IC to Mitigate Cracking and Improve Corrosion Performance

Raoufi, K., and. Weiss J.

The Economics, Performance, and Sustainability of Internally Cured Concrete, Part 2

ACI Fall 2012 Convention October 21 24, Toronto, ON
ACI WEB SESSIONS

Ronald E. Vaughn is a Sr. Sales Engineer for Northeast Solite in Saugerties, NY. Awards from the American Concrete Institute include the ASCI Chapter Activities Award, ACI Fellow, and the ACI Certification Award for Outstanding Service. He is an active member of ACI Committees C610, Field Technician Certification; C630, Construction Inspector Certification; C631, Concrete Transportation Construction Inspector Certification; 211, Proportioning Concrete Mixtures; 237, Self-Consolidating Concrete; 345, Concrete Bridge Construction, Maintenance, and Repair; E905, Training Programs and the Membership Committee.

ACI WEB SESSIONS

SP2902 HistoryandEvolutionofInternal CuringofConcrete

12CaseStudiesusing9DifferentAbsorptive AggregatesfromTexasandOklahomato EasternCanada

TheGenesis,EvolutionandAcceleratedUseofInternalCuring HowitProvidesImprovedLifeCyclesatReducedCost
Abstract Firstnoticed byT.C.Powersetalin1948,andthendescribed byBloem,GaynorandMeininger in1965as beneficial forhydration bysupplying waterinternally, construction usersin2012havegraspedhowtheprocessis implemented, howthehydration behaves andhowtheimprovements inmechanical properties, durability and cost maybebeneficial.Sinceexternal curingdoesnotmeetthetimedependent hydration needsoftheconcrete exceptnearthesurface,havingsufficient waterinternally available,whenasandwhereneeded,isvitalfor achievingoptimumcharacteristic qualities.Thereislowerlife cyclecostwithinternal curing(IC)andfrequently lowerfirst cost.In2012,thenumberofprojectsusinginternal curingisincreasing atanescalating ratebecause theprocessissimpleandeconomically implemented.Pavements,bridges,buildings andpervious parkinglotsare beingstarted now,inthisrecession, because construction usersaresavingdollarsastheybuild longerlasting structures whencosts andinterest ratesarelow.Developed byhundreds ofresearchers andinnovators initially to reduceautogenous shrinkage inlowwatercement ratioandhighperformance concrete, usershavefoundthatit reduces dryingshrinkage inmediumwatercement ratioconcrete.Otherattributes havebeenfoundthatinclude permeability reduction (withconsequent lesscorrosion ofreinforcing steel),greater compressive, flexural and mortarstrength, lesswarping,stronger interfacial transition zones,greaterdurability, andlowercarbonation.The amountofabsorbedwaterneeded innormalweightaggregatewasascertained byDaleCrowl in2002andproven byEricMackandNorbertDelatte in2004.Theamountoflightweight aggregateneededasanormalweightsand replacement wasreported byDaleBentz,etalinConcrete International, February,2005. Authors:Butcher, R.,Jones,B.,Kalafat,M.,Roberts,J.,Vaughn,R. Northeast Solite Corporation Richmond,Virginia23227 www.nesolite.com

