CastAway 2016

TABLE OF CONTENTS
Executive Summary..1
Project Management...2
Organization Chart.3
Hull Design and Structural Analysis..4
Development & Testing..5
Construction.....6
Project Schedule....7
Design Drawing..8
Bill of Materials...9
References..Appendix A
Mixture ProportionsAppendix B
Example Structural Calculation..Appendix C

Executive Summary
Nestled in the Flint Hills is the city of Manhattan, Kansas, dubbed the Little Apple. In 1863,
under the Morrill Act, the Kansas State Agricultural College was founded in Manhattan as the
first land grant institution. This college, over time, has become known as Kansas State
University. When the university was founded in 1863, it was primarily an agricultural school;
now it is home to nine colleges. In 1908, the College of Engineering added its Civil Engineering
Department. In 1923, the Kansas State University (K-State) chapter of the American Society of
of Civil Engineers (ASCE) was founded.
This is the 40th year that K-State has participated in the concrete canoe competition. Last
Season (2014-2015), the canoe, Free Willie, was lightweight and aesthetically appealing. It held
up well through the rain and bad weather at regional competition in Lawrence, KS. However, KState did not place well.
While K-State lost several members to graduation, this years team still features a good
mixture of old, returning talent, along with a lot of new talent. The new members are not afraid
to voice their opinion, which can help the returning members think about certain aspects in a
different light. Overall, this dynamic has proven to be very productive because it has forced the
team to question certain ideas, and in the end helps to solidify team ideas and convictions.
Last years team made many improvements compared to previous years, but there was
still much to improve upon. K-State felt the team could improve on the design paper, oral
presentation, and races. Unlike past years, K-State decided to put more emphasis on these
aspects of the competition. The team budgeted time more wisely, so that we would not be as
unhinged if surprised by something unexpected. K-State is excited for the opportunity to
showcase their improvements from last year.

Project Management
The K-State Concrete Canoe leadership team is made up of two co-captains, treasurer, paddle
coach and safety officer.. One co-captain was responsible for project management and inventory
of supplies, while the other co-captain was the primary leader in concrete mix and hull design.
The treasurer was in charge of funding and budget allocations. A paddle coach was appointed to
organizing paddle practice in an effort to greatly increase K-States paddling skills. A safety
officer was also appointed to make sure the team followed safety protocol was followed. This
included ensuring that long pants, eye protection, and closed toed shoes were worn at all times
when working in the mixing lab and the shop and enforcing other safety protocol as needed.
Specific tasks were delegated to team members in small groups to allow maximum involvement
of team members. Weekly emails were sent to keep members up to date on the schedule and
tasks. Groupme, a popular group messaging app, was also used to ensure that members were kept
up to date.
Most of the funding for the team came from the College of Engineering and from private donors.
While the team was able to get many materials donated, several purchases had to be made due to
the nature and price of some materials. K-States financial resources were divided between
recruitment and retention, materials, construction, competition expenses, and construction. The
largest of these expenses was construction.
Time sheets were utilized at each meeting to estimate total man hours spent on specific tasks.
Tasks were organized into the following categories: hull design, structural analysis, mix design
and testing, construction, and design paper (Table 1).

