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arkable trait of concrete: it's plastic and malleable when newly mixed, strong and durable
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BASE MATERIAL
CONCRETE
Wej-it Fastening Systems
Technical Manual
Note: the information and data contained herein was current as of November 2008.
However, the material is subject to change and is updated as needed.
In its simplest form, concrete is a mixture of paste and aggregates. The paste, composed of Portland cement and water, coats
the surface of the fine and coarse aggregates. Through a chemical reaction called hydration, the paste hardens and gains
strength to form the rock-like mass known as concrete.
Within this process lies the key to a rem
when hardened. These qualities explain why one material, concrete, can build skyscrapers, bridges, sidewalks, superhighways,
houses and dams.
Proportioning
The key to achieving a strong, durable concrete rests in the careful proportioning and mixing of the ingredients. A concrete
mixture that does not have enough paste to fill all the voids between the aggregates will be difficult to place and will produce
rough, honeycombed surfaces and porous concrete. A mixture with an excess of cement paste will be easy to place and will
produce a smooth surface; however, the resulting concrete is likely to shrink more and be uneconomical.
A properly designed concrete mixture will possess the desired workability for the fresh concrete and the required durability and
strength for the hardened concrete. Typically, a mix is about 10 to 15 percent cement, 60 to 75 percent aggregate and 15 to 20
percent water. Entrained air in many concrete mixes may also take up another 5 to 8 percent.
Portland cement's chemistry comes to life in the presence of water. Cement and water form a paste that
coats each particle of stone and sand. Through a chemical reaction called hydration, the cement paste
hardens and gains strength. The character of the concrete is determined by the quality of the paste. The
strength of the paste, in turn, depends on the ratio of water to cement. The water-cement ratio is the
weight of the mixing water divided by the weight of the cement. High-quality concrete is produced by
lowering the water-cement ratio as much as possible without sacrificing the workability of fresh concrete.
Generally, using less water produces a higher quality concrete provided the concrete is properly placed,
consolidated, and cured.
Other Ingredients
Although most drinking water is suitable for use in concrete, aggregates are chosen carefully. Aggregates comprise 60 to 75
percent of the total volume of concrete. The type and size of the aggregate mixture depends on the thickness and purpose of the
final concrete product. Almost any natural water that is drinkable and has no pronounced taste or odor may be used as mixing
water for concrete. However, some waters that are not fit for drinking may be suitable for concrete.
Excessive impurities in mixing water not only may affect setting time and concrete strength, but also may cause efflorescence,
staining, corrosion of reinforcement, volume instability, and reduced durability. Specifications usually set limits on chlorides,
sulfates, alkalis, and solids in mixing water unless tests can be performed to determine the effect the impurity has on various
properties. Relatively thin building sections call for small coarse aggregate, though aggregates up to six inches (150 mm) in
diameter have been used in large dams. A continuous gradation of particle sizes is desirable for efficient use of the paste. In
addition, aggregates should be clean and free from any matter that might affect the quality of the concrete.
Hydration Begins
ic
based materials represent products that defy the label of "concrete," yet
The aggregate used in
ranges from 100 to
Soon after the aggregates, water, and the cement are combined, the mixture starts to harden. All portland cements are hydraul
cements that set and harden through a chemical reaction with water. During this reaction, called hydration, a node forms on the
surface of each cement particle. The node grows and expands until it links up with nodes from other cement particles or adheres
to adjacent aggregates.
The building up process results in progressive stiffening, hardening, and strength development. Once the concrete is thoroughly
mixed and workable it should be placed in forms before the mixture becomes too stiff.
During placement, the concrete is consolidated to compact it within the forms and to eliminate potential flaws, such as
honeycombs and air pockets. For slabs, concrete is left to stand until the surface moisture film disappears. After the film
disappears from the surface, a wood or metal hand float is used to smooth off the concrete. Floating produces a relatively even,
but slightly rough, texture that has good slip resistance and is frequently used as a final finish for exterior slabs. If a smooth,
hard, dense surface is required, floating is followed by steel troweling.
