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Suggested Citation:"Front Matter." National Academies of Sciences, Engineering, and Medicine. 2013. Long-Term Performance of Epoxy Adhesive Anchor Systems. Washington, DC: The National Academies Press. doi: 10.17226/22470.
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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 757 Long-Term Performance of Epoxy Adhesive Anchor Systems Ronald A. Cook Elliot P. Douglas Todd M. Davis Changhua Liu University of florida Gainesville, FL Subscriber Categories Bridges and Other Structures • Construction • Materials TRANSPORTAT ION RESEARCH BOARD WASHINGTON, D.C. 2013 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 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. This program is supported on a continuing basis by funds from participating member states of the Association and it receives the full cooperation and support of the Federal Highway Administration, United States Department of Transportation. The Transportation Research Board of the National Academies was requested by the Association to administer the research program because of the Board’s recognized objectivity and understanding of modern research practices. The Board is uniquely suited for this purpose as it maintains an extensive committee structure from which authorities on any highway transportation subject may be drawn; it possesses avenues of communications and cooperation with federal, state and local governmental agencies, universities, and industry; its relationship to the National Research Council is an insurance of objectivity; it maintains a full-time research correlation staff of specialists in highway transportation matters to bring the findings of research directly to those who are in a position to use them. The program is developed on the basis of research needs identified by chief administrators of the highway and transportation departments and by committees of AASHTO. Each year, specific areas of research needs to be included in the program are proposed to the National Research Council and the Board by the American Association of State Highway and Transportation Officials. Research projects to fulfill these needs are defined by the Board, and qualified research agencies are selected from those that have submitted proposals. Administration and surveillance of research contracts are the responsibilities of the National Research Council and the Transportation Research Board. The needs for highway research are many, and the National Cooperative Highway Research Program can make significant contributions to the solution of 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 at: http://www.national-academies.org/trb/bookstore Printed in the United States of America NCHRP REPORT 757 Project 04-37 ISSN 0077-5614 ISBN 978-0-309-28357-1 Library of Congress Control Number 2013950626 © 2013 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, FTA, or Transit Development Corporation 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 project that is the subject of this report was a part of the National Cooperative Highway Research Program, conducted by the Transportation Research Board with the approval of the Governing Board of the National Research Council. The members of the technical panel selected to monitor this project and to review this report were chosen for their special competencies and with regard for appropriate balance. 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 Governing Board of the National Research Council. The opinions and conclusions expressed or implied in this report are those of the researchers who performed the research and are not necessarily those of the Transportation Research Board, the National Research Council, or the program sponsors. The Transportation Research Board of the National Academies, the National Research Council, and the sponsors of the National Cooperative Highway Research Program do not endorse products or manufacturers. Trade or manufacturers’ names appear herein solely because they are considered essential to the object of the report.

