Self-Consolidating Concrete for Cast-in-Place Bridge Components (2016)

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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 819 Self-Consolidating Concrete for Cast-in-Place Bridge Components George Morcous University of nebraska-LincoLn Omaha, NE Kejin Wang Peter C. Taylor iowa state University Ames, IA Surendra P. Shah consULtant Evanston, IL Subscriber Categories Bridges and Other Structures • Materials TRANSPORTAT ION RESEARCH BOARD WASHINGTON, D.C. 2016 www.TRB.org 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 is the most effective way to solve 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 results in increasingly complex problems of wide inter- est to highway authorities. These problems are best studied through a coordinated program of cooperative research. Recognizing this need, the leadership of the American Association of State Highway and Transportation Officials (AASHTO) in 1962 ini- tiated an objective national highway research program using modern scientific techniques—the National Cooperative Highway Research Program (NCHRP). NCHRP is supported on a continuing basis by funds from participating member states of AASHTO and receives the full cooperation and support of the Federal Highway Administration, United States Department of Transportation. The Transportation Research Board (TRB) of the National Academies of Sciences, Engineering, and Medicine was requested by AASHTO to administer the research program because of TRB’s recognized objectivity and understanding of modern research practices. TRB is uniquely suited for this purpose for many reasons: TRB maintains an extensive com- mittee structure from which authorities on any highway transportation subject may be drawn; TRB possesses avenues of communications and cooperation with federal, state, and local governmental agencies, univer- sities, and industry; TRB’s relationship to the Academies is an insurance of objectivity; and TRB maintains a full-time staff of specialists in high- way transportation matters to bring the findings of research directly to those in a position to use them. The program is developed on the basis of research needs identified by chief administrators and other staff of the highway and transporta- tion departments and by committees of AASHTO. Topics of the highest merit are selected by the AASHTO Standing Committee on Research (SCOR), and each year SCOR’s recommendations are proposed to the AASHTO Board of Directors and the Academies. Research projects to address these topics are defined by NCHRP, and qualified research agencies are selected from submitted proposals. Administration and surveillance of research contracts are the responsibilities of the Acad- emies and TRB. The needs for highway research are many, and NCHRP can make significant contributions to solving highway transportation problems of mutual concern to many responsible groups. The program, however, is intended to complement, rather than to substitute for or duplicate, other highway research programs. Published reports of the NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM are available from Transportation Research Board Business Office 500 Fifth Street, NW Washington, DC 20001 and can be ordered through the Internet by going to http://www.national-academies.org and then searching for TRB Printed in the United States of America NCHRP REPORT 819 Project 18-16 ISSN 0077-5614 ISBN 978-0-309-37562-7 Library of Congress Control Number 2016947690 © 2016 National Academy of Sciences. All rights reserved. COPYRIGHT INFORMATION Authors herein are responsible for the authenticity of their materials and for obtaining written permissions from publishers or persons who own the copyright to any previously published or copyrighted material used herein. Cooperative Research Programs (CRP) grants permission to reproduce material in this publication for classroom and not-for-profit purposes. Permission is given with the understanding that none of the material will be used to imply TRB, AASHTO, FAA, FHWA, FMCSA, FRA, FTA, Office of the Assistant Secretary for Research and Technology, PHMSA, or TDC endorsement of a particular product, method, or practice. It is expected that those reproducing the material in this document for educational and not-for-profit uses will give appropriate acknowledgment of the source of any reprinted or reproduced material. For other uses of the material, request permission from CRP. NOTICE The report was reviewed by the technical panel and accepted for publication according to procedures established and overseen by the Transportation Research Board and approved by the National Academies of Sciences, Engineering, and Medicine. 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The National Academy of Sciences was established in 1863 by an Act of Congress, signed by President Lincoln, as a private, non- governmental institution to advise the nation on issues related to science and technology. Members are elected by their peers for outstanding contributions to research. Dr. Marcia McNutt is president. The National Academy of Engineering was established in 1964 under the charter of the National Academy of Sciences to bring the practices of engineering to advising the nation. Members are elected by their peers for extraordinary contributions to engineering. Dr. C. D. Mote, Jr., is president. The National Academy of Medicine (formerly the Institute of Medicine) was established in 1970 under the charter of the National Academy of Sciences to advise the nation on medical and health issues. Members are elected by their peers for distinguished contributions to medicine and health. Dr. Victor J. Dzau is president. The three Academies work together as the National Academies of Sciences, Engineering, and Medicine to provide independent, objective analysis and advice to the nation and conduct other activities to solve complex problems and inform public policy decisions. The Academies also encourage education and research, recognize outstanding contributions to knowledge, and increase public understanding in matters of science, engineering, and medicine. Learn more about the National Academies of Sciences, Engineering, and Medicine at www.national-academies.org. The Transportation Research Board is one of seven major programs of the National Academies of Sciences, Engineering, and Medicine. The mission of the Transportation Research Board is to increase the benefits that transportation contributes to society by providing leadership in transportation innovation and progress through research and information exchange, conducted within a setting that is objective, interdisciplinary, and multimodal. The Board’s varied committees, task forces, and panels annually engage about 7,000 engineers, scientists, and other transportation researchers and practitioners from the public and private sectors and academia, all of whom contribute their expertise in the public interest. The program is supported by state transportation departments, federal agencies including the component administrations of the U.S. Department of Transportation, and other organizations and individuals interested in the development of transportation. Learn more about the Transportation Research Board at www.TRB.org.

