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Influence of Coarse Aggregate in Portland Cement Concrete on Spalling of Concrete Pavements

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Technical Report Documentation Page I. Report No. I 2. Government Accession No. 3. Recipient's Catalog No. FHWA/TX-97 /1244-11 4. Title and Subtitle 5. Report Date INFLUENCE OF COARSE AGGREGATE IN PORTLAND November 1995 CEMENT CONCRETE ON SP ALLING OF CONCRETE Revised: October 1996 PAVEMENTS 6. Performing Organization Code 7. Author( s) 8. Performing Organization Report No. Sanjaya P. Senadheera and Dan G. Zollinger Research Report 1244-11 9. Performing Organization Name and Address 10. Work Unit No. (fRAIS) Texas Transportation Institute The Texas A&M University System 11. Contract or Grant No. College Station, Texas 77843-3135 Study No. 0-1244 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered Texas Department of Transportation Interim: Research and Technology Transfer Office September 1992-August 1995 P.O. Box 5080 14. Sponsoring Agency Code Austin, Texas 78763-5080 15. Supplementary Notes Research performed in cooperation with the Texas Department of Transportation and the U.S. Department of Transportation, Federal Highway Administration. Research Study Title: Evaluation of the Performance of Texas Pavement Made with Different Coarse Aggregates 16. Abstract Spalling is a form of distress in concrete pavements. However, the current state of knowledge and the available prediction models on spalling indicate a lack of understanding of the spalling mechanism. This research attempts to fill the need to develop a framework to incorporate spalling in the design of concrete pavements based on a mechanistic approach. The report presents results from a comprehensive field survey on spalling in concrete pavements in Texas. Based on the results from this field survey, a mechanism for spalling is proposed. According to this mechanism, spalling is the culmination of damage initiated as· delaminations early in the life of pavements. The development of delaminations is related to the concrete mix design and conditions at the time of paving including ambient conditions and the method of curing. The delaminations are extended into spalls as a result of fatigue damage induced by traffic and temperature fluctuations in the pavement. Early-age analysis of concrete pavements was performed using a finite element program developed to predict stresses in the pavement caused by shrinkage. Results from the analysis indicated that a high level of stress sufficient to create delaminations may be generated at a very early age. The coarse aggregate type in concrete was noted to have a significant effect on the level of spalling. Based on results from laboratory studies, a mechanism on how the aggregate type influences spalling is proposed. This proposed spalling mechanism is included in a framework to incorporate spalling in the design of concrete pavements. 17. Key Words 18. Distribution Statement Spalling, Cracking, Coarse Aggregate, Curing, No restrictions. This document is available to the Properties of Aggregates, Evaluation of Aggregates public through NTIS: National Technical Information Service 5285 Port Royal Road Springfield, Virginia 22161 19. Security Classif.(of this report) 20. Security Classif.( of this page) 21. No. of Pages I 22. Price Unclassified Unclassified 222 1 1 Form DOT F 1700.7 (8-72) Reproduction of completed page authorized INFLUENCE OF COARSE AGGREGATE IN PORTLAND CEMENT CONCRETE ON SPALLING OF CONCRETE PAVEMENTS by Sanjaya P. Senadheera Research Assistant Texas Transportation Institute and Dan G. Zollinger Associate Research Engineer and Associate Professor Texas Transportation Institute Research Report 1244-11 Research Study Number 0-1244 Research Study Title: Evaluation of the Performance of Texas Pavement Made with Different Coarse Aggregates Sponsored by the Texas Department of Transportation in Cooperation with U.S. Department of Transportation Federal Highway Administration November 1995 Revised: October 1996 TEXAS TRANSPORTATION INSTITUTE The Texas A&M University System College Station, Texas 77843-3135 IMPLEMENTATION STATEMENT The spalling research discussed in this report "'ill assist in developing an understanding of the factors that cause spalling in concrete pavements. Spalling was found to result from pre-existing delaminations just below the surface of the pavement. These delaminations were found to occur as early as one week after construction, which suggests that the development of these delaminations is strongly related to the early aged bond strength of the mortar and the coarse aggregate. Factors relative to the construction process were found to be important in terms of the rate of water loss from the surface of the pavement during the hardening process. Polyethylene curing was found to significantly