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    1. Concrete Materials:Aggregates:

    Coarse aggregate (gravel) Fine aggregate (sand)

    Portland cement: Type I - General Purpose Type II - Modified Type III - High-Early Type IV - Low Heat of Hydration Type V - Sulfate resistant

    Water- should be potable, with a maximum water-to-cement ratio not

    exceeding 0.45 (lower W/C ratio for stronger concrete)Admixtures:

    Air entrainment - used to prevent freeze/thaw cracking Superplasticers - used to increase workability of fresh concrete Accelerators - used to decrease curing time Retarders - used to increase curing time & prevent false set Fly Ash - used to reduce cement needed in max

    2. Advantages of Poured-in-Place Concrete Framed Construction: Can form ANY shape Readily available, inexpensive materials Relatively fire proof Can form integral floors, walls and all other components of a building

    3. Disadvantages of Poured-in-Place Concrete Framed Construction: Very labor intensive - expensive labor Curing time Quality control

    4. Structural Properties of Concrete:

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    Compressive strength stress = 3000 PSI to >10000 PSI. The mostimportant contribution to determining concretes final 28-daycompressive strength is the W/C ratio.

    Tensile strength < 10% of compressive strength, reinforcing steel isused to carry ALL tension in members (see sketch below).

    5. Reinforcing Steel (Rebar): Conforms to ASTM A615 deformed billet steel having a yield strength of

    60 KSI. The # size refers to the diameter in 1/8ths of an inch. Example - a #5

    bar is 5/8" diameter.

    Epoxy-coated bars are used to help prevent corrosion, and are usedextensively in bridge decks. Laps, splices, bends and hooks per ACI specifications.

    6. Types of Reinforced Concrete Members:a) Beams- usually rectangular in cross-section (see sketch below):

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    b) Slabs: One-way slab - Supported along edges by walls or beams. Main tension

    reinforcing bars span one direction perpendicular to support (see sketchbelow).

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    Two-way slab - Supported by columns. Main tension reinforcing bars

    span BOTH directions. Sometimes called "flat plate". Capitals may beused above the column to reduce the "punching shear" (see sketchbelow).

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    c) Columns- usually square, rectangular or circular in cross-section (seesketch below):

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    Removable Forms (Cast-in-Place)Concrete Home>Building Systems> Removable Forms (Cast-in-Place)

    Cast-in-place (CIP) concrete walls aremade with ready-mix concrete

    placed into removable forms erected on site. Historically, this has beenone of the most common forms of building basement walls. The sametechniques used below grade can be repeated with above-grade walls toform the first floor and upper levels of homes.

    Early forays into this technology were done more than 100 years ago by

    Thomas Edison. He saw the benefit of building homes with concrete wellbefore it was widely understood. As technology developed,

    improvements in forming systems and insulation materials increased theease and appeal of using removable forms for single-familyconstruction. These systems are strong. Their inherent thermal mass,coupled with appropriate insulation, makes them quite energy efficient.Traditional finishes can be applied to interior and exterior faces, so thebuildings look similar to frame construction, although the walls areusually thicker.

    History Advantages Components (Insulation, etc.) Installation, Connections, Finishes Sustainability and Energy Building Codes Comparative Costs Projects

    History

    The technology for casting concrete in removable formsthe beginning of the reinforced concreteconstruction industrydates back at least to the 1850s, not long after portland cement was patented. Thepredominant use of removable forms for single-family homes was for below-grade (basement) walls.Thomas Edison was one of the first to recognize the potential for above-grade applications and do somedemonstration projects, several single-family homes made entirely of concrete.

    Since that time, advancements in forming and placing technology, concrete mixtures, and insulation

    strategies have made construction of concrete homes using removable forms a well accepted buildingtechnique.

    Advantages

    Cast-in-place provides benefits to builders and building owners alike.

