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Module 4 Production of Concrete

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Module 4 Production of Concrete

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nurhidayah218
Copyright
© © All Rights Reserved
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IMM SA CONCRETE QUALITY TRAINING MODULE 4: PRODUCTION OF CONCRETE ed ant repre pro wit Sn On. MODULE 4: PRODUCTION OF CONCRETE Objectives >» To provide a comprehensive overview of quality control and batching procedures to be adopted by batching plants in accordance with BS EN 206-1; > To introduce durability classes and service life of concrete structures based on the requirements of BS EN 206-1, BS 8500-1, SS544-1 ‘hs ocuent 1 copyrighted ons reprodcon probed except full thou ten opera! of AMUSO Sn Bg MODULE 4: GENERAL INFORMATION TOPICS: DAY 14 > CONTROL OF CONSTITUENT MATERIALS > MAINTENANCE AND CALIBRATION OF BATCHING PLANTS > COMPLIANCE AND CONFORMITY > STATISTICAL DISTRIBUTION FOR STRENGTH DAY 2 > PRODUCTION CONTROL > BATCHING PLANTS’ LAYOUT > DURABILITY REQUIREMENTS AND EXPOSURE CLASSES, IMM SA “ws docunent i copyghed and is reproduction i pohied ect fl whet water areal 3 MSM. Se Bhd MODULE 4: GENERAL INFORMATION TIME OF LESSONS: Day1 Day 2 > MORNING 1: from 9 am to 10.30 am D> MORNING 1: from 9 am to 10.30 am Break:15' Break:15‘ > MORNING 2: from 10.45 am to 1.00 pm > MORNING 2: from 10.45 am to 1 pm Lunch break (from 1.00 pm to 2.00 pm) Lunch break (from 1.00 pm to 2.00 pm) > AFTERNOON 1: from 2.00 pm to 3.30 pm > AFTERNOON 1: from 2.00 pm to 3.30 pm Break: 15' Break: 15! » AFTERNOON 2: from 3.45 pm to 5.15 pm » AFTERNOON 2: from 3.45 pm to 5.15 pm > AFTERNOON 3: from 5.15 pm to 5.30 pm (Q&A, review) > AFTERNOON 3: from 5.15 pm to 5.30 pm (Q&A, review) ii | ‘Ths document capped ond reproduction proses cet fl thou ten pool of MSO Sn. ee MODULE 4: GENERAL INFORMATION TIME OF LESSONS: Day 3: PRACTICAL SESSION > MORNING 1- BATCHING PLANT: from 9.00 am to 11.00 am Break:15‘ > MORNING 2 - BATCHING PLANT: from 11.00 am to 1 pm Lunch break (from 1.30 pm to 2.30 pm) at KTC > AFTERNOON 1 - KTC: from 2.30 pm to 3.30 pm Break: 15° > AFTERNOON 2 - KTC: from 3.45 pm to 4.30 pm (Q&A, review) + Final test ‘This document is copyrighted end ts reproduction is prohibited exces in full withe eae ttn eso f MSN Sar Bk MODULE 4: GENERAL INFORMATION KEEP YOUR PHONE OFF: BE ON TIME: DON’T FALL ASLEEP: DON’T BE A TEENAGER: DON’T TALK AND KEEP OR TRY NOTTO What does OK. LY & QUESTIONS FOR LATER: TTYL mean? 7 (000: know. love you, tak to you later (OK. | wi ask your sister, iti j Te a! aa poe ep on a oral gOS tm SA CONTROL OF CONSTITUENT MATERIALS CONTROL OF CONSTITUENT MATERIALS BS EN 206-1: > “The constituents, equipment, production procedures and concrete shall be controlled with regard to their conformity with the specifications of concrete and the requirements of this standard. The control shall be such that significant changes that influence the properties are detected and appropriate corrective action taken.” > Hence batching plants must have a system in place to control the conformity of materials delivered and to control the fluctuations of the properties of the concrete they produce. bi ‘Ths dcamartcanyihted ond ks reroduten robbed ceil tout witen pina of AMS Sin Bhd mere CONTROL OF CONSTITUENT MATERIALS A procedure shall be put in place to ensure the correct delivery, storage and use of constituents including: Checking that the delivered material is what was ordered; Checking that it is being discharged into the correct location; Preventing discharge of any materials that are clearly not conforming; Storing materials in a way that minimises the risk of contamination or deterioration; ber». « Keeping records of deliveries; Sto ema consamy, Testing of suspect deliveries for all properties for which conformity with the relevant standard or other Fie eee SAND GE organ cOVrRaMNAT™ Ayn vvvvvyy specification is in doubt; > Checks on the water content of the aggregates. 