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2009.10.20 17:33

시멘트 콘크리트 포장의 현장 시공 품질관리 핸드북





시멘트 콘크리트 포장의 현장 시공 품질관리 핸드북


목      차

1. 개 요········································································································································· 3
1.1. 목적········································································································································ 3
1.2. 적용 범위································································································································· 3
1.3. 용어 정의································································································································· 4
2. 재 료········································································································································· 9
2.1 시멘트······································································································································ 9
2.1.1 종류 및 품질기준······················································································································ 9
2.1.2 포장, 운반 및 저장··················································································································· 10
2.1.3 시험 및 승인··························································································································· 11
2.2 잔골재····································································································································· 12
2.2.1 잔골재 정의 및 종류 ················································································································ 12
2.2.2 잔골재 품질기준······················································································································ 13
2.2.3 잔골재 저장 ··························································································································· 15
2.3 굵은 골재································································································································· 15
2.3.1 굵은 골재 정의 및 종류 ············································································································ 15
2.3.2 굵은 골재 품질기준·················································································································· 16
2.3.3 굵은 골재 저장 ······················································································································· 18
2.4 물··········································································································································· 18
2.5 혼화재료·································································································································· 19
2.5.1 혼화재료 정의 및 종류 ············································································································· 19
2.5.2 품질 기준 ······························································································································ 21
2.6 기타 재료································································································································· 23
2.6.1 줄눈 재료 ······························································································································ 23
2.6.2 양생 재료 ······························································································································ 23
2.6.3 강재 ····································································································································· 24
2.6.4 거푸집 재료 ··························································································································· 24
2.6.5 분리막 ·································································································································· 24

3. 시 공 ········································································································································ 29
3.1 시공 일반································································································································· 29
3.2 시공 장비································································································································· 29
3.3 포설 현장 준비·························································································································· 36
3.4 배 합······································································································································· 40
3.4.1 시공 일반 ······························································································································ 40
3.4.2 배합 기준 ······························································································································ 40
3.4.3 시방 배합 ······························································································································ 40
3.4.4 현장 배합 ······························································································································ 41
3.5 시험 포장 ································································································································ 41
3.6 콘크리트 제조 ·························································································································· 41
3.6.1 재료의 계량 ··························································································································· 41
3.6.2 비비기 ·································································································································· 42
3.6.3 레디믹스드 콘크리트 ··············································································································· 42
3.6.4 콘크리트의 운반 ····················································································································· 42
3.6.5 기상 조건 ······························································································································ 43
3.7 다웰바····································································································································· 43
3.7.1 다웰바의 시공상태 기준············································································································ 44
3.7.2 다웰바 시공방법······················································································································ 46
3.7.3 다웰바 어셈블리의 형태············································································································ 49
3.7.4 다웰바 어셈블리 보관방법········································································································· 50
3.7.5 다웰바 어셈블리 고정방법········································································································· 50
3.8 콘크리트 포설 및 다짐················································································································ 52
3.9 표면 마무리······························································································································ 56
3.10 양 생······································································································································ 58
3.11 줄눈 절단································································································································ 61
3.12 줄눈 시공································································································································ 62
3.13 줄눈 주입재 주입······················································································································ 69
3.14 포장면 보호 및 교통 개방··········································································································· 71

4. 특수 부위 콘크리트 포설 ·············································································································· 75
4.1 접속슬래브 및 철근보강 콘크리트 슬래브························································································ 75
4.2 터널내 콘크리트 포장·················································································································· 76
4.3 보도, 자전거도 등의 콘크리트 포장································································································· 78

5. 특수기상 조건에서의 콘크리트 포설 ······························································································· 81
5.1 개요········································································································································· 81
5.2 서중 콘크리트···························································································································· 81
5.3 한중 콘크리트···························································································································· 83

