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Progress Report on Concrete Mix Designs for O’Hare Modernization Plan University of Illinois Department of Civil and Environmental Engineering July 14, 2005 Project Goal Investigate cost-effective concrete properties and pavement design features required to achieve long-term pavement performance at Chicago O’Hare International. Project Objectives Develop material constituents and proportions Characterize strength, volume stability,and fracture properties of airfield concrete mixes Develop / improve models to predict material behavior. Evaluate material properties and structural design interactions, e.g., joint spacing joint types Saw-cut timing Project Objectives Material constituents and mix design Laboratory tests Test for material properties Analysis of existing concrete mix designs Concrete properties Modeling Optimal joint types and spacing. Long-term performance at ORD 2005 Accomplishments Tech Notes (TN) TN2: PCC Mix Design TN3: Fiber Reinforced Concrete for Airfield Rigid Pavements TN4: Feasibility of Shrinkage Reducing Admixtures for Concrete Runway Pavements TN11: Measurement of Water Content in Fresh Concrete Using the Microwave Method TN12: Guiding Principles for the Optimization of the OMP PCC Mix Design TN15: Evaluation, testing and comparison between crushed manufactured sand and natural sand TN16: Concrete Mix Design Specification Evaluation TN17: PCC Mix Design Phase 1 TN2: PCC Mix Design Mix Id. Water Type I Cement Type C Fly Ash Coarse aggregate (# 57 Limestone, 1" max size. ) Fine aggregate Steel Fibers Air entrainment admixture (Excel Air) Water Reducer (Excel Redi Set) Properties W/CM fr7 fr28 Air Slump Proposed Mix #1905 (2000) 280 541 135 Revised Mix #1905 (2000) 262 588 100 Proposed Mix #1933 Mix #1994 (2000) (2000) 280 262 588 588 100 130 Mix K-5 003Units 00(2004) 258 lb/yd3 541 lb/yd3 135 lb/yd3 1850 1850 1850 1800 1840 lb/yd3 1125 0 1103 0 1115 0 1100 85 1117 0 lb/yd3 lb/yd3 N/A 7 N/A N/A 6.8 oz/yd3 29 15 28 29 30.4 oz/yd3 Proposed Mix #1905 0.41 N/A N/A 5-8 2 Revised Mix #1905 0.38 788 1030 5-8 3 +/- 1 Proposed Mix #1933 Mix #1904 0.41 0.36 802 N/A 842 N/A 5-7 5-8 3 +/- 1 3 +/- 1 Mix K-5 003-00 0.38 770 855 6.2 1 Units psi psi % in Survey of Existing Mixes Airport Capital Airport St. louis Lambert St. louis Lambert Mix Id. N/A Mix 1 F Mix 4 F Water Cement Type C Fly Ash GGBS Coarse aggregate #1 Coarse aggregate #2 Fine aggregate Fibers Air entrainment admixture Water Reducer 233 490 150 1842 1156 N/A 19.6 250 510 80 1866 1225 5.6 14.2 258 535 80 1834 1220 5.6 14.2 St. louis Lambert Mix 4 F w/ fibers 258 535 80 1834 1220 3 5.6 14.2 I I I I Materials Properties Cement Type Coarse aggregate # 1 max. size. (in) Coarse aggregate # 2 max. size. (in) Fine aggregate type AEA type WR type Fiber type Concrete Properties W/CM fr28 Air Slump N/A - 3/4" (#67) 3/4" (#67) - River Sand Polychen AEA Grace AE VRC Daracem Polychen Grace MC 400 N/A - - - - 0.36 770 5.5 4 1/2" 0.42 1033 7.6 2" 0.42 850 7 3 3/4 " Mix 3 F Mix 5 F 248 354 88 148 1872 1228 3 17.7 258 310 93 217 1808 1232 3.1 18.6 St. louis Lambert Mix 5 F w/fibers 258 310 93 217 1808 1232 3 3.1 18.6 I I I St. louis Lambert St. louis Lambert Fort Californ Califor Wayne ia nia Mix 6 F Mix P 5 Mix 1 Mix 1 Mix 2 258 372 93 155 1836 1206 3.1 18.6 250 680 