Curing begins after the exposed surfaces of the concrete has hardened sufficiently to resist marring.
Curing ensures the continued hydration of the cement and the strength gain of the concrete. Concrete
surfaces are cured by sprinkling with water fog, or by using moisture-retaining fabrics such as burlap or
cotton mats. Other curing methods prevent evaporation of the water by sealing the surface with plastic or
special sprays (curing compounds).
Special techniques are used for curing concrete during extremely cold or hot weather to protect the
concrete. The longer the concrete is kept moist, the stronger and more durable it will become. The rate of
hardening depends upon the composition and fineness of the cement, the mix proportions, and the
moisture and temperature conditions. Most of the hydration and strength gain take place within the first
month of concrete's life cycle, but hydration continues at a slower rate for many years. Concrete continues
to get stronger as it gets older.
The Forms of Concrete
Concrete is produced in four basic forms, each with unique applications and properties. Ready mixed concrete, by far the most
common form, accounts for nearly three-fourths of all concrete. It's batched at local plants for delivery in the familiar trucks with
revolving drums. Precast concrete products are cast in a factory setting. These products benefit from tight quality control
achievable at a production plant. Precast products range from concrete bricks, paving stones, bridge girders, to structural
components and panels for cladding.
Concrete masonry, another type of manufactured concrete, may be best known for its conventional 8 x 8 x 16-inch block.
Today's masonry units can be molded into a wealth of shapes, configurations, colors, and textures to serve an infinite spectrum
of building applications and architectural needs. Cementshare many of its qualities. Conventional materials in this category include mortar, grout, and terrazzo. Soil-cement and rollercompacted concrete-"cousins" of concrete-are used for pavements and dams. Other products in this category include flowable fill
and cement-treated bases. A new generation of advanced products incorporates fibers and special aggregate to create roofing
tiles, shake shingles, lap siding, and countertops. And an emerging market is the use of cement to treat and stabilize waste.
Reinforced concrete is formed using concrete meeting a certain compressive strength combined with rebar (reinforcing steel).
The function of the concrete is to resist compressive forces while the rebar resists tensile forces. The design and construction
requirements for reinforced concrete buildings are published by the American Concrete Institute (ACI) in document ACI 318,
Building Code Requirements for Structural Concrete. The type of concrete that is used is based upon the requirements of the
structure into which the concrete will be placed. In ASTM 150 (American Society for Testing and Materials) you will find the
requirements for the most commonly used Types of Portland cement. It also contains such things as Terminology, Chemical
Composition, Physical Properties, Sampling, Test Methods and Referenced Documents.
Concrete aggregate is important. Its hardness and strength will affect the life (wear) of your drill bits, drill speed and hole
configuration. ASTM C 33 is another useful document. It outlines the Standard Specification for Concrete Aggregate. Since
concrete mix designs consist of both course and fine aggregates it’s helpful to know what the acceptable limits are in terms of
size and quantity. It also contains Grading requirements for both course and fine aggregate and provides information on
Soundness, Deleterious Substances, Methods of Sampling and Testing and Referenced Documents as well.
normal weight concrete can range from 135 to 165 lb/ft3 however the unit weight for normal weight concrete generally ranges
from 145 to 155 lb/ft3.
Structural lightweight concrete is used when it is beneficial to lower the weight of the structure being built. It
115 lb/ft3 while lightweight aggregate range from 55 to 70 lb/ft3. This information is located in ASTM C 330. It has been
demonstrated that structural lightweight concrete will affect the load bearing capacities of most anchors and fasteners by
lowering their performance by as much as 40%. To determine precisely how an anchor or fastener is affected it is necessary to
conduct on site tests. An upside to structural lightweight concrete is that it provides better fire resistance than normal weight
concrete.
Another form of concrete is lightweight insulating concrete. This is used for thermal insulating and is outlined in ASTM C 332.