SelfCuringConcrete,WhyNot?
byBryantMather
Inaletter intheSeptember 2000issueof Concrete International, D.Srinivasan asked,Will therebeaselfcuringconcrete? Myanswer to thisisstronglyaffirmativeforthree reasons. First,mostoftheconcrete thatisproduced and placedeachyearallovertheworldalreadydoes selfcure.Someofitwasntintended tohave anythingdonetoitsexterior surface.But finishingdidinfacttakeplace,andyetthe concretes abilitytoserveitsintendedpurpose hadnotbeensignificantlyreduced. ItwasthisfactthatpromptedRussellFling, whenhebecameACIPresident,toaskthe TechnicalActivitiesCommittee (TAC)tore establishtheInstitutesCuringCommittee. The chargetothecommittee arosefromPresident Flingsexperience thatalotoftheconcretewith whichhewas concernedreceivednotreatment underthe labelofcuring,yetseemed tobenoworsefor thathavingbeenthecase.Iwasgiventhejobof chairingthatcommittee.Thecommittees reportstated initsSection1.2: Curingisthemaintainingofasatisfactory moisturecontentandtemperature inconcrete duringitsearlystagessothatdesiredproperties maydevelop.Curingisessentialinthe productionofconcretethatwillhavethe desiredproperties.Thestrengthanddurability ofconcretewillbefullydevelopedonlyifitis cured.Noactiontothisendisrequired, however,whenambientconditionsofmoisture, humidity,andtemperature aresufficiently favorabletocuring.Otherwise,specifiedcuring measuresshallstartassoonasrequired. Second,mostoftheconcreteintheworldis placedinquantitiesthatareofsufficient thicknesssuchthatmostofthematerialwill remaininsatisfactoryconditionsoftemperature andmoistureduringitsearlystages.Thisisso regardlessofwhatstepsaretaken,ornottaken, toensurethatsuchconditionsaremaintainedin theexteriorlayer. Third,therearecasesinwhichconcretehas beengreatlyassistedinmovingtowardaself curingstatuseitherinadvertentlyordeliberately throughactionstakenintheselectionanduseof materials.I thinkitmayhavebeenRudyValore whotoldmethefollowingstoryaboutconcrete inDallas,TX.Cedricengineersandcontractorsto usestructurallowdensity Wilson,atTexasIndustries,wastryingto encourage (lightweight)aggregate concrete.He arrangedforitsexperimental useinhalfofthe constructionofthesecondfloorslabofasmall motelonastreetcorner;theotherhalfwas placedusingnormaldensityaggregate. Thelow densityaggregates were batchwet.Whenthe timecame,inthelateafternoon,toapplythe whitepigmentedcuringcompoundthatwould formaprotectivemembrane, thecontractors representative atthesitedecidedtoskipthis stepsincethewinddirectionwassuchthat,had heappliedit,alotofeffortwouldhavebeen spentgetting membranematerialoffthecars parked downwind.Thenextmorning,Cedricwentto seehowhislowdensityconcretehadturned outandwassurprisedandpleased.Thenormal densityconcretewasvirtuallydestroyedby dryingshrinkagecracks.Ontheotherhand,the lowdensityconcretehadpracticallynocracking enoughabsorbedwater hadbeenbroughtto theconcrete,thoughnotincludedinthewater cementratio,toeffectivelycompensateforthe contractorsfailuretoapplyformingcuring compound. WeattheCorpsofEngineers Concrete Laboratoryusedthis

Curing,internal supplyingwaterthroughout afreshlyplacedcementitious mixtureusing reservoirs,viaprewettedlightweight aggregates,thatreadilyreleasewateras neededforhydrationortoreplacemoisture lostthroughevaporationorselfdesiccation.

ACITerminology2011

Concrete International

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IC to Mitigate Cracking and Improve Corrosion Performance

Raoufi, K., and. Weiss J.

InternalCuringEvolution
ReduceorEliminateChemicalandAutogenous ShrinkageandCracking GreaterEarlyAgeandLaterCompressiveStrength GreaterEarlyAgeandLaterFlexuralStrength GreaterEarlyAgeandLaterMortarStrength ReducedPermeability ReducedWarping ReducedCarbonation Provision ofLongerLife LowerLifeCycleCost ImprovedHydrationofCementandCementitious Materials

LargestContinuousOverWaterSteelBridge(4miles) 3500PSIMixwith105Density 2nd BridgeBuiltin1973andthe2AsphaltLayerwasremovedfrom theDeckandtheLWDeckwasfoundtobeinExcellentCondition Theapproacheswithnormalweightconcretehadtobereplaced

ImprovedDensityofInterfacialTransitionZone(ITZ) LessReinforcementCorrosion

Chesapeake Bay Bridge Under Construction - 1952

TheLWaggregateintheconcretein1952wasbatched atSSD

Limestonewithabsorptiongreaterthan1%asInternalCuring

Absorbent Limestone Bridge No sign of Cracking in 12/2011 Chesapeake Bay Bridge 60 Years Later - January 2012

TypeKCementwithIC

15%MoistureinIC@100lbs/yd=15lbwater

Main Avenue Bridge Deck, Cleveland, Ohio Type K Cement and IC to Improve Curing No cracking 12/2011

CLEVELAND BRIDGE DECK Using IC Compressive Strength 20% Greater No cracking 12/2011

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IC to Mitigate Cracking and Improve Corrosion Performance

Raoufi, K., and. Weiss J.

