1

Concrete and Masonry

Section 13
Unit 39
2
Introduction
Most buildings have concrete and/or masonry
components.
The ability to use concrete and masonry materials is an
essential skill for construction and, repair and
maintenance of buildings.
bioen.okstate.edu/Home/fharry/3011/600_PP/3_Concrete.ppt


3
Concrete
4
Concrete
Concrete is a mixture of stone aggregates, sand, Portland
cement, and water that hardens as it dries.*
Concrete does not dry, it goes through a chemical reaction
called hydration.
*Agricultural Mechanics, Herren
5
Concrete - cont.
Advantages
Fireproof
Insect & rodent proof
Decay resistant
Storm resistant
Wear resistant
Waterproof (water
resistant)
Strong
Attractive
UV resistant
Doesnt require expensive
equipment.
Available locally
Low original and maintenance
costs
Sanitary and easy to keep clean
Recyclable
Concrete is truly a versatile building material. It can be formulated
with very specific performance characteristics in mind and include
lightweight, heavyweight, porous, fiber-reinforced, mass, high-
performance and cellular concretes.
6
Concrete - cont.
Disadvantages
Labor intensive
Requires moving a lot of weight
Requires forms
Dense material
Special skills required to place and finish
7
Seven (7) Characteristics of Concrete
7. Resistant to freezing and thawing
6. Weak in tension
5. Very strong in compression
4. Fire resistant
3. Resists manures and most chemicals.
2. Resists attack by water
1. Durable
8
Def: The ability of concrete to resist weathering action,
chemical attack and abrasion while maintaining its
desired engineering properties.
Characteristic 1
Durability
Concrete ingredients, their proportioning, interactions between them,
placing and curing practices, and the service environment determine
the ultimate durability and life of concrete.
9
Characteristic 2
Resists Attack by Water
Watertightness: the ability of concrete to hold back or retain water
without visible leakage.
Permeability: the amount of water migration through concrete
when the water is under pressure or the ability of
concrete to resist penetration by water or other
substances.
Two characteristics;
watertightness and permeability.
10
Characteristic 2
Resists Attack by Water -cont.
1. Permeability of the paste
2. Permeability and gradation of the aggregate
3. Quality of the paste
4. Quality of the paste--aggregate transition zone
5. Relative proportion of paste to aggregate
Factors that affect
permeability and water
tightness include:
Low permeability concrete requires a low
water-cement ratio.
Moist curing also reduces permeability.
The same properties of concrete that make it less permeable also
make it more watertight.
11
Characteristic 3
Resists manures and most chemicals.
1. Good quality concrete is resistant to the acids of manure.
2. Concrete is very alkaline, pH is usually greater than 12.5.
3. Resistance can be increased with surface treatments.
4. Concrete is susceptible to deterioration by sulfates.
12
Characteristic 4
Fire Resistant
The strength of concrete will deteriorate with high temperatures.
1. Concrete provides the best fire resistance of
any building material.
2. It does not burn, it cannot be 'set on fire' like
other materials in a building and it does not
emit any toxic fumes, smoke or drip molten
particles when exposed to fire.
3. Concrete and its mineral constituents enjoy
the highest fire resistance classification.
13
Characteristic 5
Strong in Compression
The compressive strength depends
on:
1. The strength of the aggregate
2. Proportion of aggregate sizes
3. Type of Portland cement
4. Purity of water
5. Uniformity of mixture
6. Procedures used in placing,
finishing and curing


Material
Compress ive
Stren gth
(lb/in
2
)
Concrete 25,0 00
Wood* 2 4,00 0
Stone
Granite 10,0 00
Limestone 10,0 00
Marble 10,0 00
Sandst one 5,00 0
* Paral l el to th e grai n
14
Compressive Strength Influenced by Water/cement Ratio
15
Characteristic 6
Concrete is weak in tension
Does this table and picture show why steel reinforcement is use in
concrete?


