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Materials and Structures ISSN 1359-5997 Mater StructDOI 10.1617/s11527-014-0414-4
Bond of tension bars in underwaterconcrete: effect of bar diameter and cover
Camille A. Issa & Joseph J. Assaad
1 23
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ORIGINAL ARTICLE
Bond of tension bars in underwater concrete: effect of bardiameter and cover
Camille A. Issa • Joseph J. Assaad
Received: 14 October 2013 / Accepted: 28 August 2014
� RILEM 2014
Abstract This research project is undertaken to
assess the effect of washout loss on the drop in bond
properties of reinforcing steel bars embedded in
underwater concrete (UWC). Special emphasis was
placed to evaluate bond using the same concrete
mixtures that were subjected to washout. Testing was
realized using the beam-end specimen method, and
parameters evaluated included level of washout loss,
bar diameter, and concrete cover. Test results showed
that bond between steel and UWC is affected by the
level of washout loss, which in turn is directly
influenced by the mixture composition. Similarly to
bond in concrete cast and consolidated above water,
the ultimate UWC bond strength increases for smaller
bar diameters and higher confinement reflected by
increased concrete covers. UWC mixtures with
increased washout losses exhibited higher drops in
compressive, tensile, and bond strengths, as compared
to concrete cast above water. Two boxes depending on
the level of washout loss, i.e. from 4.2 to 6.9 % and
from 8.8 to 10.8 %, have been proposed to predict the
extent of bond decrease in UWC mixtures.
Keywords Underwater concrete �Washout loss �Bond properties � Concrete cover � Bar diameter
1 Introduction
Bond of steel reinforcement to concrete cast and
consolidated above water has been studied extensively
over the last decades and large amount of experimental
and analytical data are published in literature [1–3].
For deformed bars, ACI 408 committee reported that
force transfer from the reinforcement to surrounding
concrete occurs by chemical adhesion between both
materials, frictional forces arising from the roughness
of interface, and mechanical bearing of the steel ribs
against the concrete surface [1]. Numerous parameters
were found to affect the bond behavior including bar
properties (i.e., yielding strength, cover, size, position
in the cast element, geometry, relative rib area, epoxy
coating, and others) and concrete properties (i.e.,
tensile strength (ft), compressive strength (f’c), den-
sity, presence of mineral admixtures, workability,
method of consolidation, and others). The develop-
ment (or embedment) length required to ensure
adequate transfer of stresses can be calculated using
equations specified in various Building Codes [4–6].
For instance, Eq. 12.1 in ACI 318 Building Code
reports that the development length for tension bars is
inversely proportional to the square root of f’c,
multiplied by additional factors to account for special
C. A. Issa
Civil Engineering Department, Lebanese American
University (LAU), P.O. Box 36, Byblos, Lebanon
J. J. Assaad (&)
Holderchem Building Chemicals,
P.O. Box 40206, Baabda, Lebanon
e-mail: [email protected]; [email protected]
Materials and Structures
DOI 10.1617/s11527-014-0414-4
Author's personal copy
design considerations [4]. For example, for bars coated
with epoxy, ACI 318 recommends multiplying the
development length by a factor of 1.5 for bars with a
cover less than 3 db or clear spacing between bars less
than 6 db (where db is the bar diameter), and a factor of
1.2 for other cases [4]. In the AASHTO bridge
specification, these factors are 1.5 and 1.15, respec-
tively [5].
The current knowledge for bond behavior and use
of existing equations and factors to evaluate develop-
ment and splice lengths become unwarranted when
casting takes place underwater. In fact, the in situ ft
and f’c for underwater concrete (UWC) is highly
dependent on the mixture proportions and casting
conditions, thus making difficult a realistic estimation
of the contribution of concrete strength to the bond
against steel bars. Typical residual f’c values reported
in literature varied from 80 to 90 % for UWC cast
using the tremie/hydrovalve technique [7], 50–70 %
for self-consolidated UWC depending on turbulence
of water and location of extracted cores for strength
testing [8], and as low as 40 % for concrete having a
slump of 230 mm made without anti-washout admix-
ture (AWA) [9]. The drop in UWC strength can be
attributed to a combination of factors such as washout
loss of cementitious particles together with alteration
in concrete homogeneity due to aggregate segregation.
Additionally, water infiltration within the freshly cast
concrete during placement increases the specified
water-to-cement ratio (w/c), thus reducing ft and f’c.
Several testing methods are available in literature to
evaluate washout loss of UWC. For example, Sakata
proposed measuring the turbidity of water using
standard light transmittance apparatus following the
drop of 0.5-kg of fresh concrete into a vessel
containing around 5 l of water [10]. By calibration
using known dispersions of cement in water, the
amount of washout occurring as a result of concrete
falling through water can be determined. Another test
developed by Hughes [7] consisted on evaluating the
segregation susceptibility of coarse aggregate of fresh
concrete when placed under water. This later test
describes the scattering of concrete after having
dropped over a cone from two hoppers, once in air
and another time through water. The US Army Corps
of Engineers proposed using a more practical proce-
dure (CRD C61 test method) for assessing washout
loss of UWC [11]. This test consists on placing
approximately 2 kg of fresh concrete in a wire-mesh
basket and allowing it to free fall vertically in a 2-m
high column of water. The sample is then hauled
slowly to the surface at a constant speed of 0.5 m/s and
weighed to determine washout loss. Staynes and
Corbett reported that CRD C61 test results relate well
to practical underwater casting conditions that corre-
spond to the free fall of concrete from a pump delivery
hose through 1–2 meters of water [12].
2 Context and objectives of this project
Limited studies were undertaken to assess the effect of
washout loss and aggregate segregation on the drop in
UWC bond strength. Also, no design provisions or
correction factors have been proposed to enable
adequate estimation of development length for bars
in tension during underwater works. The lack of
research is primarily due to the difficulty of obtaining a
representative concrete sample capable of reflecting
actual UWC properties that result during underwater
casting. For instance, the common approach to eval-
uate f’c of UWC consists on dropping fresh concrete
into molds placed in water tanks. However, this
approach presents the inconvenience of not reflecting
actual conditions or accurately estimating the degree
of washout loss that the fresh UWC sample has
undergone during the dropping process in water [13,
14]. On the other hand, it is not accurate to correlate
washout loss to compressive or bond strength deter-
mined from cores extracted from existing underwater
structures, given the direct effect of the casting method
on washout loss [8, 15].