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 AUTHOR ACKNOWLEDGMENTS The research reported herein was performed under NCHRP Project 18-16 by the University of Nebraska- Lincoln (UNL) and Iowa State University (ISU); Dr. George Morcous, Professor of Construction Engineer- ing at UNL, was the principal investigator. The other authors of this report are Dr. Kejin Wang, Professor of Civil Engineering at ISU; Dr. Peter C. Taylor, Director of the National Concrete Pavement Technology Center at ISU; Dr. Surendra P. Shah, Consultant; Micheal Asaad, Research Assistant and Ph.D. Candidate at UNL; and Xuhao Wang, Post-Doctoral Associate at ISU. CRP STAFF FOR NCHRP REPORT 819 Christopher W. Jenks, Director, Cooperative Research Programs Christopher Hedges, Manager, National Cooperative Highway Research Program Amir N. Hanna, Senior Program Officer Natasha R. Donawa, Senior Program Assistant Eileen P. Delaney, Director of Publications Ellen M. Chafee, Senior Editor NCHRP PROJECT 18-16 PANEL Field of Materials and Construction—Area of Concrete Materials David Hohmann, HDR Engineering, Inc., Austin, TX (Chair) Teck L. Chua, Vulcan Materials Company, Herndon, VA Donald J. Janssen, Seattle, WA Jugesh Kapur, Burns and McDonnell, Bismarck, ND Kristin L. Langer, Pennsylvania DOT, Harrisburg, PA M. Myint Lwin, Olympia, WA Madhwesh Raghavendrachar, California DOT, Sacramento, CA Anton K. Schindler, Auburn University, Auburn, AL Brett S. Trautman, Missouri DOT, Jefferson City, MO Susan N. Lane, FHWA Liaison Frederick Hejl, TRB Liaison

