This document discusses flooring systems for food processing facilities and focuses on concrete substrates and monolithic resin flooring systems. It provides details on concrete composition, including Portland cement types and fly ash. Concrete behaviors like shrinkage and cracking are explained. Defects during concrete installation from freeze/thaw effects, chemical attack, crazing, scalling, spalling, blisters, and dusting are also outlined. The document then discusses tile, brick, and mortar (CRBT) flooring systems and their limitations before focusing on monolithic resin systems using epoxy, acrylic, polyurethane, polyester, and vinyl esters. Application methods for monolithic systems are also mentioned.
This document discusses materials used for repairing and rehabilitating reinforced concrete structures. It covers various repair strategies like load reduction, crack repair, and strengthening of structural elements. It also discusses different types of materials used for surface preparation, corrosion protection, bonding, structural repairs, and other purposes. Key materials mentioned include cement mortars, polymer-modified cement products, epoxies, acrylics, and chemicals. The document provides guidelines on selecting appropriate materials based on properties like shrinkage, bond strength, thermal expansion, and durability. It also outlines various applications of polymer mortars and epoxies in structural repair and rehabilitation work.
Module on fibre reinforced and foam concreteErankajKumar
This document discusses fibre reinforced concrete and foam concrete. It defines fibre reinforced concrete as a composite material consisting of fibres mixed into cement, mortar or concrete to increase structural integrity. Various fibre types are described, including steel, polypropylene, glass, polyester, carbon and natural fibres. Applications of fibre reinforced concrete include pavements, tunnels, dams and bridges. Foam concrete is defined as a lightweight concrete containing cement, water and a foaming agent with no large aggregates. It has advantages like lightweight, thermal insulation, self-leveling properties and fire resistance. Foam concrete is used in construction of walls, floors, pipes and as backfill material.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Bio-inorganic composites as repair mortar for Heritage structuressushendhukc
The document discusses bio-inorganic composites as repair mortars for heritage structures. It provides background on traditional lime mortars used in historical structures in India. Specifically, it examines the lime mortar used in the Vadakunnathan Temple from the 7th century, which contains natural herbal admixtures. The document then outlines the preparation of traditional herbal lime mortars and reference lime mortars in the laboratory. It finds that the laboratory prepared herbal lime mortar achieves higher compressive strength and lower porosity compared to the reference lime mortar due to reactions with compounds in the herbal extract.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Module on admixture , polymer and exposy resinsErankajKumar
The document discusses admixtures, polymers, and epoxy resins used in construction materials. It begins by defining admixtures as chemical compounds added to concrete mixes to modify properties such as workability, hydration rate, and strength. Common admixtures include accelerators, retarders, air-entrainers, and water reducers. The document then classifies and describes various admixture types and discusses their functions, advantages, and disadvantages. It provides details on specific admixture materials and how they affect concrete properties. The overall purpose is to educate civil engineering students on admixture fundamentals and applications in construction technology and management.
Materials and Methods for Repair and Rehabilitationdevidaddy
This document provides descriptions of materials and methods for repairing and rehabilitating concrete structures. It discusses additional reinforcement, autogenous healing of cracks, and conventional concrete placement. Additional reinforcement involves adding conventional reinforcement or prestressing steel to carry tensile forces causing cracking. Autogenous healing is a natural process where moisture and absence of tension allows cracks to close via precipitation within the cracks. Conventional concrete placement involves removing defective concrete and replacing it with a new concrete mix that integrates with the existing structure.
IPANEX is a liquid admixture added to concrete to make it waterproof by densifying its microstructure. It works by controlling hydration to produce a more homogeneous, fine-grained structure with smaller, more tortuous pores that restrict water penetration. Testing shows IPANEX concrete has significantly reduced permeability and chloride ion ingress. It provides advantages like increased strength, durability, corrosion resistance and waterproofness without organic chemicals that could degrade over time. IPANEX is recommended for applications requiring impermeable concrete under water pressure like foundations, tanks, and marine structures.
This document discusses materials used for repairing and rehabilitating reinforced concrete structures. It covers various repair strategies like load reduction, crack repair, and strengthening of structural elements. It also discusses different types of materials used for surface preparation, corrosion protection, bonding, structural repairs, and other purposes. Key materials mentioned include cement mortars, polymer-modified cement products, epoxies, acrylics, and chemicals. The document provides guidelines on selecting appropriate materials based on properties like shrinkage, bond strength, thermal expansion, and durability. It also outlines various applications of polymer mortars and epoxies in structural repair and rehabilitation work.
Module on fibre reinforced and foam concreteErankajKumar
This document discusses fibre reinforced concrete and foam concrete. It defines fibre reinforced concrete as a composite material consisting of fibres mixed into cement, mortar or concrete to increase structural integrity. Various fibre types are described, including steel, polypropylene, glass, polyester, carbon and natural fibres. Applications of fibre reinforced concrete include pavements, tunnels, dams and bridges. Foam concrete is defined as a lightweight concrete containing cement, water and a foaming agent with no large aggregates. It has advantages like lightweight, thermal insulation, self-leveling properties and fire resistance. Foam concrete is used in construction of walls, floors, pipes and as backfill material.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Bio-inorganic composites as repair mortar for Heritage structuressushendhukc
The document discusses bio-inorganic composites as repair mortars for heritage structures. It provides background on traditional lime mortars used in historical structures in India. Specifically, it examines the lime mortar used in the Vadakunnathan Temple from the 7th century, which contains natural herbal admixtures. The document then outlines the preparation of traditional herbal lime mortars and reference lime mortars in the laboratory. It finds that the laboratory prepared herbal lime mortar achieves higher compressive strength and lower porosity compared to the reference lime mortar due to reactions with compounds in the herbal extract.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Module on admixture , polymer and exposy resinsErankajKumar
The document discusses admixtures, polymers, and epoxy resins used in construction materials. It begins by defining admixtures as chemical compounds added to concrete mixes to modify properties such as workability, hydration rate, and strength. Common admixtures include accelerators, retarders, air-entrainers, and water reducers. The document then classifies and describes various admixture types and discusses their functions, advantages, and disadvantages. It provides details on specific admixture materials and how they affect concrete properties. The overall purpose is to educate civil engineering students on admixture fundamentals and applications in construction technology and management.
Materials and Methods for Repair and Rehabilitationdevidaddy
This document provides descriptions of materials and methods for repairing and rehabilitating concrete structures. It discusses additional reinforcement, autogenous healing of cracks, and conventional concrete placement. Additional reinforcement involves adding conventional reinforcement or prestressing steel to carry tensile forces causing cracking. Autogenous healing is a natural process where moisture and absence of tension allows cracks to close via precipitation within the cracks. Conventional concrete placement involves removing defective concrete and replacing it with a new concrete mix that integrates with the existing structure.
IPANEX is a liquid admixture added to concrete to make it waterproof by densifying its microstructure. It works by controlling hydration to produce a more homogeneous, fine-grained structure with smaller, more tortuous pores that restrict water penetration. Testing shows IPANEX concrete has significantly reduced permeability and chloride ion ingress. It provides advantages like increased strength, durability, corrosion resistance and waterproofness without organic chemicals that could degrade over time. IPANEX is recommended for applications requiring impermeable concrete under water pressure like foundations, tanks, and marine structures.
Ground water can be controlled through both permanent and temporary exclusion methods. Permanent exclusion methods include sheet piling, diaphragm walls, slurry trench cut-offs, chemical grouting, resin grout, cement grout, clay/cement grout, and bituminous grout, which form barriers to water flow. Temporary exclusion lowers the water table using methods like sump pumping, well-point systems, horizontal drains, and electro-osmosis. Excavation works require ground water control to stabilize soils and exclude water from entering the excavation area.