Recently, Assaad and Issa adopted a new approach
to assess the effect of washout loss and aggregate
segregation on the drop in UWC bond properties [16].
The approach consisted of subjecting a series of UWC
samples taken from the same batch to washout loss as
per the CRD C61 test method, and then after securing
enough materials, the samples are vigorously mixed
together in a clean container for subsequent use in
bond testing. For simplicity reasons, the direct pullout
bond test was used as it required the least amount of
UWC materials (around 5-kg of washed samples were
enough to fill the specimen measuring 150-mm in
diameter and 120-mm in height). Steel bars having
12-mm diameter whether coated or not with epoxy
were tested. The authors reported that bond strength is
directly dependent on the level of washout loss which,
Materials and Structures
Author's personal copy
in its turn, is affected by the mixture composition and
casting conditions [16]. For example, the residual
bond strength dropped from 90 to 65 % for mixtures
possessing CRD C61 washout loss values ranging
from 7.5 to 15 %, respectively, and aggregate segre-
gation varying from 70 to 95 kg/m3, respectively. The
hydrostatic water pressure at the casting location and
interfacial concrete/water velocity are crucial param-
eters that can magnify the drop in UWC strength [17].
Although the previous studies enabled good under-
standing of UWC bond properties, it is important to
note that the tests done using the direct pullout method
cannot be conclusive mainly because of the dissimi-
larity between the pullout test conditions and actual
loading situations encountered in service, especially in
flexural members [1, 18]. In fact, as the bar is loaded in
tension during a direct bond test, the concrete is
restrained in compression against the loading frame.
This is quite unrealistic compared to real engineering
situations which makes difficult the extrapolation of
such data to real-life design. Therefore, the main
objective of this paper is to evaluate bond properties
between UWC and steel bars using tests realized as per
the general guidelines of ASTM A944 for beam-end
specimen [19]. Unlike the direct pullout test, the
beam-end specimen is capable of duplicating the stress
state occurring in structural members where both
concrete and steel are placed in tension. Washout loss
of UWC was measured using an adapted version of the
CRD C61 test capable of securing greater amounts of
materials for testing. A total of 30 mixtures sampled in
dry or washed conditions were tested to quantify the
effect of washout on the drop in UWC bond properties
for different bar diameters and concrete covers.
Regression models enabling the prediction of bond
strength are established with respect to the level of
washout loss, bar diameter, concrete cover, f’c, and ft
values.
3 Experimental program
3.1 Materials
Portland cement conforming to ASTM C150 Type I
was used in this study. Its Blaine surface area and
specific gravity were 345 m2/kg and 3.14, respec-
tively. A polycarboxylate-based high-range water-
reducing (HRWR) admixture and liquid cellulosic-
based AWA with specific gravities of 1.1 and 1.12,
respectively, and solid contents of 40 and 30 %,
respectively, were employed. The gradations of
crushed limestone aggregate having nominal maxi-
mum particle size of 20 mm and siliceous sand were
within ASTM C33 specifications [20]. The coarse
aggregate and sand had fineness moduli of 6.4 and 2.5,
respectively, and bulk specific gravities of 2.72 and
2.65, respectively.
Commercially available deformed bars complying
to ASTM A615 [21] specification, Grade 60, were
used to evaluate bond properties. Four types of bars
including No. 13, 16, 19, and 25 with nominal
diameter (db) of 12.7, 15.9, 19.1, and 25.4 mm,
respectively, were tested. Their bond indexes (or,
relative rib area ratio) were equal to 0.048, 0.069,
0.088, and 0.106, respectively. The bond index was
calculated as (de2–di2)/4 db S, where de is the external
bar diameter (top of rib), di is core diameter (bottom of
rib), and S is longitudinal spacing of the ribs [22]. The
bars had upper yield and tensile strengths equal to
420 ± 6 MPa and 625 ± 10 MPa, respectively, when
tested as per ASTM E8 [23].
3.2 Mixture proportioning
As summarized in Table 1, two series of UWC
mixtures proportioned to achieve different compres-
sive strengths in dry condition (f’c(dry)) of 32 ± 2 and
57 ± 3 MPa were tested; the corresponding cement
content increased from 350 to 425 kg/m3, respec-
tively, and w/c decreased from 0.56 to 0.47, respec-
tively. In each series, different combinations of
admixtures commonly used for proportioning flow-
able to highly flowable UWC for repair or new
construction were used. The AWA was added at
0.5 % of cement mass, while the HRWR was adjusted
to secure a slump of 220 mm or slump flow of
450 mm. Also, a UWC mixture having 220 mm
slump made without AWA was tested. Additional
discussion regarding the mixture composition and
optimization of washout loss of UWC can be seen in
other publications [17, 24]. The sand-to-total aggre-
gate ratio was fixed at 0.46 for all tested concrete. A
gluconate-based set-retarder was added at a dosage of
0.35 % of cement mass to minimize slump or slump
flow loss during testing. It is to be noted that the
mixture codification used throughout the paper refers
Materials and Structures
Author's personal copy
to cement content-w/c-Consistency (S22: slump of
220 mm; SF45: slump flow of 450 mm)-AWA.
3.3 Mixing and characterization of fresh
properties
All mixtures were prepared in an open-pan mixer of
100-Liters capacity. The mixing sequence consisted of
homogenizing the sand, aggregate, and around 50 %
of mixing water before introducing the cement. After
one minute of mixing, the other 40 % of water was
added, followed by the HRWR, and then the AWA
diluted in the remaining 10 % of water. The concrete
was mixed for two additional minutes.
