Tower

The common structural problems in the design of steel lattice towers for different purposes are outlined.
The details of design are discussed in relation to a specific category of tower, the high voltage transmission tower. The influence on the tower design of the user's functional demands is explained and the background for the load assumptions is pointed out.
Different aspects affecting the overall design and the detailing are discussed and problems connected with the structural analysis are explained. The effect of joint eccentricities is discussed on the basis of a very common design example using angle sections. The use of different detailing is mentioned.
The need for erection joints is stated and the types of joints are discussed. Corrosion protection is briefly dealt with and its influence on the tower design is pointed out.
Tower foundations are not treated in this lecture.

1. INTRODUCTION

Towers or masts are built in order to fulfil the need for placing objects or persons at a certain level above the ground. Typical examples are:
  • single towers for antennae, floodlight projectors or platforms for inspection, supervision or tourist purposes.
  • systems of towers and wires serving transport purposes, such as ski lifts, ropeways, or power transmission lines.
For all kinds of towers the designer should thoroughly study the user's functional requirements in order to reach the best possible design for the particular structure. For example, it is extremely important to keep the flexural and torsional rotations of an antenna tower within narrow limits in order to ensure the proper functioning of the equipment.
The characteristic dimension of a tower is its height. It is usually several times larger than the horizontal dimensions. Frequently the area which may be occupied at ground level is very limited and, thus, rather slender structures are commonly used.
Another characteristic feature is that a major part of the tower design load comes from the wind force on the tower itself and its equipment, including wires suspended by the tower. To provide the necessary flexural rigidity and, at the same time, keeping the area exposed to the wind as small as possible, lattice structures are frequently preferred to more compact 'solid' structures.
Bearing in mind these circumstances, it is not surprising to find that the design problems are almost the same irrespective of the purpose to be served by the tower. Typical design problems are:
  • establishment of load requirements.
  • consistency between loads and tower design.
  • establishment of overall design, including choice of number of tower legs.
  • consistency between overall design and detailing.
  • detailing with or without node eccentricities.
  • sectioning of structure for transport and erection.
In this lecture, towers for one particular purpose, i.e. the high voltage transmission tower, have been selected for discussion.

2. HIGH VOLTAGE TRANSMISSION TOWERS

2.1 Background

The towers support one or more overhead lines serving the energy distribution. Most frequently three-phase AC circuits are used requiring three live conductors each. To provide safety against lightning, earthed conductors are placed at the top of the tower, see Figures 1 and 2.
The live conductors are supported by insulators, the length of which increases with increasing voltage of the circuit. To prevent short circuit between live and earthed parts, including the surrounding environment, minimum mutual clearances are prescribed.
Mechanically speaking, the conductors behave like wires whose sag between their points of support depends on the temperature and the wire tension, the latter coming from the external loads and the pre-tensioning of the conductor. As explained in Section 2.4, the size of the tension forces in the conductor has a great effect upon the tower design.

2.2 Types of Towers

An overhead transmission line connects two nodes of the power supply grid. The route of the line has as few changes in direction as possible. Depending on their position in the line various types of towers occur such as (a) suspension towers, (b) angle suspension towers, (c) angle towers, (d) tension towers and, (e) terminal towers, see Figure 1. Tension towers serve as rigid points able to prevent progressive collapse of the entire line. They may be designed to serve also as angle towers.
To the above-mentioned types should be added special towers required at the branching of two or more lines.
In Figure 2 examples of suspension tower designs from four European countries are presented. Note similarities and mutual differences.

2.3 Functional Requirements

Before starting the design of a particular tower, a number of basic specifications are established. They are:
a. voltage.
b. number of circuits.
c. type of conductors.
d. type of insulators.
e. possible future addition of new circuits.
f. tracing of transmission line.
g. selection of tower sites.
h. selection of rigid points.
i. selection of conductor configuration.
j. selection of height for each tower.
The tower designer should notice that the specifications reflect a number of choices. However, the designer is rarely in a position to bring about desirable changes in these specifications. Therefore, functional requirements are understood here as the electrical requirements which guide the tower design after establishment of the basic specifications.
The tower designer should be familiar with the main features of the different types of insulators. In Figure 3 three types of insulators are shown. They are all hinged at the tower crossarm or bridge.
Figure 4 shows the clearances guiding the shape of a typical suspension tower. The clearances and angles, which naturally vary with the voltage, are embodied in national regulations. Safety against lightning is provided by prescribing a maximum value of the angle v. The maximum swing u of the insulators occurs at maximum load on the conductor.

