Treatment of imperfections in precast structural elements

The present work evaluates imperfections of precast concrete elements that do not meet the quality intended in design, gives rules and possible evaluation systems and offers recomendations for prevention, the effect the imperfections can have and actions for rectification. At last, the document should be read in conjunction with relevant codes and standards.

Diseño, fabricación, caracterización y aplicaciones constructivas de hormigones de consistencia seca con adiciones de materiales de procedencia orgánica e inorgánica de neumáticos fuera de uso (NFUs)

La siguiente investigación está centrada en establecer las diferencias en la reutilización, en los hormigones de consistencia seca, de dos tipos de caucho obtenidos en el proceso del reciclado del neumático, caucho reciclado del neumático (CRN): los tamaños del granulado (4-8 mm) de caucho reciclado de alta calidad (CR: Caucho Limpio) y el desecho del proceso del reciclado: fibra textil y de acero con trazas de caucho (desecho del caucho reciclado, IR: Caucho de impurezas). Ambos tipos fueron clasificados y añadidos como árido en sustitución del árido grueso (grava) desde el 20 al 100% del volumen. El comportamiento físico y mecánico del IR en los hormigones fue comparado con el hormigón de referencia y las series con el CR para el futuro uso en piezas de hormigón prefabricado. En ambos casos se aprecia una reducción de las resistencias mecánicas en proporción con las cantidades de caucho de sustitución, pero menos en series con IR con una combinación satisfactoria de fibra textil y metálica. El IR muestra mayores pérdidas en propiedades tales como trabajabilidad y densidad, pero también con un incremento de la porosidad. Estos hechos facilitan nuevas opciones para los desechos procedentes del CRN en los hormigones y por lo tanto menores gastos de energía, logrando una tasa de éxito en el proceso de reciclado cercano al 100%. The following research is focused on establishing the differences in the re-use as aggregate in dry consistency concretes of two types of rubber obtained in the process of tyre recycling, recycled rubber from tyres (RRT): granulated sizes (4–8 mm) of high quality recycled rubber (CR: Clean Rubber) and the waste of the recycling process: steel and textile fibers with rubber tracks (waste from recycled rubber, WRR). Both types were classified and added as aggregate in substitution of coarse aggregates from 20 to 100 % by volume. The physical and mechanical behavior of IR in concretes was compared with reference concrete and series with CR for a future use in precast concrete pieces. In both samples a reduction of mechanical resistance occurs in proportion with the amounts of rubber of substitution, but less in serials with IR with a successful combination of steel and textile fiber. IR shows furthermore a reduction in properties such as workability and density, but also an increment in porosity. These facts facilitate new options for waste from CRN in concretes and therefore lower energy costs, achieving a success rate in the recycling process close to 100 %.

