Casting of Concrete Frames

Bungag, Jediann M.
Collo, Mikhail Hans N.
Manalo, Jomel S.
CE151P A3
Casting
It is a manufacturing process by which a liquid
material is usually poured into a mold, which contains a
hollow cavity of the desired shape, and then allowed to
solidify.
Concrete Frames
structural components of a building made up of
concrete and reinforcements.
Concrete

It is structural material consisting of a hard, chemically
inert particulate substance, known as
aggregate (usually sand and gravel), that is bonded
together by cement and water.

It is construction material that hardens to a stone like
mass


Aggregate
Concrete Cement
Classifications of Concrete

Reinforced Concrete
Prestressed Concrete
Precast Concrete


Reinforced Concrete

Concrete in which steel is embedded in such a manner
that the two materials act together in resisting forces.
In reinforced concrete, the tensile strength of steel and
the compressive strength of concrete work together to
allow the member to sustain these stresses over
considerable spans.



Prestressed Concrete

Concrete reinforced by either by pretensioning or
posttensioning, allowing it to carry a greater load or span
a greater distance than ordinary reinforced concrete.



Precast Concrete

Concrete cast into structural members under factory
conditions and then brought to the building site.
Precast concrete components include slabs, beams,
columns, walls, stairways, modular boxes, and even
kitchens and bathrooms with precast fixtures.

Types of Concrete

Standard Ready-Mix Concrete
Architectural and Decorative Concrete
Rapid-setting Concrete
Fiber-reinforced Concrete
Fluid-fill Concrete
Roller Compacted Concrete


Standard Ready-Mix Concrete
It is the most common form of concrete. It is prepared for
delivery at a concrete plant instead of mixed on the
construction site, which guarantees the quality of the
concrete.

Architectural and Decorative Concrete
This type of concrete can provide a structural function, as
well as an aesthetic or decorative finish. It can offer
smooth or rough surfaces or textures, as well as a variety
or range of colors.



Rapid-setting Concrete
This concrete allows fast formwork removal, accelerated
construction sequencing, and rapid repair for such jobs as
roads and airport runways.

Fiber-reinforced Concrete
Concrete designed with micro or macro fibers that can
significantly increase the ductility of concrete, making it
highly resistant to crack formation and propagation.



Fluid Fill Concrete
Fluid mortar or concrete simplifies the process of laying
pipe and cable by surrounding the pipe or cable with a
tightly packed shell that provides protection from the
elements, prevents settling, and enables crews to work
quickly.

Roller Compacted Concrete
Compacted in place and cured, roller-compacted concrete
is a zero slump concrete with the abrasion resistance to
withstand high velocity water.
Concrete Frame Structures

Concrete frame structures are a very common - or
perhaps the most common- type of modern
building. As the name suggests, this type of
building is formed of a frame, or skeleton of
concrete.
Beams
It is a long, sturdy piece of squared timber or metal
spanning an opening or part of a building, usually to support
the roof or floor above.
Foundations
It is the lowest load-bearing part of a building,
typically below ground level.
Columns
A column is an upright pillar or post. Columns may
support a roof or a beam, or they can be purely decorative.
Shear Walls
A shear wall is a wall composed of braced panels to
counter the effects of lateral load acting on a structure.
Slabs
It serves as a walking surface but may also serve as a
load bearing member.
Reinforcements

Rebar (reinforcing bar)
-It is serves as the skeleton of the reinforced concrete.
-Rebar is used because although concrete is very strong
in compression it is virtually without strength in tension.
Rebar (reinforcing bar)

Metallic Reinforcing Bars
Steel most common type of rebar used in construction.

Non-metallic reinforcing bars
This type of reinforcements are usually used in building with
huge magnetic machines to become nonmagnetic buildings.