The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished scholars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare. On the authority of the charter granted to it by the Congress in 1863, the Academy has a mandate that requires it to advise the federal government on scientific and technical matters. Dr. Ralph J. Cicerone is president of the National Academy of Sciences. The National Academy of Engineering was established in 1964, under the charter of the National Academy of Sciences, as a parallel organization of outstanding engineers. It is autonomous in its administration and in the selection of its members, sharing with the National Academy of Sciences the responsibility for advising the federal government. The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achievements of engineers. Dr. C. D. Mote, Jr., is president of the National Academy of Engineering. The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the services of eminent members of appropriate professions in the examination of policy matters pertaining to the health of the public. The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an adviser to the federal government and, on its own initiative, to identify issues of medical care, research, and education. Dr. Harvey V. Fineberg is president of the Institute of Medicine. The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy’s purposes of furthering knowledge and advising the federal government. Functioning in accordance with general policies determined by the Academy, the Council has become the principal operating agency of both the National Academy of Sciences and the National Academy of Engineering in providing services to the government, the public, and the scientific and engineering communities. The Council is administered jointly by both Academies and the Institute of Medicine. Dr. Ralph J. Cicerone and Dr. C. D. Mote, Jr., are chair and vice chair, respectively, of the National Research Council. The Transportation Research Board is one of six major divisions of the National Research Council. The mission of the Transporta- tion Research Board is to provide 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 activities 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 individu- als interested in the development of transportation. www.TRB.org www.national-academies.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 04-37 by the Department of Civil and Coastal Engineering at the University of Florida (UF). Dr. Ronald A. Cook, P.E., Professor of Civil Engineering at UF, was the Project Director and Principal Investigator. The other authors of this report were Dr. Elliot P. Douglas, Associate Professor of Materials Science and Engineering at UF; Todd M. Davis, P.E., Research Assistant in Civil Engineering at UF; and Changhua Liu, Research Assistant in Materials Science and Engineering at UF. The work was done under the general supervision of Professors Cook and Douglas at UF. Dr. Rolf Eligehausen, Dr. Jan Hofmann, and Ronald Blochwitz of the IWB laboratory at the University of Stuttgart in Stuttgart, Germany, were subcontracted for a portion of the experimental phase of the project. The researchers are grateful to the Florida Department of Transportation State Materials Office for pro- viding the use of their laboratories for concrete batching and dynamic shear rheometer (DSR) machine. CRP STAFF FOR NCHRP REPORT 757 Christopher W. Jenks, Director, Cooperative Research Programs Crawford F. Jencks, Deputy Director, Cooperative Research Programs Edward T. Harrigan, Senior Program Officer Anthony Avery, Senior Program Assistant Eileen P. Delaney, Director of Publications Scott E. Hitchcock, Editor NCHRP PROJECT 04-37 PANEL Field of Materials and Construction—Area of General Materials Christopher Hahin, Illinois DOT, Springfield, IL (Chair) Mark A. Gaines, Washington State DOT, Olympia, WA Craig J. Beissel, AECOM, Mechanicsburg, PA Mark J. Bloschock, Gibraltar Cable Barrier Systems, Marble Falls, TX Peter O. Jansson, Michigan DOT, Lansing, MI Justin M. Ocel, Federal Highway Administration, McLean, VA Madhwesh Raghavendrachar, California DOT, Sacramento, CA Michael M. Sprinkel, Virginia DOT, Charlottesville, VA Joey Hartmann, FHWA Liaison Stephen F. Maher, TRB Liaison

F O R E W O R D By Edward T. Harrigan Staff Officer Transportation Research Board This report presents proposed revisions to AASHTO materials, design, and construc- tion specifications; design and quality assurance guidelines; and test methods for adhesive anchors in concrete. Thus, the report will be of immediate interest to materials, design, and construction engineers in state DOTs and the highway industry with responsibility for selection and use of adhesive anchors in concrete highway structures. Adhesive anchor systems have widespread use throughout the world. They are used to anchor both threaded rods and reinforcing bars into hardened concrete. Common transpor- tation structure applications for adhesive anchor systems include bridge widening, structure- mounted signs and appurtenances, luminaires and light poles, concrete repair and rehabilita- tion, barrier retrofitting, utility installation on existing structures, and tunneling finishing. The objective of NCHRP Project 4-37, “Long-Term Performance of Epoxy Adhesive Anchor Systems,” was to develop proposed standard test methods, materials specifications, design specifications and guidelines, construction specifications and guidelines, and quality assur- ance guidelines for the use of adhesive anchor systems in transportation structure applica- tions. Development of these standards was founded on the results of a comprehensive pro- gram of laboratory experiments to determine, predict, and verify the long-term performance of adhesive anchors under sustained load in their typical service applications and environ- ments. The research was conducted by the University of Florida (Gainesville, Florida) with the participation of the University of Stuttgart (Stuttgart, Germany). The research investigated the effects of various parameters on the long-term bond strength of adhesive anchors in hardened concrete. Testing was conducted on three adhe- sives of different chemistries that had passed current product evaluation criteria requiring sustained load testing at 110°F. A stress versus time-to-failure approach was used to evaluate the effects of various parameters on the sustained load performance of adhesive anchors. Within the range of parameters studied, only elevated service temperature (>120°F) and manufacturer’s minimum cure time were shown to influence the sustained load perfor- mance beyond that predicted by short-term tests of fully cured adhesive. Rheological analysis of the adhesives alone was conducted to investigate any correla- tion with anchor testing in concrete, but no consistent relationships were discovered that applied to all three adhesives investigated. Additionally the effect of early-age concrete on the bond strength of adhesive anchors was investigated. This report fully documents the research and includes the following 13 appendixes: APPENDIX A: ACI 355.4 Tables 3.1, 3.2, 3.3, 10.5, and 10.6 APPENDIX B: ACI–AASHTO Resistance Factor Investigation