Following the end of mixing, the workability, air
content, and washout mass loss were evaluated. The
slump, slump flow, and air content were determined as
per ASTM C143 [25], C1611 [26], and C231 [27],
respectively. Values of air content were found equal to
2.3 ± 0.4 % for all tested mixtures. Filling ability of
flowable UWC having 450 mm slump flow was
evaluated using the L-box test, and found to vary
from 38 to 55 % [17]. All characterization of fresh
properties was realized under laboratory conditions
where ambient temperature and relative humidity was
21 ± 3 �C and 60 ± 8 %, except for washout testing
as per the adapted CRD C61 test where outdoor
temperature varied from 14 to 20 �C.
3.4 Evaluation of washout mass loss
Washout of UWC was determined using two different
methods. The first was according to the standard CRD
C61 test which consists on placing a fresh concrete
sample in a wire-mesh basket and allowing it to free
fall vertically in a 1.7-m high column of water [11].
The sample was then slowly retrieved to the surface
and weighed to determine washout loss. Cumulative
washout loss after 3 drops in water is reported and
referred to as W3. Around 2-kg are normally used
when testing washout loss as per the CRD C61 test
method.
In order to secure enough washed materials for
subsequent filling in the beam-end specimen mold, an
adapted version of the CRD C61 test was developed.
The principle is quite similar to the standard test,
however, a larger wire-mesh basket (i.e., 300 mm in
diameter) was used to allow testing up to 8 kg of fresh
concrete. The circular perforations of the basket as
well as the distance between adjacent perforations
remained the same as in the original CRD C61 test
(i.e., 3 and 5 mm, respectively). The differences
between the standard and adapted CRD C61 test
methods are listed in Table 2. After 15 s at the bottom
of the test column, the basket was retrieved at constant
speed of 0.5 m/s, and weighed to determine washout
mass loss referred to as W. Washout tests were
conducted using a large water container measuring
2.2 m in height and 1.8 m in diameter (Fig. 1).
Different UWC mixtures were batched and tested
for washout to validate the procedure and select the
appropriate number of drops in water to be used in this
testing program. The mixtures possessed different
cohesiveness levels secured by adjusting the HRWR to
yield various consistency levels and/or adding various
AWA concentrations to modify mixture viscosity. As
can be seen in Fig. 2, W determined after 1 drop tends
to under-estimate W3, mostly due to increased con-
crete volume (8 kg vs. 2 kg) that reduces the extent of
relative washout upon contact with water. Conversely,
the increase in the number of drops to three led to
higher W values with considerable decrease in the
Table 1 Mixture composition of tested UWC
f’c(dry) = 32 ± 2 MPa f’c(dry) = 57 ± 3 MPa
Cement content = 350 kg/m3
and w/c = 0.56
Cement content = 425 kg/m3
and w/c = 0.47
Water, kg/m3 196 200
Fine aggregate, kg/m3 820 790
Coarse aggregate, kg/m3 970 930
Combination of admixtures used HRWR adjusted to yield slump of 220 mm
AWA = 0.5 % of c.m.; HRWR adjusted for 220 mm slump
AWA = 0.5 % of c.m.; HRWR adjusted for 450 mm slump flow
Materials and Structures
Author's personal copy
correlation coefficient (R2) to 0.73. Hence, W deter-
mined after two drops in water was selected through-
out this project when using the adapted CRD C61 test,
as almost similar washout values than the intrinsic W3
were obtained with acceptable R2 of 0.93.
Generally speaking, W and W3 determined using
the adapted or standard CRD C61 tests are similarly
affected by the mixture composition. For example,
lower values are obtained for UWC prepared with
combinations of higher cement content and lower w/c.
Also, the addition of AWA resulted in lower washout,
for given consistency level. This can be attributed to
the mode of function of such additives which binds
part of the mixing water, increases cohesiveness, and
leads to lower washout upon concrete contact with
surrounding water [24]. The increase in the level of
consistency (i.e., from slump of 220 mm to slump flow
of 450 mm) led to higher washout. Additional discus-
sion regarding the effect of mixture composition on
washout variations can be seen in other references [17,
24].
3.5 Determination of UWC bond properties
3.5.1 Securing materials for bond testing
As already noted, the bond stresses of UWC to
embedded steel were determined using the same
concrete samples that were subjected to washout.
The procedure used for securing enough materials is as
follows:
Two operators holding two wire-mesh baskets
containing approximately 8-kg of fresh concrete each
stood around the 1.8-m diameter water container
(Fig. 1). The baskets were dropped twice in water,
retrieved to determine W, and then moved to a clean
container which was covered by wet burlap. Subse-
quently, other fresh samples were taken from the same
concrete batch, subjected to similar washout loss
testing, and again stored in the same container. This
process was repeated a third time to obtain a total mass
Table 2 Differences between standard and adapted CRD C61
test methods
Standard
CRD
C61 test
Adapted CRD
C61 used for
testing larger
concrete
volumes
Height of water tube 1.7 m 2.2 m
Diameter of water tube 200 mm 1.8 m
Diameter of the basket 130 mm 300 mm
Nominal diameter of the
basket’s perforations
3 mm 3 mm
Distance between
adjacent perforations
5 mm 5 mm
Sample used for testing Around 2 kg Around 8 kg
Number of drops in water 3 drops 2 drops
Washout referred to as: W3 W
Fig. 1 Photo of the container used for measuring washout of
larger UWC volumes as per the adapted CRD C61 test
R² = 0.96
y = 0.92 xR² = 0.93
y = 1.14 xR² = 0.73
0
2
4
6
8
10
12
14
16
0 2 4 6 8 10 12 14
Was
ho
ut
loss
as
per
ad
apte
d C
RD
C
61 t
est
(W),
%
Intrinsic CRD C61 washout loss (W3), %
W after 1 drop
W after 2 drops
W after 3 drops
y = 0.801 x
Fig. 2 Relationships between intrinsic W3 and washout
determined using the adapted CRD C61 test
Materials and Structures
Author's personal copy
of around 45 kg (taking into consideration the material
lost due to washout), which was then rigorously mixed
for filling the beam-end specimen mold. The entire
time needed to complete the three cycles of washout
did not exceed 20 min, whereby slump and slump flow
loss thresholds were limited to less than 30 mm. It is to
be noted that the washout values obtained from both
operators between the first and last cycle of testing
were found to vary by ± 0.55 % for UWC mixtures
having a total washout loss ranging from 4 to 6 %.