Glass - stronger than traditional concrete with the unique
ability to flex without breaking but quite costly.
Plastic can be as strong as steel.
Wood innovative rebar that can be used to have an
environment friendly structure.
Types of Reinforcing Steel Bars

Welded Wire Fabric
- It is made from a series of steel wires arranged at right angles
and electrically welded at all steel wires crossings.
- This is commonly used in road pavements, box culverts and
drainage structures, and small concrete canals.
Types of Reinforcing Steel Bars

Sheet-Metal Reinforcing Bars

- Sheet-metal reinforcing is composed of annealed sheet steel
pieces bent into corrugations about 1/16 inch depth, with
holes punched at regular spacing.
- It is commonly used in floor slabs, stairs and roof construction.
Types of Reinforcing Steel Bars

Stainless Steel Reinforcing Bars
- It can be used as an alternative reinforcing steel bars with
carbon steel reinforcement
- Can be a cost-effective solution in areas subject to corrosion
problems, or where repair is difficult and expensive.
Types of Reinforcing Steel Bars

Expanded Metal and Wire Mesh Reinforcement
- Expanded metal is made by shearing a sheet of steel into
parallel lines and the expanded to form a diamond shape or
square shape between each cut.
- Wire mesh reinforcement can be used on sidewalks, small
concrete pads or walkable surfaces that do not receive high
live nor load charges.
Reinforcements are used to surpass:

1. Deflection the appearance or efficiency of any part of the
structure must not be adversely affected by
deflections.

2. Cracking local damage due to cracking to spalling must not
affect the appearance and efficiency of the
structure.

3. Durability this must be considered in terms of proposed
life of structure and its condition of exposures.
Reinforcements are used to surpass:

4. Excessive Vibration it may cause discomfort or alarm as well
as damage.

5. Fatigue must be considered if cyclic loading is likely.

6. Fire this must be considered in terms of resistance to
collapse, flame penetration and heat transfer.
Casting of Concrete Frames
Materials needed in Casting Concrete Frames:

Concrete
Reinforcements
Forms or molder
Concrete Mixer

The Process of Casting Concrete Frames:

Step 1: The Sale
The owner of the structure will choose a contractor.
After the contract has been signed, work can begin.

The Process of Casting Concrete Frames:

Step 2: Site Work
Before concrete can be placed, the site needs to be prepared.
Prepare a sub base where the concrete should be placed.

The Process of Casting Concrete Frames:

Step 3: Forming
Concrete forms are made from wood, metal or plastic, and
can range in height from 4 inches to many feet.
These forms will serves as the molder of the concrete.
Reinforcements can be prepared at this time.
The Process of Casting Concrete Frames:

Step 4: Placement
Concrete mixer are used to mix concrete.
Liquid concrete are poured in the frame allowing it to solidify
after period of time.

The Process of Casting Concrete Frames:

Step 5: Early Finishing
Once the concrete is placed into forms, a board is used to
screed the top surface of the concrete.
Floats are then use to further compact the concrete.
The Process of Casting Concrete Frames:

Step 6: Finishing
The most basic type of finish is known as a "broom finish".
A special broom is pulled across the concrete surface creating a
rough textured surface.
Other types of finishing: stamped, textured and smooth trowel
The Process of Casting Concrete Frames:

Step 7: Curing
The curing process lasts 28 days, with the first 48 hours being
the most critical.
A liquid chemical can be applied that helps the concrete cure
slowly and evenly, which helps reduce cracks, curling, and
surface discoloration.
The Process of Casting Concrete Frames:

Step 8: Maintenance
Occasional soap and water cleaning is also advised to keep
your concrete looking its best.
Sealing and regular maintenance will also minimize the chances
from staining and discoloration caused by natural or manmade
contamination.
Factors That Can Affect Concrete Casting Quality

Unsteady Weather
-Hot Weather
-Cold Weather
-Rainy Weather
Analysis of Condition
Health and Safety
Hot Weather
Dehydration
To fast dehydration will lead to cracks in the construction.
Cold Weather
Hardening process will stop.
we will get a weak construction with pores, cracks and
corrosion on the reinforcement.
Rainy Weather
Concrete floor may have a rough surface.
That can gives us extra cost considering integrally cast and
smoothing out the surface.
Analysis of Condition
The surface of the concrete should be checked every year,
to register possible damages.
A small crack can very fast stimulate to a much bigger
damage.
Health and Safety
Prevent accidents for this can be a cause of delay for
construction process.
Did you ever wonder how they cast
concrete over water?

Large steel plates are driven under water.
It should reach the hard rock at the bottom of the water.

The water is then pumped out from the driven steel plate.
After all the water has been pumped out, let the ground at
the bottom get dried.


The reinforcements are then applied.
The concrete is then poured inside the steel plates.

The concrete will then get hard after a period of time.