1790 1280 N/A N/A 218 288 192 1424 615 1198 N/A N/A 300 489 122 1570 400 1165 N/A N/A 258 479 85 1400 475 1310 1.7 16.92 I I I I II 1" (57) 1" (57) 3/4" (#67) 3/4" (#67) 3/4" (#67) 3/4" (#67) 3/4" (#67) 3/4" (#67) 1" (57) - River Sand River Sand Polychen AE VRC Polychen MC 400 St. louis St. louis Lambert Lambert Polychen AE VRC Polychen MC 400 GRT Polymesh fibers 0.42 905 7 3 3/4 " - - - River Sand Polychen AE VRC Polychen MC 400 River Sand Polychen AE VRC Polychen MC 400 - - River Sand Polychen AE VRC Polychen MC 400 GRT Polymesh fibers 0.42 700 5 1 1/4 " 0.42 675 5 3" 0.42 675 5 3" - - River River Sand Sand Polychen GRT AEA AE VRC Polychen GRT KB MC 400 1000 lb/yd3 lb/yd3 lb/yd3 lb/yd3 lb/yd3 lb/yd3 lb/yd3 lb/yd3 oz/yd3 oz/yd3 1/2 x #4" N/A,FM N/A,FM Sechelt = 2.68 = 2.96 Sand 3/8" 3/8" N/A N/A MBAE N/A N/A Pozz 200N - - - - - 0.42 675 5 3" 0.37 1280 6 1 1/2" 0.45 N/A N/A N/A 0.49 N/A N/A N/A 0.46 767 3 3 1/4" Units psi % in Tech Note 3 Fiber Reinforced Concrete for Airfield Rigid Pavements 225 Plain 0.48% Synthetic Macro Fiber 200 0.32% Synthetic Macro Fiber 175 Load (kN) 150 125 100 75 50 25 0 0 1 2 3 4 5 6 7 8 9 10 11 12 Average Interior Maximum Surface Deflection (mm) Final cost: reduction of 6% to an increase of 11% 13 Tech Note 4 Feasibility of Shrinkage Reducing Admixtures for Concrete Runway Pavements Reduced Shrinkage and Cracking Potential ~ 50% reduction Cost limitations (?) Figure 1. Unrestrained shrinkage of mortar bars, w/c = 0.5 (Brooks et al. 2000) Tech Note 11 Measurement of Water Content in Fresh Concrete Using the Microwave Method Strengths: quick, simple, and inexpensive Limitations: need accurate information on cement content aggregate moisture and absorption capacity TN 12: Guiding Principles for the Optimization of the OMP PCC Mix Design 1st order: Strength, workability 2nd Order: Shrinkage, fracture properties LTE & strength gain Tech Note 15 Evaluation, testing and comparison between crushed manufactured sand and natural sand Gradation According to ASTM C-33 100 Manufactured Sand(ms) Natural Sand(ns) ASTM Fine ASTM Coarse 80 PERCENTAGE PASSING. Gradation physical properties Finness Modulus ms = 3.12 ns = 2.64 60 40 20 0 200 100 50 30 16 8 4 0.375 ASTM SIEVE NUMBER ASTM C-128 ASTM C-29 Material BSG(ssd) BSG(dry) AC(%) Manufactured sand Natural sand 2.7 2.43 2.63 2.38 2.59 2.15 Bulk density Bulk density dry(kg/m3) ssd(kg/m3) 1628 1703 1670 1740 % Voids 38.1 28.3 Manufactured vs Natural Sand Visual evaluation 4mm Material retained in the #8 sieve shows difference in the particle shape 500mm 4mm 500mm Sieve No. 8 Sieve No. 50 The Manufactured sand shows a rough surface and sharp edges due to the crushing action to which it was subjected. Tech Note 16 Concrete Mix Design Specification Evaluation Preliminary P-501 evaluation Strength, shrinkage, and material constituent contents P-501 Guidelines Our View max w/cm = 0.50 Ok 3 Min cement content = 500 lb/yd This could be lower min flexural strength = 600 psi @ 28 d 700 ok, could be 90 d fly ash content range = 10-20% Ok fly ash + slag range = 25-55% Ok max slag when temp < 55 F = 30% Ok air content = 5.5% for 1.5" topsize CA Ok air content = 6.0% for 0.75" topsize CA Ok 2005 Accomplishments Specification Assistance On-site meetings at OMP headquarters Continued specification recommendations: Material constituents (aggregate type and size, SCM, etc.) Modulus of rupture and fracture properties of concrete Shrinkage (cement content, w/c ratio limits,etc.) Saw-cut timing, spacing and depth Pavement design TN17: PCC Mix Design Phase 1 Develop mix design factorial and verify fresh and hardened concrete properties Variable Aggregate Size W/CM Cement Content Total aggregate content More later … Values 0.75" or 1.5" 0.38 or 0.44 3 488lb/yd or 588lb/yd Varies Project Tasks and Progress Literature Review Survey of existing mix designs Review of mix design strategies Status Done, TN2, 3, 4, 15 Done, TN 12 Volume Stability Tests Drying and Autogenous shrinkage Optimization of concrete mixes to reduce volumetric changes In progress, TN 12 and TN 17. Strength Testing Modulus of rupture, splitting and compressive strength Fracture energy and fracture surface roughness In progress, TN 12 and TN 17 Start tests in July Project Tasks and Progress Joint Type Design Slab size and jointing plans: productivity, cost, performance. Optimization of concrete aggregate interlock to ensure shear transfer. Joint (crack) width prediction model for concrete materials. In progress, TN 3. Requires fracture results. In progress, TN 12. Fracture tests In progress, need shrinkage/creep results. Project Tasks and Progress Saw-cut timing and depth Saw-cut timing criteria for the expected materials Analytical model / Validation Review in progress, requires fracture results. Fiber Reinforced Concrete Materials Overview of structural fibers for rigid pavement Literature Review done, TN 3. PCC Mix Optimization – Phase I Factor Levels Three variables changed independently: Coarse aggregate top size ¾” and 1.5” top sizes Total cementitious content 588lb/yd3 versus 688lb/yd3 Water / cementitious ratios 0.38 versus 0.44 Phase I was used to develop Phase II mixes. PCC Mix Optimization – Phase I Mix Design Five mixes proposed to investigate 3 variables: w/cm water (lb/yd^3) cement (lb/yd^3) fly ash (lb/yd^3) CA (lb/yd^3) FA (lb/yd^3) AEA (oz/yd^3) WR (oz/yd^3) 0.75" 688.38.ST 0.38 262 588 100 1850 1103 14 - Course Aggregate Top Size 1.5" 688.38 688.44 588.38 0.38 0.44 0.38 261 303 217 588 588 488 100 100 83 1842 1772 1982 1083 1042 1166 14 16 16 7 Water reducer was added as necessary 588.44 0.44 251 488 83 1924 1132 16 7 PCC Mix Optimization – Phase I Results Values within range for a typical O’Hare mix Air (%) UW (lb) Typical O'Hare Mix (CA 3/4") 688.38.ST 7 36.05 Slump (in) fc' 7 (psi) 3.75 3690 Additional Laboratory Mixes (CA 1.5") 688.38 6 36.70 4.75 688.44 3 37.60 9 588.38 5.5 36.75 3 588.44 4 37.70 6 3000 2720 2400 2280 fr 7 (psi) fr 28 (psi) 768 790 PCC Mix Optimization – Phase II Phase II mix objectives: Mechanical Properties Meet specified strength, air content, workability, etc Maximize fracture resistance & ductility Volume Stability Minimize shrinkage Load Transfer Maximize aggregate interlock PCC Mix Optimization – Phase II Experimental Design Primary factors of interest: Max. aggregate size, w/c ratio, cement content and fly ash /cementitious ratio. Agg. Size W/CM Fly Ash/CM ID MIX No. 0.75" 0.38 0.15 688.38.ST 688.38 1 2 1.5" 588.38 3 0.44 0.15 0.00 688.44 588.44 535.44 4 5 6 No water reducers are added in Phase II 0.18 455.44 7 PCC Mix Optimization – Phase II Mix Design Mixes identical to Phase I with the addition