Such variation was less than ± 0.9 % for mixtures
having total washout varying from 7 to 11 %.
3.5.2 Bond strength of UWC to steel bars
Given the difficulty to secure large volumes of washed
UWC materials, bond properties were determined
using adapted beam-end specimens following the
general guidelines of ASTM A944 [19]. The speci-
mens measured 220 mm in width, 250 mm in length,
and either 250 or 300 mm in height depending on
concrete cover. The front and side views of tested
specimen are shown in Fig. 3a, b, respectively. The
test bar enters the beam-end specimen at the loaded
end, extends into the specimen along a short un-
bonded length, extends further along a bonded length,
and has an additional un-bonded length before termi-
nating within a hollow steel conduit to provide access
to the free end for measuring slip. The bar ribs were
randomly oriented in the test set-up. The specimen is
positioned in a test rig so that the bar can be pulled
slowly from the concrete. When the bar is pulled
during testing, the specimen is restrained from trans-
lation through a compression reaction plate, and
restrained from rotation through a tie-down, thus
approximating boundary conditions of simply sup-
ported beams [1, 18].
All steel bars were properly cleaned with a wire
brush prior to use. They were embedded inside the
specimens at fixed lengths (Le) of 90 mm, resulting in
db/Le ratios equal to 0.141, 0.177, 0.212, and 0.282 for
No. 13, 16, 19, and 25 bars, respectively. It is to be
noted that the rib orientation parameter was not
considered in this study, as the bars were randomly
embedded inside the specimen. Two concrete covers
(Cc) of 60 and 100 mm were tested in this project,
resulting in various Cc/db varying from 2.4 to
relatively high ratios of 7.9 which may be particularly
specified for underwater applications. Tolerances for
bonded lengths, concrete covers, and overall specimen
dimensions were ± 2, 3, and 5 mm, respectively. Two
stirrups placed on each side were provided for shear
resistance, but were oriented parallel to the ‘‘pull’’
direction to avoid confining the test bar along its
bonded length. The closed stirrups were made of No.
10 plain bars (ASTM A615) with db of 9.5 mm.
The concrete samples were placed in two consec-
utive lifts in the beam-end specimen molds, and
Fig. 3 Front and side views of the adapted beam-end specimen test
Materials and Structures
Author's personal copy
internally vibrated using a 150-Hz frequency vibrator.
Care was taken in the insertion of the vibrator to avoid
as much as possible the formation of air bubbles
around the steel bars. Also, bond of reference mixtures
sampled in dry conditions (i.e. without immersion in
water) was determined. The UWC and reference
specimens were demolded after 24 h, covered with
plastic bags, and allowed to cure at 23 �C for 28 days.
Before testing, the specimen was shimmed and aligned
so that the test bar was parallel to the loading frame.
The tensile load was gradually applied at a rate of
25 ± 4 kN per minute until bond failure occurred. The
rebar’s relative slips to concrete were monitored from
measurements of two LVDTs placed at the loaded and
free bar surfaces.
3.6 Determination of f’c and ft of UWC mixtures
A procedure similar to the one described earlier was
adopted to secure materials used for determining the
residual compressive and tensile strengths of UWC.
However, only one cycle was enough to secure enough
washout concrete for filling some 100 9 200 mm
steel cylinders. Note that strength of reference mix-
tures sampled in dry conditions was also determined.
All UWC and reference mixtures were placed in two
lifts in the molds and consolidated by rodding, as per
ASTM C31 Standard Practice [28]. All samples
(whether sampled in dry or wet conditions) were
demolded after 24 h, cured in water under similar
conditions, and tested at 28 days for compressive and
tensile strengths as per ASTM C39 [29] and C496 [30]
Test Methods, respectively.
4 Test results and discussion
Table 3 summarizes the properties of reference con-
crete mixtures sampled in dry conditions including
tensile strength (ft(dry)), compressive strength (f’c(dry)),
ultimate bond strength (su(dry)) representing the max-
imum peak load, normalized bond stress which is the
ratio of su(dry) to the square root of f’c(dry), and mode of
failure (MF). The bond stresses were calculated as the
ratios of measured pullout loads divided by the
corresponding rebar’s embedded area (3.14 9 db 9
bonded length (Le) of 90-mm), assuming a uniform
load distribution along the embedded length [31].
Also, the various Cc/db ratios are indicated in Table 3. Ta
ble
3C
om
pre
ssiv
e,te
nsi
le,
and
bo
nd
pro
per
ties
of
test
edco
ncr
ete
sam
ple
din
dry
con
dit
ion
s(i
.e.,
wit
ho
ut
imm
ersi
on
inw
ater
)
f t(d
ry),
MP
a
f’c(d
ry),
MP
a
Bar
No.
