sika haki debindo 2019 file4/6/2019 · perkembanganadmixture beton 3 developments in pce...
TRANSCRIPT
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MISHRA SYAUKANI, ST - IR HARTONO HIOE
PT. SIKA INDONESIA
PERKEMBANGAN TEKNOLOGI MATERIAL UNTUKMENDUKUNG PENINGKATAN KINERJA ELEMEN DANSTRUKTUR BANGUNAN
PERKEMBANGAN ADMIXTURE BETON
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DEVELOPMENTS IN PCE SUPERPLASTICIZERSCONCERN IN CONCRETE
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DEVELOPMENTS IN PCE SUPERPLASTICIZERSCONCERN IN CONCRETE – LONG TERM
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DEVELOPMENTS IN PCE SUPERPLASTICIZERSCONCERN IN CONCRETE – EARLY STRENGTH CAPACITY
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DEVELOPMENTS IN PCE SUPERPLASTICIZERSBEBERAPA PENYEBAB KEGAGALAN PEKERJAAN BETON
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DEVELOPMENTS IN PCE SUPERPLASTICIZERSEFEK KEGAGALAN PEKERJAAN BETON
Bagian2 bangunan
yang sering terjadi kegagalan betonKerusakan awal pada beton
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Beberapa Tantangan dan situasi yang umum terjadi pada adukan beton
Type Semen yang bervariasi
Kondisi Fly Ash yang tidak konsisten
Slump Loss Beton yang tinggi
Kebutuhan slump retensi yang panjang (extended slump requirement)
Penambahan admixture di lapangan untuk menaikkan slump kembali
Issue tentang setting time beton (long setting dan flash setting)
Kemudahan adukan beton untuk dipompa
Perkembangan Kuat tekan umur beton
DEVELOPMENTS IN PCE SUPERPLASTICIZERSCONCERN IN CONCRETE
APAKAH ITU BETON??
0.5%
70%
18%
9%2.5% Aggregat
Semen
Additif
Air
Admixtures
Aggregat berpengaruh
pada klasifikasi:
- 0/≤4 mm Agg. Halus
- 0/>4 mm Agg. Kasar
Semen mempengaruhi
kuat tekan dari beton:
Additif mempengaruhi
durabilitas dari beton:
Air mempengaruhi
density dari beton:
Admixtures mengontrol
workabilitas dan durabilitas :
Beton adalah sistem
yg terdiri dari 5 komponen OBAT BETON - ADMIXTURE
Obat beton adalah cairan kimia ataupun powder
yang dicampurkan ke dalam adukan beton untuk
dapat mengubah karakter adukan beton
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+ + + +
Obat Beton
“admixture”
OBAT BETON - ADMIXTURE
• Type A Water-reducing admixtures
• Type B Retarding admixtures
• Type C Accelerating admixtures
• Type D Water-reducing & retarding admixtures
• Type E Water-reducing & accelerating admixtures
• Type F Water-reducing, high range admixtures
• Type G Water-reducing, high range & retarding admixtures
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What do we need for such kind of concrete?
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0,0%
5,0%
10,0%
15,0%
20,0%
25,0%
0 0,2% 0,4% 0,6% 0,8% 1,0% 1,2% 1,4% 1,6% 1,8%
Dosage
Wa
ter
red
uc
tio
n %
Ra
ng
e o
f P
lasti
ciz
er
Ra
ng
e o
f S
up
erp
lasti
ciz
er
Concrete Technology- AdmixturesDefinition- plasticizer and superplasticizer
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Quality I
Watertight ConcreteBasement & all Infrastructure
Elasticity
w/c and binder concept
Corrosion Resistant ConcreteHarbor all structures seaside
Steel surface protection
w/c and binder concept
Frost & Freeze / Thaw
Resistant ConcreteBridge Retaining Wall
Expansion pores
w/c
Sulfate Resistant ConcreteTunneling
Binder concept
w/c
Fire Resistant ConcreteRailway Station Underground structure
Expansion Capillary
Mix Design (CEM / Aggreg.)