of two mixes to investigate O’Hare specification extremes w/cm water (lb/yd^3) cement (lb/yd^3) fly ash (lb/yd^3) CA (lb/yd^3) FA (lb/yd^3) AEA (oz/yd^3) 0.75" 688.38.ST 0.38 262 588 100 1850 1103 14 Course Aggregate Top Size 1.5" 688.38 571.38 688.44 571.44 0.38 0.38 0.44 0.44 261 217 303 251 588 488 588 488 100 83 100 83 1842 1982 1772 1924 1083 1166 1042 1132 14 16 16 16 No water reducers are added in Phase II 535.44 0.44 235 535 0 1984 1167 16 555.44 0.44 244 455 100 1942 1142 16 PCC Mix Optimization – Phase II Testing Fresh concrete properties Slump, Air Content, Unit Weight Mechanical Testing Compressive strength at 7 and 28 days Modulus of Elasticity at 7 and 28 days Split tensile strength at 7 and 28 days Modulus of Rupture at 7 and 28 days Stability Testing Drying and Autogenous Shrinkage trends for 28+ days Fracture tests Early-ages (<48 hrs) Mature age (28 days) PCC Mix Optimization Preliminary Strength Summary Compressive Strength (psi) Mix Age (days) 7 28 688.44 3367 4258 588.38 3525 3860 688.38 3361 3902 Splitting Strength (psi) 7 28 284 437 429 443 454 469 Toward a shrinkage specification How much shrinkage is acceptable? Little information in the literature State of California Materials and Research Lab ASTM C157-64 used Three classes defined Class A: <320 microstrain Class B: <480 microstrain Class C: <640 Shrinkage over 735 microstrain is considered very severe Toward a shrinkage specification Other recommendations Non standard test: 8x8x2” specimens Sealed 2 d, air dried 26 d, soaked 4 d, initial measurement taken, oven dried at 122 F and 17% RH Building research station (UK), “Shrinkage of natural aggregates in concrete”, Build. Res. Stat. dig., no. 35, 1963. Toward a shrinkage specification Do we know exactly how much shrinkage is acceptable? Not exactly We know when a material is really bad and when a material is really good Bad materials should be avoided, and strategies should be examined for approaching low shrinkage concrete at minimal cost PCC Mix Optimization – Phase II Shrinkage Results All mixes show similar drying shrinkage As expected, mixes 688.44 and 688.38 that have a higher amount of cementitious material (688 lb) show higher shrinkage compared to mix 588.38 (588lb of cementitious material) Experimental Shrinkage Data for all Mixes 688.44 Drying 688.38 Drying 0.5 Shrinkage (mm/m) The water cementitious ratio is not a significant factor so far. 0.6 588.38 Drying 0.4 0.3 0.2 0.1 0 0 5 10 15 20 25 Age of Concrete (days) 30 35 40 PCC Mix Optimization – Phase II Shrinkage Results All mixes show similar drying shrinkage As expected, mixes 688.44 and 688.38 that have a higher amount of cementitious material (688 lb) show higher shrinkage compared to mix 588.38 (588lb of cementitious material). Experimental Shrinkage Data for all Mixes 0.6 688.44 Drying Shrinkage (mm/m) The w/c ratio is not a significant factor so far. 688.38 Drying 0.5 588.38 Drying 0.4 0.3 0.2 0.1 0 0 5 10 15 20 25 Age of Concrete (days) 30 35 40 PCC Mix Optimization – Phase II Shrinkage models vs. experimental results ACI Model Experimental (688.38) Experimental Data Data vs. vs. Shrinkage Shrinkage Models Models (588.38) (688.44) 0.5 0.5 0.45 0.45 Fine/Total agg. Entrapped air Volume/Surface Relative humidity 0.4 0.4 Shrinkage (mm/m) Shrinkage (mm/m) Cement content 0.35 0.35 