ADMIXTURE ,The major reasons for using
admixtures, Air-Entraining Admixtures, Water-Reducing Admixtures ,Superplasticizers (High-Range Water
Reducers), Retarding Admixtures, Accelerating Admixtures, Corrosion Inhibitors, Shrinkage-Reducing Admixtures, introduction in polymer , types of polymer, classification of polymer , characteristics of polymer, properties of polymer , strength of polymer , application of polymer ,
Module on Special and high performance concreteErankajKumar
The document discusses different types of special concretes used in construction, including grouting, guniting, underwater concreting, and hot and cold weather concreting. Grouting involves injecting cement grout into cracks and voids to improve stability. Guniting uses a cement-sand mix applied at high pressure to repair damaged concrete. Underwater concreting requires special techniques like the tremie method and uses additives to allow placement under water. Hot and cold weather concreting require precautions like cooling or heating aggregates and protecting fresh concrete to account for temperature effects.
This document discusses polymers used for concrete repair. It describes two main types of polymers: those used to modify cementitious systems and thermosetting resin systems like epoxy, polyester, and acrylic. Polymer latexes are used as admixtures in cementitious systems where they improve properties like strength, permeability, and bonding. Resin repair mortars are used for smaller repairs under 12mm and rely on impermeability for steel protection. Epoxy, polyester, and acrylic resins are discussed in more detail regarding their chemical curing processes and appropriate uses in concrete repair.
An Experimental Study on SIFCON using M – Sand and Partially Replacing Cement...IRJET Journal
This document presents the results of an experimental study on Slurry Infiltrated Fibre Concrete (SIFCON) using manufactured sand (M-sand) and partially replacing cement with silica fume. Various tests were conducted to evaluate the mechanical properties of SIFCON specimens containing 4%, 6%, 8%, and 10% steel fibers. The results show that compressive, tensile, and flexural strengths generally increased with higher fiber content up to 8%, above which the strengths decreased due to poor bonding. Non-destructive tests found rebound number and pulse velocity were highest for 8% fiber content, confirming 8% as the optimum amount. The study demonstrates that M-sand and silica fume can be used to
Module on pozzolanic materials and fly ash ErankajKumar
This document discusses pozzolanic materials and fly ash. It defines pozzolanic materials as finely powdered materials that can be added to lime or cement mortar to increase durability through chemical reactions. The document outlines various natural and manufactured sources of pozzolanic materials including volcanic ash, burnt clay, slag, ashes of organic origin, and certain sands. It also discusses the properties and reactivity of pozzolans and their effects on mortar and concrete qualities like strength and stiffness. Additionally, the document defines fly ash as a byproduct of burning coal used in concrete for its cementitious properties. It notes the two main types of fly ash, Class C and Class F, and outlines fly ash's
CON 122 Session 5 - High Performance Concrete Admixturesalpenaccedu
This document discusses high-performance concrete admixtures. It defines high-performance concrete as concrete with desired properties and uniformity that cannot be routinely obtained using only traditional constituents and normal mixing, placing, and curing practices. High-performance concretes are developed to meet specific construction needs and often require a combination of admixtures. Key properties of high-performance concretes include enhanced fresh/plastic properties, mechanical properties, and durability properties. The document focuses on corrosion inhibitors and shrinkage-reducing admixtures.
Walia International Machines is a multi divisional,vacuum de watering machine,vacuum dewatering machine,vacuum dewatering machines,vacuum de dewatering machines
Address : Walia International Machines Corporation,408 Vishwadeep , District Centre, Janak Puri New Delhi- 110058,India
Website : http://waliainternational.com
Telefax : 011 – 25546044 ,25521275
Emails : info@waliainternational.com
This document provides information on waterborne epoxy coating systems from Huntsman Advanced Materials. It discusses:
1. Huntsman's waterborne epoxy resins and hardeners that can be used for various coating applications on cementitious or metal substrates.
2. Key selection factors for the appropriate resin and hardener combination based on the targeted application and substrate.
3. Examples of basic formulations for a waterborne clear epoxy sealer and waterborne low VOC floor coating.
1. There are a variety of backer board options available for tile installation, including traditional fiberglass-reinforced cement boards and innovative products that incorporate recycled materials.
2. Backer boards come in different thicknesses and dimensions to provide a stable surface for tile in floors, walls, and countertops. They also offer options for wet or dry areas.
3. Newer backer boards have lightweight foam cores with fiberglass mesh and cement coatings, making them easier to handle while maintaining strength and affordability. Proper board selection depends on the application.
This document summarizes a study on structures built on black cotton soil. It discusses the formation and properties of black cotton soil, which causes issues for construction due to its swelling and shrinkage characteristics. Various tests are described that can evaluate the soil properties, such as swelling pressure, free swell index, consolidation, and triaxial tests. Different foundation types for structures in black cotton soil are outlined, including spread footings, mat foundations, pile foundations, and drilled shafts. Safety precautions are also discussed, such as limiting loads on the soil and building deep foundations below the crack zone.
This document discusses pozzolana and fly ash in concrete technology. It defines pozzolana as a finely powdered material that can be added to lime or cement mortar to increase durability by chemically reacting with calcium hydroxide. The document lists various natural and manufactured sources of pozzolanic materials including volcanic ash, calcined clay, mineral slag, and ashes of organic origin. It describes how the properties of pozzolanic materials like particle size and chemical composition affect their reactivity and the strength and setting of composites. The document also discusses how pozzolanic reactions enhance concrete properties like stiffness over time and that pozzolanic materials can improve sustainability by enabling the use of industrial and
IRJET-Study on Strength Properties of SifconIRJET Journal
This document summarizes a study on the strength properties of Slurry Infiltrated Fiber Reinforced Concrete (SIFCON). SIFCON is a type of fiber concrete with a high fiber content (5-20% by volume) that provides high strength and ductility. The study investigated different mix proportions of SIFCON by varying the steel fiber content from 6-12% by volume. Testing showed that compressive, tensile, and flexural strength increased with higher fiber content. The 12% fiber mix achieved a 36% increase in compressive strength over conventional concrete. Based on strength and economy, 12% fiber content was found to be optimal for SIFCON. The document concludes that SIFCON is a
This product data sheet describes FlexiDry, an additive that enables accelerated drying and hardening of floor screeds. It allows for light foot traffic within 12 hours and final floor finishes to be applied within 7, 14, or 21 days depending on the dosage of FlexiDry used. FlexiDry provides benefits such as low shrinkage, compatibility with underfloor heating and other flooring materials, and logistical advantages from its low volume requirement.
IRJET- Experimental Investigation on Engineered Cementious CompositeIRJET Journal
This document presents an experimental investigation on engineered cementitious composite (ECC). ECC is a type of ultra-ductile fiber reinforced concrete characterized by high ductility and tight crack control. It is made from similar ingredients as normal concrete but with the addition of polyvinyl alcohol fibers and a superplasticizer. The document discusses the ingredients and mixing process of ECC. It then summarizes the results of compressive and flexural strength tests on ECC and normal concrete cubes and slabs. The results show that the ECC achieved higher strengths compared to normal concrete due to the addition of fibers, and also exhibited greater ductility. The document concludes that ECC is more durable and flexible than normal concrete making it suitable for seismic regions.
This document discusses self-curing or internal curing concrete, which provides internal water reservoirs through the use of materials like lightweight aggregates or super absorbent polymers to hydrate cement particles. Proper curing is important for concrete to develop strength and durability. Self-curing concrete reduces the need for external curing and can perform better in areas without sufficient water for curing. The document examines using polyvinyl alcohol as a self-curing agent and finds that it helps retain water in concrete and reduces weight loss compared to conventional mixes without compromising strength. Self-curing concrete offers advantages like reduced cracking, permeability and improved durability.
Traders and suppliers of a comprehensive variety of Acid Resistance Lining, Acid Proof Brick, Carborundum Tiles, Industrial Heavy Duty Tiles, Acid Resistant Tiles and Water Proofing.