DEVELOPMENTS IN PCE SUPERPLASTICIZERSCONCRETE REQUIREMENTS
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Quality II
DEVELOPMENTS IN PCE SUPERPLASTICIZERSCONCRETE REQUIREMENTS
Alkali-Silica-Reaction Resistant
ConcreteAirstrip / Highway
Aggregate concept
Mix design & binder concept
Abrasion Resistant ConcreteDischarge unit of a dam Gen. Hydro
Power
Surface hardness
Mix design (aggregates)
w/c
Chemical Resistant ConcreteWaste water treatment
Surface protection
w/c and binder
High Strength ConcretePile High rise building
w/c
Binder content and concept
Shrinkage Controlled ConcreteAll types of high durable concrete
w/c
Shrinkage reducer
Binder content and concept
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Quality III
DEVELOPMENTS IN PCE SUPERPLASTICIZERSLIMITS OF WATER REDUCTION
High
Low
Qu
ali
ty /
Du
rab
ilit
y
Good
Bad
Pra
ctic
al /
Fea
sib
le
Influencing:
- Quality of Binder
- Knowledge of people
- Quality control concept
- ..
Influencing:
Quality of local aggregates -
Local conditions (temp./…) -
Experiences of worker -
On site supervision -
0,20 0,30 0,40 0,50 0,60 0,70
Water / Binder - ratio
Achievable concrete quality
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Quality III
DEVELOPMENTS IN PCE SUPERPLASTICIZERSLIMITS OF WATER REDUCTION
High
Low
Qu
ali
ty /
Du
rab
ilit
y
Good
Bad
Pra
ctic
al /
Fea
sib
le
0,20 0,30 0,40 0,50 0,60 0,70
Water / Binder - ratio
Achievable concrete qualitySummary IV
DEVELOPMENTS IN PCE SUPERPLASTICIZERSLIMITS OF WATER REDUCTION
Required
w/c ratio
Therefore min.
Water content
Cement content
to achieve
Comments
0.50approx.
140 l/m3≥ 280 kg/m3
Workability must be ensured
Example:
Pumped concrete: Total ≤ 0.125mm: ≥ 400 kg/m3
Self-compacting concrete : Total ≤ 0.125mm: ≥ 500 kg/m3
0.40approx.
140 l/m3≥ 350 kg/m3
It must be possible to achieve the required softness
(liquefaction) with water reducers (HRWR)
0.30approx.
140 l/m3≥ 450 kg/m3
Shrinkage may not over-compensate for the benefits of the
low W/C, Example:
Cement content 500 kg/m3: →Ɛcs (182d): 0.55‰
Cement content 250 kg/m3: →Ɛcs (182d): 0.30‰
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DEVELOPMENTS IN PCE SUPERPLASTICIZERSPASTE VOLUME OPTIMIZATION
Concrete with different paste quality will have different mechanical strengths.
W/C=0.75 W/C=0.65 W/C=0.55 W/C=0.45
350 kg/m3 350 kg/m3 350 kg/m3 350 kg/m3
15 N/mm2 25 N/mm2 35 N/mm2 45 N/mm2
But concrete with different paste volume but same paste quality we will have “same” mechanical strengths.
W/C=0.65 W/C=0.65 W/C=0.65 W/C=0.65
1034 kg/m3 600 kg/m3 350 kg/m3 200 kg/m3
25 N/mm2 25 N/mm2 25 N/mm2 25 N/mm2
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Definition paste volume
“Crane & Bucket” Concrete280 kg/m3 / w/c= 0.58 / 30% Sand with 10% fines (≤ 0.125mm)
Cement paste 251 liter
Fine paste 273 liter
Pumped Concrete340 kg/m3 / w/c= 0.50 / 40% Sand with 10% fines (≤ 0.125mm)
Cement paste 278 liter
Fine paste 306 liter
Self Compacting Concrete420 kg/m3 / w/c= 0.42 / 50% Sand with 10% fines (≤ 0.125mm)
Cement paste 310 liter
Fine paste 343 liter
→ 250l to 280l fine paste
→ 280l to 320l fine paste
→ 320l to 380l fine paste
DEVELOPMENTS IN PCE SUPERPLASTICIZERSPASTE VOLUME OPTIMIZATION
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DEVELOPMENTS IN PCE SUPERPLASTICIZERSPASTE VOLUME OPTIMIZATION
Definition paste volume
Lignosulphonates
hig
hWorkability Early strength development
wa
ter
red
uct
ion
low
Melaminesulphonates
Naphthalenesulphonates
Polycarboxylate
DEVELOPMENT IN PCE SUPERPLASTICIZERPCE TECHNOLOGY
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Key Requirements
1st Priority
Water Reduction
Slump Retention
Setting Time
costs
1st Priority as well!
