ConCrete Portable Handbook R. Dodge Woodson AMSTERDAM • BOSTON • HEIDELBERG • LONDON  NEW YORK • OXFORD • PARIS • SAN DIEGO  SAN FRANCISCO • SINGAPORE • SYDNEY • TOKYO Butterworth-Heinemann is an imprint of Elsevier Butterworth-Heinemann is an imprint of Elsevier 225 Wyman Street, Waltham, MA 02451, USA The Boulevard, Langford Lane, Kidlington, Oxford, OX5 1GB, UK © 2012 Elsevier Inc. All rights reserved. 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Library of Congress Cataloging-in-Publication Data Woodson, R. Dodge (Roger Dodge), 1955-   Concrete portable handbook / R. Dodge Woodson.         p. cm.   Includes bibliographical references and index.   ISBN 978-0-12-382176-8 (alk. paper)  1.  Concrete—Handbooks, manuals, etc.  I. Title.   TA439.W584 2011   624.1'834—dc23   2011016242 British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library. For information on all Butterworth-Heinemann publications  visit our website at: www.elsevierdirect.com Printed in the United States of America 11  12  13  14  15    10  9  8  7  6  5  4  3  2  1 Typeset by: diacriTech, India This book is dedicated to my daughter, Afton, and her new husband, Giovanni. May Mr. and Mrs. Sinclair enjoy a healthy, happy, productive marriage for their future years. This page intentionally left blank Short Contents 1. basic Information 1 20. avoiding on-the-Job Injuries 175 2. Concrete Materials 5 21. Worksite Survival 185 3. durability and Protection 19 appendix I: background Facts and Issues 4. Mixing and Placing Concrete 23 Concerning Cement and 5. Concrete Formwork 41 Cement data 195 6. reinforcement 47 appendix II: Concrete Pavement technology 7. General design Consideration 53 Update 285 8. requirements for Strength and appendix III: Foundry Sand Facts for Serviceability 59 Civil engineers 299 9. Inspecting In-Place Concrete 65 appendix IV: Increasing the Quality of 10. Concrete Failure 83 Concrete and Concrete 11. Concrete repair Preparation 95 related Products 379 12. removal and repair 103 appendix V: Concrete and Masonry 13. rehabilitation Work 113 Construction 403 14. Maintenance Matters 133 appendix VI: Glossary of abbreviations 427 15. Specialized repairs 139 appendix VII: Common definitions 431 16. Problem Solving 149 appendix VIII: Industry resources 437 17. Code requirements 153 Glossary 443 18. How Much do You know? 165 Index 449 19. Working with Code requirements 171 v This page intentionally left blank Full Contents Acknowledgments  xi bundling bars 48 About the Author  xiii How Much Coverage Is needed? 50 Column Support 50 Introduction  xv Some Spiral Facts 52 ties 52 1. basic Information 1 Structural Integrity 52 Paperwork 1 7. General design Consideration 53 Inspection 2 Special Considerations 3 analysis 53 length of Spans 54 2. Concrete Materials 5 Columns 54 live load assumptions 55 aggregates 16 t-beam Construction 55 Water 16 Joist Construction 56 Steel reinforcement 17 Finished Flooring 57 admixtures 17 Storage of Materials 18 8. requirements for Strength and Serviceability 59 3. durability and Protection 19 design Strength 61 Complicated Calculations 61 Special exposure Conditions 19 local Practices 62 Corrosion Protection 21 Common Sense 62 4. Mixing and Placing Concrete 23 9. Inspecting In-Place Concrete 65 average Compressive Strength 23 Plans and Specs 66 Site Preparation 25 Judging the Site 66 Mixing Concrete 26 Quality of Installation 66 depositing Concrete 34 Cracked Concrete 67 Curing 37 Crack activity 70 Weather Conditions 38 Crack occurrence 70 disintegration 71 5. Concrete Formwork 41 Scaling 71 Form removal 41 dusting 72 embedded Items 43 distortion 72 Construction Joints 44 erosion 72 Pre-Formed Concrete Products 44 Seal Failure 73 Special Cases of Spalling 73 6. reinforcement 47 delamination 74 Standard Hooks 47 Crack Surveys 74 Condition of reinforcement Materials 48 Sizing Cracks 74 reinforcement