Basics of subgrade preparation for industrial floors

BY BOYD C. RINGO CONSULTANT CHAIRMAN, ACI COMMITTEE 360, DESIGN OF SLABS ON GRADE CINCINNATI, OHIO

lace a concrete floor on an unstable subgrade and youll probably pay for it two ways. During construction youll either waste concrete or build a floor thats too thin in spots because the subgrade surface is uneven. After construction, the floor is likely to settle and crack because of poor subgrade support. St re n g t hening the subgrade can be costly and time-consuming once the floor is in place, so it makes sense to place the slab on strong and stable soil at the start.

Identify unsuitable soils and subgrade conditions

Investigate soil conditions before the floor is built. The grading contractor is responsible for making sure a concrete floor is placed on adequate support. A geotechnical engineering firm that inspects the site and takes soil samples can supply data needed for design and construction decisions. Needed information may include: Types and conditions of soils (both site soils and borrow materials) Soil properties (grain size, liquid limit, plastic limit, plasticity index, moisture-density relationship) Water table elevation Drainage conditions Organic soils such as peat, muck, and organic silts or clays are not suitable subgrade materials. They are weak, compressible, hard to drain, and cant be adequately comCompaction of this graded granular fill improves subgrade support for slabs on grade by decreasing the void content. Pay particular attention to soil compaction in utility trenches and near footings.

pacted. Fortunately theyre often near the surface where they can be removed along with sod, roots, and other organic material. Howe ve r, they also may be present well below grade. Make sure that any fill materials also are free of organic matter. Some clayey soils make unsuitable subgrades because they swell or shrink with changes in moisture

content. Soil test results, especially the plasticity index (PI), are helpful indicators of swelling potential. As the PI increases above 10, swelling potential also increases.

Improve the subgrade soil

Compaction improves the properties of all but the organic soils by decreasing void content. This in-

creases soil strength and reduces the chances of rutting during construction or settlement later. Laboratory tests may be run to find the optimum moisture content that yields maximum density of compacted fine-grained soil (see Concrete Construction, August 1985, page 683). Expansive soil compacted at a moisture content seve ra l percent above optimum isnt as likely to cause shrinkage and swelling problems. Pay particular attention to soil compaction in utility trenches and near footings. Carefully compact backfill so there arent any soft spots. If compaction isnt uniform, the slab may crack as it bears on the hard spots and bridges the soft areas. If soils are highly expansive, consider soil stabilization. Sometimes it costs less to stabilize an expansive soil than to remove and replace it. Lime or portland cement can be mixed with some clays to reduce the plasticity index and improve performance. There also are pro p ri e t a ry chemicals that are injected into the soil to stabilize it.

tors are best for granular soils. Sheepsfoot rollers work best for clay soils, and rammers can be used in confined areas. Supplement field density and moisture content tests with visual observation. An experienced inspector can form a small ball of the soil by squeezing it in his hands, then breaking it apart between two fingers and a thumb. If the ball breaks cleanly without crumbling, moisture content is at near optimum. Under winter conditions, when frozen materials are likely, dont use frozen materials for fill and dont place fill on frozen ground. Anytime the temperature drops below 25 _ F. take precautions to prevent freezing of the soils being placed or of the ground on which theyre placed. Also, dont place concrete on a frozen subgrade.

correct it before the job has gone so far that correction is too costly. There are several possible reasons for compacted densities being below specified values. Soil too wet or too dry (must be near optimum moisture content) Layers of soil are compacted too thick Improper compaction equipment or methods (rollers too light, not enough passes) Not enough tests taken L a b o ra t o ry density tests on soil sample not representative of soil being used in the field A prejob conference is a good time to discuss both the compaction methods to be used and the frequency of tests. Good subg rades dont just happen. Theyre properly planned, constructed, and tested.

Control subgrade elevation

Correct subgrade elevation ensures that floor thickness will be uniform. Often the subgrade is rough graded to plus or minus a 10th of a foot and a granular subbase is then used as a leveling course for fine grading. The subbase surface should be no more than 3/8 inch above specified elevation after fine grading. The subbase must be compacted to specified density before concrete is placed. Otherwise the base will shift and deform during concrete placing, causing the floor thickness to vary. Check final subgrade or subbase elevation before placing concrete. Use a scratch template, stringline, or elevation shots with a level.

Inspect subgrade preparation methods during construction

For floors placed on fills, observe the earthwork operations from start to finish. Make sure the fill is placed on firm soil and that all layers are firmly compacted. Upper layers cant be properly compacted if theyre resting on a soft support. Check the quality of fill materials being placed and the loose thickness of layers. Use field density tests to verify that specified density is achieved. Remove soft spots in existing soils or fills. Backfill with adequately compacted replacement soils. Make sure that correct compaction equipment is being used. Vibratory rollers or flat plate vibra-

References 1. American Concrete Institute Committee 302, Guide For Concrete Floor and Slab Construction, ACI 302.1-80, 1980. 2. American Concrete Institute Committee 316, Recommendations for Construction of Concrete Pavements and Concrete Bases, ACI 316R-82, 1982. 3. Schmidt, N. O., and C. O. Riggs, Methods for Achieving and Measuring Soil Compaction, Concrete Construction, August 1985.

Deal with compaction problems immediately

If field compaction test results are unacceptable, find the cause and

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