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Heat of hydration is a source of problem in mass concrete since it causes the difference between the inner and the outer temperatures increase excessively, which leads thermal cracks. The first step in fighting against this problem is to keep the initial temperature of concrete as low as possible. From this point of view, Preplaced Aggregate Concrete (in short PAC) is quite advantageous, because the friction taking place among the coarse aggregates during the mixing operation causes the initial temperature of concrete increase. However, since coarse aggregates are not subjected to the mixing operation in PAC method, comparatively lower initial temperatures can be achieved. On the other hand, making PAC by the conventional injection method is quite troublesome, since it requires special equipment and experienced workmanship. Because of this, it would be very useful to investigate alternative methods for making PAC. In this research, a new method for making PAC has been investigated. The new method is briefly based on increasing the fluidity of the grout by new generation superplasticizers to such an extent that, it fills all the voids in the preplaced coarse aggregate mass when it is poured over, without requiring any injection. In the scope of the study, twelve concrete cube specimens, each with 1 m volume, have been prepared / one of which as conventional concrete, seven of which as PAC by injection method, and four of which as PAC by the new method mentioned above. In order to examine the specimens that have been prepared by three different methods from thermal properties point of view, the difference between the central and the surface temperatures of the specimens have been followed by the thermocouples located in the specimens during preparation. Also, in order to examine the mechanical properties of the specimens, three core specimens have been taken from each specimen at certain ages, compressive strength and modulus of elasticity tests have been carried out on these core specimens. As a result of the experiments it has been observed that, the PAC specimens prepared by injection method performed better from thermal properties point of view, but worse from mechanical properties point of view than conventional concrete. On the other hand, the PAC specimens prepared by the new method have performed both as well as the other PAC specimens from thermal properties point of view, and as well as conventional concrete from mechanical properties point of view.

Made available in DSpace on 2014-12-17T14:58:08Z (GMT). No. of bitstreams: 1 RamsesOCL_DISSERT.pdf: 6940131 bytes, checksum: ccaad3b0fc7afbcfa4cdd535d7f2c612 (MD5) Previous issue date: 2011-07-29 / This work presents the results, analyses and conclusions about a study carried out with objective of minimizing the thermal cracks formation on cemented carbide inserts during face milling. The main focus of investigation was based on the observation that milling process is an interrupted machining process, which imposes cyclic thermal loads to the cutting tool, causing frequent stresses changes in its superficial and sub-superficial layers. These characteristics cause the formation of perpendicular cracks from cutting edge which aid the cutting tool wear, reducing its life. Several works on this subject emphasizing the thermal cyclic behavior imposed by the milling process as the main responsible for thermal cracks formation have been published. In these cases, the phenomenon appears as a consequence of the difference in temperature experienced by the cutting tool with each rotation of the cutter, usually defined as the difference between the temperatures in the cutting tool wedge at the end of the cutting and idle periods (T factor). Thus, a technique to minimize this cyclic behavior with objective of transforming the milling in an almost-continuous process in terms of temperature was proposed. In this case, a hot air stream was applied into the idle period, during the machining process. This procedure aimed to minimize the T factor. This technique was applied using three values of temperature from the hot air stream (100, 350 e 580 oC) with no cutting fluid (dry condition) and with cutting fluid mist (wet condition) using the hot air stream at 580oC. Besides, trials at room temperature were carried out. Afterwards the inserts were analyzed using a scanning electron microscope, where the quantity of thermal cracks generated in each condition, the wear and others damages was analyzed. In a general way, it was found that the heating of the idle period was positive for reducing the number of thermal cracks during face milling with cemented carbide inserts. Further, the cutting fluid mist application was effective in reducing the wear of the cutting tools. / Este trabalho apresenta os resultados, an?lises e conclus?es de um estudo realizado com objetivo de minimizar o processo de forma??o e evolu??o de trincas de origem t?rmica em insertos de metal duro usados no fresamento frontal. O foco principal da pesquisa baseou-se na observa??o de que, por ser um processo de corte interrompido, o fresamento imp?e um carregamento t?rmico c?clico ? ferramenta de corte, conduzindo a frequentes varia??es de tens?es nas camadas superficial e sub-superficial de seu gume cortante. Tal caracter?stica leva ? forma??o de trincas no substrato, perpendiculares a aresta de corte, as quais auxiliam na acelera??o do desgaste e no fim de vida da ferramenta. Muitos trabalhos foram publicados sobre o assunto enfatizando a ciclagem t?rmica imposta pelo processo de fresamento como a principal causa da forma??o das trincas t?rmicas. Neste caso, o fen?meno surge como conseq??ncia da diferen?a de temperatura sofrida pela ferramenta de corte a cada giro da fresa, normalmente definida pela diferen?a entre as temperaturas no gume cortante imediatamente ao final das fases ativa e inativa (fator T). Assim, prop?s-se neste trabalho uma t?cnica que visa amenizar esta ciclagem t?rmica caracter?stica, por aproximar o fresamento frontal de um processo quase cont?nuo do ponto de vista t?rmico. Neste caso, um jato de ar quente foi aplicado na fase inativa da fresa durante todo o processo de usinagem, com objetivo de minimizar o fator T. Esta t?cnica foi aplicada usando tr?s valores de temperatura do jato de ar, 100, 350 e 580 ?C na condi??o a seco e 580?C na condi??o com fluido de corte aplicado por n?voa. Al?m disso, tamb?m foram realizados ensaios a temperatura ambiente. Ao final dos ensaios de fresamento, os insertos foram conduzidos a um microsc?pio eletr?nico de varredura, onde a quantidade de trincas t?rmicas geradas em cada condi??o, o desgaste e demais avarias foram analisadas. De maneira geral, observou-se que o aquecimento da fase inativa forneceu resultados positivos na redu??o da quantidade de trincas t?rmicas no fresamento frontal com insertos de metal duro. Al?m disso, a aplica??o de fluido de corte por n?voa foi eficaz na diminui??o do desgaste das ferramentas de corte ensaiadas.

