Rebar Concrete BUILDING CONSTRUCTION PowerPoint Presentation on CD
(available quantity 4,567)
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Includes the Adobe Acrobat Reader for reading and printing publications.
Numerous illustrations and matrices.
Contains the following key public domain (not copyrighted) U.S. Government publication(s) on one CD-ROM in both Microsoft PowerPoint and Adobe Acrobat PDF file formats:
TITLE:
Basic Building Construction I and II, 64 slides
SLIDE TOPICS, SUBTOPICS and CONTENTS:
Basic Building Construction I Structural Concrete, Reinforcing Steel & CMU Masonry Structural Concrete Mix Design- Contractor submits the mix design he proposes to use. It shows evidence from previous testing of the strength of the mix. It is reviewed by the government engineers and approved or disapproved. Designer specifies required strength in the specifications- Usually 28 MPa at 28 days.
Concrete- Temperature Field Testing of Concrete- Temperature Temperature- ACI requires temperature to be between 5 C and 32 C. If concrete temp is 5C-29C then the concrete has to be placed within 90 minutes of batching. If concrete temp is 30-32 C then it must be placed within 45 minutes of batching. If the concrete is more than 32 C then it cannot be used, and QC Manager should reject it. Check your projects specifications, humidity may affect allowable temperatures. Structural Concrete- Slump Normally, on USACE projects the slump of the concrete must be between 25mm & 100mm Check specifications for frequency of slump testing
Structural Concrete- Air Some contracts require concrete to have air entrainment Generally the required air entrainment is 3-5% The purpose of air entrainment is to prevent spalling of concrete due to freeze-thaw cycles Important for concrete that is exposed to the weather
Structural Concrete- Compressive Strength Specimens will be taken at the job site and tested in a lab for compressive strength Check your specs for frequency of testing Cylinders should not be disturbed for 24 hours and should be kept under the same conditions as the concrete that was placed
Structural Concrete- Pre-Placement Inspection Inspect formwork- No voids, proper dimensions, oiled or wet down, clean Rebar- Check sizes, spacing, lap lengths, clearance, free or oil or other foreign materials. Light surface rust is acceptable. Generally, rebar cover should be: 75mm for concrete cast against earth, 50 mm for formed surfaces, 25mm for tops of slabs not exposed to weather- Check your specs Structural Concrete- Pre-Placement Inspection Joints- Check location and construction of joints- Control joints, expansion joints, construction joints. Smooth dowels in control joints should be level & square to the joint. Often, one end is required to be painted and/or greased. Plumbing- Sleeves, pipes, etc Electrical- Conduit, sleeves, etc Other- Anchor bolts, block outs, water stops, etc Chamfer strips for exposed corners
Structural Concrete- Vapor Barrier Generally, designers require a polyethylene vapor barrier below slabs on grade (SOG’s), to prevent water vapor from permeating the concrete slab Usually the requirement is a 0.15mm polyethylene sheet, overlapped at least 30cm at the joints. Punctured areas should be overlaid with new polyethylene prior to concrete placement Care must be taken to avoid damaging the barrier during placement Structural Concrete- Capillary Water Barrier Generally, designers require a capillary water barrier below the vapor barrier for slabs on grade Capillary water barriers usually consist of a poorly graded crushed rock or gravel, “poorly graded” refers to fairly uniform gradation that has voids and allows water to easily pass through If sharp edges of crushed rock pose a risk of puncture to the vapor barrier, some specs allow a layer of sand on top to protect the vapor barrier- Check your specs Structural Concrete- Placing Concrete should not be placed on mud or standing water Surfaces to receive the concrete (forms, rebar, etc.) must be at least 5C On USACE projects, any concrete with a thickness of 10cm or deeper must be properly vibrated Vibrator should be inserted and removed vertically, not dragged horizontally Concrete should not be allowed to drop more than 1.8 meters Except for slabs, concrete should be deposited in layers of not more than 30cm and each layer vibrated Structural Concrete- Placing Concrete should be deposited as close to it’s final position as possible Concrete should not be allowed to drop more than 1.8 meters Concrete should be placed in a manner to avoid “cold joints” Immediately after placing, concrete should be screeded to proper elevation