Material
Tension Stren gth
(lb/in
2
)
Concrete 2,50 0
Wood* 10 15, 000
Steel 50 70, 000
* Paral l el to th e grai n
16
Characteristic 7
Concrete is resistant to freezing and thawing
The resistance decreases as the permeability increases.
When concrete spaces are 91% or more full of water, freezing
will damage the concrete.
When water freezes to ice it occupies 9% more volume than
that of water.
Air entrained concrete is less permeable.
Example of freezing damage:
17
Concrete Constituents
18
Concrete Constituents
Concrete: a mixture of aggregate and Portland cement paste.
Aggregate: usually sand, gravel and/or crushed stone.
Process: the paste binds the aggregates into a rocklike mass as the
paste hardens because of the chemical reaction (hydration)
of the Portland cement and water.
Paste: Portland cement and water
Proportion of Constituents
Basic concrete mix:
Air 6%
Portland cement 11%
Coarse aggregate 41%
Fine aggregate 26%
Water 16%
19
20
Admixtures
Admixtures are materials other than cement,
aggregate and water that are added to concrete
either before or during its mixing to alter its
properties, such as workability, curing temperature
range, set time or color. (http://www.toolbase.org/)
Admixtures cannot compensate for bad practice and low
quality materials.
21
Admixtures - cont.
Addition of fiber to concrete makes it tough and fatigue resistant.
Such type of admixtures are used extensively in important
engineering projects.
Common admixtures
Retarding admixtures
Accelerating admixtures
Super plasticizers
Water reducing admixtures
Air-entraining admixtures
Additional admixtures
Bonding,
Shrinkage reduction,
Damp proofing and
Coloring.
22
Types of Cement
Different types of Portland cement are manufactured to meet
many different applications of concrete.
Type I Normal
Type IA Normal, air-entrained
Type II Moderate sulfate resistance (MSR)
Type IIA MSR, air-entrained
Type III High early strength (HES)
Type IIIA HES, air-entrained
Type IV Low heat of hydration
Type V High sulfate resistance
Types I & IA are the most common.
23
Air Entrained
Developed during the 1930s
Recommended for nearly all concretes that are
exposed to freezing and thawing, and deicing
chemicals.
Produced by using air-entraining
cement or by using an air-
entraining admixture.
Spalding is a characteristic of
using concrete without air
entrainment.
24
1. Increased freeze-thaw resistance
2. Increased deicer-scaling resistance
3. Improved sulfate resistance
4. Equivalent Strength
5. Improved workability
25
Aggregate
26
Aggregate
Concrete should include at least two different sizes of
aggregate--fine and coarse.
Fine = 1/4 inch or less (not to include fines)
Coarse = 1/4 to 2 inch
Standard practice is to crush stone and the use screens to
separate the sizes.
The correct proportion of fine aggregate and coarse aggregate can
then be mixed together.
Aggregate should be 60 to 80 % of the volume. (cheapest
material).
Stream bank aggregate must be tested for excessive silt and
clay. (page 557, Fig 39-2)
27
Aggregate-cont.
Aggregate diameter must not exceed 1/5 of void in
forms were rebar is used.
The largest recommended aggregate size is 2 inches
for most applications.
Aggregate diameter must not exceed 1/3 of slabs that
do not use rebar.
28
Purchasing Concrete
29
Purchasing Introduction
For large jobs in is common practice to have the concrete
delivered to the site.
The cost of having concrete delivered is determined by:
Quantity
Mix
Minimum charge
Unload fee
Mileage fee
30
Purchasing Concrete - Quantity Needed
Quantity needed
Concrete is sold by the cubic yard (yd
3
).
To determine the quantity need calculate the volume
in cubic inches (in
3
) or cubic feet (ft
3
) and convert to
cubic yards (yd
3
or just yd).
27 ft
3
= 1 yd
46656 in
3
= 1 yd
Common practice to add 5 to 10% for waste and
volume errors.
31
Purchasing Concrete Quantity - Example
Determine the yards of concrete that will be required to pour a
driveway that is 26 feet wide, 120 feet long and 6 inches thick.
Solution:


ft
3
= 26 ft x 120 ft x 6 in x
1 ft
12 in
= 1, 560 ft
3



yd
3
= 1560 ft
3
x
1 yd
3
27 ft
3
= 57.777... or 58 yd
3

Adding 10%.