    Owners appreciate:

    strong walls safety and disaster resistance mold, rot, mildew, and insect resistance (below grade can require termite protection) sound-blocking ability for insulated systems, energy efficiency and resultant cost savings

    Thomas Edison with model of aconcrete house (circa 1910). Themodel is now on exhibit at the EdisonNational Historic Site.Credit U.S. Department of the Interior,National Park Service, Edison NationalHistoric Site.

    http://www.cement.org/homes/index.asphttp://www.cement.org/homes/index.asphttp://www.cement.org/homes/ch_buildsys.asphttp://www.cement.org/homes/ch_buildsys.asphttp://www.cement.org/homes/ch_buildsys.asphttp://www.cement.org/homes/ch_bs_removable.asp#historyhttp://www.cement.org/homes/ch_bs_removable.asp#historyhttp://www.cement.org/homes/ch_bs_removable.asp#advantageshttp://www.cement.org/homes/ch_bs_removable.asp#advantageshttp://www.cement.org/homes/ch_bs_removable.asp#componentshttp://www.cement.org/homes/ch_bs_removable.asp#componentshttp://www.cement.org/homes/ch_bs_removable.asp#installationhttp://www.cement.org/homes/ch_bs_removable.asp#installationhttp://www.cement.org/homes/ch_bs_removable.asp#installationhttp://www.cement.org/homes/ch_bs_removable.asp#installationhttp://www.cement.org/homes/ch_bs_removable.asp#codeshttp://www.cement.org/homes/ch_bs_removable.asp#codeshttp://www.cement.org/homes/ch_bs_removable.asp#costshttp://www.cement.org/homes/ch_bs_removable.asp#costshttp://www.cement.org/homes/ch_bs_removable.asp#projectshttp://www.cement.org/homes/ch_bs_removable.asp#projectshttp://www.cement.org/homes/ch_bs_removable.asp#projectshttp://www.cement.org/homes/ch_bs_removable.asp#costshttp://www.cement.org/homes/ch_bs_removable.asp#codeshttp://www.cement.org/homes/ch_bs_removable.asp#installationhttp://www.cement.org/homes/ch_bs_removable.asp#installationhttp://www.cement.org/homes/ch_bs_removable.asp#componentshttp://www.cement.org/homes/ch_bs_removable.asp#advantageshttp://www.cement.org/homes/ch_bs_removable.asp#historyhttp://www.cement.org/homes/ch_buildsys.asphttp://www.cement.org/homes/index.asp
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    Contractors and builders like:

    familiarity expands business to include more than basements cost effective building technology (reusable forms lower placement costs)

    Components, Including Insulation

    Cast-in-place (CIP) concrete systems are relatively straightforward. Stepsrequired include the placement of temporary forms and placing fresh concreteand steel reinforcement. Although it is possible to batch concrete on site, readymixed concrete is widely available and is usually delivered by a ready mixsupplier. And in 2011, the average distance to most project sites from a readymix plant is just about 14 miles.

    Although uninsulated walls were common in the past, changing energy coderequirements are more or less eliminating walls without insulation in mostclimates. (Note that this is the case with all types of systems, includingconcrete, wood, and steel. Energy is simply too important in terms of its costand environmental impact.) Concretes thermal mass helps moderate

    temperature swings, but cannot provide the improved energy performance

    mandated by codes unless the wall system contains insulation. In the past,therefore, insulation may have been an optional component of a cast-in-placesystem, but it is increasingly included in contemporary construction.

    The most common formwork materials for casting concrete in place are steel,aluminum, and wood. Many wood systems are custom manufactured and maybe used only once or a few times. Steel and aluminum forming systems, on theother hand, are designed for multiple reuses, saving on costs. Metal panel forms are usually 2 to 3 ft wideand come in various heights to match the wall. Most common are 8 and 9 ft tall panels.

    Installation, Connections, Finishes

    Casting concrete in place involves a few distinct steps: placing formwork, placing reinforcement, and pouring

    concrete. Builders usually place forms at the corners first and then fill in between the corners. This helpswith proper alignment of forms and, therefore, walls. Reinforcement bars (rebar for short) can be erected

    before either form face as a cage or after one side of the formwork is installed. Once both form faces aretied together and braced, concrete is placed in the forms via truck chute, bucket, or pump. Forms shouldalways be filled at an appropriate rate based on formwork manufacturer recommendations to preventproblems. Although blowouts are uncommon with metal and wood forms, misalignment could potentiallyoccur.

    For single-family residential construction, wall thicknesses can range from 4 to 24 in. Uninsulated walls aretypically 6 or 8 in. thick. Walls with insulation are generally thicker when they contain an internal layer ofinsulation: either the inner or outer wall layer has to serve a structural function. CIP walls are generallythicker than frame walls (wood or steel).

    Reinforcement in both directions maintains the wall strength. Vertically, bars are usually placed at 1 to 4 fton center, and tied to dowels in the footing or basement slab for structural integrity. Horizontally, bars aretypically placed at about 4 ft spacings in residential applications. Additional bars are placed at corners andaround openings (doors, windows) to help control cracking and provide strength.

