Monolithic concrete and its application

The durability and versatility of monolithic concrete have made it a popular construction method. Using this method, concrete is poured into a single, continuous form to produce a solid, well-built structure. Monolithic concrete offers an uninterrupted, seamless surface, in contrast to conventional techniques that require individual blocks or panels.

Applications for monolithic concrete are numerous, ranging from large-scale commercial projects to residential structures. Because of its strength and durability, it is perfect for structures that must withstand a lot of stress and environmental elements. The technique also has good insulating qualities, which can improve a building’s energy efficiency.

Homeowners and builders can make more informed decisions about their construction projects if they are aware of the advantages and uses of monolithic concrete. This method enhances the building’s overall appearance and functionality in addition to offering a strong and trustworthy foundation.

For a range of building requirements, monolithic concrete provides a robust, seamless solution. Its sturdy, unbroken construction makes it perfect for building water- and fire-resistant floors, walls, and foundations. Monolithic concrete is a great option for anything from large-scale industrial projects to residential homes because it minimizes joints and weak points and allows builders to create a cohesive and stable structure by pouring concrete continuously.

Advantages and disadvantages of monolithic concrete technology

Nowadays, utility buildings (wells, cesspools, toilets, cellars, sheds, etc.) as well as multi-story residential buildings, shopping and entertainment complexes, private and country homes, and utility buildings are all constructed using monolithic construction technology. Numerous key benefits of monolithic concrete over alternative building technologies account for its appeal:

• Relatively low cost of construction.
• The ability to erect the "box" of the structure on your own, without attracting expensive hired labor of masons.
• Several times higher construction speed with all other things being equal: strength, durability, seismic resistance and fire resistance.
• The ability to build at sub-zero ambient temperatures.
• The ability to obtain any architectural forms and layouts, due to the “flexibility and plasticity” of the material.

Additionally, monolithic construction has drawbacks.

• The need for high-quality noise and heat insulation.
• Additional costs for heating poured structures in the cold season.
• The need for special care during the setting and strength gain period.
• Complexity of formwork installation.

Composition of monolithic concrete

Generally speaking, heavy concrete grade M200, M250, or M300 is used to erect the foundation, floor slabs, and walls of a low-rise monolithic building. The grade selection is influenced by the local climate and groundwater table in the future building’s location.

The "golden mean" in monolithic construction is heavy concrete grade M200, which is made up of water, quarry sand, crushed granite with a particle fraction of 10–20 mm, and Portland cement CEM I 32.5N PC (M400) or CEM I 42.5N PC (M500). Antifreeze, hydraulic and strength additives, setting accelerators, and a plasticizer are added to the concrete depending on the pouring conditions.

Proportions for the preparation of one cubic meter of material and the grades of concrete used in monolithic construction. Table.

Formwork for monolithic concrete

Any structure cannot be constructed monolithically without the use of formwork, a technological component. Concrete structures such as buildings are constructed using various forms of formwork. Removable formwork that is prefabricated is the most popular kind.

Sometimes permanent formwork consisting of polystyrene foam blocks, corrugated sheets, or hollow elements made of lightweight concrete is used to construct the walls of private low-rise buildings. One term for permanent formwork is "two in one." External finishing is done by corrugated sheets, while thermal insulation is done by hollow blocks and polystyrene foam.

Private developers prefer to create their own prefabricated panel formwork from scrap materials, even though permanent formwork has many advantages. Panels made of laminated plywood that resists moisture or panels taken down from wooden boards and beams are utilized for these purposes.

With the help of wooden blocks, nuts, and steel threaded studs, the panels are joined into a single structure. The formwork’s dimensions and contraction are determined by the intended construction: a foundation, a wall of a house, a cellar made of reinforced concrete, a staircase, etc. Let’s take a closer look at the monolithic structures mentioned above.

Monolithic cellar made of concrete

Concrete cellars are inexpensive and simple to construct. Any home craftsman without a construction degree can construct a structure similar to this one. Principal building phases:

• Digging a pit. For the needs of a family of 4, a structure 2.5 meters wide, 2.5 meters long and 2 meters high will be sufficient.
• Manufacturing panel formwork for walls. Panels 1 meter wide are knocked down from planed boards 20-25 mm thick and wooden blocks cut 40×40 mm.
• Installing the formwork. Panels can be installed directly on the floor of the cellar, ensuring a wall thickness of 150 mm. For this, measured separations made of bars 150 mm long and 20×20 in cross-section are inserted between the wall of the pit and the panels. From the side of the cellar space, the panels are braced with 50×50 mm bars.
• Laying monolithic concrete. Any brand of concrete from the brands listed above can be used to fill the walls. The walls are poured into the formwork in uniform portions throughout perimeter. At the same time, reinforcement with a diameter of 12-15 mm is inserted vertically into the concrete with a step of 250-300 mm.
• Dismantling of the formwork. In the warm season, dismantling the formwork can begin 72 hours after pouring the last portion of concrete.
• Reinstallation of formwork above. Pouring the next "portion" of the wall, reinforcement, 72-hour curing, dismantling, reinstallation, etc..
• Assembly of formwork for the ceiling. The formwork for a monolithic ceiling consists of a large wooden panel with the dimensions of the internal space of the cellar (the panel provides a 700×700 mm opening for the hatch and 2 openings with a diameter of 150 mm in opposite diagonal corners for the supply and exhaust ventilation pipes). Wooden beams 100×100 mm or wooden logs with a diameter of 100 mm. A square frame with internal dimensions of 2.5×2.5 meters, knocked down from boards 25 mm thick, 100-120 mm wide and a square frame with internal dimensions of 700×700 mm (to form the opening of the hatch), also knocked down from boards 25 mm thick, width 100-120 mm
• Installation of formwork for the ceiling. The wooden shield is placed on logs or beams along the upper edge of the walls. A square frame of 2.5×2.5 meters is installed on top of the upper edge of the walls. A square frame 700×700 mm is installed on the hatch opening.
• Installation of reinforcement over the entire area of ​​the floor. For the manufacture of the reinforcing belt, you can use a wire with a diameter of 6 mm tied into a mesh with a cell of at least 50×50 mm.
• Installation of ventilation pipes. One pipe with a diameter of 150 mm is exposed above the cellar (exhaust pipe), the second, also with a diameter of 150 mm, inside the cellar (supply pipe). The exhaust pipe should protrude from the floor slab by 1.5 meters and end in the cellar along the lower edge of the floor. The supply pipe does not reach the floor of the cellar by 150 mm and protrudes outward from the floor slab by 70 mm.
• The grade of concrete for a monolithic floor is the same as for pouring walls.
• Pouring concrete, ironing the outer surface of the slab, curing for 7 days, dismantling the formwork.

