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TRANSPORTAT ION RESEARCH BOARD WASHINGTON, D.C. 2008 www.TRB.org 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 607 Subject Areas Materials and Construction Specifications and Protocols for Acceptance Tests on Processing Additions in Cement Manufacturing Peter C. Taylor CONSTRUCTION TECHNOLOGY LABORATORIES, INC. Skokie, IL 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 Boardâs 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 607 Project 18-11 ISSN 0077-5614 ISBN 978-0-309-09934-9 Library of Congress Control Number 2008926693 © 2008 Transportation Research Board COPYRIGHT PERMISSION 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. Such approval reflects the Governing Boardâs judgment that the program concerned is of national importance and appropriate with respect to both the purposes and resources of the National Research Council. The members of the technical committee selected to monitor this project and to review this report were chosen for recognized scholarly competence and with due consideration for the balance of disciplines appropriate to the project. The opinions and conclusions expressed or implied are those of the research agency that performed the research, and, while they have been accepted as appropriate by the technical committee, they are not necessarily those of the Transportation Research Board, the National Research Council, the American Association of State Highway and Transportation Officials, or the Federal Highway Administration, U.S. Department of Transportation. Each report is reviewed and accepted for publication by the technical committee according to procedures established and monitored by the Transportation Research Board Executive Committee and the Governing Board of the National Research Council. The Transportation Research Board of the National Academies, the National Research Council, the Federal Highway Administration, the American Association of State Highway and Transportation Officials, and the individual states participating in the National Cooperative Highway Research Program do not endorse products or manufacturers. Trade or manufacturersâ names appear herein solely because they are considered essential to the object of this report.
CRP STAFF FOR NCHRP REPORT 607 Christopher W. Jenks, Director, Cooperative Research Programs Crawford F. Jencks, Deputy Director, Cooperative Research Programs Amir N. Hanna, Senior Program Officer Eileen P. Delaney, Director of Publications Hilary Freer, Senior Editor NCHRP PROJECT 18-11 PANEL Field of Materials and ConstructionâArea of Concrete Materials Daniel P. Johnston, South Dakota DOT, Pierre, SD (Chair) Mark E. Felag, Rhode Island DOT, Providence, RI Michael J. Bergin, Florida DOT, Gainesville, FL J. Bruce Blair, Lafarge North America, Inc., Herndon, VA Al Innis, Holcim (US) Inc., Dundee, MI D. Stephen Lane, Virginia DOT, Charlottesville, VA Elizabeth J. âLisaâ Lukefahr, Texas DOT, Austin, TX Scott Schlorholtz, Iowa State University Suneel Vanikar, FHWA Liaison Frederick Hejl, TRB Liaison AUTHOR ACKNOWLEDGMENTS The research reported herein was performed under NCHRP Project 18-11 by Construction Technol- ogy Laboratories, Inc. (CTL). Dr. Peter Taylor, Principal Engineer, was the principal investigator. The work was done under the general supervision of Dr. Taylor. Sample preparation and testing were con- ducted by the staff of CTL Group. Assistance with the literature review was provided by Prof. M.D.A. Thomas. Assistance with the statistical analyses was provided by Dr. Susanne Aref. 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
This report presents recommended changes to the cement specifications and test pro- tocols contained in AASHTO Standard Specifications for Transportation Materials and Methods of Sampling and Testing (AASHTO M 85). These changes pertain to the amount of processing additions that can be incorporated in the cement and the tests required for evaluating acceptability of cements incorporating processing additions. The report also pre- sents a recommended specification for evaluating processing additions that may be used in amounts exceeding those stipulated in the cement specification. These specifications will guide materials engineers and cement producers in evaluating cements and assuring that highway concrete is not deleteriously affected by the presence of such additions. The infor- mation contained in the report will be of immediate interest to state materials engineers and others involved in specifying and evaluating concrete mixtures for use in highway pave- ments and structures. Processing additions, such as granulated blast furnace slag, limestone, and fly ash, are interground with clinker in the manufacture of some portland cements to improve the effi- ciency of the manufacturing process. These additions also may improve product quality, reduce carbon dioxide emissions and energy requirements during the cement manufactur- ing process, and provide other economic and environmental benefits. However, there has been considerable debate recently about the effects of such additions on cement and con- crete properties and on the performance and durability of the highway pavements and structures in which these materials are used. In addition, current cement specifications do not address, in a consistent manner, the use of such additions in cement manufacturing. Also, limited research has dealt with the effects of incorporating processing additions in cement manufacturing on concrete properties and durability, and there are no clear con- clusions concerning the