Structural Concrete- Finishing After screeding, concrete should be “bull-floated” before bleedwater is present on top If required by the design, troweling occurs after bleedwater has disappeared and concrete has partially hardened Exposed edges may be required to be edged with an edging tool for attractive appearance
Structural Concrete-Curing Immediately after placement, concrete shall be protected from premature drying, extremes in temperatures, rapid temperature change, mechanical injury and damage from rain and flowing water for the duration of the curing period. Check specs for length of curing period During curing period the concrete must be kept wet- burlap, immersion, etc
Structural Concrete-Curing Temperature of concrete must be kept above 5C during curing period Contractor is required to monitor curing with periodic inspections and corrective action Curing is VERY important, especially in the hot dry conditions of Afghanistan
Structural Concrete- Saw Cut Joints If the contract requires sawcut joints, sawcutting should be done as soon as possible without spalling the concrete or tearing out the coarse aggregate If sawcutting is done too late, uncontrolled cracking may occur Structural Concrete-Formwork Forms shall be mortar tight, properly aligned and adequately supported to produce concrete surfaces meeting the surface requirements specified in the contract- Check your spec for tolerances USACE specs allow the soil to be used as forms of concrete that won’t be visible, as long as the soil is strong enough to hold a vertical face Check dimensions, plumbness, elevation, straightness, etc. Formwork for exposed concrete should be inspected for general appearance and condition, clean, & oiled with a form realeasing agent; the concrete will only look as well as the surface of the forms
Structural Concrete-Form Removal Forms should be removed carefully to prevent damage to the new concrete Generally, vertical forms may be removed after 24 hours, if the concrete is of sufficient strength to support itself Generally, supporting forms of beams, elevated slabs, windows, doors, etc. may be removed after concrete has reached 70% of it’s design compressive strength. Concrete must be inspected after form removal and deficiencies repaired per the requirements of the specs (honeycombs, etc.) Reinforcing Steel Generally, designers base their design on reinforcing steel yield strength of 420 MPA Contractors must submit their rebar with certification of the yield strength of the steel Contractors should also submit “mill certificates” showing the results of testing from the factory for the steel used by the contractor. Reinforcing Steel If the design drawings do not include enough detail to fabricate the rebar and install the rebar, shop drawings should be submitted for review showing lengths, lap lengths, bending details, etc. Structural reinforcement should be deformed (not smooth) Considerations during inspection: size, spacing, splices, cover, free of loose rust, oil, support, etc. Reinforcing steel should be tied together securely with steel wire of 1.6mm diameter or larger
Masonry- CMU
CMU- Concrete Masonry Unit (concrete block) Contractor must submit test results showing that the CMU they plan to use complies with the compressive strength requirements. Generally, CMU on USACE projects must comply with ASTM C 90
Masonry- CMU ASTM C 90 Requirements Sizes- ASTM C 90 specifies thickness of block ASTM C 90 requires that the average compressive strength of three CMU tested must be 13.1 MPA (1900 PSI) or greater, with no specimen falling below 11.7 MPA (1700 PSI) ASTM C 140 specifies that actual procedure for testing, frequency of testing, etc. Masonry- CMU Mortar Mortar- Generally required to have a compressive strength of 13.7 MPA (140 kg/cm2) The project specifications may give a mix design, or the contractor may have to submit one- check your specs Generally, compressive strength of mortar is tested ASTM C 109, using small cubes. Mortar should be mixed in a mixer for no less than 3 minutes, and no more than 5 minutes Masonry- CMU Mortar Ingredients should be accurately measured by volume using measuring boxes, enough water added to make the mortar workable Any mortar not used within 2-1/2 hours after mixing must be discarded Mortar that will be exposed on the final construction should have tooled joints (concave) Masonry- CMU Grout Generally, grout is required to have a 28 day minimum compressive strength of 14 MPA- but check your specs, as it may vary Generally, grout should have a slump of 20-25 cm Grout mixed on the site should be mixed for at least 5 minutes Grout should be vibrated once it is deposited in the CMU cells
