Precast 101: Npca Precast Learning LAB

Precast Show 2019
NPCA PRECAST LEARNING

LAB
• What is it?
• A new library of short, educational
videos
• What can I learn?
• Topics cover production best practices and sales and PRECAST 101
marketing
Presented by Kayla Hanson
• How many videos are available?
• Four videos are currently available NPCA
• Videos will be added each year
• How do I access it?
• NPCA members can access the videos for free at
precast.org/education and click the Precast Learning
Lab button.
precast.org/education precast.org/education
1 2
OVERVIEW HISTORY
• What is precast?
• Raw materials
• Strength development
• Reinforcement
• Types of precast concrete
• Production
• Curing
• Testing and quality control
3 4
WHAT IS PRECAST? WHAT IS PRECAST?

• Composite material • Precast concrete: concrete cast elsewhere
• Made of natural ingredients, manufactured than its final location, cured in a controlled
materials, and industrial byproducts environment
• Displays highest strength in compression
• Service life can approach around 100 years
• Structural and architectural
• Infrastructure, residential, commercial,
industrial, natural habitats
5 6
NPCA 1
Precast Show 2019
RAW MATERIALS RAW MATERIALS
• Paste • Paste
• Aggregates • Cement
• Water
• SCMs
• Admixtures
• Aggregates
7 8
PORTLAND CEMENT
PORTLAND CEMENT
• Joseph Apsdin
• 1778-1855
+ + =
9 10
PORTLAND CEMENT PORTLAND CEMENT
11 12
NPCA 2
Precast Show 2019
CEMENT TYPES – ASTM C150 CEMENT TYPES – ASTM C150

• Type I: For general use when the special properties specified for any other • Type I: For general use when the special properties specified for any other type
type are not required are not required
• Type IA: Air-entraining cement for the same uses as Type I, where air- • Type IA: Air-entraining cement for the same uses as Type I, where air-
entrainment is desired entrainment is desired
• Type II: For general use, or when moderate sulfate resistance is desired • Type II: For general use, or when moderate sulfate resistance is desired
• Type IIA: Air-entraining cement for the same uses as Type II, where air- • Type IIA: Air-entraining cement for the same uses as Type II, where air-
• Type II(MH): For the same uses as Type II, and when moderate heat of hydration • Type II(MH): For the same uses as Type II, and when moderate heat of
is desired hydration is desired
• Type II(MH)A: Air-entraining cement for the same uses as Type II(MH), where • Type II(MH)A: Air-entraining cement for the same uses as Type II(MH),
air-entrainment is desired where air-entrainment is desired
• Type III: For use when high early strength is desired • Type III: For use when high early strength is desired
• Type IIIA: Air-entraining cement for the same uses as Type III, where air- • Type IIIA: Air-entraining cement for the same uses as Type III, where air-
• Type IV: For use when a low heat of hydration is desired • Type IV: For use when a low heat of hydration is desired
• Type V: For use when high sulfate resistance is desired • Type V: For use when high sulfate resistance is desired
13 14
CEMENT TYPES – ASTM C150 CEMENT TYPES – ASTM C150