2.4 Loads on Towers, Loading Cases

The loads acting on a transmission tower are:
a. dead load of tower.
b. dead load from conductors and other equipment.
c. load from ice, rime or wet snow on conductors and equipment.
d. ice load, etc. on the tower itself
e. erection and maintenance loads.
f. wind load on tower.
g. wind load on conductors and equipment.
h. loads from conductor tensile forces.
i. damage forces.
j. earthquake forces.
It is essential to realize that the major part of the load arises from the conductors, and that the conductors behave like chains able to resist only tensile forces. Consequently, the dead load from the conductors is calculated by using the so-called weight span, which may be considerably different from the wind span used in connection with the wind load calculation, see Figure 5.
The average span length is usually chosen between 300 and 450 metres.
The occurrence of ice, etc. adds to the weight of the parts covered and it increases their area exposed to the wind. Underestimation of these circumstances has frequently led to damage and collapse. It is, therefore, very important to choose the design data carefully. The size and distribution of the ice load depends on the climate and the local conditions. The ice load is often taken as a uniformly distributed load on all spans. It is, however, evident that different load intensities are likely to occur in neighbouring spans. Such load differences produce longitudinal forces acting on the towers, i.e. acting in the line direction.
The wind force is usually assumed to be acting horizontally. However, depending on local conditions, a sloping direction may have to be considered. Also, different wind directions (in the horizontal plane) must be taken into account for the conductors as well as for the tower itself. The maximum wind velocity does not occur simultaneously along the entire span and reduction coefficients are, therefore, introduced in the calculation of the load transferred to the towers.
The tensile forces in the conductors act on the two faces of the tower in the line direction(s). If they are balanced no longitudinal force acts on a tower suspending a straight line. For angle towers they result in forces in the angle bisector plane, and for terminal towers they cause heavy longitudinal forces. As the tensile forces vary with the external loads, as previously mentioned, even suspension towers on a straight line are affected by longitudinal forces. For all types of towers the risk of mechanical failure of one or more of the conductors has to be considered.
The loads and loading cases to be considered in the design are usually laid down in national regulations.

2.5 Overall Design and Truss Configuration

The outline of the tower is influenced by the user's functional requirements. However, basically the same requirements may be met by quite different designs. In general, the tower structure consists of three parts: the crossarms and/or bridges, the peaks, and the tower body.
Statically speaking, the towers usually behave like cantilevers or frames, in some cases with supplementary stays. For transmission lines with 100 kV voltage or more, the use of steel lattice structures is nearly always found advantageous because they are:
  • easily adaptable to any shape or height of tower.
  • easily divisible in sections suitable for transport and erection.
  • easy to repair, strengthen and extend.
  • durable when properly protected against corrosion.
By far the most common structure is a four-legged tower body cantilevering from the foundation, see Figure 6. The advantages of this design are:
  • the tower occupies a relatively small area at ground level.
  • two legs share the compression from both transverse and longitudinal loads.
  • the square or rectangular cross-section (four legs) is superior to a triangular tower body (three legs) for resisting torsion.
  • the cross-section is very suitable for the use of angles, as the connections can be made very simple.
The following remarks in this section relate mainly to a cantilever structure. However, many features also apply to other tower designs.
For a cantilever structure, the tower legs are usually given a taper in both main directions enabling the designer to choose the same structural section on a considerable part of the tower height. The taper is also advantageous with regard to the bracing, as it reduces the design forces (except for torsional loads).
The bracing of the tower faces is chosen either as a single lattice, a cross bracing or a K-bracing, possibly with redundant members reducing the buckling length of the leg members, for example see Figure 6. The choice of bracing depends on the size of the load and the member lengths. The most common type is cross bracing. Its main advantage is that the buckling length of the brace member in compression is influenced positively by the brace member in tension, even with regard to deflection perpendicular to the tower face.
Generally, the same type of bracing is chosen for all four tower body faces, most frequently with a staggered arrangement of the nodes, see Figure 7. This arrangement provides better space for the connections, and it may offer considerable advantage with respect to the buckling load of the leg members. This advantage applies especially to angle sections when used as shown in Figures 10 and 11, since it diminishes the buckling length for buckling about the 'weak' axis v-v. For further study on this matter see [1].
Irrespective of the type of bracing, the tower is generally equipped with horizontal members at levels where leg taper changes. For staggered bracings these members are necessary to 'turn' the leg forces. Torsional forces, mostly acting at crossarm bottom levels, are distributed to the tower faces by means of horizontal bracings, see Figure 8.
Cross arms and earthwire peaks are, in principle, designed like the tower itself. However, as the load on the cross arms rarely has an upward component, cross arms are sometimes designed with two bottom chords and one upper chord and/or with single lattice bracings in the non-horizontal faces.