Caracterización no destructiva del proceso de curado en materiales cementicios

La calidad del hormigón prefabricado se determina mediante ensayos de rotura a compresión en probetas transcurridos los 28 días de curado, según establece la EHE-08. Sin embargo, en la plantas de prefabricados es necesario además saber cuándo el hormigón está listo para ser procesado (destensado, cortado, trasladado), por lo que es necesario hacer ensayos de resistencia a la compresión entre las 48 y 72 horas, este tiempo se determina a partir de la experiencia previa adquirida y depende de las condiciones de cada planta. Si las probetas no han alcanzado el valor establecido, normalmente debido a un cambio en las condiciones climatológicas o en los materiales utilizados como el tipo de cemento o agregados, la solución adoptada suele ser dejar curar el material más horas en la pista para que alcance la resistencia necesaria para ser procesado. Si sigue sin alcanzarla, lo cual sucede muy ocasionalmente, se intenta analizar cuál ha sido el motivo, pudiéndose tirar toda la producción de ese día si se comprueba que ha sido un fallo en la fabricación de la línea, y no un fallo de la probeta. Por tanto, esta metodología de control de calidad, basada en técnicas destructivas, supone dos tipos de problemas, costes y representatividad. Los métodos no destructivos que más se han aplicado para caracterizar el proceso de curado del hormigón son los ultrasónicos y la medida de la temperatura como se recoge en la bibliografía consultada. Hay diferentes modelos que permiten establecer una relación entre la temperatura y el tiempo de curado para estimar la resistencia a compresión del material, y entre la velocidad de propagación ultrasónica y la resistencia. Aunque estas relaciones no son generales, se han obtenido muy buenos resultados, ejemplo de ello es el modelo basado en la temperatura, Maturity Method, que forma parte de la norma de la ASTM C 1074 y en el mercado hay disponibles equipos comerciales (maturity meters) para medir el curado del hormigón. Además, es posible diseñar sistemas de medida de estos dos parámetros económicos y robustos; por lo cual es viable la realización de una metodología para el control de calidad del curado que pueda ser implantado en las plantas de producción de prefabricado. En este trabajo se ha desarrollado una metodología que permite estimar la resistencia a la compresión del hormigón durante el curado, la cual consta de un procedimiento para el control de calidad del prefabricado y un sistema inalámbrico de sensores para la medida de la temperatura y la velocidad ultrasónica. El procedimiento para el control de calidad permite realizar una predicción de la resistencia a compresión a partir de un modelo basado en la temperatura de curado y otros dos basados en la velocidad, método de tiempo equivalente y método lineal. El sistema inalámbrico de sensores desarrollado, WilTempUS, integra en el mismo dispositivo sensores de temperatura, humedad relativa y ultrasonidos. La validación experimental se ha realizado mediante monitorizaciones en probetas y en las líneas de prefabricados. Los resultados obtenidos con los modelos de estimación y el sistema de medida desarrollado muestran que es posible predecir la resistencia en prefabricados de hormigón en planta con errores comparables a los aceptables por norma en los ensayos de resistencia a compresión en probetas. ABSTRACT Precast concrete quality is determined by compression tests breakage on specimens after 28 days of curing, as established EHE-08. However, in the precast plants is also necessary to know when the concrete is ready to be processed (slack, cut, moved), so it is necessary to test the compressive strength between 48 and 72 hours. This time is determined from prior experience and depends on the conditions of each plant. If the samples have not reached the set value, usually due to changes in the weather conditions or in the materials used as for example the type of cement or aggregates, the solution usually adopted is to cure the material on track during more time to reach the required strength for processing. If the material still does not reach this strength, which happens very occasionally, the reason of this behavior is analyzed , being able to throw the entire production of that day if there was a failure in the manufacturing line, not a failure of the specimen. Therefore, this method of quality control, using destructive techniques, involves two kinds of problems, costs and representativeness. The most used non-destructive methods to characterize the curing process of concrete are those based on ultrasonic and temperature measurement as stated in the literature. There are different models to establish a relationship between temperature and the curing time to estimate the compressive strength of the material, and between the ultrasonic propagation velocity and the compressive strength. Although these relationships are not general, they have been very successful, for example the Maturity Method is based on the temperature measurements. This method is part of the standards established in ASTM C 1074 and there are commercial equipments available (maturity meters) in the market to measure the concrete curing. Furthermore, it is possible to design inexpensive and robust systems to measure ultrasounds and temperature. Therefore is feasible to determine a method for quality control of curing to be implanted in the precast production plants. In this work, it has been developed a methodology which allows to estimate the compressive strength of concrete during its curing process. This methodology consists of a procedure for quality control of the precast concrete and a wireless sensor network to measure the temperature and ultrasonic velocity. The procedure for quality control allows to predict the compressive strength using a model based on the curing temperature and two other models based on ultrasonic velocity, the equivalent time method and the lineal one. The wireless sensor network, WilTempUS, integrates is the same device temperature, relative humidity and ultrasonic sensors. The experimental validation has been carried out in cubic specimens and in the production plants. The results obtained with the estimation models and the measurement system developed in this thesis show that it is possible to predict the strength in precast concrete plants with errors within the limits of the standards for testing compressive strength specimens.

New Courthouse at El Ejido

The courthouse at El Ejido has a trapezoid floor plan (47 m × 55/26 m) and comprises two distinct volumes that are structurally connected at the basement level and by the footbridges on the upper storeys. A third trapezoid unit featuring a glazed curtain wall facade cantilevers 8 m off the main facade of the front volume. This facade is a structural diaphragm wall, constituted by nine rows of vertical precast concrete members separated by horizontal cast-in-place, self-compacting concrete chords. The location of the courthouse in a seismic area and the small number of horizontal supports for the facade make this wall potentially vulnerable. The high risk, in particular, during construction required careful planning based on a detailed analysis of the interaction between the structure and the ancillary resources used to build it

Influencia de la configuración geométrica de placas prefabricadas para forjados en las tensiones originadas por la transferencia del pretensado en elementos realizados con armaduras pretesas ancladas por adherencia

