Brigham Young University 2016 Design Report Brigham Young University WASATCH 2016

Contents Executive Summary ...... ii Project Management ...... 1 Project Management Resource Allocation ...... 2 Organization Chart ...... 3 Hull Design ...... 4 Structural Analysis ...... 4 Development and Testing ...... 6 Construction ...... 9 Project Schedule ...... 11 Construction Drawing and Bill of materials ...... 12 Appendix A – References ...... 13 Appendix B – Mixture Proportions ...... 15 Appendix C –Example Structural Calculation ...... 16

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Executive Summary the students of the figurative mountains that each of Brigham Young University is located in us climbs to achieve success in our own lives. More Provo, Utah on a hill overlooking Utah Lake. BYU specifically, Y mountain and the rest of the Wasatch has participated in Rocky Mountain Conference reminds the members of BYU’s concrete canoe team since 1976 but has not been as successful in the that great goals can be achieved by combining a lot concrete canoe competition in the past three years as of concrete and even more determination. in years past. The BYU team took 8th place in 2013, The design of the canoe shape draws nd 10th place in 2014 and 8th place in 2015. This year, influence from 2011’s Black Hull which placed 2 the Wasatch team sought to implement the best overall and medaled in each of the five races. Similar practices of previous years and improve on the areas to Black Hull, Wasatch’s shape was planned to that were less successful. mimic a standard canoe that the team would practice Table 1: Wasatch specifications. in before the canoe was built to help the team be Specifications familiar with the shape of the canoe before race day. Name Wasatch Several innovations were explored this year in the Maximum Length 20 ft Wasatch’s creation. In recent years, cracking has Maximum Width 33 in been a major problem. In order to reduce this, this Maximum Depth 16 in year’s mix included the use of shrinkage reducer and Average Hull Thickness 1.25 in increased the use of pre-soaked expanded shale Weight 383 lbs aggregate from last year’s mix. Primary Color Grey Structural Mix Proportions Two other influences from previous years Moist Unit Weight 72.9 pcf were the uses of bamboo and carbon fiber mesh in Dry Unit Weight 58.2 pcf the reinforcement system, similar to Canoegar, and Compressive Strength 1680 psi Black Hull respectively. The bamboo was chosen Tensile Strength 2310 psi because it is lightweight, has sufficient tensile Composite Flexural Strength 590 psi strength, and it allows for a mechanical bond with the Air Content 5% concrete due to its porosity. However, instead of Patch Mix Proportions tying the bamboo into a cage to provide transverse Moist Unit Weight 59 pcf strength like was done for Canoegar, a carbon fiber Dry Unit Weight 58 pcf Compressive Strength 1570 psi mesh was used to minimize thickness. Tensile Strength 300 psi Due to the fact that the majority of Composite Flexural Strength 270 psi participants from the previous year graduated, two Air Content 6% team members split the project manager’s Reinforcement responsibilities. In order to provide a higher level of 2 Carbon Fiber Mesh 30 ft detail for the concrete mix design, one manager was 1/4 Inch Bamboo 130 ft given responsibility to oversee this task. Another Grace Fibers 0.48 lb manager supervised the physical design of the canoe, The Wasatch theme comes from the name of the design of the reinforcement and the organization the mountain range that runs along Utah valley. In of the practices. Four other students served 1906, a group of students from BYU and the nearby as captains; tasks related to the mix design, BYHS painstakingly constructed a large concrete Y construction, paddling practices, and aesthetics were on the face of a mountain near Provo. Y Mountain delegated to newer members who served as captains. overlooks BYU and serves as a constant reminder to

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Brigham Young University WASATCH 2016

