Causes & Cures for Cracking of Concrete Barriers
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MDOT RC-1448 CSD-2003-01 CAUSES & CURES FOR CRACKING OF CONCRETE BARRIERS August 2004 Center for Structural Durability A Michigan DOT Center of Excellence This report presents the results of research conducted by the authors and does not necessarily reflect the views of the Michigan Department of Transportation. This report does not constitute a standard or specification. Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. MDOT Project Manager Research Report RC-1448 John F. Staton, P.E. 4. Title and Subtitle 5. Report Date Causes and cures for cracking of concrete barriers August 2004 7. Author(s) 6. Performing Organization Code Dr. Haluk Aktan, Ph.D, P.E. and Mr. Upul Attanayaka WSU 9. Performing Organization Name and Address 8. Performing Org Report No. Department of Civil & Environmental Engineering College of Engineering Wayne State University CSD-2003-01 5050 Anthony Wayne Drive Detroit, MI 48202 12. Sponsoring Agency Name and Address 10. Work Unit No. (TRAIS) Michigan Department of Transportation Construction and Technology Division 11. Contract Number: P.O. Box 30049 Lansing, MI 48909 2002-0341 11(a). Authorization Number: 15. Supplementary Notes 13. Type of Report & Period Covered Final 03/2002 – 08/2003 14. Sponsoring Agency Code 16. Abstract The research objective was to investigate the causes of premature deterioration of concrete bridge barriers with the goal of developing strategies for corrective actions. The synthesis of all the data collected in various tasks revealed that barrier deterioration starts with early formation of vertical cracking as a result of the tensile stress due to early-age thermal load. Volume change of concrete due to temperature and shrinkage occurs simultaneously. An increase in drying shrinkage arising from delays in curing also affects the barrier cracking. Additionally, drying shrinkage, beyond the very early ages, increases the width of cracks that have formed due to thermal loads. Penetration of moisture and other corrosive agents through the cracks causes reinforcing steel corrosion leading to horizontal cracking and finally the delamination and spall. Insufficient consolidation of concrete often observed in slipformed barriers accelerated the deterioration. Concrete parameters controlling the thermal load are the cement type, content, and fineness, ambient temperature at the time of concrete placement, and the time of inception of curing. From field inspection data and the finite element results it was found that the minimum possible full-length vertical crack spacing is equal to barrier height. One of the most important recommendations drawn from this study is the implementation of crack arrestors at about 3- feet intervals. The crack arrestors, some with cracks formed at full length, should be sealed with durable silicone-based flexible material during first scheduled maintenance cycle. Additional recommendations include the substitution of cement with mineral admixtures and the development of detailed specifications for barrier construction. 17. Key Words 18. Distribution Statement Bridge barrier, premature-deterioration, concrete, thermal No restrictions. This document is available to the public load, shrinkage, transverse cracking through the Michigan Department of Transportation. 19. Security Classification (report) 20. Security Classification (Page) 21. No of Pages 22. Price Unclassified Unclassified CAUSES AND CURES FOR CRACKING OF CONCRETE BARRIERS Submitted to the RESEARCH ADVISORY PANEL Submitted by the CENTER FOR STRUCTURAL DURABILITY A Michigan DOT Center of Excellence Department of Civil & Environmental Engineering 5050 Anthony Wayne Drive Detroit, MI 48202 Dr. Haluk Aktan, Ph.D, P.E Mr. Upul Attanayaka Professor Graduate Research Assistant Tel: 313-577-3825 Tel: 313-577-9293 Fax: 313-577-9850 Fax: 313-577-9850 E-mail: [email protected] E-mail: [email protected] August 2004 EXECUTIVE SUMMARY This research need was established in a report by J.F. Staton and J. Knauff (1999), titled, “Evaluation of Michigan’s Concrete Barriers”. The report described that many of the current generation barriers used by the Michigan Department of Transportation (MDOT) are deteriorating at a rate greater than expected. This study was designed in order to further evaluate the observations described in the above report and to develop a comprehensive understanding of the barrier life span, from construction to repair or replacement. The objectives of this project were to investigate the causes of concrete bridge barrier deterioration with the goal of developing strategies for corrective action. The strategies were developed by examining and determining the distress states and mechanisms. Material selection, mixture