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SW8031133_HISTORICAL FILE_20040603
STORMWATER DIVISION CODING SHEET POST -CONSTRUCTION PERMITS PERMIT NO. SW kjQ3��3� DOC TYPE El CURRENT PERMIT ❑ APPROVED PLANS HISTORICAL FILE ❑ COMPLIANCE EVALUATION INSPECTION DOC DATE 2LAIL(d 03 YYWMMDD UNITED STATES POSTAL SERVICE First -Class Mill Postage & Fees Paid USPS Permit No G-10 • Sender Please print your name, address, and ZIP+4 in this box • F h Carolina Drive Ext mington, NC 28405 (Attu BEV c� ' i33 11lIlIIlIll!'Ik1�111lII11!lI11lIIIllllli!l�IE1l1�1i1lFl�lillil • Complete items 1, 2, and 3 Also complete item 4 If Restricted Delivery is desired w Print your name and address on the reverse so that we can return the card to you ■ Attach this card to the back of the mailplece, or on the front If space permits Article Addressed to q;l WC": A. x ❑ Agent ❑ dressee ocel by (PrWad Name) D to o Rellvery D Is delivery address ci ferent from Item 1 ❑ es If YES, enter delivery address below ❑ No 3 Service Type JIKI Certified Mall ❑ Express Mall ❑ Registered ❑ Return Receipt for Merchandise ❑ Insured Mail ❑ C O D 4 Restricted Delivery? (Extra Fee) ❑ Yes 2 Articl(Rens rftmNumb7002 1000 0005 23a9 81=5 (Tiansfer from service !a P5 Form 3811, August 2001 Domestic Return Receipt 102595-02 M 1540 l State Stormwater Management Systems Permit No SW$ 031133 STATE OF NORTH CAROLINA DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES DIVISION OF WATER QUALITY STATE STORMWATER MANAGEMENT PERMIT HIGH DENSITY DEVELOPMENT In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North Carolina as amended, and other applicable Laws, Rules, and Regulations PERMISSION IS HEREBY GRANTED TO Mr Bryan English Georgetown Center Brunswick County FOR THE construction, operation and maintenance of an infiltration trench in compliance with the provisions of 15A NCAC 2H 1000 (hereafter referred to as the "stormwater rules') and the approved stormwater management plans and specifications and other supporting data as attached and on file with and approved by the Division of Water Quality and considered a part of this permit This permit shall be effective from the date of issuance until June 3, 2014, and shall be subject to the following specified conditions and limitations I. DESIGN STANDARDS 1 This permit is effective only with respect to the nature and volume of stormwater described in the application and other supporting data 2 This stormwater system has been approved for the management of stormwater runoff as described on page 3 of this permit, the Project Data Sheet The stormwater control has been designed to handle the runoff from 22,241 square feet of impervious area This system must be operated with a vegetated filter 3 The tract will be limited to the amount of built -upon area indicated on page 3 of this permit, and per approved plans 4 All stormwater collection and treatment systems must be located in either dedicated common areas or recorded easements The final plats for the project will be recorded showing all such required easements, in accordance with the approved plans 5 The runoff from all built -upon area within the permitted drainage area of this project must be directed into the permitted stormwater control system A permit modification must be submitted and approved prior to the construction of additional built -upon area from outside of the approved drainage area 2 State Stormwater Management Systems Permit No SW8 031133 DIVISION OF WATER QUALITY PROJECT DESIGN DATA SHEET Project Name Permit Number Location Applicant Mailing Address Application Date Receiving Stream/River Basin Stream Index Number Classification of Water Body Drainage Area, acres Onsite, sq ft Offsite, sq ft Total Impervious Surfaces, sq ft Design Storm Trench Dimensions, LxWxH/Pipe Dia Required Storage Volume, ft3 Provided Storage Volume, ft3 Bottom Elevation, FMSL Temporary Storage Elevation, FMSL Type of Soil Time to Drawdown, hours Georgetown Center SW8 031133 Brunswick County Mr Bryan English 4705 Southport -- Supply Hwy Southport, NC 28461 June 3, 2004 Dutchman's Creek / Cape Fear CPF17 18-88-9-3-(1) "Sc Sw HQW" 065 28,155 none 22,241 101, 110' x 6' x 3 52'/6" & 120 x 4' x 3 52'/6" 1,782 1,806 23 88 2740 Baymeade 113 Seasonal High Water Table, FMSL 2188 3 State Stormwater Management Systems Permit No SW8 431133 IL SCHEDULE OF COMPLIANCE l The stormwater management system shall be constructed in its entirety, vegetated and operational for its intended use prior to the construction of any built -upon surface 2 During construction, erosion shall be kept to a minimum and any eroded areas of the system will be repaired immediately 3 The permittee shall at all times provide the operation and maintenance necessary to assure the permitted stormwater system functions at optimum efficiency The approved Operation and Maintenance Plan must be followed in its entirety and maintenance must occur at the scheduled intervals including, but not limited to a Semiannual scheduled inspections (every 6 months) b Sediment removal c Mowing and revegetation of slopes and the vegetated filter d Immediate repair of eroded areas e Maintenance of all slopes in accordance with approved plans and specifications f Debris removal and unclogging of outlet structure, onfice device, flow spreader, catch basins and piping g Access to the outlet structure must be available at all times 4 Records of maintenance activities must be kept and made available upon request to authorized personnel of DWQ The records will indicate the date, activity, name of person performing the work and what actions were taken The facilities shall be constructed as shown on the approved plans This permit shall become voidable unless the facilities are constructed in accordance with the conditions of this permit, the approved plans and specifications, and other supporting data 6 Upon completion of construction, prior to issuance of a Certificate of Occupancy, and prior to operation of this permitted facility, a certification must be received from an appropriate designer for the system installed certifying that the permitted facility has been installed in accordance with this permit, the approved plans and specifications, and other supporting documentation Any deviations from the approved plans and specifications must be noted on the Certification A modification may be required for those deviations 7 if the stormwater system was used as an Erosion Control device, it must be restored to design condition prior to operation as a stormwater treatment device, and prior to occupancy of the facility The permittee shall submit to the Director and shall have received approval for revised plans, specifications, and calculations prior to construction, for any modification to the approved plans, including, but not limited to, those listed below a Any revision to any item shown on the approved plans, including the stormwater management measures, built -upon area, details, etc b Project name change c Transfer of ownership d Redesign or addition to the approved amount of built -upon area or to the drainage area e Further subdivision, acquisition, or sale of all or part of the project area The project area is defined as all property owned by the permittee, for which Sedimentation and Erosion Control Plan approval or a CAMA Major permit was sought f Filling in, altering, or piping of any vegetative conveyance shown on the approved plan n State Stormwater Management Systems Permit No SW$ 031133 9 The permittee shall submit final site layout and grading plans for any permitted future areas shown on the approved plans, prior to construction If the proposed BUA exceeds the amount permitted under this permit, a modification to the permit must be submitted and approved prior to construction 10 A copy of the approved plans and specifications shall be maintained on file by the Permittee for a minimum of ten years from the date of the completion of construction ll At least 30 days prior to the sale or lease of any portion of the property, the pennittee shall notify DWQ and provide the name, mailing address and phone number of the purchaser or leasee An access/maintenance easement to the stormwater facilities shall be granted in favor of the permittee if access to the stormwater facilities will be restricted by the sale or lease of any portion of the property 12 The permittee must maintain compliance with the proposed built -upon area and ensure that the runoff from all the built -upon is directed into the permitted system 13 The Director may notify the permittee when the permitted site does not meet one or more of the minimum requirements of the permit Within the time frame specified in the notice, the permittee shall submit a written time schedule to the Director for modifying the site to meet minimum requirements The permittee shall provide copies of revised plans and certification in writing to the Director that the changes have been made 14 The permittee must maintain the current permitted drainage area No additional runoff from outside of the permitted drainage area boundary may enter the permitted stormwater facilities without first applying for and receiving a permit modification III. GENERAL CONDITIONS This permit is not transferable except after notice to and approval by the Director In the event of a change of ownership, or a name change, the permittee must submit a formal permit transfer request to the Division of Water Quality, accompanied by a completed name/ownership change form, documentation from the parties involved, and other supporting materials as may be appropriate The approval of this request will be considered on its ments and may or may not be approved The permittee is responsible for compliance with all permit conditions until such time as the Division approves the transfer request 2 Failure to abide by the conditions and limitations contained in this permit may subject the Permittee to enforcement action by the Division of Water Quality, in accordance with North Carolina General Statute 143-215 6A to 143-215 6C 3 The issuance of this permit does not preclude the Permittee from complying with any and all statutes, rules, regulations, or ordinances which may be imposed by other government agencies (local, state, and federal) which have jurisdiction 4 In the event that the facilities fail to perform satisfactorily, including the creation of nuisance conditions, the Permittee shall take immediate corrective action, including those as may be required by this Division, such as the construction of additional or replacement stormwater management systems 5 The permittee grants DENR Staff permission to enter the property during normal business hours for the purpose of inspecting all components of the permitted stormwater management facility 6 The permit may be modified, revoked and reissued or terminated for cause The filing of a request for a permit modification, revocation and