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Application of Engineered Cementitious Composites (ECC) in Precast Ultrathin White-Topping (PUWT)
– A Field Demonstration on Jurong Island, Singapore
Jishen Qiu 仇霽申Assistant ProfessorDept. of Civil Engineering, HKUST
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My Research: New Construction Materials
Raw Material Production
Design & Construction
Operation & Maintenance
End of Life & Demolition
Recycling
Bacteria‐enhanced healingEngineered living brick
Alternative Binder
MgO
Hydrogel
Micromechanics to Bendable Concrete Self‐Healing Concrete
Jishen Qiu, PhD.2016 PhD. Nanyang Technological University2019‐Now Assistant Professor HKUST
Today’s topic
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Project Roadmap (2-3 years)
State‐owned for‐profit companyLargest industrial manager in Singapore
Public University
Major Concrete Plant
1. A real‐world challenge:road surface maintenance
2. A maturing material/technology:fatigue‐resistant ECC + ultrathin
white‐topping
4. Field demonstration
3. Upscaling production
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Road surface in Singapore
• Year‐round hot and humid climate
• Mostly asphalt, susceptible to surface rutting
and cracking
• Frequent maintenance and repair
Motivation: Road Surface Damage
Asphalt road surface cracking and ruttingJunction of Semi Rd. and Adam Rd., Singapore
Credit: Strait Times
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• Asphalt surface of 150‐200 mm thick
• Sensitive to heavy vehicles (bus and
lorries)
• Distresses only in the top inches
• Base and subbase remain
mechanically sound
Problem Identification
Illustration of Flexible PavementCredit: Pavement Interactive
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Traditional Solutions & Their Drawbacks
1 Mill off full depth & repave with asphalt • Overnight construction• Same problem occurs quickly
2 Mill off the distressed inches & white‐topping (concrete)• Enhanced mechanical strength• Multiple days of road closure
3 Mill off & precast concrete slab (maturing technology)• Fast construction & enhanced strength• Full‐depth R/C slab: complicated manufacturing • Full‐depth milling‐off• Slab‐base and inter‐slab joint design
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Review: Prefabricated Concrete Pavement
Precast Cast‐in‐place
Durability of precast vs. cast‐in‐place concrete under wheel‐pressure test
Kohler et al. 2008Complicate Joint Design: dowel bar + dent grouting (left);
pre‐stressing the joint (right)Credit Fort Miller Inc. (left) & Chang et al. 2004 (right)
• Reinforcement is mandatory
• Complicated joint design and manufacture
• Prefabrication on site (not plausible in Singapore)
Limit by the brittle nature of concrete
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Project Roadmap
1. A real‐world challenge:road surface maintenance
2. A new material/technology:fatigue‐resistant ECC + ultrathin
white‐topping
4. Field demonstration
3. Upscaling production
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ECC and Its Basic Properties
Tensile Load (N)
Normal Concrete
Fiber Reinforced Concrete (FRC)
ECC
Deformation (mm)
Ductility~1‐5%
Bridging stress σ
Stable crack openingδ<50 μm
Bridging stress σ
Before healing
After healing
Self‐healing of ECC cracksYang et al. 2009
Common ingredient of ECC: cement, fly ash, ultrafine silica sand, polymer fiber (no aggregates)
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ECC – “Bendable Concrete”
Multiple cracking of ECCCredit: ACE‐MRL Lab at University of Michigan
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Video Clip
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Fatigue-induced Damage in ECC
• Premature failure – losing the signature multiple cracking and ductility• Attributed to the fiber‐bridging deterioration under cyclic loads
ECC under different cyclic loading Qian et al. 2012
monotonic~5k cycles
~50k cycles
~500k cycles
Fiber‐bridging stress vs load cycles Zhang et al. 2000
Fibe
r‐bridging
Stress (MPa)
0 2000 4000 6000 8000 10000Load cycles
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Micromechanics for ECC Fatigue
P
Cyclic P
Macro‐scale:composite behavior
Bridging stress σ
δ
σMeso‐scale: fiber‐bridging
crack opening δ
tensile stress σ
Fiber‐bridging
Damage
Healing
fiber displacement u
load on fiber P
Single‐fiber pullout
Damage?
Healing?
