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TXDOT AND FLY ASHAndy Naranjo, P.E.Construction Division
TxDOT Concrete Stats
Concrete Consumption Per Year
-
500,000
1,000,000
1,500,000
2,000,000
2,500,000
3,000,000
3,500,000
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014
Conc
rete
Con
sum
ption
, CY
Retaining Walls
Bridge Decks
PS Beams
Substructure
Drilled Shafts
Pavement
2
TxDOT consumes approximately 150,000 to 200,000 tons of fly ash
annually
CRCP Stats
3
0
3000
6000
9000
12000
15000La
ne M
iles
of C
oncr
ete
Pave
men
t
CRCPJCP
Lane Miles of Concrete Pavement Per Year
E l P a s oE l P a s o
O d e s s aO d e s s a
A m a r i l l oA m a r i l l o
L a r e d oL a r e d o
L u b b o c kL u b b o c k
S a n A n g e l oS a n A n g e l o
P h a r rP h a r r
A b i l e n eA b i l e n e
W a c oW a c o
A u s t i nA u s t i n
T y l e rT y l e r
B r y a nB r y a n
Y o a k u mY o a k u m
P a r i sP a r i s
C h i l d r e s sC h i l d r e s s
L u f k i nL u f k i n
S a n A n t o n i oS a n A n t o n i o
D a l l a sD a l l a s
W i c h i t a F a l l sW i c h i t a F a l l s
A t l a n t aA t l a n t a
B r o w n w o o dB r o w n w o o d
H o u s t o nH o u s t o n
B e a u m o n tB e a u m o n t
F o r t W o r t hF o r t W o r t h
C o r p u s C h r i s t iC o r p u s C h r i s t i
§̈¦20
§̈¦10
§̈¦35
§̈¦40
§̈¦27
§̈¦69
§̈¦44
§̈¦110
¢67
¢90
¢87
¢82
¢62
¢59
¢79
¢180
¢84
¢69
¢83
¢77
¢80
¢281
¢385
¢60
¢287
¢285
¢96
¢290
¢190
¢70
¢183
¢380
¢57
¢54
¢271
¢175
¢181
¢81
¢277
¢377
¢75
¢259
¢283
¢71
Class C Fly Ash
Class F Fly Ash
4
Durability Requirements
Premature Deterioration: ASR, DEF, SRC
– TxDOT relies heavily on fly ash for mitigation these type of distresses
High Performance Concrete: Typically required in coastal and North Texas
– Concrete Mix Options 1-4: All rely on SCM to meet requirements
• Fly ash only locally available option
• Small amount of Silica Fume used in Panhandle
– Permeability: State mandate to use brine solution as deicing material
Mass Concrete Placements
– High volume fly ash mixes needed to reduce peak temperatures during curing large concrete elements
5
Air Entrainment
6
Dallam Sherman Hansford Ochiltree Lipscomb
Hartley Moore
Hutchinso
nRoberts Hemphill
Oldham Potter Carson Gray Wheeler
Deaf Smith Randall Armstrong DonleyCollings-woth
Parmer Castro Swisher Briscoe Hall
Child
ress
Bailey Lamb Hale Floyd Motley
Dickens King KnoxCoch
ran
HockleyLubbock
Crosby
GarzaLynnTerryYoakum
Gaines Dawson Borden Scurry Fisher Jones
Kent Stonewall HaskellThrock-morton
Baylor
WilbargerWichita
WICHITAFALLS
Clay
Archer
YoungJack
Howard Mitchell NolanTaylor
CallahanEastland
Glasscock Sterling Coke Runnels
Shac
kelfo
rd
ReaganIrion
Mon
tagu
e
Cooke Grayson Fannin
Lamar
Delta
Red River
PARIS
Bowie
Wise Denton CollinHunt Hopkins
RainsWood
Upshur
Marion
Cass
Titus
Morr
is
Camp
ATLANTA
Harrison
Smith Gre