6. 하절기 콘크리트 포장 초기균열 방지를 위한 시공관리 ········································································ 89
6.1 적용범위···································································································································· 89
6.2 초기균열의 정의 및 특징··············································································································· 91
6.2.1 초기균열의 정의························································································································ 91
6.2.2 초기 균열의 문제점···················································································································· 92
6.2.3 초기균열 발생 온도 조건············································································································· 94
6.3 초기균열 방지를 위한 시공관리 방안······························································································· 97
6.3.1 하절기 콘크리트 포장의 줄눈컷팅 시기·························································································· 98
6.3.2 하절기 양생제의 적정 살포기준량································································································· 99
6.3.3 하절기 슬래브 표면 수분유지를 위한 양생제 살포기준량·································································· 100
6.3.4 하절기 콘크리트 포장 초기 온도 관리를 위한 차광막 설치 기준························································· 104

7. 품질관리····································································································································· 111
7.1 개요········································································································································· 111
7.2 품질 시험 ································································································································· 111
7.3 품질 및 규격의 관리···················································································································· 114
7.4 검사········································································································································· 119
7.5 콘크리트 포장 결함원인 분석을 위한 시공일자 현장 표식방안····························································· 120



표 목 차

표 2.1 시멘트의 종류···························································································································· 9
표 2.2 시멘트의 물리 성능···················································································································· 10
표 2.3 잔골재의 입도··························································································································· 13
표 2.4 잔골재의 유해물 함유량의 허용치································································································· 14
표 2.5 잔골재의 물리적 성질················································································································· 14
표 2.6 굵은 골재의 입도······················································································································· 16
표 2.7 굵은 골재의 유해물 함유량의 허용치····························································································· 17
표 2.8 굵은 골재의 물리적 성질············································································································· 17
표 2.9 콘크리트용 화학 혼화제의 종류···································································································· 20
표 2.10 플라이애시 품질기준 (KS L 5405) ································································································ 21
표 2.11 고로슬래그 미분말 품질기준 (KS F2563) ······················································································· 22
표 2.12 콘크리트용 화학 혼화제 품질 기준 ······························································································ 22
표 3.1 배치플랜트 운영 방식················································································································· 31
표 3.2 포장용 콘크리트의 배합기준········································································································ 40
표 3.3 시멘트 콘크리트 재료의 계량 허용오차·························································································· 42
표 3.4 미국 각 주별 다웰바 시공기준 ····································································································· 46
표 3.5 미국 각 주별 다웰바 자동삽입방법 사용여부··················································································· 48
표 3.6 미국 주요 주의 다웰바 어셈블리 고정방법······················································································ 52
표 3.7 계절별 포설된 콘크리트 포장의 적정 줄눈절단시기·········································································· 65
표 3.8 (표 3.7)에서 사용된 콘크리트의 배합설계······················································································· 65
표 3.9 공법별 줄눈재의 종류················································································································· 69
표 3.10 주입형 줄눈재 시공을 위한 단면제원··························································································· 70
표 3.11 성형 줄눈재 시공을 위한 단면제원······························································································ 70
표 6.1 미국 각 주의 콘크리트 포설 제한 대기온도···················································································· 89
표 6.2 국내 일반적 양생제 살포 기준···································································································· 100
표 6.3 미국 각주의 양생제 살포량 기준································································································· 102
표 6.4 양생제 살포기* 운행 속도와 분사량에 따른 적정 살포 횟수······························································ 102
표 7.1 포장콘크리트용 재료의 품질 시험······························································································· 112
표 7.2 규격관리의 빈도와 관리한계······································································································ 115
표 7.3 콘크리트의 품질관리················································································································ 117



그 림 목 차

그림 1.1 무근콘크리트 포장의 단면도   ··································································································· 4
그림 3.1 시멘트 콘크리트 포장 공사 시공 순서 ························································································25
그림 3.2 배치플랜트에 있어서 각 재료의 흐름 ·························································································26
그림 3.3 배치플랜트 계통도 ·················································································································27
그림 3.4 배치플랜트의 분류 ·················································································································28
그림 3.5 슬립폼 페이버 개요 및 적정 페이버 사용 ····················································································31
그림 3.6 철재암(Arm) 설치 방법 개략도 ·································································································33
그림 3.7 일반적 유도선의 설치 기준 ······································································································34
그림 3.8 MIT-SCAN을 활용한 다웰바 시공 상태 현장 조사 ········································································35
그림 3.9 다웰바 시공 불량으로 인한 포장파손(스폴링) ··············································································39
그림 3.10 다웰바의 5가지 시공상태 ·······································································································40