7” Sempgratne comurdy le rot ii A ‘Wicocumerseapyrahed ond reproduce probed eet nfl wines wen oper of MASON Sb. Bh pin CONTROL OF CONSTITUENT MATERIALS CEMENT > General suitability is established for cement conforming to BS EN 197-1; CONTROL OF CONSTITUENT MATERIALS CEMENT Inspection/test Purpose imum frequency Inspection of delivery ticket. | To ascertain if the consignment is as Bardeber prior to discharge ordered and from the correct source 7 > The delivery ticket must be accompanied by a declaration or certificate of conformity to BS EN 197-1; > Itis recommended that samples are taken once per week from each cement type and stored for testing in case of doubt/dispute; > Third party testing is recommended at least once a year or in case of doubt (for instance, when large fluctuation of the strength of concrete occur). ‘his cecuren 1 copyghted ond its repreucton prohibited ect fl hou writen eer of HMSO San Bhs Tot =Test of yops 600) CONTROL OF CONSTITUENT MATERIALS Table 4— Chemical quirements glen 9 ae can coun cau eeu ‘Tas deeumert capped ond ts reorodcion Isprohied cet fllwthau writen approvl of MSO Si. ha CONTROL OF CONSTITUENT MATERIALS PULVERISED FLY ASH (PFA) > General suitability is established for PFA conforming to BS EN 450-1; ‘is documert copyhted ond sreprodacion prohibited cept ful without writen aproal ef MIMSOI Sh, Bh 4a CONTROL OF CONSTITUENT MATERIALS PFA Inspection/test Purpose Minimum frequency inspection of delivery ticket To ascertain if the consignment is as Each deliver prior to discharge ordered and from the correct source ae Y > The delivery ticket must be accompanied by a declaration or certificate of conformity to BS EN 450-1; > Itis recommended that samples are taken once per week from each PFA type and stored for testing in case of doubt/dispute; > Third party testing is recommended at least once a year or in case of doubt. ‘ms ocuren copyrighted ones reprodacren is prohied __ CONTROL OF CONSTITUENT MATERIALS Table 5 — Limi votes for seg rele Topeny Loss em anton oat Ra vane Tawar oq aremest ‘wegan arcane Toenconse sc cazonecee se ascsse ‘Ms dccument scapyrtted ond ts reprencton potted except flluthout wren appro of MHS Sen Bb CONTROL OF CONSTITUENT MATERIALS GROUND GRANULATED BLAST FURNACE SLAG (GGBS) > General suitability is established for GGBS conforming to BS EN 15167-1; ‘us oocumert i copynghed ond reprdecon poked except fluiheut wren oppor of MIMS. Se. Bhd CONTROL OF CONSTITUENT MATERIALS Inspection/test Purpose Minimum frequency Inspection of delivery ticket To ascertain if the consignment is as spection Each delivery prior to discharge ordered and from the correct source > The delivery ticket must be accompanied by a declaration or certificate of conformity to BS EN 15167-1; > It is recommended that samples are taken once per week from each GGBS type and stored for testing in case of doubt/dispute; > Third party testing is recommended at least once a year or in case of doubt. Iisdocamert scopyahced ond is reprececion speed exept nll without water appro of MUSOL. IMM SA JEST CERTIFICATE CONTROL OF CONSTITUENT MATERIALS “wage Sen aT TREE CONTROL OF CONSTITUENT MATERIALS ADMIXTURE > General suitability is established for admixture conforming to BS EN 934-1/2 CONTROL OF CONSTITUENT MATERIALS ADMIXTURE Inspection/test Purpose Minimum frequency Inspection of delivery ticket | To ascertain ifthe consignment is as each detfva prior to discharge ordered and from the correct source v Test for identification accord | 5, comparison with manufacturer's stated to EN 934-2, e.g. density.oh# | FOF® infrared ~ > ee = In case of doubt > The delivery ticket must be accompanied by a declaration or certificate of conformity to BS EN 934-1/2; > Itis recommended that samples are taken once per week from each admixture type and stored for testing in case of doubt/dispute; > Third party testing is recommended at least once a year or in case of doubt. "Ts documen copyrighted an ts reprodueton ponte exept fl without wien Creel f MMEON. Sa Bh IMM SA 20 CONTROL OF CONSTITUENT MATERIALS AGGREGATES: > General suitability is established for aggregates conforming to BS EN 12620 CONTROL OF CONSTITUENT MATERIALS Inspection/test AGGREGATES Purpose Minimum frequency Inspection of delivery ticket prior to discharge To ascertain if the consignment is as ordered and from the correct source Each delivery Inspection of the aggregate prior to. discharge For comparison with normal appearance with respect to the grading, shape and impurities Each delivery Test by sieve analysis according to BS EN 933-1 To assess compliance with standard or other agreed grading First delivery from new source where this information is not available from the aggregate supplier. In case of doubt following visual