Guidelines for Concrete Mixtures Containing Supplementary Cementitious Materials to Enhance Durability of Bridge Decks (2007)

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TRANSPORTAT ION RESEARCH BOARD WASHINGTON, D.C. 2007 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 566 Subject Areas Bridges, Other Structures, and Hydraulics and Hydrology • Materials and Construction Guidelines for Concrete Mixtures Containing Supplementary Cementitious Materials to Enhance Durability of Bridge Decks John S. Lawler James D. Connolly Paul D. Krauss Sharon L. Tracy WISS, JANNEY, ELSTNER ASSOCIATES, INC. Northbrook, IL Bruce E. Ankenman NORTHWESTERN UNIVERSITY Evanston, 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. 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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. 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CRP STAFF FOR NCHRP REPORT 566 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 Natalie Barnes, Editor NCHRP PROJECT 18-08A PANEL Field of Materials and Construction—Area of Concrete Materials Donald A. Streeter, New York State DOT, Albany, NY (Chair) Nicholas J. Carino, National Institute for Standards and Technology, Gaithersburg, MD Doran L. Glauz, California DOT, Sacramento, CA Aly A. Hussein, South Carolina DOT, Columbia, SC Colin L. Lobo, National Ready Mixed Concrete Association, Silver Spring, MD H. Celik Ozyildirim, Virginia DOT, Charlottesville, VA Kevin R. Pruski, Texas DOT, Austin, TX Scott Schlorholtz, Iowa State University, Ames, IA John B. Wojakowski, Hycrete Technologies, Topeka, KS (formerly Kansas DOT) Paul Virmani, FHWA Liaison Victoria Peters, FHWA Liaison Frederick Hejl, TRB Liaison AUTHOR ACKNOWLEDGMENTS These guidelines were developed under NCHRP Project 18-08A by Wiss, Janney, Elstner Associates, Inc. (WJE), which was the contractor for this study. John S. Lawler, Associate III, assumed the role of principal investigator for this project at approximately the halfway point after the initial principal investigator, Sharon L. Tracy, joined United States Gypsum Corp. Bruce E. Ankenman, Associate Professor of Industrial Engineering and Management Sciences at Northwestern University, contributed his expertise in statistical experimental design and is a coauthor of this report. The other contributing authors from WJE are James D. Connolly and Paul D. Krauss. The hard work of Todd Nelson, Leo Zegler, Ryan Keesbury, John Drakeford, Matt Kern, Joe Zacharowski, and the rest of the staff of WJE is also gratefully acknowledged. 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 guidelines to facilitate highway agencies’ use of supplementary cementitious materials to enhance durability of concrete used in highway construction, especially bridge decks. Encompassed in these guidelines is a methodology for selecting optimum concrete mixture proportions. The methodology focuses on durability aspects of concrete and the performance requirements for specific environmental conditions and is presented in a text format and as a computational tool, in the form of a Visual Basic–driven Microsoft® Excel spreadsheet. Background information, a user’s guide, and a hypothetical case study are also available. These guidelines should be of interest to state engineers and others involved in the design and construction of concrete bridge decks and other structures incorporating supplementary cementitious materials. The use of supplementary cementitious materials, such as fly ash, silica fume, slag, and natural pozzolans, in concrete construction has become a widely used practice that is accepted by many state highway agencies, primarily because of the favorable effects on dura- bility. A great deal of research has been performed on properties of concrete containing one or more supplementary cementitious materials; however, research has not provided clear conclusions on the optimum use of these materials to reduce permeability and cracking and thus enhance durability and long-term performance. Without such information, selection of optimum types and proportions of supplementary cementitious materials cannot be ensured, which can lead to the use of materials and mixtures that result in undesirable performance and often the need for premature and costly maintenance or repair. Thus, research was needed to develop an appropriate methodology for designing concrete mix- tures containing supplementary cementitious materials for use in bridge deck construction. Under NCHRP Project 18-8A, “Supplementary Cementitious Materials to Enhance Durability of Concrete Bridge Decks,” Wiss, Janney, Elstner Associates, Inc., of North- brook, Illinois, worked with the objective of developing a methodology for designing hydraulic cement concrete mixtures incorporating supplementary cementitious materials that will result in enhanced durability of cast-in-place concrete bridge decks. This research considered the use of fly ash, silica fume, slag, and natural pozzolans both singularly and in combination. To accomplish this objective, the researchers developed a statistically based experimen- tal methodology that can be used to identify the optimum concrete mixture proportions for a specific set of conditions. The methodology incorporates the following six steps: 1. Defining concrete performance requirements 2. Selecting durable raw materials F O R E W O R D By Amir N. Hanna Staff Officer Transportation Research Board