A concrete monolith cellar is prepared. The hatch structure needs to be installed, the walls need to be painted white, mushrooms need to be placed on the ventilation pipes, and canned goods, potatoes, carrots, beets, and other vegetables can be loaded.

Monolithic slab foundation

When building on problematic soils, a monolithic slab foundation is ideal for residential and utility buildings. This kind of building can support a large amount of weight, withstands earthquakes, is impervious to groundwater erosion, and has a slab foundation that doubles as a subfloor.

The latter lets you avoid spending as much on antiseptics to treat them and wooden joists for the flooring. The slab needed to build a two-story house is only 40 cm thick.

You can use straightforward technology to build this kind of foundation on your own. Steps involved in building a slab foundation 40 cm thick:

• Digging a pit 0.6 meters deep, planning the bottom of the pit.
• Filling a 20 cm thick sand layer, tamping.
• Filling a 20 cm thick crushed stone layer, tamping.
• Manufacturing formwork. Shields are knocked down from edged boards 25 mm thick. The width of the shield should be 20 cm. In this case, when filling the foundation, the size of 20 cm will provide the necessary thickness of the plate. On the outer surface, the shields are enhanced by bars.
• Installation of formwork. When installing the formwork, the horizontality of the upper cut of the shield should be ensured. This will make it possible to use the upper cut of the shields in the quality of the beacon of the upper surface of the plate. Horizontal can be ensured by adding soil, lining of brick pieces, lining of wooden bars and checking the construction level.
• Reinforcement installation. “Factory” construction reinforcement with a diameter of 12 mm should be used. Important! A reinforcing belt for a slab foundation is collected on a knitting wire and in any case on welding.
• Pouring concrete. A very important stage. One of the main questions is the required amount of concrete for the foundation monolithic slab. The answer to this question will be given by a special concrete calculator for a monolithic slab foundation, which can be found on the Internet. At the same time, the required volume of building material can be calculated by simple arithmetic. Multiply the length, width and height of the slab in linear meters, we get the amount of concrete in cubic meters. The best grade of concrete for a monolithic foundation is heavy concrete M200 or M250.
• Ironing the surface of the slab and covering the structure with polyethylene film.
• Dismantling the formwork no earlier and no later than 7-10 days.

The "monolithicity" principle will be broken if the monolithic slab is not poured as soon as possible. This will neutralize the benefits of the foundation and severely reduce its bearing capacity.

The optimal course of action is to compute the theoretical consumption of concrete, multiply it by 1.1 to increase it by 10%, and then place an order for ready-made building materials from a concrete plant. Should the purchase of prefabricated materials be unfeasible, you must be equipped to continuously make concrete on your own.

Monolithic concrete stairs

Depending on how many floors a modern private home has, one, two, or three stairs may be required. Due to the following objective benefits, monolithic concrete stairs are preferred over their wooden and steel counterparts:

• Ability to “fit” into any dimensions of the allocated space.
• Ability to implement any architectural forms.
• Durability, strength and low cost of construction.
• Ability to build on your own.

Concrete stairs are built and outfitted exclusively for each individual based on the unique circumstances. General specifications include the need for reinforcement, care for freshly poured concrete, and a concrete grade of at least M200.

Monolithic concrete wall

Concrete monolithic walls possess a high degree of compressive strength. Specifically, the strength of the following structures is correlated with monolithic concrete walls that have a 120 mm thickness:

• Brickwork 25 cm thick.
• A wall made of foam concrete blocks 65 cm thick.
• A wall made of aerated concrete blocks 40 cm thick.

This allows for significant cost savings on basic materials. Simultaneously, monolithic low-rise building practice suggests that the following guidelines be followed: Buildings with one or two stories must have monolithic walls with a minimum concrete thickness of 20 cm, and structures with more than two stories must have walls constructed with a minimum concrete thickness of 55 centimeters.

Conclusion

Since the cost of traditional "stone" building materials increased significantly, monolithic construction has become more and more popular for buildings and structures. A private developer can cut construction costs significantly by using monolithic construction technologies, which minimize the need for costly hired labor.

For a range of construction applications, monolithic concrete provides a strong and adaptable solution. Its smooth, one-pour construction process yields a sturdy structure resistant to severe strain and external influences. For applications ranging from floors and walls to foundations and entire building frames, this makes it perfect.

Beyond its strength, monolithic concrete has many advantages. Because the pour is continuous, there are fewer joints and possible weak points, which improves durability and imperviousness to water infiltration. This feature also aids in energy efficiency because the solid mass lowers energy expenses and helps to regulate temperature.

Monolithic concrete can produce dependable and long-lasting results when used in construction projects. It is a well-liked option for both residential and commercial applications due to its strength and adaptability. Building professionals can create a long-lasting, sturdy, and effective structure by using monolithic concrete.

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