University of Waterloo - 2014 Concrete Canoe Design Report The Dark Horse
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The Dark Horse University of Waterloo 2014 Concrete Canoe Design Report
The Dark Horse Table of Contents Executive Summary ………………………………………………………………………………ii Project Management ………………………...……………………………….……………………1 Organizational Chart ……………………………………………………………………………2 Hull Design and Structural Analysis ……………………………………..………….……………3 Development and Testing ……………………….………………..………………………….……5 Construction …………………………………..……………………..……………………………7 Project Schedule …………………………………………………..………………………………8 Design Drawing …………………………………………………………………………………10 . List of Figures Figure 1 – Breakdown of Project Costs ……………….………………………………………..…1 Figure 2 – Breakdown of Project Manpower ………....………..………………………….………1 Figure 3 – In-Water Stress Distribution ………...….…..…..…………..………………….………4 Figure 4 – Concrete Design Development …………....……..…………………………….………6 Figure 5 – Completed Formwork …….…………….…………………..………….………………7 . List of Tables Table 1 – The Dark Horse Specifications…................………………..………………………..…ii Table 2 – The Dark Horse Concrete Properties…..……………………………………………..…ii Table 3 – Project Milestone Variance ………...……..………………………….………………1 Table 4 – Summary of Analysis Results …………………….………………..………….………4 Table 5 – Comparison of Analysis to Material Strengths …………………….………….………7 . List of Appendices Appendix A – References ……………………………………………………………………..…11 Appendix B – Mixture Proportions ………...……..………………………….…………………12 Appendix C – Bill of Materials …………………….………………..………….………………14 . University of Waterloo i
The Dark Horse
Executive Summary
The University of Waterloo was founded in ability to succeed through grit and ingenuity.
1957 and quickly grew to become one of the The University of Waterloo Concrete Canoe
premier universities in Canada. It is home to the team has set high expectations for itself and
largest faculty of engineering in Canada and the will seek to make a name for itself as it
largest cooperative education program in the competes at CNCCC 2014 and beyond.
world. Together, Waterloo’s coop model and
“everything you discover at Waterloo belongs One of the teams sources of innovation came
to you” philosophy has led to the university from the use of a latex polymer modifier and
becoming a center for innovation and microfibers, which, when incorporated into the
technological development. concrete mix, led to high tensile strength and
elasticity within the concrete. They also helped
Waterloo’s Concrete Canoe team was founded prevent cracking when the canoe is placed
last summer and will compete for the first time under service loads.
in 2014. The team has developed a significant
member base since its inception and has built Throughout the project, the team utilized
on existing knowledge and techniques from sustainable practices to follow the latest trend
Waterloo’s Concrete Toboggan team to toward green building. Materials such as fly
develop the collective skills required to ash, blast furnace slag, and Poraver® recycled
compete in this competition. glass were used to reduce the environmental
impact of the concrete. Additionally, the
A major focal point for the University of formwork was designed so that it was 95%
Waterloo Concrete Canoe team is to involve recyclable by weight percentage.
younger students heavily in the design and
construction process, in order to train them and When summed together, each component of the
sustain team growth for future competitions. project showcases the valiant effort that
The team’s philosophy is that long term success Waterloo students are known to apply at school
is the ultimate goal, and so care has been taken or at the workplace. Despite facing enormous
by the project management team to ensure that hurdles from competing for the first time, like
a succession plan is in place. a dark horse the team leapt through every
challenge and rode past the problems to a
A dark horse is a symbol often identified with competition worthy canoe.
an individual or group which emerges from the Table 1. The Dark Horse Specifications
shadows to succeed beyond expectations. This Specification Value
symbolism has been used throughout history to Length (mm) 6604
describe many who refuse to be bound by their Width (mm) 849
perceived limits. The team acknowledges their Depth (mm) 348
Thickness (mm) 28.6
collective lack of experience and that success Weight (kg) 156 (E)
typically requires significant iterations. Colour Dark grey and gold
However, the team remains confident in their Reinforcement Glass fibre mesh and GFRP bars.
Table 2. The Dark Horse Concrete Properties
Density (Wet/Dry) Compressive Strength Tensile Strength Modulus of Rupture
Concrete Mix
(kg/m3) (MPa) (MPa) (MPa)
Structural Mix 1153 / 1103 13.4 0.8 0.3 (E)
Main Mix 1089 / 864 10.3 1.1 0.4 (E)
Finish Mix 1200 / 1150 (E) 12.0 (E) 0.5 (E) 0.3 (E)
Note: Quantities marked with (E) are estimated and the exact quantity will be coordinated prior to the competition.
University of Waterloo ii
The Dark Horse
Project Management responsible for ensuring quality control was
implemented throughout the project.
Waterloo’s project management team faced the
enormous task of starting the university’s first Project milestones were identified as points
concrete canoe team in over a decade. The during the project that a key task was finished.
startup process began in summer 2013 with the These milestones, and the schedule variance
captains discussing the team’s feasibility. An associated with them, are listed in Table 3.
initial budget was created with the estimate Table 3. Project Milestone Variance
based upon research into other concrete canoe Milestone Variance Reason
Hull Design Complete +15 days Larger task scope than
team’s annual costs. The Dark Horse was (3D Model Complete) anticipated
financed through monetary and material Mix Design Finalized +14 days Additional testing
Pour Canoe +14 days Delayed hull design
sponsorship donations. A breakdown of the Sanding and Patching +7 days Low manpower during
project costs is provided in Figure 1. Complete coop work term
Substantial Competition +0 days Finish on schedule
3% Canoe Materials, $370
7% The project fell two weeks behind schedule
26% Tools, $860
11% during the fall term, and additional delays
Formwork Materials, $1350
occurred in January as difficulties arose
14% Administration, $1,620
removing the formwork. To ensure the canoe
Registration, $4,700 was finished on time, weekly look ahead
39%
Team Travel, $3,100 schedules were issued so team members could
Figure 1. Breakdown of Project Costs
plan their personal time alongside the canoe
schedule, which led to an increase in manpower
The captains made a work breakdown that brought the project back on schedule. A
structure, and from there a project schedule to total of 3750 man-hours were spent on this
determine every required task and when it project as shown in Figure 2.