inspection. Periodically depending on local or delivery conditions ‘his document copyrighted ards raroducion is pried exeptn fll tov writen apeoel of MMO Se. ha IMM SA CONTROL OF CONSTITUENT MATERIALS Inspection/test AGGREGATES Purpose Minimum frequency Test for impurities To assess the presence and quantity of impurities First delivery from new source where this information is not available from the aggregate supplier. In case of doubt following visual inspection. Periodically depending on local or delivery conditions Test for water absorption to EN 1097-6 To assess the effective water content of concrete First delivery from new source where this information is not available from the aggregate supplier. In case of doubt scene coyrhted and tepid eet ine whet win ero o MMI Sn Eeee CONTROL OF CONSTITUENT MATERIALS A procedure shall be put in place to ensure the correct delivery, storage and use of constituents including: 1. 2. Pare Checking that the delivered material is what was ordered; Checking that it is being discharged into the correct location; Preventing discharge of any materials that are clearly not conforming; Storing materials in a way that minimises the risk of contamination or deterioration; Keeping records of deliveries; Testing of suspect deliveries for all properties for which conformity with the relevant standard or other specification is in doubt; Checks on the water content of the aggregates. Rs reed proted exept ni without witen approve of AAMSO 56m Bhd. 24 CONTROL OF CONSTITUENT MATERIALS AL hyPes cae Krom are serie suyppliGe/Soarce CONTROL OF CONSTITUENT MATERIALS > Dilemma: sand having different colour and grading but declared from the same source and supplied by the same quarry??? » Darker colour frequently means more organic matter CONTROL OF CONSTITUENT MATERIALS > Itis always advisable to inspect each source before approving the materials; > Carry out regular inspection to the quarries; > Carry out independent third party testing on suspect batch of materials; > If possible, deal only with suppliers with accredited quality system; > If possible, avoid dealing with traders and procure from the source. ‘hs gocumentcopyrhced ands reproduction prahtes ecpeinflltnot wren oppo of MSN. Se Bra CONTROL OF CONSTITUENT MATERIALS SWAMPY AREA > clay and silt CONTROL OF CONSTITUENT MATERIALS CONTROL OF CONSTITUENT MATERIALS CONTROL OF CONSTITUENT MATERIALS | CONTROL OF CONSTITUENT MATERIALS A procedure shall be put in place to ensure the correct delivery, storage and use of constituents including: Checking that the delivered material is what was ordered; . . Checking that it is being discharged into the correct location; Preventing discharge of any materials that are clearly not conforming; Storing materials in a way that minimises the risk of contamination or deterioration; Keeping records of deliveries; Pare ne> Testing of suspect deliveries for all properties for which conformity with the relevant standard or other | specification is in doubt; 7. Checks on the water content of the aggregates; CONTROL OF CONSTITUENT MATERIALS Sand being discharged in the wrong stockpile ‘Ths docuentcopyhced ands reproduce prone cpt fl whos writen opnroa af MMSOIL Sah, Bk CONTROL OF CONSTITUENT MATERIALS A procedure shall be put in place to ensure the correct delivery, storage and use of constituents including: Checking that the delivered material is what was ordered; Checking that it is being discharged into the correct location; Preventing discharge of any materials that are clearly not conforming; Storing materials in a way that minimises the risk of contamination or deterioration; Keeping records of deliveries; Testing of suspect deliveries for all properties for which conformity with the relevant standard or other specification is in doubt; 7. Checks on the water content of the aggregates; if j "is document i copyated ond is reproductions potted expel thot writen appro! of MASON San hd tenia Oak wna __ CONTROL OF CONSTITUENT MATERIALS eg Sand contaminated by black water being discharged at the stockpile us documen copyrighted ands reprocucton prone cpt fl who writen opoaof MSIL Sa Bhd IMM SA CONTROL OF CONSTITUENT MATERIALS Aprocedure shall be put in place to ensure the correct delivery, storage and use of constituents including: 1 2 3 4. aa Checking that the delivered material is what was ordered; Checking that it is being discharged into