2.6 Structural Analysis

Generally, the structural analysis is carried out on the basis of a few very rough assumptions:
  • the tower structure behaves as a self-contained structure without support from any of the conductors.
  • the tower is designed for static or quasi-static loads only.
These assumptions do not reflect the real behaviour of the total system, i.e. towers and conductors, particularly well. However, they provide a basis from simple calculations which have broadly led to satisfactory results.
Generally speaking, a tower is a space structure. It is frequently modelled as a set of plane lattice structures, which are identical with the tower body planes together with the planes of the cross arms and the horizontal bracings mentioned in Section 2.5.
In a simplified calculation a four-legged cantilevered structure is often assumed to take the loads as follows:
a. centrally acting, vertical loads are equally distributed between the four legs.
b. bending moments in one of the main directions produce an equal compression in the two legs of one side, and equal tension in the two legs of the other side. The shear forces are resisted by the horizontal component of the leg forces and the brace forces (thus, the leg taper has a significant influence on the design of the bracing).
c. torsional moments broadly produce shear forces in the tower body faces, i.e. in the braces.
A classical analysis assuming hinges in all nodes leads to very simple calculations. However, the effect of redundancies should be considered, especially concerning the forces and moments in the brace members.
Although this approach is satisfactory in most cases attention must be drawn to the function of redundant members, which in some cases may change the load distribution considerably. In addition, the effect of fixed connections (as opposed to hinged connections) must be considered, since they produce moments in the bracing members. The effect of eccentricities in the joints should also be taken into account, see Section 2.7.
Finally, the distribution of an eccentric horizontal load is studied. In Figure 9 the force H is acting at the cross arm bottom level. Without horizontal bracing in the tower, three tower body planes are affected by H. The deflections of the plane lattice structures of the tower body deform the rectangle ABCD to a parallelogram A¢ B¢ C¢ D¢ . By adding member AC or BD this deformation is restricted and all four tower body planes participate in resisting the force H.

2.7 Detailing of Joints

The detailed design is governed by a number of factors influencing the structural costs once the overall design has been chosen, such as:
  • simple and uniform design of connections.
  • simple shaping of structural components.
  • details allowing for easy transportation and erection.
  • details allowing for proper corrosion protection.
As an introductory example of design and calculation, a segment of a four-legged tower body is discussed, see Figure 10. All members are made of angle sections with equal legs. The connections are all bolted without the use of gussets, except for a spacer plate at the cross bracing interconnection. This very simple design requiring a minimum of manufacturing work is attained by the choice and orientation of the leg and brace member sections.
By choosing the design described above, some structural eccentricities have to be accepted. They arise from the fact that the axes of gravity of the truss members do not intersect at the theoretical nodes. According to the bending caused by the eccentricities they may be classified as in-plane or out-of-plane eccentricities. In Figure 11, the brace forces C and T meet at a distance eo from the axis of gravity. The resultant force DS produces two bending moments: Me = DS´ eo and Mf=DS´ e1. These moments are distributed among the members meeting at the joint according to their flexural stiffness, usually leaving the major part to the leg members. As z-z is the 'strong' axis of the leg section, a resultant moment vector along axis v-v will be advantageous. This is achieved, when eo=-e1¢ . In this case C and T intersect approximately at the middle of the leg of the section. Usually this situation is not fully practicable without adding a gusset plate to the joint.
Additional eccentricity problems occur when the bolts are not placed on the axis of gravity, especially when only one bolt is used in the connection (eccentricities ec and et).
The out-of-plane eccentricity causing a torsional moment, V = H´ e2, acting on the leg may be measured between the axes of gravity for the brace members (see Figure 11). However, the torsional stiffness of the leg member may be so moderate - depending on its support conditions - that V cannot be transferred by the leg and, consequently, e2 must diminish. The latter causes bending out-of-plane in the brace members.
The leg joint shown in Figure 10 is a splice joint in which an eccentricity e3 may occur. In this case there is a change of leg section, or the gravity axis for the four (or two) splice plates in common does not coincide with the axis of the leg(s). For legs in compression the joint must be designed with some flexural rigidity to prevent unwanted action as a hinge.
The joint eccentricities have to be carefully considered in the design. As the lower part of the leg usually is somewhat oversized at the joint - this is, in fact, the reason for changing leg section at the joint - a suitable model would be to consider the upper part of the leg centrally loaded and thus, let the lower part resist the eccentricity moment. The splice plates and the bolt connections must then be designed in accordance with this model.
The bolted connections might easily be replaced by welded connections with no major changes of the design. However, except for small structures, bolted connections are generally preferred, as they offer the opportunity to assemble the structural parts without damaging the corrosion protection, see Section 2.8.
This introductory example is very typical of the design with angle sections. Nevertheless some additional comments should be added concerning the use of gussets and multiple angle sections.
The use of gussets is shown in Figure 12. They provide better space for the bolts, which may eliminate the in-plane eccentricities, and they allow for the use of double angle sections. In the latter case out-of-plane eccentricities almost vanish.
For heavily loaded towers it might be suitable to choose double or even quadruple angle sections for the legs. Figure 13 shows some possibilities.
Towers designed with other profiles than angles
In principle any of the commercially available sections could be used. However, they have to compete with the angle sections as regards the variety of sections available and the ease of designing and manufacturing simple connections. So far only flat bars, round bars and tubes have been used, mostly with welded connections. The use is limited to small size towers for the corrosion reasons mentioned above.
In other contexts, e.g. high rise TV towers, circular sections may be more interesting because their better shape reduces wind action.
Construction joints and erection joints
The tower structure usually has to be subdivided into smaller sections for the sake of corrosion protection, transportation and erection. Thus a number of joints which are easy to assemble on the tower site, have to be arranged. Two main problems have to be solved: the position and the detailing of the joints.
In Figure 14 two examples of the joint positions are shown. The framed structure is divided into lattice structure bodies, each of which may be fully welded, and stays. The cantilevered structure usually is subdivided into single leg and web members.
The two types of joints are lap (or splice) joints and butt plate joints. The former is very suitable for angle sections. The latter is used for all sections, but is mostly used for joints in round tube or bar sections. Figure 15 shows some examples of the two types.