Stability
Robustness
Smoothness
…
DEVELOPMENTS IN PCE SUPERPLASTICIZERSPCE TECHNOLOGY
Water
CH / Ligno
SNF / SMF
PCE
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Ligno Sulphonates
Carbohydrates
Naphthalenes
Melamines
PCE
Vinyl Copolymers
• electrostatic inter particle repulsion
• reduced surface tension
• retarding
• water reduction up to 10%
• electrostatic inter particle repulsion
• better setting behavior
• water reduction up to 20%
• electrostatic inter particle repulsion
• water reduction up to 25%
• electrostatic inter particle repulsion
• steric hindrance
• water reduction up to 40%
DEVELOPMENTS IN PCE SUPERPLASTICIZERSPCE TECHNOLOGY
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PCE Technology
Polycarboxyl-ether (PCE) are basically built by the following:
carboxyl groups:
determine the absorption behavior
backbone:
determine the water reduction and the workability
side chains:
determine the water reduction and the workability
DEVELOPMENTS IN PCE SUPERPLASTICIZERSPCE TECHNOLOGY
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DEVELOPMENTS IN PCE SUPERPLASTICIZERSPCE TECHNOLOGY
Major action mode
Water reduction type PCE’s
Slump retention type PCE’s
Slump controlling type PCE’s
Combinations out of it
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HIGH EARLY STRENGTH
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CONCRETE ADMIXTURE SOLUTIONPCE TECHNOLOGY – BETON KERAS DALAM HITUNGAN JAM
CONCRETE ADMIXTURE SOLUTIONMODE OF ACTION - WATER REDUCER PCE
time
slu
mp
0 5 10 20 30 40 50
CONCRETE ADMIXTURE SOLUTIONMODE OF ACTION - WATER REDUCER PCE
Water Reducers PCE, memiliki karakter pengurangan air yang tinggi
Water reducers PCE, cenderung memiliki slump retensi yang pendek
Water reducers PCE, dapat menghasilkan beton flow tinggi
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Slu
mp
Time
- 25% Water reduction- 90 menit - slump retention
WR
Time
Slump keeper
WR
Water reducer
WR
Time
Slump controller
Time
Target :
Beton High Early Strength
dengan retensi slump hingga 90 menit
Salt & Pepper
Polymer performanceContoh Profil Produk Admixture
CONCRETE ADMIXTURE SOLUTIONPCE TECHNOLOGY – KOMBINASI BEBERAPA TYPE PCE
- Kuat tekan awal tinggi sehingga Proses Steam Curing bisa dihilangkan
- Beton flow tinggi sehingga tidak memerlukan vibrasi
- Pembukaan cetakan lebih cepat, sehingga meningkatkan produktivitas
CASE STUDY 1 - HIGH EARLY STRENGTH
PRECAST - FRANCE
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0
100
200
300
400
500
600
5h 6h 7h 1d 3d 7d 14d 28d
PNS base
PCE base
HIGH EARLY STRENGTH
Demoulding time
accelerated by approx. 2
hours
Concrete casting cycle time
improved to 3 x times a day
Higher ultimate strength
PRECAST - INDONESIA
CASE STUDY 2 - HIGH EARLY STRENGTH
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SLUMP RETENTION
CONCRETE ADMIXTURE SOLUTIONSLUMP RETENTION
2 Different Actions:
Adsorption of the polymer
(backbone) on the cement
grain
Improved workability (side
chain) due to steric hindrance
CONCRETE ADMIXTURE SOLUTIONMODE OF ACTION – SLUMP RETENTION
Mode of action:
time
slu
mp
0 5 20 40 80 100 120
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CONCRETE ADMIXTURE SOLUTIONMODE OF ACTION – SLUMP RETENTION
Slump retention PCE, mampu memperpanjang slump retensi beton
Initial slump cenderung lebih kecil dibandingkan type PCE water reducers
Slump retention PCE, tidak menyebabkan tertundanya pengerasanbeton
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Slu
mp
