and Prestressing Systems...................................................................................11-8 11.4 Special Provisions for Prestressed Concrete Construction.....................................................11-13 11.5 Post-Tensioning Technology.....................................................................................................11-19 11.6 Pretensioning Technology.........................................................................................................11-24 11.7 Prestressed Concrete Buildings.................................................................................................11-29 11.8 Prestressed Concrete Bridges....................................................................................................11-33 11.9 Prestressed Concrete Piling.......................................................................................................11-46 11.10 Tanks and Other Circular Structures.......................................................................................11-54 11.11 Prestressed Concrete Sleeper (Ties).........................................................................................11-55 11.12 Prestressed Concrete Floating Structures.................................................................................11-56 11.13 Prestressed Concrete Pavements...............................................................................................11-58 11.14 Maintenance, Repair, and Strengthening of Existing Prestressed Concrete Structures........11-58 11.15 Demolition of Prestressed Concrete Structures......................................................................11-60 11.16 The Future of Prestressed Concrete Construction..................................................................11-61 Acknowledgments.................................................................................................................................11-62 References..............................................................................................................................................11-62 viii Concrete Construction Engineering Handbook 12 Unbonded Post-Tensioning System Technology in Building Construction Florian G. Barth...................................................................................12-1 12.1 Developments in Unbonded Post-Tensioning...........................................................................12-1 12.2 General Notes and Standard Details..........................................................................................12-6 12.3 Evaluation and Rehabilitation of Building Structures..............................................................12-22 12.4 Demolition of Post-Tensioned Structures...............................................................................12-36 12.5 Defining Terms...........................................................................................................................12-42 References..............................................................................................................................................12-44 13 Concrete for Offshore Structures George C. Hoff........................................................................13-1 13.1 Introduction.................................................................................................................................13-1 13.2 Types of Concrete Structures......................................................................................................13-2 13.3 Concrete Quality........................................................................................................................13-18 13.4 Concrete Materials.....................................................................................................................13-19 13.5 Concrete Properties...................................................................................................................13-22 13.6 Design Considerations..............................................................................................................13-24 13.7 Safety Considerations................................................................................................................13-25 13.8 Construction Practices..............................................................................................................13-25 13.9 Construction Locations.............................................................................................................13-26 13.10 Marine Operations....................................................................................................................13-31 13.11 Cost Considerations..................................................................................................................13-31 13.12 Summary....................................................................................................................................13-31 References..............................................................................................................................................13-32 14 Foundations for Concrete Structures Manjriker Gunaratne......................................................14-1 14.1 Foundation Engineering..............................................................................................................14-1 14.2 Site Exploration..........................................................................................................................14-27 14.3 Shallow Footings........................................................................................................................14-32 14.4 Mat Footings..............................................................................................................................14-37 14.5 Retaining Walls...........................................................................................................................14-43 14.6 Pile Foundations........................................................................................................................14-57 14.7 Caissons and Drilled Piers........................................................................................................14-76 References..............................................................................................................................................14-79 15 Specialized Construction Applications Husam S. Najm............................................................15-1 15.1 Introduction.................................................................................................................................15-2 15.2 Preplaced-Aggregate Concrete....................................................................................................15-2 15.3 Underwater Concrete..................................................................................................................15-6 15.4 Vacuum Processing....................................................................................................................15-13 15.5 Portland Cement Plaster Construction....................................................................................15-16 15.6 Self-Consolidating Concrete (SCC).........................................................................................15-19 15.7 Mass Concrete............................................................................................................................15-22 15.8 Roller-Compacted Concrete......................................................................................................15-23 Acknowledgment...................................................................................................................................15-26 References..............................................................................................................................................15-26 16 Structural Concrete Repair Randall W. Poston.............................................................................16-1 16.1 Introduction.................................................................................................................................16-1 16.2 Limit States Design for Repair....................................................................................................16-2 16.3 Evaluation.....................................................................................................................................16-3 16.4 Structural Implications................................................................................................................16-8 16.5 Repair Principles........................................................................................................................16-10 16.6 Repair of Unbonded Post-Tensioned Concrete Structures.....................................................16-16 16.7 Construction Issues...................................................................................................................16-19 16.8 Long-Term Repair Performance...............................................................................................16-20 16.9 Case Study..................................................................................................................................16-20 References..............................................................................................................................................16-41 Contents ix 17 Joints in Concrete Construction Edward G. Nawy.....................................................................17-1 17.1 Introduction.................................................................................................................................17-1 17.2 Construction Joints......................................................................................................................17-2 17.3 Contraction Joints.......................................................................................................................17-3 17.4 Expansion Joints..........................................................................................................................17-6 17.5 Joints in Slabs on Grade and Pavements.................................................................................17-10 References..............................................................................................................................................17-15 18 Automation in Concrete Construction Miroslaw J. Skibniewski and Raghavan Kunigahalli....18-1 18.1 Categories of Construction Automation....................................................................................18-1 18.2 Automated Construction Equipment and Related Hardware..................................................18-1 18.3 Economics and Management of Robots....................................................................................18-7 18.4 Computer-Aided Design.............................................................................................................18-8 18.5 Conclusions and Future Activities............................................................................................18-16 References..............................................................................................................................................18-17 19 Equipment for Concrete Building Construction Aviad Shapira.............................................19-1 19.1 Introduction.................................................................................................................................19-1 19.2 Equipment Selection....................................................................................................................19-2 19.3 Concrete Equipment..................................................................................................................19-12 19.4 Cranes.........................................................................................................................................19-21 19.5 Truck Loaders.............................................................................................................................19-43 19.6 Belt Conveyors...........................................................................................................................19-45 19.7 Material Handlers......................................................................................................................19-45 19.8 Hoists and Lifts..........................................................................................................................19-47 19.9 Mechanized Form Systems........................................................................................................19-48 Acknowledgment...................................................................................................................................19-51 References..............................................................................................................................................19-51 20 Roller-Compacted Concrete Ernest K. Schrader...........................................................................20-1 20.1 Introduction.................................................................................................................................20-1 20.2 Advantages and Disadvantages...................................................................................................20-7 20.3 Aggregates and Mixture Proportions.......................................................................................20-11 20.4 Material Properties....................................................................................................................20-21 20.5 Design.........................................................................................................................................20-40 20.6 Construction..............................................................................................................................20-54 Defining Terms......................................................................................................................................20-70 References..............................................................................................................................................20-71 21 Nondestructive Test Methods Nicholas J. Carino.........................................................................21-1 21.1 Introduction.................................................................................................................................21-1 21.2 Methods to Estimate In-Place Strength.....................................................................................21-2 21.3 Methods for Flaw Detection and Condition Assessment.......................................................21-28 21.4 Concluding Remarks.................................................................................................................21-62 References..............................................................................................................................................21-63 22 Fiber-Reinforced Composites Edward G. Nawy...........................................................................22-1 Part A. Fiber-Reinforced Concrete 22.1 Historical Development..............................................................................................................22-2 22.2 General Characteristics................................................................................................................22-2 22.3 Mixture Proportioning................................................................................................................22-4 22.4 Mechanics of Fiber Reinforcement.............................................................................................22-5 22.5 Mechanical Properties of Fibrous Concrete Structural Elements............................................22-8 22.6 Steel-Fiber-Reinforced Cement Composites............................................................................22-14 22.7 Prestressed Concrete Prism Elements as the Main Composite Reinforcement in Concrete Beams........................................................................22-17