would be completed. It was identified that the
fall semester would be critical as the vast 9% General Meetings, 320 hrs
majority of the team would be spread across Project Management, 870 hrs
Canada on coop work terms during the winter, 40% 23% Finance / Sponsorship, 270 hrs
leading to a major manpower decrease after Mix Design, 450 hrs
December. Because of this, the schedule was 7% Hull Design, 320 hrs
frontloaded by having most of the design and 9% 12% Construction, 1470 hrs
construction work, including pouring the
canoe, completed by the end of November. The Figure 2. Breakdown of Project Manpower
critical path was determined by identifying any Safety was a central focus during construction
task that would delay the entire project if not activities. MSDS sheets were made available,
completed on time. These tasks are shown in and personal protective equipment was worn at
red on the project schedule. all times. Prior to work being completed, pre-
job safety instructions (PSIs) were completed
In September recruitment began and key team by the team. A PSI lists each task step, any
members were assigned to leadership roles. potential hazards, and the steps taken to control
The design of the canoe was split into three each hazard. PSIs were discussed during
sections: mix, hull, and formwork. Splitting the toolbox talks prior to work being completed so
workload allowed the team to accelerate the every team member was aware of the hazards
design process, while giving the captains more and corrective actions. The implementation of
opportunity to oversee the entire project. The this system led to zero incidents throughout
design manager and these leads were canoe construction.
University of Waterloo 1
The Dark Horse Organizational Chart University of Waterloo 2
The Dark Horse
Hull Design and Structural Analysis
The canoe was designed with a length of
The design of The Dark Horse focused on 6604mm from bow to stern accommodates
developing a comprehensive understanding of paddlers’ in all race configurations. A 254mm
the design problem and developing a working and 25mm rocker extends from front to center,
model as a basis for future competition entries. and from center to back, respectively. The
Since there was no previous data as a basis for approximate symmetry between the two
the team, initial canoe geometry was based off rockers and their magnitude provides increased
the base ASCE design, research, and lateral stability to the canoe by counteracting
application of basic fluid mechanic principles. the strong rocking motion caused by paddling.
Geometry was further refined according to
available design parameters, such as loading The body of the canoe tapers to a streamlined
cases, passenger geometry, and accessible “V” shape on either end to assist in speed and
materials. Materials, as discussed in tracking. Tapering is unsymmetrical and
development and testing, were developed in hydrodynamic; the “tear-drop” shape reduces
conjunction with design to provide required drag. The midline height of the canoe is
strength per analysis results. 348mm. A height buffer was provided to be
conservative due to lack of experimental data.
The geometry of The Dark Horse is based
off of the sample canoe provided by ASCE. A Three loading cases were considered for
literature review was performed to investigate competition configurations: unloaded, two-
the effects of design components on canoe paddlers, and four paddlers. The canoe in
performance and from there modifications to transport was considered as an additional
the sample design were undertaken. Although loading case. Loads include: the weight of
features such as speed and maneuverability canoe, governed by concrete; and the weight of
were considered, design priority was placed in individual paddlers. The canoe had an
functionality and stability. estimated weight of 156 kilograms (kg)
consisting primarily of concrete modelled as a
A beam of 849 millimeters was determined uniformly distributed load. Paddlers were
to accommodate the geometry of a typical estimated to have a maximum weight of 90kg
kneeling paddler. A larger beam was preferred and were modelled in competition
for stability over the increased racing configurations as individual point loads.
performance of a smaller beam. The shape of
the hull was also chosen with stability in mind: The premise of the analysis was to model canoe
the hull transitions from rounded at each end to sections as a 2-D beam on an elastic foundation.
soft chine flat-bottomed within the middle Principal sections were positioned at 1 inch and
third. Flatness increases initial stability during 1 foot intervals in the transverse and
loading and is advantageous to the beginner longitudinal directions, respectively. Principal
skill level of Waterloo’s paddlers. However, to nodes were formed where sections intersected
accommodate for the racing courses and with canoe outline. Water resistance was
rougher waters, a rounded bow was utilized to considered as an elastic foundation modelled
provide greater maneuverability. The sides of with uniformly distributed springs with
The Dark Horse are slightly flared for stiffness, k. Spring supports were established at
increased stability due to the increased surface principal nodes to monitor beam (canoe)
area in contact with water in contrast to a canoe behaviour at these points in terms of stress,
with straight sides. shear, and deflection.
University of Waterloo 3
The Dark Horse
Stiffness of the spring supports resists
displacement (delta) per unit length of the Table 4. Summary of Analysis Results
beam. However, the heave and roll motion of Maximum Stress in Water [MPa]
the floating canoe must be taken into account Longitudinal 0.673
Transverse -0.575
by considering the moment caused by Overall (Von Mises) 0.918
buoyancy forces. Haukaas states that for Forces in Water [kN/m]
rectangular shapes, the stiffness that resists Longitudinal -16.65
rotation phi, per unit length of the beam is: Transverse 33.86
Maximum Stress in Transport [MPa]
12 Overall (Von Mises) 1.21
where kϕ is the stiffness providing resistance
against torsion of the beam, ρw is the mass
density of water, g is the gravitational constant,
and b is the cross sectional width based on the
axis. The canoe section at the beam is roughly
rectangular but the rounded bottom of the ends
have zero resistance against rotation (Haukaas,
2012).
The canoe will be braced and encompassed in
foam and secured to its trailer using a padded
harness and strap configuration during Figure 3. In-water Stress Distribution
transport. The greatest concern during transport
is stress due to self-weight: each end of the As such, higher strength concrete structural ribs
canoe cantilevers from the mid-section causing were placed transversely at sections
negative bending and high tensile stress. As corresponding to racing configurations to
self-weight is a static dead load, a factor of distribute the concentrated loads across the
safety of 1.4 was applied. Accordingly, canoe surface. This may help prevent severe
placement of foam against and supporting both cracking due to tensile stresses or shear failure
interior and exterior walls of the canoe will act (similar to punching shear failure of columns).
to ensure that net pressure against walls is Similarly, tensile reinforcement, including
minimal. GFRP, was placed in areas identified as under
tensile stress per analysis.