Pullout load P
u
Micro‐scale: single‐fiber response
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Single Micro-fiber Pullout Test
Single‐fiber Pullout Specimen, PVA fiber𝜙=40𝜇m Testing setup
I mm
Qiu et al. 2016, Fatigue‐induced deterioration of the interface between micro‐polyvinyl alcohol (PVA) fiber and cement matrix. Cement and Concrete ResearchQiu et al. 2017, Fatigue‐induced in‐situ strength deterioration of micro‐polyvinyl alcohol (PVA) fiber in cement matrix. Cement and Concrete Composites
• First to conduct this test (a micro fiber cyclically pulled out from cement matrix)• Cyclically loaded vs. Pristine (as control)• Effect of loading magnitude, number of load cycles, and embedment angles are studied
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Findings from Our Lab Study
Footprint of the fatigue‐debonding
I 𝛍m
Monotonic Loading → Cyclic Loading
• Polymer fiber debonds from cement matrix at a
significantly lower load level
• The loose fiber abraded by the reciprocate
movement and gets weaker
• The fatigue‐induced fiber‐bridging loss can be
quantified
Crack opening (𝛍m)
Fibe
r‐bridging
stress (M
Pa)
Qiu et al. 2016, A micromechanics‐based fatigue dependent fiber‐bridging constitutive model. Cement and Concrete ResearchQiu et al. 2018, Effect of self‐healing on fatigue of engineered cementitious composites (ECC). Cement and Concrete Composites
Predicted fiber‐bridging loss vs load cycles
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Design Fatigue-resistance ECC
Qiu et al. 2017, Micromechanics‐based investigation of fatigue deterioration of engineered cementitious composite (ECC). Cement and Concrete Research
ECC S‐N (fatigue life‐load) curve: experimental data vs our modeling
Our Approach: Self‐healing of ECC → Mechanical Recovery → Longer Fa gue Life
81969
130988
245130
Control fatigue+healing x1 fatigue+healing x2
Flexural fatigue endurance life (load cycles)
Effect of healing on ECC fatigue life
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Water
CO2CO2 CO2
CO32
-
Ca2+
Ca2+
Ca2+
Ca2+
Ca2+
Healing Products CaCO3
Cement matrix
Healing
fiber
Healing Products CaCO3
Ca2+
Ca2+ Ca2
+Ca2
+
Ca2+
Ca2+
Ca2+
CO32
-
fiberCO3
2-
Healing
Enhance the Healing-induced Recovery
• The mechanical recovery is from the fiber‐cement interfacial healing
• Fiber surface coating enhances this interfacial healing (on‐going research)
Qiu et al. 2019 Autogenous healing of interface between fiber and hydraulic cement matrix. Cement and Concrete Research
One of the nano‐scale coating recently developed at HKUST
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Precast Ultrathin White-topping
The white‐topping
Fast‐hardening grout
Asphalt Base
Surface‐rutting asphalt
Mill‐off
85mm
Precast ECC slab
3‐4 m
70‐80m
m
Installation
11 pm to 7 am
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Structural Design Considerations
75 m
m ECC Slab 1 ECC Slab 2
Existing Asphalt
Fast‐hardening Grout
Corundum Particle (for skid resistance)
Shear keys at the bottom of slabBitumen (Sealant)
Slab‐to‐base bond• Shear‐key
Inter‐slab joint• The base guarantee the load‐transfer
Low skid resistance of ECC (no coarse aggregate)• Corundum added into ECC mix design• Expose by steel‐wire brushing
ECC with corundum
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Project Roadmap
1. A real‐world challenge:road surface maintenance
2. A new material/technology:fatigue‐resistant ECC + ultrathin
white‐topping
4. Field demonstration
3. Upscaling production
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Factors on fiber dispersion
• Rheological the fresh cement
• Mixer type and power
Challenges in Large-Scale ECC Mixing
PVA fiber received in bundles,needs to be separate by shearflow of fresh cementCredit: Nycon
1 mm
Lab planetary mixer (3‐10 L)Credit: Myers Associates
Gravity drum mixer (1000 L)• No revolution, no rotation• Unworkable balling
Twin shaft mixer (3000 L)• Revolution, no rotation• Unknown fiber dispersion
Planetary (500 L‐3000 L)• Revolution & rotation• Good fiber dispersion
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Start Select fly ash source
Select fly ash content within
allowable range
Mid‐scale mix & test
Full‐scale mix & test
Failure
PassPass
Allowable fly ash reached?