• Type I: For general use when the special properties specified for any other type • Type I: For general use when the special properties specified for any other type
are not required are not required
• Type IA: Air-entraining cement for the same uses as Type I, where air- • Type IA: Air-entraining cement for the same uses as Type I, where air-
• Type II: For general use, or when moderate sulfate resistance is desired • Type II: For general use, or when moderate sulfate resistance is desired
• Type IIA: Air-entraining cement for the same uses as Type II, where air- • Type IIA: Air-entraining cement for the same uses as Type II, where air-
• Type II(MH): For the same uses as Type II, and when moderate heat of hydration • Type II(MH): For the same uses as Type II, and when moderate heat of hydration
is desired is desired
• Type II(MH)A: Air-entraining cement for the same uses as Type II(MH), where • Type II(MH)A: Air-entraining cement for the same uses as Type II(MH), where
air-entrainment is desired air-entrainment is desired
• Type III: For use when high early strength is desired • Type III: For use when high early strength is desired
• Type IIIA: Air-entraining cement for the same uses as Type III, where air- • Type IIIA: Air-entraining cement for the same uses as Type III, where air-
• Type IV: For use when a low heat of hydration is desired • Type IV: For use when a low heat of hydration is desired
• Type V: For use when high sulfate resistance is desired • Type V: For use when high sulfate resistance is desired
15 16
SUPPLEMENTARY
CEMENT TYPES – ASTM C150
CEMENTITIOUS MATERIALS
• Type I: For general use when the special properties specified for any other type
are not required
• Type IA: Air-entraining cement for the same uses as Type I, where air- • Supplementary cementitious materials (SCMs)
entrainment is desired
are used in conjunction with portland cement
• Type II: For general use, or when moderate sulfate resistance is desired
• Pozzolanic vs. hydraulic
• Type IIA: Air-entraining cement for the same uses as Type II, where air-
entrainment is desired • Can arrived pre-blended with hydraulic cement –
• Type II(MH): For the same uses as Type II, and when moderate heat of hydration ASTM C595
is desired
• Fly ash
• Type II(MH)A: Air-entraining cement for the same uses as Type II(MH), where
air-entrainment is desired • Slag
• Type III: For use when high early strength is desired
• Silica fume
• Type IIIA: Air-entraining cement for the same uses as Type III, where air-
entrainment is desired
• Type IV: For use when a low heat of hydration is desired
• Type V: For use when high sulfate resistance is desired
17 18
NPCA 3
Precast Show 2019
SUPPLEMENTARY
CHEMICAL ADMIXTURES
CEMENTITIOUS MATERIALS
• Most SCMs offer increased long-term strength • Air-entraining
• SCMs typically increase density, decrease
permeability, and improve durability • Water-reducing
• Early-age strength gain is often lower in mixes using • Plasticizers
SCMs compared to mixes using just Portland cement • Accelerators
• The finer particle size can also increase water
demand and make finishing tougher • Retarders
• Corrosion inhibitors
• Fly ash – ASTM C618 • Coloring
• Slag – ASTM C989
• Silica fume – ASTM C1240
19 20
WATER NORMAL WEIGHT AGGREGATES

• Water must be potable
• Well water or city water FINE COARSE COARSE
AGGREGATE AGGREGATE AGGREGATE
• Well water must conform to ASTM C1602 (CRUSHED STONE) (GRAVEL)
(SAND)
21 22
LIGHTWEIGHT AGGREGATES HEAVYWEIGHT AGGREGATES

EXPANDED EXPANDED
CLAY SHALE
GEOTHITE MAGNETITE
23 24
NPCA 4
Precast Show 2019
AGGREGATE SIZES AGGREGATES

• Fine aggregates: less than 5mm (0.2 in.) • Together, coarse aggregate and fine aggregate
• Coarse aggregates: greater than 5mm (0.2 in.) make up about:
• 60% - 75% of the concrete VOLUME
• 70% - 85% of the concrete MASS
❑ Clean
❑ Hard
❑ Strong
❑ Durable
❑ Free of impurities
25 26
AGGREGATE GRADING MAXIMUM AGGREGATE SIZE

Distance Between
Form
Forms (B)
B/5  MSA
Aggregate
Depth (D) Reinforcing Aggregate
D/3  MSA Bars
Slabs on Grade
Rebar Spacing (S)

3/4S  MSA
27 28
CONCRETE STRENGTH CONCRETE STRENGTH
• What does 5,000 psi mean?