reduce the formation of the delaminated fracture surface. The study also discusses other factors. Use of improved curing techniques can result in reduced maintenance costs for spall repair damage and other related cost benefits to the Texas Department of Transportation. v DISCLAIMER The contents of this report reflect the views of the authors who are responsible for the facts and accuracy of the information presented herein. The contents do not necessarily reflect the official views or policies of the Federal Highway Administration or the Texas Department of Transportation. This report does not constitute a standard, specification, or regulation. Vll ACKNOWLEDGMENT Research findings presented in this report are a result ofjoint efforts between the Texas Transportation Institute, Texas A&M University, and the Center for Transportation Research, University of Texas at Austin. The authors would like to thank the staff of the Texas Department of Transportation for their support throughout this study as well as the U.S. Department of Transportation, Federal Highway Administration. Vlll TABLE OF CONTENTS Page LIST OF FIGURES ....................................................... x1 LIST OF TABLES ....................................................... xv SUMMARY ........................................................... xvii CHAPTER 1: INTRODUCTION . 1 CHAPTER 2: EXISTING KNOWLEDGE BASE ON SP ALLING . 7 Field Observations . 7 Modeling of Spalling . 10 Results From Other Studies on Spalling Data Analysis . 12 CHAPTER 3: FIELD STUDY OF CONCRETE PAVEMENTS............ 15 Introduction . 15 Field Survey Sections . 16 Selection of Survey Sections and Performance of Field Surveys . 16 Observations from Field Surveys . 20 Factors Related to Pavement Construction ........................ 36 Preliminary Analysis ofSpalling Data . 42 Texas Rigid Pavement Database (TRPD) ......................... 42 Results . 42 CHAPTER 4: EFFECT OF AGGREGATES ON SPALLING . 47 Properties of Aggregates in Portland Cement Concrete . 48 Physical Properties . 48 Chemical Properties . 49 Geometric Properties . 51 Interfacial Bond Between Cement Paste and Aggregate . 54 Morphological Nature of the Bond . 54 Chemical Nature of Bond . 56 Mechanical Nature of Bond . 57 Effect of Bond on Concrete Performance . 58 Methods ofhnproving Cement Paste-Aggregate Bond ............... 59 Laboratory Studies on Concrete Made with Different Coarse Aggregates . 61 Fracture Mechanics Concepts . 63 Application of Fracture Mechanics to Concrete ..................... 69 Experimental Program . 73 Indirect (Split) Tensile Test ofNotched Cylinders . 75 IX Test Factorial . 78 Results . 79 Test Factorial . 79 Results . 83 Analysis of Fracture Surface Area of Failed Indirect Tensile Fracture Test Specimens . 86 Size-Effect Beam Fracture Test . 90 Microscopical Examination of Portland Cement Concrete . 96 CHAPTER 5: DELAMINATION OF CONCRETE PAVEMENTS . 101 Factors Affecting Delamination in Concrete Pavements . 101 Prediction of the Occurrence ofDelaminations by Early-Age Stress Analysis of Concrete Pavements . I 04 Factors Affecting Pore Humidity . I 06 Finite Element Computer Program . 108 Sensitivity Analysis of Early-Age Concrete Pavements . 115 Results from the Analysis of Early-Age Concrete Pavements . 119 Discussion of Results . 122 CHAPTER 6: SP ALLING AS A DESIGN CRJTERJON . 131 Influence of Interface Friction at Delaminations Faces on Spalling . 131 Finite Element Model . 135 Loading Conditions . 136 Material Characterization . 136 Results . 13 7 Development ofSpalling Model Based on Available Data ................. 137 Failure Time Theory and Concept of Survivability . 139 Spalling Model Based on Available Data . 145 Results from the Proposed Spalling Model . 146 Framework for an Improved Spalling Model . 151 Design Framework for Spalling Based on the Calibration Method . 155 Proposed Improved Design Framework . 160 CHAPTER 7: CONCLUSIONS AND RECOMMENDATIONS .................. 163 Conclusions . 163 Recommendations . 166 REFERENCES . 16 7 APPENDIX A 175 APPENDIXB 197 APPENDIXC 201 x LIST OF FIGURES Figure Page 1 Typical Spall in Concrete Pavements . 2 2 Schematic Diagram for Coring, Indicating Coring Positions and Notations . 20 3 Types of Spalls (a) Type-I and (b) Type-Il ............................... 23 4 Two Modes of the Type-II Spall (a) Mode-I and (b) Mode-II ................ 24 5 Concrete Core Taken at a Transverse Crack Indicating Delaminations . 25 6 Schematic Diagram Indicating the Location of the Core Shown in Fig. 5 . 27 7 Type-II Spall With Delamination Extending Beyond the Spall . 27 8 Stages of Spall Development (a) De-Bonding Cracks at the Aggregate-Paste Interface, (b) Delamination, and (c) Spalling . 29 9 Orientation of Spalling in SH-6 East Bypass in Bryan/College Station: (a) Spalling Only on Upstream Side of
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