Geometry was plotted in AutoCAD and
coordinates were exported to Microsoft Excel.
Basic calculations were performed to predict
waterline under load cases. 2D analysis was
performed in SAP2000. Point loads were
applied to the model per unloaded and race
configurations; notable findings are listed in the
table below. Tensile force in the area of applied
point loads (paddlers) were determined to be
17.5 kN/m. In-water stress distribution is
modelled in 3D in Figure 3.
University of Waterloo 4
The Dark Horse
Development and Testing aggregate was formed. Testing showed that
mixes composed according to the fuller curve
As a new team much of the baseline material were slightly weaker in compression, but
selection was determined by cost and lighter and stronger in tension than mixes with
availability. Several cementitious materials, different aggregate grading schemes.
aggregates, and admixtures were tested and Therefore, the fuller gradations were used to
used in the final concrete mix in The Dark increase the tensile cracking resistance in the
Horse. St. Mary’s GU grey Portland Cement canoe. During initial tests, it became apparent
was the base cementitious material, and that the high absorption rate of the Poraver
supplementary cementitious materials such as reduced the amount of free water available for
Fly Ash Type C, Silica Fume, and Slag were hydration of the cementitious materials. For all
used to reduce the amount of Portland Cement subsequent test batches and the canoe mixes,
used. Poraver was selected as the base graded Poraver aggregate were soaked
aggregate due to its availability and overnight to bring them to the saturated surface
sustainability. Since most of these materials are dry condition.
industrial by-products, the concrete mix is a
very sustainable building material. 19 mm long M100 microsynthetic fibres were
added to the concrete at a rate of 600 g/m3 to
The pozzolanic properties of fly ash and silica provide three dimensional plastic shrinkage
fume generate a secondary cementitious reinforcement, crack resistance, and decreased
matrix/gel that increases overall compressive permeability. These are desirable properties
and flexural strength. In addition, these given the thin structure of the hull and the
materials decrease the permeability and constant exposure to water. The team found it
improves workability of the concrete, both of challenging to sufficiently disperse the fibres in
which are advantageous characteristics for this the mix and observed clumps forming.
application. Slag is a hydraulic cement which Therefore, the sequence of additions to the mix
increases setting time in addition to providing was changed, and the fibres were added with
effects similar to the pozzolans. This aided in the coarse aggregate prior to the addition of the
the prevention of cold joints, since the batching cementitious dry mixture. The fibres were also
and casting of the canoe took place in separate hand separated to ensure that they functioned as
rooms and batches needed to be wheeled over they were designed to.
and hand applied onto the formwork.
Delvo® Stabilizer was introduced into the mix
Various Poraver aggregate proportions were at a rate of 1120 mL/m3 to slow the curing
considered for the aggregate in the concrete. process and avoid cold joints. It also served the
These expanded glass spheres act as purpose of curbing segregation of the
lightweight aggregate in the concrete and cementitious materials, aggregates, and fibres.
inherently entrain air into the concrete while Rheomac® VMA Viscosity modifier was
providing some compressive strength across added to the mixture at a rate of 1723 mL/m3
the voids. By varying the Poraver size to increase the viscosity and enhance the
distribution, both a standard mix and a denser finishing properties of the concrete. A viscous
and stronger structural mix (used for the ribs) concrete was required to prevent it from sliding
were created. down the sides of the hull and to retain a
uniformly dense structure during the
The aggregate grading schemes were construction process which involved the hand
determined using a modified fuller curve in application of the concrete on a male mould.
order to ensure that a densely packed matrix of
University of Waterloo 5The Dark Horse
15 Compression Tension 1.5
Rehabilicrete® Part B, a latex based polymer
Split Cylinder Test
Strength (MPa)
modifier was included in the design to increase
Compressive
10 1
the flexural capacity and elasticity of the
(MPa)
concrete as well as to reduce the permeability
5 0.5
of the cementitious matrix. For initial tests, the
polymer modifier was added at a 1/3 ratio to the
0 0
volume of the cementitious materials as
Control Phase 1 Phase 2 Canoe
prescribed by the manufacturer. However, this
Figure 4. Concrete Design Development
ratio reduced the viscosity of the concrete
beyond a useful level. A balance between the Analysis of the design model resulted in two
water to cementitious ratio and the workability main objectives for the canoe reinforcement.
of the concrete was achieved at a polymer First, reinforcement was required to provide
additive to cementitious ratio of 20% by sufficient stiffness along the length of the canoe
weight. to prevent cracking in the tension zones under
service loads. Secondary reinforcement was
Glenium 7700, a high range water reducer, and required to provide sufficient resistance to
Micro Air, an air entrainment additive, were point load cases such as a paddler’s knee. In
considered in varous tests but were not included order to achieve the first objective, the team
in the final mix. The plasticity provided by the selected #3 (9.53 mm) glass fibre reinforced
Glenium was deemed excessive for a male polymer V-Rod LM Bent Bars, which have a
mold application as the cementitious mix and strength of 850 MPa, a modulus of elasticity of
polymer modifier provided a sufficient degree 40 GPa, and an area of 71.26 mm2. For the
of workability. In early tests the addition of secondary reinforcement the team selected
both the air entrainment mixture and the SikaWrap G 350 Grid glass fibre mesh. This
polymer modifier resulted in excessive grid was selected for its high strength to weight
foaming of the concrete mix and subsequently, ratio and thin profile despite its lower stiffness
overly large void ratios which negatively compared to other materials. Welded steel wire
impacted the strength of the concrete. It was fabric was considered as an alternative material
determined that air entrainment from foaming for its increased stiffness, but the additional
caused by the polymer modifier and the air weight required to meet strength requirements
within the Poraver aggregate was sufficient. could not be justified. Therefore, the thickness
of the longitudinal reinforcing was required to
Samples of the test mixes and construction tests supply sufficient rigidity to the structure.
were tested in compression (ASTM C39M-14),
in tension (ASTM C496M-11), and for the As a result of successive testing, the final
modulus of rupture (ASTM C78M 10e1). The materials used exceeded the values determined
various changes made during the mix in the analysis. The higher reinforcement level
development created a final mix that was 41% was still included in the canoe to provide a
stronger in tension and 25% stronger in conservative design with adequate stiffness.
compression as shown in the following table.
