Self-Consolidating Concrete for Precast, Prestressed Concrete Bridge Elements (2009)

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TRANSPORTAT ION RESEARCH BOARD WASHINGTON, D.C. 2009 www.TRB.org N A T I O N A L C O O P E R A T I V E H I G H W A Y R E S E A R C H P R O G R A M NCHRP REPORT 628 Subject Areas Bridges, Other Structures, and Hydraulics and Hydrology • Materials and Construction Self-Consolidating Concrete for Precast, Prestressed Concrete Bridge Elements Kamal Henri Khayat UNIVERSITY OF SHERBROOKE Sherbrooke, QC A N D Denis Mitchell MCGILL UNIVERSITY Montreal, QC Research sponsored by the American Association of State Highway and Transportation Officials in cooperation with the Federal Highway Administration

NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM Systematic, well-designed research provides the most effective approach to the solution of many problems facing highway administrators and engineers. Often, highway problems are of local interest and can best be studied by highway departments individually or in cooperation with their state universities and others. However, the accelerating growth of highway transportation develops increasingly complex problems of wide interest to highway authorities. These problems are best studied through a coordinated program of cooperative research. In recognition of these needs, the highway administrators of the American Association of State Highway and Transportation Officials initiated in 1962 an objective national highway research program employing modern scientific techniques. 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CRP STAFF FOR NCHRP REPORT 628 Christopher W. Jenks, Director, Cooperative Research Programs Crawford F. Jencks, Deputy Director, Cooperative Research Programs Amir N. Hanna, Senior Program Officer Eileen P. Delaney, Director of Publications Natalie Barnes, Editor Andréa Briere, Editor NCHRP PROJECT 18-12 PANEL Field of Materials and Construction—Area of Concrete Materials Wayne Kling, Delaware DOT, Dover, DE (Chair) Bijan Khaleghi, Washington State DOT, Olympia, WA Ralph A. Browne, Texas DOT, Euless, TX Teck L. Chua, Concrete Engineering, Inc., Springfield, VA Lieska K. Halsey, Nebraska DOR, Lincoln, NE Charles A. Ishee, Florida DOT, Gainesville, FL James R. Kochsiek, Minnesota DOT, Maplewood, MN M. Myint Lwin, Federal Highway Administration, Washington, DC Anton K. Schindler, Auburn University, Auburn, AL Gary Crawford, FHWA Liaison Frederick Hejl, TRB Liaison AUTHOR ACKNOWLEDGMENTS The research presented herein was performed under NCHRP Project 18-12 by the Cement and Con- crete Research Group of the Department of Civil Engineering at the University of Sherbrooke, Sherbrooke, Quebec, Canada, and McGill University, Montreal, Quebec, Canada. Dr. Kamal Henri Khayat, Professor at the Department of Civil Engineering and Director of the Cement and Concrete Research Group at University of Sherbrooke, was the principal investigator. Professor Denis Mitchell of the Department of Civil Engineering and Structural Mechanics at McGill University served as the subcontractor’s principal investigator. Mr. Wu Jian Long, Ph.D. candidate, Mr. Guillaume Lemieux, master student, Dr. Soo-Duck Hwang, post-doctoral fellow, and Dr. Ammar Yahia, research engineer, all from the University of Sherbrooke, actively participated in all aspects of this project. Dr. William D. Cook, research engineer, and Ms. Lama Baali, master student, at McGill University were involved in the structural performance of the full-scale girders. Dr. Celik H. Ozyildirim from the Virginia Transport Research Council served as a consultant to the research team. C O O P E R A T I V E R E S E A R C H P R O G R A M S