• What kind of stresses do we anticipate?
29 30
NPCA 5
Precast Show 2019
CONCRETE STRENGTH LOADS AND FORCES

• Self-weight
• Stress = load per unit area • Hydrostatic loads
• Load = 36,000 lb
• Handling loads
• Area = 9 in.2
• Thermal movement
• Stress = 36,000 lb/9 in.2 = 4,000 lb/in.2 = 4,000 psi
• Concrete shrinkage
Load = 36,000 lb
• Buoyant forces
3 in. • Soil forces
• Wheel loads
3 in.
A = 9 in.2 • Wind, snow, rain,

and seismic loads
31 32

• What kind of loads and stresses do we anticipate? • What kind of loads and stresses do we anticipate?
• Point loads • Point loads
• Distributed loads • Distributed loads
33 34

• How do these forces act on the structure? • How do these forces act on the structure?
• Compression • Compression
• Tension • Tension
• Flexure • Flexure
• Torsion • Torsion
• Axial • Axial
35 36
NPCA 6
Precast Show 2019

• How do these forces act on the structure? • How do these forces act on the structure?
• Compression • Compression
• Tension • Tension
• Flexure • Flexure
• Torsion • Torsion
• Axial • Axial
37 38
CONCRETE STRENGTH REINFORCEMENT

• How do these forces act on the structure? • Reinforcement supplies strength to withstand
• Compression tensile and shear forces
• Tension
• Flexure
• Torsion
• Axial
39 40
CONCRETE STRENGTH REINFORCEMENT
41 42
NPCA 7
Precast Show 2019
MAIN HYDRATION PRODUCTS TRADITIONAL REBAR

• CSH: calcium silicate hydrate
• Greatest contributor to concrete strength • 60,000 ksi minimum tensile yield strength (Gr.
• CH: calcium hydroxide 60)
• Contributes very little to concrete strength • Elastic vs. plastic deformation
43 44
COMMON REBAR TYPES REBAR MARKINGS
• ASTM A615: deformed and plain carbon-steel

bars
• ASTM A706: low-alloy steel deformed and
plain bars
• ASTM A767: zinc-coated (galvanized) steel
bars
• ASTM A775: epoxy-coated reinforcing steel
bars
• ASTM A955: deformed and plain stainless-
steel bars
45 46
REBAR SIZE CHART REINFORCEMENT ISSUES
47 48
NPCA 8
Precast Show 2019
BOND EPOXY-COATED REINFORCEMENT
49 50
EPOXY-COATED REINFORCEMENT GALVANIZED REINFORCEMENT
51 52
FIBERGLASS REINFORCEMENT STEEL FIBER REINFORCEMENT
53 54
NPCA 9
Precast Show 2019
STEEL FIBER REINFORCEMENT SYNTHETIC FIBERS
55 56
PRESTRESSING
WELDED WIRE REINFORCEMENT
• Prestressed: concrete placed in compression
prior to supporting applied loads
• ASTM A185, ASTM A1064
• Pre-tension
• Post-tension
57 58
PRESTRESSING POSITIONING OF REINFORCEMENT
59 60
NPCA 10
Precast Show 2019
CONCRETE COVER
CONCRETE COVER
• Concrete cover over reinforcement must

always be ½” or greater
• Some ASTM standards have additional
requirements
• Example: ASTM C478 (for precast manholes)
requires at least ¾” concrete cover
61 62
CEMENT AND WATER HYDRATION
WATER
CEMENT
HYDRATION PRODUCTS
63 64
CEMENT HYDRATION WATER TO CEMENT RATIO

• Water to cement ratio (w/c): weight of water /
Calcium Silicate Calcium weight of cement in the batch
Hydrate Hydroxide
• Water to cementitious materials ratio (w/cm):
(Greatest contributor to weight of water / weight of all cementitious
strength) materials in the batch
• In the right quantities, water and

cement will create a very strong,
durable, and impermeable paste
• Water demand varies day-to-day
65 66
NPCA 11
Precast Show 2019
WATER TO CEMENT RATIO CEMENT AND WATER