No
Yes
End
Batching adjusted?
Failure
Adjust batching sequence
No
Yes
Select mixer type
Tuning the Factors of Mixing
Prime FA Secondary FA
Impurity
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Final Design of the Mixing
Select fly ash source
Select fly ash content
Adjust batching sequence
Select mixer type
Twin shaft mixerPrimary Fly Ash, 50% cement
replacement
Step Original batching Modified batching1 FA ash
Silica sand Type I cement Expansive cement
FA ash Silica sand Expansive cement
2 Water Super‐plasticizer Shrinkage‐reducing
agent
50% water Super‐plasticizer Shrinkage‐reducing
agent
3 Fiber Type I cement
4 50% water
5 Fiber 22
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Wheel Test
Wheel pressure
500 mm -500 mm
• Vehicle weight (cyclic) + elevated temperature• Four sessions:
o10 tons, 100000 cycleso10 tons, 40°C 50000 cycleso10 tons + braking force 1000 cycleso10 tons + braking force, 40 °C 500 cycles
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Verified Structural/Material Design
Test result: Comparable slab corner displacement with structural design
No visible damage at the cored joint
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Project Roadmap
1. A real‐world challenge:road surface maintenance
2. A new material/technology:fatigue‐resistant ECC + ultrathin
white‐topping
4. Field demonstration
3. Upscaling production
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1 2 3
In‐slab thermocouple Grouting & lifting holes Surface corundum
ECC Slab Manufacturing (1)
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4 5 6
Lifting ring Shear keysFibers minimizes the spalling during tearing‐off
Strain gauges
ECC Slab Manufacturing (2)
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Video Clips
Casting ECC slabFlipping ECC Slab
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Field Demonstration of ECC-PUTW
2400mm
3400
mm
2400mm
1700
mm
Traffic direction
2.4m x 8 =19.2 m
Hole for lifting anchors
Hole for grouting
Selected construction site: a bus stop on Jurong Island (J6)
Site Selection Criteria
• Regular heavy vehicle
• Braking force
• No shadow
Construction Plan
• 5 large slabs (3.4 x 2.4 m)
• 4 small slabs (2.4 x 1.7 m)
• 1 with minor reinforcement
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ECC Slabs Installation (1)
1 2 3
Thermocouple installed in asphalt base
Closer look of processed asphalt base
Mill off top asphalt Clean‐up by water jetting Place the slabs
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ECC Slabs Installation (2)
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data loggers Before After
5 6
Grout and bitumen
Install monitoring devices Adjustment slab position Grouting and sealing
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The shelter and cabinet housing data loggers
The new bus stop opened to traffic in July 2018, after a 2‐day construction
Opening to Traffic & Monitoring
Bottom strain at the corner of a large slab (DMS 6)Temperature‐induced strain in 24 hours 20 micronHeavy truck‐induced strain 40 micronThe first cracking of ECC 200 micron
200 µm
Healed cracks on‐site32
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Channel News Asia Strait Times
Media Coverage
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• ECC is suitable for prefabricating thin structural members of large dimensions
• Know‐hows on the quality control of large‐scale ECC mixing, esp. in twin‐shaft
mixer
• Construction method matters
• PUTW‐ECC is a promising option to repair/upgrade road surface with high traffic
What We Learned
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Thanks for your attentions
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ECC vs. Fiber-UHPC
ECC UHPCCompressive Strength 50‐80 MPa 100‐150 MPa
Tensile ductility 1.0%‐4.0% 0.5‐1.0%
Fiber type and fraction PVA fiber, 26kg/m3 Steel fiber, 150‐200 kg/m3
Unit weight 2000 kg/m3 (4 slabs) 2600 kg/m3 (3 slabs)
Workability Medium SP for self‐compacting High SP for self‐compacting
Effect on tires Acceptable skid resistance with corundum
Steel fiber is dangerous to tires (forbidden in Germany)
Raw material cost $$$$ $$‐$$$
Life cycle cost $$ $$
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