Table 5. Comparison of Analysis to Material Strengths
Concrete Analysis Actual
Compressive Strength (MPa) 1.21 10.31
Tensile Strength (MPa) -0.575 1.11
Reinforcement Analysis Actual
Fibre Mesh Strength (kN/m) 16.65 75
University of Waterloo 6The Dark Horse
Construction canoe, required minimal curvature for the top
zone of the canoe. This section was
The construction process was planned for approximately 5100mm long by 300mm high
completion in three phases; formwork and was framed with lumber and surfaced with
construction, concrete mixing, and concrete 13mm plywood. Five strips were recessed on
placement. It was also identified that following either side of the framing to accommodate the
the construction process, periodic monitoring construction of structural ribs.
of environmental conditions would be required.
Early consideration was given to the materials The foam areas of the formwork were sized for
and schematic design to be used for the construction in 50mm strips, the nominal size
construction of formwork. Both male and of foam sheets. Pieces were individually cut
female formwork options were considered, and and glued into place around the wood framing.
while both presented viable options, it was Sanding of the foam was completed both by
determined that it would be more advantageous hand and using powered belt sanders in order to
to use a male formwork due to the ability to achieve a smooth contour that matched closely
form the non-uniform inner surface and hand the finalized hull design geometry. Six layers
finish the uniform exterior. Materials of tapered 13mm plywood strips were used
considered for construction included wood and along the bottom edge of the formwork in order
rigid foam. Due to the complex inner geometry to provided contour to the top edge in
resulting from five structural ribs, it was accordance with the hull design. To prevent the
concluded that rigid foam would be more formwork materials from pulling moisture out
appropriate for use as it provided more flexible of the concrete mix, a 6mm polyethylene sheet
constructability. It was found that using rigid was placed over the form and sealed using Tuck
foam for the entire formwork resulted in high Tape. Figure 5 shows the completed formwork
costs associated with materials and CNC prior to the placement of concrete.
manufacturing. In order to create a more cost
effective design, a wood frame was constructed
for areas of consistent geometry, with local
areas of foam for areas of high curvature. Due
to the limited scope of foam construction, it was
planned to hand finish the form in lieu of
contracting out the manufacturing process.
In order to construct the form to accurately
match the hull design, sections on regular
intervals were output from a 3D model and Figure 5. Completed Formwork
used as the basis for the formwork design.
Using the section coordinates, contour plots of GFRP reinforcing bars were placed as required,
the inner surface of the canoe were generated at supported by small nails placed into the
intervals of one inch in height. These were formwork or on chairs made from cubes of
used to interpolate the section profile across the rigid foam. Concrete was placed onto the form
entire length of the canoe. in lifts, so as to allow layers of fibre mesh
reinforcing to be placed appropriately.
The ends and bottom of the canoe are areas with Concrete was batched in a lab nearby the
high curvature, thus requiring rigid foam formwork and transported using wheelbarrows
construction. The center region of the canoe, while protected using moistened burlap sheets.
approximately 900mm from the ends of the All concrete was placed during a single day in
University of Waterloo 7The Dark Horse
order to prevent construction joints and gunwales. It was determined that it would be
promote cohesion throughout the hull. With advantageous to use a very thin patch mix to fill
the use of hydration retarding admixtures, it small cracks, localized honeycombing, and
was anticipating that adjacent concrete layers voids developed during the construction
would need to be placed within two hours of process.
each other. Structural ribs were placed first,
followed by the remainder of the hull, in 10mm Sanding of the canoe was completed on both
lifts. Concrete was applied to the surface of the the outside and inside of the canoe prior to the
formwork by hand and blended in to the placement of the patch mix, in order to level the
existing layers in order to achieve a monolithic finish surface and provide a good substrate for
hull. Quality control was achieved through the patch mix. Both hand sanding and powered
dedicated monitoring individuals who used pre belt and orbital sanders were used with varying
manufactured thickness gauges to ensure grits of sand paper. Once the profile was
consistent hull thickness and accuracy in accepted by the design team, the patch mix was
placement of mesh sheets. Upon the placement batched and placed in one thin lift across the
of the final lifts of concrete, moistened entire surface of the canoe, with the inner and
finishing tools were used to smooth the outer outer sections completed on different days. A
surface. A pre-manufactured curing tent was humid environment was provided as
placed over the concrete and a humidifier was appropriate. Additional hand sanding was
inserted to provide an ideal hydration completed of the patch mix so as to provide a
environment. Test cylinders and prism were smooth finish surface prior to chemical sealing.
cast throughout the concrete pour from each
batch, and were placed in the curing tent to Upon completion of sanding the canoe to reach
ensure comparable curing conditions. an acceptable finish surface using increasingly
fine grit sanding paper, two coats of stain were
Formwork was intended to be removed by applied to achieve the grey colour with gold
sliding the cured canoe off of the formwork, decals in line with Waterloo’s theme, The
which was greased prior to concrete placement. Dark Horse. Finally, two coats of sealer were
Friction and wedging around the structural ribs applied to protect and waterproof the concrete
made this process very difficult, and thus the and to provide a glossy finished look.
formwork was deconstructed from the inside
out. Exposed rigid foam at the ends of the
canoe were easily accessed and removed.