F O R E W O R D This report presents recommended guidelines for the use of self-consolidating concrete (SCC) in cast-in-place highway bridge components. These guidelines address the selection of constituent materials, proportioning of concrete mixtures, testing methods, fresh and hard- ened concrete properties, production and quality control issues, and other aspects of SCC. The report also presents proposed changes to the AASHTO LRFD Bridge Design and Con- struction Specifications to address use of SCC for cast-in-place highway bridge components. The information contained in the report will guide materials and bridge engineers in evaluat- ing, selecting, and specifying SCC mixtures for use in cast-in-place concrete bridge compo- nents, thereby facilitating construction, improving the 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 and structures. SCC is a specially proportioned hydraulic cement concrete that enables the fresh concrete to flow easily into the forms and around the reinforcement and prestressing steel without segregation. Use of this type of concrete for the manufacture of precast, prestressed concrete bridge elements has increased in recent years because it helps increase the rate of production and safety, reduce labor needs, and lower noise levels at manufacturing plants. However, use of cast-in-place SCC in bridge construction has been limited because of the lack of design and construction guidelines and concerns about certain design and construction issues that may influence the structural integrity of the bridge system. NCHRP Project 18-12 (see NCHRP Report 628: Self-Consolidating Concrete for Precast, Prestressed Concrete Bridge Elements) focused on the application of SCC in precast, pre- stressed bridge elements; some of the findings of this research are applicable to cast-in-place concrete bridge components. However, use of SCC in cast-in-place applications requires the consideration of conditions other than the controlled conditions existing in precast con- crete plants and the issues that are perceived to influence constructability, 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 cast-in-place bridge components manufactured with SCC, such as workability, 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 applications and to propose related changes to AASHTO LRFD Bridge Design and Construction Specifications. Under NCHRP Project 18-16, “Self-Consolidating Concrete for Cast-in-Place Bridge Com- ponents,” the University of Nebraska-Lincoln worked with the objectives of (1) developing guidelines for the use of self-consolidating concrete in cast-in-place concrete in highway bridge By Amir N. Hanna Staff Officer Transportation Research Board

components and (2) recommending relevant changes to the AASHTO LRFD Bridge Design and Construction Specifications. To accomplish these objectives, the researchers reviewed available information on the use of SCC in structural applications and investigated its use in cast-in-place, concrete bridge components. The investigation included an extensive labora- tory testing program that covered the types and ranges of materials used in SCC mixtures and considered the properties that affect constructability and performance. The project considered the use of SCC for cast-in-place concrete bridge substructure components (such as piers, pier caps, footings, abutment walls, and wing walls) and superstructure components (such as girders, stringers, floor beams, arches, diaphragms, connections, closure pours, rails, and concrete-filled tubes) but not for other bridge components (such as deep foundations, drilled shafts, bridge decks, and approach slabs). Based on this review and analysis of test results, the research proposed changes to the AASHTO LRFD Bridge Design and Construction Specifica- tions (included as Attachment A) and guidelines for the use of SCC in cast-in-place bridge components (included as Attachment B). The proposed guidelines and changes to LRFD Bridge Design and Construction Specifications 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. Six appendices contained in the research agency’s final report provide detailed information on the different aspects of the experimental program. These appendices are not published herein, but are available online at http://www.trb.org/Main/Blurbs/174472.aspx.

C O N T E N T S Note: Photographs, figures, and tables in this report may have been converted from color to grayscale for printing. The electronic version of the report (posted on the web at www.trb.org) retains the color versions. 1 Summary 5 Chapter 1 Research Approach 5 1.1 Literature Review and Survey 5 1.2 Experimental Investigation 21 1.3 Full-Scale Bridge Components 30 Chapter 2 Results, Interpretation, and Application 30 2.1 Fresh Concrete Properties 34 2.2 Early-Age Concrete Properties 34 2.3 Hardened Concrete Properties 47 2.4 Full-Scale Bridge Components 53 Chapter 3 Conclusions and Recommendations for Research 53 3.1 Mix Proportions and Fresh and Early-Age Concrete Properties 54 3.2 Mechanical, Visco-Elastic, and Durability Properties 55 3.3 Full-Scale Bridge Components: Constructability and Structural Performance 56 3.4 Recommendations for Future Research 57 References 59 Glossary 62 Acronyms A-1 Attachment A Proposed Changes to the AASHTO LRFD Bridge Design and Construction Specifications B-1 Attachment B Proposed Guidelines for Use of Self-Consolidating Concrete in Cast-in-Place Bridge Components