2.8 Corrosion Protection

Today, corrosion protection of steel lattice towers is almost synonymous with hot-galvanising, possibly with an additional coating. The process involves dipping the structural components into a galvanic bath to apply a zinc layer, usually about 100 m m thick.
No welding should be performed after galvanizing, as it damages the protection. The maximum size of parts to be galvanized is limited by the size of the available galvanic bath.

3. CONCLUDING SUMMARY


  • The overall design of a lattice tower is very closely connected with the user's functional requirements. The requirements must be studied carefully.
  • A major part of the design loads on the tower results from the wind force on tower and equipment.
  • The occurrence of an ice cover on the tower and equipment must be considered in the design.
  • For towers supporting wires, differential loads in the wire direction must be taken into account.
  • For systems of interconnected towers it must be considered that the collapse of one tower may influence the stability of a neighbouring tower.
  • In most cases a cantilevered tower with four legs is preferred, as it offers structural advantages and occupies a relatively small ground area.
  • The type of bracing greatly affects the stability of both legs and braces. K-bracings and/or staggered cross bracings are generally found advantageous.
  • Horizontal braces at certain levels of the tower add considerably to its torsional rigidity.
  • Angle sections are widely used in towers with a square or rectangular base, as they permit very simple connection design.
  • Both in-plane and out-of-plane eccentricities in the connections must be considered.
  • A proper, long lasting corrosion protection must be provided. The protection method influences the structural design.

TESTS FOR CONCRETE QUALITY CHECKING

Tests for checking quality of concrete should be done for the following possible purposes:
1. To detect the variation of quality of concrete being supplied for a given specification.
2. To establish whether the concrete has attained a sufficient strength or concrete has set sufficiently for stripping, stressing, de-propping, opening to traffic etc.
3. To establish whether the concrete has gained sufficient strength for the intended purpose.
There are so many tests available for testing different qualities of concrete. Different tests give results for their respective quality of concrete. Thus it is not possible to conduct all the tests as it involves cost and time. Thus, it is very important to be sure about purpose of quality tests for concrete. The most important test for quality check of concrete is to detect the variation of concrete quality with the given specification and mix design during concrete mixing and placement. It will ensure that right quality of concrete is being placed at site and with checks for concrete placement in place, the quality of constructed concrete members will be as desired.
Tests For Concrete Quality Checking
Following are the lists of various tests conducted for Concrete Quality:

Tests on hardened concrete:

Tests on fresh concrete:

