Innovative Concrete Mixes in MnROAD Phase 2 Initiatives
Bernard Igbafen Izevbekhai. PhD; P.E.
Research Operations Engineer,
Minnesota Dept. of Transportation
MnROAD Workshop
February 11 2015
• High Performance (60 Year Design) Concrete Pavement • Pervious Concrete Overlay • Pervious Concrete Pavement Study (Full Depth) • Design Guide for Concrete Bonded Concrete on
Existing Asphalt Pavements (Whitetopping) • Design and Construction Guidelines for Thermally
Insulated Concrete Pavements • Unbonded Concrete Overlay • Concrete Pavement Optimization – Determining the Lower Threshold of Slab Thickness for High Volume Roads
2008 INITIATIVES
Material
Size/ Type
Specific Gravity
Absorp. Factor
Mix #1 3A41HPC1
Cement I / II 3.15 410
Fly Ash C / F 2.55 175
Slag GR-100 2.90 Other
F Agg 1 C.SAND 2.63 0.009 1123
F Agg 2 C.SAND 2.64 0.008 1154
C Agg 1 CA-50(#67) 2.69 0.013 627
C Agg 2 1.5"(#4) 2.75 0.013 224
C Agg 3 #9 2.69 0.014 C Agg 4 3/8 GRANITE 2.67 0.004 Admix 1 AEA 4.0
Admix 2 SIKAMENT 6.0
Admix 3 DELVO Design Water 205
HIGH PERFORMANCE CONCRETE
Size/ Specific Absorp. Mix #2
Material Type Gravity Factor PERVIOUS
Cement I / II 3.15 296
Fly Ash C / F 2.55 89
Slag GR-100 2.90 207
Other F Agg 1 C.SAND 2.63 0.009 225
F Agg 2 C.SAND 2.64 0.008
C Agg 1 CA-50(#67) 2.69 0.013 C Agg 2 1.5"(#4) 2.75 0.013 C Agg 3 #9 2.69 0.014
C Agg 4 3/8 GRANITE 2.67 0.004 2245
Admix 1 AEA 12.0
Admix 2 SIKAMENT Admix 3 DELVO 12.0
Design Water 172
PERVIOUS CONCRETE FULL DEPTH
Cross-sectional Layout of Pervious Concrete cells in a MnDOT MnROAD facility.
PERVIOUS CONCRETE MIXTURE
PERVIOUS DEPLOYMENT
CITY OF ROCHESTER PERVIOUS SHOULDER
DETROIT LAKES BOAT LANDING CITY OF SHOREVIEW CITY STREET
2 LIFT CONCRETE
Cell 70 Cell 71 Cell 73 Cell 72
Innovative
Diamond
Grind
Traditional
Diamond
Grind
Traditiona
l Diamond
Grind
Traditiona
l Diamond
Grind
Exposed
Aggregate
3" HMA 3" EAC 3" EAC
6" RAC 6" RAC 6” LCST 6" LCST
8" Class 5 8" Class 6 8" Class 7
Clay Clay Clay
Recycled Low Cost Exposed Aggregate
Water (lbs/cy) 234 172 283
Cement (lbs/cy) 360 240 616
Fly Ash (lbs/cy) 240 360 109
W/CM 0.39 0.29 0.39
Sand (OD lbs/cy) 1200 1263 843
CA1 (OD lbs/cy) 825 787 1133
CA2 (OD lbs/cy) 920 1102 843
Max Slump (in) 3 3 3
% Air 7 7 7
Multi-Air 25 (oz/cy) 2 - 15 2 - 15 2 - 15
Sike 686 (oz/cwt) 1 - 7 1 - 5 1 - 5
Admixture 3
0-30 oz/cwt Sikaset
NC (non-chloride
accelerator)
0-30 oz/cwt Sikaset
NC (non-chloride
accelerator)
0-5 oz/cwt Delvo as
needed for slump
retentions
THREE MIXES IN 2010 INITIATIVE
• Total cost difference is within margin of error
• Basis: Recycled agg: $ 8.75/Ton vs. 20.72/Ton
• 2 –Lift LCCA may show better ROI
• Kansas DOT 2009 Illinois Tollway 2013 INVEST
360,006 tons of asphalt, 304,643 tons of concrete and
Source: C.S Mc Crossan
RECYCLE COST- EFFECTIVENESS & DEPLOYMENT POTENTIAL
120
125
130
135
140
145
150
155
160
165
Un
it W
eig
ht
lb/in
2
DD Vibratory
DD Static
DD Rubber
NUCLEAR DRY DENSITY PROGRESSION
• If the RCC is too dry, the surface will appear dusty or grainy and may even shear (tear) horizontally.