Construction
To construct the canoe, the team used a female mold based on previous years teams experience.
The hull design was drawn using AutoCAD and then sent to Global Manufacturing Solutions
Inc. who produced a mold for the canoe. The mold was made out of styrofoam with a
polyurethane coating to prevent the concrete from bonding to the styrofoam. The company
shipped the mold on schedule and also shipped an additional mold section for the bow of the
canoe in order to make a mock mold for the presentation.
In preparation for Pour Day, the team organized all of the materials a week prior. This included
cutting the carbon fiber reinforcement to the desired lengths and shape and preparing the
aggregates and admixtures materials for the mix. The mold was also assembled at this time. A
frame of wooden two-by-fours was placed around the three pieces of the main mold and fixed
together using ratchet straps.
On pour day, the mold was wiped down with wet rags to remove any dirt or dust that had
accumulated.The mold was then sprayed with a releasing agent made of canola oil. While the
mold was being prepared, another group of team members began mixing the concrete in the
mixing lab. After each batch of concrete was finished, it was delivered to the construction table.
Once these tasks were completed, the majority of the team worked on filling the mold with a
layer of concrete. After the layer was finished, a blanket of 1.5 by 1.5 carbon reinforcing grids
was placed along entire mold. The reinforcement was cut to length with the seams of the
reinforcement running along the bottom of the canoe. Another of concrete was added along
with an additional layer of reinforcement. One final layer of concrete was added on the top
and then hand finished by the team. Each layer of concrete was checked for thickness using
toothpicks marked at a , , and lengths before moving on to the next step. Although Cast
Away was designed for thickness, the canoes actual thickness varies from to 1 in some
places, especially along the bottom corners of the canoe .
Upon completion of pouring, the team covered CastAway with a wooden frame that held four
humidifiers. The entire assembly was then covered with a tarp in order to ensure the concrete
would cure properly for the following 28 days. After the concrete finished curing, the team
removed the mold from the canoe and went through various methods of freeing the concrete and
settled on the easiest method of simply cutting and removing the styrofoam from the mold. The
styrofoam was then cleaned up and disposed of properly. The seams of the mold pieces created
two slight ridges in the CastAways hull. The team then sanded theses ridge down to create the
smoothest possible surface. The canoe was then finished with a top coat of concrete mixed
without aggregates or fibers and with a titanium dioxide concrete pigment. Decals with the name
and school were then placed on CastAway.

HULL DESIGN AND STRUCTURAL ANALYSIS

Last year, Free Willie utilized a female mold. This did not allow for structural members, making it
much lighter. Free Willie was 20 feet long with a maximum depth of 14 inches and a maximum
width of 30 inches. The hull design was modeled after the standard hull design provided by the
ASCE National Concrete Canoe Competition. This year, CastAway also utilized the simplicity of
a female mold. K-State believes the female mold provides a cleaner finished product.
Improvements made on the hull design from last year include adding bulkheads consisting of
foam encased in concrete. Cast Away also deviates from the standard hull design with its
asymmetrical hull design.By shifting the widest part of the canoe one foot from the stern, the
canoe will appear longer hydraulically. This increases the maximum theoretical speed and
allows the canoe to track better in water. Previous canoes were designed with a U-shaped
design. However, this design was found to be slightly unstable during races. For this reason, a
flatter cross-sectional shape was chosen for Cast Away. This flat-bottom cross-section will
provide for greater stability for amateur paddlers. Cast Away, which was designed in AutoCad,
has a length of 19.425 inches, maximum width of 30 inches, and a maximum height of 16
inches. The overall hull thickness ranges from inch to 1 inch, and weighs an estimated 280
pounds.
For structural analysis, the canoe shape was modeled as a rectangular beam. The case
analyzed was the four person load case from the co-ed race. The estimated weight of the
canoe, men, and women, respectively, are 280, 200, and 150 lbs (overestimation was applied to
utilize conservative values throughout the analyses). Each paddler was analyzed as a point
load. Maximum shear and bending stress locations were obtained through hand calculations
and excel. The concept used to find these values involved flipping the canoe and load cases so
that the distributed load of the buoyancy force is on top of the beam and the point loads of the
paddlers is on the bottom. In an approximate analysis, the point loads of the four paddlers were
simplified to be two symmetrical point loads. To find critical shears and moments, the proper
load cases were found using trial and error in excel. Shear and moment diagrams were
completed to find the maximum shear and moment locations. The maximum compressive stress
found was 32.03 PSI due to the positive bending moment in the center of the canoe. The
maximum tensile stress of 10.68 PSI occurred due to the same moment. Maximum shear stress
was found to be 341.875 PSI. The results of these analyses were used to determine the
required design strength values shown in Table 2.
Due to the lack of structural members in Cast Away, it was necessary to have a strong concrete
mix design. K-State was pleased with the mix from last year, so the fall semester was spent
slightly tweaking this design. Different designs were mixed and tested until a final design was
settled on. The compressive strength of this final design averaged 3200 psi after 7 days and
5000 PSI after 28 days. Based on the structural analysis and the results shown in Table 2, this
concrete mix should be sufficient for Cast Away to compete safely in Rolla, MO.