Placement
Lightweight Aggregate Infiltration Base Prior to Placement of Pads 1-4

PERVIOUSPAVEMENT

PERVIOUSPAVEMENT TESTPADS

Pad 4 Internal Curing No Poly Control Texture Addition of 100# of LWAS Texture

Pad 3 Internal Curing No Poly

Pad 2 Internal Curing No Poly

Pad 1 Reference/Control Poly Sheeting 14 Days

PERVIOUSPAVEMENTMIXTUREDESIGNS
TABLEI CONTROL CEMENT FINENORMALWEIGHTAGGREGATE 2.61sg FINELIGHTWEIGHTAGGREGATE 1.80sg COARSEAGREGATE 2.68sg SIKAMENT686 SIKAAEA14 WATER AIRCONTENT W/CRATO pcy(kg/m3) 600 (360) 668 (400) 0 2620 (1570) 6oz/cwt (3.9mL/k) 2oz/cwt (1.3mL/k) 166 (75) 6% 0.28 50IC pcy (kg/m3) 600 (360) 668 (400) 50(30) 2620 (1570) 6oz/cwt (3.9mL/kg) 2oz/cwt (1.3mL/kg) 166 (75) 6% 0.28 100 IC pcy(kg/m3) 600 (360) 518 (315) 100 (60) 2620 (1570) 6oz/cwt (3.9mL/kg) 2oz/cwt (1.3mL/kg) 166 (75) 6% 0.28 150 IC pcy(kg/m3) 600 (360) 518 (315)

FLEXURAL AND COMPRESSIVE STRENGTHS

pcy(kg/m3) Pad1 0 50(30) 100(60) 150(90)

Flexural psi(mPa) 210(1.4) 315(2.2) 535(3.7) 425(2.9)

Compressive psi(mPa) 1155(8.0) 1225(8.5) 3825(26.4) 2930(20.2)

150 (90) 2620 (1570) 6oz/cwt (3.9mL/kg) 2oz/cwt (1.3mL/kg) 166 (75) 6% 0.28

Pad2 Pad3 Pad4

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IC to Mitigate Cracking and Improve Corrosion Performance

Raoufi, K., and. Weiss J.

4,500 4,000 3,500 3,000 2,500 2,000 1,500 1,000 500 0 0

COMPRESSIVE STRENGTH vs TIME for TEST PADS 1 THROUGH 4

100LB IC 150LB IC
0lbs/yd IC 50lbs/yd IC 100lbs/y d IC 150lbs/y d IC

DENVER WATER IC SLAB PLACEMENT 10 Million Gallon Water Storage Tank with 285 lb IC = 43 lb/yd (5 gal)

50LB IC CONTR

14 21 Concrete Age (Days)

28

35

DENVERWATERMonolithicPour ContractoralsousedICwalls& columns Noshrinkagecracks

DENVERWATER ICROOF PREPARATION

DIFFERENTAGGREGATESUSED FORDIFFERENT INTERNALCURINGAPPLICATIONS

ConcreteDensity 105 115 Inverted 123128 ModifiedDensity TypeofAggregates lightweightcoarseandlightweightfineaggregate lightweightcoarseandnormalweightfineaggregate normal weightcoarseandlightweightfineaggregate lightweightandnormalweightcoarse, normalweightfineand/orlightweightfineaggregate

Three Story Building in Tulsa Oklahoma Physical Properties and Compressive Strengths
7 Day Air Slump Concrete Compressive Strength Content Temperatur % e 2.8 4.0 4.6 5.0 7.5 7.0 83 F 78 F 83 F 5136 psi 4190 psi 3550 psi 28 Day Compressive Strength

Date

7/27/11 7/27/11 7/30/11

7064 psi 6440 psi 4911 psi

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IC to Mitigate Cracking and Improve Corrosion Performance

BOULEVARD BRIDGE , RICHMOND, VA NON-AIR MIX - AFTER 50 YEARS Wearing
Surface

Raoufi, K., and. Weiss J.