Be careful not to confuse it with structural lightweight concrete.
of the
While the type of admixtures, cement and aggregate have an effect on the compressive strength of the concrete, the water to
cement ratio is the primary factor affecting the strength. As the water to cement ratio decreases, the compressive strength
cement increases. In order to determine the compressive strength of concrete, test specimens are formed in cylinders according
to ASTM C 31 and crushed at specific time intervals according to ASTM C 39. The resulting strength is documented to the
nearest 10 psi increment.
Any load capacity listed in this manual is for concrete that has cured a minimum of 28 days unless otherwise noted. Job site tests
are recommended for installations in concrete where the material strength or condition is unknown. The load capacities listed in
this manual were conducted in un-reinforced concrete test members to provide data which is useable regardless of the possible
benefit of reinforcement.
Concrete Reinforcing Bar (Rebar)
In the United States, the size designations of these mild steel bars used to reinforce concrete are set by ASTM International.1
Distributors usually stock rebar in 20- and 60-foot lengths. Most bars are “deformed,” that is, a pattern is rolled onto them which
helps the concrete get a grip on the bar. The exact patterns are not specified, but the spacing, number and height of the bumps are.
Between 1947 and 1968, a separate standard (ASTM A 305) covered the deformations. Since 1968 the deformation requirements
have been incorporated in the basic standard. Plain bars are also made, but are used only in special situations in which the bars are
expected to slide (for example, crossing expansion joints in highway pavement).
Three grades are defined, with metric equivalents:
According to the standard (sec. 20.3.5), "it shall be permissible to substitute a metric size bar of Grade 280 for the
corresponding inch-pound size bar of Grade 40, a metric size bar of Grade 420 for the corresponding inch-pound size bar of Grade
60, and a metric size bar of Grade 520 for the corresponding inch-pound size bar of Grade 75." Nothing is said regarding substituting
inch-pound size bars when the specification is metric.
metric
grade
in pounds
per square inch
in
megapascals
The size designations are the number of eighths of an inch in the diameter of a plain round bar having the same weight per
foot as the deformed bar. So, for example, a number 5 bar would have the same mass per foot as a plain bar 5/8 inch in diameter.
The metric size is the same dimension expressed to the nearest millimeter.
Sizes and Dimensions
Bar
designation
number
3 0.375 10 0.376
4 0.500 13 0.668
5 0.625 16 1.043
6 0.750 19 1.502
7 0.875 22 2.044
8 1.000 25 2.670
9 1.128 29 3.400
10 1.270 32 4.303
11 1.410 36 5.313
14 1.693 43 7.650
18 2.257 57 13.60
Specifications require that the producer roll into the bar:
Nominal diameter in
inches (not including
the deformations)
Metric
designation
number
Weight in
pounds
per foot
A letter or symbol identifying the mill that produced the bar.
The bar size.
A symbol indicating the type of steel. for example, means the bar was rolled from a new billet.
If the bar is grade 60 or 75, or metric 420 or 520, a mark indicating its grade. Two styles of marking the grade are used.
o
Grade Metric grade Continuous line system
60 420
75 520
Hard versus Soft Metrification
Various laws2 require federally-funded projects to use materials with metric designations. To meet this requirement, in 1979
ASTM issued standard A 615M-79, which described a set of reinforcing bar sizes in whole number SI units. This standard was
specified in some contracts.
The cost of producing and stocking two different sets of nearly identical sizes proved onerous. In April 1995, the Concrete
Reinforcing Steel Institute and the Steel Manufacturers Association decided to mount a campaign to replace the initial hard metric
sizes with soft. In a soft conversion to metric, the original dimensions are simply restated to the nearest number of SI units. In
1996, ASTM changed A 615M to soft metric sizes. For example, a bar with the metric designation "25", formerly 25 millimeters in
diameter, became 25.4 mm in diameter, the same as a size 8 (1-inch) bar.
1 line running the length of the bar
offset at least five spaces from the center of the bar
2 lines running the length of the bar
offset at least five spaces from the center of the bar
Number system
number stamped onto bar
60 4
75 5
As a result, the metrically-sized bars are identical to the original inch-sized bars, except for the markings and a small
difference in strength (the new metric standard calls for a stronger bar, see the table below).