The report contains three parts. The first part is a summary and overall presentation of thermal cracks and preventing measures against such cracks. This is a theoretical part where the interested designer can get acquainted with various alternatives, be guided to more detailed literature, and receive some practical information regarding the design of the respective measures. The second part deals with calculation of the risk for thermal cracks and design of water cooling as a limiting measure. Two complementary methods are reviewed for efficient calculation: • the handbook method CraX1 (by Lulea University of Technology) is used for quick verification • finite differential analysis in the calculation tool ConTeSt Pro for more precise projecting Here is also presented a development of existing standards through design of the cooling system by means of the Bernoulli equation. Comparison is made with the approximation with Manning’s formula, which occurs in the field today. The calculation part is concluded with a calculation example. In addition to prescribing good project planning, the example also highlights some of the calculation programs’ possibilities and limitations. The third part of the report evaluates the current calculation of the risk for thermal cracking in young concrete, as well as the design and implementation of thereto related measures. This is done through studies of reference objects and interviews with all parts involved, i.e. clients, consultants, contractors and suppliers. The report aims to a compilation and transfer of skill and experience, so that potential for improvement in the prevention of thermal cracking can be identified, and the design can be improved with regard to the conditions of the construction phase. / Rapporten innehaller tre delar. Den forsta delen utgor en sammanstallning och oversiktlig presentation av temperatursprickor samt forebyggande atgarder mot sadana sprickor. Det ar en teoretisk del dar den intresserade projektoren kan satta sig in i olika alternativ, vagledas till utforligare litteratur, samt fa en del praktisk information infor projekteringen av respektive atgard. Den andra delen avhandlar berakning av risk for temperatursprickor samt projektering av vattenkylning som sprickbegransande atgard. Tva kompletterande metoder gas igenom for effektiv berakning: • handboksmetoden CraX1 (fran Lulea tekniska universitet) for snabbare kontroller • finita differensanalyser i berakningsprogrammet ConTeSt Pro for noggrannare projektering Har presenteras aven en utveckling av nuvarande standarder via dimensionering av kylsystem for vatskekylning med hjalp av Bernoullis ekvation. Jamforelse gors med approximationen med Mannings formel, vilken i dagslaget forekommer i branschen. Berakningsdelen avslutas med ett berakningsexempel. Forutom att foreskriva god projektering, belyser exemplet dessutom nagra av berakningsprogrammens mojligheter och begransningar. Rapportens tredje del utvarderar den nuvarande berakningen av risk for temperatursprickor i ung betong, samt projekteringen och genomforandet av tillhorande atgarder. Detta gors via studier av referensobjekt och intervjuer med samtliga involverade aktorer, d.v.s. bestallare, konstruktorer, entreprenorer och leverantorer. Rapporten syftar till en sammanstallning och aterforing av kompetens och erfarenhet, sa att forbattringspotential i forebyggandet av temperatursprickor kan identifieras, och projekteringen kan forbattras med hansyn till produktionens forutsattningar.

