basics of a good road concrete pavements
TRANSCRIPT
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Basics of a Good Road
- Concrete Pavements
Road Scholar Program
Part II
Mike Byers
Indiana Chapter – American Concrete
Pavement Association
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Changes have occured in
Materials & Construction
Demand to build it faster, under
traffic & last longer
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Central Mix Batch Plant
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Cement Sand
Water
Aggregate
BASIC CONCRETE
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Cross Section of
Hardened Concrete
Concrete made with
siliceous rounded gravel
Concrete made with crushed
limestone
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Range in Proportions
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Quality Control Check
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Consider the Difference Between
Lab and Production Concrete Although all batches are
intended to be exact
duplicates, this is not so in
practice
Larger Measuring Tools
More Rapid Production
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Concrete Mix Design
Variance and Corrections • Mix Design Sheet
includes a number of
variables that can
affect the quality of
concrete
– Water Cement (W/C)
Ratio
– Aggregate info
– Air Entrainment %
– Unit Weights (Yields)
Design Factors Design Factors (cont.)
Test Batch Size 27 cuft Air Content 6.50%
Cement Content 470 #/cy Fine Agg/total Agg 47.00%
Fly Ash Content 70 #/cy Air Entr. Content 2.50 oz/cyd
W/C ratio 0.420 Admix #1 Content (WR) 4.00 oz/cwt Cemt.
Material Size/Type Source Bulk S.G.(SSD) Absorb. Moist.
Cement Type 1 lone STAR 3.15 --- ---
Fly Ash Class C ROCKPORT 2.74 --- ---
Fine Agg. #23 Sand M.M.KY.AVE. 2.68 0.85% 1.00%
Coarse Agg. #8 Stone M.M.WAVERLY 2.65 0.95% 4.00%
Air Entrmnt. Dairavair 1400 WR GRACE --- --- ---
Admix. #1 WRDA 82 W.R.GRACE --- --- ---
Aggregate Weights for 1 CUYD
(in pounds)
Fine Coarse
SSD 1,478.44 1,648.51
Dry 1,465.97 1,633.00
Wet 1,480.63 1,698.32
Free Water 2.20 49.81
Water Weights for 1 CYD
(in pounds)
Free Water 52.01
Mix Water 174.79
=========
Total Water 226.80Batch Weight for:
Cement 470 # 17.41 # 470.00 #
Fly Ash 70 # 2.59 # 70.00 #
Mix Water 175 # 6.47 # 174.79 #
Fine Aggregate 1,481 # 54.84 # 1,480.63 #
Coarse Aggregate 1,698 # 62.90 # 1,698.32 #
Air Entrainment 2.5 oz 0.093 oz 2.500 oz
Admix #1 (WR) 21.6 oz 0.800 oz 21.600 oz
============= ======== ========
Total 3,894 # 144.21 # 3,893.75 #
1 Cyd 1 Cft 27.0 Cft
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Batching
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Batching/Mixing
Course aggregate & sand being
transferred to aggregate bin
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Central Mix Batch Plant
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Truck Mixed Concrete Aggregates
Fly
As
h
Ce
me
nt
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Portland Cement
is a hydraulic cement,
meaning that it hardens by a
CHEMICAL REACTION
with water
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Hydration Products
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SEMs of Hardened
Cement Paste
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Cement and Its Impact on Concrete Performance
Module 1 - Cement’s Role in Sustainability
Module 2- Cement Manufacturing
Module 3- Types and Applications of Cement
Module 4- Cement Characteristics
Module 5- Impact of Cement on Concrete
Properties
Module 6- Abnormal Reactions and Compatibility
of Materials with Cement
If you work with concrete, you need to understand cement.
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Cement Paste
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Aggregate Gradation Affects
• Workability
• Pumpability
• Economy
• Porosity
• Shrinkage
• Durability
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Admixtures
• Air-entraining admixtures
• Water-reducing admixtures
• Plasticizers
• Accelerating admixtures
• Retarding admixtures
• Hydration-control admixtures
• Corrosion inhibitors
• Shrinkage reducers
• ASR inhibitors
• Coloring admixtures
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Pozzolans
• Fly Ash
• Microsilica – silica fume
• GGBFS – ground granulated blast furnace slag
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SEM of Fly Ash Particles
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SEM of Silica Fume Particles
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SEM of Slag Particles
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CEMENT + WATER
CS(glue) + Ca(OH)2 +H2O
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Ca(OH)2 +H2O + Pozzolan
CS(glue) + H2O
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Types of Fly Ash
•Class F
•Class C
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Class F Fly Ash
• Eastern Coal
• High Sulfur Content
• LOI varies with source
• No cementitious properties
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Class C Fly Ash
• Western Coal
• Low Sulphur Content
• Low LOI
• Consistent LOI
• Slightly cementitious
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Effects of Fly Ash
• Placability
• Durability
• Time of Set
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Air Entraining Admixtures
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Air Entrained Non-Air Entrained
• We all know that water expands when it freezes.