Time
- 20% Water reduction- 180 menit - slump retention
WR
Time
Slump retention
WR
Water reducer
WR
Time
Slump controller
Time
Target :
Beton High Slump
dengan retensi slump 3 jam lebih
Salt & Pepper
Polymer performanceContoh Profil Produk Admixture
CONCRETE ADMIXTURE SOLUTIONPCE TECHNOLOGY – KOMBINASI BEBERAPA TYPE PCE
Hermitage Plaza Paris France
2 High Rise Buildings: 323m height / 93 floors
9 hours slump retention
High 1 day strength / final strength
CASE STUDY 1 - SLUMP RETENTION
Long pumping distances
Shanghai Financial Tower - China
Mass Foundation Concreting
28000 m3 , continuous placing in 40 hours
Fresh concrete – no bleeding no segregation
Initial slump 20 cm After 2-hours, min. slump 18 cm
CASE STUDY 2 - SLUMP RETENTION
Bored Pile Concrete - Indonesia
Travel time approx. 1 hours
6 hours slump retention – 20 ± 2 cm
Concrete setting time 24 – 28 hours
Fresh concrete – no bleeding /segregation
Initial slump 20 cm After 6-hours, slump 18 cm
CASE STUDY 3 - SLUMP RETENTION
PENINGKATAN KINERJA PENANGANANKERUSAKAN STRUKTUR BETON
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PENYEBAB KERUSAKAN
• KESALAHAN PERENCANAAN
• KESALAHAN PEMILIHAN MATERIAL
• KESALAHAN PELAKSANAAN
• PENGARUH LUAR
KESALAHAN PELAKSANAAN
PENGARUH LUARTahapan Penanganan Kerusakan :
dilakukan oleh pihak yang
kompeten dan profesional
INVESTIGASI
EVALUASI
PELAKSANAAN
DOWNGRADE
PERBAIKAN
PERKUATAN
BONGKAR
MASA LAYAN
KEBUTUHAN STRUKTUR
URGENSI
KESELAMATAN UMUM
BATASAN-BATASAN :
WAKTU
BIAYA
KEINDAHAN
KEMUDAHAN
PELAKSANAAN
INVESTIGASI
• LOKASI DAN BESARNYA KERUSAKAN
• DATA-DATA STRUKTUR
• KONDISI LINGKUNGAN
• GAMBARAN DARI LOKASI STRUKTUR
PENGAMATAN VISUAL
DOKUMENTASI
TESTING
TESTING
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TESTINGSNI ASTM C805:2012
Metode uji angka pantul beton kerasPengujian dilaksanakan untuk menyelidiki secara cepat suatu area
yang luas dari struktur yang terbuat dari beton, akan tetapi tidak
dimaksudkan sebagai alternatif untuk menetapkan kekuatan beton.
SNI ASTM C597:2012 Metode uji kecepatan rambat gelombang melalui beton
Metode uji ini dimaksudkan sebagai acuan dan pegangan dalam
pengujian kecepatan rambat gelombang melalui beton. Adapun
tujuannya adalah untuk mengetahui keseragaman dan mutu beton
relatif, mengindikasi adanya lubang atau retak pada beton dan untuk
evaluasi agar dapat dilakukan perbaikan retak secara efektif.
TESTINGSNI 2847:2013
Persyaratan beton structural untuk gedung
PERBAIKAN PERBAIKANREPAIR APPLICATION PROCEDURE – ACISurface Repair Using Form-and-Pour Techniques (ACI RAP-4)
- What is the purpose of this repair?
- When do I use this technique?
- How do I prepare the surface?
- How do I select the proper repair material?
- What equipment do I need?
- What are the safety considerations?
- Repair procedure
- How do I check the repairs?
PERKUATAN PERKUATAN - FRP ACI 440.2R-17
Guide for the design and construction of externally bonded
FRP systems for strengthening concrete structures
Regangan Design :
Lentur : εfd = 0.41 ≤ 0.9 εfu (NSM : εfd = 0.7 εfu)Geser : Complete wrap : εfe = 0.004 ≤ 0.75 εfu
U wrap and 2 sides : εfe = κv εfu ≤ 0.004
Confinement : Axial murni : εfe = κε εfu (κε = 0.55)
Kombinasi Axial-Momen : εfe = 0.004 ≤ κε εfu (κε = 0.55)
Partial factor reduksi (ψf) :
Lentur : 0.85
Geser : Complete wrap - 0.95
U wrap and 2 sides - 0.85
Confinement : 0.95
εfu = CE εfu*CE : Reduksi Faktor akibat LIngkunan
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THANK YOU FOR YOUR ATTENTION