Mitigation of Cracking in Cast-In-Place Reinforced Concrete Box Culverts in Alabama by Layton ...

288 Pages·2012·10.95 MB·English

by  Will Minton

Mitigation of Cracking in Cast-In-Place Reinforced Concrete Box Culverts in Alabama

by

Layton Wilson Minton

A thesis submitted to the Graduate Faculty of
Auburn University
in partial fulfillment of the
requirements for the Degree of
Master of Science

Auburn, Alabama
December 8, 2012

Keywords: thermal stresses, joints, temperature and shrinkage reinforcement

Copyright 2012 by Layton Wilson Minton

Approved by

Anton K. Schindler, Chair, Professor of Civil Engineering
Robert W. Barnes, James J. Mallett Associate Professor of Civil Engineering
James S. Davidson, Professor of Civil Engineering
Abstract

Significant cracking was observed in Alabama Department of Transportation (ALDOT)
cast-in-place (CIP) reinforced concrete box culverts in the Anniston East Bypass (AEB) project
in Anniston, AL. Numerous wide, transverse cracks were observed inside the culvert barrels,
and cracking was also observed in the culvert wingwalls.
Because of the cracking problems in the AEB project, crack condition surveys were done
of other CIP reinforced concrete box culverts throughout Alabama to investigate the distress. An
instrumentation and testing plan was also developed for a CIP reinforced concrete box culvert
under construction in order to evaluate the stress, strain, and temperature development as well as
other properties. The amount of temperature and shrinkage reinforcement required to produce
acceptable average crack widths in CIP reinforced concrete box culverts was investigated as
well.
It was concluded that the transverse cracking was most likely a result of restrained
thermal and drying shrinkage deformations in the concrete. Transverse contraction joints in the
culvert barrel and vertical wingwall joints were proposed to control the occurrence of these
cracks. The amount of longitudinal temperature and shrinkage reinforcement was also
recommended to be increased to control the crack widths to 0.012 in. (0.30 mm).
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Acknowledgements

I would first like to thank Dr. Anton Schindler for the guidance and instruction he
provided throughout this research project and my time as a graduate student. I also thank Dr.
Robert Barnes and Dr. James Davidson for their contributions to this thesis. Billy Wilson, Ryan
Whaley, Dr. Junsuk Kang, Adam Wilkinson, and Stephen Swindall also deserve thanks. This
project would not have been completed without their help. Finally, I must thank my parents, Bill
and Lesa Minton, and my brother Carson. None of this would have been possible without their
love and support.
I also must thank Rodney McCain, Russell Taylor, Eric Robbins, Curtis Lowe, Leonard
Hope, Terence Williamson, Sharon Fuller and Sergio Garcia of the Alabama Department of
Transportation (ALDOT). Their help in obtaining culvert plans, and coordinating culvert visits
was invaluable to the research effort. I would also like to thank ALDOT for funding this
research project.
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Table of Contents