Project Management categories was divided into subcategories in order to In order to follow the schedule and achieve easily achieve the scope. The team captains would the scope of the project, project management was regularly check the critical path to ensure that leaders broken down into six categories. These included hull would be held accountable to the deadlines that were design, mixture design, aesthetics, safety, agreed on. reinforcement design, and construction. Due to the Due to the few number of captains on the limited number of returning students, a large focus team, weekly meetings were easy to accomplish. The was placed on recruiting new members. With the few captains would meet together to discuss all major returning veterans and a large number of new issues. When important milestones in the critical recruits, the team amassed 520 man hours on path were discussed in those meetings, the team Wasatch. The majority of time was spent on members that were directly involved with the tasks developing a concrete mixture, and constructing the were also consulted so that all relevant parties could canoe. contribute. After a course of action was decided on, The budget allotted to the team was set at a captain would directly oversee the completion of $1,500 this year. However, unforeseen expenses the task. This enabled the captains to always be required the team to participate in a fundraiser to aware of the progress made on each task and to increase the budget to $2,000. Previously, the contribute to each milestone as much as possible. practice that the team used were available free Both project managers and several captains of charge; this year, the organization that owned the completed university required safety trainings. practice canoes only offered them at a discount These trainings were supervised by a professor and instead. Even more expensive than the cost of took each person approximately 2 hours to complete. paddling practice, the largest expense was the Safety procedures for mixing concrete, use of hand purchasing of the Poraver aggregates. Despite the tools, use of power tools, proper use of personal previous year’s team’s efforts to build a sufficient protective equipment, and proper laboratory stockpile of Poraver, several bags of aggregates still maintenance, were all taught through online and in- needed to be purchased. person trainings conducted by a professor and the head laboratory manager. All team participants were Table 2: Major project milestones. Milestone Activites On Time Reason If Late required to complete another ½ hour of general Hull Design Selection Yes safety training with regard to material testing, under Mix Selection No Unsatisfactory mix results the direction of the laboratory manager. There were Reinforcement Collection Yes no accidents in the laboratory this year. Mold Creation No Manufacturor complications Canoe Pour Day No Delay in mix selection Table 3: Labor hour allocation. Canoe Completion No Delay in mix selection Time Spent on Project Submit Design Paper Yes Project Management 24 hrs Towards the beginning of September 2015, Hull Design and Structural Analysis 70 hrs two of the team captains met to outline the critical Mix Design and Testing 105 hrs path for the project. The critical path organized a Mold Construction 22 hrs projected schedule for various stages of the project Canoe Construction 81 hrs including mix design, hull design, construction, Finishing* 50 hrs finishing and the design report. Each of these main Academics 38 hrs

*The time for finishing is an estimate since it has not been completed by the date of the design paper submittal.

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Brigham Young University WASATCH 2016

Project Management Resource Allocation

Figure 1: Person Hours with Paddling – The person hour breakdown Figure 2: Person Hours without Paddling – The person hour breakdown shows the distribution of all of the 520 person hours for the project. shows the distribution of all of the non-paddling practice person hours. Including paddling practice, it accounts for ¼ of the overall person The Mix design and Testing accounted for the largest portion of time, hours. approximately 27% of the person hours.

Note that some of the categories are estimated hours, as they are still Note that some of the categories are estimated hours, as they are still ongoing activities. ongoing activities.

Figure 3: Project Budget Allocation & Comparison – The project management Figure 4: Project Total Budget Allocation – in an effort to try and limit team used the 2015 Final budget as a guideline while determining the 2016 expenditures, the Team’s overall budget was reduced from the 2015 Final budget. Note there are a few areas that are estimated in the 2016 Actual expenditures. The 2016 Actual expenditures is currently estimated to come in budgetary numbers are these areas still have ongoing expenses. under budget by $16. This will be almost 30% less than last year.

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Brigham Young University WASATCH 2016

Organization Chart Project Co -manager Project Co-manager

CHRIS BENDER MARIA STARKEY Senior Senior 2 Years Participating 3 Years Participating 2Years Registered 3 Years Registered Organized meetings and schedule. Set finances and oversaw Oversaw all aspect of the project, design of mixes and testing especially the overall design of process and managed materials the canoe shape

Construction Captain Aesthetics Captain Mix Design Captain Paddling Captain

CLAY HANSEN HANNAH TYLER COUTU BYRON YATES Junior Senior Freshman RASMUSSEN 1 Years Participating 3 Years Participating 1 Years Participating Sophomore 1 Years Registered 1 Year Registered 1 Years Registered 2 Years Participating Oversaw mix and Managed all aspects of 1 Years Registered Coordinated physical physical construction, Managed aesthetics testing process, and fabrication of training and paddling curing and of final product and transportation. reinforcement practice. display.

CONSRUCTION TEAM: MIX DESIGN TEAM: PADDLING TEAM Annie Romney, Byron Yates, Amelia Theobald, Byron Yates, Annie Romney, Byron Yates, Chris Bender, Clay Hansen, Gabrielle Jones, Hannah Chris Bender, Emily Patterson, Emily Patterson, Gabrielle Jones, Rasmussen, Jeffrey Derricott, Gabrielle Jones, Hannah Hannah Rasmussen, Katrina Rasmussen, Jeffrey Derricott, Kate Corbett*, Maria Starkey, Holbrook, Maria Starkey, Robert Maria Starkey, Nate Lant*, Saul Thompson, Saul Ramirez Tyler Nate Lant, Saul Ramirez, Tyler Ramirez, Tyler Coutu Coutu, Luke Kevan Coutu

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Brigham Young University WASATCH 2016