0.3 0.3 0.25 0.25 0.2 0.15 Exp. Exp. Total Total ACI ACI Drying Drying 0.1 0.05 FIB FIB 2000 2000 Drying Drying 0 0 5 10 10 15 20 25 30 35 Age of of Concrete Concrete (days) Age (days) This model underestimates the experimental results during the first 28 days for the mixes done so far. 40 PCC Mix Optimization – Phase II Shrinkage models vs. experimental results FIB 2000 Model Volume/Surface Relative humidity Type of cement 0.45 0.45 0.4 0.4 Shrinkage (mm/m) Shrinkage (mm/m) fc at 28 days Experimental (688.38) Experimental Data Data vs. vs. Shrinkage Shrinkage Models Models (588.38) (688.44) 0.5 0.5 0.35 0.35 0.3 0.3 0.25 0.25 0.2 0.15 Exp. Exp. Total Total ACI ACI Drying Drying 0.1 0.05 FIB FIB 2000 2000 Drying Drying 0 0 5 10 10 15 20 25 30 Age of of Concrete Concrete (days) Age (days) This model fits the experimental results during the first 28 days for the mixes done so far. 35 40 Concrete Shrinkage Summary - 1.5” max aggregate size Concrete Age Drying Age MIX 588.38 MIX 688.38 MIX 688.44 1 0 0 0 0 *units in microstrain 3 2 107 118 112 7 6 213 233 235 14 13 303 338 332 28 27 367 405 412 Fracture Properties The relationship between Fracture Energy and Joint Performance Fracture Energy is characterized using GF The Shear Stiffness is a good indicator of Joint Performance Load vs Displacement 4000 3500 3000 Load (N) 2500 2000 1500 1000 500 0 0 0.1 0.2 0.3 0.4 0.5 CMOD (mm) 0.6 0.7 0.8 0.9 1 Fracture Properties Wedge Splitting Test Test configuration Low self weight effect Ideal for early age testing Similar to beam test Load vs. CMOD curve Load vs Displacement 4000 3500 3000 Load (N) 2500 2000 1500 1000 500 0 0 0.1 0.2 0.3 0.4 0.5 CMOD (mm) 0.6 0.7 0.8 0.9 1 Fracture Properties Obtaining the Fracture Energy Calculation of area under the curve Load vs Displacement 4000 ft 3500 3000 Load (N) 2500 2000 1500 1000 500 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 CMOD (mm) GF = Area under the Curve Cracking Area 0.8 0.9 1 Fracture Properties Effect of aggregate size on Fracture Energy Larger coarse aggregate and higher Crushing Value increase Fracture Energy Fracture Properties Effect of Aggregate Type on GF Fracture Properties Other significance of GF GF better characterize the effect of coarse aggregate on concrete performance. For w/c = 0.49 f’c (12 hrs) = 3.80 – 4.20 MPa f’c (28 days) = 31.7 – 38.1 MPa GF (12 hrs) = 52.7 – 194.5 N/m GF (28 days) = 93.7– 573.3N/m Requirements for Saw-cut Timing s Stress Strength Time Stress = f(thermal/moisture gradients, slab geometry, friction) Strength (MOR,E) and fracture parameters (Gf / KIC cf / CTODc) with time Saw-cut Timing and Depth Notch depth (a) depends on stress, strength, and slab thickness (d) Stress = f(coarse aggregate,T, RH) a d Tasks for FY 2006 PCC Mix Optimization Fracture testing (finish Fall 2005) Alternative cementitious materials/admix. (Phase III) FRC, HVFA, Slag Manufactured Sand (?) Design and Construction Issues Saw-cut timing (Dec. 2005) Joint (crack) width prediction (Summer 2006) Slab curling analysis* (Summer 2006) Proposed New Ideas Two-layer concrete pavements Multi-functional rigid pavement Cost saving GREEN-CRETE Recycled concrete aggregate Effect of recycled aggregate on mechanical and volumetric properties of concrete Experimental pavement section and pavement instrumentation Multi-layer concrete