Rapporten innehåller inledningsvis en faktadel med allmän information kring temperatursprickor i betong. Här presenteras bl a uppkomsten av fenomenet, vilka typer av sprickor som förekommer och vad ett tvång är. Tanken är att ge läsaren tillräcklig kunskap för att kunna förstå sig på de övriga delarna i rapporten. Resultatet och det huvudsakliga arbetet redovisas i form av tabeller med tillhörande illustrationer där det går att utläsa vilken sprickrisk som förekommer vid flera specifika fall och vilken åtgärd som bör vidtas för att eliminera sprickrisken. Som konstruktör kan du med din egen indata, dvs. dimensioner och temperaturer, följa tabellen och finna resultatet för ditt specifika fall. De konstruktionstyper som presenteras är bottenplatta, stödmur och plattrambro. En tillhörande databas i elektronisk form finns tillgänglig som en bilaga där varje beräknat fall är sparat. Filerna är enkla att modifiera för att göra det möjligt att genomföra ytterliggare beräkningar i de fall tabellerna är otillräckliga. Rapporten innehåller även ett avsnitt med förutsättningar till tabellerna där det går att utläsa arbetsgången och vilka parametrar som har använts. / The initial part of the report contains general information about thermal cracks. This section describes the origin to the cracks, what type of cracks that occurs and the force causing the problem. The major reason with this chapter is to give the reader enough knowledge to understand the rest of the report. The result and the main work are presented in tables with belonging illustrations. Each table contains the risk of cracking that occurs in several specific concrete structures and how to eliminate the risk. The report covers the following three types of structures: baseplate, retaining wall and integral bridge. The constructor can with his/her own dimensions and temperatures simply use the table to find the risk of cracking. A database including all the calculated files for each specific case is attached to the report. The files can easily be modified by the user in case the information in the tables is insufficient. All the precise circumstances and priority in the project are presented in the chapter “Förutsättningar och arbetsgång”.

Järnvägsbron vid Årstaberg kommer när den är klar att mäta 1,4 km, här passerar över 550 tåg per dygn. Bron är en del av projektet Citybanan och kommer att fungera som en spårväxel som styr fjärr-, regional- och godståg till den gamla östra Årstabron. Pendeltågen kommer då färdas på bron över Årstaviken och in i den nya järnvägstunneln vid Södra station. Entreprenaden gick från början till danska företaget Pihl och Son som efter en del problem gick i konkurs, underentreprenören Züblin fick då ta över projektet. Med en ny platsledning gjordes en hel del förändringar på arbetsgången och arbetsmomenten. Från 4 veckor per sektion, där en sektion mäter ca 30 meter lyckades Züblin tillslut effektivisera till 2 veckor. Det speciella med detta projekt är den formvagn som används, den så kallade MSS:en (Moving Scaffolding System) som är relativt ovanlig i Sverige. Författarnas uppgift var att undersöka och utreda för ytterligare effektiviseringar samt redogöra för de effektiviseringar som redan gjorts av Züblin. För att ta reda på hur arbetsgången går till har en sektion av överbyggnaden följts under byggprocessen. Författarna har tagit del av tekniska detaljer som temperatursprickor, armering, spännarmering, betongkvalité och inte minst själva formvagnen. För att få en uppfattning granskades dokument och handlingar om projektet parallellt med intervjuer med inblandade och sakkunniga. Eftersom många effektiviseringsåtgärder var genomförda när författarna påbörjade examensarbetet hos Züblin lämnades inte mycket utrymme för effektiviseringar av tekniska åtgärder. Effektiviseringar som författarna har kommit fram till gäller främst arbetsmetoder och material där mer prefabricering på armering och formning över brostöd, användning av rullarmering och självkompakterande betong. Med tanke på att inga tester och provningar har utförts är detta spekulationer som tagits i samråd med inblandade nyckelpersoner med stor erfarenhet inom sina respektive områden. / The railway bridge at Årstaberg will measure 1,4 km when finished, over 550 trains passes by every 24 hours. The bridge is a part of the project Citybanan and will serve as a railway gear that directs the long-distance, regional- and cargo trains to the old Årstabron. The commuter trains will then travel on the bridge over Årstaviken and into the new railway tunnel at Södra Station. The first contractor was the Danish company Phil & Son, who after some struggles and problems went bankrupt. The subcontractor Züblin then took over the project. With the new site management, whole new changes were made considering the workflow and other operations. From 4 weeks per section, were one section measures 30 meters, Züblin managed to reach 2 weeks. The authors' task was to investigate for further efficiency and account for the efficiency improvements already made by Züblin. In order to receive a full understanding about the workflow on sight, every step of the process has been followed on one section of the superstructure under the construction process. The technical details have been analyzed such as temperature cracks, reinforcement, stressing and concrete quality. Documents about the project had to be examined and interviews with the involved experts and thoroughly follow the operations on site. Since many efficiency measures were implemented when the authors began this degree project at Züblin, not much space was left for technical efficiency improvements. The efficiencies that caught the attention is mostly working methods and material use where more prefabrication should be utilized considering the reinforcement and forming over pillars, use of rolled reinforcement and self- consolidating concrete. Considering no tests or try-outs have been made this is only speculations which have been discussed with the involved experts with great experience in their field.

This thesis aims to compare the relationship of physical-mechanical properties of tool materials made of WC-Co sintered carbides with their resistance to initiation and propagation of thermal cracks. The paper presents the results of testing the basic physical-mechanical properties of the three samples sintered carbides with different percentage of Co binder. Next, this thesis describes the progress and results of quench experiment and cutting tests using, which was described resistance of the tested samples to thermal and mechanical shock, depending on the values of physical-mechanical properties.