the correct location; Preventing discharge of any materials that are clearly not conforming; Storing materials in a way that minimises the risk of contamination or deterioration; Keeping records of deliveries; Testing of suspect deliveries for all properties for which conformity with the relevant standard or other specification is in doubt; Checks on the water content of the aggregates; CONTROL OF CONSTITUENT MATERIALS Proper way of stockpiling aggregates ‘Ta coemer copied andes prdtn&proied epin fw ite cpa of MSO. Bh PEN aii CONTROL OF CONSTITUENT MATERIALS Improper way of stockpiling aggregates This document icepyshed ond reardueton prone excel wheat wren spree ef MMS Sa Bk IMM SA CONTROL OF CONSTITUENT MATERIALS E Improper way of stockpiling aggregates IMisdocumert scopypted od is reproduction probed ecptin ul witht written opp ef MIMI. Bhd IMM SA CONTROL OF CONSTITUENT MATERIALS CONTROL OF CONSTITUENT MATERIALS A procedure shall be put in place to ensure the correct delivery, storage and use of constituents including: Checking that the delivered material is what was ordered; Checking that it is being discharged into the correct location; Preventing discharge of any materials that are clearly not conforming; Storing materials in a way that minimises the risk of contamination or deterioration; Keeping records of deliveries; . Testing of suspect deliveries for all properties for which conformity with the relevant standard or other specification is in doubt; 7. Checks on the water content of the aggregates; oi ‘is cocumen capytted ond its reprducten is pohied except fll thou wren apo of SOILS Bk a CONTROL OF CONSTITUENT MATERIALS > Especially for aggregates dragged from river beds or quarried from pits located in proximity of clayey areas, it is advisable to carry out sand equivalent and/or methylene blue test; » Organic impurities test allows to quickly detect the presence of humic matter that can adversely affect setting time of the concrete. “ecocument copy ts cepaduction prot apt nfl wthout writen poral ef MEO Sdn. Bh 2 CONTROL OF CONSTITUENT MATERIALS A procedure shall be put in place to ensure the correct delivery, storage and use of constituents including: Checking that the delivered material is what was ordered; Checking that it is being discharged into the correct location; Preventing discharge of any materials that are clearly not conforming; Storing materials in a way that minimises the risk of contamination or deterioration; Keeping records of deliveries; PAR wN a Testing of suspect deliveries for all properties for which conformity with the relevant standard or other specification is in doubt; 7. Checks on the water content of the aggregates. ‘Tis documents copyhted ond its repreducton is prohibted except fl wibost wen oppo of MSIL Sar Bh CONTROL OF CONSTITUENT MATERIALS Type of test AGGREGATES Inspection/test Purpose Minimum frequency Water content of fine uous measuring system, To determine the dry mass of aggregate and the water to be Hf not continual, daily, depending on local and weather conditions more or di ngeregates! ying test or equivalent added less frequent tests may be required Water content of coarse To determine the dry mass of caer fond md aggregates Drying test or equivalent aggregate and the water to be tions added Recommended minimum 3 times a day "Ths eocumen cepnred on reproduction pred ecet nfl tna tn pro! of HAMS Sn, ht IMM SA CONTROL OF CONSTITUENT MATERIALS Moisture content of fine and coarse aggregates can be determined by means of the following: > Drying test (ASTM 1566); > Moisture probes; > Speedy moisture test. Ms docamentscopyiphted ends reproduction i prohisited except nfl thou wten aproal of MISONL Sen. Bb. 45 CONTROL OF CONSTITUENT MATERIALS > Total moisture content is measured in accordance with ASTM C 566, “Total Moisture Content of Aggregate by Drying,” by measuring the mass of a sample of the aggregate representative of the moisture content in the supply being tested, drying the sample, and obtaining the mass again. M — Mop W%= Mop Where: > M- Mass of original sample > MOD — mass of oven dry aggregate "Wis document iscopyegted ond reproduction prahied ezrin fl whet water aprevel of MMS Sd Bk 46 CONTROL OF CONSTITUENT MATERIALS Surface moisture content: » Surface (or free moisture content) of an aggregate can be subtracting the absorption from the total moisture content. ‘mis documents