    Openings for doors and windows require bucks to surround the opening, contain the fresh concrete duringplacement, and provide suitable material for fastening window or door frames.

    Floors and roofs can be concrete or wood and light-gauge steel. Ledgers are anchored by bolts adhered intoholes in the concrete. For heavy steel floors, weld plates are installed inside the formwork so they becomeembedded in the fresh concrete. This provides an attachment for steel joists, trusses, or angle irons.

    Cast-in-place concrete wallsdone with metal forms

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    Basement wall form used as deck form in new rib floor system. Adjustable rib formsupports deck form and can span from 12 to 16 feet.

    Finishes on CIP systems are dependent on the presence of insulation and on the formed face. Finishes can

    alternately be attached with furring strips. Almost any type of finish can be used with removable formconcrete wall systems. Wallboard remains the most common interior finish. Exteriors are much more variedand depend on customer preference. Form liners attached to the exterior form face can impart any type oftexture; alternately, other traditional finishes such as masonry or siding can be attached to the wall

    following form removal.

    Insulation can be placed on inside or outside faces or in the center portion of the wall. To place theinsulation on the face, plastic fittings are inserted into the foam board and become embedded in theconcrete. These are flanged to hold the foam and the flanges provide an attachment for finishes andfixtures. Face insulation can also be applied after the formwork is stripped. If foam is embedded in the

    formwork prior to concrete placement, composite fittings are used to tie together the two concrete faces(through the foam insulation layer). The inner wall is usually the structural layer, so its thicker and containsthe rebar, whereas the outer concrete layer has the finish applied. Foam insulation is most often EPS,expanded polystyrene. It can be XPS, extruded polystyrene, which is stronger, but also more costly.

    Sustainability and Energy

    A major appeal of insulated CIP walls is reduced energy to heat and cool the building. Savings are primarilyattributed to insulation, thermal mass, and low air infiltration. Typical R-value for EPS and XPS foams are,respectively, 4 and 5 per in. Thermal mass acts like a storage battery to hold heat or cold, moderating

    temperature swings. CIP walls have 10% to 30% better air tightness than comparable framed wallsbecause the concrete envelope contains few joints. In addition to saving energy and money associated withheating and cooling, concrete walls also provide more consistent interior temperatures for occupants,increasing their comfort.

    CIP systems are also suited to the use of recycled materials. Concrete can be made using supplementarycementing materials like fly ash or slag to replace a portion of the cement. Aggregate can be recycled(crushed concrete) to reduce the need for virgin aggregate. Most steel for reinforcement is recycled. Somepolystyrene is made with recycled material as well. Some of these techniques contribute toward achievingpoints in certain green rating systems such as LEED.

    Building Codes

    For one and two family dwellings, the International Residential Code (IRC) addresses foundations and belowgrade walls in Section R404 and above grade walls in R611 for homes up to two stories plus a basement. For

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    larger buildings like multi-family and commercial structures, engineers follow the International Building Code(IBC) for structural design.

    Door and window openings are cast into concrete walls.

    Comparative Costs

    Cast-in-place concrete requires the erection of temporary forms, so this is labor intensive. But many typesof forms can be reused, so there is not necessarily a big cost for the formwork. Also, concrete is historicallymore stable in price than either wood or steel.

    Residential CIP Project

    Ancient Art Form Inspires Contemporary Sustainable Home

    At 3300 sq ft, the Origami-Loft House in Venice, Fla., isnt exactly small, but it lives even larger, adding astudy loft, reading space, and game room to the typical living areas. The spacious feeling is due to manyreasons: a top ceiling height of 24 ft, geometric folds in walls that create separate rooms, and lots of lightevery room opens to the outdoors while transom windows and interior glass partitions let the light flowfreely.

    As the living room shows, tall ceilings and open floor plans give a spacious feeling to the

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    interior. Photo courtesy C. Pyatte.

    Set in a traditional neighborhood on a quarter-acre lot, the project respects its surroundings. From the

    street, the house presents a sensibly executed faade, whereas the rear of the house has dramatic curvesand cascading volumes. DesignerJONATHAN PARKS ARCHITECT (JPA)selected cast-in-place concrete wallsto allow for the complex geometries and openness while providing the strength necessary to resist coastalweather along the Gulf of Mexico, which includes a long hurricane

    season.