Spacing 48 Mapping 75 vii viii FUll ContentS Joint Inspections 76 Plug-Feather Splitter 108 Core drilling 76 Prep Work 108 Underwater Concrete 76 reinforcing Steel 110 High-resolution acoustic Mapping System 78 anchors 110 Side Scanner 78 other Means of Underwater testing 79 13. rehabilitation Work 113 laboratory Work 80 Prestressing Steel 114 Chemical analysis 80 autogenous Healing 114 Physical analysis 80 Conventional Placement 115 nondestructive testing 80 Crack arrest techniques 118 other Considerations 82 drilling and Plugging 118 drypacking 119 10. Concrete Failure 83 Fiber-reinforced Concrete 121 Unintentional loads 83 Flexible Sealing 122 Chemical reactions 84 Gravity Soak 123 Corrosion 89 Chemical Grouting 124 Freezing and thawing 91 Hydraulic-Cement Grouting 124 Settlement and Movement 91 High-Strength Concrete 124 Shrinkage 92 Jacketing 125 Fluctuations in temperature 93 Judicious neglect 125 Polymer overlays 125 11. Concrete repair Preparation 95 Polymer Coatings 126 Polymer Concrete 127 Compressive Strength 95 Polymer Impregnation 127 Modulus of elasticity 96 Polymer Injection 127 thermal expansion 96 Pre-Cast Concrete 129 bonding 96 Preplaced-aggregate Concrete 130 drying Shrinkage 96 rapid-Hardening Cement 130 Creep 98 roller-Compacted Concrete 130 Permeability 98 routing and Sealing 130 Planning a repair 99 Shotcrete 131 Manufacturer’s data 102 Shrinkage-Compensating Concrete 131 12. removal and repair 103 14. Maintenance Matters 133 removal Methods 104 Stains 133 blasting 104 Stain removal 135 Crushing 105 Cleaning details 135 Cutting 105 Coatings and Sealing Compounds 138 Impacting Methods 106 boom-Mounted Concrete breakers 106 15. Specialized repairs 139 Spring-action Hammers 106 Hand-Held Impact breakers 107 rehabbing lock Walls 139 Hydromilling 107 Cast-in-place 140 rotary-Head Milling 107 blasting lock Walls 140 Pre-Splitting 107 anchors 142 Chemical agents 108 Concrete Placement 142 Piston-Jack Splitters 108 Shotcrete 143 FUll ContentS ix Preplaced-aggregate Concrete 143 19. Working with Code requirements 171 Pre-Cast Concrete 143 lax Jobs 171 Cutoff Walls 144 Strict Code enforcement 172 Pre-Cast Concrete applications 144 Safety 172 Underwater repairs 145 Fees 172 Geomembrane Work 147 know Your Inspectors 173 roller-Compacted Concrete 147 local Jurisdictions 173 Common Sense 173 16. Problem Solving 149 bad design data 150 20. avoiding on-the-Job Injuries 175 Chemical attack 150 Very dangerous 175 alkali–aggregate reaction 150 General Safety 177 Freezing 151 Clothing 178 Moving Water 151 Jewelry 179 Cavitation 151 eye and ear Protection 179 the roundup 151 Pads 179 17. Code requirements 153 tool Safety 180 Power Mixers 181 Concrete Selection 153 Co-Worker Safety 183 Compressive Strength 154 Field-Cured Specimens 154 Putting Concrete in Place 155 21. Worksite Survival 185 Mixing Concrete 155 open Wounds 186 Placing Concrete 156 Splinters and Foreign objects 188 Curing 156 eye Injuries 189 Form design 156 Scalp Injuries 189 Form removal 157 Facial Injuries 190 embedded Items 157 nose bleeds 190 Construction Joints 158 back Injuries 190 reinforcement 158 legs and Feet 191 Column reinforcement 159 Hand Injuries 191 Connections 159 Shock 191 Spirals 160 Checklist of Shock Symptoms 192 ties 160 burns 193 Shrinkage 161 Heat-related Problems 194 Structural Integrity requirements 161 live loads 161 t-beams 162 appendix I: background Facts and Issues Concerning Joist Construction 162 Cement and Cement data 195 First Step 162 Preface 198 Units of Measurement 199 18. How Much do You know? 165 Contents 201 true or False Quiz 165 Part 1: overview of Hydraulic Cements 204 Multiple-Choice Questions 167 references Cited in Part 1 245 Correct answers for true–False Questions 170 Glossary of terms 248 Correct answers for Multiple-Choice links to other Sources of Information on Cement Questions 170 and Concrete 260