Concr
ete
cover
,C
c=
60
mm
Concr
ete
cover
,C
c=
100
mm
Cc/
db
s u(d
ry),
MP
a(k
N)
s u(d
ry)7
Hf’
c(d
ry)
MF
(Sli
p,m
m)
Cc/
db
s u(d
ry),
MP
a(k
N)
s u(d
ry)7
Hf’
c(d
ry)
MF
(Sli
p,m
m)
350-0
.56-S
22
2.6
333.1
13
4.7
212.6
(45.2
)2.1
9P
(0.6
4)
7.8
712.8
(45.9
)2.2
2P
(0.7
2)
16
--
--
6.2
912.5
(56.3
)2.1
8P
(0.8
)
19
3.1
48.4
5(4
5.6
)1.4
7S
(0.6
)5.2
39.2
(49.6
)1.6
S(0
.51)
350-0
.56-S
22-A
WA
2.5
832.4
13
4.7
214.2
(50.9
)2.4
9P
(0.4
5)
7.8
716
(57.5
)2.8
2P
(0.5
8)
25
--
--
3.9
48.1
(58.1
)1.4
2S
(0.5
2)
350-0
.56-S
F45-A
WA
2.5
532.2
16
3.7
710.7
(48.1
)1.8
9P
(0.7
7)
--
--
425-0
.47-S
22
4.6
257.3
13
4.7
214.8
(53.1
)1.9
6P
(0.8
3)
7.8
717.5
(62.8
)2.3
1P
(0.7
1)
16
3.7
712.5
(56.1
)1.6
5P
(0.5
)6.2
815.1
(67.7
)1.9
9P
(1.0
5)
19
--
--
5.2
312.1
(65.3
)1.6
P/S
(0.4
4)
425-0
.47-S
22-A
WA
4.8
158.2
25
2.3
66.4
(45.9
)0.8
4S
(0.3
1)
--
--
Mix
code
refe
rsto
cem
ent
conte
nt-
w/c
-Consi
sten
cy(S
22:
slum
p=
220
mm
;S
F45:
slum
pfl
ow
=450
mm
)-A
WA
MF
refe
rsto
mode
of
fail
ure
(PP
ull
out;
SS
pli
ttin
g;
P/S
Pull
out
wit
hm
inim
alsp
litt
ing)
The
ult
imat
epull
out
forc
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Materials and Structures
Author's personal copy
The washout loss (W) of UWC mixtures tested as
per the adapted CRD C61 test along with the
resulting ft, f’c, su, normalized bond stress, and MF
are summarized in Table 4 (the intrinsic W3 values
are given for indication purposes). The residual Dft,
Df’c, and Dsu values are calculated as [1—(strength
in dry conditions–strength after washout)/strength in
dry conditions] 9 100. Such indices will be used in
this paper to quantify the relative decrease in UWC
strength resulting from washout loss. It is to be
noted that for the 425-0.47-S22 mixture having a Cc
of 100 mm, bond failure occurred slightly after
yielding of the No. 13 bar for specimens sampled in
dry conditions or after washout loss. For all other
tests, bond failure occurred before yielding of test
bars.
Several mixtures were tested three times to evaluate
the validity of the testing procedure developed to
determine strength properties of UWC using the same
samples that were used for washout measurement.
Acceptable reproducibility of ft, f’c and su values was
obtained throughout testing as the coefficient of
variation (C.O.V.) was less than 11.4, 6.5 to 14.2 %,
respectively.
4.1 Modes of failure
Under similar conditions, the modes of failure that
resulted during UWC testing (i.e., pullout vs. splitting)
were quite similar to those observed when using
concrete cast above water [1, 32]. For instance, failure
was by pullout mode for specimens tested using bars
No. 13 and 16, whereby the bar pulled out slowly as
the load dropped steadily (Fig. 4, left). Nevertheless,
minimal splitting was noticed along the top surface of
the test bar No. 16 for the 350-0.56-SF45-AWA UWC
mixture sampled after washout and having a Cc of
60 mm, as shown in Fig. 4 (middle).
Splitting failure occurred when tests are realized
with bars No. 25 and some of those prepared with bars
No. 19. In fact, at approximately � to � of the load
capacity, three radial cracks appeared on the front
loaded-end face, which extended on the two side and
top faces, as shown in Fig. 4 (right) for the 350-0.56-
S22-AWA mixture. The radial cracks widened as the
bar is being pulled out from the specimen. Note that a
pullout failure accompanied with minimal splitting
took place for bar No. 19 in the 425-0.47-S22 mixture
having a Cc of 100 mm.
4.2 Pullout force versus displacement responses
Typical variations of the pullout force versus dis-
placement (slip of the bar at free end) curves
determined on UWC and reference mixtures with Cc
of 100 mm and bars No. 13 and 25 are plotted in
Fig. 5. For given bar diameter, UWC subjected to a
certain washout loss exhibited initially similar trends
of pullout force versus displacement responses, as
compared to the reference mixture sampled in dry
conditions. Thus, all curves yielded initially a stiff
response that varied up to around 10 or 15 % of the
maximum force, beyond which the bars free end
started to slip noticeably. In this region, the bond
resistance consists mainly of chemical adhesion and
friction at the interface between the bar and concrete
matrix [1, 3, 33].
Following the formation of internal cracks and
initiation of debonding, the stiffness of the ascending
curves gradually softens until reaching a maximum
pullout force value. The ultimate force and corre-
sponding slip were, however, directly dependent by
the type of concrete, i.e., whether sampled in dry
conditions or after washout loss. Hence, the maximum
force decreased from 45.2 kN for the 350-0.56-S22
reference concrete to 37.3 kN when the UWC was
sampled after 8.8 % washout loss. As can be seen in
Tables 3 and 4, UWC mixtures sampled after being
subjected to some washout are characterized by lower
compressive and tensile strengths than those sampled
in dry conditions. For instance, ft decreased from 2.63
to 2.25 MPa and f’c from 33.1 to 26.8 MPa for the
350-0.56-S22 mixture. This can reduce the concrete
confining stresses against the steel bar, thus decreasing
bond resistance and leading to internal cracking at
lower bond stresses.
As shown in Fig. 5, the decrease in maximum
pullout force due to washout is coupled with shifting
of the bars free end displacement towards lower
values. Hence, the slip at failure for No. 25 bars
decreased from 0.51 to 0.38 mm for the 350-0.56-S22-
AWA mixtures sampled in dry or washed conditions,
respectively. Practically, this indicates that the pullout
deformation and ability to redistribute load tend to
decrease for concrete mixtures (such as UWC sub-
jected to some washout) characterized by lower matrix
strength and toughness [34]. The debonding continues
in the post-peak region for both UWC and reference
mixtures until the entire length is totally debonded,
Materials and Structures
Author's personal copy
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4.5
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54
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13
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1.7
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Materials and Structures
Author's personal copy
causing the steel bars to slide out dynamically from the
specimens.