Wood framing was disassembled using caution
to avoid excessive stress in the hull during
removal. Once the plywood framing skin and
rigid foam were all that remained, a relief cut
was made down the centerline of the canoe,
allowing for the remaining formwork to be
removed in large sections. Following the
formwork removal, the hull was inspected to
identify any defect and mark all locations of
reinforcement chairs to be filled with additional
concrete. Some minor shrinkage cracks across
the width of the canoe were found, as well as
localized honeycombing at the top edge of the
University of Waterloo 8The Dark Horse
Project Schedule
ID Task Name Duration Baseline Start Baseline Finish Actual Start Actual Finish Start Finish September October November December January February March April May June
Variance Variance 9/8 9/15 9/22 9/29 10/6 10/13 10/20 10/27 11/3 11/10 11/17 11/24 12/1 12/8 12/15 12/22 12/29 1/5 1/12 1/19 1/26 2/2 2/9 2/16 2/23 3/2 3/9 3/16 3/23 3/30 4/6 4/13 4/20 4/27 5/4 5/11 5/18 5/25 6/1 6/8
0 Waterloo Canoe Schedule 244 days Wed 9/11/13 Mon 5/12/14 Wed 9/11/13 NA 0 days 0 days
1 Project Start Up 9 days Wed 9/11/13 Thu 9/19/13 Wed 9/11/13 Thu 9/19/13 0 days 0 days
2 Expansion Meeting with SDC Director 1 day Wed 9/11/13 Wed 9/11/13 Wed 9/11/13 Wed 9/11/13 0 days 0 days Expansion Meeting with SDC Director
3 2014 Rules and Regulations Publication 1 day Mon 9/16/13 Mon 9/16/13 Mon 9/16/13 Mon 9/16/13 0 days 0 days 2014 Rules and Regulations Publication
4 Recruitment Meeting 1 day Thu 9/19/13 Thu 9/19/13 Thu 9/19/13 Thu 9/19/13 0 days 0 days Recruitment Meeting
5 Project Management Team 227 days Fri 9/20/13 Sun 5/4/14 Fri 9/20/13 NA 0 days 0 days
6 Project schedule and team planning 14 days Fri 9/20/13 Thu 10/3/13 Fri 9/20/13 Thu 10/3/13 0 days 0 days Project schedule and team planning
7 Project tracking (cost, time, risk, etc) 213 days Fri 10/4/13 Sun 5/4/14 Fri 10/4/13 NA 0 days 0 days Project tracking (cost, time, risk, etc)
8 Safety program implementation 213 days Fri 10/4/13 Sun 5/4/14 Fri 10/4/13 NA 0 days 0 days Safety program implementation
9 Preliminary competition registration 6 days Sat 1/25/14 Fri 1/31/14 Sat 1/25/14 Thu 1/30/14 0 days -1 day Preliminary competition registration
10 Competition registration 24 days Sat 2/1/14 Mon 2/24/14 Sat 2/1/14 Mon 2/24/14 0 days 0 days Competition registration
11 Sponsorship Team 235 days Thu 9/12/13 Sun 5/4/14 Thu 9/12/13 NA 0 days 0 days
12 Create sponsorship brochure 9 days Thu 9/12/13 Fri 9/20/13 Thu 9/12/13 Fri 9/20/13 0 days 0 days Create sponsorship brochure
13 Develop list of companies to contact 27 days Sat 9/21/13 Thu 10/17/13 Sat 9/21/13 Thu 10/17/13 0 days 0 days Develop list of companies to contact
14 Fall 2013 WEEF Proposal 9 days Fri 10/4/13 Fri 10/18/13 Thu 10/10/13 Fri 10/18/13 6 days 0 days Fall 2013 WEEF Proposal
15 Source corporate sponsorship 206 days Fri 10/11/13 Sun 5/4/14 Fri 10/11/13 NA 0 days 0 days Source corporate sponsorship
16 Spirit Team 174 days Thu 11/14/13 Tue 5/6/14 Thu 11/14/13 NA 0 days 0 days
17 Decide on spirit theme 15 days Thu 11/14/13 Thu 11/28/13 Thu 11/14/13 Thu 11/28/13 0 days 0 days Decide on spirit theme
18 Develop theme (cheers, t-shirts, logo, etc) 129 days Fri 11/29/13 Sun 4/6/14 Fri 11/29/13 NA 0 days 0 days Develop theme (cheers, t-shirts, logo, etc)
19 Fall team building event 1 day Sat 11/16/13 Sat 11/16/13 Sat 11/30/13 Sat 11/30/13 14 days 14 days Fall team building event
20 Spring team building event 1 day Tue 5/6/14 Tue 5/6/14 NA NA 0 days 0 days Spring team building event
21 Mix Design Team 87 days Thu 10/3/13 Sat 12/14/13 Thu 10/3/13 Sat 12/28/13 0 days 14 days
22 Concrete initial mix design 28 days Thu 10/3/13 Wed 10/16/13 Thu 10/3/13 Wed 10/30/13 0 days 14 days Concrete initial mix design
23 Obtain concrete materials 27 days Thu 10/3/13 Wed 10/16/13 Thu 10/3/13 Tue 10/29/13 0 days 13 days Obtain concrete materials
24 Pour Trial Mix Cylinders 1 day Thu 10/17/13 Thu 10/17/13 Fri 10/25/13 Fri 10/25/13 8 days 8 days Pour Trial Mix Cylinders
25 Pour Mix 1-4 Cylinders 1 day Thu 10/24/13 Thu 10/24/13 Thu 10/31/13 Thu 10/31/13 7 days 7 days Pour Mix 1-4 Cylinders
26 Mix 1-4 7 day Testing 1 day Thu 10/31/13 Thu 10/31/13 Thu 11/7/13 Thu 11/7/13 7 days 7 days Mix 1-4 7 day Testing
27 Mix 1-4 14 day Testing 1 day Thu 11/7/13 Thu 11/7/13 Thu 11/14/13 Thu 11/14/13 7 days 7 days Mix 1-4 14 day Testing
28 Mix 1-4 28 day Testing 1 day Thu 11/21/13 Thu 11/21/13 Thu 11/28/13 Thu 11/28/13 7 days 7 days Mix 1-4 28 day Testing
29 Pour Mix 5-6 Cylinders 1 day Tue 11/5/13 Tue 11/5/13 Tue 11/19/13 Tue 11/19/13 14 days 14 days Pour Mix 5-6 Cylinders
30 Mix 5-6 7 day testing 1 day Tue 11/12/13 Tue 11/12/13 Tue 11/26/13 Tue 11/26/13 14 days 14 days Mix 5-6 7 day testing