Masonry- CMU Grout CMU cells should be inspected prior to grout placement to make sure they are not full of mortar droppings and foreign material. Grout that has not been used within 1-1/2 hours after mixing must be discarded
Masonry- Joints Check drawings for masonry joint locations, and details of construction Rebar runs through some joints and not through others, familiarity with the drawing details are critical to proper QA surveillance
Masonry- Steel Reinforcement Vertical reinforcement should be imbedded in the concrete footing or slab supporting the wall Check drawings for size, spacing and lap length, a common lap length is 40 bar diameters Drawing details often require extra rebar at corners, doors & windows Check specifications for required clearances from CMU, commonly it is 13mm Check drawings and specs for requirement of horizontal reinforcing- size and spacing Masonry- Misc. QA Considerations Some common miscellaneous considerations for QA’s related to masonry - Tolerances. Check the specifications for allowable tolerances for straightness and plumbness - “Running Bond” pattern. - Temperatures. See specifications for temperature limitations of masonry work - Bond beams, lintels, etc Basic Building Construction II Finishes: Cementious Plaster, Terrazzo Tile, Ceramic Tile Cementitious Plaster Mixture of cement, sand, water and sometimes lime (to increase workability and decrease permeability) Also known as “stucco” when used on exterior walls 4 parts sand: 1 part cement: 3/4-1.5 part lime for first and second coats. 3 parts sand; 1 part cement: ¾-1.5 parts lime for finish coat (per ASTM C926) Plaster should be mechanically mixed for 3-5 minutes Cementitious Plaster Generally applied in three coats: First coat- “Splash Coat”: Very high slump, promotes bonding between surface and the plaster Second Coat- “Scratch Coat”: Many designs require 1 cm thickness, once it starts hardening the surface is scratched horizontally for bonding with the next coat Third coat- “Finish Coat”: Usually 1 cm thick, must have straight, plumb, smooth etc.
Cementitious Plaster Surface Preparation- Smooth concrete surfaces should be roughened prior to placing splash coat Surfaces should be clean and free of dirt and loose materials Temperatures should be above 5 C for 48 hours prior to plaster application Generally, the contracts require the use of stop beads & corner beads. Check YOUR contract. Cementitious Plaster Curing- The specs for many of our contracts require scratch coat to be moist cured for 72 hours and finish coat for 48 hours minimum Plaster Stop Bead Scratch Coat & Finish Coat Corner Bead with Finish Coat on Right Side, CMU on left side Corner Beads Installed on Sides of Windows, Stop Bead at Bottom Terrazzo Tile Most designs at AED use a damp mortar leveling bed on top of concrete floor Floor should be swept clean and free of trash and loose material Tile should be layed out from centerline of room. Adjustments may be made to avoid thin tiles at the edges If there are floor drains, the tile should be sloped toward the drain
Terrazzo Tile String lines should be used for correct elevation and alignment Once tiles are set, a grout consisting of white cement & marble dust is used to fill the joints Tiles are then ground smooth. This may be done in 3-4 steps with progressively smoother stones Finally, tiles are sealed and polished Terrazzo Tile Set on a Damp Mortar Bed White Cement Grout Grinding the Tile Ceramic Tile Temperatures of 10ºC should be maintained during tile installation and for 7 days after completion A pre-mixed adhesive mortar should be used, manufactured specifically for use with ceramic tile Adhesive mortar should be applied with a notched trowel Ceramic Tile Tile should be layed out from center line of wall, some adjustments can be made to avoid the use of very thin tiles on the sides “Jointing crosses” should be used to maintain consistent joint size A pre-mixed grout should be used for filling of joints. It is forced into the joints with a rubber trowel. After 15-30 minutes, the tile should be cleaned with a damp sponge. When finished the joint should be concave. Ceramic Wall Tile Being Installed Note the mortar was applied with notched trowel, jointing crosses being used
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