  • Workability Tests (slump test and others)
  • Bleeding
  • Air content
  • Setting time
  • Segregation resistance
  • Unit weight
  • Wet analysis
  • Temperature
  • Heat generation
Of these many tests for concrete quality, in practice well over 90% of all routine tests on concrete are concentrated on compression tests and slump tests. It is also desirable to conduct fresh concrete temperature and hardened concrete density determination tests.
Slump Test on Concrete
The reasons for the selection of compressive strength test and slump test in practice for quality control testing of concrete are:
1. All or most other properties of concrete are related to its compressive strength.
2. Compressive strength test is the easiest, most economical or most accurately determinable test.
3. Compressive strength testing is the best means available to determine the variability of concrete.
4. Slump tests also checks for variation of construction materials in mix, mainly water-cement ratio.
5. Slump test is easy and fast to determine quality of concrete before placement based on recommended slump values for the type of construction.
6. Slump test is most economical because it is done at site and does not require any laboratory or expensive testing machine.
7. Slump tests is done before the placement of concrete, so the quality of control is high as rejected mix can be discarded before pouring into the structural member. So, dismantling or repair of defective concrete members can be avoided.

REBOUND HAMMER TEST ON CONCRETE

Rebound hammer test (Schmidt Hammer) is used  to  provide  a  convenient  and rapid indication of the compressive strength of concrete. It consists of a spring controlled mass that slides on a plunger within a tubular housing.
The operation of rebound hammer is shown in the fig.1. When the plunger of rebound hammer is pressed against the surface of concrete, a spring controlled mass with a constant energy is made to hit concrete surface to rebound back. The extent of rebound, which is a measure of surface hardness, is measured on a graduated scale. This measured value is designated as Rebound Number (rebound index). A concrete with low strength and low stiffness will absorb more energy to yield in a lower rebound value.
Operation of the rebound hammer
Fig: Operation of the rebound hammer
The rebound hammer test method is used for the following purposes:
(a)  To find out the likely  compressive  strength  of  concrete  with  the  help  of suitable co-relations between rebound index and compressive strength.
(b)  To assess the uniformity of concrete.
(c)  To assess the quality of concrete in relation to standard requirements.
(d)  To assess the quality of one element of concrete in relation to another.
Rebound hammer test method can be used to differentiate the acceptable and questionable parts of the structure or to compare two different structure based on strength.
Principle of Rebound Hammer Test:
Rebound hammer test method is based on the principle that the rebound of an elastic mass depends on the hardness of the concrete surface against which the mass strikes. The operation of the rebound hammer is shown in figure above. When the plunger of rebound hammer is pressed against the concrete surface, the spring controlled mass in the hammer rebounds. The amount of rebound of the mass depends on the hardness of concrete surface. Thus, the hardness of concrete and rebound hammer reading can be correlated with compressive strength of concrete. The rebound  value  is  read  off  along  a  graduated  scale  and is designated  as  the rebound  number  or  rebound  index.  The  compressive  strength  can  be  read directly from the graph provided on the body of the hammer.

PROCEDURE FOR REBOUND HAMMER TEST ON CONCRETE

Procedure for rebound hammer test on concrete structure starts with calibration of the rebound hammer. For this, the rebound hammer is tested against the test anvil made of steel having Brinell hardness number of about 5000 N/mm2.
After the rebound hammer is tested for accuracy on the test anvil, the rebound hammer is held at right angles to the surface of the concrete structure for taking the readings. The test thus can be conducted horizontally on vertical surface and vertically upwards or downwards on horizontal surfaces as shown in figure below:
Rebound Hammer for Testing Concrete Compressive Strength
Rebound Hammer Positions for Test on Concrete Structure
Fig: Rebound Hammer Positions for Testing Concrete Structure
If the rebound hammer is held at intermediate angle, the rebound number will be different for the same concrete.

