AGGREGATE PROPORTIONING FOR SLIP FORMED PAVEMENTS AND FLOWABLE CONCRETE By MARLLON DANIEL COOK Bachelor of Science in Civil Engineering Oklahoma State University Stillwater, Oklahoma 2012 Master of Science in Civil Engineering Oklahoma State University Stillwater, Oklahoma 2013 Submitted to the Faculty of the Graduate College of the Oklahoma State University in partial fulfillment of the requirements for the Degree of DOCTOR OF PHILOSOPHY July, 2015 AGGREGATE PROPORTIONING FOR SLIP FORMED PAVEMENTS AND FLOWABLE CONCRETE Dissertation Approved: Dr. M. Tyler Ley Dissertation Adviser Dr. Bruce W. Russell Dr. Stephen Cross Dr. Peter Clark ii Name: MARLLON DANIEL COOK Date of Degree: JULY, 2015 Title of Study: AGGREGATE PROPORTIONING FOR SLIP FORMED PAVEMENTS AND FLOWABLE CONCRETE Major Field: CIVIL ENGINEEERING Abstract: This is an investigation into developing a relationship between aggregate proportioning and the workability of concrete for slip formed pavements and flowable concrete applications. Workability tests were developed for each application. Various aggregate proportioning techniques and aggregate concepts were evaluated. The aggregate proportioning technique based off gradation was shown to predictably change the workability of the concrete. Almost 800 different mixtures were conducted to validate workability tests and also develop gradation and proportioning limits for slip formed pavement and flowable concrete applications. These gradation and proportioning limits were further investigated to find insights into a mechanism. iii TABLE OF CONTENTS Chapter Page I. BASIC CONCRETE MIXTURE DESIGN AND WORKABILITY CONCEPTS ...1 1.0 Introduction ........................................................................................................1 1.1 Cementitious Material & Water .........................................................................2 1.2 Aggregate ...........................................................................................................2 2.0 Concrete Mixture Design ...................................................................................5 2.1 Proportioning of Paste........................................................................................5 2.2 Proportioning of Aggregate ...............................................................................6 2.3 Proportioning Concrete to Meet a Specification ................................................7 2.3 Concrete Proportioning Methods .......................................................................7 3.0 Workability of Concrete ....................................................................................8 3.1 Workability Behavior of Fresh Concrete ...........................................................9 4.0 Workability Issues of Concrete ........................................................................10 4.1 Inadequate Flow and Stiffness .........................................................................11 4.2 Consolidation Issues ........................................................................................11 4.3 Cohesion Issues of Fresh Concrete ..................................................................11 4.4 Edge Slumping Issues ......................................................................................12 4.5 Surface Finishability Issues .............................................................................13 5.0 Measuring the Workability of Concrete ..........................................................13 6.0 Understanding the Aggregate Effects on Workability .....................................14 7.0 Objectives ........................................................................................................15 II. A WORKABILITY TEST FOR SLIP FORMED PAVEMENTS..........................19 1.0 Introduction ......................................................................................................19 1.1 Current Laboratory Tests for the Workability of Concrete .............................20 1.2 Objectives ........................................................................................................21 2.0 Development of the Box Test ..........................................................................21 2.1 the Box Test Procedure for Comparing the Workability of Mixtures .............25 2.2 Detailed description of the Box Test Procedure ..............................................26 3.0 Materials and Methods .....................................................................................27 3.1 Materials ..........................................................................................................27 3.2 Mixture Design ................................................................................................28 3.3 Mixing and Testing Procedure .........................................................................30 4.0 Results ..............................................................................................................30 4.1 Validating the Box Test ...................................................................................30 iv Chapter Page 4.2 Validating the Procedure for Comparing the Workability of Mixtures ...........32 5.1 Discussion ........................................................................................................35 5.2 Procedure for Comparing the Workability of Different Mixtures ...................35 5.3 Slump and Box Test Measurements ................................................................38 5.4 Improvements to the Box Test .........................................................................38 5.5 Practical Implications.......................................................................................39 6.0 Conclusion .......................................................................................................39 III. THE EFFECTS OF COARSE AGGREGATE ON THE WORKABILITY OF SLIP FORMED CONCRETE PAVEMENTS ................................................................43 1.0 Introduction ......................................................................................................43 1.1 Aggregate Concepts .........................................................................................44 1.2 Combined Gradation Techniques ....................................................................45 1.3 Voids Content ..................................................................................................46 1.4 Specific Surface Area ......................................................................................47 1.5 Objectives ........................................................................................................48 2.0 Materials and Methods .....................................................................................48 2.1 Materials ..........................................................................................................48 2.2 Mixture Design ................................................................................................49 2.3 Mixing and Testing Procedure .........................................................................51 2.4 Using the Box Test to Evaluate the Workability of Mixtures .........................52 3.0 Results ..............................................................................................................53 4.0 Discussion ........................................................................................................62 4.1 Box Test vs. Slump Test ..................................................................................62 4.2 Voids Content and Specific Surface Area .......................................................62 4.3 Coarseness Factor Chart ..................................................................................63 4.4 Individual Percent Retained Chart ...................................................................63 4.5 Aggregate Characteristics and Shape...............................................................64 4.6 Evaluating Gradation with the Power 45 Chart ...............................................64 4.7 Nominal Maximum Coarse Aggregate Size ....................................................65 4.8 Proportioning with the Power 45 and Estimated Min. Voids Content ............65 4.9 Proportioning with a 60/40 blend ....................................................................66 4.10 Practical Implications.....................................................................................67 5.0 Conclusion .......................................................................................................68 IV. INVESTIGATION OF COARSE AGGREGATE GRADATION ON THE WORKABILITY OF SLIP FORMED CONCRETE PAVEMENTS ...................74 1.0 Introduction ......................................................................................................74 1.1 Gradation .....................................................................................................75 1.2 Objectives ....................................................................................................79 2.0 Materials and Methods .....................................................................................79 v 2.1 Materials ....................................................................................................79 2.2 Mixture Design ..........................................................................................79 2.3 Sieve