Development and Testing

When K-State first began concrete design work for this season, the team read the concrete
design specifications found in Section 3 of the 2016 ASCE National Concrete Canoe
Competition Rules and Regulations. The team next reviewed concrete mix designs from
previous years to decide the best materials and ratios. The team members then made several
different mix designs and tested cylinders of cured concrete to decide on the most effective
concrete mix design.
Testing occurred during the fall semester. K-State felt that Free Willie had a strong, workable
mix. For this reason, K-State decided not to change the the amount of aggregates or
admixtures. Instead, K-State concentrated on varying the cementitious materials while still
keeping a water-to-cement (w/c) of 0.42. Cementitious materials included in the mix were type
III portland cement (ASTM C150) and fly ash (ASTM C618). K-State continued to use type III
portland cement due to its high strength gain early in curing. Testing from previous years also
showed that fly ash increased the compressive strength of the mix while also reducing density.
K-State also used slag cement and silica fume to decrease weight and density.
K-State also used Fibermesh 300 (ASTM C1116). These fibrillated, synthetic fibers have been
used in the past. Testing showed that this material increased the tensile strength of the
concrete. Fiberglass mesh reinforcement was also used to increase tensile strength. C-GRID
C12 (1.5 in x 1.5 in) was used due to its light-weight, thin cross-section, and high strength
compared to other similar products. The reinforcement was measured to have a 77.4% open
area.
Cast Away utilized the same aggregates as Free Willie. A mixture of K15, K37, 0.5mm-1mm,
and 1-2mm beads were used. The smoother finish and high workability provided by the use of
smaller beads helped to decrease the total amount of time spent during construction and
finishing of the canoe.
Cast Away also used the same high range water reducer (HRWR), retarder, and air entraining
admixture (AEA). HRWR used was ADVA Cast 530 (ASTM C494 Types A and F, ASTM C1017
Type 1). Using this admixture improved the strength of the canoe and reduced the weight in
comparison to previous years. The retarder, Daratard 17 allowed the team more time to place
the canoe. For an AEA, Cast Away utilized Darex AEA Ed (ASTM C260). This allowed for a light
and workable mix.
After testing several different mix designs, the team settled on the mix proportions provided in
Appendix B. Theoretical density was found to be 68.81 pcf and actual density of the concrete
was found to be 60.33 pcf.The 7-day compressive strength was found to be 3200 PSI, which
met the requirement of 40.92 PSI with load factor from the structural analysis.
Sustainable design is an important factor in construction. K-State utilized several different
sustainable products. The glass beads used as aggregates are manufactured from postconsumer recycled glass. Slag cement, fly ash, and silica fume are all by-products of different
industries. Silica fume is a by-product of silicon production. Fly ash and coal slag are both byproducts of power generation.

Appendix A - References
American Concrete Institute Committee 318. (2011). Building Code Requirements for Structural
Concrete (ACI 318-11) and Commentary.
American Concrete Institute Committee E-701. (2013). Chemical Admixtures for Concrete.
ASTM. (2012). Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens.
C39/C39M-11a, West Conshohocken, Pa.
ASTM. (2012). Standard Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric)
of Concrete. C138/C138M-10b, West Conshohocken, Pa.
ASTM. (2012). Standard Specification for Portland Cement. C150/C150M-11, West Conshohocken, Pa.
ASTM. (2011). Standard Specification for Air-Entraining Admixtures for Concrete. C260/C260M-10a,
West Conshohocken, Pa.
ASTM. (2013). Standard Test Method for Flexural Strength of Concrete (Using Simple Beam With
Center-Point Loading). C293/C293M-10, West Conshohocken, Pa.
ASTM. (2012). Standard Specification for Chemical Admixtures for Concrete. C494/C494M-11, West
Conshohocken, Pa.
ASTM. (2013). Standard Specification for Coal Fly Ash and Raw of Calcined Natural Pozzolan fo Use
in Concrete. C618-12a, West Conshohocken, Pa.
ASTM. (2012). Standard Specification for Slag Cement for Use in Concrete and Mortars. C989M-11,
West Conshohocken, Pa.
ASTM. (2011). Standard Specification for Fiber-Reinforced Concrete. C1116/C1116M-10a, West
Conshohocken, Pa.
ASTM. (2007). Standard Specification for Chemical Admixtures for Use in Producing Flowing
Concrete. C1017/C1017M-07, West Conshohocken, Pa.

Appendix D - Sample Structural Calculation