CAST IN PLACE CONCRETE

Material Specifications

Cast in concrete is a concrete that is formed and it ready to be poured at the location. The master specification number for this type of concrete is 03 30 00. There are many manufacturers that produce and carry this concrete. Some manufacturers include Advance Concrete Forms, Inc., Amvic Inc., Ceme-Tube LLC, Ellis Manufacturing Co. Inc., Greenblock Worldwide, LLC, High Concrete Group, LLC, Octaform Systems Inc., Reddiform ICF, Symons, and Universal Building Products, Inc. There are many more then what is listed here; this is just a hand full. There is no common generic name for this specific concrete, but the abbreviation is CIP Concrete.

Material Applications

The materials primary use is concrete for foundations and structures, slabs on grade, walls, beams, columns, floors, roofs, large portions of bridges, pavements, and etc. The physical properties of cast in place concrete are strength, long term durability, and fire resistant and low coefficient thermal expansion. Cast in place concrete has many different types of finishes. Some of these finishes include colored concrete, exposed aggregate, and form linear textures. Special inserts are available to create thin brick or think block masonry surfaces. The surface can also be painted or plaster with stucco texture, although these finishes may require maintenance time to time which is unnecessary with these cast in treatments. This concrete can be placed in pretty much any shape and or form. The dimensions would have to come from the contractor and the specific job that it to be poured. The normal weight is 150pcf. Cast in place concretes acoustic property will provide similar performance regarding sound transmission from exterior to the interior of the building. However, distressed and open joints between panels can provide a condition in which sound transmission to the interior may be increased.

Structural properties include beams, columns, joist, slab or other structural members. Primary structure is slabs and secondary structure is walls, countertops, pools, trench drains, etc. A non-structural property of cast-in-place concrete is non-structural RC walls which include mullions, spandrels and sidewalls.

Installation

Preparation is the first step in the installation process. Make sure that the sub grade is not muddy, spongy, or frozen. Check that all areas where concrete is to be placed shall be thoroughly cleaned to ensure proper placement and bonding. Last, keep forms and sub grade wet and remove all standing water prior to placing concrete. Next set up the forms, they shall be constructed to the shape, line, and grade that is required and shall be maintained sufficiently rigid to prevent deformation under load, including placing and compacting of concrete. Forms shall be tight enough to prevent leakage of mortar. Formwork shall be secured to prevent sagging, yielding, bulging, depressions, waves, or other defects in the finished work. Forms shall be smooth and free from warp. Temporary openings shall be provided at base of column and wall forms for cleaning and inspection. Rebar, ties, and anchor bolts can be used for extra strength. Install these before placing the concrete. Concrete shall be mixed only in such quantities as are required for immediate use. The maximum allowable time between charging of the material in the mixing drum and final placing for mean ambient temperatures below 90F shall be ninety (90) minutes or 300 drum revolutions, which ever comes first. Placing the concrete is the next step. All concrete shall be mechanically vibrated, except for slabs on grade that are six inches or less in thickness. Concrete shall be

placed in layers not over 24 inches deep. Each layer shall be consolidated by mechanical internal-vibrating equipment supplemented by hand spading, rodding, and tamping to work concrete into all angles and narrow places. Duration of vibration shall be limited to the time necessary to produce satisfactory consolidation without causing objectionable segregation. Vibrators shall be applied vertically and at uniformly spaced points not farther apart than the visible effectiveness of the machine. The vibrator shall not be

inserted into lower courses that have begun to set. Vibrators shall not be used to transport concrete inside forms. The use of form vibrators or form tamping will not be permitted. The concrete shall be deposited, as nearly as possible, in its final position and shall not be caused to flow laterally in the form for any considerable distance. Each pour shall be completed in a continuous operation with no interruptions in excess of forty-five minutes. Each layer shall be placed and compacted before the preceding layer has taken initial set. Next, would be Screeding, Floating, Troweling, Brooming & Nonslip Finishing, it all depends on what type of finish the job calls for. Last all finished concrete shall be cured by a curing method compatible with the final floor finish for a minimum of 7 days. The cost of the cast in place concrete depends on various factors. These factors include grading, sub base preparation, concrete forms and finishing, reinforcement, and the cost of concrete. You can also add the extras of stamped, stained, decorative driveway, patio, and walkway concrete. The price per SF (square foot) or applicable cost measurement is approximately $2.50-$4.50 SF (plain concrete)

Material Background Concrete is a hardened building material created by combining a chemically inert mineral aggregate (usually sand, gravel, or crushed stone), a binder (natural or synthetic cement), chemical additives, and water. To make this type of concrete there is a specific solution that combines cement, water, and aggregates. Not every job will have the same solution it depends on the contractor and the jobsite. Portland cement, the kind most often used in concrete, is made from a combination of a calcareous material (usually limestone) and of silica and alumina found as clay or shale. Aggregates, which comprise 75 percent of concrete by volume, improve the formation and flow of cement paste and enhance the structural performance of concrete. Fine grade comprises particles up to 20 of an inch (five millimeters) in size, while coarse grade includes particles from 20 to 79 of an inch (20 millimeters). For massive construction, aggregate particle size can exceed 1.50 inches (38 millimeters). A wide range of chemicals are added to cement to act as plasticizers, super plasticizers, accelerators, dispersants, and water-reducing agents. Called admixtures, these additives can be used to increase the workability of a cement mixture still in the nonset state, the

