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Fiber-Reinforced ECC, VHPC, and UHPC in Bridge Structures
H. Celik Ozyildirim, Ph.D., P.E.Mary Sharifi, M.E.C.E.
QAW, Williamsburg, 2020
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Outline
• Cracks, joints• Fiber-reinforced concrete (FRC)• High Performance FRC
– ECC– VHPC– UHPC
• Field Applications • Prepackaged Material• Conclusions
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Cracks
Charlie RobsonFormer VDOT State Materials Engineer
There are two kinds of concrete:• One cracked• One about to crack
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Plastic Shrinkage Cracks
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Eliminated by proper curing!
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Crack over the Pier
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Leaking Joints
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Leaking Joints
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Leaking Shear Keys
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Why Fiber-reinforced Concrete (FRC)
• Fibers can improve tensile and flexural strengths• Fibers can be used to limit crack length and
width. Fibers provide residual strength (load carrying ability after cracking).
• It is difficult to penetrate tight cracks (<0.1 mm wide). Crack widths > 0.2 mm can be and should be sealed.
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Why Fiber-reinforced Concrete (FRC)
• Connections, short lap splices
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Tests
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Splitting Tensile Strength
Concrete is weak in tension!
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Flexural Test
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Tests
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Cube CompressiveStrength
Cylinder CompressiveStrength
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Pull-out Test
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Typical pullout test graph
150
5000
10000
15000
20000
25000
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6
Load
(lbf
)
Displacement (in)
slipsteel
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FRC
• Synthetic fibers in low amounts, 1.5 lb/yd3
(0.1%) are used to minimize plastic shrinkage cracks.
• Larger amounts of structural fibers (steel or synthetic) up to 2% needed for crack control in hardened concrete.
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Early Work with FRC - Lexington
9 lb/yd3
0 0.02 0.04 0.06 0.08
Load
(lbf
)
Deflection (in)
Residual strength
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Lexington – FRC 2000
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Lexington Crack Survey - FRC
Crack Control Fiber
Total Length (ft) 151 59
Average Width (mm) 0.53 0.29
After 5 years
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Flexural Test - FRC
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0
1000
2000
3000
4000
5000
6000
0 0.05 0.1 0.15
Load
(lbf
)
Deflection (in)
No fiber
Deflection Hardening
Deflection Softening
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Tight Cracks
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High Performance FRC
• Self-consolidating• Contain structural fibers at high dosage• Deflection harden enabling tight cracks (<0.1 mm)
– ECC: engineered cementitious composite has high ductility
– VHPC: very high performance concrete has high compressive strength and ductility
– UHPC: ultra high performance concrete has very high compressive strength and ductility
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Fibers
• ECC
• VHPC / UHPC
23Steel OL fiberSteel fiber hooked end
PVA fiber
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ECC
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• ECC is also known as bendable concrete
• 2% PVA fibers by volume. • 7-d comp. str. > 4,000 psi• High splitting tensile str.
Polyvinyl alcohol fiber (PVA)
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Deflection
Tight cracks (<0.1 mm)
ECC
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VHPC
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• High compressive strength > 11,500 psi at 28 days
• High splitting tensile strength• High pull-out strength (new test)
Steel fiber
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UHPC
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• Very high compressive strength > 17,000 psi (per ASTM C1856)
• High splitting tensile strength• High pull-out strength (new test)• UHPC at early ages achieve VHPC strength
Steel fiber
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ECC Field Application– 2013 on
• Shear Keys– Winchester– Surry
• Closure Pours– I-64 Bridge over Dunlap Creek
• Culvert Repairs
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ECC Mixtures
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28-day Flexural Strength
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ECC Mixing
• In small amounts use mortar mixer
• In larger amounts used RMC trucks; however, fiber dispersion is difficult in truck mixing
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Shear Keys - ECC
31Route 645 Bridge, 2013
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Route 645 - Shear Keys - 2013
ECC with PVA fibersUHPC
Non-shrink grout
After 3 months, only ECC did not leak
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Link Slabs (Closure Pours) - FRC
33I-64 Dunlap Creek Bridges: 2014, 2015, included ECC
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Link Slab (Closure Pour)
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ECC – Culvert Repairs – 2017, 2018
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Trailer Pump and RMC Truck
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ECC Test Results for Prepackaged Material
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28-day flexural strength
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VHPC Field Application- 2018 on
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• In adjacent member connections when there are block-outs.
• Planning to use in partial depth link slabs
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Block-outs
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VHPC in Block-outs
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VHPC Work at Bristol - 2018
• The mix was self consolidating, but very sticky
41Difficult to make in RMC trucks!
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VHPC work at Sperryville - 2019
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Compressive strength > 11,500 psi
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VHPC Test Results for Prepackaged Material
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28-day flexural strength with hooked end steel fiber
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UHPC Field Application
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UHPC - Steel Fibers
Brass coated steel fibers
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UHPC - Route 624 - 2007
28-d compressive strength > 30,000 psi with steam curing
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UHPC Beams
Plant had twin shaft mixer
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Flexural Strength
484-in-thick beams at 2 months
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UHPC - Tight Cracks
1-in-thick beam
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UHPC - 2019
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Planetary mixer
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UHPC Test Results for Prepackaged Material
28d flexural strength
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Conclusion
• Fibers provide residual strength after cracking, which limits the size and length of cracks and can be used in shear keys, connections, closure pours, block-outs, and culvert repairs.
• The level of residual strength depends on the type and amount of fibers.
• Concretes with fibers that exhibit strain and deflection hardening limit cracks widths below 0.1 mm.
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Acknowledgements
• FHWA• VDOT CO• VDOT Districts• VTRC• Industry
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Thank You.