58 yd
3
x 1.1 = 63.8 or 64 yd
3

Purchasing - Mix
Two factors which determine the ideal mix.
Environment
Intended use
32
Environmental factors
Soil phosphates
Freeze thaw
De-icers
Use factors
Maximum Load
Vibration
Purchasing Basic Mix
33
Purchasing Slump
The inches of slump indicates the water-cement ratio and the
quality of the concrete.
34

Concrete Construction
Slump, in.
Maximum Minimum
Reinforced foundations walls and footings 3 1
Plain footings, caissons, substructure walls 3 1
Beams and reinforced walls 4 1
Building columns 4 1
Pavements and slabs 3 1
Mass concrete 3 1
Slump is determine through a slump test.
Slump - Test
A slump test is conducted using an
Abrams cone, slump cone.
A slump cone is 8 inches in diameter at
the bottom, 4 inches in diameter at the
top and 12 inches tall.
35
Slump Test cont.
36
Steps:
1 Moisten cone
2 Place cone on moist, smooth non absorbent level surface
that is larger the the lugs on the cone.
3 While standing on the lugs, fill the cone 1/3 and uniformly
rod 25 times.
4 Fill the cone 2/3 full and rod the 25 times insuring the rod
just penetrates the first layer.
5 Over fill the cone and rod 25 times
6 Strike off the excess with the rod.
7 Slowly lift the cone vertically and place on surface beside
concrete.
8 Place rod across the top of the cone and the concrete and
measure the distance from the bottom of the rod to the
surface of the concrete.
9 This distance is the inches of slump.

37
Mixing Concrete
38
Introduction
Small jobs can be mixed at the site.
Concrete weights over 4,000 pounds per cubic yard.
Therefore, it is important to determine amount of concrete
first, because even a small volume of concrete can
require moving a lot of material.
Using Quikcrete is a popular option to reduce the work.
For more information go to:
http://www.nrmca.org/aboutconcrete/
39
Quikrete
40
Mixing Concrete
Characteristics of good mix:
1. Each aggregate particle is covered with cement paste
2. Each aggregate particle is bound to others
Cement paste
Water--cement ratio must be exact proportions.
Water in aggregate must be accounted for and deducted from
water added to mix.
Water--cement ratio must be adjusted for different service
conditions.
41
Concrete Mixes


1 2 2 - 1/4
1 = 1 ft
3
(sack) of Portland cement
2 = 2 ft
3
of fine aggregate
2-1/4 = 2.25 ft
3
of coarse aggregate
The proportions of water, Portland cement, fine aggregate and
course aggregates are not the same for all concrete jobs.
When mixing concrete it is common to express the mix (receipt)
as a proportion. For example:
The proportions can be used on a volume or weight basis
42
Proportions
The proportions must be changed to meet the service
conditions.

Intended use

Cement
Fine
Aggregate
Coarse
Aggregate
Mild Exposure 1 3 4
Normal Exposure 1 2-1/4 3
Severe Exposure 1 2 2-1/4
43
Mixing--cont.
The amount of water in the aggregate must be included in the
calculations.
Effect of water in aggregate. (Fig 39-3)



Intended
Use



Maximum
Aggregate Size (in)

Water (gal) added to 1
ft
3
of cement if sand is:
Suggested Mixture for 1 ft
3
Trial
Batch

Cement
(ft
3
)
Aggregates
Damp Wet Very
Wet
Fine
(ft
3
)
Coarse
(ft
3
)
Mild 1-1/2 6-1/4 5-1/2 4-3/4 1 3 4
Normal 1 5-1/2 5 4-1/4 1 2-1/4 3
Severe 1 4-1/2 4 3-1/2 1 2 2-1/4
Water vs. strength
44
Effect of Adding Water
Adding 1 gal of water to 1 yd
3
of concrete:
Increases slump 1 inch
Decrease compressive strength by 200 psi
Increases shrinkage by 10%
Increases permeability by up to 50%
45
46
Estimating Materials - By Volume
Determine the amount of materials that will be required to
pour a concrete slab that measures 12 ft x 10 ft x 3 in. A
1-2
.
1/2-3
.
1/2 mix will be used.
Step one: determine the volume required.


ft
3
= 12 ft x 10 ft x 3 in x
1 ft
12 in
|
\

|
.
|
= 30 ft
3

Adding the 10% =


30 ft
3
x 1.1 = 33 ft
3
47
Estimating Materials - By Volume - cont.
Because the aggregate mixes together, the yield by
volume will only be about 2/3s of the total volume.


1 + 2.5 + 3.5
( )
= 7.0 ft
3

Step two: determine the yield of one batch of the receipt.


