Concrete

Defects in Concrete
Causes and Solutions

Todd Fraker
Dayton Superior

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Agenda

Basic Concrete Technology

Common Defects
Concrete Materials & Mix Proportioning
Concrete Control Tests
Curing & Protection

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Basic Concrete Technology

Concrete is…
 Portland Cement (Pozzolon) 10%
 Water 15%
 Fine Aggregate 25%
 Coarse Aggregate 45%
 Air (entrapped + entrained) 5%
 Admixtures ozs.

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Properties of Concrete

3000-6000 psi
HP 10000 and above
10% Strength in Shear vs. Compression

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ASTM Portland Cement Types

Type I-Normal General Purpose

Type II-General Use, Moderate Heat of Hydration &

Sulfate Resistance

Type III-High Early Strength. (Finer Grind Than Type I)

Type IV-Low Heat of Hydration, Massive Placements

Type V-Severe Sulfate Resistance (SO4 > 0.2-2.0%)

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 Concrete is Chemical Reaction

A Chemical Reaction that takes place in the presence of water

is called a hydration reaction.
The formation of solid concrete occurs as the Portland
Cement is coated with water or “hydrated”. This forms cement
paste which in turn binds with the aggregate to form the
concrete “matrix”.
Generally speaking, the less water used, the better the
concrete density & quality
Cement Paste

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 Cement & Concrete Admixtures

Ingredients in Concrete other than Portland Cement,

Water, and Aggregates.

Added before or during mixing

Usually Classified According to Function.

Liquid and Mineral Admixtures.

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 The Water/Cement (W/C )Ratio

The water/cement ratio must be maintained as

specified by the engineer, architect, or redi-mix
producer

Failure to maintain this mix design ratio results in a

loss of ultimate strength

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 W/C Controls Everything

Portland Cement=94 lbs/bag

Measured as lbs Water/lbs Cement
Water =8.5 lbs/gallon
Mix Design Based on Cubic Yard
Strength a Function of Portland Cement

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Water to Cement Ratio

The Lower the Ratio, the Stronger and More

Dense the Cement Mix Will Be.
• Typical W/C Values Are 0.35 to 0.50.
•Hydration Requires Only 22 - 24% H2O By Weight
Of The Cement.

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W/C Ratio & Permeability

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W/C Ratio & Strength

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 Concrete Slump

Slump measures consistency, flow, workability (ASTM

C143)
The higher the slump, the wetter the mixture, slump
measured in inches
Different slumps for different purposes
Typical range is 2- 4 inches from a 12 in. height
Increased ~ 1 in. per lb. of water

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 Weight of Cured Concrete

Typically 150 lbs/cubic foot

Most form pressures, structural support, etc is figured on
this weight.

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 Concrete

Has a High Ph.

Is Considered Alkaline.
Acids and Salts will Attack it.

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 Typical Defects
Deformation
 Curling, Delaminantion, Blisters, “Birdbaths”

Cracking
 Shrinkage; Plastic vs. Structural
 Crazing
 Map Cracking
 Joints

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 Typical Defects
Vertical Defects
▬ Honeycombing
▬ Pinking
▬ Light Dark Areas

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Vertical Typical Vertical Defects
Honeycombing
▬ Mix Design
 Increase Ratio of Fines 10%
 Increase Slump to 6-8”
▬ Vibration Technique
 Always Penetrate Previous Lift
▬ Form Joints
 Tight
▬ Rebar Congestion
 Consider Splicing Where Appropriate
▬ Segregation
 Use Tremie

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 Typical Vertical Defects
Vertical
Light Dark Areas
▬ Caused by Differential Curing
 Water Cement Ratio Varience
 Follow ACI 3 days
► Curing or Forms Left in Place

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 Typical Defects
Surface Disintegration
 Dusting
 Spalling
 Delaminations
 Chemical

Staining
 Blankets
 Materials

Others
▬ Carbonation

Freezing, Environmental

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 Typical Defects

Deformation
 Curling, Delaminantion, Blisters,
“Birdbaths”
Cracking
 Shrinkage; Plastic vs. Structural
 Crazing
 Map Cracking
 Joints

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Curling

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Curling Failure

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Curling Off-set
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More Curling Offset

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 Blistering

Blistering
 Early Finishing

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 Surface Disintegration

Spalling/Popouts
Steel Corrosion
Aggregate Contamination
ASR-Alkali Silica Reaction