This report presents recommended guidelines for the use of self-consolidating concrete (SCC) in precast, prestressed concrete bridge elements. These guidelines address the selec- tion of constituent materials, proportioning of concrete mixtures, testing methods, fresh and hardened concrete properties, production and quality control issues, and other aspects of SCC. The report also presents recommended changes to the AASHTO Load and Resis- tance Factor Design (LRFD) Bridge Design and Construction Specifications, and test pro- tocols for evaluating some of the properties of SCC. The information contained in the report will guide materials and bridge engineers in evaluating, selecting, and specifying SCC mixtures for use in precast, prestressed concrete bridge elements, thereby facilitating fabri- cation, improving working environment and safety, and reducing cost. The information contained in the report will be of immediate interest to state materials and bridge engineers and others involved in specifying and evaluating concrete mixtures for use in highway bridges. SCC is a specially proportioned hydraulic cement concrete that enables the fresh concrete to flow easily into forms and around reinforcement and prestressing steel without segrega- tion. Use of this type of concrete for the manufacture of precast, prestressed concrete bridge elements provides the benefits of increased rate of production and safety, reduced labor needs, and lower noise levels at manufacturing plants. In spite of its benefits and widespread use in Japan and Europe, the use of SCC in the United States has been limited because of concerns about certain design and construction issues that are perceived to influence con- structability, performance, and structural integrity of the bridge system. Thus, research was needed to address the factors that significantly influence the design, constructability, and performance of precast, prestressed bridge elements manufactured with SCC, such as work- ability, strength development, creep and shrinkage properties, bond to reinforcement, and durability. Research was also needed to develop guidelines for the use of SCC in these appli- cations and to recommend related changes to AASHTO LRFD Bridge Design and Construc- tion Specifications. These guidelines and enhanced specifications will provide highway agencies with the information necessary for considering SCC in precast, prestressed con- crete bridge elements as a means for expediting construction and reducing cost while increasing safety and reducing noise in manufacturing plants. Under NCHRP Project 18-12, “Self-Consolidating Concrete for Precast, Prestressed Concrete Bridge Elements,” the University of Sherbrooke, Quebec, Canada, worked with the objectives of (1) developing guidelines for the use of SCC in precast, prestressed con- crete bridge elements and (2) recommending relevant changes to AASHTO LRFD Bridge Design and Construction Specifications. To accomplish these objectives, the researchers F O R E W O R D By Amir N. Hanna Staff Officer Transportation Research Board

reviewed available information on the use of SCC in structural applications and investigated its use in precast, prestressed concrete bridge elements. The investigation included an exten- sive laboratory testing program that covered the types and ranges of materials used in SCC mixtures and considered the properties that affect constructability and performance. Based on this review and analysis of test results, the researchers recommended changes to the AASHTO LRFD Bridge Design and Construction Specifications (included as Attachment A) and guidelines for the use of SCC in precast, prestressed concrete bridge elements (included as Attachment B). In addition, the researchers proposed test protocols for evalu- ating some of the properties of SCC for which standard test methods are not readily avail- able (included as Attachment C). The recommended guidelines, changes to LRFD Bridge Design and Construction Speci- fications, and test protocols will be particularly useful to highway agencies because their use will help identify SCC mixtures that will provide the desired properties and performance and thus accrue the anticipated benefits. Incorporation of these recommendations in the relevant AASHTO documents is therefore recommended. Attachment D, “Research Description and Findings,” provides detailed information on the experimental program and data analysis, and the findings of the literature review. This attachment is not published herein but is available on the TRB website (www.trb.org/news/ blurb_detail.asp?id=9627).

C O N T E N T S 1 Summary 5 Chapter 1 Findings 5 1.1 Test Methods and Mixture Requirements 5 1.2 Selection of Concrete Constituents 7 1.3 Factorial Design to Model Fresh and Hardened Concrete Properties 9 1.4 Validation of Code Provisions to Estimate Mechanical Properties 10 1.5 Validation of Code Provisions to Estimate Visco-Elastic Properties 10 1.6 Homogeneity of In-Situ Strength and Bond to Reinforcement 10 1.7 Structural Performance 12 Chapter 2 Background and Research Approach 12 2.1 Background 13 2.2 Research Approach 21 2.3 Approach for Relevant Changes to AASHTO LRFD Bridge Design and Construction Specifications 21 2.4 Guidelines for Use of SCC in Precast, Prestressed Concrete Bridge Elements 22 Chapter 3 Interpretation, Appraisal, and Application 23 Chapter 4 Conclusions and Suggested Research 23 4.1 Test Methods and Material Requirements 23 4.2 Material Constituents and Mix Design 26 4.3 Code Provisions for Estimating Mechanical and Visco-Elastic Properties 26 4.4 Homogeneity of In-Situ Strength and Bond to Reinforcement 26 4.5 Structural Performance of AASHTO-Type II Girders 27 4.6 Recommendations for Future Research 29 Glossary 31 References A-1 Attachment A Recommended Changes to AASHTO LRFD Bridge Design and Construction Specifications B-1 Attachment B Recommended Guidelines for Use of Self-Consolidating Concrete in Precast, Prestressed Concrete Bridge Elements C-1 Attachment C Recommended Standard Test Methods D-1 Attachment D Research Description and Findings