This document summarizes an experimental study on geopolymer concrete. Geopolymer concrete is an alternative to traditional Portland cement concrete that has lower environmental impact. It uses industrial byproducts like fly ash and blast furnace slag as its binding materials rather than Portland cement. The study explored how geopolymer concrete performs compared to ordinary concrete. It investigated the effects of different mixtures on the properties of geopolymer concrete, such as strength and durability. The results showed that geopolymer concrete has higher resistance to damage than standard concrete and allows waste materials like fly ash to be recycled instead of disposed in landfills.
Experimental Study On Glass Fiber Reinforced Concrete with Partial Replacemen...IRJET Journal
This study experimentally investigates the characteristics of concrete with partial replacements of cement with ground granulated blast furnace slag (GGBS) and fly ash, as well as additions of glass fibers. Glass fiber reinforced concrete uses glass fibers instead of steel for reinforcement. The study mixes concrete with 10% fly ash replacement and 10-30% GGBS replacement, as well as 0-1% glass fiber additions. Tests are performed to determine the compressive, flexural, and split tensile strengths of the concrete mixtures at 7, 14, and 28 days. The results show that partial cement replacement with fly ash and GGBS, as well as the addition of glass fibers, can improve the strength of concrete compared to normal concrete
The project was undertaken to design M50 grade concrete using GGBS cement and POZZOLANA cement and comparing the fresh concrete and hard concrete properties with concrete designed using conventional cement.
This document provides information on concrete pavements, including:
1) Concrete is made from cement, water, fine aggregate (sand), and coarse aggregate (gravel or crushed rock), and achieves strength over time as moisture is retained.
2) Concrete pavements are rigid and can bridge small areas, but overloading or reduced foundation support can cause cracking and failure. Maintaining joints and preventing water/material infiltration is important for longevity.
3) Proper mix design, using the right cement, water, aggregates, and admixtures is essential for achieving desired strength, durability, and workability of concrete. Thorough mixing and careful placement are also required.
1. The document discusses various types of special concretes including lightweight concrete, foam concrete, self-compacting concrete, vacuum concrete, fibre reinforced concrete, ferrocement, ready mix concrete, slurry infiltrated fibre concrete (SIFCON), and shotcrete.
2. Lightweight concrete uses lightweight aggregates like shale, clay, or slate to reduce density while maintaining strength. Foam concrete is made by injecting air or gas into the mix to create a cellular structure.
3. Self-compacting concrete can be placed without vibration due to its fluidity. Vacuum concrete has water removed using vacuum mats to increase strength.
Ground water can be controlled through both permanent and temporary exclusion methods. Permanent exclusion methods include sheet piling, diaphragm walls, slurry trench cut-offs, chemical grouting, resin grout, cement grout, clay/cement grout, and bituminous grout, which form barriers to water flow. Temporary exclusion lowers the water table using methods like sump pumping, well-point systems, horizontal drains, and electro-osmosis. Excavation works require ground water control to stabilize soils and exclude water from entering the excavation area.
ADMIXTURE ,The major reasons for using
admixtures, Air-Entraining Admixtures, Water-Reducing Admixtures ,Superplasticizers (High-Range Water
Reducers), Retarding Admixtures, Accelerating Admixtures, Corrosion Inhibitors, Shrinkage-Reducing Admixtures, introduction in polymer , types of polymer, classification of polymer , characteristics of polymer, properties of polymer , strength of polymer , application of polymer ,
Module on Special and high performance concreteErankajKumar
The document discusses different types of special concretes used in construction, including grouting, guniting, underwater concreting, and hot and cold weather concreting. Grouting involves injecting cement grout into cracks and voids to improve stability. Guniting uses a cement-sand mix applied at high pressure to repair damaged concrete. Underwater concreting requires special techniques like the tremie method and uses additives to allow placement under water. Hot and cold weather concreting require precautions like cooling or heating aggregates and protecting fresh concrete to account for temperature effects.
This document discusses polymers used for concrete repair. It describes two main types of polymers: those used to modify cementitious systems and thermosetting resin systems like epoxy, polyester, and acrylic. Polymer latexes are used as admixtures in cementitious systems where they improve properties like strength, permeability, and bonding. Resin repair mortars are used for smaller repairs under 12mm and rely on impermeability for steel protection. Epoxy, polyester, and acrylic resins are discussed in more detail regarding their chemical curing processes and appropriate uses in concrete repair.
An Experimental Study on SIFCON using M – Sand and Partially Replacing Cement...IRJET Journal
This document presents the results of an experimental study on Slurry Infiltrated Fibre Concrete (SIFCON) using manufactured sand (M-sand) and partially replacing cement with silica fume. Various tests were conducted to evaluate the mechanical properties of SIFCON specimens containing 4%, 6%, 8%, and 10% steel fibers. The results show that compressive, tensile, and flexural strengths generally increased with higher fiber content up to 8%, above which the strengths decreased due to poor bonding. Non-destructive tests found rebound number and pulse velocity were highest for 8% fiber content, confirming 8% as the optimum amount. The study demonstrates that M-sand and silica fume can be used to
Module on pozzolanic materials and fly ash ErankajKumar
This document discusses pozzolanic materials and fly ash. It defines pozzolanic materials as finely powdered materials that can be added to lime or cement mortar to increase durability through chemical reactions. The document outlines various natural and manufactured sources of pozzolanic materials including volcanic ash, burnt clay, slag, ashes of organic origin, and certain sands. It also discusses the properties and reactivity of pozzolans and their effects on mortar and concrete qualities like strength and stiffness. Additionally, the document defines fly ash as a byproduct of burning coal used in concrete for its cementitious properties. It notes the two main types of fly ash, Class C and Class F, and outlines fly ash's
CON 122 Session 5 - High Performance Concrete Admixturesalpenaccedu
This document discusses high-performance concrete admixtures. It defines high-performance concrete as concrete with desired properties and uniformity that cannot be routinely obtained using only traditional constituents and normal mixing, placing, and curing practices. High-performance concretes are developed to meet specific construction needs and often require a combination of admixtures. Key properties of high-performance concretes include enhanced fresh/plastic properties, mechanical properties, and durability properties. The document focuses on corrosion inhibitors and shrinkage-reducing admixtures.
Walia International Machines is a multi divisional,vacuum de watering machine,vacuum dewatering machine,vacuum dewatering machines,vacuum de dewatering machines
Address : Walia International Machines Corporation,408 Vishwadeep , District Centre, Janak Puri New Delhi- 110058,India
Website : http://waliainternational.com
Telefax : 011 – 25546044 ,25521275
Emails : info@waliainternational.com
This document provides information on waterborne epoxy coating systems from Huntsman Advanced Materials. It discusses:
1. Huntsman's waterborne epoxy resins and hardeners that can be used for various coating applications on cementitious or metal substrates.
2. Key selection factors for the appropriate resin and hardener combination based on the targeted application and substrate.
3. Examples of basic formulations for a waterborne clear epoxy sealer and waterborne low VOC floor coating.
1. There are a variety of backer board options available for tile installation, including traditional fiberglass-reinforced cement boards and innovative products that incorporate recycled materials.
2. Backer boards come in different thicknesses and dimensions to provide a stable surface for tile in floors, walls, and countertops. They also offer options for wet or dry areas.
3. Newer backer boards have lightweight foam cores with fiberglass mesh and cement coatings, making them easier to handle while maintaining strength and affordability. Proper board selection depends on the application.
This document summarizes a study on structures built on black cotton soil. It discusses the formation and properties of black cotton soil, which causes issues for construction due to its swelling and shrinkage characteristics. Various tests are described that can evaluate the soil properties, such as swelling pressure, free swell index, consolidation, and triaxial tests. Different foundation types for structures in black cotton soil are outlined, including spread footings, mat foundations, pile foundations, and drilled shafts. Safety precautions are also discussed, such as limiting loads on the soil and building deep foundations below the crack zone.