4.3 Parameters affecting normalized bond stress
of UWC
4.3.1 Mixture composition
The effect of mixture composition on the normalized
bond stress is plotted in Fig. 6 for various UWC
mixtures tested using different steel bars placed at a
cover of 100 mm. Under given testing conditions, the
addition of AWA led to considerable improvements in
the normalized bond stress. For example, such improve-
ment was from 2.01 to 2.7 when adding AWA to the
350-0.56-S22 mixture tested using bars No. 13 (Fig. 6).
This can be related to reduction in the bleed water which
may strengthen the cement paste in the transition zone
adjacent to the reinforcing bars [1, 15, 16].
The coupled effect of higher cement content and
lower w/c is shown to increase the normalized bond
stress for UWC mixtures sampled after washout
(Fig. 6). For example, such increase was from 1.27
to 1.49 when the cement content increased from 350 to
425 kg/m3 and w/c decreased from 0.56 to 0.47,
respectively, for mixtures tested using bars No. 19.
This can normally be due to improved particle packing
and bearing strength capacity of the concrete in front
of the bar ribs which lead to an increase in bond
stresses [1].
4.3.2 Washout loss
The effect of washout is evaluated by plotting the
relationship between washout loss and the difference
between normalized bond stress determined on con-
crete sampled in dry condition minus the one deter-
mined on UWC sampled following immersion in
water (Fig. 7). Although the scatter in data mostly due
to different concrete covers and bar diameters, it is
evident that such difference is always positive, thus
confirming that bond stress of concrete to embedded
steel decreases when casting is realized under water.
Fig. 4 Typical pullout failure for bars No. 13 (left), pullout with minimal splitting for 350-0.56-SF45-AWA, bar No. 16, Cc of 60 mm
(middle), and splitting failure for 350-0.56-S22-AWA, bar No. 25, Cc of 100 mm (right)
0
10
20
30
40
50
60
0 0.25 0.5 0.75 1 1.25 1.5 1.75 2
Pu
llou
t fo
rce,
kN
Slip at free end, mm
1
2
3
4
Fig. 5 Typical responses of pullout force versus displacement
for UWC and reference mixtures
2.01
1.74
1.27
2.7
2.18
1.79
1.49
1
1.4
1.8
2.2
2.6
3
No
rmal
ized
bo
nd
str
ess
350-0.56-S22
350-0.56-S22-AWA
425-0.47-S22
Fig. 6 Effect of mixture composition on normalized bond
stress of UWC
Materials and Structures
Author's personal copy
On the other hand, it can be noted that the extent of
reduction in the normalized bond stress tends to
increase for UWC mixtures exhibiting higher washout
losses. In fact, such mixtures are characterized by a
decrease in the cementitious phase coupled with a
potential increase in the specified w/c, which can both
decrease the contribution of concrete strength to the
bond against steel [16].
It is important to note that the effect of mixture
composition and washout loss on the normalized bond
stress of UWC determined using the beam-end
specimen is quite similar to that determined using
the direct pullout bond test [16]. In other words, the
normalized stress increases for stable mixtures exhib-
iting reduced levels of washout upon casting in water.
Although the bond at failure is evaluated differently
using both methods, this suggests that the approach
that consists on subjecting UWC to washout and then
testing bond strength is appropriate to assess the drop
in normalized stress due to washout.
4.3.3 Bar diameter (db)
Typical variations of the normalized bond stresses
with respect to db for tested UWC are plotted in Fig. 8
(the effect of concrete cover can also be seen in this
figure). For given concrete cover and mixture compo-
sition, a reduction in normalized bond stress is noticed
with the increase in db. For example, the normalized
bond stress dropped from 2.01 to 1.27 for the
350-0.56-S22 mixture when db increased from 12.7
to 19.1 mm, respectively, for a cover of 100 mm. The
lowest normalized stress of 0.75 was registered for the
425-0.47-S22-AWA mixture tested using the largest
db of 25.4 mm (Table 4). This indicates that larger bar
diameters require longer development or splice length
to achieve proper transfer of stresses when designing
steel reinforcement for UWC.
The influence of db on bond behavior between steel
and concrete cast above water has been studied in
literature [1, 22]. For instance, Metelli and Plizzari
reported a reduction in bond strength by about 25 %
and secant bond stiffness by 70 % when db increased
from 12 to 50 mm, tested using the Rilem/CEB/FIP
pullout method [22]. The rebars were embedded in
cubic specimen for a length equal to 5 db and a cover of
4.5 db. In the case of this study, it is interesting to note
that the extent of bond decrease due to db is relatively
more pronounced when testing UWC mixtures sub-
jected to washout, as compared to concrete cast above
water. For example, su decreased by 43 % (i.e., from
9.2 to 5.2 MPa) when db increased from 12.7 to
19.1 mm (Cc/db equal to 4.72 and 3.14, respectively)
for the 350-0.56-S22 mixture sampled after washout.
Such decrease was equal to 33 % (i.e., from 12.6 to
8.45 MPa) when the same mixture was cast above
water under similar conditions. This highlights the
importance of using small-diameter bars when casting
is expected to occur under water.
4.3.4 Concrete cover (Cc)
Regardless of the bar diameter, the increase in Cc from
60 to 100 mm led to increased normalized bond stress
of tested UWC (Fig. 8), mostly attributed to higher
concrete confinement surrounding the embedded steel
[1, 2]. Practically, this means that the increase in
concrete cover could be beneficial to limit the
y = 0.06 x - 0.14R² = 0.84
y = 0.058 x - 0.19R² = 0.6
0.0
0.1
0.2
0.3
0.4
0.5
0.6
3 4.5 6 7.5 9 10.5 12
No
rmal
ized
bo
nd
str
ess
(dry
co
ncr
ete)
min
us
no
rmal
ized
bo
nd
st
ress
(U
WC
)
Washout loss as per adapted CRD C61, %
Cc = 60 mm
Cc = 100 mm
Linear (Cc = 60 mm)
Linear (Cc = 100 mm)
Fig. 7 Effect of washout loss on the drop in normalized bond
stress
Fig. 8 Effect of bar diameter (and concrete cover) on
normalized bond stress
Materials and Structures
Author's personal copy
detrimental effect of washout on the drop in UWC bond
strength. For example, as can be seen in Fig. 9, the use
of 100 mm Cc resulted in improved normalized bond
stress for the 425-0.47-S22 UWC mixture, despite the
5.6 % washout loss that occurred as compared to the
reference mixture sampled in dry conditions with Cc of
60 mm. Nevertheless, the 5.6 % washout may be
considered as a threshold value, beyond which further
increase in Cc may be required to compensate the
effect of washout loss on the drop in bond strength.
