Lightweight Concrete VDOT Experiences for Bridge Decks ... · SFC –Silica Fume Concrete LWCA...
Transcript of Lightweight Concrete VDOT Experiences for Bridge Decks ... · SFC –Silica Fume Concrete LWCA...
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Lightweight Concrete – VDOT
Experiences for Bridge Decks &
Overlays
Virginia Concrete Conference, 2019
H. Celik Ozyildirim, Ph.D., P.E.
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Outline
• Lightweight Concrete (LWC)
• VDOT deck applications with sand LWC
Route 269 (old Route 60)
Route 60 near Bueno Vista
Route 33
• Low cracking concrete decks: LWC option
• All LWC
• VDOT overlay applications with sand LWC
I-64 Dunlap Creek
• Conclusions
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LWC Benefits
• Low modulus of elasticity and high inelastic strain capacity
• Internal moist curing
• Low thermal coefficient of linear expansion
• Improved contact zone between the aggregate and the paste
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Pantheon
Almost 2,000 years old!
LWC dome
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LWC Use
• Reduced loads on the substructure
• More efficient structural design
(longer spans)
• Reduced cracking
• Improved durability
• Accelerated bridge construction
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VDOT Field Applications
• Since 1961 mainly in deck widening projects.
• Mainly LW coarse aggregate and normal weight
fine aggregate (sand LWC) in beams, decks, and
overlays. Maximum fresh density 120 lb/ft3.
• All LWC; both fine and coarse aggregate LW in
deck. Maximum density 105 lb/ft3.
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Route 269 – 1979 LWC Deck
212-ft long two span, LW aggregate
absorption=18%
No transverse cracks at the 33 year visit
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Route 269
Laboratory freeze-thaw testing
Field performance satisfactory
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Freezing and Thawing – ASTM C 666
Two weeks moist cure and at least 1 week drying and tested
in 2% NaCl solution. ASTM C 330 indicates 2 weeks drying.
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Route 269 – 1983 Pictures
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Route 269 – 2008 Pictures
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Route 269
No visual change between the 1983 and 2008 pictures indicating
satisfactory freeze-thaw and abrasion/wear resistance!
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Route 60 over Maury River - 1984
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Route 60 over Maury River - 1984
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Skew, some exposed aggregates, no cracks
at 30 year visit, good performance
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LWC - Rte. 33
• Over the Mattaponi River, 3,454-ft long bridge -
2,195 ft with lightweight concrete beams and
deck.
• Over the Pamunkey River, 5,354-ft long bridge
- 2,169 ft with lightweight concrete beams and
deck.
• 200 and 240 ft spans in four-span spliced
girders; and > 120 ft spans in continuous for LL
units.
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Route 33 over Mattaponi River
LWC deck = 5,000 psi
LWC beam = 8,000 psi
LW CA absorption = 5% to 6%
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Route 33 over Pamunkey River
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Route 33 over Pamunkey River
Ground section. Deck is performing satisfactorily!
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Low Cracking Deck Study - LWC
1919
2012
(i) Winchester, Staunton District
(ii) Lynchburg District
(iii) Opal, Culpeper District
2013
(iv) Nokesville, NOVA District
(v) Fredericksburg District
(vi) Richmond District
2014
(vii) Stafford, NOVA
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Opal Bridge - 2012
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Two 128’ spans
4 beams per span with LW SCC, LWC deck
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213/27/2019 21
Low Cracking Deck Study - LWC
Winchester (2 Years) Opal (1 ½ Years)
No crack on LWC deck. Cracks
in NWC approach slab
Lynchburg (1 ½ Years)
After 2 winters no cracks on
deck
I-95 Expressway, Stafford ( 6 months)
No Crack
No Crack
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Low Cracking Decks
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Drying shrinkage cracking can be minimized with the use
of one or more of the following options:
- LWC with LW coarse aggregate
- Normal weight Concrete (NWC) with SRA (shrinkage
reducing admixture)
- Shrinkage Compensating Concrete (Type K)
Proper concrete placement, consolidation and curing are
important.
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Normal weight concrete: total cementitious materials content
shall be < 600 lb/yd3. If 28-day drying shrinkage is > 0.035%,
SRA shall be used to reduce the shrinkage to acceptable
level.
Lightweight concrete: total cementitious materials content
shall be < 650 lb/yd3 and the maximum fresh density shall be
< 120 lb/ft3.
VDOT 2016 R&B Specification for
Low Cracking Bridge Deck Concrete
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All LWC
• Route 198 (Dutton Road) over Harper Creek
• Cast-in place all LWC deck, backwalls, parapets, and
substructure modifications with a maximum density of
105 lb/ft3 (2016)
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LWC Overlays on I-64 over Dunlap Creek
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Overlays on I-64
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WBL Rehabilitation: Fall-2014
EBL Rehabilitation: Summer-2015
RSLMC – Rapid set with Latex Modified Concrete
SFC – Silica Fume Concrete
LWCA – Lightweight coarse aggregate, PLWFA – Partial lightweight fine aggregate,
SRA – Shrinkage Reducing Admixture
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LWC Overlays on I-64
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Prepared in RMC Truck
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Hydro-Demolition to Remove
Deteriorated Concrete
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Overlay CuringPrompt application of wet burlap
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Mixture Proportions (lb/yd3)
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Material SFC- LWCA SFC-PLWFA
Type I/II portland cement 632 612
Silica fume 48 46
LWCA, ½ in 790 ----
Normal weight CA, ½ in ---- 1600
LWFA ---- 495
NWFA 1486 645
w/cm 0.40 0.41
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Compressive Strength – EBL
TestAge (d)
SFC-LWCASFC-
PLWFARSLMC
Compressive 1 3180 2960 3690*
strength (psi) 3 4010 3760 ----
28 5930 6200 5280
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*3.5 hours 3020 psi
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EBL
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-0.1
-0.08
-0.06
-0.04
-0.02
0
0.02
0 7 10 14 21 35 63 119 231 455
Len
gth
Ch
an
ge (
%)
Time (days)
SFC-LWCA1
SFC-LWCA2
SFC-LWCA3
SFC-LWCA4
SFC-PLWFA1
SFC-PLWFA2
SFC-PLWFA3
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LWC Overlays on I-64
SFC with lightweight coarse aggregates or
partial weight fine aggregate had shrinkage
values as high as 0.06%
Exhibited tight cracks (less than 0.1 mm).
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Conclusion
• LWC properly consolidated and cured is
performing satisfactorily.
• LWC has reduced cracking potential.
• LWC even with drying shrinkage values
considered high for NWC has been
performing well.
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Acknowledgements
• FHWA
• VDOT CO
• VDOT Districts
• VTRC
• Industry
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Thank You.