reissuance or termination does not stay any permit condition 5 State Stormwater Management Systems Permit No SW8 031133 7 Unless specified elsewhere, permanent seeding requirements for the stormwater control must follow the guidelines established in the North Carolina Erosion and Sediment Control Planning and Design Manual 8 Approved plans and specifications for this project are incorporated by reference and are enforceable parts of the permit 9 The permittee shall notify the Division any name, ownership or mailing address changes within 30 days Permit issued this the 3rd day of June 2004 NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION 'fA lfiifW Klimek, P E , Director ot Division of Water Quality By Authority of the Environmental Management Commission 2 State Stormwater Management Systems Permit No SW8 031133 Georgetown Center Stormwater Permit No SW8 031133 Brunswick County Designer's Certifeation I, , as a duly registered in the State of North Carolina, having been authorized to observe (penodically/weekly/full time) the construction of the project, (Project) for (Project Owner) hereby state that, to the best of my abilities, due care and diligence was used in the observation of the project construction such that the construction was observed to be built within substantial compliance and intent of the approved plans and specifications The checklist of items on page 2 of this form is included in the Certification Noted deviations from approved plans and specification Signature Registration Number Date SEAL 7 State Stormwater Management Systems Permit No SW8 031133 Certification Requirements 1 The drainage area to the system contains approximately the permitted acreage 2 The drainage area to the system contains no more than the permitted amount of built -upon area 3 All the built -upon area associated with the project is graded such that the runoff drains to the system 4 The outlet/bypass structure elevations are per the approved plan 5 The outlet structure is located per the approved plans 6 Trash rack is provided on the outlet/bypass structure 7 All slopes are grassed with permanent vegetation 8 Vegetated slopes are no steeper than 3 1 9 The inlets are located per the approved plans and do not cause short-circuiting of the system 10 The permitted amounts of surface area and/or volume have been provided 11 Required drawdown devices are correctly sized per the approved plans 12 All required design depths are provided 13 All required parts of the system are provided, such as a vegetated shelf, and a forebay 14 The overall dimensions of the system, as shown on the approved plans, are provided cc NCDENR-DWQ Regional Office Brunswick County Building Inspections �F W A ��� tilichael F Easley Governor i Q William G Ross Jr, Secretary North Carolina Department of Environment and Natural Resources yAlan W Klimek P E Director Q .0 Division of Water Quality Coleen H Sullins Deputy Director Division of Water Quality May 10, 2004 Mr Bryan English 4705 Southport — Supply Highway Southport, NC 28461 Subject REQUEST FOR ADDITIONAL IINFORNIATIO` Stormwater Project No SWS 031133 Georgetown Center Brunswick County Dear Mr English The Wilmington Regional Office received a Stormwater Management Permit Application for Georgetown Center on April 29, 2004 A preliminary review of that information has determined that the application is not complete The following information is needed to continue the stormvvater review i 1 Please provide a legend on the plans Please indicate the wetlands line on the legend and more clearly indicate the wetlands line on the plans / 2 Please provide the latitude and longitude on Section I of the application 3 Vincent Lewis, state soils scientist, must verify the location of the seasonal high water table I will setup an appointment with Vincent and notify you of the date All utilities must be marked on the site prior to the investigation 4 Please provide the name of the tributary that the site drains to on Section III Item 6 of the application Please revise the plans to show the vegetative filter detail The runoff in excess of 1" must bypass the system prior to entering the system The excess runoff cannot pass through the system If you cannot provide this bypass, please design the system for the 2" storm event 6 Please design the trench for a 40% void ratio q �- "to 7 The trench dimensions on the calculations are different than the dimensions on the supplement My calculations show that you must provide 1,835 cubic feet of storage Please revise 8 Please provide a cleanout elevation for the trench The sediment must be removed annually or when the depth is reduced to 75% of the original design depth 9 Please provide a 4" layer of clean sand on the bottom of the system Qar N C Division of Water Quality 127 Cardinal Drive Extension (910) 395-3900 Customer Servioe Wilmington Regional Office Wilmington, NC 28405 (910) 350-2004 Fax 1 800 623-7748 NMEIOR 1+Ir Bryan English Page 2 May 10, 2004 Please note that this request for additional information is in response to a preliminary review The requested information should be received by this Office prior to May 17, 2004, or the application will be returned as incomplete The return of a project will necessitate resubmittal of all required items, including the application fee If you need additional time to submit the information please mail or fax your request for a time extension to the Division at the address and fax number at the bottom of this Ietter The request must indicate the date by which you expect to submit the required information The DiNision is allowed 90 da-ts from the receipt of a completed application to issue the permit The construction of any impervious surfaces, other than a construction entrance under an approved Sedimentation Erosion Control Plan, is a violation of NCGS 143-215 1 and is subject to enforcement action pursuant to NCGS 143-215 5A Please reference the State assigned project number on all correspondence Any original documents that need to be revised have been sent to the engineer or agent All original documents must be returned or new originals must be provided Copies are not acceptable If you ha,.e any questions concerning this matter please feel free to call me at (910) 395-3900 Sincerely, Laurie Munn Environmental Engineer RSS/ Ism S1WQSISTORMWATIADDINFO120041031133 may04 doc cc Laurie Munn Steve Greer Kenneth L Clark, P E Enclosures 13-'PA55 L1NG-To - _. VEC-r:7ATED FI LTV TO OR SAS / �1 Ru►voFF GRATED TOP_ RUroFF 1NP-i -WALL_ 7RpaK VECUTA•! [ n r I I.TrR DLTATI, A afp u,Ip 1 nergy 30' 1)IsSi��inr.� M W0 3 •;� 1 �, f PIP111g llnw Spreader Mechanism * 50' For SA Class Waters 11 With h as reqtilred to provide non-erosJve flow Reeel vinr Stream PLAN SI:C'rfON A -A FILE MODE — 605 MEMORYTX * * * COMMUNICATION RESULT REPORT ( MAY 11 2004 OPTION REASON FOR ERROR E-1) HANG UP OR LINE FAIL E-3) NO ANSWER ADDRESS (GROUP) --- B-9104571095 P 1 B 53AM ) TTI NCDENR WIRO RESULT PAGE ------------------------- OK P 6/6 E-2) BUSY E-4) NO FACSIMILE CONNECTION Mate of forth Carolina Department of Environment and Natural Resources Wilmington Regional Office Michael F Easley, Governor William G. Ross Jr, Secretary FAX COVER SHEET Date: O a4 Tot Co: FAX #:C61 l0 Li b`3- ` 10q T- REMARKS: 'P1P&ze' No. Of Pages: _ From. yn ZA- r i n FAX#: 910-350-2004 N 127 Cardinal Drive Extension, Wilmlggton, N C. 29405-3945 Tslephorie (410)305-3900 Fax (91.4) 350.2004 An Equal Opportunky A[firmolive Athon Employer State of North Carolina Department of Environment and Natural Resources Wilmington Regional Office Michael F Easley, Governor William G Ross Jr, Secretary FAX COVER SHEET Date:C)/0LI To: CO: FAX #: C0 /0 LIT--" '�- REMARKS: PI2Q42 No. Of Pages: From: t,LAA-JU VIq U-rn n CO: _Ou7Ca_ FAX#: 910-350-2004 �I q 127 Cardinal Drive Extension, Wilmington, N C 28405-3845 Telephone (910) 395-3900 Fgx (910) 350-2004 An Equal Opportunity Affirmative Action Employer EB ENGLISH 4APRa9zoo�BUILDERS E 4705-106 Southport -Supply Highway Southport, North Carolina 28461 Mr Rich Shiver Division of Water Quality 1617 Mail Service Center Raleigh, North Carolina 27699-1617 Storm Water Permit No. Sw8 031133 Mr Rich Shiver, As specified, and condoned by due notification of this violation, English Builders, Inc is formally requesting a remission or mitigation for the charges of failing to apply for or secure a permit required by NCGS 143-215 1 I want to start by issuing a background to the 3 1-acre site that was permitted for storm water permit in 1999 A partner and I purchased this tract of land in 1998 as MIK_B LLC and proceeded to develop a plan for site development We contracted with Klien Engineering to design and apply for NC Storm Water Permit and Erosion Control Permit In Dec of 1998 we were issued an erosion control permit At that point we proceeded to clear the property and install erosion control devises I believe in Feb we were issued our storm water permit for the 3 1 acres We then began to construction of the storm water system, that consisted of dig the pond and installing the overflow system of the pond Sometime in April or May we were approached by an agent for C-3 Development (Gordon Lovingood) to purchase a portion of or property for a Hampton Inn At that time we stopped all construction at the site After a sales contract was settled upon C-3 Development developed there site plan for the motel and parking Their engineer Tripp Engineering of Wilmington contacted me about modifying our permit ( MIK-B LLC ) by our agreement of the sales contract that we ( MIK-B LLC ) would allow a modification of our permit for their project This is where I become dismayed at the events that took place 1) At the time C-3 applied for a modification of our permit, MIK-B LLC still owned the entire 3 1 acre tact of Iand 2) C-3 misrepresented the fact that they were the owners of the land and with the modification the permit was placed in C-3's name The property exchanging ownership from MIK-B LLC to C-3 did not take place till after the modification was in place 3) Charles at Tripp Engineering to authorize the modification of MIK-B LLC's permit for C-3's development plans contacted me I no way was I informed that this permit would not still be in the name of MIK-B LLC I was also assured that the remaining impervious surface was still dedicated to the remainder of the original tract 4) When we went to modify the permit for the remainder of the site we found that the permit had been taken out of our name Instead of raising a stink about the permit being taken out of our name we proceeded in the manner that is of record at this time S) I contacted C-3 to inform Gordon of our plans to connect to the storm water system He then raised the issue of us tying into the rentxon pond He said if he found that our agreements didn't allow this he would get back with me I tried to call Gordon several times and with no response I assumed that he found that we did have the right to tie into the storm water system and it was a dead issue Steve Geer project manager for Rob Armstrong and myself meet with Linda Lewis in her office Friday March 20h to go over our position and our plan to rectify this issue New plans for storm water will be applied for this week using the fast tract method to let our project move along and expedite bringing our site in to compliance to NC Standards and your office Thank you for the opportunity to present our side of the case, as we perceive it We hope that this will give you a little insight as to how we perceive we inadvertently began construction and will give some consideration in our behalf, as we perceived we were acting in the outmost professional capacity Sincerely, E Bryan English Member / Manager MIK-B LLC Land Management Group, Inc. Environmental Consultants Post Office Box 2522 Wilmington, North Carolina 28402 Telephone: 910-452-0001 Mann Office Sus to 15 Downey Branch Office Park 3805 Vrz9htsvz12e Avenue Wilmington, NC 28403 Apnl 5, 2004 P O Box 1120 504 Croatan Street Manteo, NC 27954 Phone. 