31 Finalize canoe mix design 1 day Fri 11/15/13 Fri 11/15/13 Fri 11/29/13 Fri 11/29/13 14 days 14 days Finalize canoe mix design
32 Test casted concrete 28 day 1 day Sat 12/14/13 Sat 12/14/13 Sat 12/28/13 Sat 12/28/13 14 days 14 days Test casted concrete 28 day
33 Hull Design Team 54 days Thu 10/3/13 Fri 11/15/13 Thu 10/3/13 Mon 11/25/13 0 days 10 days
34 Hull design concept 36 days Thu 10/3/13 Wed 10/9/13 Thu 10/3/13 Thu 11/7/13 0 days 29 days Hull design concept
35 Design calculations 8 days Thu 10/10/13 Wed 10/16/13 Fri 11/8/13 Fri 11/15/13 29 days 30 days Design calculations
36 3D modeling 8 days Thu 10/17/13 Thu 10/31/13 Fri 11/8/13 Fri 11/15/13 22 days 15 days 3D modeling
37 Obtain canoe reinforcement 40 days Thu 10/17/13 Fri 11/15/13 Thu 10/17/13 Mon 11/25/13 0 days 10 days Obtain canoe reinforcement
38 Formwork Design Team 58 days Thu 10/3/13 Fri 11/15/13 Thu 10/3/13 Fri 11/29/13 0 days 14 days
39 Evaluate ideas for canoe formwork 21 days Thu 10/3/13 Sun 10/27/13 Thu 10/3/13 Wed 10/23/13 0 days -4 days Evaluate ideas for canoe formwork
40 Obtain formwork material 1 day Mon 10/28/13 Thu 10/31/13 Fri 11/15/13 Fri 11/15/13 18 days 15 days Obtain formwork material
41 Build formwork 14 days Fri 11/1/13 Fri 11/15/13 Sat 11/16/13 Fri 11/29/13 15 days 14 days Build formwork
42 Construction 182 days Thu 11/7/13 Wed 5/7/14 Thu 11/7/13 NA 0 days 0 days
43 Pre-plan for casting day 22 days Thu 11/7/13 Fri 11/15/13 Thu 11/7/13 Thu 11/28/13 0 days 13 days Pre-plan for casting day
44 Cast canoe and cross section 1 day Sat 11/16/13 Sat 11/16/13 Sat 11/30/13 Sat 11/30/13 14 days 15 days Cast canoe and cross section
45 Canoe concrete curing 28 days Sun 11/17/13 Sat 12/14/13 Sun 12/1/13 Sat 12/28/13 14 days 14 days Canoe concrete curing
46 Strip formwork and rough sand 50 days Sun 12/15/13 Sat 2/22/14 Sat 1/18/14 Sat 3/8/14 34 days 14 days Strip formwork and rough sand
47 Finish sanding canoe inner 7 days Sun 2/23/14 Sat 3/1/14 Sun 3/9/14 Sat 3/15/14 14 days 14 days Finish sanding canoe inner
48 Patch and finish canoe inner 7 days Sun 3/2/14 Sat 3/15/14 Sun 3/16/14 Sat 3/22/14 14 days 7 days Patch and finish canoe inner
49 Finish sanding canoe outer 7 days Sun 3/16/14 Sat 3/22/14 Sun 3/23/14 Sat 3/29/14 7 days 7 days Finish sanding canoe outer
50 Patch and finish canoe outer 8 days Sun 3/23/14 Sat 4/5/14 Sun 3/30/14 Sun 4/6/14 7 days 1 day Patch and finish canoe outer
51 Canoe touch up sanding 6 days Sun 4/6/14 Sat 4/12/14 Mon 4/7/14 Sat 4/12/14 1 day 0 days Canoe touch up sanding
52 Stain canoe and canoe aesthetics 7 days Sun 4/13/14 Sat 4/19/14 NA NA 0 days 0 days Stain canoe and canoe aesthetics
53 Sealant application 8 days Sun 4/20/14 Sun 4/27/14 NA NA 0 days 0 days Sealant application
54 Canoe substantial completion 0 days Sun 4/27/14 Sun 4/27/14 NA NA 0 days 0 days 54 Canoe substantial completion
55 Canoe touch ups 10 days Mon 4/28/14 Wed 5/7/14 NA NA 0 days 0 days Canoe touch ups
56 Design Paper 41 days Sat 3/1/14 Fri 4/11/14 Sat 3/1/14 Fri 4/11/14 0 days 0 days
57 Teams write design paper sections 23 days Sat 3/1/14 Sun 3/23/14 Sat 3/1/14 Sun 3/23/14 0 days 0 days Teams write design paper sections
58 Combine and edit design paper 18 days Mon 3/24/14 Thu 4/10/14 Mon 3/24/14 Thu 4/10/14 0 days 0 days Combine and edit design paper
59 Submit design paper 0 days Fri 4/11/14 Fri 4/11/14 Fri 4/11/14 Fri 4/11/14 0 days 0 days 59 Submit design paper
60 Oral Presentation 23 days Sat 4/12/14 Sun 5/4/14 Sat 4/12/14 NA 0 days 0 days
61 Outline and visual aids 15 days Sat 4/12/14 Sat 4/26/14 Sat 4/12/14 NA 0 days 0 days Outline and visual aids
Gantt Chart Legend Presenters rehearse individual parts
62 Presenters rehearse individual parts 8 days Sun 4/27/14 Sun 5/4/14 NA NA 0 days 0 days
63 Competition Preparation 27 days Sat 4/12/14 Thu 5/8/14 Sat 4/12/14 NA 0 days 0 days Task
64 Presenters study design report 23 days Sat 4/12/14 Sun 5/4/14 Sat 4/12/14 NA 0 days 0 days Presenters study design report
Milestone
65 Practice paddling canoe 3 days Mon 5/5/14 Wed 5/7/14 NA NA 0 days 0 days Practice paddling canoe
Critical Combined oral presentation rehearsal
66 Combined oral presentation rehearsal 1 day Mon 5/5/14 Mon 5/5/14 NA NA 0 days 0 days
67 Practice presentation with faculty 1 day Tue 5/6/14 Tue 5/6/14 NA NA 0 days 0 days Baseline Practice presentation with faculty
68 Pack canoe in trailer 1 day Thu 5/8/14 Thu 5/8/14 NA NA 0 days 0 days Pack canoe in trailer
69 CNCCC 2014 4 days Fri 5/9/14 Mon 5/12/14 NA NA 0 days 0 days CNCCC 2014
Schedule last updated April 11, 2014
910
The Dark Horse
Appendix A - References
ASTM (2012). “Standard Specifications for
ASTM (2014). “Standard Test Method for Coal Fly Ash and Raw or Calcined Natural
Compressive Strength of Cylindrical Pozzolan for Use as a Mineral Admixture
Concrete Specimens” C39/C39M-14, West in Concete” C618-12, West
Conshohocken, PA. Conshohocken, PA.