effects of using such additions on the performance and durability of highway pavements and structures. Thus, research was needed to assess these effects, to develop recommendations to help improve cement specifications and test protocols with regard to the use of such processing additions, and to develop guidance on the use of these cements in highway concrete. Under NCHRP Project 18-11, âImproved Specifications and Protocols for Acceptance Tests on Processing Additions in Cement Manufacturing,â Construction Technology Lab- oratories, Inc., of Skokie, Illinois, worked with the objective of recommending potential improvements to specifications and test protocols to determine the acceptability of cements with processing additions. To accomplish this objective, the researchers reviewed the spec- ifications and test methods currently used for evaluating portland cement and investigated their suitability for evaluating cements incorporating processing additions. The investiga- F O R E W O R D By Amir N. Hanna Staff Officer Transportation Research Board
tion included an extensive laboratory testing program that covered the types and ranges of processing additions currently used or expected to be used in the future in the United States; considered the chemical, physical, and mineralogical characteristics of cement; and evalu- ated the properties of a large number of paste, mortar, and concrete specimens incorporat- ing different types and amounts of processing additions. The research recommended a Standard Specification for Mineral Processing Additions for Use in the Manufacturing of Hydraulic Cements (included as Attachment 1), to evaluate acceptability of processing additions when used in amounts exceeding those stipulated in the modified AASHTO M 85. Based on analysis of test results, the research recommended changes to AASHTO M 85, Standard Specification for Portland Cement (included as Attachment 2), that provides guidance on the testing and acceptance of portland cement incorporating maximum amounts of processing addition. The recommended modification to AASHTO M 85 and the recommended specification for mineral processing additions will be particularly useful to highway agencies because their use will assure that highway concrete is not deleteriously affected by the presence of such additions. Their adoption as part of the AASHTO Standard Specifications for Trans- portation Materials and Methods of Sampling and Testing is, therefore, recommended. Appendixes A through F contained in the research agencyâs final report provide detailed information on material characterization, experiment design, and data analysis. These appen- dixes are not published herein; but are available online at http://trb.org/news/blurb_detail. asp?id=8989. These appendixes are titled as follows: Appendix A: Fly Ash and Slag Characterization; Appendix B: Statistical Design and Material Combinations for Mortar Tests; Appendix C: Microscopical Examination of Coarse Fractions of Cements without SCMâs Appendix D: Conduction Calorimetry Plots; Appendix E: Analysis of Paste and Mortar Tests; and Appendix F: Analysis of Concrete Data
C O N T E N T S 1 Chapter 1 Introduction 3 Chapter 2 Review of Literature and Survey 3 Summary of Literature 3 Terminology 3 Background 4 Usage and Specifications 4 Specifications 5 Bogue Calculation 6 Verification of Processing Addition Dosage 6 Effects on Cement Characteristics 6 Dilution of the Cement 6 Particle Size Distribution, Grinding/Activation 7 Filler Effect 7 Pozzolanic Reaction 7 Latent Hydraulic Reactions 7 Effects on Fresh Concrete Properties 7 Change in Water Requirement 8 Slump Loss 8 Air Entrainment 8 Heat Generation 9 Setting Time 9 Effects on Hardened Concrete 9 Strength Development 9 Shrinkage 9 Alkali Silica Reactivity 9 Permeability 10 Chloride Penetration 10 Freeze-Thaw and Salt Scaling 10 Other Parameters 10 Interactions 10 Interaction with Alkalis 11 Interactions with Other Chemicals in Cement 11 Effect of Supplementary Cementing Materials 11 Effect of Chemical Admixtures 11 Survey of Processing Additions Use 11 Interviews with Cement Producers 12 Interviews with Users 14 Chapter 3 Experimental Work 14 Research Approach 16 Materials
16 Clinkers 16 Processing Additions 16 Sulfate System 17 Supplementary Cementing Materials 17 Aggregates 17 Materials Combinations 18 Processing Additions Dosage 19 Statistical Design of Processing Additions Combinations 19 Selection of Cements for Concrete Tests 20 Preparation of Materials Combinations 21 Tests Conducted 21 Materials Combinations Characterizations 22 Tests on Cement Pastes 22 Tests on Mortars 22 Tests on Concretes 29 Verification Tests 29 Materials 29 Tests 35 Results 37 Chapter 4 Discussion of Results 37 Materials Combination Characterization 37 Materials Analyses 37 Optimum Sulfate Content 38 Particle Size Distribution 39 Microscopy 40 Calorimetry 40 Paste and Mortar Tests 47 Effects of Limestone 48 Summary 48 Concrete Tests 53 Repeat Tests 54 Effects of Limestone 54 Effects of Concrete Mix Design 54 Summary 54 The Selection of Tests to be Used in the Protocol 55 Verification Tests 55 Evaluation of Recommendations Vis à Vis Concrete Proportioned with Supplementary Cementitious Materials 57 Chapter 5 Recommended Improvements to Specifications 60 Chapter 6 Conclusions and Recommended Research 60 Applicability to Highway Practice 60 Conclusions 61 Future Work and Recommended Research 62 References 65 Attachments 67 Proposed Standard Specification for Mineral Processing Additions for Use in the Manufacture of Hydraulic Cements 75 Proposed Standard Specification for Portland Cement