252-4 73- 3400 Bnan English 4705 Southport Supply Rd Southport, NC 28461 Reference Soils evaluation for the Old Georgetown Center stormwater project, Southport, Brunswick County, North Carolina Dear Mr English, On March 29, 2004, Land Management Group, Inc completed the soil charactenzation for a proposed stromwater infiltration basin serving the above -mentioned tract totaling approximately 0 92 acres, located off Southport Supply Road The proposed area contains both fill material and natural soils Three bonngs were made within 20' of the road nght-of-way of Southport Supply Road and at the edge of the proposed parking lot Bonngs were located at a distance of 75', 115', and 150' off the northwest property corner The boring located 75' off the property cornier contained loamy fine sand/fine sandy loam textured natural soils At this location the seasonal high water table was 60" and the infiltration ranges from 3 in/hr to 4 in/hr The other two borings contained coarse textured sandy clay loam fill matenal to depths of approximately 40" Because of this finer textured soils and the corresponding slow infiltration rate of approximately 0 5 in/hr, it is recommended the proposed basin bottom be placed to a depth of at least 40" The infiltration rates of the underlying soil is approximately 1 m/hr The seasonal high water table in these other two locations is greater than 65" Please do not hesitate to contact me at (910)452-0001 or (910)471-0509 if you have any questions Sincerely 3 Tom Gulley cc Steve Greer bk� Lightweight Concrete and Aggregates Thomas A Holm, Authorized Reprint from Standard Technical Publication 169C Copyright 1994 American Society for Testing and Materials, 1916 Race Street, Philadelphia, PA 19103 PREFACE Lightweight concrete and aggregates were first discussed by R E Davis and J Kelly in the 1956 edition of ASTM STP 169 The ASTM STP 169A and ASTM STP 169B editions were authored by D W Lewis The general presentation of this paper is similar to earlier chapters, however, additional information on elastic properties of lightweight aggregates, as well as strength making, durability, and placement characteristics of lightweight concrete is included to reflect the current state of the art This edition also includes new discussions relative to the contact zone and internal curing as well as revisions to ASTM methods for calculating the equilibrium density of structural lightweight concrete adopted by ASTM since the publication of ASTM STP 1698 in 1978 CLASSIFICATION OF LIGHTWEIGHT AGGREGATES AND LIGHTWEIGHT AGGREGATE CONCRETES ASTM Standards provide requirements for lightweight aggregates that are used in structural masonry units and insulating types of concrete Structural and insulating lightweight aggregate concretes are broadly divided into three groups based upon their use and physical properties Unit weight, thermal conductivity and compressive strength ranges normally associated with each class of concrete are summarized in (Table 1) This chapter addresses concretes where weight reduction is achieved through the use of lightweight aggregates and does not include cellular or foam concrete, where lighter weight is developed primarily by inclusion of large amounts of air or gas through foaming -type agents Nofines concretes with very large, unfilled interstitial voids produced with aggregate content deficient in fine aggregates are also excluded from this review, which restricts discussion to the predominant forms of lightweight aggregate concretes based upon inorganic lightweight aggregates Vice president of Engineering, Solrte Corporation, Richmond, VA 23261 STRUCTURAL -GRADE LIGHTWEIGHT AGGREGATE AND STRUCTURAL LIGHTWEIGHT AGGREGATE CONCRETE Structural -grade lightweight concretes generally contain aggregates made from pyroprocessed shales, clays, slates, expanded slags, expanded fly ash, and those nuned from natural porous volcanic sources Minimum compressive strength of structural -grade lightweight aggregate concrete has, in effect, been jointly established by the ASTM Specification for Lightweight Aggregates for Structural Concrete (C 330) and the Standard Building Code for Reinforced Concrete (ACI 318) [11 which requires that "Structural concrete made with lightweight aggregate, the air-dned unit weight at 28 days is usually in the range of 1440 to 1850 kg/nb(90 to 115 lb/ft,) and the compressive strength is more than 17 2 MPa (2500 psi) " This is a definition, not a specification and project requirements may permit equilibrium unit weights up to 1900 kg/m, (120 lb/fb) Although structural concrete with equilibrium unit weights from 1450 to 1920 kg/rib (90 to 120 lb/ft,) are often used, most lightweight aggregate concrete used in structures have equilibrium unit weights between 1600 to 1760 kg/m, (100 and 110 lb/ft,) Structural -grade Iightweight aggregates are produced in manufacturing plants from raw materials including suitable shales, clays, slates, fly ashes, or blast furnace slags Naturally occurring lightweight aggregates are nuned from volcanic deposits that include pumice and scoria types Pyroprocessmg methods include the rotary kiln process (a long, slowly rotating, nearly horizontal cylinder lined with refractory materials similar to cement kilns), the sintering process wherein a bed of raw materials including fuel is carried by a traveling grate under ignition hoods, and the rapid agitation of molten slag with controlled amounts of air or water No single description of raw material processing is all-inclusive and the reader is urged to consult local lightweight aggregate manufacturers for physical and mechanical properties of lightweight aggregates and the concrete made with them Increased usage of processed lightweight aggregates is evidence of environmentally sound planning, as these products utilize materials with limited structural applications in their natural state, thus mmirruzmg construction industry demands on finite resources of natural sands, stones, and gravels ASTM C 330 requires fine lightweight aggregates used in the production of structural lightweight concrete to be properly graded, with 85 to 100% passing the 4 75 mm HOLM ON LIGHTWEIGHT CONCRETE AND AGGREGATES 523 TABLE 1—Lightweight Aggregate (LWA) Concrete Classified According to Use and Physical Properties. Type of Lightweight Typical Range of Class of Lightweight Aggregate used in Lightweight Concrete Typical Range of Typical Range of Aggregate Concrete Concrete Unit Weight Compressive Strength Thermal Conductivities Structural Structural -grade (1440 to 1840) (>17) (>2500) not specified in C 330 LWA C 330 90 to 115 air dry Structural/ Either structural C 330 (800 to 1440) (3 4 to 17) (500 to 2500) C 332 from (0 22) (l 50) Insulating or insulating C 332 (50 to 90) air dry to (0 43) (3 00) oven or a combination dry Insulating of C 330 and C 332 Insulating -grade LWA (240 to 800) (0 7 to 3 4) 100 to 500 C 332 from (0 065) (0 45) C 332 (15 to 50) oven dry to (0 22) (1 50) oven dry Unit weights are in (kglm,) (lb/ft,), compressive strengths in (MPa) (psi), and thermal conductivity in (W1m - °K) (Btu • in A °F) (3/16 in ) screen with a dry loose bulk density less than 1120 kg/rrb (70 lb/fh) Four coarse aggregate gradations are provided for use in structural lightweight concrete with maximum dry loose bulk density limited to 880 kg/m3(55 lb/ fb) Combined fine and coarse aggregate formulations must not exceed a maximum dry loose unit weight of 1040 kg/m, (65 Ib/%) Tests are conducted in accordance with ASTM Test Method for Unit Weight and Voids in Aggregate (C 29) using the shoveling procedure INSULATING -GRADE LIGHTWEIGHT AGGREGATES AND INSULATING LIGHTWEIGHT CONCRETES Very light nonstructural concretes, employed primarily for high thermal resistance, incorporate low -density lowstrength aggregates such as vermiculite and perlite With low unit weights, seldom exceeding 800 kg/m,(50 lb/ft3), thermal resistance is high These concretes are not intended to be exposed to the weather and generally have a compressive strength range from about 0 69 to 6 89 MPa (100 to 500 psi) ASTM Specification for Lightweight Aggregates for Insulating Concrete (C 332) limits thermal conductivity values for insulating concretes to a maximum of 0 22 W/ m-K (1 50 Btu - in 2 /h - ftz°F) for concrete having an oven -dry density of 800 kg/m, (50 lb/fti) or less, and to 0 43 W/m G K (3 0 Btu - in - /h 2 ffi°F) for those weighing up to 1440 kg/m,(90 lb/%) Lighter concretes are those made with Group I aggregates (perlites and vermiculite), while higher unit weights result from the use of Group II aggregates (expanded shales, expanded slags and natural lightweight aggregates) Thermal conductivity values may be determined in accordance with ASTM Test Method for Steady -State Thermal Performance of Building Assemblies by Means of a Guarded Hot Box (C 236) and ASTM Test Method for Steady -State Heat Flux Measurements and Thermal Transmission Properties by Means of the Guarded -Hot - Plate Apparatus (C 177) Oven -dried specimens are used for both thermal conductivity and unit weight tests on the insulating concretes Moisture content of insulating materials directly affects both the thermal conductivtty and unit weight, but to varying degrees A I % increase in moisture content will increase unit weight by an equivalent 1 % but may increase thermal conductivity by as much as 5 to 9% [2] Use of oven -dried specimens provides an arbitrary basis for comparison but clearly does not duplicate in-service applications The controlled test conditions serve to permit classification of materials and to provide a standardized reference environment STRUCTURAL/INSULATING LIGHTWEIGHT AGGREGATE CONCRETES Widespread industrial applications that call for "fill" concretes require modest compressive strengths with densities intermediate