Abstract ………………………………………………………………………………………..… ii
.
Acknowledgements …………………………………………………………………………….. iii
.
List of Tables ………………………………………………………………………………….. xv
.
List of Figures …………………………………………………………………………………. xvi
.
Chapter 1 Introduction ……………………………………...………………………………..... 1
.
1.1 Background …………………………………………………………………................ 1
.
1.1.1 Box Culverts ………………………………………………………………......… 1
..
1.1.2 Culvert Cracking in the Anniston East Bypass (AEB) ………………………..… 3
..
1.2 Objectives …………………………………………………………….……................. 7
.
1.3 Research Approach ………………………………………………………………........ 7
.
1.4 Definitions and Terminology …………………………………………………...…….. 8
.
1.4.1 Culvert Terminology ………………………………………………….…………. 8
.
1.4.2 Definitions ……………………………………………………………………….. 9
.
1.4.3 Joint Terminology ……………………………………………………..……..… 11
..
1.5 Thesis Outline ………………………………………………………………….......... 12
.
Chapter 2 Literature Review ……………………………………………………………….… 14
.
2.1 Introduction …………………………………………………………………….......... 14
.
2.2 Early-Age Cracking Mechanisms ………………………………………………...…. 15
.
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2.2.1 Thermal Stresses …………………………………………...……………..…… 15
.
2.2.2 Plastic Shrinkage ………………………………………………………….......... 21
.
2.2.3 Autogenous and Chemical Shrinkage …………………………………….......... 22
.
2.2.4 Drying Shrinkage ……………………………………………………………… 24
.
2.3 Long-Term Durability ………………………………………………………….......... 27
.
2.3.1 Corrosion ………………………………………………………………….......... 27
.
2.4 Other Causes of Concrete Distress ………………………………………………...… 30
.
2.4.1 Inadequate Curing …………………………………………………………...…. 30
.
2.5 Crack Control ……………………………………………………………………...… 31
.
2.5.1 Reinforcement ………………………………………………………….............. 31
.
2.5.2 Joints …………………………………………………………………………… 34
.
2.5.2.1 Construction Joints …………………………………………..…........... 35
.
2.5.2.2 Contraction Joints ……………………………………………………… 37
.
2.5.2.3 Expansion Joints ………………………………………………….......... 43
.
2.5.2.4 Joint Sealants, Joint Fillers, and Waterstops ……………...………….… 45
.
2.6 Crack Repair ………………………………………………………………….……… 49
.
2.6.1 Epoxy Injection ………………………………………………………...………. 50
.
2.6.2 Routing and Sealing ……………………………………………………….…… 51
.
2.7 AASHTO Reinforced Concrete Box Culvert Construction and Design Practices ...… 53
.
2.7.1 Wall Height Construction Limitations …………………...…………….............. 53
.
2.7.2 Concrete Protection from Environmental Conditions ……………………..…… 53
.
2.7.2.1 Protection from Hot-Weather Conditions ……………………………… 53
.
2.7.2.2 Protection from Cold-Weather Condition ……………………………… 54
.
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2.7.3 Joints …………………………………………………………………………… 54
.
2.7.3.1 Construction Joints …………………………………………………..… 54
.
2.7.3.2 Contraction Joints ……………………………………………………… 55
.
2.7.3.3 Expansion Joints …………………………………………………..…… 55
.
2.7.3.4 Waterstops ……………………………………………………………… 56
.
2.7.3.5 Concrete Culvert Joint Sealants ……………………………………...… 56
.
2.7.4 Reinforcement ………………………………………………………………...... 57
.
2.8 Box Culvert Construction Practices of SASHTO States ……………………….......... 58
.
2.8.1 Arkansas State Highway and Transportation Department (AHTD)………….… 58
.
2.8.1.1 General Construction …………………………………………...……… 58
.
2.8.1.2 Wall Height Construction Limitations ……………………………….… 58
.
2.8.1.3 Concrete Protection from Environmental Conditions …………….......... 59
.
2.8.1.3.1 Protection from Hot-Weather Conditions …………………….......... 59
.
2.8.1.3.2 Protection from Cold-Weather Conditions ………………………… 59
.
2.8.1.4 Joints …………………………………………………………………… 59
.
2.8.1.4.1 Joint Waterproofing ……………………...………………………… 59
.
2.8.1.4.2 Joint Filler …………………………………………………….......... 59
.
2.8.1.4.3 Joint Sealant ………………………………………………...……… 59
.
2.8.2 Florida Department of Transportation (FDOT) ………………………...……… 60
.
2.8.2.1 General Construction ………………………………………………...… 60
.
2.8.2.2 Wall Height Construction Limitations ………………………….……… 62
.
2.8.2.3 Concrete Protection from Environmental Conditions ...………………... 62
.
2.8.2.3.1 Protection from Hot-Weather Conditions……...…………………… 62
.
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2.8.2.3.2 Protection from Cold-Weather Conditions ………………………… 62
.
2.8.2.4 Joints …………………………………………………………………… 63
.
2.8.2.4.1 Construction Joints ………………………………………………… 63
.
2.8.2.4.2 Joint Waterproofing …………………………………………........... 63
.
2.8.2.4.3 Joint Filler ………………………………………………...…........... 63
.
2.8.2.4.4 Joint Sealant …………………………………………...…………… 64
.
2.8.3 Georgia Department of Transportation (GDOT) ……………………………… 64
.
2.8.3.1 General Construction …………………………………………...……… 64
.
2.8.3.2 Concrete Protection from Environmental Conditions ……………......... 65
.
2.8.3.2.1 Protection from Cold-Weather Conditions ………………………… 65
.
2.8.3.3 Joints …………………………………………………………………… 65
.
2.8.3.3.1 Construction Joints ……………………………………………….... 65
.
2.8.3.3.2 Joint Waterproofing ...……………………………………………… 66
.
2.8.3.3.3 Joint Filler …………………………………………………..…........ 66
.