copyhted ond ts reproductn prohibited eceptinflthou wrten appro of IMS Se Bh = &® Free (ersaorecaien) a7 CONTROL OF CONSTITUENT MATERIALS Example: Calculation of total and surface moisture W et > An aggregate sample has an absorption of 1.2% and a mass of 847.3 g when wet vt ‘00 > After oven drying, it has a mass of 792.7 g > Calculate the total moisture content and surface moisture content ‘i document capi ond ts reroduton Is probed weep nfl without writen pervs of MISO So. Bh IMM SA 48 ___CONTROL OF CONSTITUENT MATERIALS soul oy Argh Example: Calculation of total and surface moisture Ws Oe ie (ee 847.39 -792.7g _ W% = Total moisture content = 792.7 g Surface moisture content = 6.9% — 1.2% = 5.7% LA Re Hasorbtior ubvely, partapate Conte Oy Wie Greco wor” reason) ‘isdocaren: is copyrhted ond is epoducion prone exept. ful utoutwrten apa 2f MSO Sen Bb. CONTROL OF CONSTITUENT MATERIALS MOISTURE PROBES: + Continuous measurements; + Installed at each hopper bin of fine aggregates; + The moisture value is transferred to the batching 5 software in order to make the necessary adjustments; * Better accuracy; + However, maintenance shall be performed frequently. CONTROL OF CONSTITUENT MATERIALS MOISTURE PROBES: ‘sdocament copyrighted ond is repracetion prohibed except nfl without writen spree ef MANSON. SB. Bh IMM SA CONTROL OF CONSTITUENT MATERIALS SPEEDY MOISTURE TESTER: * Single measurement; + Portable equipment; « Not always accurate; + It is always advisable to have it calibrated against oven-dry method. IMM SA Ths cecumen i copys ond is reproduction prohibeedexetin fl utheut wnt opel MMSO. Se. Bhd ‘gon tate OF K Oven dy t : ganeowr xa ‘ ut Ee: wath a 3rapod oven Ae spends, yemete- forrnala to correlate 9 acl speedy oul rats on CONTROL OF CONSTITUENT MATERIALS SPEEDY MOISTURE TESTER: + The basic principle behind this method is that the free moisture in the sand reacts with calcium carbide reagent to form a gas called acetylene gas; This gas exerts @ pressure on the intemal side of the walls of speedy moisture meter which is reflected by a pressure dial; The pressure dial is calibrated in such a way that pressure reading reflects the percent moisture by wet weight of soil directly. IMM SA This documents eoprighted ond is reprodscton i proited except fil whut writen approval f MMSONL Sa Bh. CONTROL OF CONSTITUENT MATERIALS IMPORTANCE OF MEASURING CORRECTLY THE MOISTURE CONTENT: * The specified water/cement ratio (as per mix design) requires a certain amount of free water, i.e. water that will later participate in the hydration process; + If water brought in by moist aggregates is not taken into account, extra water is dosed in the concrete mixer and the water/cement ratio increases; + In addition, if moisture content is not considered, less aggregates are dosed into the mixer because part of the measured weight is given by water. ii j ‘Ths couamen cere nds readecon pone ep nfl tout wen oppo! of MSO Sen. nner CONTROL OF CONSTITUENT MATERIALS EXAMPLE: yeh] COMPONENT oni ay ye WATER ae) DOSAGE AS PER MIX DESIGN* (ke/m3) 160 400 800 10mm 120 5 we aay CEMENT @ 4 ee 0 myo oft be 870 ao 6 ay ew 20mm a ate HiGORETICAL Miku RATIO = 0.40 * Considering aggregates in Saturated Surface Dry (SSD) Conditions Bahicated Sustscs Diy (980) Prisdocamer copied ond ts reprodecton prohibited xcept nfl without waten apo of MSO Sd Bh free watcr-— participate In nydration process 55 CONTROL OF CONSTITUENT MATERIALS EXAMPLE: AGGREGATES poner ete ima DESIGN* | soisTURE CONTENT (36) | WATER CONTENT (ke) SAND (kg) 800 7% 56 10 mm (kg) 3e— y 2% 26 LY 20 mm (kg) 870 1% 87 TOTAL WATER CONTENT OF AGGREGATES (kg) aa Bl * Considering aggregates in Saturated Surface Dry (SSD) Conditions "ic document i copyighted ond ts reprodcton i probtied eee fellow wrt appro of NSO. Se, Bh IMM SA | make hag fatty aunty (> adtnent of Mle dur to motored condition . pe” fay Pecuroey of warkinon es - eke © Jao’ CONTROL OF CONSTITUENT MATERIALS Ome LO cto EXAMPLE: jo hak, ve DOSAGE AS PER MIX DESIGN* | QUANTITIES TO BE DOSED BY eomroueNT (kg/m3) THE PLANT**(kg/m3) WATER 160 160 (67.3}92.7 |, waiter conning CEMENT 400 400 fom he, se sgilesd She SAND 800 200 +56) en “qd Ter jibe 10mm 120 120488 4226- (A tared Eby 422. is 20mm 870 870 +672 878.7 * Saturated Surface Dry (SSD) Conditions aed “Tek ie oun tue core of agentes lie Ti coeament capyghed ae ts reprdneton prone cpt fl hot wten ero of MMS Se