APPENDIX C: Anchor Pullout Tests—University of Florida APPENDIX D: Anchor Pullout Tests—University of Stuttgart APPENDIX E: Adhesive-Alone Tests—University of Florida APPENDIX F: Early-Age Concrete Evaluation—University of Stuttgart APPENDIX N: AASHTO Standards and Specifications Flowchart APPENDIX O: AASHTO Test Method APPENDIX P: AASHTO Material Specification APPENDIX Q: AASHTO Design Specification APPENDIX R: AASHTO Design Guideline APPENDIX S: AASHTO Quality Assurance Guideline APPENDIX T: AASHTO Construction Specification In addition, seven appendixes are available to download from the NCHRP Project 04-37 web page at http://apps.trb.org/cmsfeed/TRBNetProjectDisplay.asp?ProjectID=2495: APPENDIX G: Concrete Mix Designs APPENDIX H: Adhesive Anchor Post-Test Split-Core Investigations APPENDIX I: Short-Term Test Results APPENDIX J: Time to Rupture versus Time to Tertiary Creep Comparison APPENDIX K: Sustained Load Creep Test Results APPENDIX L: Stress versus Time-to-Failure Plots APPENDIX M: Early-Age Concrete Investigation Short-Term Test Results

C O N T E N T S 1 Summary 3 Chapter 1 Background 3 Introduction 3 Background on Behavior/Design of Anchors 6 Parameters Influencing Bond Strength 10 Test Methods and Material Specifications Related to Adhesive Anchor Systems 31 Design Guidelines and Specifications Related to Adhesive Anchor Systems 40 Quality Assurance Guidelines and Construction Specifications Related to Adhesive Anchor Systems 44 Summary 45 Chapter 2 Research Approach 45 Research Plan 46 Parameters Identified for Testing 50 Testing Program 52 Anchor Pullout Tests—University of Florida 53 Anchor Pullout Tests—University of Stuttgart 54 Adhesive-Alone Tests—University of Florida 54 Early-Age Concrete Evaluation—University of Stuttgart 54 Short-Term Anchor Pullout Data Reduction 57 Sustained Load Anchor Pullout Data Reduction 58 Assessment of a Parameter’s Impact on Sustained Load Performance 58 Suggested Improvements 58 Summary 59 Chapter 3 Findings and Applications 59 Short-Term Anchor Pullout Load Testing 66 Sustained Load Anchor Pullout Testing 70 Anchor Pullout Testing Stress versus Time-To-Failure Test Results 83 Adhesive-Alone Testing 96 Adhesive-Alone Testing to Anchor Pullout Testing Correlation 99 Influence on Sustained Load 103 Early-Age Concrete Evaluation 105 Summary 108 Chapter 4 Proposed AASHTO Specifications 108 Material and Testing 111 Design 112 Construction and Quality Assurance 113 Summary

114 Chapter 5 Conclusions and Suggested Research 114 Conclusions 115 Suggestions 115 Suggested Research 116 References 119 Abbreviations A-1 Appendix A ACI 355.4 Tables 3.1, 3.2, 3.3, 10.5, and 10.6 B-1 Appendix B ACI—AASHTO Resistance Factor Investigation C-1 Appendix C Anchor Pullout Tests—University of Florida D-1 Appendix D Anchor Pullout Tests—University of Stuttgart E-1 Appendix E Adhesive-Alone Tests—University of Florida F-1 Appendix F Early-Age Concrete Evaluation—University of Stuttgart G-1 Appendixes G–M N-1 Appendix N AASHTO Standards and Specifications Flowchart O-1 Appendix O AASHTO Test Method P-1 Appendix P AASHTO Material Specification Q-1 Appendix Q AASHTO Design Specification R-1 Appendix R AASHTO Design Guideline S-1 Appendix S AASHTO Quality Assurance Guideline T-1 Appendix T AASHTO Construction Specification Note: Many of the photographs, figures, and tables in this report 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.

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TRB’s National Cooperative Highway Research Program (NCHRP) Report 757: Long-Term Performance of Epoxy Adhesive Anchor Systems describes standard test methods and specifications, design guidelines and specifications, and quality assurance guidelines and construction specifications for the use of adhesive anchor systems in transportation structures.

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