This document discusses pozzolana and fly ash in concrete technology. It defines pozzolana as a finely powdered material that can be added to lime or cement mortar to increase durability by chemically reacting with calcium hydroxide. The document lists various natural and manufactured sources of pozzolanic materials including volcanic ash, calcined clay, mineral slag, and ashes of organic origin. It describes how the properties of pozzolanic materials like particle size and chemical composition affect their reactivity and the strength and setting of composites. The document also discusses how pozzolanic reactions enhance concrete properties like stiffness over time and that pozzolanic materials can improve sustainability by enabling the use of industrial and
IRJET-Study on Strength Properties of SifconIRJET Journal
This document summarizes a study on the strength properties of Slurry Infiltrated Fiber Reinforced Concrete (SIFCON). SIFCON is a type of fiber concrete with a high fiber content (5-20% by volume) that provides high strength and ductility. The study investigated different mix proportions of SIFCON by varying the steel fiber content from 6-12% by volume. Testing showed that compressive, tensile, and flexural strength increased with higher fiber content. The 12% fiber mix achieved a 36% increase in compressive strength over conventional concrete. Based on strength and economy, 12% fiber content was found to be optimal for SIFCON. The document concludes that SIFCON is a
This product data sheet describes FlexiDry, an additive that enables accelerated drying and hardening of floor screeds. It allows for light foot traffic within 12 hours and final floor finishes to be applied within 7, 14, or 21 days depending on the dosage of FlexiDry used. FlexiDry provides benefits such as low shrinkage, compatibility with underfloor heating and other flooring materials, and logistical advantages from its low volume requirement.
IRJET- Experimental Investigation on Engineered Cementious CompositeIRJET Journal
This document presents an experimental investigation on engineered cementitious composite (ECC). ECC is a type of ultra-ductile fiber reinforced concrete characterized by high ductility and tight crack control. It is made from similar ingredients as normal concrete but with the addition of polyvinyl alcohol fibers and a superplasticizer. The document discusses the ingredients and mixing process of ECC. It then summarizes the results of compressive and flexural strength tests on ECC and normal concrete cubes and slabs. The results show that the ECC achieved higher strengths compared to normal concrete due to the addition of fibers, and also exhibited greater ductility. The document concludes that ECC is more durable and flexible than normal concrete making it suitable for seismic regions.
This document discusses self-curing or internal curing concrete, which provides internal water reservoirs through the use of materials like lightweight aggregates or super absorbent polymers to hydrate cement particles. Proper curing is important for concrete to develop strength and durability. Self-curing concrete reduces the need for external curing and can perform better in areas without sufficient water for curing. The document examines using polyvinyl alcohol as a self-curing agent and finds that it helps retain water in concrete and reduces weight loss compared to conventional mixes without compromising strength. Self-curing concrete offers advantages like reduced cracking, permeability and improved durability.
Traders and suppliers of a comprehensive variety of Acid Resistance Lining, Acid Proof Brick, Carborundum Tiles, Industrial Heavy Duty Tiles, Acid Resistant Tiles and Water Proofing.
This document summarizes an experimental study on geopolymer concrete. Geopolymer concrete is an alternative to traditional Portland cement concrete that has lower environmental impact. It uses industrial byproducts like fly ash and blast furnace slag as its binding materials rather than Portland cement. The study explored how geopolymer concrete performs compared to ordinary concrete. It investigated the effects of different mixtures on the properties of geopolymer concrete, such as strength and durability. The results showed that geopolymer concrete has higher resistance to damage than standard concrete and allows waste materials like fly ash to be recycled instead of disposed in landfills.
Experimental Study On Glass Fiber Reinforced Concrete with Partial Replacemen...IRJET Journal
This study experimentally investigates the characteristics of concrete with partial replacements of cement with ground granulated blast furnace slag (GGBS) and fly ash, as well as additions of glass fibers. Glass fiber reinforced concrete uses glass fibers instead of steel for reinforcement. The study mixes concrete with 10% fly ash replacement and 10-30% GGBS replacement, as well as 0-1% glass fiber additions. Tests are performed to determine the compressive, flexural, and split tensile strengths of the concrete mixtures at 7, 14, and 28 days. The results show that partial cement replacement with fly ash and GGBS, as well as the addition of glass fibers, can improve the strength of concrete compared to normal concrete
The project was undertaken to design M50 grade concrete using GGBS cement and POZZOLANA cement and comparing the fresh concrete and hard concrete properties with concrete designed using conventional cement.
This document provides information on concrete pavements, including:
1) Concrete is made from cement, water, fine aggregate (sand), and coarse aggregate (gravel or crushed rock), and achieves strength over time as moisture is retained.
2) Concrete pavements are rigid and can bridge small areas, but overloading or reduced foundation support can cause cracking and failure. Maintaining joints and preventing water/material infiltration is important for longevity.
3) Proper mix design, using the right cement, water, aggregates, and admixtures is essential for achieving desired strength, durability, and workability of concrete. Thorough mixing and careful placement are also required.
1. The document discusses various types of special concretes including lightweight concrete, foam concrete, self-compacting concrete, vacuum concrete, fibre reinforced concrete, ferrocement, ready mix concrete, slurry infiltrated fibre concrete (SIFCON), and shotcrete.
2. Lightweight concrete uses lightweight aggregates like shale, clay, or slate to reduce density while maintaining strength. Foam concrete is made by injecting air or gas into the mix to create a cellular structure.
3. Self-compacting concrete can be placed without vibration due to its fluidity. Vacuum concrete has water removed using vacuum mats to increase strength.
The document discusses concrete moisture testing and the importance of testing concrete moisture levels before installing flooring. It notes that fast track construction and adaptive reuse of old buildings often leads to flooring failures later due to excess moisture in the concrete. Proactively testing the concrete moisture level can help prevent costly repairs from moisture-related flooring failures, estimated at $1-2 million per week. The company Reliant Testing Engineers provides calcium chloride testing services to test concrete moisture levels according to industry standards.
IRJET- Behaviour of Mineral Admixture on Strength and Durability of ConcreteIRJET Journal
This document discusses the effects of mineral admixtures on the strength and durability of high performance concrete (HPC). Two HPC mixes were designed - a control mix without admixtures and a mix replacing 15% cement with fly ash and 10% with silica fume. Testing found the admixture mix achieved higher 7-day and 28-day compressive strengths than the control. Durability testing also indicated the admixture mix had better resistance to chloride and sulfate attack over 180 days. The improved performance is attributed to the pozzolanic reactions of fly ash and silica fume creating a denser microstructure in the concrete.
Concrete is the most common building material used in construction. It is made by mixing cement, aggregate such as sand or gravel, and water. Concrete can be molded into any shape needed and hardens over time. It provides strength and durability as a building material. Concrete properties depend on its composition, with cement binding the aggregates and filling spaces between them. Proper mixing, placing, and curing of concrete results in a strong, long-lasting building material. Common concrete elements in construction include foundations, slabs, columns, beams, bridges, and highways.
1. The document discusses advances in concrete technology, including various admixtures that can improve the properties of concrete such as workability, strength, and durability.
2. It describes how plasticizers and super plasticizers can reduce the water-cement ratio while maintaining or improving workability. Retarders can delay the setting time of concrete to allow for longer transportation or pouring times.
3. The document also covers air-entraining admixtures, mineral admixtures, waterproofers, bonding agents, colorants, and corrosion inhibitors - explaining how each can enhance properties of concrete for different applications.
The use of cellular (foamed) concrete in geotechnical engineering.Denis_O_Sullivan
This document discusses the use of foamed concrete as a lightweight fill material for various civil engineering applications. It provides background on foamed concrete, including its manufacture, properties, applications, and case studies. Specific case studies discussed include using foamed concrete to widen a road over unstable peat soil, filling a masonry arch bridge, stabilizing limestone mines, and reinstating trenches. The document concludes that foamed concrete is a useful lightweight fill material that is cheaper and faster to place than traditional fills.
This document discusses concrete technology and provides information on various topics related to concrete construction. It begins with an overview of concrete admixtures and their classification. It then discusses ready mix concrete and includes information on quality control measures in concrete projects. The document also covers common defects in concrete, repair methods, and different varieties of concrete. It concludes with sections on concreting under extreme conditions and the past, present, and future of concrete.