Bh 57 ese vot. 2 9442 96x dt > 2Us2 (g2-4xaf > 9.45 E-FKIL 8-99 ST Rn AD wads tone CONTROL OF CONSTITUENT MATERIALS EXAMPLE: If moisture content of aggregates is not taken into account and 160 kg of water are dosed by the plant, the total content of water in the mix and the water/cement ratio will be: Total water content = 160 + 67.3kg = 227.3 kg 227.3 Actual water cement ratio = 0 kg = 0.568 >> 0.40 MAINTENANCE AND CALIBRATION OF BATCHING PLANTS BATCHING PLANTS LAY OUT 4 cas, Aggregate storage hepper 2. Aggregate weighing hopper 3. Extracting belt conveyor MAINTENANCE AND CALIBRATION OF BATCHING PLANTS + REQUIREMENTS FOR BATCHING EQUIPMENT (BS EN 206-1 par 9.6.2.2) Where batching by mass Load in % of the full scale Maximum permissible error in % of the load Minimum load * to 20 % Pull scale 20 % Full scale to maximum load Where batching by volume Measured volume <301 Maximum permissible error in % of the volume imum load and maximum ‘hiscecunentscopyrgted ends reproduce prohibited ect flwthost writen oppo of MMSOI. Sar Bk 3% are provided by the manufacturer of the e — CHEUC TRE CAUBRATION DF WEIGHING scqLEl— at MAINTENANCE AND CALIBRATION OF BATCHING PLANTS TOLERANCE FOR THE BATCHING PROCESS OF CONSTITUENTS (BS EN 206-1 par 9.7) Constituent | Tolerance Cement | Water Yc 43%) (nas ( +3 %pf required quantity Total aggregates Additions and fibres used at > 5 % by mass of cement _ allowance for error ut 40 nacharical operraton Admixtures, additions and fibres used at <5% by mass of! cement G/umu) NOTE The tolerance is the difference between the target value and the measured value. +5 % of required quantity MAINTENANCE AND CALIBRATION OF BATCHING PLANTS WEIGHING SCALES FOR AGGREGATES Aggregate, bub bude MAINTENANCE AND CALIBRATION OF BATCHING PLANTS MAINTENANCE AND CALIBRATION OF BATCHING PLANTS silo ery by mk Weighing scale for admixture MAINTENANCE AND CALIBRATION OF BATCHING PLANTS op plane, Wage ay TE SUTe aie Me lag AE AE AO, st CALIBRATION OF WEIGHING SCALES: Flushing system for admixtures in place! IMM SA Misaecman copyghted onde reproduction roid expt fitout writen arora ef MASONS Bh i nde et tat MAINTENANCE AND CALIBRATION OF BATCHING PLANTS Maintenance of truck mixers: worn blades properly maintained blades "This eee i epyihed ents reedetenprohbed etn fll miter oppo MO in Be oe eee aclntck. expiry dates rud-be comthuonls . bam d Partnering asinine sank stirred ered H MAINTENANCE AND CALIBRATION OF BATCHING PLANTS Common issues with admixtures (liquid and mineral): > Liquid admixtures expire; » Stability depends on how long they seat in the drums and ambient temperature > segregation = varying properties from batch to batch; » Powder microsilica tends to form lumps, blocking the screws; > Often preferred to use silica slurry (50% powder + 50% water + stabilizers). MAINTENANCE AND CALIBRATION OF BATCHING PLANTS Yield Test: ‘Sometimes it can happen that a certain volume of concrete is ordered to the batching plant but far less/more is actually delivered on site; As a consequence, disputes arises because the Contractor has to order extra trucks to compensate for the missing volume. Fresh concrete after batching shall meet the requirements of BS EN 206-1 par 9.7, i.e. when 1m? is ordered to the plant, a volume of 1m? + 3% shall be produced; Differences between ordered and delivered volume may arise due to: + Mix design out of yield (the sum of the volumes of the components does not give 1 m:); * Batching plant is not calibrated; + Batching system does not work properly, ves ~— is a suitable method to ascertain the precision of the batching plant in terms of volume produced, ‘hr cocome i proMe ons edcin poh erga ten enero of SO in Ba eee 14 MAINTENANCE AND CALIBRATION OF BATCHING PLANTS Yield Test: * When the batching plant delivers concrete below yield, the Contractor is paying for 1 m° of concrete but actually receiving less > More concrete trucks must be ordered to fill a specified volume > extra costs; + When the batching plant delivers concrete over yield, the Contractor is receiving concrete with a lower content of cement per cubic meter > potential failures of strength, issues with durability. Iisdocumert scopygted ond is eprodacton prohties eept in uluthut written opr! of MMSOI. Sa MAINTENANCE AND CALIBRATION OF BATCHING PLANTS Yield Test: (0D Gebne volune, OF dre cont ter 1. Avolume of 1 mé of concrete is ordered to the batching plant; im Q When hardened, en WOigh He yrgcay. 