between the structural- and msulatinggrade concretes These concretes may be produced with high air mixes with structural -grade lightweight aggregate, with sanded insulating lightweight aggregate mixes, or with formulations incorporating both structural- and insulating -grade lightweight aggregates Compressive strengths from 3 4 to 17 MPa (500 to 2500 psi) are not uncommon with thermal resistance less than concretes containing only insulating -grade lightweight aggregate LIGHTWEIGHT AGGREGATE PROPERTIES Internal Structure of Lightweight Aggregates Lightweight aggregates develop low particle specific gravity because of the cellular pore system Cellular structure within the particles is normally developed at high temperatures by formation of gases due to the reaction of heat on certain raw material constituents coincident with incipient fusion causing gas expansion to be trapped in the viscous, pyroplastic mass Strong, durable lightweight aggregates are produced when small -size, well -distributed, noninterconnected pores are enveloped in a continuous, crack free, vitreous phase [3] (Fig 1) PARTICLE SHAPE AND SURFACE TEXTURE Depending on the source and the method of production, lightweight aggregates exhibit considerable differences in 524 TESTS AND PROPERTIES OF CONCRETE FIG 1 -Contact zone -structural lightweight concrete from 30-year-old bridge deck, W P Lane Memorial Bridge over the Chesapeake Bay, Annapolis, Maryland compression strength 24 MPa (3500 psi), density 1680 kglm,(105 lb/ft.) particle shape and texture Shapes may be cubical, rounded, angular, or irregular Textures may range from fine pore, relatively smooth skins to highly irregular surfaces with large exposed pores Particle shape and surface texture directly influence workability, coarse -to -fine aggregate ratio, cement content requirements, and water demand in concrete mixes, as well as other physical properties SPECIFIC GRAVITY The specific gravity of an aggregate is the ratio between the mass of a quantity of the material and the volume occupied by the individual particles contained in that sample This volume includes the pores within the particles but does not include the voids between the particles In general, the volume of the particles is determined from the volume displaced submerged in water when penetration of water into the particles during the test is limited by previous saturation Specific gravity of individual particles depends both on the specific gravity of the poreless vitreous material and the pore volume within the particles, and generally increases when particle size decreases The specific gravity of the pore -free vitreous material may be determined by pulverizing the lightweight aggregate in a jar null and then following procedures used for determination of the specific gravity of cement in the ASTM Test Method for Density of Hydraulic Cement (C 188) BULK UNIT WEIGHT OF LIGHTWEIGHT AGGREGATES Aggregate bulk unit weight is defined as the ratio of the mass of a given quantity of material and the total volume occupied by it This volume includes the voids between as well as within the particles Unit weight is a function of particle shape, density, size, gradation, and moisture content, as well as the method of packing the material (loose, vibrated, rodded) and varies not only for different materials, but for different sizes and gradations of a particular material Table 2 summarizes the maximum unit weights for lightweight aggregates listed in ASTM C 330, ASTM Specification for Lightweight Aggregates for Concrete Masonry Units (C 331), and ASTM C 332 Minimum unit weights for perlite and vermiculite are also provided to linut over -expanded, weak particles that would break down in mixing Density of insulating concrete is usually determined in an over -dry condition, using oven -dry weight and dimensions of specimens associated with to those subjected to either thermal conductivity or compressive strength tests Density of insulating concretes made with perlite or vermiculite aggregates or cellular concretes may range from 240 to 800 kg/rrb (15 to 50 lb/ft.), while those made with other types of lightweight aggregates are usually in the range of 800 to I440 kg/nv (50 to 90 lb/ft3) TOTAL POROSITY Void content (within particle pores and between particles' voids) can be determined from measured values of particle specific gravity and bulk unit weight If, for example, measurements on a sample of lightweight coarse aggregate are 2 3 bulk dry loose unit weight, 770 kg/rry (48 lb/fib), particle specific gravity, 1400 kg/m,, and specific gravity of poreless vitreous material, 2500 kg/mb, TABLE 2 —Requirements of ASTM C 330, C331, and C 332 for Dry Loose Unit Weight of Lightweight Aggregates Maximum Minimum Aggregate Unit Weight, Unit Weight, Size and Group kglm,(lb/ft ,) kg/m,(ib/ft,) ASTM C 330 AND C 331 fine aggregate coarse aggregate combined fine and coarse aggregate ASTM C 332 Group I Perhte Vermiculite Group 2 fine aggregate coarse aggregate combined fine and coarse aggregate (1120)(70) (880)(55) (1040)(65) (196) (12) (120) (7 5) (160) (10) (88) (5 5) (1120)(70) (880)(55) (1040)(65) HOLM ON LIGHTWEIGHT CONCRETE AND AGGREGATES 525 then the fractional pore volume of an individual particle is 2500-1400 = 0 44 2500 and the fractional interstitial void volume (between particles) is 1 11400-7700 rm For this example, total porosity (pores and voids) would then equal [0 45 + (0 44 X 0 55)] m 0 69 GRADATION Gradation requirements are generally smular to those provided for normal -weight aggregate with the exception that lightweight aggregate particle size distribution permits a higher weight through smaller sieves This modification recognizes the increase in specific gravity typical for the smaller particles of most lightweight aggregates, and that while standards are established by weights passing each sieve size, ideal formulations are developed through volumetric considerations An exception to the procedures of ASTM Method for Sieve Analysis of Fine and Coarse Aggregates (C 136) requires reduction of the weight of fine aggregate sample tested according to the lightweight aggregate's unit weight, and sieving time not to exceed 5 min Producers of structural Iightweight aggregate normally stock materials in several standard size formulations of coarse, mtermediate, and fine aggregate By combining size fractions or by replacing some or all of the fine fraction with a normal -weight sand, a wide range of concrete unit weights may be obtained The aggregate producer is the best source of information for the proper aggregate combinations to meet fresh unit weight specifications and equilibrium unit weights for dead load design considerations Normal -weight sand replacement will typically increase unit weight from about 80 to more than 160 kg/rm (5 to 10 lb/%) Using increasing amounts of cement to obtain high strengths above 35 MPa (5000 psi) concrete will increase air dry density from 32 to 96 kg/m, (2 to 6 lb/fli) ABSORPTION CHARACTERISTICS Due to their cellular structure, lightweight aggregates absorb more water than their normal -weight aggregate counterparts Based upon a 24-h absorption test, conducted in accordance with the procedures of ASTM Test Method for Specific Gravity and Absorption of Coarse Aggregate (C 127) and ASTM Test Method for Specific Gravity and Absorption of Fine Aggregate (C 128), structural - grade lightweight aggregates will absorb from 5 to more than 25% by weight of dry aggregate By contrast, normal -weight aggregates generally absorb less than 20/0 of moisture The important difference in measurements of stockpile moisture contents is that with lightweight aggregates the moisture is largely absorbed into the interior of the particles whereas in normal -weight aggregates it is primarily surface adsorption Recognition of this essential difference is important in mix proportioning, batchmg, and control Rate of absorption of lightweight aggregates is dependent on the characteristics of pore size, connection, and distribution, particularly those close to the surface Internally absorbed water within the particle is not immediately available for chemical interaction with cement as mixing water, but extremely beneficial in maintaining longer periods of curing essential to improvements in the aggregate/matrix contact zone Internal curing will also bring about reduction of permeability by extending the period in which additional products of hydration are formed in the pores and capillaries of the binder MODULUS OF ELASTICITY OF LIGHTWEIGHT AGGREGATE PARTICLES The modulus of elasticity of concrete is a function of the moduli of its constituents Concrete may be considered as a two-phase material consisting of coarse aggregate inclusions within a continuous "mortar" fraction that includes cement, water, entrained air, and fine aggregate Dynamic measurements made on aggregates alone have shown a relationship corresponding to the function E = 0 008 pi, where E is the dynamic modulus of elasticity of the particle in MPa and p is the dry mean specific gravity in kg/m, [4] (Fig 2) Dynamic moduli for usual expanded aggregates have a range of 10 to 16 GPa (1 45 to 2 3 X 10.psi), whereas the range for strong ordinary aggregates s FIG 2-Relationship between mean particle density and the mean dynamic modulus of elasticity for the particles of lightweight aggregate [12] 526 TESTS AND PROPERTIES OF CONCRETE is approximately 30 GPa (4 35 X 106psi) to 100 GPa (14 5 x 106 psi) PROPERTIES AND PRODUCTION OF LIGHTWEIGHT AGGREGATE CONCRETE Comprehensive reports detailing the properties of lightweight concretes and lightweight aggregates have been published by Shideler (5], Reichard (6], Helm [7], Carlson [8], and Valore [9,10) The first three deal with structuralgrade concretes, Carlson reported on lightweight aggregate for concrete masonry units, and Valore covered both structural and insulating concretes In most instances, test procedures for measuring properties of lightweight concretes were the same as commonly used for normalweight concretes In limited cases, special test procedures particularly suited to measure lightweight concrete characteristics were developed PROPORTIONING In general, proportioning rules and techniques used for ordinary concrete mixes apply to lightweight concrete with added attention given to concrete unit weight and the influence of the water absorption charactenstics of the lightweight aggregate [11] Most structural -grade lightweight concretes are proportioned by absolute volume methods in which the fresh concrete produced is considered equal to the sum of the absolute volumes of cement, aggregates, net water, and entrained air Proportioning by this method requires the determination of absorbed and adsorbed moisture contents and the as -used specific gravity of the separate sizes of aggregates A widely used alternative to the absolute volume procedures is to