    Like so many projects today, this house was designed with sustainabilityin mind. Starting with the energy-efficient cast-in-place concrete wallsystem, and soy-based insulation, the envelope protects againstFloridas warm temperatures. A combination of active and passive solartechniques greatly reduces the energy requirements of the building,while still providing the necessities and amenities common to Florida

    homes. This includes hot water for the home and pool via passive solarwater heating, and high interior ceiling heights to help control interiortemperatures. By collecting solar power, owners enjoy an extra 21 to 26kw hr/day and the use of Energy Star appliances reduces the draw onpower.

    Energy, however, is not the only sustainability measure considered indesign and construction of the home. Some finishes are made withrecycled materials and interior floors are covered with low VOC wood.Outside, landscaping is designed with minimal water needs, includingnative wildflower pasture grass, to conserve fresh water usage. From

    literally every angle, this concrete house delivers good looks, energyperformance, and sustainable design.

    Low Rise Commercial CIP Project

    A Curvy Concrete Car Park Sails into Sarasota

    Poised to become a signature structure in the Sarasota, Florida skyline, the Palm Avenue Parking Garageand Retail Shops includes a variety of unique retail spaces at ground level, and provides parking for 763cars, 35 motorcycles, and 80 bicycles. As an example of a mixed-use facilityparking garage and retailthePalm Avenue project shows how versatile concrete structures are.

    As the living room shows, tall ceilingsand open floor plans give a spaciousfeeling to the interior.Photo courtesy C.Pyatte.

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    Using architectural concrete as both a structural and aesthetic medium,JONATHAN PARKS ARCHITECT (JPA)created a curvaceous, free-form building to capture the spirit of the local artistic culture. The cast-in-placestructure eliminates the need for shear walls and columns between spaces, providing an open floor plan withhigh ceilings. This unobstructed layout, along with perforated metal sails that cover the faade, creates abright, airy, and safe atmosphere for a shared pedestrian and driver space, letting in light and naturalventilation while shielding cars from view.

    Cast-in-place concrete also allowed designers to produce a playful, sculptural stair design that itself attracts

    peoples interest and encourages its use rather than the elevator.

    Using civic input and capturing the spirit of the local artistic culture, this 240,000 square foot project wasdesigned for the City of Sarasota by the architecture firm, JPA, and built by Suffolk Construction. The resultis an iconic, user-friendly, environmentally-responsible design that satisfies the functional, strategic, andaesthetic needs of the City, while contributing to the overall success of downtown Sarasota.

    The garage follows a user-friendly layout, including wide express ramp and one-way traffic flow to reducevehicle conflict and facilitate easy maneuvering in and out of parking spaces. Efficient vehicle circulation isachieved by designing slightly angled parking spaces and a wide-open express ramp free of parked cars.

    Though certification is pending, the project is designed to achieve a LEED Core & Shell v3 Gold Level, in part

    through the use of a combination of storm water, interior materials, lighting, and solar techniques forrecharging electric vehicles. Highlights of the green components are noted below.

    An underground retention vault and cistern to store and treat storm water runoff from the site. A portionof the water is reused for the irrigation system. Interior materials surpass LEED requirements for off-gassings of VOCs and other toxic chemicals. Energy consumption is reduced with LED lighting and an energy management system that only providesartificial light when and where it is needed. A solar carport is located on the roof and plug-ins for electric vehicles are provided on the first floor.

    Owner:City of SarasotaArchitect:JONATHAN PARKS ARCHITECT

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    Contractor:Suffolk ConstructionCivil, Landscape, and Wayfinding:Kimley-Horn and AssociatesStructural Engineer:Walter P MooreM.E.P, Fire Protection: TLC Engineering for ArchitectureEco Consulting:Carlson Studio Eco ConsultingParking Consultants:DKS Associates

    Structural Concrete:Ceco Concrete Construction

    Aluminum Sail Fabricator:Mullets Aluminum Product, Inc.

    Resources

    Concrete Homes Council(A Council of the Concrete Foundations Association)

    The Concrete Foundations Association is an active force dedicated to the positive and constructive

    development of the above grade removable forms concrete home industry. Contact CHC for moreinformation.

    Concrete Homes Council107 First St. West

    P.O. Box 204

    Mount Vernon, IA 52314(319) 895-0761 / Fax: (319) 895-8830www.concretehomescouncil.org

    >Return to top

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    Concreteis acompositematerial composed of coarse granular material (theaggregateor filler)

    embedded in a hard matrix of material (thecementor binder) that fills the space among the aggregate

    particles and glues them together.[2]

    Concrete is widely used for makingarchitectural structures,foundations,brick/blockwalls,pavements,

    bridges/overpasses,highways, runways,parkingstructures,dams,pools/reservoirs,pipes,footingsfor

    gates,fencesandpolesand evenboats.