3. Generating an experiment design matrix 4. Performing a test program 5. Analyzing test results and predicting optimum mixture performance 6. Conducting confirmation testing and selecting best performing concrete mixture To facilitate use, the researchers presented the methodology as a computational tool, dubbed SEDOC (Statistical Experimental Design for Optimization of Concrete), in the form of a Visual Basic–driven Microsoft® Excel spreadsheet; prepared a user’s guide; and illustrated use of the methodology in a hypothetical case study. The researchers also pro- vided background information on the work performed in this project in a supplementary report. The guidelines presented herein provide a systematic approach for conducting an exper- imental study to select the optimum combination of available materials and is targeted for use in the development phase of a concrete construction project where durability is the main consideration; it is recommended for consideration and adoption by AASHTO. The research agency’s report containing background information on the methodology developed in this project and the hypothetical case study are not published herein. These documents are available on the TRB website as NCHRP Web-Only Document 110 (http:// www.trb.org/news/blurb_detail.asp?id=7715). Also, SEDOC, the computational tool for the concrete mixture optimization methodology, and the user’s guide are available on the TRB website (http://www.trb.org/news/blurb_detail.asp?id=7714).

C O N T E N T S 1 Introduction to Methodology 1 Background 1 Problem Statement and Scope of Research 2 Products of Research 2 Relationship of the Methodology to the Implementation of Concrete Mixtures Designed for Durability 3 Introduction to Supplementary Cementitious Materials 3 Statistical Design of Experiments 3 Terminology 5 Methods of Designing Experiments 5 Desirability Functions and Combining Test Results 6 Analyzing the Orthogonal Design Experiment 7 Application of Methodology 7 The Process 7 User Aids 9 Step 1 Define Concrete Performance Requirements 9 Introduction 9 Performance Definition Process 10 Example from Hypothetical Case Study 11 Guidance on Concrete Design Requirements and Appropriate Test Methods 11 Universal Performance Requirements 16 Freezing and Thawing Climates [F1] 21 Corrosion Concerns for Concrete [CL1] 24 Abrasive Environments [AB1] 25 Alkali-Silica Reactivity Potential [ASR1] 25 Cracking Resistance [CR1] 32 Worksheet for Step 1 33 Figures for Step 1 42 Tables for Step 1 45 Step 2 Select Durable Raw Materials 45 Introduction 45 Raw Materials Selection Process 46 Guidance on Raw Materials Selection 46 Cement [C] 48 Supplementary Cementitious Materials 51 Aggregates [A1] 55 Air Entraining Admixtures [AEA] 55 Chemical Admixtures [CH] 56 Example from Hypothetical Case Study

57 Worksheets for Step 2 67 Figures for Step 2 68 Tables for Step 2 76 Step 3 Generate the Experimental Design Matrix 76 Introduction 77 Generation of the Experimental Matrix 79 Considerations in Selecting the Number of Mixtures 80 Selection of the Design Matrix 80 Experimental Details 80 Mixture Proportioning and SCM Level Definition 81 Control Mixtures 81 Repeat Testing 81 Example from Hypothetical Case Study 83 Worksheets for Step 3 84 Tables for Step 3 88 Selected Orthogonal Design Matrices 96 Step 4 Perform Testing 96 Introduction 96 Test Program Considerations 96 Example from Hypothetical Case Study 97 Step 5 Analyze Test Results and Predict the Optimum Mixture Proportions 97 Introduction 97 Analysis Process 98 Data Plots and Verification 98 Desirability Functions and Individual Desirabilities 99 Overall Desirability 99 Best Tested Concrete 99 Best Predicted Concrete 101 Repeatability and Scaled Factor Effects 102 Statistical Experimental Design for Optimizing Concrete Computational Tool 102 Example from Hypothetical Case Study 104 Figures for Step 5 108 Tables for Step 5 111 Step 6 Perform Confirmation Testing and Select Best Concrete 111 Introduction 111 Confirmation Testing 111 Mixtures and Tests 112 Data Analysis: Model Checking 112 Final Selection of the BC 112 Example from Hypothetical Case Study 114 Tables for Step 6 116 Glossary of Statistical Experimental Design–Related Terms 118 References