SHRP-C-345 Synthesis of Current and Projected Concrete Highway Technology David Whiting, Alan Todres, Mohamad Nagi Construction Technology l,aboratories, Inc. 5420 Old Orchard Road Skokie, IL 60077 Thomas Yu, David Peshkin, Michael Darter ERES Consultants, Inc. 8 Dunlap Court Savoy, IL 61874 Jens Holm, Mette Andersen, Mette Geiker G.M. Idorn Consult A/S Biokken 44 DK-3460 Birkerod, Denmark Strategic Highway Research Program National Research Council Washington, DC 1993 SHRP-C-345 ISBN 0-309-05267-X SHRP-89-C-206 Program Manager: Don M. ttarriott Project Manager: hzam Jawed Program Area Secretary: Carina Hreib Copy Editor: Kathan'n Bine Brosseau August 1993 key words: admixtures aggregates fibers portland cement concrete curing of finishing of mixing of overlays placement of recycling of pavement quality control nondestructive testing Strategic Highway Research Program 2101 Constitution Avenue N.W. Washington, DC 20418 (202) 334-3774 The publication of this report does not necessarily indicate approval or endorsement by the National Academy of Sciences, the United States Government, or the American Association of State Highway and Transportation Officials or its member states of the findings, opinions, :onclusions, or recommendations either inferred or specifically cxpressed herein. ©1993 National Academy of Sciences 2MINAPI8O3 Acknowledgments The research described herein was supported by the Strategic Highway Research Program (SHRP). SHRP is a unit of the National Research Council that was authorized by Section 128 of the Surface Transportation and Uniform Relocation Assistance Act of 1987. iii Contents Acknowledgments ................................................. iii List of Figures .................................................... vii IAst of Tables .................................................... ix Foreword ....................................................... xi Abstract ........................................................ 1 Executive Summary ................................................ 3 1 Introduction ................................................... 1i 2 Current and Projected Concrete Materials Technology ..................... 15 Cements ................................................... 15 Aggregates ................................................. 32 Admixtures ................................................. 50 References ................................................. 85 3 Current and Projected Concrete Production Technology ........ ........... 104 Concrete Mix Proportioning Procedures ............................ 104 Materials Storage ............................................ 109 Batching .................................................. 110 Mixing ................................................... 1!3 Transportation and Delivery .................................... 115 References ................................................ 117 4 Current and Projected Highway Construction Practices .................... 121 Placement of Highway Concrete ................................. 121 Consolidation of Concrete ..................................... 125 Finishing of Concrete ......................................... 128 Curing of Concrete .......................................... 132 References ................................................ 141 5 Impact of l)eveloping Technologies on Applications Area ................. 144 Pavement Reconstruction Proiects ................................ 144 Full-depth Repair and Slab Replacement ........................... 159 Partial-depth Repair .......................................... 168 Overlays .................................................. 176 Concrctc Recycling .......................................... 186 Rcferenccs ................................................ 194 6 Jobsite Testing of Concrete ....................................... 203 Traditional Approaches ....................................... 203 New Developments in Nondestructive Tcsting of Concrete ............... 204 Future Trends .............................................. 235 Retbrences ................................................ 237 7 Quality Control/Quality Assurance Functions .......................... 242 Quality Assurance Schemes and Their lnaplenacntation .................. 242 Quality Assurance Schemes tbr Concrztc Pavcmcnt Construction .......... 243 Implementation of SQA ....................................... 248 Current Status of Quality Assurance Systems ........................ 250 Expected Future Trends ....................................... 252 References ................................................ 253 Appendix: European Highway Concrete Practice .......................... 255 Definition of Highway Concrete Practice ........................... 256 Belgium ................................................. 256 Denmark ................................................. 260 Finland ................................................... 264 France ................................................... 266 Germany ................................................. 269 Sweden .................................................. 273 The United Kingdom ......................................... 275 Summary of Current and Future Trends ............................ 278 References ................................................ 281 vi List of Figures 2.1 Schedule of repair works for paving concrete (Uchikawa and Kohno 1983) ................................................. 30 2.2 Curves indicate the limits specified in ASTM C 33 for fine aggregate and for one typically used size number (grading size) of coarse aggregate (Kosmatka and Panarese 1988) ............................. 34 2.3 U.S. map shows the states in which alkali-silica reactivity problems have been reported (SHRP 1991) ................................... 48 2.4 Initial and final setting periods of a cement paste containing different amounts of calcium chloride (Ramachandran 1984) ...................... 60 4.1 Concrete strength increases with age as long as moisture and a favorable temperature are present for hydration of cement (Kosmatka and Panarese 1990) ............................................... 134 5.1 Strength gain characteristics of the Fast-Track mixes .................... 148 5.2 Typical permeable base pavement sections ........................... 156 5.3 Transverse joint evaluation and rehabilitation selection for jointed concrete pavements (based on visual inspection of individual joints) ..................................................... 160 5.4 Repair layout for jointed plain concrete pavements ...................... 162 5.5 Repair layout for jointed reinforced pavements ........................ 164 vii 5.6 Schematic of typical crusher plant (Van Matre and Schutzbach 1989) ......... 189 6.1 Diagram of a typical direct transmission nuclear gage (Whiting and Tayabji 1988) ................................................ 215 6.2 Diagram of nuclear gage operating in bzckscatter mode (Whiting and Tayabji 1988) ...................................... 217 6.3 Diagram of consolidation monitoring de¢ice (CMD) (Whiting and Tayabji 1988) ...................................... 218 6.4 Twin-probe nuclear density gage (Whiti:lg and Tayabji 1988) .............. 219 6.5 Components of the fiber-optic airmeter ,Ansari 1991) .................... 222 6.6 Schematic of pullout test (In-place methods 1988) ...................... 228 7.1 A comparison of quality assurance systems for highway construction (Quality assurance 1979) ....................................... 244 7.2 Examples of expected pay curves for maximum pay factors at 100% (a) and 105% (b) (Barros, Weed, and Willenbrock 1983) .................... 249 viii List of Tables 2.1 Portland cement types and their uses ................................ 17 2.2 Effects of cements on concrete properties .............................. 20 2.3 Blended cement types and blended ratios ............................. 21 2.4 Influence of aggregate characteristics on concrete properties (Popovics 1979; Kummer and Meyer 1967; UCA 1974) ................... 36 2.5 Effects of aggregate properties on highway concrete (Marek et al. 1972) ....... 37 2.6 Summary of general aggregate types used by states (Witczak et al. 1971 ....... 39 2.7 Aggregate type code (Witczak et al. 1971) ............................ 40 2.8 Effects of concrete constituents on air entrainment (Whiting and Stark 1983) .................................................. 53 2.9 Effect of production procedures, construction practices, and environmental variables on air content (Whiting and Stark 1983) ....................... 54 2.10 Antifreeze admixture types and their eutectic temperature (Korhonen and Cortez 1991) .............................................. 83 3.1 Concrete mix proportions specified by Ohio DOT ...................... 105 5.1 Fast-Track and Fast-Track II mix proportions ......................... 149 5.2 Permeable base gradations ....................................... 154 ix 5..3 Truck load distribution Ibr mulliple-lane, controlled access highways (I leinrichs et al. I_)89) ......................................... 157 6.1 Relative advantages and disadvantages cf nuclear density :gage types (Whiting and Tayabji 1988) ...................................... 221 7.1 Typical steppcd pay schedule (l?,arros, Weed, and Willenbrock 1-(_ )8__)'_" ......... 248 X Foreword The goal of the concrete research of the Strategic Highway Research Program (SHRP) is to develop the knowledge,