ASTM (2013). “Standard Terminology ASTM (2013). “Standard Specification for
Relating to Concrete and Concrete Ground Granulated Blast-Furnace Slag for
Aggregates” C125-13, West Use in Concrete and Mortars” C989-13,
Conshohocken, PA. West Conshohocken, PA.
ASTM (2012). “Standard Test Method for ASTM (2010). “Standard Specification for
Density, Relative Density (Specific Fiber-Reinforced Concrete and Shotcrete”
Gravity) and Absorption of Coarse C1116-10, West Conshohocken, PA.
Aggregates” C127-12, West
Conshohocken, PA. ASTM (2013). “Standard Specification for
Latex and Powder Polymer Modifiers for
ASTM (2012). “Standard Test Method for Hydraulic Cement Concrete and Mortar”
Specific Gravity and Absorption of Fine C1438-14, West Conshohocken, PA.
Aggregates” C128-12, West
Conshohocken, PA. Haukaas, Terje. (2012). Beams on Elastic
Foundation. University of British
ASTM (2013). “Standard Test Method for Columbia “InRisk” Course Notes.
Density (Unit Weight), Yield, and Air Retrieved from
Content (Gravimetric) of Concrete” http://www.inrisk.ubc.ca/files/2012/11/
C138/C138M-13, West Conshohocken, Beams_on_Elastic_Foundation1.pdf
PA.
ASTM (2012). “Standard Specification for Kosmatka, S H. et al. (2011) Design and
Portland Cement” C150-12, West Control of Concrete Mixtures. The Guide
Conshohocken, PA. to Application, Methods and Materials.
Eighth Canadian Edition. Cement
ASTM (2010). “Standard Specification for Association of Canada.
Air-Entraining Admixtures for Concrete”
C260-10, West Conshohocken, PA.
ASTM (2013). “Standard Specification for
Chemical Admixtures for Concrete”
C494/494M-13, West Conshohocken, PA.
ASTM (2011). “Standard Test Method for
Splitting Tensile Strength of Cylindrical
Concrete Specimens” C496/496M-11,
West Conshohocken, PA.
University of Waterloo 11Appendix B - Mixture Proportions for Main Mix
Mixture ID: Main Canoe Mix Design Proportions (Non Actual Batched
Yielded Proportions
YD - Design Batch Size (m3): 0.04 SSD) Proportions
Amount Volume Amount Volume Amount Volume
SG
(kg/m3) (m3) (kg) (m3) (kg/m3) (m3)
Cementitious Materials
CM1 Holcim GU 3.15 166.1 0.053 7.1 2.25E-03 239.1 7.60E-02
CM2 Fly Ash 2.31 84.0 0.036 3.6 1.55E-03 121.0 5.25E-02
CM3 Slag 2.93 101.6 0.035 4.3 1.48E-03 146.3 5.00E-02
CM4 Silica Fume 2.22 39.1 0.018 1.7 7.52E-04 56.3 2.54E-02
Total Cemenitious Materials: 390.9 0.142 16.7 6.04E-03 562.6 2.04E-01
Fibers
F1 Fiber 1.30 0.60 4.62E-04 0.023 1.76E-05 0.77 5.93E-04
Total Fibres: 0.60 4.62E-04 0.023 1.76E-05 0.77 5.93E-04
Aggregates
Poraver ® 0.25mm - 0.50mm
A1 0.59 43.89 0.074 1.87 3.17E-03 63.09 1.07E-01
Absorption: 25%
Poraver ® 0.50mm - 1.00mm
A2 0.47 28.02 0.060 1.20 2.54E-03 40.36 8.59E-02
Absorption: 25%
Poraver ® 1.00mm - 2.00mm
A3 0.39 33.36 0.086 1.42 3.65E-03 48.03 1.23E-01
Absorption: 25%
Poraver ® 2.00mm - 4.00mm
A4 0.32 43.00 0.134 1.84 5.73E-03 61.98 1.94E-01
Absorption: 27.5%
Total Aggregates: 148.26 0.35 6.32 1.51E-02 213.46 5.10E-01
Water
W1 Water for Cement hydration (W1a + W1b) 148.53 0.15 5.95 5.96E-03 200.96 2.01E-01
W1a. Water from Admixtures 61.12 1.71 86.84
1.00
W1b. Additional Water 87.41 4.24 114.11
W2 Water from Aggregates, SSD 37.07 1.63 54.92
Total Water (W1 + W2): 185.60 0.15 7.58 5.96E-03 255.88 2.01E-01
Solids Content of Latex, Dyes and Admixtures in Powder Form
S1 HC RehabiliCRETE 150 1.00 46.90 0.047 1.67 1.67E-03 56.27 5.64E-02
Total Solids of Admixtures: 46.90 0.05 1.67 1.67E-03 56.27 5.64E-02
Admixtures (including Pigments in Liquid Form)
Water in Water in Water in
Percent Dosage Amount Dosage
Admixture Admixture Admixture
Solids (mL/100kg) (mL) (mL/100kg)
(kg/m3) (kg) (kg/m3)
Ad1 HC RehabiliCRETE 150 1.00g/cm3 50% 9380.72 46.90 3332.00 1.67 13329.08 66.65
Ad2 BASF Delvo ® Stabilizer 1.06g/cm3 40% 1723.00 8.62 37.50 0.02 2448.21 12.24
Ad3 BASF Rheomac ® VMA 362 1.00g/cm3 40% 1120.00 5.60 32.50 0.02 1591.41 7.96
Water from Admixtures (W1a): 61.12 1.71 86.84
Cement-Cementitious Materials Ratio N/A 0.425 0.425 0.425