• Entrained Air acts as a natural shock absorber when the water in the concrete freezes.
• Entrained Air loses some of its effectiveness in a soupy mix.
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Air Entrainment/
Hardened Concrete
• Better freeze-thaw resistance
• Increased watertightness
• Reduced concrete weight
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Water Reducing Admixtures
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Water Reducing Admixtures
What Are They?
• Admixtures that either increase slump
of freshly-mixed mortar or concrete
without increasing water content OR
maintain slump with a reduced
amount of water, the effect being due
to factors other than air entrainment. (ACI 116.R-2)
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Water Reducer Chemical Action
Cement
Flocculation
Water
Molecule
Cement
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Quality Control
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Quality Control is an Active Process
• Tests provide information
– to better understand material
– to verify production as compared to target and set points
– to make adjustments
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Quality Control Charts
• Economical
method based on
statistics and
probability
• Provide a method
to assess on a
continuous basis
• Graphical
Representation
Required Average Strength f’cr= f’c +ts
Required Strength f’r
0 15 30 45 60Number of Samples (n)
600
700
800
900
Fle
xu
ral
Str
en
gth
(p
si)
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Proper QC Helps to Avoid Big
Surprises in QA • Here we see
samples tested
by the
contractor in
“their schedule”
600 700 800 900Flexural Strength (psi)
0
10
20
30
40
Nu
mb
er
of
Oc
cu
ren
ce
s
• When the
agency tested
• mean - 752 psi
• std dev – 45 psi
• mean - 762 psi
• std dev – 49 psi
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500 600 700 800 900 1000Flexural Strength (psi)
Nu
mb
er
of
Oc
cu
ren
ce
s
Sp
ecif
ied
Str
en
gth
, f’
r
What Are the Practical Implications
of Having Tighter Quality Control
• We can not design structures based on the mean measured strength but we will use it for designing the mixture
• Assumption: 1/1000 tests are below the design strength (f’r=570 psi)
• Consider two contractors with measured variation
X = 680psi
s = 45 psi
X = 810psi
s = 100 psi
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200 400 600 800 1000Standard Deviation (psi)
0
1
2
3
4
Fle
xu
ral S
tren
gth
(p
si)
What Does Improving the Quality
Control Mean in Real Life
Minimum
Quality Level
f’r = 570 psi
Minimum
Flexural
Strength
Poor
Quality
Control
Target Strength for
Poor Quality Control
Good
Quality Control
Good
Quality
Control
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Research – New Frontiers,
Problem Solving
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Premature Joint Deterioration
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Premature Joint Deterioration
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Premature Joint Deterioration
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Premature Joint Deterioration
• Air voids filled with
hydration products
(secondary products)
• Secondary product
(ettringite) in air
entrained small
bubbles
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“Drying of Concrete
with Deicers”
Spragg et al. submitted 2010
1.0
0.8
0.6
0.4
0.2
0.0
-0.2
Vo
lum
e o
f W
ate
r L
os
s(m
m3 o
f w
ate
r /
mm
2 o
f s
urf
ac
e)
0 24 48 72 96 120 144 168 192 216
Time (h)
DI Water
MgCl2 0.9%
MgCl2 30%
CaCl2 0.96%
CaCl2 32%
NaCl 0.7%
NaCl 23%
0 10 20 30 40
Concentration (Mass %)
0
20
40
60
80
100
RH
(%
)
NaCl
CaCl2
MgCl2 (c)
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Slab –Silver Nitrate
23%
NaCl
30%
FreezeGard 32%
CaCl2
Water
No Sealer – 4 different Soaking Solutions (56 Days).
NaCl most penetrated, CaCl2 Damaged Surface, and Water
Shows No Penetration.
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Freeze-Thaw Durability
• Concrete can
experience significant
damage due to
freezing and thawing
• ASTM C666
– procedure A (freeze
and thaw in water)
• Monitor change in
dynamic elastic
modulus and mass
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Freeze-Thaw Durability
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Additional Research Efforts
• Internal Curing of Concrete
• Using Recycled Crushed Concrete as
Coarse Aggregate in Concrete
• Investigation of Deicing Chemicals
Interaction with Concrete
• Use of Slag Aggregates & Slag Cements in
Concrete – Impact on Durability
Performance
• 30+ SACs/on going projects
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Questions?
Information:
Mike Byers
Indiana Chapter ACPA
www.indianaconcretepavement.com