• Water to cement ratio (w/c): weight of water /
weight of cement in the batch
• 240 lbs water / 500 lbs cement = 0.48
• Water to cementitious materials ratio (w/cm):

weight of water / weight of all cementitious
materials in the batch
• 240 lbs water / (50 lbs fly ash + 450 lbs cement) = 0.48
WATER CEMENT CONCRETE
67 68
CEMENT AND WATER PORES AND POROSITY
• Porosity: volume of the voids / total volume
• Pores are the remnants of

mixing water
• Pores do not carry load
• More pores means less
strength
• Porosity is a volumetric ratio
WATER CEMENT CONCRETE
69 70
AGGREGATE MOISTURE
PERMEABILITY
CONTENT
• Permeability: the ability of a material or
substance to pass through another material or
substance
• Measured as a speed
• More pores and higher
porosity results in higher
level of permeability
71 72
NPCA 12
Precast Show 2019
WATERTIGHTNESS
• Watertightness: constructed to
be impervious to water
• More pores and higher porosity results in

higher level of permeability
• Higher level of permeability reduces
watertightness
LOW LOW LOW

W/C POROSITY PERMEABILITY
73 74
PRODUCTION AGGREGATE STORAGE
75 76
AGGREGATE CROSS
HOPPERS
CONTAMINATION
77 78
NPCA 13
Precast Show 2019
HOPPERS HOPPERS
79 80
CEMENT STORAGE WEIGH BELTS
81 82
AGGREGATE MOISTURE PROBES MIXERS
Horizontal Shaft - Spiral Blade
83 84
NPCA 14
Precast Show 2019
MIXERS MIXERS
Twin Shaft
Horizontal Shaft - Paddle Blade
85 86
MIXERS MIXERS
Pan – Counter-Current
Pan - Turbine
87 88
MIXER PROBES AUTOMATED BATCH PLANTS
89 90
NPCA 15
Precast Show 2019
PLACING CONSOLIDATION
• Concrete should be deposited as near to its • Helps draw entrapped air to the unformed surface
final location as possible and out of the concrete
• Minimize free-fall heights to less than 6’ • Bugholes are a sign of insufficient consolidation
• Segregation is a sign of over-consolidation
91 92
CONSOLIDATION FINISHING
93 94
THREE KEYS TO CURING THREE KEYS TO CURING
Time Temperature Moisture
95 96
NPCA 16
Precast Show 2019
STEAM CURING
HOT AND COLD WEATHER CURING
97 98
QUALITY CONTROL PROGRAMS QUALITY CONTROL PROGRAMS

• Qualified and educated personnel
• Completeness of work orders and product drawings
• Quality of raw materials
• Quality of forms
• Fabrication and Positioning of Reinforcing Steel
• Concrete Quality
• Placement and consolidation of concrete
• Product dimensions
• Positioning of embedded items
• Curing of concrete
• Handling, storing and transporting products
• Recordkeeping
• Testing
99 100
CONCRETE PROPERTIES CONCRETE TESTING

• Fresh concrete properties • Unit Weight – ASTM C138 (at least weekly)
• Unit weight
• Air content
• Slump
• Slump flow, spread, or VSI
• Temperature
• Hardened concrete properties

• Strength
• Durability (resistance to abrasion, freeze/thaw, impact, fire,
etc.)
• Volume stability
• Density
• Watertightness
• Thermal and acoustic insulation
101 102
NPCA 17
Precast Show 2019
CONCRETE TESTING CONCRETE TESTING

• Air content – ASTM C231 and C173 (at least • Slump – ASTM C43 (daily)
weekly)
103 104
CONCRETE TESTING CONCRETE TESTING