Hence, the normalized bond stress remained lower
with the use of 100 mm Cc for the 350-0.56-S22 UWC
mixture having a washout value of 8.8 %, as compared
to the reference mixture sampled in dry conditions
having a Cc of 60 mm (Fig. 9).
It is to be noted that the effect of db and Cc on
normalized bond stress for UWC is similar to that
resulting from concrete cast and consolidated above
water [1, 2]. This indicates that, once hardening
occurred, both UWC and concrete cast above water
behave similarly with respect to bond against steel.
Thus, the drop in bond for UWC is mainly related to
the washout that could take place during the under-
water casting process.
Although the limited number of data points,
acceptable correlations are plotted in Fig. 10 between
Cc/db and normalized bond stress for all tested UWC,
indicating that the increase in Cc/db can result in
higher normalized bond stresses. In other words,
concrete confinement plays an important role to
provide increased resistance to bond failure during
underwater casting (as washout loss can reduce such
bond stresses). Such results are in agreement with
those determined on concrete cast above water [1, 32].
The relationships between normalized bond stress
determined on concrete sampled in dry conditions and
Cc/db are as follows:
For Cc ¼ 60 mm; Normalized bond stress dryð Þ¼ 0:551 Cc=db� 0:358 R2 ¼ 0:88
For Cc ¼ 100 mm; Normalized bond stress dryð Þ¼ 0:284 Cc=db þ 0:218 R2 ¼ 0:83
4.4 Effect of washout loss on UWC properties
4.4.1 Residual UWC strengths
The relationships between washout loss determined
using the adapted CRD C61 method and UWC residual
strengths (Dft, Df’c, and Dsu) are plotted in Fig. 11.
Mixtures with increased washout losses exhibited
higher Dft and Df’c for the 5 tested data points. As
already mentioned, this is due to washout of cemen-
titious particles coupled with potential increase in w/c
due to water infiltration inside the specimens, which
can both decrease strength of UWC. The R2 of 0.97
obtained using the compression data indicates that
washout can be better related to compressive strength,
rather than tensile strength having a lower R2 of 0.61.
Regardless of the concrete cover or bar diameter, the
increase in washout is shown to reduce proportionally
the residual bond strength (Dsu) (Fig. 11). For exam-
ple, the increase in washout from 4.5 to 10.5 % resulted
in reduced Dsu from approximately 90–65 %, respec-
tively. As reported in literature for concrete cast and
consolidated above water, the ultimate bond strength is
directly dependent on the contribution of concrete
strength and quality of the interfacial transition zone
between the paste and embedded steel [34]. Hence,
UWC mixtures exhibiting relatively low washout
possess improved resistance against dilution and
reduced risks of water inclusion inside the specimen,
thus increasing the contribution of concrete strength to
the bond against steel bars. Conversely, UWC with
higher washout becomes more prone to a decrease in
the ultimate bond strength due to cementitious losses
coupled with an increase in the specified w/c.
4.4.2 Prediction of drop in bond strength for UWC
The relationship between Dsu and the drop in
normalized bond stress calculated as the difference
2.19
1.47
1.96
1.65
2.01
1.27
2.18
1.79
1.0
1.5
2.0
2.5
3.0N
orm
aliz
ed b
on
d s
tres
s
Mix in dry conditions, Cc = 60 mm
Washed UWC mix, Cc = 100 mm
Fig. 9 Effect of concrete cover on normalized bond stress for
UWC and reference mixtures
Materials and Structures
Author's personal copy
between that determined under dry or washed condi-
tions is illustrated in Fig. 12. As expected, the
difference between normalized bond stresses
decreases for UWC mixtures possessing higher Dsu
values, with R2 of 0.9. Thus, two boxes depending on
the level of washout loss are distinguished in Fig. 12 to
predict the drop in UWC bond strength, as follows:
a. Washout loss varying from 8.8 to 10.8 %: UWC
samples possessing such levels of washout are
characterized by relatively high losses of cemen-
titious particles and potential increase in w/c,
leading to dramatic drops in residual bond
strength. The corresponding Dsu values ranged
from approximately 60–82 % (Fig. 12). In other
words, to eliminate the detrimental effect of such
levels of washout on the drop in normalized bond
stresses, the ultimate bond strength of UWC
should be increased by 18 % (100–82) to 40 %
(100–60). As earlier discussed, this can be
achieved by different ways including higher Cc,
reduced db, increased development length, addi-
tion of AWA to reduce washout, and use of higher
strength concrete.
b. Washout loss varying from 4.2 to 6.9 %: Obvi-
ously, this category of mixtures is characterized
by improved concrete/water interface capable of
resisting loss of fines and water inclusion inside
the specimen, thus leading to Dsu ranging from 78
to 93 % (Fig. 12). Therefore, the bond should be
increased by 7 % (100–93) to 22 % (100–78) in
this category of mixtures to eliminate the detri-
mental effect of washout.
It is to be noted that the two previously defined
washout boxes can also be identified in Fig. 13 when
plotting the relationship between Df’c and Dsu values
for all tested UWC. An acceptable R2 of 0.7 is
obtained. Thus, for mixtures having washout varying
from 8.8 to 10.8 %, Df’c varies from 75 to 83 %. In the
second category of UWC having 4.2 to 6.9 %
washout, Df’c ranges from 87 to 97 %.