proportion lightweight concrete mixes by the damp loose volume method [I 1 ] Specifications for structural -grade lightweight concrete usually require nummum values for compressive and tensile splitting strength, maximum limitations on slump, specified ranges of air content, and, finally, a linutation on maximum fresh unit weight Reduction of concretes' high density leads to improved structural efficiency and is, therefore, an important consideration in proporttamng lightweight concrete mixtures While this property depends pnmarily on the specific gravity of the lightweight aggregates, it is also influenced to a lesser degree by cement, water, and air contents, and proportions of coarse -to -fine aggregate When lightweight aggregates contain levels of absorbed moisture greater than that developed after a one -day immersion, the rate of further absorption will be very low and for all practical purposes lightweight concrete may be batched, placed, and finished with the same facility as their normal -weight concrete counterparts Under these conditions water/cement (w/c) ratios, while not normally specified, may be established with precision comparable to concretes containing normal -weight aggregates Water absorbed within the lightweight aggregate prior to mixing is not available for calculating the volume of cement paste at the time of setting This absorbed water is available, however, for continued cement hydration after external curing has ended The general practice is to proportion the mix for a particular lightweight aggregate on the basis of a cement content at a given slump As with normal -weight concrete, air entrainment in lightweight concrete significantly improves durability and resistance to scaling In concretes made with angular lightweight aggregates, it is also an effective means of improving workability of otherwise harsh mixtures With moderate air contents, bleeding and segregation are reduced and mixing water requirements lowered while maintaining optimum workability Because of the elastic compatibility of the lightweight aggregate and cementitious binder phases, strength reduction penalties due to high air contents will be lower for structural lightweight concrete than for normal -weight concretes [12] Recommended ranges of total air content of usual structural lightweight concretes are shown in Table 3 Air content of lightweight aggregate concretes is determined in accordance with the procedures of ASTM Test Method for Air Content of Freshly Mixed Concrete by the Volumetnc Method (C 173) Volumetric measurements assure reliable results while pressure meters will provide erratic data due to the influence of aggregate porosity Air contents higher than are required for durability considerations are frequently developed for high thermal resistance, or for lowering unit weight of semi -structural "fill" concrete, with reduced compressive strength as a natural consequence Use of water reducers, retarders, and superplasticizers will result in improved lightweight concrete characteristics in a manner similar to that of normal -weight concretes, however, superplasticizers, while effective, will increase the density of lightweight as well as other concretes MIXING, PLACING, FINISHING, AND CURING When properly proportioned, structural lightweight concrete can be delivered and placed with the same facility as ordinary concretes The most important consideration in handling any type of concrete is to avoid separation of coarse aggregate from the mortar fraction Basic principles required to secure a well -placed lightweight concrete include (a) well-proportioned, workable mixes that use a minimum amount of free water, (b) equipment capable of expeditiously moving the concrete, (e) proper consolidation in the forms, and (d) quality workmanship in finishing TABLE 3 —Total Air Content for Lightweight Concretes Maximum Size of Aggregate Air Content, % by volume (20 mm) (3/4 in ) 4 to 8 (10 mm) (3/8 in ) 5 to 9 HOLM ON LIGHTWEIGHT CONCRETE AND AGGREGATES 527 Well-proportioned structural lightweight concretes can be placed and screeded with less physical effort than that required for ordinary concrete Excessive vibratation should be avoided, as this practice serves to drive the heavier mortar fraction down from the surface where it is required for finishing On completion of final finishing, curing operations similar to ordinary concrete should begin as soon as possible Lightweight concretes batched with aggregates having high absorption carry their own internal water supply for curing within the aggregate and as a result are more forgiving to poor curing practices or unfavorable ambient conditions This "internal curing" water is transferred from the lightweight aggregate to the mortar phase as evaporation takes place on the concrete surface, thus maintaining continuous moisture balance by replacing moisture essential for an extended continuous hydration period determined by ambient conditions and the as -batched lightweight aggregate moisture content Lightweight aggregates may absorb part of the mixing water when exposed to increased pumping pressures To avoid loss of workability, it is essential to raise the presoak absorption level of lightweight aggregates prior to pumping Presoaking is best accomplished at the aggregate production plant where uniform moisture content is achieved by applying water from spray bars directly to the aggregate moving on belts This moisture content can be maintained and supplemented at the concrete plant by stockpile hose and sprinkler systems Presoaking will significantly reduce the lightweight aggregates' rate of absorption, minimizing water transfer from the mortar fraction that, in turn, causes slump loss during pumping Higher moisture contents developed during presoaking will result in increased specific gravity that, in turn, develops higher fresh concrete unit weight Higher water content due to presoaking will eventually diffuse out of the concrete, developing a longer period of internal curing as well as a larger differential between fresh and equilibrium unit weight than that associated with lightweight concretes placed with lower moisture contents Aggregate suppliers should be consulted for r ux design recommendations necessary for consistent pumpabiltty LABORATORY AND FIELD CONTROL Changes in lightweight aggregate moisture content, gradation, or specific gravity as well as usual job site variation in entrained air suggest frequent checks of the fresh concrete to facilitate adjustments necessary for consistent concrete characteristics Standardized field tests for consistency, fresh unit weight, and entrained -air content should be employed to verify conformance of field concretes with design mixes and the project specification Sampling should be conducted in accordance with ASTM Practice for Sampling Freshly Mixed Concrete (C 172) and ASTM Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method (C 173) The ASTM Test Method for Unit Weight of Structural Lightweight Concrete (C 567) describes methods for calculating the mservice, equilibrium unit weight of structural lightweight concrete In general, when variations in fresh density exceed ±2%, an adjustment in batch weights may be required to restore specified concrete properties To avoid adverse effects on durability, strength, and workability, air content should not vary more than ±1 5% from specified values DENSITY OF STRUCTURAL LIGHTWEIGHT CONCRETE Although there are numerous structural applications of all lightweight concretes (coarse and fine lightweight aggregate), usual commercial practice in North America is to design sanded lightweight concretes where part or all of the fine aggregates used is natural sand Long -span bridges using concretes with three-way blends (coarse and fine lightweight aggregates and small supplemental natural sand volumes) have provided long-term durability and structural efficiency (density/strength ratios) [14] Earliest research reports [5, 6, 15, 16] compared all lightweight concretes with "reference" normal -weight concrete while later studies reported in Refs 13, 17-19 supplemented the early findings with data based upon sanded lightweight concretes The fresh unit weight of lightweight aggregate concretes is a function of mix proportions, air contents, water demand, and the specific gravity and moisture content of the lightweight aggregate Decrease in density of exposed concrete is due to moisture loss that, in turn, is a function of ambient conditions and surface area/volume ratio of the member Design professionals should specify a maximum fresh density for lightweight concrete, as limits of acceptability should be controlled at time of placement Dead loads used for design should be based upon equilibrium density that, for most conditions and members, may be assumed to be reached after 90 days Extensive tests conducted dunng North American durability studies demonstrated that despite wide initial variations of aggregate moisture content, equilibrium density was found to be 50 kg/nu (3 1 lb/fig) above oven -dry density (Fig 3) European recommendations for in-service density are similar [4] When weights and moisture contents of all the constituents of the batch of concrete are known, an approximate calculated equilibrium density may be determined according to ASTM C 567 from the following equation E=0+50kg/nb(E=0+3lb/ft3)(1) where 0= A + 1 2W, E = calculated equilibrium unit weight, kg/nb (lb/fh), 0 = approximate oven -dry weight, kg/m3 (lb/fb), A = weight of dry aggregates in batch, kg (lb), W = weight of cement in batch, kg (lb), and 12 = weight of hydrated water of hydration (estimated at 20% by weight of cement) COMPRESSIVE STRENGTH Compressive strength test procedures for structural lightweight aggregate concretes are similar to those for 528 TESTS AND PROPERTIES OF CONCRETE TIME OF DRYING {DAYS) - FRESH DENSITY Specified for field control (unit weight bucket) Measurements on 0 X 12 (150 X 300 mm) cylinder* will average 2 50 (40kglm.) higher than field measurements on 5 pd ( 014 kgm.) unit weight bucket EQUILIBRIUM DENSITY Typically Spef (50 kglm.) greater than OVEN DRY FIG 3-Concrete density versus time of drying for structural lightweight concrete normal -weight concretes with the exception of the 21-day laboratory air 23°C (73 4°F) and 50% relative humidity drying period required by the procedures of ASTM Test Method for Splitting Tensile Strength of Cylindrical Concrete Specimens (C 496) and ASTM C 567 While most structural -grade lightweight aggregates are capable of producing concretes with compressive strengths in excess of 35 MPa (5000 psi), a limited number of lightweight aggregates can be used in concretes that develop cylinder strengths from 48-69 MPa (7000 to 10000 psi) While compressive strengths of 21 to 35 MPa (3000 to 5000 psi) are common for cast-m-place structural lightweight concretes, 41 MPa (7000 psi) strengths are