Hull Design The ends of the canoe were given a moderate The designer looked for inspiration from rocker, a sharp entry line, and a square stem. The previous years to create a hull design that would be moderate rocker was used to allow the canoe to turn easy to while staying streamlined and easily while still being able to track well. While a providing stability. In 2013, Pearl Dragon had a blunt entry line would improve buoyancy, a sharp rounded bottom which provided maneuverability but entry line was used to provide the canoe with speed made straight tracking difficult. In 2014, Shark and efficiency. The square stem was also chosen to Attack was given a flat bottom to help the canoe improve efficiency in tracking and allow the canoe maintain a straight course. This allowed for to maintain its momentum. satisfactory maneuverability while still helping the canoe sit higher in the water to reduce drag force. Structural Analysis Figure 5 shows the approximate water depth (about Determining whether the canoe would float 4 in.) at which the canoe has been calculated to rest or not was done by using AutoCAD was used to at equilibrium. create a 3D solid model of the canoe to measure the maximum volume of water that would be displaced by the canoe. Estimating a worst-case scenario unit Figure 5: Canoe design with water line. weight of concrete to be 70 pcf and an approximate While 2015’s Canoegar employed a tear average thickness of 1.25 inches, the total weight of drop shape that reduced material drag in the water, the canoe was approximated to be about 461 lbs. The the shape of the canoe was so different from the weight of the canoe, combined with an estimated standard canoes that the team had been practicing weight of 600 lbs for the four paddlers in the co-ed with that the paddlers felt that the teardrop shape race came to a total weight of about 1061 lbs. The made the canoe feel awkward during the racing maximum displaced volume was found to be about portion of the competition. To make the canoe feel 33.3 ft3 so the maximum buoyant force was found to more familiar to the paddlers, the overall shape of be about 2080 lbs. Structural analysis shows that the Wasatch was based on the Standardized Canoe canoe would remain buoyant under maximum Design used in the 2009-2011 ASCE National loading. A factor safety of about 1.96 against sinking Concrete Canoe Competitions and was only slightly was found, which is significantly improved over the modified. In 2011, the Black Hull was built using that Canoegar’s factor of safety of 1.65. These design and performed very well. This design also met calculations were performed automatically in all dimensional constraints. To reduce material drag, Microsoft Excel, which allowed us to make the team worked together to sand and seal the canoe corrections and changes rapidly. to achieve a sleek finish. Using a design that has Because the concrete reinforcement proven to be successful in the past and that will be composite was assumed to have a worst-case unit familiar to our paddlers, should allow our paddlers to weight of 70 pcf, 2 feet of bulkheads were added to perform well during the competition. each side to help the canoe pass the swamp test. This A shallow arch hull profile design (i.e., a soft brought the overall unit weight to about 60 pcf, chine with a flat bottom) was used to find a middle which is under the unit weight of water allowing the ground between the round bottom profile of Pearl canoe to float when entirely submerged underwater. Dragon and the flat bottom profile of Shark Attack. To determine shear forces and bending The shallow arch design was is intended to provide moments throughout the length of the canoe, a stability and maneuverability to the paddlers. quadratic distribution of the buoyant force was

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Brigham Young University WASATCH 2016

assumed, as well as of the canoe weight. This is because the buoyant force and canoe weight are both dependent on the canoe volume, which peaks at mid- span and gradually tapers toward the edges. When this function is integrated across the length of the canoe, it gives a shear force equation. Another integration gives the bending moments. These calculations were performed numerically in Microsoft Excel. The shear force and bending moment equations were useful in determining an optimized physical design that would allow the Figure 6: Moment diagrams for various loading scenarios. canoe to remain stable throughout its use. which are highly important factors in canoe design. Relevant parameters at the point of the Additionally, the porous nature of the bamboo will maximum moment were also calculated (and thus, allow the concrete to adhere to it more closely than maximum bending stress). The neutral axis was pre-tensioned steel. A closer bond increases the determined by dividing the cross-sectional area in stiffness and strength of the composite structure. half, and back-calculating the height of the chord that In addition, to the bamboo reinforcement gives that area, using basic trigonometric relations polypropylene fibers and a carbon fiber mesh were and MathCAD. The moments of inertia were used as shown in Figures 7 and 8. The fibers provide determined through established equations. The total the canoe with a more stable surface and help prevent internal stresses were determined using the bending microfractures. The CT275 carbon fiber grid was stress equation from Euler-Timoshenko Beam used to provide the canoe with approximately 2000 Theory. The total bending moments for four different lbs/ft of transverse tensile strength since the bamboo scenarios (2 male race, co-ed race, transportation, was only provided longitudinal strength. While the and display) are shown in Figure 6. mesh likely could have provided sufficient strength An average thickness of 1.25 inches of on its own, the bamboo also helped to decrease the concrete was chosen. This was done because 2014’s overall unit weight. Shark Attack exhibited significant cracks with a While stresses and moments for the thinner shell and 2015’s Canoegar was so thick that transportation were calculated for a static system, it became heavy and difficult to paddle. The decision stresses during transit will be minimized through a to use a mid-range shell thickness reduced the rolling canoe-carriage system which acts as a strength requirements of the concrete, mostly suspension system. This new system was built from because the moment of inertia was several times the ground up this year and will mitigate sudden larger than that of thinner shells. For a two-male dynamic loadings on the canoe during transit. loading situation, a flexural strength of only 23.7 psi is required. This is well below the compressive strength of the concrete mixture, so it was not a governing constraint. The use of bamboo for tensile reinforcement is a relatively new feature for the BYU team; it was first used in 2015’s Canoegar. Bamboo is lightweight and has high tensile strength, both of Figure 7: Fibers in concrete Figure 8: Carbon fiber mesh attached to mold