• Striations are common. May later initiate or facilitate crack paths
• Segregation: checking the aggregate gradation or plant
calibration may be necessary. • RCC should be compacted as soon as possible after it is
spread, especially in hot weather (PCA R&D Serial No. 2975). Typically within 15 min of spreading and 45 min of initial mixing.
• Agencies need a skid resistant surface.
RCC OBSERVED & VALIDATED
2013 FIBER MIXES Factoidal Hypothesis:
– Fibers do increase Slab capacity (Roessler et al, Bourdelion et al)
– Fibers are deployed in the Elastoplastic zone
– Fibers can hold parts across crack lines
– Consequently Fibers will enhance Aggregate interlock
Research Strategy: – Fibers Mix for Thin UBOL (Slab
capacity) • Contractor mixes Max aggregate
size ¾” 6.5% Fiber
– Fiber Mix for White Topping Factoria (Load Transfer) • Contractor mixes 6.5% Fiber
Actuator
Bottom Actuated
Base
24” Diameter
Piston
Load Cell 0 to 300,000 lbs
Controller
Framework
PID/PIV Feed
Forward
Adaptive Control
Resolution 32 Bit
Controller Rate 40,000 Hz
Data Acquisition
Capability 0 to 500 Hz
LVDT Accuracy 0.000001 in
LVDT Range 0.25 in
Position Accuracy 0.0001 in
FIBER CONCRETE RESIDUAL STRENGTH ANALYSIS
SUSTAINABLE CONCRETE CELL
• Meeting the needs of the present generation without
compromising the ability of future generations to meet their own
needs.’ Federal Highway Administration “United Nations Brundtland
Commission in 1987
• Implies Setting goals, Implementing Practices and Measuring
results.”
• Sustainability Supports the Environmental Economic & Quality
of Life Requirements
• USE IN-SITU CONCRETE AS AGGREGATE S
QUA
ENV ECO
(FHWA, https://www.sustainable highways.org)
Izevbekha1 2012
Initiatives Year 2013
75% RCA in 7 ½” Concrete
Class 1 Aggregate Base
Existing Clay Subgrade
• Sustainable Concrete Cell MnROAD 2013 Construction
• Elastomeric Sealers (2 sizes)
• Geocomposite Joint Drain
MnROAD Cells 613
Geocomposite Joint Drain
INTERFACIAL TRANSITION ZONE ENHANCEMENT 𝒍𝒐𝒈𝑬𝒄 = 𝑽𝒑𝒍𝒐𝒈𝑬𝒑 + 𝑽𝒂𝒍𝒐𝒈𝑬𝒂
+ 𝑽𝒊𝒍𝒐𝒈𝑬𝒊 (𝑴𝒊𝒏𝒅𝒆𝒔𝒔 𝒀𝒐𝒖𝒏𝒈 & 𝑫𝒂𝒓𝒘𝒊𝒏 𝟐𝟎𝟎𝟑)
where subscript “I” refers to ITZ “a” to aggregate and “p” to paste
Where quantity “V” refers to volume and “E” to Elastic Modulus
T𝐡𝐮𝐬 𝑬𝒄 = 𝑬𝒑𝒗𝒑
𝑬𝒂𝑽𝒂𝑬𝒊
𝑽𝒊
ITZ (20-40µm) Bulk Paste
75-100µm
AGGREGATE
Excess Bleed water; Low CSH; High
CH & High Ettrignite
Cracking occurs 10-20µm in the ITZ
More sustainable to enhance ITZ
Akkari, Izevbekhai & Olson 2014
HISTORICAL BENEFITS OF FIBERS • Improve mix cohesion, improving pumpability over long distances
• Improve freeze-thaw resistance
• Improve resistance to explosive spalling in case of a severe fire
• Improve impact resistance
• Increase resistance to plastic shrinkage during curing
PROPEX FIBER INITIATIVES • Slab Capacity Increase
• Reduce crack widths
• Improve impact & abrasion resistance
• Improve freeze-thaw resistance
• Enhance Aggregate Interlock
• Diffused Vs Flocculated Alignment
Flexural Strength vs. Age – All Mixes
CURRENT STUDY
No Significant Improvement in Flexural Strength (Akkari 2011)
Historical Benefits of Fibers Polypropylene and Nylon Fibres can: • Improve mix cohesion, improving pumpability over long distances
• Improve freeze-thaw resistance
• Improve resistance to explosive spalling in case of a severe fire
• Improve impact resistance
• Increase resistance to plastic shrinkage during curing
Structural Fibres can: • Improve ductility
• Reduce crack widths
• Improve impact & abrasion resistance
• Improve freeze-thaw resistance