presently being specified for offshore applications Light weight aggregate concrete will demonstrate a strength "ceiling" where further additions of cementitious materials will not significantly raise the maximum attainable strength Strength ceilings that differ for each lightweight aggregate source are the result of pore size and distribution as well as the strength characteristics of the porefree vitreous material surrounding the pores The strength ceiling of a particular lightweight aggregate may be considerably increased by reduction of the top size in a particular grading formulation Compressive strength tests of lightweight insulating concrete having oven -dry unit weights not exceeding 800 kg/m, (50 lb/fh) are conducted in accordance with ASTM Test Method for Compressive Strength of Lightweight Insulating Concrete (C 495) on 75 X 150 mm (3 X 6 in) cylinders Twenty-five days after molding, the specimens are oven-dned at 60 f 2 8°C (140 ± 5°F) for three days, cooled to room temperature, and tested for compressive strength at 28 days ASTM Methods of Securing, Preparing, and Testing Specimens from Hardened Lightweight Insulating Concrete for Compressive Strength (C 513) provides procedures for the determination of the compressive strength of cube specimens from hardened, field lightweight insulating concretes TENSILE STRENGTH Shear, torsion, anchorage, bond strengths, and crack resistance are related to tensile strength that is, in turn, dependent upon tensile strength of the coarse aggregate and mortar phases and the degree to which the two phases are securely bonded Traditionally, tensile strength has been defined as a function of compressive strength, but this is known to be only a first approximation that does not reflect aggregate particle strength, surface characteristics, nor the concrete's moisture content and distribution The splitting tensile strength, as determined by ASTM C 496, is used throughout North America as a simple, practical design criteria that is known to be a more reliable indicator of tensile -related properties than beam flexural tests Splitting tests are conducted by applying diametrically opposite compressive line loads to a concrete cylinder laid horizontally in a testing machine A mrmmurn tensile splitting strength of 2 0 MPa (290 psi) is a requirement for structural -grade lightweight aggregates confornung to the requirements of ASTM C 330 Tests have shown that diagonal tensile strengths of beams and slabs correlate closely with the concrete splitting strengths [20, 21 ] As tensile splitting results vary for different combinations of materials, the specifier should consult with the aggregate suppliers for laboratory -developed splitting strength data Special tensile strength test data should be developed prior to the start of unusual projects where development of early -age tensile -related handling forces occur as in precast or tilt -up members Tensile strength tests on structural lightweight concrete specimens that undergo some drying correlate better with the behavior of concrete in actual structures Moisture loss progressing slowly into the interior of concrete members will result in the development of outer envelope tensile stresses that balance the compressive stresses in the still -moist interior zones ASTM C 496 requires a sevenday moist and 21-day laboratory air drying at 23°C (73 47) and 50%0 relative humidity prior to conducting splitting tests Structural -lightweight -concrete splitting tensile strengths vary from approximately 75 to 100% of normalweight concretes of equal compressive strength Replacing lightweight fine aggregate with normal -weight fines will normally increase tensile strength ELASTIC PROPERTIES The modulus of elasticity of concrete is a function of the modulus of each constituent (border matrix, expanded and normal density aggregates) and their relative mix proportion The elastic modulus of normal -density concretes is higher because the moduli of the natural aggregate particles (and parent rock formations) are greater than the moduli of lightweight aggregate particles For practical design conditions, the modulus of elasticity of concretes with densities between 1400 to 2500 kg/nb (90 to 155 lb/ HOLM ON LIGHTWEIGHT CONCRETE AND AGGREGATES 529 ft,) and within normal strength ranges may be assumed to follow the formula [1,4] (2) where E = denotes the secant modulus in psi (MPa), P = the density in kg/m3(lb/ft,), and f = the compressive strength in MPa (psi) of a 150 by 300 min (6 by 12 in) cylinder (100 mm cube) This or any other formula should be considered as only a first approximation, as the modulus is significantly affected (t 25%) by moisture, aggregate type, and other variables The formula clearly overestimates the modulus for high -strength lightweight concretes where limiting values are determined by the modulus of the lightweight aggregate When design conditions require accurate elastic modulus data, laboratory tests should be conducted on specific concretes proposed for the project according to procedures of ASTM Test Method for Static Modulus of Elasticity and Poisson's Ratio of Concrete in Compression (C 469) Tests to determine Poisson's ratio by the static method for lightweight and sand -and -gravel concrete gave values that varied between 0 15 and 0 25 and averaged 0 20 Dynamic tests yielded slightly higher values [6] A value of 0 20 may be assumed for design purposes for both types of concretes SHRINKAGE As with ordinary concretes, shrinkage of structural lightweight concretes is principally determined by (a) shrinkage characteristics of the cement paste fraction, (b) internal restraint provided by the aggregate fraction, (c) the relative absolute volume fractions occupied by the shrinkage medium (cement paste fraction) and the restraining skeletal structure (aggregate fraction), and (d) humidity and temperature environments Aggregate characteristics influence cementitious binder quantities (the shrinking fraction) necessary to produce a required strength at a given slump Particle strength, shape, and gradation influence water demand and directly deterrrune the fractional volume and quality of the cement paste necessary to meet specified strength levels Once that interaction has been established, it is the rigidity of the aggregate fraction that restrains shrinkage of the cement paste When structural lightweight aggregate concretes are proportioned with cementitious bmder amounts similar to that required for normal aggregate concretes, the shrinkage of lightweight concrete is generally, but not always, slightly greater than that of ordinary concrete due to the lower aggregate stiffness The time rate of shrinkage strain development in structural lightweight concrete is slower, and the time required to reach a plateau of equilibrium is longer when the as -batched, lightweight -aggregate absorbed moisture is high Maximum shrinkage strains of high -strength lightweight concretes are slightly greater than high -strength normal -weight concretes containing similar binder content [22] ASTM C 330 lumts shrinkage of structural lightweight concretes to less than 0 07% after 28 days of drying in a curing cabinet maintained at 37 8°C ( 100°F) at a relative humidity of 32% Concrete mixtures used in the specimen prisms are prepared with a cement content of 335 kg/nb (564 lblyd3) with water contents necessary to produce a slump of 50 to 100 mm (2 to 4 in ) and air content of 6 �: 10% Specimens are removed from the molds at one day, and moisture cured until seven days at which time the accelerated drying is initiated Shrinkage of block concrete is limited to O 10% when determined in accordance with procedures outlined in ASTM C 331 The ASTM Test Method for Length Change of Hardened Hydraulic Cement Mortar and Concrete (C 157) is followed using fixed proportions of one part cement to six parts aggregate by dry loose volumes, with sufficient water to produce a slump of 50 to 76 min (2 to 3 in ) Initial length measurements are made after seven days moist storage with final shrinkage measurements at the age of 100 days after storage in laboratory air at 23°C (73 4°F) and 50% relative humidity CREEP Time -related increases in concrete strain due to sustained stress can be measured according to procedures of ASTM Test Method for Creep of Concrete in Compression (C 512) Creep and shrinkage characteristics on any concrete type are principally influenced by aggregate characteristics, water and cement content (paste volume fraction), age at time of loading, type of curing, and applied stress -to -strength ratio Other second -level variables also influence creep and shrinkage but to a lesser degree As creep and shrinkage strains will cause increase in long-time deflections, loss of prestress, reduction in stress concentration, and changes in camber, it is essential for design engineers to have an accurate assessment of these time -related characteristics as a necessary design input ACI Committee 213 [l 1] demonstrates wide envelopes of one-year specific creep values for low -strength all -lightweight, normally cured concretes Test results for higher -strength, steam -cured sanded -lightweight concretes have a range of values that narrows significantly and closely envelopes the performance of the normal -weight "reference" concrete These values are principally based upon the results of the comprehensive testing program of Shideler [5] Long-term investigations by Troxell [23] on normal -weight concretes report similar wide envelopes of results for differing natural aggregate types so comparisons with "reference" concretes should be based upon data specific to the concretes considered Additional large-scale creep testing programs are reported in Refs 7 and 19, and Valore [10] has provided a comprehensive report that also includes European data on structural as well as insulating -grade lightweight concretes DURABILITY Numerous accelerated freeze/thaw testing programs conducted on structural lightweight concrete in North 530 TESTS AND PROPERTIES OF CONCRETE America [24,25] and in Europe [4] researching the influence of entrained -air volume, cement content, aggregate moisture content, specimen drying times, and testing environment have arrived at smular conclusions air -entrained lightweight concretes proportioned with high -quality binder provide satisfactory durability results when tested under usual laboratory freeze/thaw programs Observations of the resistance to deterioration in the presence of deicing salts on mature bridges indicate similar performance between structural lightweight and normal -weight concretes [3] Comprehensive investigations into the longterm weathering performance of bridge decks [26] and marine structures [27] exposed for many years to severe environments support the findings of laboratory investigations and suggest that properly proportioned and placed lightweight concretes perform