strength of cement after application, and the material's water tightness. Further, they can decrease the amount of water necessary to obtain workability and the amount of cement needed to create strong concrete. Accelerators, which reduce setting time, include calcium chloride or aluminum sulfate and other acidic materials. Plasticizing or super plasticizing agents increase the fluidity of the fresh cement mix with the same water/cement ratio, thereby improving the workability of the mix as well as its ease of placement. Typical plasticizers include polycarboxylic acid materials; super plasticizers are sulfonated melamine formaldehyde or sulfonated naphthalene formaldehyde condensates. Set retarders, another type of admixture, are used to delay the setting of concrete. These include soluble zinc salts, soluble borates, and carbohydrate-based materials. Gas forming admixtures, powdered zinc or aluminum in combination with calcium hydroxide or hydrogen peroxide, are used to form aerated concrete by generating hydrogen or oxygen bubbles that become entrapped in the cement mix.

The manufacturing process is fairly simple. First, the cement is prepared. Next, the other ingredientsaggregates (such as sand or gravel), admixtures (chemical additives), any necessary fibers, and waterare mixed together with the cement to form concrete. The concrete is then shipped to the work site and placed, compacted, and cured. Steps of the Manufacturing Process The limestone, silica, and alumina that make up Portland cement are dry ground into a very fine powder, mixed together in predetermined proportions, preheated, and heated to a high temperature that will burn off impurities without fusing the ingredients. Next the material is burned in a large rotary kiln at 2,550 degrees Fahrenheit (1,400 degrees Celsius). At this temperature, the material partially fuses into a substance known as clinker. A modern kiln can produce as much as 6,200 tons of clinker a day. The clinker is then cooled and ground to a fine powder in a tube or ball mill. A ball mill is a rotating drum filled with steel balls of different sizes (depending on the desired fineness of the cement) that crush and grind the clinker. Gypsum is added during the grinding process. The final composition consists of several compounds: tricalcium silicate, dicalcium silicate, tricalcium aluminate, and tetra calcium aluminoferrite. The cement is then mixed with the other ingredients: aggregates (sand, gravel, or

crushed stone), admixtures, fibers, and water. Aggregates are pre-blended or added at the ready-mix concrete plant under normal operating conditions. The mixing operation uses rotation or stirring to coat the surface of the aggregate with cement paste and to blend the other ingredients uniformly. A variety of batch or continuous mixers are used. Once the concrete mixture is ready, it is transported to the work site. There are many methods of transporting concrete, including wheelbarrows, buckets, belt conveyors, The first step in making concrete is to prepare the cement. One type of cement, Portland cement, is considered superior to natural cement because it is stronger, more durable, and of a more consistent quality. To make it, the raw materials are crushed and ground into a fine powder and mixed together. Next, the material undergoes two heating stepscalcining and burning. In calcining, the materials are heated to a high temperature but do not fuse together. In burning, however, the materials partially fuse together, forming a substance known as "clinker." The clinker is then ground in a ball milla rotating steel drum filled with steel balls that pulverize the material. After the Portland cement is prepared, it is mixed with aggregates such as sand or gravel, admixtures, fibers, and water. Next, it is transferred to the work site and placed. During placing, segregation of the various ingredients must be avoided so that full compaction-elimination of air bubbles-can be achieved. The word concrete comes from the Latin word "concretus" (meaning compact or condensed). Europe was the first to use concrete in general. The Romans used concrete extensively from 300BC to 476AD, a span of more than seven hundred years. A method for producing Portland cement was patented by Joseph Aspdin on 1824. The usage of concrete, world wide is twice as much as steel, wood, plastics, and aluminum combined. Concrete's use in the modern world is only exceeded by the usage of naturally occurring water.

Environmental Impact

Cast in place concrete can last well over hundreds of years; it all depends on the quality of the concrete itself, as well as the quality of the overall installation process. Maintenance requirements depend on the form and finish the concrete is in. The

most common issues is cracking, and wearing which can be resolved in a few ways. You can fill in the cracks and repair surface damage. Another solution is resurfacing-covering an old surface with fresh concrete. A good surface repair can last for many years, but if there is underlying structural damage, it is only temporary solution. Recycling concrete has become better known now because of all the new law and general requirements that pertain to it. Concrete is commonly recycled in urban areas into fill and road base material at the end of service life. Concrete, which must be free of trash, wood, paper and other such materials? is collected from demolition sites and put through a crushing machine, often along with asphalt, bricks, and rocks. Crush recycled concrete can sometimes be used as the dry aggregate for brand new concrete if it is free of contaminants, though the use of recycled concrete limits strength and is not allowed in many jurisdictions.

Cast In Place Concrete Commercial Images

Apartment Building

Hotel

Water/Sewer Construction

Preparing Cast In Place Concrete

Mixing Of Cast In Place Concrete

Finished Product

A Cast In Place Concrete Home In Argentina

Cast In Place Concrete Foundation

Cast In Place Concrete Stairs

Cast In Place Concrete Retaining Wall