그림 3.11 다웰바 자동삽입 시공순서 ······································································································43

그림 3.12 다웰바 시공방법에 따른 시공상태 분석결과(시험도로) ·································································44
그림 3.13 국내에서 사용되는 다웰바 어셈블리의 표준 형태 ········································································45
그림 3.14 체어바의 다양한 형태 ············································································································45
그림 3.15 다웰바 어셈블리의 현장 야적모습과 시공 전 파손 모습 ································································46
그림 3.16 다웰바 어셈블리의 밀림(좌-정상, 우-밀림) ··················································································47
그림 3.17 다웰바 어셈블리 고정방법 ······································································································47
그림 3.18 피막 양생제 살포 모습 ···········································································································55
그림 3.19 차광막 설치의 한 예 ··············································································································56
그림 3.20 차광막에 따른 슬래브 표면 온도 저감 효과 ················································································56
그림 3.21 줄눈 절단 시기에 따른 콘크리트 표면 형상 ················································································59
그림 3.22 적정 줄눈 절단 시기 설정 개념 ································································································60
그림 3.23 계절별 시공 콘크리트 상부의 온도변화 패턴 ··············································································60
그림 3.24 2007년 6월11일 Sawcutting Window ························································································62
그림 3.25 2007년 10월18일 Sawcutting Window ·······················································································62
그림 3.26 스크래치 테스트 (절단가능 강도 현장확인시험) ··········································································63
그림 3.27 성숙도의 개념 ······················································································································64
그림 3.28 줄눈절단가능시기와 콘크리트 최고온도의 관계 ··········································································64

그림 4.1 노측(路側)구조물이 있는 경우 레일의 설치 예 ··············································································70
그림 4.2 보도, 자전거도 등의 줄눈 예 (단위:mm) ·······················································································71
그림 6.1 포설계절에 따른 슬래브 온도 변화 패턴 ······················································································80
그림 6.2 콘크리트 포장 초기균열의 예 ····································································································81
그림 6.3 균열 발생시기와 균열 틈의 크기간의 관계(연속철근콘크리트포장) ···················································81
그림 6.4 균열 발생시기와 균열모양 간의 관계(연속철근콘크리트포장) ··························································82
그림 6.5 초기균열 발생메커니즘 ············································································································82
그림 6.6 초기균열사례(Y형 균열이나 펀치아웃 발생 가능성이 높아진다.) ······················································84
그림 6.7 포설계절과 초기균열 발생 빈도 ·································································································85
그림 6.8 포설시각과 초기균열 발생 패턴 ·································································································85
그림 6.9 포설당시의 대기온도와 장기적인 포장상태간의 관계 ·····································································85
그림 6.10 시멘트 주성분의 시간에 따른 수화열 발생률 ···············································································86

그림 6.11 포설계절에 따른 슬래브 온도 변화 패턴 ·····················································································86

그림 6.12 시공시기에 따른 온도 낙차폭 ···································································································87
그림 6.13 적정 줄눈컷팅 시기 설정 개념 ··································································································89
그림 6.14 양생제 살포량과 증발량 관계 ···································································································91
그림 6.15 외국의 양생제 살포 농도(좌) 와 국내의 살포 농도(우) ····································································92
그림 6.16 양생제 살포기 분사량 측정 ······································································································93
그림 6.17 양생제 살포기 분당 평균 분사량 계산예 ·····················································································93
그림 6.18 과도한 저속살포에 의한 양생제 흐름 ·························································································94
그림 6.19 차광막의 적용 예(좌:독일, 우:국내) ····························································································95
그림 6.20 하절기 차광막에 의한 슬래브 온도 저감 효과 예(슬래브 표면) ························································95
그림 6.21 차광막 설치 구간(좌)과 미설치 구간(우)의 슬래브 수직 온도편차 ····················································96
그림 6.22 차광막 구조의 한 예 ···············································································································96
그림 6.23 소성상태에서의 균열(건조수축 균열) ·························································································97

그림 7.1 시공현장 표식 및 설치 개략도 ··································································································109







출처 : KPRC

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