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

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NCHRP
NATIONAL
COOPERATIVE
HIGHWAY
RESEARCH
PROGRAM
REPORT 566
Guidelines for Concrete Mixtures
Containing Supplementary
Cementitious Materials to Enhance
Durability of Bridge Decks
TRANSPORTATION RESEARCH BOARD 2007 EXECUTIVE COMMITTEE*
OFFICERS
CHAIR:Linda S. Watson,CEO, LYNX–Central Florida Regional Transportation Authority, Orlando
VICECHAIR:Debra L. Miller,Secretary, Kansas DOT, Topeka
EXECUTIVEDIRECTOR:Robert E. Skinner, Jr.,Transportation Research Board
MEMBERS
J. Barry Barker,Executive Director, Transit Authority of River City, Louisville, KY
Michael W. Behrens,Executive Director, Texas DOT, Austin
Allen D. Biehler,Secretary, Pennsylvania DOT, Harrisburg
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Larry L. Brown, Sr.,Executive Director, Mississippi DOT, Jackson
Deborah H. Butler,Vice President, Customer Service, Norfolk Southern Corporation and Subsidiaries, Atlanta, GA
Anne P. Canby,President, Surface Transportation Policy Partnership, Washington, DC
Nicholas J. Garber,Henry L. Kinnier Professor, Department of Civil Engineering, University of Virginia, Charlottesville
Angela Gittens,Vice President, Airport Business Services, HNTB Corporation, Miami, FL
Susan Hanson,Landry University Professor of Geography, Graduate School of Geography, Clark University, Worcester, MA
Adib K. Kanafani,Cahill Professor of Civil Engineering, University of California, Berkeley
Harold E. Linnenkohl,Commissioner, Georgia DOT, Atlanta
Michael D. Meyer,Professor, School of Civil and Environmental Engineering, Georgia Institute of Technology, Atlanta
Michael R. Morris,Director of Transportation, North Central Texas Council of Governments, Arlington
John R. Njord,Executive Director, Utah DOT, Salt Lake City
Pete K. Rahn, Director,Missouri DOT, Jefferson City
Sandra Rosenbloom,Professor of Planning, University of Arizona, Tucson
Tracy L. Rosser,Vice President, Corporate Traffic, Wal-Mart Stores, Inc., Bentonville, AR
Rosa Clausell Rountree,Executive Director, Georgia State Road and Tollway Authority, Atlanta
Henry G. (Gerry) Schwartz, Jr., Senior Professor,Washington University, St. Louis, MO
C. Michael Walton,Ernest H. Cockrell Centennial Chair in Engineering, University of Texas, Austin
Steve Williams,Chairman and CEO, Maverick Transportation, Inc., Little Rock, AR
EX OFFICIO MEMBERS
Thad Allen(Adm., U.S. Coast Guard), Commandant, U.S. Coast Guard, Washington, DC
Thomas J. Barrett(Vice Adm., U.S. Coast Guard, ret.), Pipeline and Hazardous Materials Safety Administrator, U.S.DOT
Marion C. Blakey,Federal Aviation Administrator, U.S.DOT
Joseph H. Boardman,Federal Railroad Administrator, U.S.DOT
John A. Bobo, Jr.,Acting Administrator, Research and Innovative Technology Administration, U.S.DOT
Rebecca M. Brewster,President and COO, American Transportation Research Institute, Smyrna, GA
George Bugliarello,Chancellor, Polytechnic University of New York, Brooklyn, and Foreign Secretary, National Academy of Engineering,
Washington, DC
J. Richard Capka,Federal Highway Administrator, U.S.DOT
Sean T. Connaughton,Maritime Administrator, U.S.DOT
Edward R. Hamberger,President and CEO, Association of American Railroads, Washington, DC
John H. Hill, Federal Motor Carrier Safety Administrator, U.S.DOT
John C. Horsley,Executive Director, American Association of State Highway and Transportation Officials, Washington, DC
J. Edward Johnson,Director, Applied Science Directorate, National Aeronautics and Space Administration, John C. Stennis Space Center, MS
William W. Millar,President, American Public Transportation Association, Washington, DC
Nicole R. Nason,National Highway Traffic Safety Administrator, U.S.DOT
Jeffrey N. Shane,Under Secretary for Policy, U.S.DOT
James S. Simpson, Federal Transit Administrator, U.S.DOT
Carl A. Strock(Lt. Gen., U.S. Army), Chief of Engineers and Commanding General, U.S. Army Corps of Engineers, Washington, DC
*Membership as of March 2007.
NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM
NCHRP
REPORT 566
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, ELSTNERASSOCIATES, INC.
Northbrook, IL
Bruce E. Ankenman
NORTHWESTERNUNIVERSITY
Evanston, IL
Subject Areas
Bridges, Other Structures, and Hydraulics and Hydrology • Materials and Construction
Research sponsored by the American Association of State Highway and Transportation Officials
in cooperation with the Federal Highway Administration
TRANSPORTATION RESEARCH BOARD
WASHINGTON, D.C.
2007
www.TRB.org
NATIONAL COOPERATIVE HIGHWAY NCHRP REPORT 566
RESEARCH PROGRAM
Systematic, well-designed research provides the most effective Project 18-08A
approach to the solution of many problems facing highway ISSN 0077-5614
administrators and engineers. Often, highway problems are of local ISBN: 978-0-309-09897-7
Library of Congress Control Number 2007905315
interest and can best be studied by highway departments individually
or in cooperation with their state universities and others. However, the © 2007 Transportation Research Board
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
COPYRIGHT PERMISSION
cooperative research.
Authors herein are responsible for the authenticity of their materials and for obtaining
In recognition of these needs, the highway administrators of the
written permissions from publishers or persons who own the copyright to any previously
American Association of State Highway and Transportation Officials published or copyrighted material used herein.
initiated in 1962 an objective national highway research program
Cooperative Research Programs (CRP) grants permission to reproduce material in this
employing modern scientific techniques. This program is supported on publication for classroom and not-for-profit purposes. Permission is given with the
a continuing basis by funds from participating member states of 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,
Association and it receives the full cooperation and support of the
method, or practice. It is expected that those reproducing the material in this document for
Federal Highway Administration, United States Department of educational and not-for-profit uses will give appropriate acknowledgment of the source of
Transportation. any reprinted or reproduced material. For other uses of the material, request permission
from CRP.
The Transportation Research Board of the National Academies was
requested by the Association to administer the research program
because of the Board’s recognized objectivity and understanding of
NOTICE
modern research practices. The Board is uniquely suited for this
purpose as it maintains an extensive committee structure from which 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
authorities on any highway transportation subject may be drawn; it
the Governing Board of the National Research Council. Such approval reflects the
possesses avenues of communications and cooperation with federal, Governing Board’s judgment that the program concerned is of national importance and
state and local governmental agencies, universities, and industry; its appropriate with respect to both the purposes and resources of the National Research
Council.
relationship to the National Research Council is an insurance of
objectivity; it maintains a full-time research correlation staff of 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
specialists in highway transportation matters to bring the findings of
balance of disciplines appropriate to the project. The opinions and conclusions expressed
research directly to those who are in a position to use them. or implied are those of the research agency that performed the research, and, while they have
The program is developed on the basis of research needs identified been accepted as appropriate by the technical committee, they are not necessarily those of
the Transportation Research Board, the National Research Council, the American
by chief administrators of the highway and transportation departments
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and by committees of AASHTO. Each year, specific areas of research Administration, U.S. Department of Transportation.
needs to be included in the program are proposed to the National Each report is reviewed and accepted for publication by the technical committee according
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needs are defined by the Board, and qualified research agencies are The Transportation Research Board of the National Academies, the National Research
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selected from those that have submitted proposals. Administration and
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surveillance of research contracts are the responsibilities of the National Cooperative Highway Research Program do not endorse products or manufacturers. Trade
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The needs for highway research are many, and the National
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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
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.
F O R E W O R D
By Amir N. Hanna
Staff Officer
Transportation Research Board
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
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