The following points should be observed during testing.
(a) The concrete surface should be smooth, clean and dry.
(b) Ant loose particles should be rubbed off from the concrete surface with a grinding wheel or stone, before hammer testing.
(c) Rebound hammer test should not be conducted on rough surfaces as a result of incomplete compaction, loss of grout, spalled or tooled concrete surface.
(d) The point of impact of rebound hammer on concrete surface should be at least 20mm away from edge or shape discontinuity.
Six readings of rebound number is taken at each point of testing and an average of value of the readings is taken as rebound index for the corresponding point of observation on concrete surface.
How the correlation between compressive strength of concrete and rebound number is obtained:
The most suitable method of obtaining the correlation between compressive strength of concrete and rebound number is to test the concrete cubes using compression testing machine as well as using rebound hammer simultaneously. First the rebound number of concrete cube is taken and then the compressive strength is tested on compression testing machine. The fixed load required is of the order of 7 N/ mm2when the impact energy of the hammer is about 2.2 Nm. The load should be increased for calibrating rebound hammers of greater impact energy and decreased for calibrating rebound hammers of lesser impact energy. The test specimens should be as large a mass as possible in order to minimize the size effect on the test result of a full scale structure. 150mm cube specimens are preferred for calibrating rebound hammers of lower impact energy (2.2Nm), whereas for rebound hammers of higher impact energy, for example 30 Nm, the test cubes should not be smaller than 300mm.
The concrete cube specimens should be kept at room temperature for about 24 hours after taking it out from the curing pond, before testing it with the rebound hammer. To obtain a correlation between rebound numbers and strength of wet cured and wet tested cubes, it is necessary to establish a correlation between the strength of wet tested cubes and the strength of dry tested cubes on which rebound readings are taken. A direct correlation between rebound numbers on wet cubes and the strength of wet cubes is not recommended. Only the vertical faces of the cubes as cast should be tested. At least nine readings should be taken on each of the two vertical faces accessible in the compression testing machine when using the rebound hammers. The points of impact on the specimen must not be nearer an edge than 20mm and should be not less than 20mm from each other. The same points must not be impacted more than once.
Interpretation of Rebound Hammer Test Results:
After obtaining the correlation between compressive strength and rebound number, the strength of structure can be assessed. In general, the rebound number increases as the strength increases and is also affected by a number of parameters i.e. type of cement, type of aggregate, surface condition and moisture content of the concrete, curing and age of concrete, carbonation of concrete surface etc. Moreover the rebound index is indicative of compressive strength of concrete up to a limited depth from the surface. The internal cracks, flaws etc. or heterogeneity across the cross section will not be indicated by rebound numbers.
As such the estimation of strength of concrete by rebound hammer method cannot be held to be very accurate and probable accuracy of prediction of concrete strength in a structure is ± 25 percent. If the relationship between rebound index and compressive strength can be found by tests on core samples obtained from the structure or standard specimens made with the same concrete materials and mix proportion, then the accuracy of results and confidence thereon gets greatly increased.

PREPARATION OF BAR BENDING SCHEDULE


Preparation of Bar Bending Schedule
Bar bending schedule (or schedule of bars) is a list of reinforcement bars, vis-à-vis, a given RCC work item, and is presented in a tabular form for easy visual reference. This table summarizes all the needed particulars of bars – diameter, shape of bending, length of each bent and straight portions, angles of bending, total length of each bar, and number of each type of bar. This information is a great help in preparing an estimate of quantities.
Figure 1 depicts the shape and proportions of hooks and bends in the reinforcement bars – these are standard proportions that are adhered to:
(a) Length of one hook = (4d ) + [(4d+ d )] – where, (4d+ d ) refers to the curved portion = 9d.
(b) The additional length (la) that is introduced in the simple, straight end-to-end length of a reinforcement bar due to being bent up at  say 30o to 60o, but it is generally 45o) = l1 – l2 = la
Where,
Hooks and bends in reinforcement
Fig: Hooks and bends in Reinforcement
Giving different values to clip_image005 respectively), we get different values of la, as tabulated below:
length of bent up bars
Figure 2 presents the procedure to arrive at the length of hooks and the total length of a given steel reinforcement.
Typical Bar Bending Schedule
Fig: Typical Bar Bending Schedule