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Brigham Young University WASATCH 2016

Development and Testing Dosages of a high range water reducer, The goal for 2016 was to compromise ® between being economical to comply with a limited ADVA 195, were used budget, preserve overall strength, ensure as prescribed, allowing workability, and maintain a unit weight less than that for a lower water- of water. The mixture for last year’s canoe, ratio. The ratio and water Canoegar, was the baseline for mix design reducer dosage were development this year. The canoe was approximately alternately reduced, until 1.25 inches thick, with a concrete density just slightly test mixes were created lower than water, and a compressive strength of with adequate slumps, about 1680 psi; it was overdesigned to prevent the consistency, and challenges seen in the previous years (cracking in strengths. Throughout transit, uneven and insufficient thickness, etc.). A the iterative process, main focus for Wasatch’s mixture design was to water was added to each improve the mix by decreasing the overall density. mixture incrementally to This was done to improve increased buoyancy in prevent the addition of comparison respect to previous canoes while Figure 9: Compressive testing. too much. The final maintaining economic viability, strength, mixture had a dosage workability. 1.39 fl oz/cwt and water/cement ratio of under .32 This initial change caused several and was workable enough for team members to adjustments made to the particle distribution. Several construct the canoe with ease, but it had enough attempts were made to adjust to a few new aspects of plasticity so when the mixture was applied to the the mixture design. After initial modifications were mold it held its shape. made, the aggregate particle distribution and the The first few tested mixtures began with a aggregate to cementitious materials ratio changed water to cement ratio of 0.36 to 0.4 with extremely minimally. Distribution of aggregate particles high slumps, leading to significant stratification in changed slightly between the larger sizes of Poraver® samples and lower compression strength. We from the baseline mix. The properties of the decreased the water to cement ratio eventually to expanded glass aggregates used in the baseline and 0.32 and even somewhat lower. final mixture designs are shown in Table 4. Cracking has been a recurring issue in the past, so a special effort was made this year to avoid Table 4: Aggregate Properties Aggregate Porover® Expanded Shale this problem. A female mold was used to stop the Material Source Post-consumer Recycled Glass Raw Shale restrained shrinkage cracking caused in male molds Particle Size 0.04-4 mm 0.5-2 mm from past years. Fresh concrete sliding and collecting Specific Gravity 0.37-0.80 1.8 at the base of the mold was prevented through the Absorption 23-35% 16% process of application, beginning from the bottom of Volume in Mix 54% 3% the female mold and building up the vertical sides. The final mixture design was volumetrically Sufficient consolidation was achieved with an composed of 57% aggregates with a dry unit weight average dose of high-range water reducer, as shown of 58.2 pcf. The final 28-day compressive strength in Table 4, which is often used in self-consolidating . recorded is 1680psi according to testing as shown in ® Figure 5 (ASTM C873). Shrinkage reducer, Eclipse Floor 200, was The water-cement ratio of the baseline used to mitigate cracking caused by drying mixture design was also set low at 0.32 to aid with Table 5: Admixture Doasages cracking prevention and to increase the strength of Recommended Actual the concrete mixture. Multiple variations ranging Admixture Type Dosage Dosage from 0.34 to 0.4 were tested, many with high slumps, ADVA® 195 HRWR 3-15 1.39 fl oz/cwt substantial stratification, and lower strength. Eclipse® Floor 200 SRA 0.2-2 0.30 gal/yd³

