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This publication is published as an aid to cooling tower purchasers and designers. Efforts have been made to assure the accuracy and reliability of the data contained herein. However, CTI makes no warranty of fitness for particular purpose or merchantability. The reproduction of any part of this or any other CTI code or standard is a violation of federal Law.
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CTI - Recommended Guidelines for Portland Cement Concrete for Mechanical Draft Cooling Towers
This publication is published as an aid to cooling tower purchasers and designers. Efforts have been made to assure the accuracy and reliability of the data contained herein. However, CTI makes no warranty of fitness for particular purpose or merchantability. The reproduction of any part of this or any other CTI code or standard is a violation of federal Law.
This publication is published as an aid to cooling tower purchasers and designers. Efforts have been made to assure the accuracy and reliability of the data contained herein. However, CTI makes no warranty of fitness for particular purpose or merchantability. The reproduction of any part of this or any other CTI code or standard is a violation of federal Law.
Recommended Guidelines for Portland Cement Concrete for Mechanical Draft Cooling Towers
Revised February 07 ESG-153 (07)
Foreword This Cooling Technology Institute (CTI) publication is published as an aid to cooling tower purchasers and designers. It may be used by anyone desiring to do so, and efforts have been made by CTI to assure the accuracy and reliability of the data contained herein. However, CTI makes no warranty of fitness for particular purpose or merchantability nor any other warranty expressed, implied or statutory. In no event shall CTI be liable or responsible for Incidental, Consequential or Commercial losses or damage of any kind resulting from this publication's use; or violation of any federal, state, or municipal regulation with which this publication may conflict or for the infringement of any patent resulting from the use of this publication. All CTI codes and standards are copyrighted with all rights reserved to CTI. The reproduction of any part of this or any other CTI code or standard is a violation of Federal Law. One must recognize and appreciate commitment by a number of volunteer members who donate their time to develop and update CTI codes and standards. The monies spent for code development, administrative staff support and publication are essential and constitute a substantial drain on CTI. The purchase price of these documents helps to offset these costs. Reproduction and distribution by others, in addition to being unethical, undermines this system and constitutes a further financial drain on CTI. When copies are needed, you are requested to call or write the Cooling Technology Institute, P.O. Box 73383, Houston, Texas 77273, (281) 583-4087. Please request that your associates buy the required codes and standards rather than copy them. Your cooperation in this matter is greatly appreciated. Nothing contained herein is to be construed as granting any right for the manufacture, sale or use in connection with any method, apparatus, or product covered by letters patent, nor as insuring anyone against liability for infringement of letters patent. This guideline document summarizes the best current state of knowledge regarding the specific subject. This document represents a consensus of those individual members who have reviewed this document, its scope and provisions. It is intended to aid all users or potential users of cooling towers.
Approved by the CTI Executive Board.
This document has been reviewed and approved as part of CTIs Five Year Review Cycle. This document is again subject to review in 2012.
Copyright 2007 Approved by the by Cooling Technology Institute CTI - Guideline CTI Executive Board Printed in U.S.A. ESG-153
Recommended Guidelines for Portland Cement Concrete for Mechanical Draft Cooling Towers
1.0 Scope 1.1 This guideline offers recommendations for the use of Portland cement concrete in the use of mechanical draft cooling towers. The contents are applicable for towers, basins and auxiliary structures of both cast in place and precast concrete construction, except for prestressed construction. Erection methods are not covered in these guidelines, and any construction loads applied to structural members must be included in the design. 1.2 Recommendations for service in fresh and brackish/seawater environments are offered in this standard in Table 1. Technical requirements for design and construction in high sulfate, chloride or other aggressive environments should be referred to design consultants experienced in concrete design for special environments. 1.3 The technical recommendations outlined in this guideline are primarily to assure that the concrete designed and used in mechanical draft towers possess characteristics for adequate durability. Requirements for the design strength of the concrete, reinforcing steel and other parameters should be referred to licensed professional engineers familiar with the design and erection of cooling towers. 