CALCULATE QUANTITIES OF MATERIALS FOR CONCRETE

Quantities of materials for the production of required quantity of concrete of given mix proportions can be calculated by absolute volume method. This method is based on the principle that the volume of fully compacted concrete is equal to the absolute volume of all the materials of concrete, i.e. cement, sand, coarse aggregates and water.
concrete-materials-calculation-for-any-volume
The formula for calculation of materials for required volume of concrete is given by:
quantities-of-mateirals-for-concrete-formula
Where, Vc = Absolute volume of fully compacted fresh concrete
W =Mass of water
C = Mass of cement
Fa = Mass of fine aggregates
Ca = Mass of coarse aggregates
Sc, Sfa and Sca are the specific gravities of cement, fine aggregates and coarse aggregates respectively.
The air content has been ignored in this calculation.
This method of calculation for quantities of materials for concrete takes into account the mix proportions from design mix or nominal mixes for structural strength and durability requirement.
Now we will learn the material calculation by an example.
Consider concrete with mix proportion of 1:1.5:3 where, 1 is part of cement, 1.5 is part of fine aggregates and 3 is part of coarse aggregates of maximum size of 20mm. The water cement ratio required for mixing of concrete is taken as 0.45.
Assuming bulk densities of materials as follows:
Cement = 1500 kg/m3
Sand = 1700 kg/m3
Coarse aggregates = 1650 kg/m3
Specific gravities of concrete materials are as follows:
Cement = 3.15
Sand = 2.6
Coarse aggregates = 2.6.
The percentage of entrained air assumed is 2%.
The mix proportion of 1:1.5:3 by dry volume of materials can be expressed in terms of masses as:
Cement = 1 x 1500 = 1500
Sand = 1.5 x 1700 = 2550
Coarse aggregate = 3 x 1650 = 4950.
Therefore, the ratio of masses of these materials w.r.t. cement will as follows =
Ratio of masses of cement, sand and coarse aggregates
= 1 : 1.7 : 3.3
The water cement ratio = 0.45
Now we will calculate the volume of concrete that can be produced with one bag of cement (i.e. 50 kg cement) for the mass proportions of concrete materials.
Thus, the absolute volume of concrete for 50 kg of cement =
Volume of concrete for 1 bag of cement
Thus, for the proportion of mix considered, with on3 bag of cement of 50 kg, 0.1345 m3 of concrete can be produced.
We have considered an entrained air of 2%. Thus the actual volume of concrete for 1 cubic meter of compacted concrete construction will be = 1 -0.02 = 0.98 m3.
Thus, the quantity of cement required for 1 cubic meter of concrete = 0.98/0.1345 = 7.29 bags of cement.
The quantities of materials for 1 m3 of concrete production can be calculated as follows:
The weight of cement required = 7.29 x 50 = 364.5 kg.
Weight of fine aggregate (sand) = 1.5 x 364.5 = 546.75 kg.
Weight of coarse aggregate = 3 x 364.5 = 1093.5 kg.

COMPRESSIVE STRENGTH OF CONCRETE CUBES

Compressive strength of concrete: Out of many test applied to the concrete, this is the utmost important which gives an idea about all the characteristics of concrete. By this single test one judge that whether Concreting has been done properly or not.
For cube test two types of specimens either cubes of 15 cm X 15 cm X 15 cm or 10cm X 10 cm x 10 cm depending upon the size of aggregate are used. For most of the works cubical moulds of size 15 cm x 15cm x 15 cm are commonly used.
Dimension, tolerance and materials of 150 mm cube mould.
S.No.
Description
Requirements
1
Distance between opposite faces, mm
150 ± 0.2
2
Height of mould, mm
150 ± 0.2
3
Thickness of wall plate, mm
8
4
Angle between adjacent interior faces and between interior faces and top and bottom plates of mould.
90 ± 0.50
5
Length of base plate, mm
280
6
Width of base plate, mm
215
7
Thickness of base plate, mm
8
8
Permissible variation in the planeness of interior faces:
for new moulds, mm
for moulds in use, mm
0.03
0.05
9
Permissible variation in the planeness of base plate, mm
0.03
10
materials
a)   Side plate
b)   Base plate
Cast iron
Cast iron
TAMPING ROD
As per IS:10086-1982, the tamping rod shall be 16±0.5 mm dia and 600±2 mm long with a rounded working end and shall be made of mild steel.
Note:- For aggregates larger than 38 mm, bigger than 150 mm moulds are to be used. See IS:10086-1982
CASTING OF CUBES:
The cube mould plates should be removed, properly cleaned assembled and all the bolts should be fully tight. A thin layer of oil then shall be applied on all the faces of the mould. It is important that cube side faces must be parallel.
After taking concrete samples and mixing them, the cubes shall be cast as soon as possible. The concrete sample shall be filled into the cube moulds in layers approximately 5 cm deep. In placing each scoopful of concrete, the scoop shall be moved around the top edge of the mould as the concrete slides from it, in order to ensure a symmetrical distribution of the concrete with in the mould. Each layer shall be compacted either by hand or by the vibration as described below.
COMPACTION BY HAND:
Each layer of the concrete filled in the mould shall be compacted by not less than 35 strokes by tamping bar. The strokes shall be penetrate into the underlying layer and the bottom layer shall be rodded throught its depth. Where voids are left by the tamping bar the sides of the mould shall be tapped to close the voids.
COMPACTION BY VIBRATION:
When compacting by vibration each layer shall be vibrated by means of an electric or pneumatic hammer or vibrator or by means of a suitable vibrating table until the specified condition is attained.
CURING :
The casted cubes shall be stored under shed at a place free from the vibration at a temperature 220C to 330C for 24 hours covered with wet straw or gunny sacking.
The cube shall be removed from the moulds at the end of 24 hours and immersed in clean water at a temperature 240C to 300C till the 7 or 28-days age of testing. The cubes shall be tested in the saturated and surface dry condition.
For the true representation of actual strength of concrete in the structure, extra cubes shall be cast, stored and curded as per the identical conditions of that structure, and tested at required age.
concrete cubesconcrete cube mould
This concrete is poured in the mould and tempered properly so as not to have any voids. After 24 hours these moulds are removed and test specimens are put in water for curing. The top surface of these specimen should be made even and smooth. This is done by putting cement paste and spreading smoothly on whole area of specimen.
These specimens are tested by compression testing machine after 7 days curing or 28 days curing. Load should be applied gradually at the rate of 140 kg/cm2 per minute till the Specimens fails. Load at the failure divided by area of specimen gives the compressive strength of concrete.
compressive-strength-test-on-concrete-cubes