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shrinkage. A lower dosage from within the did not provide sufficient tensile support for the prescribed range, as shown in Table 4, was chosen canoe, and the created aesthetic problems in the final since other precautions against cracking were taken. product. The deleterious effects seemed to outweigh Another effort to minimize cracking was the the benefits, so change was obviously necessary. For addition of internal curing through the use of the Wasatch, the team combined the bamboo method presoaked expanded shale from Utelite®, which of last year’s Canoegar with the carbon fiber grid of BYU used last year. Expanded shale, often used in 2011’s Black Hull. Research showed that bamboo bridge decks, has been proven to reduce long term strips attached to a gridded carbon fiber frame with cracking significantly. The lightweight aggregate has wire ties could be a strong form of reinforcement, as an average dry-rodded unit weight of 111 pcf and an shown in Figure 11. Tests performed by the Wasatch absorption of 16%. This aggregate was donated, team showed the bamboo to have a specific gravity which reduced the overall cost of the canoe. of 0.88 which assisted with the lighter weight of the Further research after making the 2015 canoe Wasatch and a tensile strength of at least 23,800 psi showed that the minimal 2-6% of shale considered (ASTM E8), an attribute that more than compensated previously (in efforts to minimize the use of dense for the concrete’s tensile weakness. However, the material) was not sufficient to have any benefit on hydraulic wedge curing. Thus, the percentage was increased from 6% grips, shown in to 17% to provide an amount of water that would be Figure 8, pulling released would have a significant impact. each end of the The final design was a binary mixture, using bamboo to test about 61% cement and 39% . Material the tensile donations were obtained from Grace Construction to strength caused assist with financial restrictions. To increase weak points and workability and strength gain without adding more the bamboo failed cement, Class “F” Fly Ash was used to replace a longitudinally, portion of the cement. The mix from last year not truly in included , which was a safety hazard for tension. A more the team members and captains. Due to this accurate test challenge and decreased access, tests were could not be performed on mixes with cement and fly ash, which performed due to tested to have sufficient properties. lack of equipment, but the maximum tensile strength is at least greater than the estimated tensile Figure 11: Bamboo/CT275 frame. strength found. To improve the adhesion between the concrete and the bamboo, similar to adding ribs to , the smooth outside of the shoots was sanded down with a size 60 sandpaper. Concerns with this method of reinforcement Figure 10: Cementitious materials breakdown. included the absorption and volumetric expansion of the bamboo due to the water in the concrete. To Previously, BYU Concrete Canoe has used determine if these concerns would cause structural pre-tensioned cables as tensile reinforcement, but complications, the mixture design team performed a this proved difficult to work around in construction, number of tests to fully characterize the bamboo

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reinforcement. These tests showed that the mixture, absorption, 27%, could be problematic. Since the cementitious volume of the bamboo only had a 3.7% increase material when fully submerged for 24 hours, the resulting breakdown, and thickness was not an issue so the bamboo frame was fiber content. presoaked, changing the bamboo’s absorption to 0% For example, and allowing the concrete to retain all required water the final and even contributing some additional internal mixture design curing. was designated For the second time, polypropylene fibers as “JAGGF,” were used by the mixture design team. These “J” for the final synthetic fibrillated fibers, Grace Fibers™, aggregate decreased plastic shrinkage, contributed a particle multidimensional tensile reinforcement, and distribution, decreased the permeability of the Wasatch. The “A” for the baseline mixture 2.5 lbs. per cubic yard, was water-cement maintained. ratio of 0.32, Figure 12: Mixing a test batch of concrete A modified third-point test (ASTM C78) was “G” for the performed on a composite 6”x 2”x 36” slab to volumetric 57% of aggregates in the final design, simulate the tension experienced in the walls of the etc. These five letter labels made it easier to track canoe. The composite modulus of rupture was found mixture design progress. The groundwork to be 590 psi. accomplished for the Wasatch this year will create Many materials used in the Wasatch are an easier baseline for following designs to begin environmentally sustainable. Fly ash, otherwise an with. Also, a surplus of materials purchased this unused coal combustion byproduct, was used as a year will provide the 2017 team with another pozzolanic cement replacement and the Poraver® advantage. aggregate is made of post-consumer recycled glass. The transportation system was also The bamboo used as reinforcement is also completely reconstructed due to the fact that last significantly less harmful to the environment than a year’s system failed upon return to BYU after steel product would be, due to steel processing Rocky Mountain Conference. The new system pollution. reused the wheels and tie-down supports from the The mixture last system and recycled leftover steel beams from design system from last the Steel Bridge team to create a strong year was revised to transportation system that will serve the concrete improve ease of use for canoe team for years to come. future years. The The Wasatch team was also focused on being program allowed users economically sustainable as is seen through the to choose previously team’s frugality, meeting the budget goal that was created options or to given to the team. This frugality was mainly create new options accomplished through the donation of many under five categories materials by Grace Construction, including fibers, and enter them into a fly ash, and silica fume, and Utelite, which donated

new mixture design. The the expanded shale aggregate. five-category system described the aggregate distribution, water- cement ratio, aggregate Figure 12: Testing the strength of proportion in the total the bamboo.

