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COMPUTATIONAL RESEARCH AND THEORY FACILITY LAWRENCE BERKELEY NATIONAL LABORATORY Ana Lua, Melissa Meikle, Peng Tieng, Qudsia Wahab University of California, Berkeley The Computational Research and Theory Facility at Ernest Orlando Lawrence Berkeley National Laboratory is a facility that will enable cutting-edge research to be performed. DPR Construction is responsible for managing the project, which is expected to be completed in December 2014. Some key features are: 140,000 gross-square-feet with 4 levels • Computing level with supercomputers requiring base isolation 100 yards from the Hayward fault 18 months dedicated to excavation work Aim for LEED Gold accreditation The two main methods of placement used were: Concrete pumps Pneumatic guns for shotcrete Concrete was mostly placed into formwork made of Douglas fir, which was reused 2-3 times. Metal formwork, Stay-form®, is used to make a keyway pattern for the next concrete pour to alleviate cold joints. Finishing requirements were described in the specifications. These include: Broom finish Trowel finish Float finish Trowel and fine broom finish Rough / Smooth form finish The centrally mixed concrete used in the project were transported from: CEMEX Berkeley plant, 5 miles from site CEMEX Oakland plant, 11 miles from site • Central Concrete San Jose, 46 miles from site The majority of mixes were from Berkeley with an expected delivery time of 90 minutes. MIXING & TRANSPORTATION PLACEMENT FINISHING Proximity to Hayward Fault Problem: Improper consolidation, rebar placement, and inadequate concrete cover Solution: Reduce rebar, consult structural engineers Timing of Trucks Problem: Trucks had to be turned away Solution: Use retarder to delay set time Curing Problem: Water leakage after 7-days of curing Solution: Traps installed to keep water out CONSTRUCTION ISSUES We would like to express great appreciation to Tim Hart, Tim Kemper, Ian White, Rory Shortreed from LBNL and Mike Miller from DPR Construction for being accommodating during our site visits and providing us details about the project. Also, many thanks to Professor Monteiro for expanding our knowledge of concrete materials and construction. ACKNOWLEDGMENT Heavy reinforcement was required due to facility’s proximity to Hayward fault. These are not coated with epoxy. A 3 inch concrete cover was maintained to prevent corrosion issues. REINFORCEMENT INTRODUCTION Consolidation was primarily done using: Internal vibrators Vibrating formwork for retaining walls 28-day curing was typically specified. Curing compounds were used to protect fresh concrete from direct sunshine and drying winds Approximately 20 different mix designs were incorporated into the building. The table above displays the properties and compositions of 4 mixes. Most of these mixes contained: Cement: Type I, II, & V Aggregates: Mined from Pleasanton, CA Fly Ash: Class F Jim Bridger Fly Ash • Chemical Admixtures: WRDA 64 (water reducer), Recover® (water reducer and retarder), Daravair 1000 (air entrainer) MIX DESIGN Properties High Early Strength Concrete Fiber Reinforced Concrete Shotcrete Controlled Density Fill 28-Day Compressive Strength(psi) 5,000 @ 3-days 3,000 5,000 100 w/c 0.39 0.55 0.42 0.86 Slump (in) 4 4 2 NA Air Content (%) 2.5 7.6 2.5 10 Clinker Composition (%) C 3 S 60 64 61 60 C 2 S 15 11 13 14 C 3 A 4 8 4 4 C 4 AF 11 8 11 12 Mix Material Percentage of Total Weight (%) Cement 19 6 17 1 Fly Ash Class F 0 6 3 8 Coarse Aggregate 42 40 21 43 Fine Aggregate 33 41 50 39 Water 7 7 9 8 CONSOLIDATION & CURING

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COMPUTATIONAL RESEARCH AND THEORY FACILITY

LAWRENCE BERKELEY NATIONAL LABORATORY

Ana Lua, Melissa Meikle, Peng Tieng, Qudsia Wahab

University of California, Berkeley

Style

The Computational Research and Theory

Facility at Ernest Orlando Lawrence

Berkeley National Laboratory is a facility

that will enable cutting-edge research to

be performed. DPR Construction is

responsible for managing the project,

which is expected to be completed in

December 2014. Some key features are:

• 140,000 gross-square-feet with 4 levels

• Computing level with supercomputers

requiring base isolation

• 100 yards from the Hayward fault

• 18 months dedicated to excavation work

• Aim for LEED Gold accreditation

The two main methods of placement used

were:

• Concrete pumps

• Pneumatic guns for shotcrete

Concrete was mostly placed into formwork

made of Douglas fir, which was reused 2-3

times. Metal formwork, Stay-form®, is

used to make a keyway pattern for the

next concrete pour to alleviate cold

joints.

Finishing requirements were described in

the specifications. These include:

• Broom finish

• Trowel finish

• Float finish

• Trowel and fine broom finish

• Rough / Smooth form finish

The centrally mixed concrete used in the

project were transported from:

• CEMEX Berkeley plant, 5 miles from site

• CEMEX Oakland plant, 11 miles from site

• Central Concrete San Jose, 46 miles

from site

The majority of mixes were from Berkeley

with an expected delivery time of 90

minutes.

MIXING & TRANSPORTATION PLACEMENT

FINISHING

Proximity to Hayward Fault

• Problem: Improper

consolidation, rebar

placement, and

inadequate concrete

cover

• Solution: Reduce

rebar, consult structural engineers

Timing of Trucks

• Problem: Trucks had to be turned away

• Solution: Use retarder to delay set time

Curing

• Problem: Water leakage after 7-days of

curing

• Solution: Traps installed to keep water

out

CONSTRUCTION ISSUES

We would like to express great appreciation to Tim

Hart, Tim Kemper, Ian White, Rory Shortreed from

LBNL and Mike Miller from DPR Construction for

being accommodating during our site visits and

providing us details about the project. Also, many

thanks to Professor Monteiro for expanding our

knowledge of concrete materials and construction.

ACKNOWLEDGMENT

Heavy reinforcement was required due to

facility’s proximity to Hayward fault.

These are not coated with epoxy. A 3 inch

concrete cover was maintained to prevent

corrosion issues.

REINFORCEMENT

INTRODUCTION

Consolidation was primarily done using:

• Internal vibrators

• Vibrating formwork for retaining

walls

28-day curing was typically specified.

Curing compounds were used to protect

fresh concrete from direct sunshine and

drying winds

Approximately 20 different mix designs

were incorporated into the building. The

table above displays the properties and

compositions of 4 mixes. Most of these

mixes contained:

• Cement: Type I, II, & V

• Aggregates: Mined from Pleasanton, CA

• Fly Ash: Class F Jim Bridger Fly Ash

• Chemical Admixtures: WRDA 64 (water

reducer), Recover® (water reducer and

retarder), Daravair 1000 (air entrainer)

MIX DESIGN

Properties

High Early

Strength

Concrete

Fiber

Reinforced

Concrete

Shotcrete

Controlled

Density

Fill

28-Day

Compressive

Strength(psi)

5,000

@ 3-days 3,000 5,000 100

w/c 0.39 0.55 0.42 0.86

Slump (in) 4 4 2 NA

Air Content

(%) 2.5 7.6 2.5 10

Clinker Composition (%)

C3S 60 64 61 60

C2S 15 11 13 14

C3A 4 8 4 4

C4AF 11 8 11 12

Mix Material Percentage of Total Weight (%)

Cement 19 6 17 1

Fly Ash Class

F 0 6 3 8

Coarse

Aggregate 42 40 21 43

Fine

Aggregate 33 41 50 39

Water 7 7 9 8

CONSOLIDATION & CURING