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Mass concreting refers to the process of placing large volumes of concrete, such as in gravity dams. The heat generated during the cement hydration process and differential cooling rates within the concrete mass can lead to a temperature gradient, which can result in thermal cracks in the concrete mass.
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Portland blast-furnace cement is made by blending Portland cement clinker with granulated blast-furnace slag, which accounts for 25 to 65 percent of the cement's weight. Despite its similarities to ordinary Portland (Type I) cement in terms of fineness and setting times, its early strength is lower, though it achieves comparable strength later on. It's particularly suited for mass concrete structures and marine environments due to its lower heat of hydration and superior sulfate...
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The process of manufacturing concrete masonry units begins by mixing stiff concrete composed of Portland cement, aggregates, and water. This mixture is then poured into metal molds. To ensure the concrete settles uniformly and to avoid separation of its components, the mixture in the molds is subjected to vibration. Shortly after, the still-wet blocks are removed from the molds and placed on racks.
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Concrete is a vital construction material extensively used worldwide, primarily valued for its strength, durability, and versatility, which it provides for various structural designs. Concrete generally comprises ingredients like Portland cement, coarse gravel, fine sand, and water. Concrete can be mixed by simple hand methods or industrially at computer-controlled plants. The mixture consists of aggregates and a paste made from water and Portland cement. This paste coats the aggregates and,...
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Accelerating concrete curing is achieved by applying heat and additional moisture. This process accelerates the hydration of the cement, resulting in an earlier strength gain in the concrete. Steam curing is a method wherein the concrete products are either transported through a chamber on a conveyor belt or encased in plastic, allowing steam at atmospheric pressure to circulate freely around them. This process begins with a phase of moist curing that typically lasts between 3 to 5 hours, after...
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Bleeding in Fresh Concrete01:22

Bleeding in Fresh Concrete

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Bleeding in fresh concrete occurs when water from the mix rises to the surface. This happens because the mix's solid components fail to retain all the water as they settle, leading to separation where water collects at the top. The severity of bleeding can be measured by assessing the total settlement or by noting the decrease in height per unit height of concrete.
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Lightweight Concrete Produced Using a Two-Stage Casting Process.

Jin Young Yoon1, Jae Hong Kim2, Yoon Yi Hwang3

  • 1School of Urban and Environmental Engineering, Ulsan National Institute of Science and Technology, 50 UNIST-gil, Ulju-gun, Ulsan 689-798, Korea. dc4408@naver.com.

Materials (Basel, Switzerland)
|August 10, 2017
PubMed
Summary

A novel two-stage casting process produces ultra-lightweight concrete by segregating aggregates and grout. This method achieves minimal density, suitable for non-structural applications with strengths up to 20 MPa.

Keywords:
aggregategroutlightweight concretetwo-stage concretevolume fraction

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Area of Science:

  • Materials Science
  • Civil Engineering
  • Concrete Technology

Background:

  • Lightweight concrete density is determined by aggregate type and volume fraction.
  • High aggregate volume fractions, needed for low density, can cause segregation in conventional mixing.
  • Existing methods struggle to achieve very low densities without compromising structural integrity.

Purpose of the Study:

  • To introduce a two-stage casting process for producing ultra-lightweight concrete.
  • To investigate the effect of this process on concrete density and compressive strength.
  • To determine the suitability of the resulting concrete for specific applications.

Main Methods:

  • A two-stage casting process was developed, involving separate placement of lightweight aggregates and cementitious grout.
  • Lightweight aggregates were placed in a frame first, followed by filling interstitial voids with grout.
  • Compressive strength was evaluated, considering the influence of aggregate shape (irregular vs. round).

Main Results:

  • The proposed casting process successfully produced lightweight concrete with the lowest achievable density.
  • The process mitigates aggregate segregation issues common in conventional mixing.
  • Concrete strength was limited to 20 MPa, with irregular aggregates compensating for weakness.

Conclusions:

  • The two-stage casting process is effective for manufacturing very low-density lightweight concrete.
  • This concrete is suitable for non-structural elements and structural composites.
  • The material achieves a balance between very low density and a maximum compressive strength of 20 MPa.