The grade mark for grade 420 is either a "4" or a single longitudinal grade line. The grade mark for grade 520 is either a "5"
or two longitudinal grade lines.
Type of steel mark
Mark
S billet A615 A615 A615 A615M A615M A615M
I rail A616 A616 — A996M A996M —
Applicable ASTM Standard by Grade
Meaning
40 & 50 60 75 300 & 350 420 520
IR
A axle A617 A617 — A996M A996M —
W
Rail Meeting Supplementary
Requirements S1
Low-alloy
Grades and Minimum Steel Strength
Corresponding
old US
grade
40 40,000 psi 300
60 60,000 psi 420
75 75,000 psi 520
minimum
yield strength
soft metric
A616 A616 — — — —
— A706 — — A706M —
minimum yield strength
current
grade
original
hard metric
specs
300 MPa
(43,400 psi)
400 MPa
(58,000 psi)
500 MPa
(72,500 psi)
1996
revisions
— —
420 MPa
(60,900 psi)
520 MPa
(75,400 psi)
415 MPa
(60,100 psi)
—
proposal
2. ASTM International issues a series of specifications for rebar:
A615/A615M-05a: Standard Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement. (covers grades 40 and
60/soft metric grades 420 and 520)
A616: Standard Specification for Rail-Steel Deformed Bars for Concrete Reinforcement. (covers grades 50 and 60).
A617: Standard Specification for Axle-Steel Deformed Bars for Concrete Reinforcement. (covers grades 40 and 60)
A706/A706M-96b: Standard Specification for Low-Alloy-Steel Deformed and Plain Bars for Concrete Reinforcement. (grade 60 only)
2. Metric Conversion Act of 1975; Omnibus Trade and Competitiveness Act of 1988 (Public Law 100-418, section 5164); Executive
Order 12770, "Metric Usage in Federal Government Programs."
The strengths listed in the table above are calculated based on the stresses in the following table. The allowable tension is based on
the building code ACI 318. Section 9.4 permits designs based on a yield strength of up to a maximum of 80,000 psi. Currently there
is no ASTM specification for Grade 80 reinforcement. However, deformed reinforcing bars No. 6 through No. 18 with a yield strength
of 75,000 psi (Grade75) are included in the ASTM A 615 specification. “Section 3.5.3.2 requires that the yield strength of greater
than 60,000 psi be taken as the stress corresponding to a strain of 0.35 percent. The 0.35 percent limit is to ensure that the elastoplastic stress-strain curve assumed in 10.2.4 will not result in unconservative values of member strength. Therefore the designer
should be aware that if ASTM A 615, Grade 75 bars are specified, the project specifications need to include a requirement that the
yield strength of the bars shall be determined in accordance with Section 9.2.2 of the ASTM A 615 specification.”
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(ACC) Autoclaved Concrete is an aerated lightweight material that has been used in other parts of the world but is relatively new to
the market in United States. It’s made of pulverized sand, water, cement and lime however there is no large aggregate in the
mixture. The ingredients are all mixed together to make a paste which is then deposited into molds for forming. The chemical
reaction created creates and traps air bubbles within the solid mix. The batch is allowed to set and then before final hardening
occurs is cut into portions of the desired size. The portions are them hardened & cured in an autoclave utilizing steam under
pressure. ACC is available as you might imagine in a wide variety and combinations of block height, length, thickness’ and
compressive strengths. ACC is used successfully in many applications such as mines, firewalls, shaft wall construction highway sound
walls, exterior wall panels, reinforced panels, load bearing vertical panels, floor and roof panels.
ASTM C 1386 contains specifications for ACC unreinforced block elements and ASTM C 1452 contains those for reinforced panel
elements.