Las piezas pretensadas de hormigón presentan zonas muy solicitadas correspondientes a la zona de transferencia. En muchos casos se ha detectado figuración en tales zonas cuyo origen está ligado a la transferencia de la fuerza de pretensado, pudiendo llegar a causar el rechazo de la pieza. En el caso de las piezas prefabricadas con armaduras pretesas adherentes, no siempre es posible disponer armado transversal para controlar esta fisuración, ya sea por el proceso constructivo, ya sea por disponer en general de secciones transversales muy optimizadas. Recientemente se desarrolló una nueva tipología de piezas de hormigón prefabricado para forjados unidireccionales pretensadas con armadura activa pretesa y sin armadura transversal. La tipología se asimila a una sección en PI invertida, con alas de gran envergadura en comparación con el ancho de nervio, y armadura activa distribuida en las alas. Este diseño parece propenso a la aparición de fisuración en el momento de la transferencia del pretensado. Así, se han producido fallos de carácter frágil: colapso de piezas ya colocadas en obra, separándose la losa inferior de los nervios y cayendo sobre el piso. Las herramientas de análisis usuales han resultado inútiles al aplicarse a la investigación de esta patología. Para afrontar el estudio de los problemas detectados en la tipología, se ha analizado el fenómeno de las tensiones de tracción en la zona de transferencia, usualmente denominadas exfoliación y estallido, así como los métodos de análisis aplicables a elementos pretesos sin armadura transversal. En algunas ocasiones se trata del resultado de trabajos desarrollados para piezas postesadas, o para calcular cuantías de armadura transversal, adaptados a posteriori. También existen métodos desarrollados específicamente para piezas pretesas sin armadura transversal. Junto a los factores considerados en los métodos existentes se han localizado otros, no tenidos en cuenta habitualmente, pero que pueden ser determinantes en piezas no convencionales, como son: la existencia de pretensado superior e inferior, la falta de simetría de la sección transversal, el ancho variable de las piezas, una relación entre el ancho del ala y el espesor de los nervios elevada, la distribución transversal del pretensado en relación al ancho variable. Además, la mayoría de los métodos se han basado en simplificaciones bidimensionales. Para tener en cuenta la influencia de estos factores, se han modelizado piezas en las que varían tanto la geometría de la sección transversal y la cuantía de pretensado, como la ley de adherencia o la distribución de armadura activa en la sección. Estos modelos se han analizado mediante el método de elementos finitos, efectuándose u análisis elástico lineal tridimensional. En general, los métodos existentes no han predicho adecuadamente las tensiones obtenidas mediante elementos finitos. Sobre los resultados obtenidos por elementos finitos se ha desarrollado un ajuste experimental, que presentan un alto grado de correlación y de significación, así como una reducida dispersión y error relativo. En consecuencia, se propone un método de obtención de la tensión máxima de exfoliación, consistente en varias ecuaciones, que tienen en cuenta las peculiaridades de la configuración de las piezas citadas y permiten considerar cualquier ley de adherencia, manteniendo la coherencia con la longitud de transmisión. Las ecuaciones se emplean para la obtención de la tensión máxima de exfoliación en piezas de la tipología estudiada cuya armadura activa se sitúe fuera del núcleo central de la sección transversal. Respecto al estallido, se propone una modificación de los métodos existentes que, comparado con los resultados del análisis por elementos finitos, mejora el valor medio y la dispersión a valores admisibles y del lado de la seguridad. El método considera la geometría de la sección y la distribución del pretensado en la losa inferior. Finalmente, se ofrecen estrategias de diseño para piezas de la tipología o semejantes. End zones of prestressed concrete members are highly stressed. Cracking have often appeared at end zone, and its beginning is related to prestress release. Some members become rejected because of these cracks. Sometimes it is not possible having transverse reinforcement in order to control cracking, when referring to pretensioned precast members. The reason may be the construction process or highly optimized crosssections. A new typology of precast concrete members designed for one-way composite floors was recently developed. The members, without transverse reinforcement, are prestressed with pretensioned wires or strands. This typology is similar to an inverted TT slab, with a large flange related to the web thickness and prestressing reinforcement spread across the flange. This design is highly susceptible to appear cracking at prestress release. Therefore, brittle failures have been reported: fail of slabs laid in place on a construction site, resulting in the separation of the flange from the webs,, and the subsequent fall on the lower floor. Usual analytical methods have been useless to study the failure. End zone tensile stresses have been analysed to study the detected typology problems. These tensile stresses are usually called spalling and bursting (also called splitting in the U.S.). Analysis methods applicable to pretensioned members without transverse reinforcement have been analysed too. Some methods were originally developed for postensioned concrete or for obtaining the amount of transverse reinforcement. In addition, there are methods developed specifically for pretensioned members without transverse reinforcement. Some factors, frequently ignored, have been found, such as lower and upper prestress, lack of symmetry in the cross section, variable width, a high ratio between flange width and web thickness or prestressing reinforcement location related to variable width. They can play a decisive role in non-conventional members. In addition, most methods are based on 2D simplifications. Finite Element modelling has been conducted in order to consider the influence of these factors. A linear 3D approach has been used. The modelled members vary according to cross section geometry, bond behaviour, or prestressing reinforcement location. In general, the obtained tensile stresses don’t agree with existing methods. An experimental adjustment has been conducted on the obtained results, with a high correlation ratio and significance level as well as a low dispersion and relative error. Therefore, a method to obtain the maximum spalling stress is proposed. The proposal consists on some equations that consider the special features of the typology and bond behaviour. Consistency between transmission length and bond behaviour is considered too. The equations are used to calculate maximum spalling stress for the studied typology members whose prestressing reinforcement is located out of the core of the cross section. In relation to bursting, a modification of existing methods is proposed. Compared to finite element results, the proposal improves mean value and dispersion, whose ranges are considered acceptable and secure. The method takes into account cross section geometry and location of prestressing reinforcement across the lower flange. Finally, strategies to design members of this typology or similar are proposed.

