Innovative Concrete Mixes in MnROAD Phase 2 Initiatives

Bernard Igbafen Izevbekhai. PhD; P.E.

Research Operations Engineer,

Minnesota Dept. of Transportation

MnROAD Workshop

February 11 2015

• High Performance (60 Year Design) Concrete Pavement • Pervious Concrete Overlay • Pervious Concrete Pavement Study (Full Depth) • Design Guide for Concrete Bonded Concrete on

Existing Asphalt Pavements (Whitetopping) • Design and Construction Guidelines for Thermally

Insulated Concrete Pavements • Unbonded Concrete Overlay • Concrete Pavement Optimization – Determining the Lower Threshold of Slab Thickness for High Volume Roads

2008 INITIATIVES

Material

Size/ Type

Specific Gravity

Absorp. Factor

Mix #1 3A41HPC1

Cement I / II 3.15 410

Fly Ash C / F 2.55 175

Slag GR-100 2.90 Other

F Agg 1 C.SAND 2.63 0.009 1123

F Agg 2 C.SAND 2.64 0.008 1154

C Agg 1 CA-50(#67) 2.69 0.013 627

C Agg 2 1.5"(#4) 2.75 0.013 224

C Agg 3 #9 2.69 0.014 C Agg 4 3/8 GRANITE 2.67 0.004 Admix 1 AEA 4.0

Admix 2 SIKAMENT 6.0

Admix 3 DELVO Design Water 205

HIGH PERFORMANCE CONCRETE

Size/ Specific Absorp. Mix #2

Material Type Gravity Factor PERVIOUS

Cement I / II 3.15 296

Fly Ash C / F 2.55 89

Slag GR-100 2.90 207

Other F Agg 1 C.SAND 2.63 0.009 225

F Agg 2 C.SAND 2.64 0.008

C Agg 1 CA-50(#67) 2.69 0.013 C Agg 2 1.5"(#4) 2.75 0.013 C Agg 3 #9 2.69 0.014

C Agg 4 3/8 GRANITE 2.67 0.004 2245

Admix 1 AEA 12.0

Admix 2 SIKAMENT Admix 3 DELVO 12.0

Design Water 172

PERVIOUS CONCRETE FULL DEPTH

Cross-sectional Layout of Pervious Concrete cells in a MnDOT MnROAD facility.

PERVIOUS CONCRETE MIXTURE

8-18 BAND FOR WELL GRADED AGGREGATES

From 2008 Mixes were Traditionally Well Graded Aggregates

2008 MISCELLANY

PERVIOUS DEPLOYMENT

CITY OF ROCHESTER PERVIOUS SHOULDER

DETROIT LAKES BOAT LANDING CITY OF SHOREVIEW CITY STREET

2 LIFT CONCRETE

Cell 70 Cell 71 Cell 73 Cell 72

Innovative

Diamond

Grind

Traditional

Diamond

Grind

Traditiona

l Diamond

Grind

Traditiona

l Diamond

Grind

Exposed

Aggregate

3" HMA 3" EAC 3" EAC

6" RAC 6" RAC 6” LCST 6" LCST

8" Class 5 8" Class 6 8" Class 7

Clay Clay Clay

2 LIFT CONCRETE

Recycled Low Cost Exposed Aggregate

Water (lbs/cy) 234 172 283

Cement (lbs/cy) 360 240 616

Fly Ash (lbs/cy) 240 360 109

W/CM 0.39 0.29 0.39

Sand (OD lbs/cy) 1200 1263 843

CA1 (OD lbs/cy) 825 787 1133

CA2 (OD lbs/cy) 920 1102 843

Max Slump (in) 3 3 3

% Air 7 7 7

Multi-Air 25 (oz/cy) 2 - 15 2 - 15 2 - 15

Sike 686 (oz/cwt) 1 - 7 1 - 5 1 - 5

Admixture 3

0-30 oz/cwt Sikaset

NC (non-chloride

accelerator)

0-30 oz/cwt Sikaset

NC (non-chloride

accelerator)

0-5 oz/cwt Delvo as

needed for slump

retentions

THREE MIXES IN 2010 INITIATIVE

INTERFACE OF 2 LIFT CONCRETE

REQUIRE A HUGE PARADIGM SHIFT

TIME LAG BETWEEN TWO LIFTS

• Total cost difference is within margin of error

• Basis: Recycled agg: $ 8.75/Ton vs. 20.72/Ton

• 2 –Lift LCCA may show better ROI

• Kansas DOT 2009 Illinois Tollway 2013 INVEST

360,006 tons of asphalt, 304,643 tons of concrete and

Source: C.S Mc Crossan

RECYCLE COST- EFFECTIVENESS & DEPLOYMENT POTENTIAL

ROLLER COMPACTED CONCRETE

ROLLER COMPACTED CONCRETE

120

125

130

135

140

145

150

155

160

165

Un

it W

eig

ht

lb/in

2

DD Vibratory

DD Static

DD Rubber

NUCLEAR DRY DENSITY PROGRESSION

• If the RCC is too dry, the surface will appear dusty or grainy and may even shear (tear) horizontally.

• Striations are common. May later initiate or facilitate crack paths

• Segregation: checking the aggregate gradation or plant

calibration may be necessary. • RCC should be compacted as soon as possible after it is

spread, especially in hot weather (PCA R&D Serial No. 2975). Typically within 15 min of spreading and 45 min of initial mixing.