Self-compacting concrete (SCC) is a highly fluid concrete that can spread and consolidate under its own weight without vibration. It was developed in Japan in the 1980s to solve issues with vibration and ensure durable concrete structures. SCC spreads easily and fills forms completely, even around dense reinforcement. This eliminates the need for vibration and ensures uniform consolidation, but it requires precise material proportions and testing. While allowing for complex designs and construction time savings, SCC is also more expensive than traditional concrete due to material and testing costs. It therefore provides benefits for certain applications but cannot be used universally.
Experimental Studies on Cellular Light Weight Concrete Based On Foam, Fly Ash...IRJET Journal
- The document discusses experimental studies on cellular lightweight concrete (CLWC) made using foam, fly ash, and silica fume. CLWC is a cementitious material that is lighter in weight than conventional concrete, weighing 400-1950 kg/m3.
- Due to its lower strength compared to conventional concrete, CLWC is suitable for non-load bearing applications like walls. Additions like fly ash and silica fume are used to improve the properties of CLWC.
- The document provides details on the production of CLWC including the typical constituents of cement, aggregates, admixtures, and the role of fly ash. Compressive strength, water absorption and density are some key properties examined.
Concrete is a building material made by mixing cement, sand, gravel and water. It has high compressive strength but low tensile strength. Reinforced concrete uses steel bars to increase tensile strength. Concrete ingredients include cement, aggregates and water. Admixtures like accelerators and retarders are used to control setting time. Proper mixing, placing, compaction and curing are required to produce high quality concrete.
This document provides an overview of pervious concrete, including its environmental benefits, applications, performance characteristics, construction procedures, and testing methods. Key points include:
- Pervious concrete allows rainwater to seep through it, reducing runoff and recharging groundwater while meeting EPA stormwater regulations.
- It has sufficient strength for many pavement applications despite its high porosity (15-25% voids) and permeability rates of 480 in/hr or more.
- Applications include pavements for parking lots where it can eliminate the need for retention ponds and swales by capturing and filtering rainwater.
- Proper construction techniques like vibration and curing are important for performance. Visual inspections, infiltration tests
A pdf file on High Performance Concrete giving full details about High Performance Concrete, their use,advantages,disadvantages,strength,applications,tensile strength,bridges.
Design a suitable splice and bolted connection for extending a column of rolled steel cross section ISHB200@40 kg/m. The column is to support service axial compressive load, bending moment and shear force of 1000 KN, 50 KN and 90 KN respectively. The column ends are smooth finished. Ordinary bolts of M20 grade 4.6 are available for splicing.
Admixtures are ingredients added to concrete other than cement, water and aggregates to achieve desired properties. Common admixtures include air-entraining, plasticizers, retarding, accelerating, corrosion inhibiting, waterproofing and grouting admixtures. Air-entraining admixtures introduce tiny air bubbles that allow space for ice expansion and prevent cracking. Plasticizers improve workability while using less water. Retarders slow hydration for placing large pours over time. Accelerators speed strength gain. Corrosion inhibitors protect reinforcement. Waterproofers make concrete less permeable. Mineral admixtures like fly ash and slag improve properties and provide environmental benefits.
Report on Types of Cement_TusharDas_SEM5.pdfTusharDas100
This document discusses different types of cement and their properties. It outlines 10 main types of cement:
1. Ordinary Portland Cement (OPC) is the most widely used type for concrete, mortar, and plaster construction.
2. Portland Pozzolana Cement (PPC) has high chemical resistance and is used in marine structures, bridges, and mass concrete works.
3. Rapid and extra rapid hardening cements gain strength faster, used for quick construction projects.
4. Low heat cement produces less heat during curing and is used in mass concrete like dams. Sulfate resisting cement is used where soils/water contain sulfates.
It also outlines physical
This document provides information on concrete admixtures. It discusses the history of admixture use dating back to ancient Rome, China, Mesoamerica and Peru. Common types of chemical admixtures are then outlined, including air-entraining, water-reducing, retarding, accelerating, super plasticizers, and corrosion-inhibiting admixtures. Specific admixture products are also highlighted and their benefits described. The document concludes with definitions and purposes of chemical admixtures like super plasticizers and retarding admixtures.
Fresh concrete -building materials for engineersmusadoto
General introduction
CONCRETE
is a building Material made from a mixture of gravel ,sand ,cement,water and air ,forming a stone like mass on hardenning.
FRESH CONCRETE
It is a concrete that has not reached the final setting time.
Similar to 2 Flooring Systems; The Effects of Composition and Application (20)
2. Flooring systems The Effects of Composition and Application
PREFACE
Problem
The food processing economy is growing steadily and you have
determined that the addition of a new facility will best help you meet
the increased demand. You have toured existing facilities and you are
concerned that the flooring systems in these buildings do not provide
protection from the typical forms of floor abuse within a food processing
facility.
You have acquired a site that provides the required acreage for current
and future demands, transportation access to major thoroughfares
and appropriate space for staff parking. With the construction of a new
facility, your goal is to incorporate a flooring system that will provide
the characteristics needed to achieve protection from the everyday
production challenges. What concrete substrate should be used?
Should the floor have an epoxy or polyurethane finish? How is the floor
finish applied?
Solution
In order to design and construct the floor system within a food processing
facility, you must understand a floor’s composition, characteristics,
reactions to finishes and applications before choosing the correct
system.
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3. Flooring systems The Effects of Composition and Application
Concrete (substrate) FLY ASH
The use of volcanic ash, known as pozzolanic, was introduced as a
The intent of this investigation is to determine which industrial flooring component of the ancient Roman aqueducts and building structures.
system is best suited to meet the needs of a specific food processing Fly ash, having similar properties to the ancient pozzolanic, greatly
facility. It is important to understand that it is the concrete substrate improves the strength and durability of concrete. Also known as flue-
and its exposure to chemical, mechanical and thermal aggressions ash, fly ash is a residue generated during the combustion of coal. The
that will determine which flooring system should be used to provide ash that does not rise is known as bottom ash and the ash that rises and
the highest level of protection. Because the concrete substrate is the is caught in an electrostatic precipitator or particle filtration equipment
building component at risk, an understanding of its composition and before reaching the chimney is named fly ash.
behavior will be reviewed.
There are two classes of fly ash: Class F fly ash and Class C fly ash.
Concrete is the mixture of water, large and small aggregate, and The primary difference between the two classes is the percentage of
Portland cement. Portland cement mixed with water creates a paste calcium, silica, alumina and iron. Class F fly ash can have a volatile
that coats the surfaces of the aggregates, hardens and gains strength effect on the entrained air content in concrete, reducing its resistance
as it dries. The strength and durability of the rock-like mass is achieved to the freeze/thaw damage. Class F fly ash also contains less than 20
by the proportional mixing of ingredients. If the amount of paste is percent lime and requires the use of an activator. For these reasons,
not great enough to fill the voids between the aggregate, the finished Class F is seldom used. Class C fly ash has more than 20 percent lime
concrete will produce a honeycomb surface and be porous. However, and does not require the addition of an activator.
if there is more paste than required, the surface will be smooth but the
concrete will be likely to shrink and require frequent patching, which As a result, Class C fly ash is the primary additive to Portland cement.
could be a costly error. While its spherical shape increases the workability of the cement and
reduces the amount of water needed, it also has the ability to increase
While the proportion of the basic ingredients is the key to providing the the concrete’s strength, chemical resistance and durability. Fly ash can
correct composition, there are a variety of other components within the be substituted for up to 30 percent of the standard Portland cement
concrete that will change and provide the characteristics needed for a content of concrete.
specific condition. The amount of time to set, the release of heat during
the cure process, the introduction of microscopic air pockets to combat There are five basic types of Portland cement.
a freeze/thaw effect and the introduction of fly ash into the Portland
cement mix all provide different qualities that address the needs of a • Type I – General purpose
specific facility or application. The composition of Type I is suitable for all uses where special
properties are not required. An example of a special property would
be a need for temperature control during the hydration of the concrete.