2. The concrete produced by the batching plant is poured into a formwork of Kowa infvensions (iu lgalare tro (nominally 1m x 1m x 1m); dene = The volume of concrete in the form is measured to check whether the tolerance of + 3% is met; After 24 hours, hardened concrete in the form is demoulded and lifted by an excavator or similar equipment; Adynamometric weighing scale is connected to the mock up and the weight of the concrete in the form is measured to check whether the tolerance of + 3% is met. IMM SA Tris documen copyrighted and seared prone ecaptn fitout writen opal f MUS Sde Oh 76 MAINTENANCE AND CALIBRATION OF BATCHING PLANTS Measurement of volume . J nnohld 2% Vege lal x on ‘Thseocuren: capyrobted andi reprecucten i pohived ect fllhou writen oppo of MMSON. Sa Bk Lifting of mock up » > 2 21-001 = O0l m= 5-44 on IMM SA MAINTENANCE AND CALIBRATION OF BATCHING PLANTS A Fi Lifting of mock up Weighing of mock up ‘i aecament cpa nd proton poe xen fil wht writen apc of MSO Sé. Bie wean 7 MAINTENANCE AND CALIBRATION OF BATCHING PLANTS Yield Test: Example 1 Design unit weight of concrete = 2,340 kg/m?; Volume ordered to the batching plant = 1 m= 1,000 litres; Lower limit for volume = 1,000 - (1,000 x 3%) = 970 litres = 0.97 m?, Upper limit for volume = 1,000 + (1,000 x 3%) = 1,030 litres = 1.03 m*, Lower limit for unit weight = 2,340 — (2,340 x 3%) kg/m3 = 2,270 kg/m; Upper limit for unit weight = 2,340 + (2,340 x 3%) kg/m = 2,410 kg/m3; Measured yolume during yield test = 0.900 m* = 900 litres > OUT OF TOLERANCE = FAILED; Measured weight of mock up = 2,250 kg; Actual unit weight of concrete in the form = 2,250 kg / 0.90 m? = 2,500 kg/m’ > OUT OF TOLERANCE = FAILED. ‘recent cpl od epodicn aid ep ton ten prot MEO Sn, Bh nies MAINTENANCE AND CALIBRATION OF BATCHING PLANTS Yield Test: Example 2 Design unit weight of conerete = 2,340 kg/m®; Volume ordered to the batching plant = 1 m? = 1,000 litres; Lower limit for volume = 1,000 — (1,000 x 3%) = 970 litres = 0.97 m?; Upper limit for volume = 1,000 + (1,000 x 3%) = 1,030 litres = 1.03 m®; Lower limit for unit weight = 2,340 — (2,340 x 3%) kg/m3 = 2,270 kg/m; Upper limit for unit weight = 2,340 + (2,340 x 3%) kg/m3 = 2,410 kg/m’; Measured volume during yield test = 0.980 m* = 980 litres > WITHIN TOLERANCE = PASS; Measured weight of mock up = 2,300 kg; Actual unit weight of concrete in the form = 2,300 kg / 0.98 m* = 2,346 kg/m? > WITHIN TOLERANCE = PASS. if j ‘Ths documents copyratted ands repreaucten i prohiied except in fl who tan opprevel of IMMSOL Sh ht Wess MAINTENANCE AND CALIBRATION OF BATCHING PLANTS Yield test: cost implications for the contractor and the client Consider the previous example whereby concrete was produced with a yield of only 0.90 m3, i.e. when ordering (and paying for) 1 m of concrete, only 0.90 m3 (or 900 litres) of concrete are received on site; For a 1,000 m° pour, this would mean 100 m° of concrete “missing” (but fully paid for) and an extra 100 mS to be ordered (and be paid for); Assuming an arbitrary price of the concrete of RM 300.00/m’, this would mean an extra cost of RM 30,000.00; For a Project of 1,000,000 m° of concrete and same yield of 0.90 m3, the volume of concrete missing would be 100,000.00 m and extra costs would be RM 30,000,000.00; And so on.... iscocumene weopyeed es epocutn proNbed exept ol without writen oor of MMO Sek at COMPLIANCE AND CONFORMITY » Sometimes the terms Compliance and Conformity are used interchangeably > not correct; (People ) comply with (e.g. the contractor complies with the specification); (Things bonform to (e.g. cement conforms to BS EN 197-1). ‘Ths decent copyrighted ond reproduction i prohied except n full thou ten ape of MSD Sn. Bk COMPLIANCE AND CONFORMITY — CONCRETE STRENGTH x by concrete Syppiiew — perio dicat concrete producer to show that the concrete supplied conformed to its specification; cL conguitant —t0 endure Mar graders done covrectiy > Identity test: test(s) undertaken by the specifier to determine if a batch or series of batches of concrete came from a > Conformity: set of tests and evaluation undertaken by the conforming population and conform to project's specifications. lutte. batch stonelardl “mt patois. denatin » PRODUCTION CONTROL ® Production control comprises all measures necessary to maintain the properties of concrete in conformity to specified