Bridge Decks -- New Construction and

Overlays

(Fly Ash and Silica Fume Combination)

Project:

Bridge Deck Construction New York State DOT High-Performance Concrete

Requirements:

Resist chloride ion penetrationMinimize cracking

Concrete Mixture:

Portland cement 500 lb/yd3

Fly ash 135 lb/yd3

Silica fume 40 lb/yd3

w/cm 0.40Slump 3-4 inchesAir 6.5 %Wet cure 7 days

Concrete Performance:

“Results indicated that Class HP decks performed better than previously specified concrete in resisting both longitudinal and transverse cracking.”

Rapid chloride permeability: < 1,600 coulombs

Compressive strength,28 days: > 5,400 psi

Project:

Requirements:

Resist chloride ion penetrationMinimize cracking

Bridge Deck ConstructionNew York State DOT High-Performance Concrete

Concrete Mixture:

Portland cement 300 kg/m3

Fly ash 80 kg/m3

Silica fume 25 kg/m3

w/cm 0.40Slump 75-100 mmAir 6.5 %Wet cure 7 days

SI

Concrete Performance:

SI

Rapid chloride permeability: < 1,600 coulombs

Compressive strength,28 days: > 37 MPa

“Results indicated that Class HP decks performed better than previously specified concrete in resisting both longitudinal and transverse cracking.”

Bridge Deck Overlay

(High Silica Fume Content)

Project:

Bridge Deck Overlay, Ohio DOTBeverly, Ohio

Requirements:

Resist chloride ion penetration4,500 psi at 28 daysRCP < 1,000 coulombs

Concrete Mixture:

Portland cement, Type I 700 lb/yd3

Silica fume 70 lb/yd3

w/cm 0.36Slump 4-8 in.Air 6-10%HRWRA 20 fl oz/cwtWRA, Type D 3 fl oz/cwt

Concrete Performance:

Rapid chloride permeability 600 coulombs

Compressive strength,28 days 7,000 psi

Project:

Bridge Deck Overlay, Ohio DOTBeverly, Ohio

Requirements:

Resist chloride ion penetration31 MPa at 28 daysRCP < 1,000 coulombs

Concrete Mixture:

Portland cement, Type I 415 kg/m3

Silica fume 41.5 kg/m3

w/cm 0.36Slump 100-200 mmAir 6-10%HRWRA 1.3L/100 kgWRA, Type D 165 ml/100 kg

Concrete Performance:

Rapid chloride permeability 600 coulombs

Compressive strength,28 days 48 MPa

Parking Structure

Project:Parking StructureGeneral Mitchell AirportMilwaukee, Wisconsin

Requirements:

Resist chloride ion penetration2,000 psi at 36 hours5,700 psi at 56 days

Concrete Mixture:

Portland cement, Type I 565 lb/yd3

Fly ash, Class C 100 lb/yd3

Silica fume 39 lb/yd3

w/cm 0.35WRA 12 fl oz/yd3

Slump, maximum 9 in.Additional WRA and HRWRA in SF slurry

Concrete Performance:

Compressive strength,36 hours: > 2,000 psi

Cores taken at 2 - 10 months averaged < 1,000 coulombs

Slump used: 6 - 7.5 in.

Project:

Parking StructureGeneral Mitchell AirportMilwaukee, Wisconsin

Requirements:

Resist chloride ion penetration14 MPa at 36 hours40 MPa at 56 days

Concrete Mixture:

Portland cement, Type I 335 kg/m3

Fly ash, Class C 60 kg/m3

Silica fume 17 kg/m3

w/cm 0.35WRA 440 mL/m3

Slump, maximum 230 mmAdditional WRA and HRWRA in SF slurry

Concrete Performance:

Compressive strength,36 hours > 14 MPa

Cores taken at 2 - 10 months averaged < 1,000 coulombs

Slump used: 150- 90 mm

High-Rise Columns

Project:

Key Bank TowerCleveland, Ohio

Requirements:

High ultimate strength, > 12,000 psiHigh modulus, > 6,800,000 psiPumpable, 57 stories

Concrete Mixture:

Portland cement, Type I 685 lb/yd3

GGBFS 285 lb/yd3

Silica fume 80 lb/yd3

w/cm 0.24Slump, minimum 10 in. HRWRA 30-50 fl oz/cwtWRA, Type A 4 fl oz/cwt

Concrete Performance:

Modulus > 7,000,000 psi

Compressive strength,28 days > 14,000 psi56 days > 15,000 psi

Project:

Key Bank TowerCleveland, Ohio

Requirements:

High ultimate strength, > 83 MPaHigh modulus, > 47 GPaPumpable, 57 stories

Concrete Mixture:

Portland cement, Type I 406 kg/m3

GGBFS 169 kg/m3

Silica fume 47 kg/m3

w/cm 0.24Slump, minimum 250 mm HRWRA 2.0-3.3 L/100 kgWRA, Type A 260 mL/100 kg

Concrete Performance:

Modulus > 48 GPa

Compressive strength,28 days > 97 MPa56 days > 103 MPa

HPC Bridge

Project:

I-25 and Yale Bridge, Colorado DOTDenver, Colorado

Requirements:

Reduced number of spans with shallow superstructure depthCompressive strength: 10,000 psi

Concrete Mixture:

Portland cement, Type I 730 lb/yd3

Silica fume 35 lb/yd3

w/cm 0.29HRWRA 44-131 fl oz/yd3

WRA 15-58 fl oz/yd3

Project:

I-25 and Yale Bridge, Colorado DOTDenver, Colorado

Requirements:

Reduced number of spans with shallow substructure depth Compressive strength: 69 MPa

Concrete Mixture:

Portland cement, Type I 433 kg/m3

Silica fume 21 kg/m3

w/cm 0.29HRWRA 1.7-5.1 L/m3

WRA 0.6-2.2 L/m3

Shotcrete Rehabilitation

Project:

Seismic RetrofitLittlerock Dam, California

Requirements:

Provide adequate seismic stability for maximum credible earthquakeCompressive strength of 6,000 psi at 28 days in a 4-in. thick overlay

Concrete Mixture:

Portland cement, Type I 682 lb/yd3

Silica fume 70 lb/yd3

Steel fibers 100 lb/yd3

w/cm 0.45Slump 2-4 in.

Concrete Performance:

Compressive strength, cores,> 21 days, average 7,300 psi

Pulloff testing of cores satisfied project requirements of 150 psi

Average shotcrete thickness: 4.7 in.

Project:

Seismic RetrofitLittlerock Dam, California

Requirements:

Provide adequate seismic stability for maximum credible earthquakeCompressive strength of 41 MPa at 28 days in a 100-mm thick overlay

Concrete Mixture:

Portland cement, Type I 405 kg/m3

Silica fume 41 kg/m3

Steel fibers 60 kg/m3

w/cm 0.45Slump 50 - 100 mm

Concrete Performance:

Compressive strength, cores,> 28 days, average > 50 MPa

Pulloff testing of cores satisfied project requirements of 1.0 MPa

Average shotcrete thickness: 119 mm

HPC Constructability

Project:

Canister Storage BuildingHanford Nuclear Site, WA

Requirements:

Ease of placementTemperature control of mass concreteHigh early strength for strippingHigh durability

Concrete Mixture:

Portland cement, Type I 391 lb/yd3

Fly ash, Class F 150 lb/yd3

Silica fume 60 lb/yd3

w/cm 0.37Slump 8 in.HRWRA 150 fl oz/yd3

Mid-range WRA 60 fl oz/yd3

Concrete Performance:

Concrete temperature, as delivered < 70 deg Fin place < 100 deg F

Compressive strength,28 days > 6,300 psi 90 days > 7,500 psi

Concrete Mixture:

Portland cement, Type I 232 kg/m3

Fly ash, Class F 89 kg/m3

Silica fume 36 kg/m3

w/cm 0.37Slump 200 mmHRWRA 5.8 L/m3

Mid-range WRA 2.3 L/m3

Concrete Performance:

Concrete temperature, as delivered < 21 deg Cin place < 38 deg C

Compressive strength,28 days > 43 MPa90 days > 52 MPa