CONCRETE INGREDIENTS
• Type II – Precaution against moderate sulfate action
WATER When concrete is located in a structure that comes in contact with
The use of potable water in mixing the concrete batch is not necessary;
groundwater drainage containing sulfate concentrations, the composition
however, the use of water with excessive impurities might affect both
of Type II is most appropriate. The moderate speed at which the heat is
the setting time and strength. The water should be tested to verify
released during the hydration stage is less than that of Type I. Type II is
that levels of chloride, sulfates, alkalis and solids are within approved
best suited for structures of considerable mass such as retaining walls.
ranges to prevent concrete failures such as efflorescence, corrosion of
reinforcement, staining, volume instability and reduced durability.
• Type III – Achieves high strength quickly
Type III is similar to Type I but contains a slightly higher amount of gypsum
AGGREGATES and a finer grind. When compared to type I and II, this modification
Coarse aggregate (gravel or crushed stone) and fine aggregate (sand)
obtains the seven day compressive strength in just three days and its
comprise 60 to 75 percent of the concrete’s volume. Desired thickness
twenty-eight day compressive strength in just seven. Because of this
and end use will determine the type and size of the aggregate used.
reduction in time, the long-term strength is reduced. Type III is typically
used for the construction of precast concrete products because of its
PORTLAND CEMENT quick turnover time.
In 1824 Joseph Aspdin, an English mason, named his recently patented
cement product ‘Portland’ cement. The term ‘Portland’ was chosen
• Type IA, IIA, IIIA – Air Entraining
because he felt that the color of the mixture resembled the natural
This modified version of Types I, II and III introduces an air-entraining
limestone located on the Isle of Portland in the English Channel.
agent that produces microscopic air bubbles which create air pockets
allowing space for the concrete to expand and contract during the
This appearance is achieved by combining calcium, silicon, aluminum
freeze/thaw process. These air pockets comprise 9 to 10 percent of
and iron. Gypsum is then added in the final grinding process to regulate
the concrete volume.
the setting time of the concrete. The raw materials used to create the
cement are limestone, shells, chalk (or marl) shale, clay, slate (or blast
furnace slag), silica sand and iron ore.
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4. Flooring systems The Effects of Composition and Application
• Type IV – Minimization of heat generated CURING
Type IV should be used in massive concrete structures such as a Once the concrete has hardened enough to resist disfiguring marks and
gravity dam where the temperature rise during the curing period is a blemishes, known as marring, the process of curing will begin. Curing is
critical factor. The speed of heat loss during the hydration period is low the prevention of evaporation that can be achieved by applying moisture
and the strength of the composition is developed at a slower rate than retaining fabrics such as burlap or cotton mats, sprinkling of water
Type I. fog, or sealing the surface with a plastic or special curing compound
to ensure that the hydration process continues. Much of the hydration
• Type V – Precaution against severe sulfate action and strength gain occurs within the first month of the concrete life
Type V is sulfate-resistant, and should be used when the concrete is cycle and will be governed by the specific mixture proportions, climate
exposed to high levels of sulfate typically located in the adjacent soils temperature, moisture conditions and scheduling parameters.
and groundwater.
CHEMICAL ADMIXTURES
CONCRETE PRODUCTION
WATER-REDUCING
PROPORTIONING The traditional water-reducing agent reduces the amount of water
Water, large aggregate, small aggregate and Portland cement comprise needed by 5 to 10 percent, which increases the concrete’s strength
the mix that, when designed properly, provides a workable concrete without increasing the amount of cement, thereby reducing the water-
that is both durable and strong. Typically, the mix is 15 to 20 percent cement ratio. The development of a mid-range admixture reduces the
water, 60 to 75 percent aggregate and 10 to 15 percent cement. If an water content by 8 percent and provides a more consistent setting time
air-entrained agent is included, it will make up 9 to 10 percent of the within a wider range of temperatures.
concrete volume. (Figure 1)
RETARDING
While having the additional ability to act as a water-reducing admixture,
6% air the primary function of a retarding agent is to counteract the acceleration
rate of the concrete that occurs in hot weather conditions.
11% Portland cement ACCELERATING
Typically used in cold weather conditions, this agent increases the rate
41% course aggregate of strength development and reduces the time needed for curing, which
(gravel or crushed stone)
allows the finishing operations to begin earlier.
SUPERPLASTICIZER
The addition of this agent reduces the water content by 12 to 30
percent and can be added on the job site to make a high-slump flowing
20% fine aggregate concrete. The effect on the concrete is an increase in fluidity rendering it
(sand)
workable and able to be placed with little to no vibration or compaction.
16% water Also referred to as a plasticizer or high range water reducer (HRWR),
the chemical reaction remains active for only 30 to 60 minutes, and the
Figure 1: Concrete basics (approximate percentages) concrete becomes unworkable quickly.
The workability of the concrete is determined by the quality of the paste. AIR-ENTRAINING
The strength of the paste depends on the ratio of water to cement. This This surface-active agent stabilizes the microscopic air bubbles that are
ratio is the weight of the water divided by the weight of the cement. created by the shearing action of the mixture and aggregates during the
Obtaining a high quality concrete is produced by lowering the water- concrete’s plastic stage. When mixed properly, the presence of these
cement ratio without sacrificing the workability of the concrete. Typically, voids will increase the durability when exposed to moisture during the
using less water produces a higher quality concrete but only if it is cycles of freezing and thawing and improve the resistance to surface
properly placed, consolidated and cured. scalling caused by chemical deicers.
HYDRATION Variations in the air content is often a disadvantage when using this
The setting and hardening of the concrete mixture begins with the agent and several of the common causes to be aware of are the quality
introduction of water to the Portland cement. This process, known as and proportions of the materials; method and duration of the mixing;
hydration, is the chemical reaction that begins when a node forms on and the placing and finishing methods used.
the surface of each cement particle. As the nodes expand and adhere to
the adjacent aggregate, the process of progressive stiffening, hardening
and strength development creates a workable mixture that will become
a water-insoluble concrete.
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5. Flooring systems The Effects of Composition and Application
CONCRETE BEHAVIOR Shrinkage and cracking
While the ingredients of the mixture can be adjusted, chemical agents
can be introduced and finish protectants can be applied, the natural Concrete slab
behavior of concrete will maintain its vulnerability to improper curing
and unstable settings.
SHRINKAGE Subgrade
Shrinkage occurs as concrete dries during the hydration process. The
drying and shrinkage of concrete occurs over long periods of time with Slab surface warmer and wetter than subgrade
thick slabs shrinking slower than thin slabs. The top of a concrete slab
generally shrinks more than the bottom causing the corner edges at
Shrinkage and cracking
joints or cracks to curl upward. This creates a visible rise in the concrete
surface often seen at joint intersections.
CRACKING Concrete slab
The effect of shrinkage and curling creates a tensile stress within the
concrete. As the concrete rises, the tensile stress (the force required to
pull something apart until the moment it breaks) exceeds the strength
within concrete, creating a separation or crack. (Figure 2) Subgrade
Slab surface cooler and drier than subgrade
Plastic Settlement Cracks
These are cracks that occur during the plastic stage of concrete setting. Figure 2: Concrete slab cracking
During this stage, the solids within the mix settle while the water rises
(bleed water) and if there is a restraint within the slab (reinforcing bars,
etc.) the mixture above the restraint will not settle as far and create
mirror like cracks along the restraints. (Figure 3)
Settlement cracks
CONCRETE DEFECTS DURING INSTALLATION
FREEZE/THAW EFFECT
Concrete has strong compression strength but its tensile strength
is weak. As water is absorbed into the porous surface, the internal
moisture can freeze and cause spalling and cracking. In order to avoid Large aggregate particles
these effects, the use of an air-entrained agent will provide micro-scopic Reinforcing bars
voids that allow the moisture to expand without damaging the concrete
Section A-A
slab.