requirements PRODUCTION CONTROL It includes the following (EN 206-1): > > > > » > Selection of materials; Control on equipment; Concrete mix proportioning; Concrete production; Inspection and tests; The use and interpretation of the results of the tests on constituent materials, fresh and hardened concrete (Conformity control). ‘is cocumentscopygtes ands eprducton iprohted cpt fluo wton oppo of MSI Sa Bh IMM SA, PRODUCTION CONTROL We have seen in previous modules that, when a specification is received, mix proportions are selected that: ?. strongth requiremet—(¢ Inergin) > min cement Goatert-Ls deyondls on empsure class duralsifhy) imitati it i (0). wierosilica , > Conform to limitations on constituent materials; 4 3 an Tite ot constfuerrt- G57. GGRS, » Are expected to give the specified characteristic strength plus a margin; > Satisfy the maximum W/C ratio; > Satisfy the minimum cement content. ‘Ths document cpyatad an its reprosucton probed ecetin ful without wien approve of MSO. Sd Bra 86 sloiigieal data PRODUCTION CONTROL setenny Bos > For convenience, if the mix proportions are controlled by the maximum re ratio pr rium eee) content, the producer will equate these to a target strength for production control purposes 8 8 3 strengen cnn) a8 Vas wooo g | 4000 PRODUCTION CONTROL » When supplying concrete, the producer will batch the mix proportions that are expected to give the target strength; a scatter of results due to batching and i > When a concrete is tested there will be § « i i 3 testing variability; > We need to understand how data “mi Sie wma wna maar ina Hand Gah Hanah Fang Tae disperse > we need to understand statistical distributions. "This cocumen copys ordtsreroducton i probed exceptin fll thou ten pero! of ASO. Sn. 86 STATISTICAL DISTRIBUTIONS > Measured properties of physical systems or of products of certain manufacturing processes are a8 aoe subjected to vari ions (height distribution of humans, weight of newbems, thickness of tiles, vara si seek ‘ srenath of of bricks, strength of concrete, tc), perma patch Knogses oF conven’ in 56 So EE TT aX chomwan cevsery of cluwuth orate p 7) > Some vartatiins are ried by the intrinsic uncertainties inGesting and others are related to variations of materials properties that generate the observed scatters, ranges etc.; von, ruolsture, Sule exrodhruchowtcalled tie imavhine » We are now mostly interested in variations induced by fluctuations in materials properties; » We generally define (for the simplest types of distribution) mean values i.e. the most representative ones of a distribution and minimum/maximum values that define the “boundaries” of the distributions. ‘miscocment copyrighted ons reproduction protie expt ul wiht writen opal af MIMI Sa Bhd STATISTICAL DISTRIBUTIONS wedi CG AAndard deviation = STATISTICAL DISTRIBUTIONS > For manufacturing processes such as concrete production we need to make sure that variations over a target mean value are limited; Gp sunndard deviation > For instance for concrete we want that: values of strength achieved over a control period are not below some minimum limits set by design or above some limits set by economy. Compressive Stent Mat z 8 GURY tee bngi Srengrh hotel oe wnat toa. VF Coney STATISTICAL DISTRIBUTIONS — GAUSS CURVE > Distributions of values of certain measured properties of an object, a system or a living creature have different shapes; The Normal Distribution (or Gauss curve or errors curve or bell shaped curve) distribution is amongst the most common (and simpler to evaluate); In a normal distribution the mean value (u) represent the most probable one with values above and below the mean becoming less and less probable the more we move away from it; We call of the curve a certain portion above and below the mean where only “outliers” are foun characteishe srengty An outlier is a limited number of values that - because they are much larger or much lower than the mean value - are considered exceptional, hence they are rare events. chara closy Seren gt feb STATISTICAL DISTRIBUTIONS —- GAUSS CURVE > If we have a certain number n of values of compressive strength strength of cubes: x,, XytXy tXgtXgtXgte +X n ¢ Xp, Xg) X, We define the mean as: (85-6242 £2) + (5 BP Joy Far tramgdar = 5 72 65 109 2 AQ gy Geer > We define the standard deviation as: hou Te Oe Cla riotde tin

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