    Famous concrete structures include theHoover Dam,thePanama Canaland the RomanPantheon.

    Concrete technology was known by theancient Romansand was widely used in theRoman Empire

    theColosseumwas built largely of concrete and the concrete dome of the Pantheon is the world's largest.

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    After the Empire was destroyed, use of concrete became scarce until the technology was re-pioneered in

    the mid-18th century.

    conceptAccording to my concept the volumes of the gallery originate in the subtraction of all the bus station plan

    areas from the total mass of the building-up estate. Then the volumes adapt to sunlight by declining the

    external walls and their internal spaces are arranged in the levels of the reflected shades. Thanks to this

    process the services of both functions have been interconnected since the very beginning. The gallery

    has been a waiting room for the bus station and the free spaces of the bus station have been a place for

    exhibitions.

    Tereza Stastna

    The diploma project task was to design a gallery and a bus center. The student explores the possibilities

    of exhibiting pieces of art in connection with a traffic facility and the mutual influence of these two

    functions. The student places the gallery programme in three odd cones whose plan is a negative imprint

    of a bus center operation. The volume of the towers is formed by light. The design allows for a full-value

    functioning of both programmes and as an impressive work of art increases the value of the area.

    Petr Hajek

    Waitakere City Council has signed off on its concept plan for the New Lynn bus and rail development project, and it isdue to start work by the end of the year. The projectcalled the Transport Oriented Development (TOD)calls forthe railway and station to be placed in a trench, to have a new bus terminal located right alongside, new roadconnections and a variety of other improvements. The concept plan represents Waitakere City Councils projectscope designed to help develop a world class town centre, to serve Waitakere and the Auckland region, until at least2060. New Lynn is identified by Waitakere and the regional Growth Strategy as a major sub-regional growth centre

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    whose population and commercial sectors are expected to double within the foreseeable future.

    The main part of the project is being carried out by ONTRACK - owners of the rail tracks and corridor. ONTRACK isfunded to duplicate and lower the track into a trench and to build the station platforms. However, there is a hugeamount of detail that must be resolved to determine how well what is built serves New Lynn. We are building for a bigand busy future and so it is critical we get that detail right, says Mayor Bob Harvey. We have had many expertsworking on a painstaking analysis of exactly what should go where, and how it will function and what will make people

    want to use it, he says. That is all covered in the concept plan which were offering to ONTRACK and our otherregional partners such as ARTA and theARA, saying that this is our view of how the project should be built in detail,he says.

    The exact location of the station is considered critical to user convenience and safety, with entrances outside theintersection of Memorial Drive and Totara Avenue. Station location is also vital to developing an effective bus/railinterchange, with bus stops immediately outside the station. This meant having sufficient road room to accommodatea large and busy fleet of buses providing feeder services to and from the New Lynn ward area, and other parts of theregion. Many of these buses would coincide with train services in both directions, running at 10 minute intervals. Toavoid unnecessary congestion, bus layover locations will be taken to the edge of town and the current bus station inNew Lynn will cease to function and become available for commercial or retail development.

    This project is the centrepiece of a much larger revitalisation plan for the town centre and the location and aestheticof the new amenities is considered vital to the development of a town centre people want to live in, establishbusinesses in and socialise in. Accordingly the concept plan calls for attractive buildings, structures and open spaces

    to encourage people to use the area. People using the area not only add to the bustle of an attractive town centre,but being able to over-look rail and bus platforms adds to their safety. Right now New Lynn is cut in half by therailway. Not only is that inhibiting development, but road and rail traffic are in conflict resulting in road congestion.That will get much worse as the town centre grows and train services become more frequent.

    Using the TOD model, which we have seen working to good effect at Subiaco in Perth, we can rejoin the two halvesand get rail and road out of each others way. Better bus and rail services will promote the use of public transport andfree up the roads for commercial traffic. More people living in higher density housing adds to the economic viability ofthe town centre as a business locationoffering more jobs; it also provides patronage for public transport. So thebenefits are circular, says Mayor Bob Harvey. The council will provide the concept plan to ONTRACK, ARTA, theARA and other major players in the development of Auckland infrastructureand recommended for adoption. TheGovernment has already committed $120 million to the project, and council is providing funding of $20 million.

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