New courthouse at El Ejido

The courthouse at El Ejido has a trapezoid floor plan (47 m. x 55 / 26 m.) and comprises two distinct volumes that are structurally connected at basement level and by footbridges on the upper storeys. A third trapezoid unit featuring a glazed curtain wall façade cantilevers 8 m. off the main façade of the front volume. This façade is a structural diaphragm wall, constituted by nine rows of vertical precast concrete members separated by horizontal cast-in-place, self-compacting concrete chords. The location of the courthouse in a seismic area and the short number of horizontal supports for the façade make this wall potentially vulnerable. The particularly high risk during construction called for careful planning based on a detailed analysis of the interaction between the structure and the ancillary resources used to build it

Concrete Meccanos: Precast Constructions after the Second World War in the Netherlands

Estudio de soluciones prefabricadas de hormigón no estandarizadas en los Países Bajos tras la Segunda Guerra Mundial.

Bond Modelling of prestressed concrete during the prestressing force release

This paper presents an analytical model for simulating the bond between steel and concrete, in precast prestressed concrete elements, during the prestressing force release. The model establishes a relationship between bond stress, steel and concrete stress and slip in such concrete structures. This relationship allows us to evaluate the bond stress in the transmission zone, where bond stress is not constant, along the whole prestressing force release process. The model is validated with the results of a series of tests and is extended to evaluate the transmission length. This capability has been checked by comparing the transmission length predicted by the model and one measured experimentally in a series of tests.

Bond modelling of prestressed concrete during the prestressing force release

This paper presents an analytical model for simulating the bond between steel and concrete, in precast prestressed concrete elements, during the prestressing force release. The model establishes a relationship between bond stress, steel and concrete stress and slip in such concrete structures. This relationship allows us to evaluate the bond stress in the transmission zone, where bond stress is not constant, along the whole prestressing force release process. The model is validated with the results of a series of tests, considering different steel indentation depths and concrete covers and is extended to evaluate the transmission length. This capability has been checked by comparing the transmission length predicted by the model and one measured experimentally in two series of tests.

Study of bond stress-slip relationship and radial dilation in prestressed concrete

This paper presents two test procedures for evaluating the bond stress–slip and the slip–radial dilation relationships when the prestressing force is transmitted by releasing the steel (wire or strand) in precast prestressed elements. The bond stress–slip relationship is obtained with short length specimens, to guarantee uniform bond stress, for three depths of the wire indentation (shallow, medium and deep). An analytical model for bond stress–slip relationship is proposed and compared with the experimental results. The model is also compared with the experimental results of other researchers. Since numerical models for studying bond-splitting problems in prestressed concrete require experimental data about dilatancy angle (radial dilation), a test procedure is proposed to evaluate these parameters. The obtained values of the radial dilation are compared with the prior estimated by numerical modelling and good agreement is reached

Quality assurance for precast plants and treatment of imperfections for architectural facades

Quality is the threshold or minimum level required to satisfy the consumer´s demands. In construction the quality is objective, and established by standards. It is very difficult to establish the costs of “no quality” in construction. Each precast unit shall be traceable to a specific set of quality control records.

An analytical model for simulating the bond of prestressed concrete during the prestressed force release

A bond analytical model is proposed in this paper. The model is capable of reproducing the bond stress developed between the steel and concrete, in precast prestressed elements, during the entire process of prestressing force release. The bond stress developed in the transmission zone, where the bond stress is not constant, is also obtained. The steel and concrete stresses as well as the slip between both materials can be also estimated by means of the relation established in the model between these parameters and the bond stress. The model is validated with the results of a series of tests, considering different steel indentation depths and concrete covers and it is extended to evaluate the transmission length. This has been checked by comparing the transmission length predicted by the model and one measured experimentally in two series of tests.

An analytical model for simulating the bond of prestressed concrete during the prestressed force release

A bond analytical model is proposed in this paper. The model is capable of reproducing the bond stress developed between the steel and concrete, in precast prestressed elements, during the entire process of prestressing force release. The bond stress developed in the transmission zone, where the bond stress is not constant, is also obtained. The steel and concrete stresses as well as the slip between both materials can be also estimated by means of the relation established in the model between these parameters and the bond stress. The model is validated with the results of a series of tests, considering different steel indentation depths and concrete covers and it is extended to evaluate the transmission length. This has been checked by comparing the transmission length predicted by the model and one measured experimentally in two series of tests.