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 Surface Disintegration

Delaminations
 Premature Finishing
 High W/C Ratio at Surface29

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 Early Finishing
A cross-
sectional view of
a core. Arrows
indicate irregular
voids caused by
entrapped water
under the
surface. Note
top of slab on
right hand side
much darker due
to change in
water/cement
ratio.
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 Window of Finishability

Along with improper curing can contribute

to poor surface quality

Too soon leads to surface defects

Too late leads to flatness problems and

poor surface finish

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operations ACI 302 WINDOW
Finishing

Bull float Power Trowel

Waiting
Screeding Straightedge
Placing Power float
1 Time 2 3 4
Concrete
behavior

Power
float walk Power
Bleedwater Sheen behind float rider

Stiffening 1” 3/4” 1/2” 1/4” 1/8” visible not visible

challenges
Finishing

Hitting
the
Premature finishing Late finishing
(may result in surface gap (may result in
defects) surface defects)
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 Flyash Considerations

Class C Preferred-Non-Reactive. “Hydraulic in

Nature”
Cement Replacement Not to Exceed 25%.
Slows Strength Curve.
Reduces Water Demand.
All May Affect Bondbreaker Performance.
Slows Bleed Rate

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FLYASH

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 Bleed Water

Inhibited by Fly ash

Top of Slab

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 Surface Disintegration

Dusting
 Improper/Lack of Curing
 High Surface W/C
 Carbonation
 Salamanders
 Fresh Air

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 Spalling

Improper curing
Rapid evaporation
Sealing surface
prematurely
Too low w/c ratio
Aggregate
Contamination
Freezing

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 Plastic Shrinkage Cracks

Occur when rate of evaporation

exceeds rate of bleed

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 Crazing

Improper Curing
 Rapid surface drying

Over-Finishing
Too long a delay from
final troweling to
application of curing
compound
High W/C ratio
“Blessing” Surface

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Improperly Designed Structural Cracks

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 Jointing

Isolation Joints
 Isolate slab from fixed object column, wall, etc.

Contraction Joints
 Predetermine cracking

Construction Joints
 Cold joints, key joints

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Isolation Joints

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No
Isolation

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Contraction Joints

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 Staining
Chemical
 Environmental
 Blankets
 Jobsite Materials

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 Importance of Curing
Permeability or Density
Compressive Strength
Cracking
Dusting
Abrasion Resistance
Loss of Durability

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Heat, Wind, Humidity Effect

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Happy Concrete

Stable cool environment (50F is best)

100% humidity
No thermal cycling

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 Evaporation is Increased
by...

Heat
Low humidity
Wind

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 Methods of Temp Control

•Reflectance: applying a sun reflecting coating or

covering

•Covering: applying a cover that is not necessarily

reflective

•Heating: heating the concrete, heating the area around

the concrete

•Cooling: cooling the concrete, cooling the area around

the concrete

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 General Curing Requirements

Time 3-7 days (minimum)

3 days if no thermal cycling
7 days in freeze/thaw cycling
Temperature 50o -100oF (may be higher)
Apply curing compound as soon as the bleed water has
dissipated and finishing operations have ceased

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Problems Associated With Improper
Curing.
Surface Crazing
Delamination
Surface Plastic Shrinkage
Spalling
Premature wear of horizontal surfaces
Curling
Slab curling
Surface permeability

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 Curing Methods

Moist Curing-Water Supplied Continuously

Sheet Membrane-Plastic or Poly Laid on Top or
Summer Curing Blankets
Wet Burlap-Burlap kept Continuously Moist
Curing Paper
Membrane Forming Curing Compounds*

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Moist Curing

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Sheet Membrane

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Curelap or Burlene

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Curing Compound

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 Types of Curing Compounds

•Waxes
•Resins
•Polymers

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Compressive Strength

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Winter Protection

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ACI Guidelines-306R 1997

Definition
 In a 3 Day Period-Average Daily Temperature
Less Than 40F or Is Not Greater Than 50F For
More Than ½ of any 24 Hour Period.

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 Why Protect?
Neglect of Protection Against Early Freezing Can Cause
Immediate Destruction or Permanently Weakened
Concrete

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Objectives of Winter Protection

Prevent Damage to Concrete Due to Freezing at Early Ages

Assure Concrete Develops Required Strength Prior to
Removal of Forms, Shores, or Reshores
Maintain Curing Conditions
Limit Rapid Temperature Changes
Provide Protection Consistent With Long-Term Use of the
Structure or Intended Service Life

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 Conclusions
Defects Happen
Concrete Will Shrink
Curing and Protection is Essential
Pay Attention to Mix Design and Conditions of Pour
Right Process is the Answer
“Never time to do it right, but always time to do it over”

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