4.5 Regression models for evaluating bond
strength in UWC
A series of regression models have been developed to
determine the ultimate bond strength of UWC, and
subsequently being able to assess the effect of given
variable on its magnitude. The models given in Eqs. 1
to 5 below are considered valid within the conditions
of the testing program, i.e. concrete having an f’c
varying from 25 to 58 MPa, ft from 2.25 to 4.8 MPa,
Cc/db from 2.36 to 7.87, db/Le from 0.141 to 0.282, db
from 12.7 to 25.4 mm, and W3 ranging from 0 %
(corresponding to reference concrete cast above
water) to 11 %. Note that the W3 values (Table 4)
were chosen in the regression models so as to use the
intrinsic washout losses determined using the stan-
dardized CRD C61 test method.
Equations 1 and 2 have been proposed as a function
of concrete tensile strength (ft). Acceptable accuracy
resulting in R2 of 0.71 and 0.76 is obtained when
comparing the predicted-to-measured values. The
signs of the estimates (±) indicate the positive or
negative effect of given variable on the ultimate bond
strength. For example, the increase in ft and Cc/db
leads to an increase (?) in bond. Conversely, the
increase in db/Le and W3 will reduce (-) the bond.
y = 0.537 x - 0.604R² = 0.87
y = 0.308 x - 0.149R² = 0.82
0.5
1.0
1.5
2.0
2.5
3.0
2 3 4 5 6 7 8 9
No
rmal
ized
bo
nd
str
ess
Cc / db ratio
Cc = 60 mm
Cc = 100 mm
Fig. 10 Relationships between normalized bond stress and Cc/
db ratios
y = -4.36 x + 111.7R² = 0.69
y = -3.61 x + 113.6R² = 0.97
y = -2 x + 106.01R² = 0.61
60
70
80
90
100
3 4.5 6 7.5 9 10.5 12
Res
idu
al s
tren
gth
s, %
Washout loss as per adapted CRD C61, %
Bond
Compression
Tensile
Linear (Bond)
Linear (Compression)
Linear (Tensile)
Fig. 11 Effect of washout loss on residual compressive, tensile,
and bond strengths of UWC
Materials and Structures
Author's personal copy
smax MPað Þ ¼ 0:078þ 0:68Cc
db
� 0:09W3
� �ft
R2 ¼ 0:71� �
ð1Þ
smax MPað Þ ¼ 2þ 0:45Cc
db
� 5:2db
Le
� 0:08W3
� �ft
R2 ¼ 0:76� �
ð2Þ
Higher R2 of 0.79 and 0.88 are obtained between
the predicted-to-measured values when using Eqs. 3
and 4, respectively. Those later models have been
proposed as a function of the square root of f’c,
suggesting that compressive strength can better be
used to predict the ultimate UWC bond strength.
smax MPað Þ ¼ 0:22þ 0:336Cc
db
� 0:052W3
� � ffiffiffiffif0c
q. . .
R2 ¼ 0:79� �
ð3Þ
smax MPað Þ¼ 1:64þ0:22Cc
db
�4:5db
Le
�0:046W3
� � ffiffiffiffif0c
q
R2¼0:88� �
ð4Þ
Given that Le remained fixed at 90 mm throughout
the testing program, Eq. 4 has been re-formulated into
Eq. 5 whereby the term db/Le is changed to db, as
follows:
smax MPað Þ¼ 2:6þ0:15Cc
db
�0:09db�0:044W3
� � ffiffiffiffif0c
q
R2¼0:91� �
ð5Þ
5 Summary and conclusions
This study aims at assessing the effect of washout loss
on the drop in UWC bond strength. Special emphasis
was placed to evaluate bond properties using the same
concrete mixtures that were subjected to washout as
per an adapted version of the CRD C61 test. Tests
were realized using the beam-end specimen method,
and parameters evaluated included level of washout
loss, bar diameter, and concrete cover.
For given bar size and concrete cover, test results
showed that bond between steel and UWC is affected
by the level of washout loss, which in turn is directly
influenced by the mixture composition. For example,
the increase in cement content, decrease in w/c, and
addition of AWA can reduce washout loss and risks of
increase in w/c, thus improving the contribution of
UWC strength to the bond against steel bars. Similarly
to bond behavior in concrete cast and consolidated
above water, ultimate bond strength of UWC increases
for smaller bar diameters and higher confinement
reflected by increased concrete covers. Practically,
this means that the increase in concrete cover could
limit the detrimental effect of washout on the drop in
UWC bond strength. UWC mixtures with increased
washout losses exhibited higher drops in compressive,
tensile, and bond strengths, as compared to the
concrete cast above water. Two boxes depending on
the level of washout loss, i.e. from 4.2 to 6.9 % and
from 8.8 to 10.8 %, have been proposed to predict the
y = -0.013 x + 1.3R² = 0.90
0.0
0.1
0.2
0.3
0.4
0.5
0.6
60 65 70 75 80 85 90 95 100
No
rmal
ized
bo
nd
str
ess
(dry
co
ncr
ete)
min
us
no
rmal
ized
b
on
d s
tres
s (U
WC
)
Residual bond strength, %
Washout = 4.2% to 6.9% => To increase UWC bond by 7% to 22%
Washout = 8.8% to10.8% => To increase UWC bond by 18% to 40%
Fig. 12 Effect of washout loss on residual bond strength and
normalized bond stress of UWC
y = 50.41 e0.0068x
R² = 0.70
70
75
80
85
90
95
100
60 65 70 75 80 85 90 95 100
Res
idu
al c
om
pre
ssiv
e st
ren
gth
, %
Residual bond strength, %
Washout = 8.8% to10.8%
Washout = 4.2% to 6.9%
Fig. 13 Effect of washout loss on residual compressive and
bond strengths of UWC
Materials and Structures
Author's personal copy
extent of bond decrease in UWC mixtures. Regression
models developed as a function of washout loss, bar
diameter, concrete cover, and compressive or tensile
strengths have been proposed to estimate the corre-
sponding ultimate bond strength.
Acknowledgments The authors would like to acknowledge
the support provided by CNRS-Lebanon and University
Research Council of the Lebanese American University
(LAU), Byblos, Lebanon. The authors also wish to thank the
experimental support provided by the Laboratory of the Civil
Engineering Department in LAU.
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