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Construction so the pour team could Similar to past years, BYU worked with lean on the frame without Foam Fab to create a Styrofoam mold for Wasatch. damaging the mold. In the past few years, the BYU team has attempted For the past two both male and female molds. The captains agreed years, Styrofoam molds that a male mold was easiest to use primarily due to were prepared and coated with vegetable oil or Figure 15: The mold with the reinforcement that was chosen. Last year, a sheetrock. female mold was chosen and the canoe ended up paint. Neither of these being thicker than originally planned because the methods proved effective at improving the ease of reinforcement wouldn’t lie flat against the mold. removing the canoe from the mold, and the team Neither the bamboo nor the CT275 grid would understood that something new was warranted. arrange themselves easily in a female mold; After consulting with a professor, the team felt that however, they could easily be arranged on top of a coating the foam mold in sheetrock would help to male mold and weighed down over spacers to help fill some of the voids that the concrete would bond the canoe achieve its intended thickness. to if the foam were left bare. Furthermore, a layer of A Styrofoam mold plastic wrap was wrapped around the canoe to was selected for the create an impermeable membrane between the construction of the mold concrete and the foam mold. Figures # and # show because it was readily the application of sheetrock and plastic wrap to the available and easy to use. mold. This also allowed the mold to be easily The Styrofoam cross removed from the concrete. sections used in the mold Figure 13: Assembling Since bamboo was used last year, leftover were but by a local company the foam mold. bamboo was used to reduce budget expense. The that has been working with the canoe team for the bamboo was cut laterally into pieces so that it past several years. The mold was constructed using would be made thinner to allow the bamboo 2-inch-wide precut pieces of Styrofoam. These reinforcement to be completely covered by pieces were then glued together to form the basic concrete. The bamboo, upon handling, was found to shape of the canoe. This have a waxy surface coating it. This coating was basic mold was smoothed sanded off to allow the concrete to bond well with it first using a steel brush, but it also made the bamboo more susceptible to followed by progressively water absorption. This could be a problem for the finer sandpaper to create a canoe since cement requires water for hydration. smooth finished product. This problem was solved by soaking the bamboo The ends of the mold were lengths in water before pouring the concrete. hand-carved and measured The two days before Figure 14: Sanding down by the project manager in the canoe was cast, materials the valleys in the mold. charge of hull design to were gathered and organized. ensure that it met the original design shape. A Three different mixing wooden rail was also assembled to provide stations were assembled and structural support for the Styrofoam This frame also tools were provided and laid out for those pouring the provided additional precautions during construction Figure 16: Assembling canoe. Concrete cylinders the reinforcement.

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were cast and cut to form .175 inch spacers to hold beams were attached to the table, in preparation for up the mesh and bamboo reinforcement. Steel ties the curing process. were used to join the mesh and bamboo into a To aid in the curing reinforcement cage over the mold. Weights were process, the same curing tied to the mesh to force the cage to “hug” the mold, system that was constructed forcing the mesh and bamboo to maintain an even last year was used. A plastic distance from either edge of the concrete. tent was erected over the In previous years, some teams poured the canoe and a misting nozzle canoe in two or more phases. Last year, the was installed above the mold Figure 18: Smoothing the canoe before curing. Canoegar was poured in one monolithic pour in a to provide a humid curing female mold due to the increased thickness of the environment. The misting nozzle was controlled by design. One lift was chosen to save on time and a computer program pre-programed to run for 10 avoid any cracking, requiring as well-organized a seconds every 45 min. By regulating the process as possible. This year was conducted in a environment with the plastic tent and the precise similar manner: the pour was conducted in only one control of the water applied, an optimum cure was lift to ensure that the construction was efficient. achieved. The three mixing stations were prepped for When the canoe groups of two to three, to guarantee accuracy and finished curing, the whole improve efficiency. Each measuring team was set apparatus was turned up to measure aggregates and fibers, cementitious upside down and set on the materials, or water and admixtures. As containers floor. Incisions into the of each mixture were completed, they were brought Figure 19: Inside the mold were made two feet to a mixing team of four to five who would then canoe’s curing tent. from either end. The two combine all ingredients in feet on the ends of the Styrofoam mold were left in a wheelbarrow. Each the canoe to be used as bulkheads. The rest of the batch was transferred to Styrofoam mold was removed and saved and reused those placing the as supports for the canoe and to create the cross concrete. section display. A team ranging Many materials and methods used in the from three to five construction process had sustainable aspects. In individuals worked addition to reusing and recycling supplies left Figure 17: Pouring the together to place the behind from previous year’s teams, the misting concrete onto the mold concrete, consolidate, system is still reusable for years to come. shape, and smooth the concrete. Hand-held Furthermore, the old transportation system failed vibrators were used to work the concrete around and during transportation back to the university last year underneath the reinforcement and consolidate the so a new system was constructed. The new mixture. The depth was frequently checked to transportation system was constructed using ensure consistent thickness of 1 ¼ inches. The leftover steel from the BYU Steel Bridge Team. slump of the concrete made it challenging to form Members of the Steel Bridge Team helped weld the the bow and stern in the designed shape. Wood steel sections together to create a long lasting forms were used to help prevent slump on one end. transportation system that will be used to safely As the last batch of concrete was placed, wooden bring future canoes to and from competitions.