Following are the procedure for Compressive strength test of Concrete Cubes

APPARATUS
Compression testing machine
PREPARATION OF CUBE SPECIMENS
The proportion and material for making these test specimens are from the same concrete used in the field.
SPECIMEN
6 cubes of 15 cm size Mix. M15 or above
MIXING
Mix the concrete either by hand or in a laboratory batch mixer
HAND MIXING
(i)Mix the cement and fine aggregate on a water tight none-absorbent platform until the mixture is thoroughly blended and is of uniform color
(ii)Add the coarse aggregate and mix with cement and fine aggregate until the coarse aggregate is uniformly distributed throughout the batch
(iii)Add water and mix it until the concrete appears to be homogeneous and of the desired consistency
SAMPLING
(i) Clean the mounds and apply oil
(ii) Fill the concrete in the molds in layers approximately 5cm thick
(iii) Compact each layer with not less than 35strokes per layer using a tamping rod (steel bar 16mm diameter and 60cm long, bullet pointed at lower end)
(iv) Level the top surface and smoothen it with a trowel
CURING
The test specimens are stored in moist air for 24hours and after this period the specimens are marked and removed from the molds and kept submerged in clear fresh water until taken out prior to test.
PRECAUTIONS
The water for curing should be tested every 7days and the temperature of water must be at 27+-2oC.
PROCEDURE
(I) Remove the specimen from water after specified curing time and wipe out excess water from the surface.
(II) Take the dimension of the specimen to the nearest 0.2m
(III) Clean the bearing surface of the testing machine
(IV) Place the specimen in the machine in such a manner that the load shall be applied to the opposite sides of the cube cast.
(V) Align the specimen centrally on the base plate of the machine.
(VI) Rotate the movable portion gently by hand so that it touches the top surface of the specimen.
(VII) Apply the load gradually without shock and continuously at the rate of 140kg/cm2/minute till the specimen fails
(VIII) Record the maximum load and note any unusual features in the type of failure.

NOTE

Minimum three specimens should be tested at each selected age. If strength of any specimen varies by more than 15 per cent of average strength, results of such specimen should be rejected. Average of there specimens gives the crushing strength of concrete. The strength requirements of concrete.

CALCULATIONS
Size of the cube =15cm x15cm x15cm
Area of the specimen (calculated from the mean size of the specimen )=225cm2
Characteristic compressive strength(f ck)at 7 days =
Expected maximum load =fck x area x f.s
Range to be selected is …………………..
Similar calculation should be done for 28 day compressive strength
Maximum load applied =……….tones = ………….N
Compressive strength = (Load in N/ Area in mm2)=……………N/mm2
=……………………….N/mm2
REPORT
a) Identification mark
b) Date of test
c) Age of specimen
d) Curing conditions, including date of manufacture of specimen
f) Appearance of fractured faces of concrete and the type of fracture if they are unusual
RESULT
Average compressive strength of the concrete cube = ………….N/ mm2 (at 7 days)
Average compressive strength of the concrete cube =………. N/mm2 (at 28 days)

Percentage strength of concrete at various ages:

The strength of concrete increases with age. Table shows the strength of concrete at different ages in comparison with the strength at 28 days after casting.
Age
Strength per cent
1 day
16%
3 days
40%
7 days
65%
14 days
90%
28 days
99%

Compressive strength of different grades of concrete at 7 and 28 days

Grade of Concrete
Minimum compressive strength N/mm2 at 7 days
Specified characteristic compressive strength (N/mm2) at 28 days
M15
10
15
M20
13.5
20
M25
17
25
M30
20
30
M35
23.5
35
M40
27
40
M45
30
45