• Slump flow, spread, VSI – ASTM C1611 (daily*) • Temperature – ASTM C1064 (daily)
105 106
DIFFERENT TYPES OF PRECAST WET CAST CONCRETE
• Conventional wet-cast
• Dry-cast
• Self consolidating concrete (SCC)
• High-performance concrete (HPC)
• Ultra high-performance concrete (UHPC)
107 108
NPCA 18
Precast Show 2019
DRY CAST CONCRETE SELF-CONSOLIDATING CONCRETE
109 110
HIGH PERFORMANCE
OVERVIEW
CONCRETE AND ULTRA-HIGH
PERFORMANCE CONCRETE • What is precast?
• Raw materials
• Strength development
• Reinforcement
• Types of precast concrete
• Production
• Curing
• Testing and quality control
111 112
PRECAST 101
Presented by Kayla Hanson
NPCA
khanson@precast.org
precast.org/education
113
NPCA 19

Precast 101: Npca Precast Learning LAB

Uploaded by

Copyright:

Available Formats

You might also like

Precast 101: Npca Precast Learning LAB

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Precast 101: Npca Precast Learning LAB

Uploaded by

Copyright:

Available Formats

Precast Show 2019

NPCA PRECAST LEARNING

WHAT IS PRECAST? WHAT IS PRECAST?

RAW MATERIALS RAW MATERIALS

PORTLAND CEMENT PORTLAND CEMENT

CEMENT TYPES – ASTM C150 CEMENT TYPES – ASTM C150

CEMENT TYPES – ASTM C150 CEMENT TYPES – ASTM C150

WATER NORMAL WEIGHT AGGREGATES

LIGHTWEIGHT AGGREGATES HEAVYWEIGHT AGGREGATES

AGGREGATE SIZES AGGREGATES

AGGREGATE GRADING MAXIMUM AGGREGATE SIZE

Rebar Spacing (S)

CONCRETE STRENGTH CONCRETE STRENGTH

• What does 5,000 psi mean?

CONCRETE STRENGTH LOADS AND FORCES

A = 9 in.2 • Wind, snow, rain,

CONCRETE STRENGTH CONCRETE STRENGTH

CONCRETE STRENGTH CONCRETE STRENGTH

CONCRETE STRENGTH CONCRETE STRENGTH

CONCRETE STRENGTH REINFORCEMENT

CONCRETE STRENGTH REINFORCEMENT

MAIN HYDRATION PRODUCTS TRADITIONAL REBAR

COMMON REBAR TYPES REBAR MARKINGS

• ASTM A615: deformed and plain carbon-steel

REBAR SIZE CHART REINFORCEMENT ISSUES

BOND EPOXY-COATED REINFORCEMENT

EPOXY-COATED REINFORCEMENT GALVANIZED REINFORCEMENT

FIBERGLASS REINFORCEMENT STEEL FIBER REINFORCEMENT

STEEL FIBER REINFORCEMENT SYNTHETIC FIBERS

PRESTRESSING POSITIONING OF REINFORCEMENT

• Concrete cover over reinforcement must

CEMENT AND WATER HYDRATION

CEMENT HYDRATION WATER TO CEMENT RATIO

• In the right quantities, water and

WATER TO CEMENT RATIO CEMENT AND WATER

• Water to cementitious materials ratio (w/cm):

WATER CEMENT CONCRETE

CEMENT AND WATER PORES AND POROSITY

• Porosity: volume of the voids / total volume

• Pores are the remnants of

• More pores and higher porosity results in

LOW LOW LOW

PRODUCTION AGGREGATE STORAGE

CEMENT STORAGE WEIGH BELTS

AGGREGATE MOISTURE PROBES MIXERS

Horizontal Shaft - Spiral Blade

Horizontal Shaft - Paddle Blade

MIXER PROBES AUTOMATED BATCH PLANTS

THREE KEYS TO CURING THREE KEYS TO CURING

Time Temperature Moisture

QUALITY CONTROL PROGRAMS QUALITY CONTROL PROGRAMS

CONCRETE PROPERTIES CONCRETE TESTING

• Hardened concrete properties

CONCRETE TESTING CONCRETE TESTING

CONCRETE TESTING CONCRETE TESTING

DIFFERENT TYPES OF PRECAST WET CAST CONCRETE

DRY CAST CONCRETE SELF-CONSOLIDATING CONCRETE