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Project Schedule

Estimated Estimated Actual Start Actual Finish Task Name Start Finish September October November December January February March April 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 Team Leader Meeting 9/3/2015 9/3/2015 9/3/2015 9/3/2015

First Meeting and Start 9/17/2015 9/17/2015 9/17/2015 9/17/2015 Mix Design Research 9/24/2015 9/24/2015 9/24/2015 9/24/2015 Design and Testing 10/1/2015 12/24/2015 10/8/2015 2/2/2016 Final Mix Selection 1/7/2015 1/7/2015 2/2/2016 2/2/2016

Hull Design Theme selection 10/8/2015 10/8/2015 10/22/2015 10/22/2015 AutoCAD canoe design 10/6/2015 12/18/2015 10/6/2015 12/18/2015

Construction Structural Analysis 1/4/2016 1/12/2016 1/4/2016 1/12/2016 Christmas Break 12/19/2015 1/4/2016 12/19/2015 1/4/2016 Mold Construction/Preparation 1/7/2016 1/8/2016 2/2/2016 2/9/2016 Weigh out materials 1/14/2016 1/15/2016 Set up reinforcement 1/14/2016 1/15/2016 2/11/2016 2/11/2016 Bamboo Placed 1/14/2016 1/15/2016 2/11/2016 2/11/2016 Pour Day 1/23/2016 1/23/2016 2/13/2016 2/13/2016 Curing 1/23/2016 2/28/2016 2/13/2016 3/12/2016 Form Removal 3/7/2016 3/15/2016

Finishing Patching/ Sanding Exterior 2/28/2016 3/19/2016 Patching/ Sanding Interior 2/28/2016 3/19/2016 Sealing 3/19/2016 3/20/2016 Canoe Finished 3/19/2016 3/20/2016

Display Table 3/14/2016 3/21/2016

Design Report Outline Paper 1/11/2016 1/25/2016 2/15/2016 2/15/2016 Rough Draft 1/25/2016 2/18/2016 2/17/2016 2/23/2016 Editing 2/18/2016 2/25/2016 2/24/2016 2/25/2016 Printing and Binding 2/26/2016 2/26/2016 2/26/2016 2/26/2016

Oral Presentation Create Presentation 3/21/2016 3/25/2016 Practice and Critique 3/28/2016 4/1/2016

Paddling Practice 10/3/2015 3/26/2016 10/3/2015 3/26/2016 Team Workouts 10/3/2015 3/26/2016 10/3/2015 3/26/2016

Rocky Mountain Conference 3/31/2016 4/2/2016 3/31/2016 4/2/2016

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Bill of Materials

Item Qty Unit

Foam Mold 1 EA 1 4 in. Bamboo 13 EA CT275 Grid 60 SF Sealant 130 SF Concrete Mix (Appendix B) 6.6 CF

WASATCH

FORM DESIGN DRAWING DATE: 02/26/2016 SCALE: ALL UNITS IN INCHES DRAWN BY: CWB

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Appendix A – References ASTM (2009).“Standard Specification for Concrete Aggregates.”C33/C33M -08, West Conshohocken, PA.

ASTM (2009).“Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens.” C39/C39M-05, West Conshohocken, PA.

ASTM (2009).“Standard Test Method for Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading).”C78-08, West Conshohocken, PA.

ASTM (2009).“Standard Terminology Relating to Concrete and Concrete Aggregates.” C125-07, West Conshohocken, PA.

ASTM (2009). “Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Coarse Aggregate.” C127-07, West Conshohocken, PA.

ASTM (2009) “Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Fine Aggregate.” C128-07a, West Conshohocken, PA.

ASTM (2009).“Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates.” C136-06, West Conshohocken, PA.

ASTM (2009).“Standard Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete.” C138/C138M-09, West Conshohocken, PA.

ASTM (2009).“Standard Specification for .”C150-07,West Conshohocken, PA.

ASTM (2009).“Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory.” C192/C192M-07, West Conshohocken, PA.

ASTM (2009).“Standard Specification for Flow Table for Use in Tests of Hydraulic Cement.” C230/C230M-08, West Conshohocken, PA.

ASTM (2009).“Standard Test Method for Time of Setting of Hydraulic-Cement Paste by Gillmore Needles.”C266-08, West Conshohocken, PA.

ASTM (2009).“Standard Test Method for Static Modulus of Elasticity and Poisson’s Ratio of Concrete in Compression.” C469-02, West Conshohocken, PA.

ASTM (2009).“Standard Specification for Chemical Admixtures for Concrete.” C494/C494M-08a, West Conshohocken, PA.

ASTM (2009).“Standard Test Method for Splitting Tensile Strength of Cylindrical Concrete Specimens.”C496/C496M-04e1, West Conshohocken, PA.

ASTM (2009).“Standard Test Method for Drying Shrinkage of Mortar Containing Hydraulic Cement.” C596-07, West Conshohocken, PA.

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ASTM (2009).“Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete.” C618-08a, West Conshohocken, PA.

ASTM (2009).“Standard Specification for Pigments for Integrally Colored Concrete.” C979-05, West Conshohocken, PA.

ASTM (2009).“Standard Specification for Slag Cement for Use in Concrete and Mortars.” C989-09, West Conshohocken, PA.

ASTM (2009).“Standard Specification for Fiber-.” C1116/C1116M-09, West Conshohocken, PA.

ASTM (2009).“Standard Specification for Silica Fume Used in Cementitious Mixtures.” C1240-05, West Conshohocken, PA.