MASONRY MATERIALS
Generally speaking, concrete is capable of sustaining higher loads than brick or block. As the embedment depth of an anchor or
fastener increases, the tension load will increase up to a point at which either the capacity of the expansion mechanism or bond is
reached or the concrete fails. The strength of masonry walls is usually less than that of concrete and the consistency of this material
can vary from region to region. To form a wall individual masonry units are bonded together with a cement mortar. The VERTICAL
ROW is called the COURSE and the HORIZONTAL ROW is called a WYTHE.
The strength of the mortar is often the critical factor in product performance. Anchors or fasteners must be installed in the horizontal
mortar joint or in some cases directly into the masonry unit.
In testing products should be installed and loaded to simulate the actual anchor or fastener placement. These tests are usually done
in an unrestrained mode. That is to say that the reaction bridge is spanning the installation without influencing anchor performance.
Hollow base material require special care and consideration as the anchor or fastener must be properly sized to coincide with the wall
thickness or selected to properly expand in the void. This material is very susceptible to reverse spalling thus reducing even further
the normally thin wall thickness’. Manufacturers of hollow block often will specify the maximum load that can be applied to the
material and this must always be kept in mind. Since the strength of masonry materials varies widely, on site testing are
recommended to determine actual load capacities for any critical application that you may have.
This system is a cavity wall consisting of an exterior concrete masonry veneer and a structural CMU backup. The two wythes are
anchored with horizontal joint reinforcement.. The joint reinforcement can be ladder tri-rod type, tab type, or adjustable. To resist
shrinkage of the concrete masonry veneer, the selection of joint reinforcement should take into account the requirements for
shrinkage control in the veneer. Control joints should be placed in this concrete masonry veneer at the proper spacing and in the
proper locations.
CMU Concrete Block Walls
CMUs are
does
. Finally, they are
CMU stands for concrete masonry unit, which is the 8x8x16-inch concrete block that makes up CMU walls. CMUs have been improving in
materials and mixtures since 1882, but their general size and purpose remains the same. Popularly used as a standard building material,
simply precast concrete blocks, meaning that they have been molded to a specific shape and size to build a block or rock retaining wall.
Made from cement, aggregates and water, CMUs are formed in molding equipment and allowed to cure. Curing implies that the concrete CMU
not dry as it hardens but rather retains moisture as it strengthens. Retaining water is part of what gives the concrete block its integrity.
In addition to the ingredients listed above, CMU mixtures may include a host of optional admixtures created to enhance or change the finalized
CMU block’s characteristics. By adding such ingredients, the manufacturer may be able to strengthen, air-entrain, color, accelerate curing speed,
retard or plasticize the CMU. For example, air bubbles disperse in concrete (know as air-entraining) to protect against freezing and thawing
conditions. Plasticizers help make concrete more workable while forming it.
As they are manufactured, CMUs are generally formed in a concrete forming machine that takes moist concrete and quickly pours it into the
desired block dimensions. Placed in chambers that have extremely high temperatures, the CMU blocks undergo accelerated curing
stored for a specific period of time to promote further curing prior to shipment. These CMU blocks are designed to ultimately be the core for walls
and buildings that need to be fabricated economically, efficiently and for fire-resistance.
As the finalized CMU blocks are identical, they provide a good material to build a solid wall. The CMU blocks are stacked in layers with mortar
between each block. This process allows for flexible and versatile concrete masonry construction.
CMUs are formed for many different purposes and include various masonry unit types including split face concrete block, slotted and glazed CMUs.
Split face CMUs are formed as one unit and then split revealing the rough aggregate texture. Slotted CMUs offer high sound absorption in places
where a sound barrier wall may be need. Glazed CMUs are primarily used when an aesthetically pleasing finish is desired. Both hollow and solid
types which can be classified as load bearing or non-load bearing are used. CMU blocks are usually considered to be a load bearing masonry unit
and suitable for anchoring and fastening. However on site tests are always recommended for critical applications. ASTM C 90 describes hollow and
solid load bearing concrete masonry unit made from Portland cement, water and mineral aggregates in normal, medium and lightweight
classifications. (Standard Specification for Loadbearing Concrete Masonry Units)
CMU & Blended CMU - 8x8x16 Standard
7 5/8” = Block Width
7 5/8” = Block Height
15 5/8” = Block Face
And the Web cross sections the Hollow Cell
CMU Concrete Block Walls cont.