pavements Multi-functional rigid pavement: Volume stability and fracture resistance maximized independently Skid resistance, aggregate interlock Reduced slab curling T, RH P Functions Wear Resistant E(z), υ(z), α(z), k(z), ρ(z), D(z) h Shrinkage Resistant Fatigue Resistant z Support Layers h1, E1, υ1, α1, k1, ρ1, D1 No fibers Porous Concrete Friction/Noise Layer h2, E2, υ2, α2, k2, ρ2, D2 fB = 0.1% Shrinkage Resistant Layer h3, E3, υ3, α3, k3, ρ3, D3 fA = 0.25% h4, E4, υ4, α4, k4, ρ4, D4 fA = 0.5% Fatigue Resistant Layers Support Layers Preliminary Testing of Two-layer Concrete P Mixture 1 h1 d Mixture 2 h2 a0 CMOD 4 Material 1: 100% Plain, Material 2: 0% FRC 3.5 Material 1: 0% Plain, Material 2: 100% FRC 3 Load P (kN) Material 1: 33% Plain, Material 2: 66% FRC 2.5 Material 1: 33% FRC Material 2: 66% Plain 2 1.5 1 0.5 0 0 0.5 1 CMOD (mm) 1.5 2 Recycled Concrete Aggregate Recycled Concrete Aggregate Advantages of RCA Performance Improves strength of base when used in base layer Potential to minimize D-cracking and ASR Economic Limited haul distance Reduced disposal costs Lower aggregate cost = lower concrete cost Overall project savings Resource Conservation (RCAC is a green material) Reduced land disposal and dumping Conservation of virgin aggregates Reduced impact to landscapes G. P. Gonzalez, H. K. Moo-Young, “Transportation Applications Of Recycled Concrete Aggregate”, FHWA State of the Practice National Review September 2004. Recycled Concrete Aggregate Some potential disadvantages Reduced strength and modulus Particularly with a large amount of recycled fines Higher drying shrinkage The reduced stiffness of aggregates reduces the restraint to paste shrinkage Part of the RCA is just hydrated paste… this will also shrink when dried Recycled Concrete Aggregate Can we mitigate the disadvantages? Use low w/cm concrete (below ~0.35) Drying shrinkage will be greatly reduced due to decrease in diffusivity Strength and stiffness will be satisfactory But what about autogenous shrinkage in low w/cm? There is evidence that RCA can be used as an “internal curing agent” by saturating the aggregate prior to use Recycled Concrete Aggregate Some findings from literature When used with a very low w/cm, RCAC compressive strength can exceed 9000psi at 28 d Autogenous shrinkage can be lowered by 60% by adding saturated RCA While there are no reports in the literature, it is likely that RCA increases tensile creep, which would reduce propensity for shrinkage cracking or curling I. Maruyama, R. Sato, “A trial of reducing autogenous shrinkage by recycled aggregate”, in Proceedings of self-desiccation and its importance in concrete technology, Gaithersburg, MD, June 2005. Experimental Pavement Sections & Instrumentation Opportunity to test new ideas!! Factor Levels 16 instrumented slabs FRC vs. Plain Slab Size and Curling 80 ft Joint Type - Dowel vs. no dowels Base Type 75 ft Gaging RH and Temperature profile Strain Deflection Joint opening 400 ft DIA Project FULL-SCALE TESTING (Advanced Transportation Loading ASsembly) • 80,000 lbs max load • 85 feet loading length • 65 feet at 10mph • Uni- or Bi-directional • Variable lateral position Test ideas at UIUC Use of Manufactured Sand Gradation Coarse graded material High amount of fines (passing #200), exceeding the 3% limit recommended by ASTM.