Water-Cementitious Materials Ratio N/A 0.38 0.357 0.357
Slump, Slump Flow mm 200 +/- 3mm 244mm 244mm
M Mass of Concrete kg 833 32.2 1089.0
V Absolute Volume of Concrete m3 0.6918 0.0288 0.9718
T Theoretical Density ( = M/V) kg/m3 1205 1121 1121
3
D Design Density kg/m 833
D Measured Density kg/m3 1089 1089
A Air Content % 31% 3% 3%
Y Yield ( = M/D) m3 1.00 0.03 1.00
Ry Relative Yield ( = Y/YD) N/A 0.704
12Appendix B - Mixture Proportions for Structural Mix
Mixture ID: Structural Canoe Mix Design Proportions (Non Actual Batched
Yielded Proportions
YD - Design Batch Size (m3): 0.03 SSD) Proportions
Amount Volume Amount Volume Amount Volume
SG
(kg/m3) (m3) (kg) (m3) (kg/m3) (m3)
Cementitious Materials
CM1 Holcim GU 3.15 176.7 0.056 7.4 2.36E-03 269.1 8.56E-02
CM2 Fly Ash 2.31 89.4 0.039 3.8 1.63E-03 136.1 5.90E-02
CM3 Slag 2.93 108.1 0.037 4.5 1.55E-03 164.6 5.63E-02
CM4 Silica Fume 2.22 41.6 0.019 1.7 7.88E-04 63.3 2.86E-02
Total Cemenitious Materials: 415.72 0.151 17.47 6.33E-03 633.11 2.29E-01
Fibers
F1 Fiber 1.30 0.60 4.62E-04 0.020 1.51E-05 0.71 5.47E-04
Total Fibres: 0.60 4.62E-04 0.020 1.51E-05 0.71 5.47E-04
Aggregates
Poraver ® 0.10mm - 0.30mm
A1 0.90 50.30 0.056 2.11 2.35E-03 76.60 8.53E-02
Absorption: 25%
Poraver ® 0.25mm - 0.50mm
A2 0.59 18.43 0.031 0.77 1.31E-03 28.05 4.76E-02
Absorption: 25%
Poraver ® 0.50mm - 1.00mm
A3 0.47 30.21 0.064 1.27 2.71E-03 46.09 9.82E-02
Absorption: 25%
Poraver ® 1.00mm - 2.00mm
A4 0.39 39.63 0.102 1.66 4.27E-03 60.26 1.55E-01
Absorption: 25%
Total Aggregates: 138.57 0.25 5.823 1.07E-02 211.00 3.86E-01
Water
W1 Water for Cement hydration (W1a + W1b) 157.97 0.16 6.01 6.02E-03 217.61 2.18E-01
W1a. Water from Admixtures 40.05 0.93 47.23
1.00
W1b. Additional Water 117.92 5.08 170.39
W2 Water from Aggregates, SSD 34.64 1.63 58.92
Total Water (W1 + W2): 192.62 0.16 7.63 6.02E-03 276.53 2.18E-01
Solids Content of Latex, Dyes and Admixtures in Powder Form
S1 HC RehabiliCRETE 150 1.00 26.84 0.027 0.87 8.75E-04 31.65 3.17E-02
Total Solids of Admixtures: 26.84 0.03 0.87 8.75E-04 31.65 3.17E-02
Admixtures (including Pigments in Liquid Form)
Water in Water in Water in
Percent Dosage Amount Dosage
Admixture Admixture Admixture
Solids (mL/100kg) (mL) (mL/100kg)
(kg/m3) (kg) (kg/m3)
Ad1 HC RehabiliCRETE 150 1.00g/cm3 50% 5368.61 26.84 1747.00 0.87 5490.32 31.65
Ad2 BASF Delvo ® Stabilizer 1.06g/cm3 40% 1723.00 8.01 39.30 0.02 123.51 9.44
Ad3 BASF Rheomac ® VMA 362 1.00g/cm3 40% 1120.00 5.20 52.40 0.03 164.68 6.14
Water from Admixtures (W1a): 40.05 0.93 47.23
Cement-Cementitious Materials Ratio N/A 0.425 0.425 0.425
Water-Cementitious Materials Ratio N/A 0.38 0.344 0.344
Slump, Slump Flow mm 200 +/- 3mm 244mm 244mm
M Mass of Concrete kg 774.35 31.8 1153.0
V Absolute Volume of Concrete m3 0.5898 0.0239 0.8656
T Theoretical Density ( = M/V) kg/m3 1313 1332 1332
3
D Design Density kg/m 774
D Measured Density kg/m3 1153 1153
A Air Content % 41% 13% 13%
Y Yield ( = M/D) m3 1.00 0.03 1.00
Ry Relative Yield ( = Y/YD) N/A 0.848
13The Dark Horse
Appendix C – Bill of Materials
Unit of Total Item
Quantity Measure Unit Cost Cost
Cementitious Materials
Holcim GU Cement 72.35 kg $0.37 $27.12
Fly Ash 36.60 kg $0.13 $4.84
Blast Furnace Slag 44.26 kg $0.15 $6.83
Silica Fume 17.02 kg $0.60 $10.13
Aggregate
Poraver Size: 0.1-0.3 6.22 kg $1.54 $9.58
Poraver Size: 0.25-0.50 16.74 kg $1.54 $25.83
Poraver Size: 0.50-1.00 13.10 kg $1.54 $20.21
Poraver Size: 1.00-2.00 13.04 kg $1.54 $20.12
Poraver Size: 2.00-4.00 14.68 kg $1.54 $22.65
MasterFibre M100 223.73 g $0.03 $6.24
Admixtures
Delvo Stabilizer 0.366 L $4.73 $1.73
Rheomac VMA 362 0.318 L $5.41 $1.72
Rehabilicrete A 18.59 L $9.58 $178.07
Reinforcement
SikaWrap G 350 Grid 11 m2 $26.28 $289.08
#3 V-Rod LM Bent Bars 32.01 m $1.71 $54.60
Formwork 1 LS $1,350.00 $1,350.00
Finishing
Stain 3.78 L $44.97 $170.00
Sealer 3.78 L $9.81 $37.07
Letter Paint 0.5 L $19.70 $9.85
Total Project Cost $2,245.66
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