7.0 ft
3
x 0.66 = 4.62 ft
3

Step three: determine the number of batches required.
33 cubic feet of concrete is required, each one sack batch
will yield 4.62 cubic feet.
The number of batches =


Batches = 33 ft
3
x
1 batch
4.62 ft
3
= 7.14 batches
48
Estimating Materials - By Volume - cont.
Step four: determine the Portland cement, fine aggregate and
coarse aggregate.


Portland Cement : 1 x 7.14 = 7.14 sacks
Fine aggregate : 2.5 x 7.14 = 17.8 ft
3
Coarse aggregate : 3.5 x 7.14 = 25 ft
3

49
Concrete Mixes--cont.
When concrete ingredients are measured using weight, density
conversions must be used.
Portland cement = 94 lb/ft
3
(100 lb/ft
3
often used)
Fine aggregate = 100 lb/ft
3

Coarse aggregate = 110 lb/ft
3


50
Estimating Materials - By Weight
Determine the amount of materials that will be required to pour a
concrete slab that measures 18 ft x 12 ft x 4 in. A 1-2
.
-3
.
1/2 mix
will be used.
Step one: determine the volume required.


ft
3
= 18 ft x 12 ft x 4 in x
1 ft
12 in
|
\

|
.
|
= 74 ft
3

Adding the 10% =


74 ft
3
x 1.1 = 81.4 ft
3

51
Estimating Materials - By Weight - cont.
Step two: determine the yield of one batch.


1 + 2 + 3.5 = 6.5 ft
3
6.5 ft
3
x 0.66 = 4.29 ft
3

Step three: determine the number of batches.


Batches = 81.4 ft
3
x
1 batch
4.29 ft
3
= 23.26 batches
52
Estimating Materials - By Weight - cont.
Step four: determine the amount of cement, fine aggregate and
coarse aggregate.


Portland Cement : 1 x 23.6 = 23.6 sacks x 94
lb
sack
= 2, 218. 4 lb
Fine aggregate: 2.0 x 23.6 = 47.2 ft
3
x 100
lb
ft
3
= 4, 720 lb
Coarse aggregate: 3.5 x 23.6 = 82.6 ft
3
x 110
lb
ft
3
= 9, 086 lb
53
Workable Mix
Workability of concrete refers to the consistency of the wet
concrete.
Wetter concrete is more workable, but the higher the water
content--the poorer the quality of the concrete.
Characteristics of a workable mix:
1. Portland cement thoroughly mixed
2. Aggregate fully covered
3. Aggregates evenly distributed
4. Minimum amount of water
5. Uniform color and consistency
6. Can be mixed, moved and placed with a shovel or spade
Curing rate
Concrete gains
strength rapidly
at first but
continues to
cure for years.
Industry
standard is to
compare
strength at 28
days.
54
0
10
20
30
40
50
60
70
80
90
100
110
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56
P
e
r
c
e
n
t