2.8.3.3.4 Joint Sealant …………………………………………………...…… 66
.
2.8.4 Kentucky Transportation Cabinet (KYTC) …………………………………… 67
.
2.8.4.1 General Construction ……………………………………...…………… 67
.
2.8.4.2 Wall Height Construction Limitations ……………………………….... 68
.
2.8.4.3 Concrete Protection from Environmental Conditions ………................. 69
.
2.8.4.3.1 Protection from Hot-Weather Conditions …………...…..…………. 69
.
2.8.4.3.2 Protection from Cold-Weather Conditions …………….………….. 69
.
2.8.4.4 Joints …………………………………………………………………... 69
.
2.8.4.4.1 Construction Joints ………………………………………………… 69
.
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2.8.4.4.2 Contraction Joints …………………...…………………………….. 70
..
2.8.4.4.3 Expansion Joints ……………….……………………………….…. 70
.
2.8.4.4.4 Joint Filler …………………………………………………….…… 71
.
2.8.4.4.5 Joint Sealant ………………………….………………………….… 71
.
2.8.5 Louisiana Department of Transportation and Development (LA DOTD)…. .…. 72
.
2.8.5.1 General Construction …………………………………….……….…… 72
.
2.8.5.2 Wall Height Construction Limitations ……………………................… 74
.
2.8.5.3 Concrete Protection from Environmental Conditions …………….….... 74
.
2.8.5.3.1 Protection from Cold-Weather Conditions ………..………….…… 74
.
2.8.5.4 Joints ………………………………………………..…………….…… 74
.
2.8.5.4.1 Construction Joints …………………….…………………….……. 75
.
2.8.5.4.2 Expansion Joints …………………………………………….…….. 76
.
2.8.5.4.3 Joint Waterproofing ………………………………………….……. 78
.
2.8.5.4.4 Joint Filler ………………………………………………….……… 78
.
2.8.5.4.5 Joint Sealant ………………...……………………………….…….. 78
.
2.8.6 Mississippi Department of Transportation (MDOT) …...……………….…….. 78
.
2.8.7 North Carolina Department of Transportation (NCDOT) …………….……..... 78
.
2.8.7.1 General Construction …………………………………………….……. 78
.
2.8.7.2 Wall Height Construction Limitations …………..…………….………. 79
.
2.8.7.3 Concrete Protection from Environmental Conditions ……...….………. 79
.
2.8.7.3.1 Protection from Cold-Weather Conditions ………….…….………. 80
.
2.8.7.4 Joints …………………………………………………………….…….. 80
.
2.8.7.4.1 Construction Joints ……………….………………………….…….. 80
.
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2.8.7.4.2 Expansion Joints …………………………….……………….……. 81
.
2.8.7.4.3 Joint Filler ……………………………………..…………….…….. 81
.
2.8.7.4.4 Joint Sealant …………………………………...………….……….. 82
.
2.8.8 South Carolina Department of Transportation (SCDOT) …………….……..… 82
.
2.8.8.1 General Construction …………………………………………….……. 82
.
2.8.8.2 Concrete Protection from Environmental Conditions ………….……… 82
.
2.8.8.2.1 Protection from Hot-Weather Conditions …………..……….…….. 82
.
2.8.8.2.2 Protection from Cold-Weather Conditions ………….……….……. 83
.
2.8.8.3 Joints ………………………………………….……………….…….…. 83
.
2.8.8.3.1 Construction Joints ………………………………………………… 83
.
2.8.8.3.2 Joint Waterproofing …………………………………………...…… 84
.
2.8.8.3.3 Joint Filler ……………………………………………..…………… 84
.
2.8.9 Tennessee Department of Transportation (TDOT) …………………………….. 84
.
2.8.9.1 General Construction ………………………………………………..… 84
.
2.8.9.2 Wall Height Construction Limitations ………………………….……… 85
.
2.8.9.3 Concrete Protection from Environmental Conditions …………….……. 85
.
2.8.9.3.1 Protection from Hot-Weather Conditions ……………………..…… 85
.
2.8.9.3.2 Protection from Cold-Weather Conditions ……………..………….. 86
.
2.8.9.4 Joints …………………………………………………………………… 86
.
2.8.9.4.1 Construction Joints ………………………………………………… 86
.
2.8.9.4.2 Contraction Joints ……………………………………………......... 90
.
2.8.9.4.3 Expansion Joints …………………………………………………… 93
.
2.8.9.4.4 Joint Waterproofing …………………………………………..…… 94
.
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2.8.9.4.5 Joint Filler ………………………………………………………..… 94
.
2.8.9.4.6 Joint Sealant …………………………………………………...…… 94
.
2.8.10 Virginia Department of Transportation (VDOT) ……………………………… 95
.
2.8.10.1 General Construction ………………………………………………..… 95
.
2.8.10.2 Joints ……………………………………………………………..……. 96
.
2.8.10.2.1 Construction Joints ………………………………………………… 96
.
2.8.10.2.2 Joint Waterproofing …………………………………………..…… 96
.
2.8.10.2.3 Joint Filler ……………………………………………………….… 96
.
2.8.10.2.4 Joint Sealant ……………………………………………………...… 96
.
2.8.11 West Virginia Department of Transportation (WVDOT) ………………..……. 97
.
2.8.11.1 General Construction ………………………………………..………… 97
.
2.8.11.2 Concrete Protection from Environmental Conditions ……………..…… 97
.
2.8.11.2.1 Protection from Hot-Weather Conditions …………………..……… 97
.
2.8.11.2.2 Protection from Cold-Weather Conditions ………………………… 98
.
2.8.11.3 Joints …………………………………………………………………… 98
.
2.8.11.3.1 Joint Waterproofing ……………………………………………..… 98
.
2.8.11.3.2 Joint Filler ………………………………………………………..... 98
.
2.8.11.3.3 Joint Sealant ………………………………………………...……… 99
.
Chapter 3 Box Culvert Crack Condition Surveys ……………………..……………….…… 100
.
3.1 Introduction …………………………………………………..………………..…… 100
.
3.2 Survey Procedure ………..……………………………………...………………..… 100
.
3.3 Culverts Visited …………………………….……………………………………… 101
.
3.3.1 Anniston East Bypass (AEB) ………………………………………………… 103
.
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