equal to or better than normal - weight concretes Core samples taken from hulls of 70-year-old lightweight concrete ships as well as 30- to 40-year-old lightweight concrete bridges have demonstrated concretes with high integrity contact zone between aggregate and the matrix with low levels of microcracking Explanation of this proven record of high resistance to weathering and corrosion is due to several physical and chenucal mechanisms including superior contact zone resistance to microcracking developed by significantly higher aggregate/ matrix adhesion as well as internal stress reduction due to elastic matching of coarse aggregate and matrix phases High ultimate strain capacity is also provided by concretes with a high strength/modulus ratios The ratio at which the disruptive dilation of concrete starts is higher for lightweight concrete than for equal strength normal -weight concrete A well -dispersed void system provided by the lightweight fine aggregates may also assist the air entrainment pore system and serve an absorption function by reducing salt concentration levels in the matrix phase [27] Long-term pozzolamc action is provided when the silica -rich expanded aggregate combines with calcium hydroxide liberated during cement hydration This will minimize leaching of soluble compounds and may also reduce the possibility of sulphate salt disruptive behavior [28] It is widely recognized that while ASTM Test Method for Resistance of Concrete to Rapid Freezing and Thawing (C 666) provides a useful comparative testing procedure, there remains an inadequate correlation between accelerated laboratory test results and the observed behavior of mature concretes exposed to natural freezing and thawing The inadequate laboratory/field correlation observed for normal -weight concrete is compounded when interpreting results from laboratory tests on structural lightweight concretes prepared with aggregate moisture contents typical of commercial operations A proposed modification to ASTM C 666 [29] suggests that a 14-day air -drying period prior to the first freezing cycle will improve correlation between laboratory test data and observed field performance Durability characteristics of any concrete, both normal weight and lightweight, are primarily determined by the protective qualities of the cement paste matrix It is imperative that permeability characteristics of the concrete matrix be of high quality in order to protect steel reinforcing from corrosion, which is clearly the dominant form of structural deterioration observed in current construction The matrix protective quality of concretes proportioned for thermal resistance by using high -air and low -cement contents will be significantly reduced, Very low density, non-structural concretes will not provide resistance to the intrusion of chlorides, carbonation, etc , comparable to the long-term satisfactory performance demonstrated with high -quality, structural -grade lightweight concretes [29], For a number of years, field exposure testing programs have been conducted by the Canadian Department of Minerals, Energy and Technology (CANMET) on various types of concretes exposed to a cold marine environment at the Treat Island Severe Weather Exposure Station maintained by the U S Army Corps of Engineers at Eastport, Maine [29) Concrete specimens placed on a mid -tide wharf experience alternating conditions of seawater immersion followed by cold air exposure at low tide In typical winters, the specimens experience about 100 cycles of freezing and thawing In 1978, a series of prisms were cast using commercial normal -weight aggregates with various cement types and including supplementary cementitious materials Water -to -cement ratios of 0 40, 0 50, and 0 60 were used to produce 28-day compressive strengths of 30, 26 and 24 MPa (4350, 3770, and 3480 psi), respectively In 1980, these mixes were essentially repeated with the exception being that the 40 mm ( 1 '/, in ) gravel aggregate was replaced with a 25 mm (1 in ) expanded -shale lightweight aggregate Fine aggregates used in both 1978 and 1980 were commercially available natural sands Cement contents for the serru-lightweight concrete mixtures were approximately 480, 360 and 240 kg/nb (800, 600, and 400 lb/ydb) that produced compressive strengths of 36,30 and 19 MPa (5220, 4350, and 2755 psi), respectively All specimens continue to be evaluated annually for ultrasonic pulse velocity and resonant frequency as well as being rated visually Ultrasonic pulse velocities are measured centrally along the long axis of the prisms There were no significant differences between the structural lightweight concrete (eight years) and normal -weight concrete (ten years) after exposure to twice -daily seawater submersion and approximately 1000 cycles of freezing and thawing [29) CHEMICAL REACTION ACI Committee 201 on Durability of Concrete reports no documented instance of in-service distress caused by alkali reactions with lightweight aggregate Mielenz [30] indicates that although the potential exists for alkali aggregate reaction with some natural lightweight aggregates and expanded perlite, the volume change may be accommodated without necessarily causing structural distress Granulated blast furnace slag has been shown to be an effective inhibitor of such reactions [31], and the fine aggregate fractions of expanded shales, clays, and slates are known to be pozzolanic and may also serve to inhibit disruptive expansion Bremner [32] reports that no evidence of alkali lightweight aggregate reaction was HOLM ON LIGHTWEIGHT CONCRETE AND AGGREGATES 531 observed in tests conducted on 70-year-old marine and more than 30-year-old lightweight concrete bridge decks POPOUTS Popouts may result from delayed disruptive expansions caused by the slow hydration of particles of hard -burned time or magnesia, calcium sulfate, or unstable iron compounds To test for the presence of these materials, concrete bars prepared by methods similar to those used for the shrinkage tests are cured and tested according to the procedures of ASTM Test Method for Autoclave Expansion of Portland Cement (C 151) No popouts are permitted by ASTM C 331 and C 330 since this disruptive expansion would cause unacceptable aesthetic blemishes on exposed concrete and masonry ABRASION RESISTANCE Abrasion resistance of concrete depends on strength, hardness, and toughness characteristics of the cement paste and the aggregates, as well as on the bond between these two phases Most lightweight aggregates suitable for structural concretes are composed of solidified glassy material comparable to quartz on the Moh scale of hardness However, due to its porous system, the net resistance to wearing forces maybe less than that of a solid particle of most natural aggregates Structural -lightweight -concrete bridge decks that have been subjected to more than 100 million vehicle crossings including truck traffic show wearing performance similar to that of normal -weight concretes [33] Limitations are necessary in certain commercial applications where steel -wheeled industrial vehicles are used, but such surfaces generally receive specially prepared surface treatments Hoff [34] reports that specially developed testing procedures that measured ice abrasion of concrete exposed to arctic conditions demonstrated essentially similar performance for lightweight and normal -weight concretes BOND STRENGTH AND DEVELOPMENT LENGTH Field performance has demonstrated satisfactory performance for lightweight concrete with respect to bond and development length Because of the lower particle strength, lightweight concretes have somewhat lower bond splitting capacities than normal -weight concrete Usual North American design practice (ACI 318 Standard Building Code for Reinforced Concrete) is to dispense with concepts of bond and require slightly longer embedment lengths for reinforcement in lightweight concretes than that required for normal -weight concrete FIRE RESISTANCE When tested according to the procedures of ASTM Method for Fire Tests of Building Construction and Mate - FIG 4 -Fire endurance (heat transmission) of concrete slabs as a function of thickness for naturally dried specimens (11] rials (E 119), structural lightweight aggregate concrete slabs, walls, and beams have demonstrated greater fire endurance periods than equivalent thickness members made with normal -weight aggregates (Fig 4) Superior performance is due to a combination of lower thermal conductivity (lower temperature rise on unexposed surfaces), lower coefficient of thermal expansion (lower forces developed under restraint), and the inherent thermal stability developed by aggregates that have been exposed to temperatures greater than 1093°C (2000°F) during pyroprocessing Acknowledgments The principal sources of information for this chapter include the Guide for Structural Lightweight Aggregate Concrete (ACI 213) [11], ACI 318 Building Code Requirements for Reinforced Concrete [I], the CEB-FIP Manual of Design and Technology Lightweight Aggregate Concrete [4], and the Handbook of Structural Concrete [7] References 211 site Subject: 211 site From: "Bonkers" <bonkers@mfire com> Date: Wed, 12 May 2004 09 43 40 -0400 To: "Laurie Munn" <Laurie Munn@ncmatl net> Laurie, I hope this will suffice. Ken did his impirical tests, and utilizing that fellas paper, should be convincing enough to use 50% Steve I stopped by and got some pumice yesterday I did a void test whereby by I determined the volume of water necessary to fill an empty container I then emptied the container and filled the container with uncompacted pumice rock I then poured water into the rock filled container to order to determine the volume of voids remaining (volume displaced by added water) The percent voids can then be determined by dividing the second volume (water needed to fill voids) by the first volume (water needed to fill empty container) to determine percent voids With the pumice rock, I got a void ratio of 62 5% Just to estimate the internal voids within the pumice, I performed this same procedure on some standard #57 stone (washed granite - uncompacted) The voids on the granite came out to be 52% This means that the internal voids within the pumice rock is just over 10% of the total voids I am attaching the calculations for your use I would hope that this would suffice for the review agency to allow 50% voids (which is actually very conservative for the pumice) If you think it would help, I will send some pictures of the materials The supplier does not have a'spec sheet' that would indicated voids, only specific gravity's, unit weights, and all that good stuff VoidRatios.xls Content -Type: application/octet-stream Content -Encoding: base64 Lecture 6- properties of aquifers.doc� Content -Type: application/msword Content -Encoding: base64 1 of 1 5/12/2004 10 34 AM Kchael F Easley, Governor William G Ross Jr Secretary