Days
Strength (% 28 day)
55
Preparing Concrete Forms
56
Concrete Forms
Form: a metal or wooden structure that confines the
concrete to the desired shape or form until it hardens.
The more complex the shape of the concrete--the more
complex the forms.
Normal concrete weights between 100 & 150 lb/ft
3
,
therefore any forms supporting the weight of concrete
must be well engineered.
Forms can be constructed from dimensioned lumber and
plywood, or in some cases, metal forms can be
purchased or rented.
57
Concrete Forms Information
1. Use soft, clean straight lumber.
2. Sharpen stakes evenly.
3. Space stakes appropriately.
4. Use a level to set the forms for
the desired slope.
5. Do not drive nails into concrete
space.
6. Insure stakes do not extend
above the tops of the forms.
7. Construct the inside surface of
the forms to create the desired
shape in the finished concrete.
8. Coat all surfaces that will be in
contact with the concrete.
58
Concrete Forms--Wall Example
Board Tie
1 Boards or 3/4 Plywood
Brace
Spreader Block
Wire Tie
Stud
Concrete Footing
Stake
Wale
Agricultural Mechanics Fundamentals & Applications Herren--Fig 39-7
59
Concrete Forms--Slab Example
Form
Wall Stake
Control Joint
Concrete
Straightedge
Packed Damp Sand
Agricultural Mechanics Fundamentals & Applications Herren--Fig 39-7
60
Concrete Joints
Three (3) types of joints are used
for concrete.
Isolation joints: allow
expansion and contraction of a
concrete slab without
generating potentially
damaging forces within the
slab itself or the surrounding
structures
Control (Contraction) joints:
this type of joint allows only
for contraction or shrinkage of
the slab, as can be anticipated
during the curing process
61
Concrete Joints-cont.
Construction joints:
Construction joints can be
horizontal or vertical and are
formed when placement of the
concrete is interrupted for some
reason.
It may be the end of a day's
work or
May be that some other work
needs to be completed before
resuming the placement.
New concrete is placed against
concrete that has solidified or
skimmed over.
Butt
Dowel
Key
62
Reinforcing Concrete
Concrete is strong in compression, but weak in tension.
Reinforcement is used to increase the tension strength.
The type, size and spacing
of the reinforcement is
determined by the thickness
of the slab and the designed
load.
Fibers are also being used
to reinforce concrete.
63
Pouring, Finishing, and Curing Concrete
64
Pouring (Placing)
Concrete should be placed--not poured.
Concrete must be placed as closes to the final location as
possible.
Heavy--labor intensive to move.
Moving causes the aggregate to segregate.
Inspect forms and bracing before starting the placing.
Insure all of the tools and help are available and ready before
starting.
Starts to harden in 15 minutes
Once in place and hardening process has started--its there.
Ensure concrete does not dry out.
Dampen the soil/sand base before placing.
Protect top surface after placing.
65
Finishing Concrete
The number of processes and type of process used is
determine by the desired finished surface.
Trowel
Broom
Exposed aggregate
Grooved
Stamped
Burlap
Etc.
The finishing process has at least Four (4) steps.
Screeding
Floating
Final surface
Edging & jointing
66
(1) Screeding & (2) Floating Concrete
The process used is determined by the use of the concrete and the desired
finished surface.

1. Screeding
Screeding is striking off the concrete
surface to insure it is level with the forms
Pushes large aggregate below the
surface
Starts the smoothing process
Can be accomplished with a straight
board
2. Floating
Brings fine aggregate and cement paste
to the surface
Produces smoother surface
Uses a wooden or magnesium float
Floating should not be attempted until the concrete has hardened to
the point that stepping on it makes a very faint imprint.

67
(3) Finishing Concrete
Many options are available for the
finished surface of concrete.
Molded
Individual
In forms
Stamped
Exposed aggregate
Colored
Smooth surface
Rough surface
Other
68
(4) Edging & Jointing
Part of the finishing process may also be edging and jointing
Edging forces the large aggregate away from
the corner and rounds the corner.
Reduces breakage on the edge.
Jointing
Edging
The groove cut or formed or cut in the surface
helps control the location of the cracks.
69
Curing Concrete
70
Curing Concrete
Concrete hardens through a chemical process.
Initial strength is reached in a week.
Must be protected during this time
Potential problems.
1. Drying out
2. Excessive heat
3. Freezing temperature
Solutions
1a. Dampen base/forms before placing
1b. Cover with plastic or canvas
2a. Insulate the surface
2b. Dampen the surface
3a. Dont place on frozen ground
3a. Dont place when freezing temperature is
expected
Curing Rate
71
0
20
40
60
80
100
120
140
0 10 20 30 40 50 60 70 80 90 100
Curing Rate
Days
%
28
Days
Effect of Curing conditions
72
0
25
50
75
100
125
150
0 25 50 75 100 125 150 175 200
Air
Moist
Days
%
of
28
Days
73
Masonry
74
Introduction
Masonry is Any type of construction using brick, stone, tile or
concrete units held in place with Portland cement.
Masonry units are held in place with mortar
Mortar = Portland cement, sand and water
Other materials may be added.
75
Masonry Construction
Ancient method of construction.
Advantages:
Fireproof
Insect and rodent proof
Decay resistant
Storm resistant
Wear resistant
Water (proof) resistant
Strong
Attractive
Can be installed without
expensive equipment
Available locally
Low original and
maintenance costs
Recyclable
Disadvantages:
Strength, durability and
water resistance of finished
product dependent on
strength, durability and water
resistance of masonry units.
Labor intensive
Different skills required than
for wood frame or concrete.
76
Masonry Units
Building bricks
Pavers
Custom bricks
Stone
77
Masonry Units-cont.
Concrete blocks
(Fig 39-15)
Light weight blocks
78
Additional Topics
Estimating number of block needed
Constructing footers
Mixing mortar
Laying block
79
Questions