• Agencies need a skid resistant surface.

RCC OBSERVED & VALIDATED

2013 FIBER MIXES Factoidal Hypothesis:

– Fibers do increase Slab capacity (Roessler et al, Bourdelion et al)

– Fibers are deployed in the Elastoplastic zone

– Fibers can hold parts across crack lines

– Consequently Fibers will enhance Aggregate interlock

Research Strategy: – Fibers Mix for Thin UBOL (Slab

capacity) • Contractor mixes Max aggregate

size ¾” 6.5% Fiber

– Fiber Mix for White Topping Factoria (Load Transfer) • Contractor mixes 6.5% Fiber

Actuator

Bottom Actuated

Base

24” Diameter

Piston

Load Cell 0 to 300,000 lbs

Controller

Framework

PID/PIV Feed

Forward

Adaptive Control

Resolution 32 Bit

Controller Rate 40,000 Hz

Data Acquisition

Capability 0 to 500 Hz

LVDT Accuracy 0.000001 in

LVDT Range 0.25 in

Position Accuracy 0.0001 in

FIBER CONCRETE RESIDUAL STRENGTH ANALYSIS

FIBER CONCRETE RESIDUAL STRENGTH ANALYSIS

FIBER-ENHANCED PAVEMENT 3-INCH UNBONDED OVERLAY

SUSTAINABLE CONCRETE CELL

• Meeting the needs of the present generation without

compromising the ability of future generations to meet their own

needs.’ Federal Highway Administration “United Nations Brundtland

Commission in 1987

• Implies Setting goals, Implementing Practices and Measuring

results.”

• Sustainability Supports the Environmental Economic & Quality

of Life Requirements

• USE IN-SITU CONCRETE AS AGGREGATE S

QUA

ENV ECO

(FHWA, https://www.sustainable highways.org)

Izevbekha1 2012

Initiatives Year 2013

75% RCA in 7 ½” Concrete

Class 1 Aggregate Base

Existing Clay Subgrade

• Sustainable Concrete Cell MnROAD 2013 Construction

• Elastomeric Sealers (2 sizes)

• Geocomposite Joint Drain

MnROAD Cells 613

Geocomposite Joint Drain

RECYCLED CONCRETE AGGREGATE MIXES IN 2013 SUSTAINABLE CONCRETE

INTERFACIAL TRANSITION ZONE ENHANCEMENT 𝒍𝒐𝒈𝑬𝒄 = 𝑽𝒑𝒍𝒐𝒈𝑬𝒑 + 𝑽𝒂𝒍𝒐𝒈𝑬𝒂

+ 𝑽𝒊𝒍𝒐𝒈𝑬𝒊 (𝑴𝒊𝒏𝒅𝒆𝒔𝒔 𝒀𝒐𝒖𝒏𝒈 & 𝑫𝒂𝒓𝒘𝒊𝒏 𝟐𝟎𝟎𝟑)

where subscript “I” refers to ITZ “a” to aggregate and “p” to paste

Where quantity “V” refers to volume and “E” to Elastic Modulus

T𝐡𝐮𝐬 𝑬𝒄 = 𝑬𝒑𝒗𝒑

𝑬𝒂𝑽𝒂𝑬𝒊

𝑽𝒊

ITZ (20-40µm) Bulk Paste

75-100µm

AGGREGATE

Excess Bleed water; Low CSH; High

CH & High Ettrignite

Cracking occurs 10-20µm in the ITZ

More sustainable to enhance ITZ

Akkari, Izevbekhai & Olson 2014

ELASTO-PLASTIC ENHANCEMENT

Evaluation of ECC PVA Fibers Akkari (2011)

2013 Cells 60-63

FIBER MIXES

2013 FIBER MIX

HISTORICAL BENEFITS OF FIBERS • Improve mix cohesion, improving pumpability over long distances

• Improve freeze-thaw resistance

• Improve resistance to explosive spalling in case of a severe fire

• Improve impact resistance

• Increase resistance to plastic shrinkage during curing

PROPEX FIBER INITIATIVES • Slab Capacity Increase

• Reduce crack widths

• Improve impact & abrasion resistance

• Improve freeze-thaw resistance

• Enhance Aggregate Interlock

• Diffused Vs Flocculated Alignment

Flexural Strength vs. Age – All Mixes

CURRENT STUDY

No Significant Improvement in Flexural Strength (Akkari 2011)

Historical Benefits of Fibers Polypropylene and Nylon Fibres can: • Improve mix cohesion, improving pumpability over long distances

• Improve freeze-thaw resistance

• Improve resistance to explosive spalling in case of a severe fire

• Improve impact resistance

• Increase resistance to plastic shrinkage during curing

Structural Fibres can: • Improve ductility

• Reduce crack widths

• Improve impact & abrasion resistance

• Improve freeze-thaw resistance

BOND ENHANCEMENT

Slant shear test to evaluate compatibility and bond of fiber concrete

INITIAL

STUDIES

Evaluation of ECC PVA Fibers Akkari (2011)

ASTM 1609 ELASTO-PLASTIC PLOT

ASTM 1609 FIBER RESIDUAL STRENGTH

SUSTAINABILITY BY ALL MEANS!!

Please do not try this at work!!

FINALLY

THE ENDless Road of Research