2.0 Applicable Documents 2.1 This guideline is not intended to replace any design codes in effect in any jurisdiction. Applicable local building codes in force shall govern design and construction. 2.2 Codes and standards referenced in this document are those in common usage in the United States of America. If the work is to be performed in a location outside the United States, the standards in this document shall be used as a minimum to assure the necessary chemical and physical characteristics required in concrete for durability are obtained. 2.3 Unless otherwise noted, the latest edition of the following standards are intended for usage: American Concrete Institute (ACI): 117 Standard Specifications for Tolerances for Concrete Construction and Materials 201 Guide to Durable Concrete 301 Standard Specification for Structural Concrete 304 Guide for Measuring, Mixing, Transporting, and Placing Concrete 305R Hot Weather Concreting 306R Cold Weather Concreting 308 Standard Practice for Curing Concrete 318 Building Code Requirements for Reinforced Concrete 350 Evironmental Engineering Structures American Society for Testing Materials (ASTM): A82 Standard Specification for Steel Wire, Plain, for Concrete Reinforcement A184 Standard Specification for Fabricated Deformed Steel Bar Mats for Concrete Reinforcement A185 Standard Specification for Steel Welded Wire Fabric, Plain, for Concrete Reinforcement A615 Standard Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement A775 Standard Specification for Epoxy-Coated Steel Reinforcing Bars C33 Standard Specifications for Concrete Aggregates C94 Standard Specification for Ready Mixed Concrete C260 Standard Specification for Air-Entraining Admixtures for Concrete C494 Standard Specification for Concrete Admixtures C618 Standard Specification for Fly Ash and Raw or Calcinated Natural Pozzolon for Use as a Mineral Admixture in Portland Cement Concrete C989 Standard Specification for Ground Granulated Blast-Furnace Slag for Use in Concrete and Mortars
5 C1012 Standard Test Method for Length Change of Hydraulic-Cement Mortars Exposed to a Sulfate Solution C1017 Standard Specification for Chemical Admixtures for Use in Producing Flowing Concrete C1218 Standard Test Method for Water-Soluble Chloride in Mortar and Concrete C1240 Standard Specification for Use of Silica Fume as a Mineral Admixture in Hydraulic- Cement Concrete, Mortar, and Grout American Welding Society (AWS): D1.4 Structural Welding Code-Reinforcing Steel Concrete Reinforcing Steel Institute (CRSI): Concrete Reinforcing Steel Institute Handbook Prestressed Concrete Institute PCI Manual 116-99 Quality Control for Precast - Prestressed Concrete 3.0 Terminology 3.1 Definitions of terms relative to reinforced concrete can be found in ACI 318. 4.0 Materials 4.1 Concrete a. Cement: ASTM C150. b. Fly Ash: ASTM C618, Class C or Class F. c. Aggregates: Per ASTM C33. d. Water: Clean, fresh and potable. (Reference ACI 318, 3.4 or ACI 301) e. Air-entraining admixture: Per ASTM C260. f. Water reducing admixture: Per ASTM C494, Type A, F, or G. g. Accelerating admixtures: Per ASTM C494 Type C or E, non-chloride type only. The use of calcium chloride is not permitted. 4.2 Reinforcing Steel a. Welded steel wire fabric: Plain type, ASTM A185 in flat sheets. b. Steel Wire, Plain, for concrete reinforcement per ASTM A82. c. Reinforcing steel: ASTM A615 grade 60, deformed bars. d. Epoxy-Coated Reinforcement, per ASTM A775. e. Deformed Bar Mats for Reinforcement, per ASTM A184. f. Reinforcement supports: Provide bolsters, chairs, spacers, ect. In accordance with CRSI Manual of Standard Practice. All material to be non- corrosive. In high chloride environments, use 100% plastic or stainless steel materials. g. Reinforcing ties: Use non-corrosive reinforcing ties in all precast components. Malleable steel tie wire is permitted in cast in place concrete provided that the ends are bent away from the face of the member prior to concrete placement. h. Reinforcing shall be clean and free from loose rust, mill scale, oil grease, paint dirt or any other contaminants that may reduce its bone with concrete. 4.3 Embedments 4.3.1 Embedments such as anchor bolts, studded welded plates, threaded inserts or other metallic items that will be exposed to circulating water shall be of suitable non-corrosive material such as stainless steel or silicon bronze and appropriate for use with the water chemistry. Embedments consisting of stainless items welded with black steel embedded items shall not be allowed. 5.0 Execution 5.1 Durability Considerations 5.1.1 All concrete found within a cooling tower shall be considered exposed to earth or weather. Only concrete protected against exposure such as in a stairwell or other auxiliary structure is not to be considered as exposed. 5.1.2 For fresh water applications the minimum concrete cover provided for reinforcement shall be per the following table:
6 Table 1
Location