The way to differentiate between hollow and solid block is based on their cross sectional area. Technically, solid block is defined as
having a cross sectional bearing area which is not less than 75% of the gross area of the block when measured in the same plane.
Typical dimensions of the Block face and web based upon ASTM C 90 are as follows:
Nominal CMU Face Web
Width Thickness Thickness
Inches Inches Inches
3 ¾ ¾
4 ¾ ¾
6 1 1
8 1 ¼ 1 ¼
1 3/8 1 1/8
1o 1 ¼ 1 1/8
1 1/2 1 1/8
12 1 ¼ 1 1/8
Mortar Type Compressive
Strength
M 2500psi
S 1800psi
Center – Lime N 750psi
Masonry/Cement O 350psi
Although improving, the consistency of grout filled block walls is variable and on site testing is still the preferred way to determine
more exact performance. Some times when lateral support is needed steel reinforcing rods are installed through the block hollow
and then grouted in place. This allows the unit to act in harmony to resist lateral loads.
Brick
In 210 BC, the Great Wall of China was constructed of brick — nearly four million of them. And the Romans used kiln-burned brick in
conjunction with an efficient mortar of lime and volcanic ash to construct buildings that were both beautiful and enduring. As the
Roman Empire declined, however, the art of brick making disappeared from most of Europe, only to be revived during the late Middle
Ages by Italian and Byzantine artisans who had kept the technology alive.
Because it is made from the elements, brick stands up to them, like no other building material can. It resists pests and withstands
fire. It buffers sound. It warms us in the winter, and in the summer, helps to keep us cool. For thousands of years, brick has been the
material of choice for strength and beauty. When brick is utilized as a building façade it’s imperative to tie it to the backing wall and
building structure. One should use a non-corrosive anchor made from Stainless Steel when tying these walls together. ASTM C 62
Standard Specification for Building Brick (Solid Masonry Units Made From Clay and Shale) outlines the various grades of brick used in
structural and non-structural masonry applications. Grades such as, Grade SW (Severe Weathering), Grade MW (Moderate
Weathering) and Grade NW (Negligible Weathering). Compressive strength ranges as well as permissible variations in dimensions, a
weathering index and many other helpful pieces of information are located in this ASTM Standard along with other reference
documents such as:
ASTM C 43 – Terminology of Structural Clay Products
ASTM C 67 – Test Methods for Sampling and Testing Brick and Structural Tile
ASTM C 216 – Specification for Facing Brick (Solid Masonry Units from Clay or Shale)
Stone
Dimension stone can be defined as natural rock material quarried for the purpose of obtaining blocks or slabs that
meet specifications as to size (width, length, and thickness) and shape. Color, grain texture and pattern, and
surface finish of the stone are normal requirements. Durability (essentially based on mineral composition and
hardness and past performance), strength, and the ability of the stone to take a polish are other important
selection criteria.
Although a variety of igneous, metamorphic, and sedimentary rocks are used as dimension stone, the principal
rock types are granite, limestone, marble, sandstone, and slate. Other varieties of dimension stone that are
normally considered to be special minor types include alabaster (massive gypsum), soapstone (massive talc), and
various products fashioned from natural stone. Granite is an example of an igneous stone while marble is
metamorphic. Both of these stones tend to be harder than limestone and sandstone which are sedimentary
materials.
Natural stone is available in a variety of colors, types and textures for use in many building applications as well. But strength and
quality can vary significantly from quarry to quarry and location to location. So when checking anchor capacities be certain that you
know what material the anchors were tested in. Job site testing is recommended because of the wide variation in the strength of
stone.
ASTM C119 – Standard Terminology Relating to Dimensional Stone describes dimensional stone for use in building construction.
ASTM C 503 – Marble
ASTM C 615 – Granite
ASTM C 616 – Quartz and
ASTM C 568 – Limestone
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