North Carolina Department of Environment and Natural Wesources Alan W K imek P E ,Director Division of Water Quallty Coleen H Sullins, Deputy Director Division of Water Quality March 22, 2004 CERTIFIED MAIL 7002 1000 0005 2389 8195 fffT-URN RECEIPTREQUESTED Mr. Bryan English English Builders 4705 Southport -Supply Hwy Ste 106 Southport, NC 28461 Subject: NOTICE OF RECOMMENDATION FOR ENFORCEMENT Hampton Inn Outparcel Stormwater Permit No. SW8 031133 Brunswick County Dear Mr English This letter is to notify you that the Wilmington Regional Office of the Division of Water Quality is considering sending a recommendation for enforcement action to the Director of the Division of Water Quality The recommendation concerns the violation of North Carolina General Statute NCGS 143-215 6A(2), failing to apply for or secure a permit required by NCGS 143-2151 You have failed to obtain a State Stormwater Management Permit for the subject project On March 22, 2004, staff of the Wilmington Regional Office observed the construction of a building at this site. On November 21, 2003, you submitted a plan revision for the development of an outparcel of a permitted project, and which indicated that Gordon Lovingood was the owner who had submitted the plan as a revision to the one we previously approved On February 11, 2004, the Division sent a request for additional information to Mr Lovingood He recently indicated that he had not authorized a plan revision, and that you were the owner of the outparcel Since you are not the permittee for the Hampton Inn, you must submit an offsde permit application for the development of the outparcel If you have an explanation for this violation that you wish to present, please respond in writing to me within ten (10) days following receipt of this Notice Your explanation will be reviewed and forwarded to the Director with the enforcement package for consideration By copy of this letter to the Building Inspector, this Office is requesting that the Building Inspector consider withholding building permits and Certificates of Occupancy for this project until this matter is satisfactonly resolved If you have any questions concerning this matter, please contact Linda Lewis at (910) 395-3900 Sincerely, Ql"�_ C_V__ Rick Shiver Water Quality Regional Supervisor RSSlarl S1WQSISTORMWATIENFLETR1031133.mar04 CC. Town of Southport Building Inspections Bob Sledge Linda Lewis _,VVtl iington Regional Office Central Files M AV" WA U.S. PA al Service I_n C&TIFIED MAIL RECEIPT a- a (Domestic . • . Ir s U ' u J !! itz- m nj Postage $ 321e, C3 q �/ �/" Certified Fee .4Ln _ 1 V , �� t , 1 r�r 1 r- 1 s © � Return Receipt fee, (Endorsement Required) �0 1 O Restricted Delivery Fee � ti _ © (Endorsement Regwred} at Total Postage & Fees $ r Z Q)rLj F rl ' o Sent To 2n �i'l IS u ` o M1 ' (lc�l5 St rraet Apt No 47US PO Box No orf s� } crty State zr❑+a , , 1 �G i, �' Col ' , rl PS Form r0 April 20021 , I 1 ' , � , 1 1 1 L 1 1, f 1 i 211 Subject: 211 From: "Bonkers" <bonkers@mfire comma Date: Wed, 12 May 2004 12 47 24 -0400 To: "Laune Munn" <Laune Munn@ncmail nett Laurie, Here's the stuff from the "solite" web page Shows porosity to be 69% Page 5 or 6 Good statement, however, its so light, basic compaction, such as with no 57 isnt really applicable. C'mon, you know I'm right -) Steve Lightweight Concrete.doc Content -Type: app lication/m sword Content -Encoding: base64 1 of 1 5/12/2004 12 53 PM 211 site Subject: 211 site From: "Bonkers" <bonkers@mfire com> Date: Mon, 10 May 2004 16 32 07 -0400 To: "Laurie Munn" <Laurie Munn@ncmail net> CC: "Lisa Clark" <lpclark@ncez net> Laurie, I have your comments printed out On no 3, give me as much notice as possible, I need to get my soil guy there to talk to your soil guy Or maybe we can get Vincent to call Tom Gully, P E , I have his cel number from the site On no 4, can I stick this on the plans? If not, I'll need to get that application faxed down, please On no 6, 50% is the number used from when I did a bunch of these in Florida "Solite" is lava rock, pumice Full of voids in each peace, the 40% is the voids between the peaces Essentially a rock hard sponge, lol Otherwise I would agree with you totally -) How soon do we need to return this? Sincerely Steve I of 1 5/11/2004 7 22 AM Look for RED Subject. Look for RED From: "Bonkers" <bonkers@mfire com> Date: Tue, 11 May 2004 07 54 18 -0400 To: "Laurie Munn" <Laurie Munn@ncmail net> The deadline for the return is set at May 17, 2004, but you can request an extension if you need one Vincent is out of the office until May 19th, so you may wish to hold your resubmittal until he can get out to the site, especially since it sounds like there may be some soil issues It will be best if your soils scientist can meet him on the site I agree But that was in Tom's report, and he was Lonservative Did you make a copy of the application that you submitted? You only need to revise p 2, add the tributary name, and fax it back over Let me know if you did not make a copy I do not need an original of this sheet Sorry, I didnt keep a copy, it was pure chaos here, after Lovingood decided Bryan couldnt connect to the pond I'1 leaving out at 10 30 for meeting all day joy, lol It you can fax over earlier, call me on the cel line, I'll plug in the fax It is the department's policy to use a void ratio of 40% We do not have testing done on various types of materials I will ask the question to Raleigh, but in order to expedite the process, please design the system using a 40% void ratio Again, I agree with limestone or granite rock Pumice has ltty-Bitty holes all thru it Reality would be 55% voids, I gave you a break, lol Let me know if you have anymore questions I usually leave here by 3 30 or 4 Thanks, I didnt realize you left that early 1 of 1 5/11/2004 7 58 AM Fw Old'Georgetowne Center Site Subject: Fw Old Georgetowne Center Site From: "Bonkers" <bonkers@mfire comma Date: Tue, 11 May 2004 08 39 19 -0400 To: "Laurie Munn" <Laurie Munn@ncmail nets From Ken Clark, P E Would you be so nice to look at this -) Keep in mind, at 2" per hour percolation rate (9 9 hrs) for the first 1" of runoff, in a 24 hour event that equates to 2 42" of runoff captured and treated Ken and I came up with the "inspection pipe" simultaneously yesterday evening as a way to physically see the sediment level ----- Original Message ----- From Kenneth L Clark To bonkers(c)-mfire corn Sent Tuesday, May 11, 2004 8 12 AM Subject Old Georgetowne Center Site Steve, If you talk to the review agency today, I have a couple of issues that I would like some clarification on prior to revising plans On Comment #5 If this were a situation where we had concentrated flows going into an open storage area, then I would, fully agree that a bypass is necessary to avoid overloading the storage capability of the basin and/or producing turbulence that may cause some of the 'first flush' runoff to exit the system prematurely The way I interpret the proposed design is that the 'first flush' will flow into the trench and be retained for infiltration through the underlying soil Any runoff in excess of the'first flush' will flow to the trench, however, it is my thinking that this excess runoff will flow'over top' the first flush runoff without forcing the 'first flush' runoff up and out of the trench The measures that have been built in to insure that the trench will work this way include the elevation of the outlet swale being set above the top elevation of the'design pool' Also, having the inflow evenly distributed (i e , sheet flow) across the parking lot and over a buffer strip prior to entry into the trench eliminates points of concentrated flow that may cause turbulence that might stir the 'first flush' water back up to the top of the trench This stilling effect is further enhanced by the fact that the trench is filled with so-lite and is set on a flat grade During an extended slow rainfall event, this design will actually allow you to treat more stormwater than just the first one inch of runoff Given this further explanation, please check with the review agency to see if the design as proposed is acceptable, as I am confident it will provide the desired level of treatment Comment #6 Since we are using a pumice based stone, there are internal voids within the rock that will increase the overall void ratio Also, because the stone is so light, there is basically no compaction of the stone within the trench If the review agency is open to reviewing some empertcal data, I will get hold of some of this material do a void test just to double-check the ratio Comment #7 I performed the calculations on based on the acreage that will inflow into the infiltration trench for treatment If you run the calculations based on the total site acreage, then I come up with 1835 cf as well, however, there is considerable acreage along the tributary that is undisturbed and which will not I oft 5/11/2004 8 43 AM Fw Old,Georgetowne Center Site 4 flow into the infiltration trench Please double check with the review agency as to whether calcs should be run on actual area requiring treatment or based on entire site acreage Comment #8 Please include a PVC pipe with large performations as an 'observation point' for determining when the infiltration trench hits the recommended clean -out threshold I assume that the remaining comments are no big deal to address If you have any questions, give me a call Thanks, Ken Clark 2 of 2 5/1 1/2004 8 43 AM ATTACHMENT Old Georgetown Site Southport, NC The proposed treatment for achieving 85% TSS removal for this site is the use of a pumice -filled infiltration trench camouflaged as a landscape bed Pretreatment of stormwater directed into the trench will be accomplished by having the stormwater evenly spread across a wide parking area (defacto level spreader) then allowing the evenly distributed stormwater to flow over a stone or grass lined surface prior to entering the infiltration trench. The exception to this will be the stormwater coming from the rear parking area of the property. This stormwater will be directed into a grass lined swale prior to emptying into the infiltration trench. Because a lightweight pumice type stone providing both internal voids and an overall void ratio of at least 50% is proposed throughout the entire trench, the traditional bottom sand filter has been eliminated. This type of stone should help filter fine particles from the stormwater and will provide a good indication of maintenance needs / replacement by the level of discoloration of the stone Larger particles that do not attach to the pumice will be captured by a geosynthetic liner along the base and side of the trench prior to the stormwater entering the native soil beneath. For storm events producing rainfall in excess of the first 1-inch of runoff, stormwater will flow overtop the `treatment' stormwater and will be carried to a nearby channel via a grass lined swale