master high early strength - virginia department of transportation
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MASTERBUILDERS
ADMIXTURES High Early Strength Portland Cement Concrete
for Rapid Concrete Repair
Rod Meyers, P.E., CDT
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The CalTrans Challenge…..The CalTrans Challenge…..
Find an alternative to proprietary “fast-setting cement” concrete mixtures!Requirements:
Fast setting, user-friendly and cost effective
Develop 400 psi (2.8 MPa) within 4 hours after placement
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MASTERBUILDERS
ADMIXTURES
Hence, the Name…
400 psi in 4 hours
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4x4TM Concrete: System Components4x4TM Concrete: System Components
Selected local portland cements, and aggregatesmanufactured sand
Synthetic high-range water-reducing admixture -provides fluidity and strengthHydration control (extended-set) admixture -provides workability controlAccelerating admixture - provides early strength
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4x4TM Concrete: System Component4x4TM Concrete: System Component
Hydration control admixture: Hydration controlProvides unprecedented control over setting
Controls temperature riseProvides slump retentionEffective in long hauls
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Accelerating AdmixturesAccelerating Admixtures
Add and mix on siteUses portable dispenser systemAccelerates concrete set and strength development
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4x4TM Concrete Applications4x4TM Concrete Applications
Where Can 4x4 Concrete be Used?
Full-depth pavement replacementNew pavementBridge decksOverlaysWhere high early strength is required
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Opening 4x4TM Concrete to TrafficOpening 4x4TM Concrete to Traffic
Maturity Testing - a better indication of strength development in pavement slab.
M(t) = Σ (Ta-To) ∆t
M(t) = Temperature-time factor∆t = Time intervalTa = Avg. temperature during ∆tTo = Datum Temperature
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I-5, CA: Actual HES DataI-5, CA: Actual HES Data4x4 Concrete: I-5 in Los Angeles
3/3/02
Flexural Str, psi= = 0.001(Degree Hours)2 + 0.09 (Degree Hours)
0
100
200
300
400
500
600
0 100 200 300 400 500 600 700
Degree Hours
Flex
ural
Str
engt
h, p
si
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I-5 in CA: Actual HES DataI-5 in CA: Actual HES Data
4x4TM Concrete:Flexural Strength psi MPa
4-hour 480 3.324-hour 855 5.928-day 1250 8.6
Compressive Strength4-hour 4130 28.5
24-hour 7740 53.428-day 8250 56.9
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4x4TM Concrete: Conduct a Trial Slab4x4TM Concrete: Conduct a Trial Slab
Fully-loaded truck on slab4 hours after placement !!!
400 psiFlexuralStrength
in 4 hours
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MASTERBUILDERS
ADMIXTURES
4x4TM ConcreteProjects
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4x4 Concrete Project4x4 Concrete ProjectAlamo Truck Stop:
Ultra-Thin WhiteTopping application - Sparks Nevada
Challenge:Truck stop is a major source of revenueRutted asphalt entering and exiting weigh scaleMinimize scale closure time
Solution:Air-entrained 4x4 Concrete @ a
Deteriorated and rutted asphalt
8 in. slump (200 mm) as an ultra-thin whitetopping
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Alamo Truck StopAlamo Truck Stop
Benefits:Very user-friendly and easy to placeWeigh scale opened to traffic quicklyMinimized closure time resulted in increased revenue4x4 Concrete is expected to provide significantly longer service life compared to the asphalt
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4x4 Concrete Project4x4 Concrete ProjectPoplar Street Bridge:
Deck Repair - St Louis, Missouri
Challenge:Deteriorated bridge deckMinimize lane closure timeNight repairsRequirement 3,200 psi (22.1 MPa) in 4 hours
Solution:Air-entrained 4x4 Concrete @ a 8 in. slump (200 mm)
placed as SCC
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Poplar Street BridgePoplar Street Bridge
Benefits:Ready mix truck provided mobility to repair areasContractor optimized resources4x4 Concrete more economical than conventional repair materialsProfitable for producer and contractorMinimized lane closure timeMO DOT pleased with results
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4x4TM Concrete Project4x4TM Concrete Project
Merced Intersection Replacement:Highway 140 and Applegate Road, Merced County, CA
Challenge:Minimize disruption to traffic flow and lane closures
Solution:4x4 Concrete @ a 7 in. slump (180 mm)
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Merced Intersection ReplacementMerced Intersection ReplacementBenefits:
Very user-friendly and easy to placeExceptional high-early strength permitted rapid opening to traffic minimizing lane closuresProject was completed in only 4 days!Traffic control savings = $250,0004x4 Concrete technology allowed concrete to be used in lieu of asphalt
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4x4TM Concrete Project4x4TM Concrete Project
I-77/I-65 Pavement Replacement:West Virginia Turnpike, Beckley West Virginia
Challenge:Minimize inconvenience to motoristsDevelop high-early strength in cool springtime temperatures
Solution:Air-entrained 4x4 Concrete @ a 5 in. slump (125 mm)
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I-77/I-65 Pavement ReplacementI-77/I-65 Pavement ReplacementBenefits:
Very user-friendly and easy to placeExceptional high-early strength developedPavement replaced and opened to traffic from start to finish in only 12 hours!
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4x4TM Concrete: In Summary….4x4TM Concrete: In Summary….Producer/contractor friendlyEasy to place and finishSet time and strength performance met consistentlySave $$$$ on traffic control and placementNo post-grinding for ride qualityNo cracking to dateWin-Win-Win-Win Situation for All Parties !!!