Cast in place concrete Minimum Cover (in.) Concrete cast against and permanently exposed to earth 3-1/2 Concrete exposed to earth or weather: No. 6 through No. 18 bars: No. 5 bars, W31 or D31 wire and smaller:
2-1/2 2 Concrete not exposed to weather or in contact with ground: Slabs, walls and joists: No. 14 and No. 18 bars: No. 11 bars and smaller: Beams, columns: Primary reinforcement, ties, stirrups, spirals
2 1-1/4
2
Precast concrete (manufactured under plant control conditions)
Concrete exposed to earth or weather: Wall panels; No. 14 and No 18 bars: No. 11 bars and smaller:
2-1/2 2 Other members: No. 14 and No. 18 bars: No. 6 through No. 11 bars: No. 5 bars, W31 or D31 wire and smaller:
2-1/2 2 1-3/4 Concrete not exposed to weather or in contact with ground: Slabs, walls and joists: No. 14 and No. 18 bars: No. 11 bars and smaller:
1-3/4 1-1/8
5.1.3 For brackish or seawater exposures increase the cover requirements of ACI 318 to a minimum of 3. 5.1.4 Concrete exposed to seawater or brackish water is to be type II for moderate exposure or type V for severe exposure 5.1.5 Concrete exposed to freeze thaw cycles shall be air entrained in accordance with table 4.2.1 of ACI 318. 5.2 Design Considerations 5.2.2 Concrete strength and proportions shall be established based on ACI 301. 5.2.3 Minimum design strength for standard concrete shall be 4,500 psi at 28 days. If fly ash or silica fume are used to enhance the properties of the concrete, the design engineer shall provide mix percentage of the material. 5.2.4 Maximum water/cement ratio for fresh water exposure should be limited to .45 and the maximum water/cement ratio for use in brackish water should be limited to .40. 5.2.5 The use of lightweight concrete in precast elements is to be at the disgression of the owner and design engineer. Because of the variability of absorption rates in lightweight aggregates, only precasters with documented histories of use in similar environments shall be considered. 5.3 Selection of aggregate shall take into account location of origin and material properties to avoid reactive aggregates. Concrete coatings are permissible. Their use should be reviewed with material suppliers prior to specifying.
7 6.0 Concrete Placement 6.1 Volumetric changes from hydration shall be accounted for in the design. This shall include lengths of continuous pours and placement of joints in the slab. Construction joints must be properly addressed in the construction of slabs and basin walls to preserve the integrity of the impermeability of the construction. (Reference ACI 350) 6.2 Provide PVC waterstops or owner approved equal at all construction joints. Waterstops must be continuous. Field splice waterstops using thermostatically controlled devices specifically intended for this purpose. 6.3 Spacing of reinforcement is critical in crack prevention and crack size control. Distribution requirements for reinforcement shall conform to ACI 318 section 10.6, with the use of smaller bars placed more closely being preferable to the use of larger bars of equal total area. 6.4 All concrete must be placed within 1hours after the introduction of water to the cement and aggregates. Method of transport, distance and mix location shall be taken into consideration. 6.5 Deposit concrete as near as practical to its final position to avoid segregation in transport. Limit free fall of concrete during deposition to 4-0 unless done in such a manner that segregation is prevented and an unbroken stream of concrete is ensured. 6.6 Concrete is to be compacted in place by means of mechanical vibrators. Care must be taken to prevent over vibration. 6.7 Concrete shall be cured in accordance with the requirements of ACI 301. Curing is to begin as soon as the concrete has hardened sufficiently to prevent surface damage. Curing shall continue for a minimum of 7 days prior to being subjected to live loads or as directed by the project engineer. 6.8 Protect concrete from excessive heat and cold during curing. 6.9 Protect concrete from premature drying during curing. 6.10 All finish and level requirements shall be indicated on the basin documents. Basin slabs shall be finished to a flat slab tolerance as defined by ACI 117 section 4.5.7, or as noted on the drawings. 6.11 Protect concrete from damage during construction. Chamfer all cast in place concrete min. and chamfer or radius all precast a minimum of . 6.12 Align and install all required embedments using plywood templates immediately after placement of concrete. Installation of embedments after curing has begun shall not be allowed. 7.0 Repairs 7.1 Prior to repairs being initiated, adequate investigation of the causes of the concrete deterioration must be conducted. Any repairs must insure the proposed materials used will possess elastic and thermal expansion properties and resistance to sulfates and chlorides similar to the base material. Proposals for the repair work must include steps outlining surface preparation requirements, bonding methods, repair materials and curing methods.
Cooling Technology Institute
PO Box 73383 Houston, Texas 77273 281.583.4087 Fax: 281.537.1721 www.cti.org February 2007 Printed in USA