CHEMICAL ATTACK
Because cement is alkaline and chemically reactive, it can be damaged Settlement cracks
by acids, alkalis, salt solutions and organics such as fermenting liquids,
sugars, animal oils and sea water. The use of Portland cement types II
and V will prohibit most chemical reactions.
CRAZING
Small cracks that weaken the surface are caused by water containing
solid particles of sedimentation that have migrated to the surface of the
concrete during hydration (bleed water). A small amount of this water is A A
expected, but if spread throughout the slab with a trowel, the sediments
will absorb back into the concrete, thus changing the water to cement
ratio.
SCALLING
Improper curing, forms of nitrates, and agents that contain calcium
or sodium chloride (typically working together) cause flaking of the
concrete surface that then breaks loose, causing the surface to peel.
These flakes typically increase over time in high traffic areas. Figure 3: Plastic settlement cracking
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6. Flooring systems The Effects of Composition and Application
SPALLING Because the surface of this system is not monolithic, the use of cement
This defect is similar to scalling except the surface breaks are larger grouts located between the tile and brick are susceptible to absorption.
than flakes, indicating severe problems within the concrete slab, Even if sealed with a high level of epoxy sealer on a regular basis, the
typically caused by freeze/thaw conditions. mortar will easily stain and become inundated with debris. The severity
of these constraints when using the CRBT system is reflected by the use
BLISTERS of the monolithic system more frequently and, because of this tendency,
As water and air work their way up during the curing process, it causes the following investigation will focus on the monolithic resins only.
a rise in the concrete forming blisters. These blisters, ranging from 1/4"
to 4" in diameter, are not easily seen but can become chipped by direct Monolithic System
traffic. A monolithic system is an aggregate-filled, resin based, coating system
that provides a seamless surface able to withstand chemical exposure,
DUSTING abrasion, impact and thermal shock. Epoxy, Acrylic, Polyurethane,
A loose powder layer, similar to chalk in appearance, is produced by Polyester and Vinyl esters are the primary forms of resin.
a weak concrete surface. An unvented heat source, improper small
aggregate (sand) to cement ratio or the use of bleed water are possible Each resin is unique in its ability to protect the floor from the typical
causes of this deterioration. abuse found within a food processing facility. The following investigation
reviews the characteristics of each resin along with several methods of
FOREIGN OBJECTS application.
Debris from the surrounding job site can often work its way into the
concrete while the concrete is being set and might not be noticed until Epoxy Resin
the forms are removed. If fully embedded, the object will not have an Epoxy is the combination of two chemicals, referred to as (A) the resin
effect on the coating process. However, if a foreign object such as or compound and (B) the hardener or activator. Part (A) usually consists
plastic stripping or rope is exposed, it must be removed, typically by of Bisphenol A or Bisphenol F. Bisphenol A is a general purpose,
chipping; then the concrete must be restored. cost-effective resin that has an excellent alkali resistance, good acid
resistance and fair-to-good solvent resistance. Bisphenol F is a low
EFFLORESCENCE viscosity material that provides excellent alkali resistance, and a better
As water migrates from a drying concrete, water-soluble salts within the acid and solvent resistance than Bisphenol A.
concrete work their way out to the surface in the form of white chalk.
Part (B), the hardener, is an industrial epoxy coating catalyst that falls
into one of five standard categories: Aliphatic and cycloaliphatic amines
SPECIAL FLOOR SYSTEMS and polyamines; amides and polyamides; cycloaliphatic; amine adduct;
and novolac. The chemical makeup of each of these categories, play a
When investigating the flooring system best suited for a food processing
major role in the properties of the final cured epoxy.
facility, the driving factors that need to be addressed are the chemical
exposure, abrasion, impact and thermal shock. While each facility will
face similar challenges when looking at resistance to moisture vapor,
• Aliphatic and Cycloaliphatic Amines and Polyamines
This chemical solution is ammonia with one or more hydrogen atoms
surface gloss, slip resistance, odor, repair-ability, project schedule, etc.,
replaced by organic groups. The amine-based curing agents are
there will not be one ‘perfect’ system to be used in all facilities.
considered more durable and chemically resistant, but most likely to
produce a waxy surface layer on actively curing epoxy known as blush.
High Performance Floor Surfacing Systems (HPFSS) are used to protect
concrete substrates from chemical, mechanical and thermal aggression.
The two systems most often used are the Chemical Resistant Brick and • Amides and Polyamides
Tile (CRBT) system, composed of grout, setting bed, ceramic tile, paver This chemical solution is ammonia with a hydrogen atom replaced by
tile and/or dairy brick and the monolithic system, formed by resin and/ a carbon/oxygen and organic group. Unlike the amines, the amide is
or aggregate types. more tolerant to surface contact and less troubled by water.
Chemical Resistant Brick and Tile Systems • Cycloaliphatic
In the past, bulky, conventional, thick bed methods were employed This agent provides better water/moisture resistance, better
for the installation of industrial ceramic tile, paver tile and dairy brick weatherability, low blush and water spotting, and better chemical
applications. With the improvement in adhesive technology, a more resistance. The composition of this agent provides more of a “structural
efficient and environmentally sensitive use of materials has been stretch” and, in return, provides a better impact resistance.
introduced, resulting in a reduced weight, lower cost of material and a
more efficient use of natural resources. However, the use of the CRBT Most top grade, high performance epoxies incorporate a blend of the
in industrial installations places a large stress on the tile and paver cycloaliphatics into the ‘part B’ curing agent and is often used to judge
application and, in turn, an environment that is challenging not only for the quality and performance of the final epoxy.
the finish tile or paver but also for the installation system materials.
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7. Flooring systems The Effects of Composition and Application
• Amine Adducts • Cementitious
Amine Adduct epoxies are two-part epoxies but the curing agent This form of urethane is thermal shock resistant, has good stain
actually contains a small amount of epoxy resin. Because of this unique resistance, has excellent organic acid resistance and demonstrates
combination, the mixture starts to cure even before type (A) and (B) are good moisture tolerance during the curing process.
mixed. This mixture performs much like the other agents but with higher
overall properties, such as a better color stability, curing at a cooler • Aliphatic
temperature and curing faster than the standard epoxy. This coating provides a high level of chemical resistance, good
weathering properties and excellent UV protection while providing a
• Novolac Epoxy durable adhesive quality.
A fifth and more specialized epoxy is the Novolac Epoxy. This epoxy has
excellent heavy duty chemical resistance, low odor and low shrinkage. • Aromatic
However, it is not thermal shock resistant, will not have full chemical Aromatic coatings are useful where UV radiation is not an issue.
resistance for up to 7 days and has a tendency to chalk and discolor Polyurethane coatings made from aromatic polyisocyanates are very
when exposed to UV light. sensitive to oxidation and, as a result, prone to degradation in direct
exposure to sunlight.
ACRYLICS • Aspartic
This coating is a two-component, low VOC, urethane resin designed for
Also referred to as Methyl Methacrylate (MMA) this water-based floor high performance protection with outstanding exterior gloss and color
system will cure much faster than other applied coating systems. The retention. This resin has a high resistance to corrosion, weathering, and
coating can be applied in very cold temperatures (-20° F), resist a chemicals; offers color and gloss retention; and is suitable for use in
wide range of acids and alkalis, and provide high impact and abrasion USDA-inspected facilities
resistance. Minimum surface preparation is required and fresh
applications melt and bond, creating a monolithic system that won’t
peel. Reseal costs and down time are much shorter than other coatings. POLYESTERS/VINYL ESTERS
This system provides a much more durable finish.
Polyester prepolymers are produced by a condensation reaction of
The negatives are the need for adequate ventilation during application organic acids and polyols. The choice of reactants will establish the
due to strong odors, low adhesive strength, and extreme susceptibility resulting polymer mechanical properties, thermal stability and chemical
to poor adhesion in substrates that contain some level of humidity. resistance. This resin has a high solvent and chemical resistance, and
the ability to withstand highly corrosive exposures. It provides a good
adhesive quality, and flake fillers can be added to increase resistance
POLYURETHANES to permeation by water vapor.