design, and/or modifications to construction procedures are proposed to reduce premature deterioration. The project was designed in eight tasks including literature review, a nation wide survey of State Highway Agencies (SHAs), inspection of existing barriers, monitoring barrier construction, laboratory testing, and data synthesis. The primary goal of the project was to develop recommendations in order to minimize or eliminate barrier cracking. As a first step, a preliminary inspection of existing barriers was performed and observed distresses were documented. Observed distresses and their causes were examined in the literature review. The causes of distress are classified as design related, material related, and construction practice related. In any case, most of the distress types can be eliminated with good construction practices. Most distresses are observed at early ages and initiate from unmitigated volume change of concrete at very early ages. Improper construction practices that initiate the progression of distress are early removal of forms in form-cast barriers, insufficient consolidation, and lack of wet curing. The survey responses of State Highway Agencies provided information on their experiences with regard to the early-age cracking problem with barriers and, materials and construction practices used for concrete barriers (especially New Jersey type). CENTER FOR STRUCTURAL DURABILITY – Causes & Cures for Cracking of Concrete Barriers i All the survey respondents indicated that premature distress is observed on concrete bridge barriers. Those observed distresses are of the same types observed in Michigan. Though all the respondents identified premature distress, only Illinois, New Mexico, Vermont, and Virginia acknowledged that they have experienced an overall durability problem with the bridge barriers. Nationally, both form-cast and slipformed barriers are commonly used. Precast New Jersey type barriers are also used in States of Florida, Maryland, New Hampshire, New York, Texas, Vermont, and Virginia. Sprayed curing compound on the slipformed barrier surfaces is the most often cited method of curing. States of Illinois, Minnesota, New Hampshire, New Mexico, New York, and Washington use a different concrete mix design for the barriers than for the deck. All the respondents specified the use of ground granulated blast-furnace slag (GGBS) and flyash (FA) in the mix design for the goal of reduction of the concrete permeability. States of Massachusetts, New York, and Virginia also use silica fume (SF) along with GGBS and FA. Except in States of Alabama, Idaho, Nevada, North Dakota, Virginia, and Washington the most prevailing method of surface finishing is the rubbed method. Most of the respondents emphasized changing the mix design and curing procedure for improved durability of New Jersey type barriers. During field inspections, the condition of barriers of a total of 21 bridges consisting of 155 barrier segments with a total length of 3,729 ft. were documented. According to the inspection data, the vertical (or transverse) cracking is the leading cause of most of other distress types. The number of vertical cracks is important in establishing the deterioration rate. Horizontal cracks can be classified as either local or continuous. The local cracks are often on the barrier vertical face. Continuous horizontal cracks are also mostly observed on the vertical face, about the level of top longitudinal reinforcement. In barriers with horizontal cracking, significant section loss is often observed around the barrier top portion. The construction of four bridge superstructure replacement projects with New Jersey type barriers was monitored. In two of the projects, the barriers were slipformed. In the other two projects, barriers were form-cast using metal forms on the traffic bearing side and wood forms on the fascia. CENTER FOR STRUCTURAL DURABILITY – Causes & Cures for Cracking of Concrete Barriers ii In the slipformed barriers, concrete was not sufficiently consolidated. Though it is difficult to conclusively evaluate the barrier interior without taking well distributed core samples, while the joints were being cut, honeycombing and large cavities were observed. The curing compound was sprayed using the MDOT recommended procedure. However, the spray was not uniform over the barrier surface as specified in the MDOT Standard Specifications for Construction. Two days after placement, inspection revealed map cracking on most of the portion of the barrier surface as well as few full-length vertical cracking. In form-cast barriers, the top surface of the concrete is not covered or protected from direct atmospheric exposure. Forms were removed approximately 18 hours following construction (this is in compliance with the specification requirements).