ASTM (2009).“Standard Specification for Liquid Membrane-Forming Compounds Having Special Properties for Curing and Sealing Concrete. ”C1315-08, West Conshohocken, PA.

ASTM (2009). “Standard Specification for Latex and Powder Polymer Modifiers for Hydraulic Cement Concrete and Mortar.” C1438-99(2005)e1. West Conshohocken, PA

ASTM (2008).“Standard Test Method for Tensile Properties of Polymer Matric Composite Materials.” D3039/D3039M-08, West Conshohocken, PA.

Brigham Young University Concrete Canoe. (2010). “Black Hull.”NCCC Design Paper, Brigham Young University, Provo, UT.

Brigham Young University Concrete Canoe. (2010). “Canoegar.”NCCC Design Paper, Brigham Young University, Provo, UT.

Mindess, S.,Young, J.F., and Darwin, D. (2003). Concrete, 2nd Ed., Prentice Hall, New Jersey.

NCCC Rules (2016) “2016 ASCE National Concrete Canoe Competition Rules and Regulations.”

McCormac, Jack and Brown, Russell. Design of Reinforced Concrete, 2014. pg. 11, 38.

ASCE. (2006). “Code of Ethics.” http://www.asce.org/inside/codeofethics.cfm

ASTM (2007). “Standard Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete.” C138-07, West Conshokocken, PA.

ASTM (2007). “Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading).” C78- 07, West Conshokocken, PA.

Mamlouk, Michael S., and Zaniewski, John P. (1999). Materials for Civil and Construction Engineers, Addison Wesley, .

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Brigham Young University WASATCH 2015

Appendix B – Mixture Proportions

Cementitious Materials Component Specific Gravity Volume (ft 3 ) Amount (mass/volume) (lb/yd 3 ) Mass of all cementitious materials, cm Cement, ASTM Type I, II 3.15 2.82 c: 554.1057523 914.30 lb/yd3 c/cm ratio Fly Ash Class F 2.3 2.51 m 1: 360.1982232 0.606 Fibers Component Specific Gravity Volume (ft 3 ) Amount (mass/volume) (lb/yd 3 )

Grace Fibers 0.91 0.044026486 f 1: 2.5 Aggregates 3 Batch Quantity Base Quantity (lb/yd ) 3 Aggregates Abs (%) MC stk (%) SG Volume, SSD (ft ) 3 OD SSD (at MC stk) (lb/yd ) Utelite (Expanded 0.0% 18% 1.50 W : 207.53 W : 244.89 848.937024 W : 244.89 Shale) OD,1 SSD,1 stk,1

Size: 2-4 23.0% 1% 0.37 W OD,2: 106.40 W SSD,2: 130.87499 111.9126563 W stk,2: 106.93

Size: 1-2 20.0% 1% 0.41 W OD,3: 55.21 W SSD,3: 66.25708 62.78226444 W stk,3: 55.49

Size: 0.5-1 20.0% 1% 0.45 W OD,3: 84.89 W SSD,3: 84.891884 88.28755937 W stk,4 : 85.32

Size: 0.25-0.5 28.0% 1% 0.68 W OD,3: 51.76 W SSD,3: 66.25708 104.1266825 W stk,5 : 52.02

Size: 0.1-0.3 35.0% 1% 0.85 W OD,3: 70.40 W SSD,3: 95.037499 186.6958877 W stk,6 : 70.75

Size: 0.04-0.125 25.0% 1% 0.80 W OD,4: 48.89 W SSD,4: 61.109503 112.9846815 W stk,7 : 49.13 Admixtures Dosage Admixture lb/gal % Solids Water in Admixture (lb/yd 3 ) (fl.oz/cwt)

Adva 195 M 8.8 x 3: 1.39 s 1: 75% w admx,1: 7.91 Total Water from All Admixtures

Eclipse Floor 200 7.7 x 4: 3.00 s 2: 0% w admx,2: 0.00 7.91 lb/yd3 Water Amount (mass/volume) (lb/yd 3 ) Volume (ft 3 ) Water, lb/yd 3 w : 230.1760258 0.136619199 3 Total Free Water from All Aggregates, lb/yd ∑w free: -47.42716312 3 Total Water from All Admixtures, lb/yd ∑w admx: 7.91 3 Batch Water, lb/yd w batch: 269.69619 Densities, Air Content, Ratios and Slump cm fibers aggregates solids water Total Mass of Concrete, M, (lb, for1 914.30 2.5 664.53 0 269.69619 1851.03 yd 3 ) Absolute Volume of Concrete, 5.33 0.05 16.45 0 4.34 26.17 V, (ft 3 ) Theoretical Density, T, (= M / 70.7315221 lb/ft 3 Air Content [= (T – D)/D x 100%] 5% V) Measured Density, D 72.9 lb/ft 3 Slump, Slump flow 2.25 in. water/cement ratio, w/c: 0.29 water/cementitious material ratio, w/cm: 0.25

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