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

2. 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

3. 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

4. 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

5. 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

6. 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

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

8. Desired Durability Properties Set Limits

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

10. Fine Aggregate Impacts W/CM

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

12. Casting – Fresh Properties
Rigid Rugged Resilient

13. Slump Impact on Consolidation Effort

14. Concrete slump, Consolidation Effort and Surface Finish

15. Slump Measurement

16. Slump Target Determines Water Content

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

18. 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

19. 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

20. 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*

21. 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

22. 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

23. 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

24. 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

25. Joseph A Daczko – BASF Construction Chemicals 216 233 8293 joseph
Joseph A Daczko – BASF Construction Chemicals
Rigid Rugged Resilient