Concrete for Box Culverts – Wet Cast Concrete Joseph A. Daczko, FACI – BASF Construction Chemicals

Presentation Outline Many Performance Demands on a Concrete Mixture Wet Cast Box Culverts Specifications and Production Requirements Main Variables Impacting Hardened and Fresh Properties Admixtures and Concrete Performance Rigid Rugged Resilient

Nestle Toll House Cookies – A Recipe 2 1/4 cups all purpose flour 1 tsp baking soda 1 tsp salt 1 cup butter, softened 3/4 cup granulated sugar 3/4 cup packed brown sugar 1 tsp vanilla extract 2 large eggs 2 cups semi sweet chocolate morsels 1 cup chopped nuts

Nestle Toll House Cookies PREHEAT oven to 375o F. COMBINE flour, baking soda and salt in small bowl. Beat butter, granulated sugar, brown sugar and vanilla extract in large mixer bowl until creamy. Add eggs one at a time, beating well after each addition. Gradually beat in flour mixture. Stir in morsels and nuts. Drop by rounded tablespoon onto ungreased baking sheets. Bake for 9 to 11 minutes or until golden brown. Cool on baking sheets for 2 minutes; remove to wire racks to cool completely. Yields: About 5 dozen cookies

WHAT DO YOU WANT FROM ME? I WANT STRENGTH!! IS IT FREEZE/THAW DURABLE? HAS IT SET YET?? CONCRETE SHOULDN’T CRACK!!! IS IT FREEZE/THAW DURABLE? HOW LONG DOES IT TAKE TO MIX? HONEYCOMBING? IT’S STICKY IT’S STILL BLEEDING I CAN’T FINISH THIS LOW SHRINKAGE LOOK AT THOSE BUGHOLES WATER TIGHT FLEXURAL OR COMPRESSIVE? TOO EXPENSIVE MODULUS OF WHAT? IT’S SEGREGATING!! WRONG COLOR IT’S LOSING SLUMP LOW HEAT!! IT’S GAINING……. SLUMP? AIR’S TOO LOW AIR’S TOO HIGH

Concrete for Wet-Cast Boxes 3 Buckets of needs Performance in Service Stripping - Production Casting How do we do it? Material Selection Mixture Proportioning Admixtures Placement and Consolidation Techniques Rigid Rugged Resilient

Performance in Service Driven By Specification Strength (5000 psi design) Durability Freeze/Thaw Durability Resistance to Corrosion Rigid Rugged Resilient

Desired Durability Properties Set Limits

Variables Impacting Compressive Strength Cement Source W/CM Ratio Air Content Time Temperature

Fine Aggregate Impacts W/CM

Compressive Strength- Specification vs Production Targets ASTM C 1433 & 1577 reference design strengths of 5000 psi Demolding strengths needed? – 2000 psi? Rigid Rugged Resilient

Casting – Fresh Properties Rigid Rugged Resilient

Slump Impact on Consolidation Effort

Concrete slump, Consolidation Effort and Surface Finish

Slump Measurement

Slump Target Determines Water Content

How Admixtures Facilitate Balancing Performance Demands Concrete Strength W/CM Ratio (-) BUT Low slump SCC Flowing Concrete Moderate slump

Admixtures for Concrete Definition: a material other than water, aggregates, cementitious materials, and fiber reinforcement, used as an ingredient of a cementitious mixture to modify its freshly mixed, setting, or hardened properties and that is added to the batch before or during its mixing.- ACI Concrete Terminology. ASTM C 494 – Lists 7 basic Types Type A – Water-reducing Type B – Retarding Type C – Accelerating Type D – Water-reducing & retarding Type E – Water-reducing & accelerating Type F – Water-reducing, high range Type G – Water-reducing, high range & retarding Type S – Specific Performance

Workability retention without retardation Workability Retaining Admixture A revolutionary new admixture formulated to control the workability (slump) retention of concrete without impacting other properties. Workability retention without retardation Dosage flexibility – for flexible levels of workability retention

DESIRED PROPERTY PRIMARY ADMIXTURE Workability Mid- & High-Range WRs Workability Retention Finishability Setting High Strength Viscosity Enhancing Rheology Controlling Washout Resistance Color Freeze-Thaw Resistance Alkali-Silica Reactivity Corrosion Protection Drying Shrinkage “Waterproofing” PRIMARY ADMIXTURE Mid- & High-Range WRs Workability Retainer Mid-Range WRs Retarder / Accelerator High-Range WRs Viscosity Modifiers Rheology-Controlling Admixtures Anti-Washout Admixtures Liquid-Coloring Admixtures Air Entrainers ASR Inhibitors Corrosion Inhibitors Shrinkage Reducers “Waterproofing” Admixtures*

Concrete for Wet-Cast Boxes 3 Buckets of needs Performance in Service Stripping - Production Casting How do we do it? Material Selection Mixture Proportioning Admixtures Placement and Consolidation Techniques Rigid Rugged Resilient

Tying it Together Concrete performance demands are varied You must know your local materials Proportioned first to achieve specified hardened properties This may limit certain proportioning flexibility Set proportions and admixture use to achieve desired production performance Casting Stripping strength Rigid Rugged Resilient

Nestle Toll House Cookies – A Recipe 2 1/4 cups all purpose flour 1 tsp baking soda 1 tsp salt 1 cup butter, softened 3/4 cup granulated sugar 3/4 cup packed brown sugar 1 tsp vanilla extract 2 large eggs 2 cups semi sweet chocolate morsels 1 cup chopped nuts

Nestle Toll House Cookies PREHEAT oven to 375o F. COMBINE flour, baking soda and salt in small bowl. Beat butter, granulated sugar, brown sugar and vanilla extract in large mixer bowl until creamy. Add eggs one at a time, beating well after each addition. Gradually beat in flour mixture. Stir in morsels and nuts. Drop by rounded tablespoon onto ungreased baking sheets. Bake for 9 to 11 minutes or until golden brown. Cool on baking sheets for 2 minutes; remove to wire racks to cool completely. Yields: About 5 dozen cookies

Joseph A Daczko – BASF Construction Chemicals 216 233 8293 joseph Joseph A Daczko – BASF Construction Chemicals 216 233 8293 joseph.daczko@basf.com Rigid Rugged Resilient