ggVanZandt
Henderson TYLER
Rusk Panola
AndersonCherokee
NacogdochesFreestone
DallasDALLAS
Rockwall
Step
hens Palo
Pinto
Parker Tarrant
Kauf
man
Shelby
San
A
ugu
stin
e
SabineHoustonLUFKIN
Angelina
TylerPolk
Trinity
Jasp
er
New
ton
SanJacinto
Walker
Leon
Navarro
Ellis
Hardin
FORTWORTH
Erath
HoodJohnson
Somer
-vell
Hill
BosqueMc
LennanHamilton
Coryell
Bell
Falls
WACO
Limestone
Robertson
Madison
Milam
Brazos
Gri
mes
Burleson
BRYAN
Washington
Lee
Austin
Fayette
Harris
Montgomery Liberty
BEAUMONT
Orange
Jefferson
Chambers
Galve
ston
HOUSTON
FortBend
Brazoria
Matagorda
Wharton
Colorado
LavacaGonzales
Dewitt
YOAKUM
Jackson
Victoria
Calhoun
Walle
r
Goliad
Bee Refugio
Aran
sas
Karnes
LiveOak
JimWells
SanPatricio
Nuceces
CORPUSCHRISTI
Kleberg
Kenedy
Willacy
Hidalgo
BrooksJim
HoggZapata
Starr
PHARR
Duval
Webb
LAREDO
La SalleDimmit
Zavala Frio Atascosa
McMullen
Guadalupe
Wilson
Bexar
MedinaUvalde
Real Bandera
Kerr
Kendall
GillespieBlanco
Kinney
Maverick
SANANTONIO
Edwards
Sutton Kimble
Mason LlanoBurner
Williamson
Trayis
AUSTIN
BastropHays
CaldwellComal
Brown Comanche
BROWNWOOD
Coleman
Mills
McCulloch
San Saba Lampasas
Concho
Menard
SANANGELO
Schleicher
TomGreen
Andrews Martin
Midland
Pecos
Ector
Crane
Ward
WinklerLoving
Crockett
ValVarde
Upton
Terrell
Reeves
Culberson
JeffDavis
Brewster
Presidio
Hudspeth
El Pasd
EL PASO
ODESSA
LUBBOCK
AMARILLO
ABILENE
Cottle Foard
HardemanCHILDRESS
Fran
klin
10
10
5
5
1
1
0
0
Effective Freeze-Thaw Cycles
– Below 17°F for more then 5 hours with moisture present
Unburnt/Activated Carbon
– Primarily an issue for North Texas
– Fly Ash or Air?
2014 Spec changed the default for air entrainment.
– Only air entrain when shown on the plans
– No specified air content listed
– Must use an air entraining agent
Plant/Seasonal Outages
Unusually long outages can delay project schedules
TxDOT has made some mix design allowances for periods of fly ash shortages
– Trial batches waived
– Straight cement mixes
High Performance Concrete
– Sticking to our guns on this in most regions (North Texas and Costal)
– Will consider non-HPC mixes in substructure not over bridge joint on case by case basis
7
TxDOT Concrete Sustainability
8
Mix DesignPotential
CO2 Reduction
CO2 Equvialent (Passenger Vehichels)
520 lb/cy --
20% SCM 15% 26,500
35% SCM 27% 47,500
OAG Mix 13% 23,000
OAG Mix w/20%SCM
22% 22,000
Type IL w/20% SCM
20% 35,300
Type IL w/35% SCM
30% 51,000Potential Reduction of CO2
Project 0-6858, “Evaluating Limestone Cements with >15% Limestone• 20% and 30% limestone contents• Previous research has shown synergy
with Class C fly ashes.• Primary use in paving concrete
600,000
650,000
700,000
750,000
800,000
850,000
900,000
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020
Tons
of C
O2
Prod
uced
Year
Best Case: 100% Contains Type IL Cement and 35% SCM
15% Reduction from 2009 Level
QUESTIONS?
9