The polyurethane floor coating is a solvent based, two-component The negative of this resin is the creation of a trapped tensile strain (pre-
system. This coating is abrasion resistant, antibacterial, UV resistant, stress) by the heat and shrinkage produced during its drying process.
antifungal, and easily cleaned. In addition, this coating provides a This strain can lead to cracking or disbondment, especially in very low
tough and flexible surface that has excellent adhesion to concrete, tiles, operating temperatures, and can become brittle if not reinforced.
metals and packing unit floors.
See (Table 1) for a synopsis of the characteristics of each resin.
Cure Bond Strength Properties Resistance Safety
Epoxies - Temperature sensitive - Excellent - High strength - Good wear - Allergy
- Mix ratios important - High-low uniformity - Moderate chemical - Odor
Epoxy Novolacs - Cold, wet cure - Excellent - High strength - Heat resistant - Allergy
- High uniformity - Chemical resistant
Polyesters/Vinyl - Moisture sensitive - Will not bond to damp - High strength - Heat resistant - Flammable
Esters - Catalyzed cure surfaces - High (low) uniformity - Chemical resistant - Odor
- Shrinkage
Urethanes - Humidity sensitive - Intercoat adhesion - Gloss retention - Excellent wear - Allergy
difficult - Elastomeric - Stain resistant - Free isocyanate
- Weather resistant - VOC
Methyl-Methacrylate - Cures quickly - Moisture sensitive - Clear - Abrasion resistant - Flammable
(MMA) - Cold cure - Easy handling - Odor
- Shrinkage - High strength
Table 1: Characteristics of polymer products
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8. Flooring systems The Effects of Composition and Application
SPECIAL FLOOR SYSTEM APPLICATION Topcoat at 6-20 mils
Optional intermediate
COATING coat at 8-16 mils
The positive qualities of the coating system are that it is the most Primer at 6-8 mils
economical at 40 mils or less, and provides moderate chemical
resistance, easy cleanability, simple repair and maintenance, and UV
protection. It also seals concrete from absorption of microorganism or
contaminants, and protects concrete from sterilants.
The negatives are that it can easily scratch and develop traffic patterns,
is subject to damage from impact and thermal shock, and does not
mask surface imperfections. In addition, this application cannot be used
to modify the slope of a substrate and will need to follow the existing Concrete substrate
contour of the substrate. (Figure 4)
SELF LEVELING SYSTEMS
• Slurry Figure 4: Coatings
Slurry is a thin mixture of a liquid (typically water) and a cement, plaster
of Paris or clay particles. A primer is placed directly on the substrate
(typically 60 mils) and is then covered with a thin topcoat.
Topcoat at 8-10 mils
As an intermediate priced system, the positive qualities of the slurry Slurry at 60 mils
system are the improvement of substrate properties for thermal shock
and impact, and the masking of minor imperfections. The system also Primer at 6-8 mils
requires less skill to install, thereby increasing the installed square
footage per day.
The negatives are that it is not suitable for sloped surfaces,
requires more skill to install than coatings alone, and is less
resistant to thermal shock and impact than mortars. (Figure 5)
• Broadcast systems
Forming a seamless, monolithic floor, the broadcast system is composed Concrete substrate
of low viscosity, 100 percent solid epoxy resin and aggregate filler in the
form of finely graded silica within the slurry mix. The combination of
slurry and broadcast aggregate will range from 60 mil to 1/4" depending
Figure 5: Slurry-Smooth
on the amount of mechanical abuse, impact and abrasion.
The broadcast system provides a good slip and chemical resistance,
Topcoat at 10-20 mils
and is most suitable for areas of light to moderate chemical, impact
and traffic exposure. Similar to the slurry system, the addition of the Broadcast and grout coat
broadcast system is not suitable for sloped surfaces and is less resistant Slurry at 60 mils
to thermal shock and impact than mortars. (Figure 6) Primer at 6-8 mils
• Thick-Mil Troweled
This system is a 3/16 - 3/8" thick mortar material with aggregate fillers
in a resin matrix placed on a primer covering and substrate surface. The
troweled flooring system provides the highest physical properties and
is resistant to impact, thermal shock and abrasion. This application is
suitable for sloped surfaces, masks surface imperfections and is able to
provide pitch toward the drain while having the lowest life cycle costs.
Concrete substrate
Figure 6: Slurry-broadcast slip resistant
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9. Flooring systems The Effects of Composition and Application
The negatives of this system are that the thickness of the application
might affect equipment and door clearances; it requires the highest Topcoat at 10-20 mils
level of skill and additional time for installation; and it has the highest Grout coat
initial cost. (Figure 7) Trowelled base
Primer at 6-8 mils
SAFE QUALITY FOOD (SQF) CODE
After reviewing the special floor systems and applications, the
development of a sanitation and health program for all facility
flooring systems must be addressed. The SQF is one of several food
management programs that is recognized worldwide and benchmarked
by the Global Food Safety Initiative (GFSI). This program develops
specific management training to develop, document and record safety
procedures while working directly with HACCP plans. This program has a
three level certification that can be obtained through the implementation Concrete substrate
of the safety process and procedures.
Figure 7: Thick-mil trowelled
While this safety code is composed of 16 modules that include a
checklist for all sections of the food industry, the checklist for a food
processing facility is located in module 11. Below is a clip from the SQF SELECTING A FLOOR SYSTEM
Code, 7th Edition, July 2012.
Chemical exposure, abrasion, impact and thermal shock are the four
SQF-CODE-ED-7-MODUAL – COVERS ALL FOOD macro-categories of adversities that every food processing flooring
system will encounter. Is there a perfect floor coating and application that
PROCESSING TYPES
will protect a food processing facility? Yes, however the final decision
must be based on the challenges that are present in that specific facility.
11: FOOD SAFETY FUNDAMENTALS – GOOD What are the environmental conditions for this project? When must
MANUFACTURING PRACTICES FOR PROCESSING OF this facility be up and running? Is cost a factor? What form of cleaning,
FOOD PRODUCTS (GFSI, EI, EII, EIII, EIV AND L) pressure and/or chemical mixtures will be required? Is there high traffic
or low? The needs will be specific to each facility as will the solutions.
11.2 Construction and Control of Product
Handling and Storage Areas CONCLUSION
11.2.1 Materials and Surfaces The mixture of water, large aggregate, small aggregate and Portland
• 11.2.1.1 Product contact surfaces and those surfaces not in direct cement; the manipulation of strength, speed and workability; and the
contact with food in food handling areas, raw material storage, resistance to chemical contact, abrasions, high impact and thermal
packaging material storage, and cold storage areas shall be shock are the components, that when designed for a specific facility,
constructed of materials that will not contribute a food safety risk. provide the perfect flooring system.
11.2.2 Floors, Drains and Waste Traps Looking for the best flooring system for your facility will bring forth many
• 11.2.2.1 Floors shall be constructed of smooth, dense impact solutions and each will address the challenges at hand. However, with
resistant material that can be effectively graded, drained, an understanding of the systems’ composition and how it might react to
impervious to liquid and easily cleaned. your specific conditions will increase the value of the investigation and
• 11.2.2.2 Floors shall be sloped to floor drains at gradients suitable in turn clarify your solution.
to allow the effective removal of all overflow or waste water under
normal working conditions.
• 11.2.2.3 Drains shall be constructed and located so they can be Kevin Franz, AIA, LEED AP BD+C
easily cleaned and not present a hazard. Project Architect
• 11.2.2.4 Waste trap system shall be located away from any food A M King Construction, LLC
handling area or entrance to the premises.
(SQF Code, 7th Edition, July 2012)
References:
SQF Code A HACCP-Based Supplier Assurance, Code for the Food Industry,
7th Edition, 2012 - Module 11: Food Safety Fundamentals – good manufacturing
practices for processing of food products (GFSI, EI, EII, EIII, EIV and L)
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