0.25 Carbonation

SEBASTIAN INLET BRIDGE, FLORIDA Built in1964 in Marine Environment Study in 2006 found 0.25 Carbonization in LW, twice as much in NW & Chloride Content under 2 lb/yd. Mix had 630 lb/yd cement and 4580 PSI in 2006

No Corrosion

0.25 Carbonation
Deteriorationofsteelsuperstructurecauseddecktobereplaced

SummaryandConclusions
Sixtyyearsofconcreteinservicehasbroughttheindustry thebasic knowledgethatenablesconcretetobeperceivedasthematerialofchoice formanytypesofconstructioninthe21stCentury. Whencuredproperly andthroughoutthemass,itisabletomakeitscontributiontosustainability. ThecasestudiesrepresentthoseapplicationswhereInternalCuring(IC)can bejustifiedbasedonlifecyclecostanalysisandfrequentlyonfirst cost. Theyincludebridges(long,short,andmediumspan),buildings(even 3storyones),highwaysandparkinglots(evenperviouspavements),and utilities(suchaswatertanks). Geographically,theyencompasstheUnitedStatesandCanadafromDenver andTulsatoNewYorkCity,fromFloridatotheSt.Lawrence.

SummaryandConclusions(cont.)
Thestudiespresentedarerepresentativeofprojectsunderconstructionor onthedrawingboards.Theyshowthepossibilityofachievingimprovement inthecharacteristicsofconcrete,including: 1. Longerlife 2. Reductioninshrinkageandcracking 3. Reductioninpermeability 4. Protectionofreinforcingthroughlesscarbonation 5. Increasedearlyageandlaterageflexuralandcompressivestrength 6. Provisionofgreatermortarstrength 7. Provisionofmoreconsistencyandpredictabilityofinterfacialtransition zone(ITZ) 8. Provisionoflessvariationinmodulusofelasticity(MOE) 9. Lowerlifecyclecost

Recommendations
Starting with an optimum normal weight concrete mix design for a project, choose one or more characteristics that needs improvement. Make comparative tests substituting different amounts of preconditioned absorbent lightweight aggregate sand (LWAS) for an equal volume of the normal weight sand. Simultaneously, run 3, 7, 28, and 90 day compressive strength tests to make structural design decisions. When the optimum replacement is established, apply the benefits to a life cycle cost analysis to ascertain the degree of sustainability enhancement.

REFERENCES
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. AmericanConcreteInstitute(2008) ,ACI308R01:GuidetoCuringConcrete (Reapproved2008), ACIManualofConcretePractice AmericanConcreteInstitute.(2010).ACIConcrete Terminology.RetrievedNovember1,2010,fromAmericanConcreteInstitute: http://www.concrete.org/Technical/CCT/ACITerminology.aspx AmericanConcreteInstitute,(2010),ACIReportonPerviousConcrete,ACI522R10,reportedbyACICommittee 522. AmericanConcreteInstitute(2010), ACI231R10ReportonEarlyAgeCracking,Causes,andMitigation,page39. ASTMInternational.ASTMC3311StandardSpecificationsforConcrete Aggregates.WestConshohocken:ASTMInternational. ASTMInternational.ASTMC33009 StandardSpecificationsforLightweight Aggregates forStructuralConcrete.WestConshohocken:ASTMInternational. ASTMInternational.ASTMC12807StandardSpecificationsforSpecificGravityandAbsorptionofFineAggregate.WestConshohocken:ASTMInternational. ASTMInternational.ASTMC109/c109M08StandardTestMethodforCompressiveStrength ofHydraulicCement Mortars.WestConshohocken:ASTM International. Bentz,D.,Lura,P&Roberts,J.(2005).Mixture ProportioningforInternalCuring.ConcreteInternational,27(2),3540. Bentz,D.,Halleck,P.,Grader,A.,&Roberts,J.(2006a), FourDimensionalXrayMicrotomography StudyofWaterMovementduringInternalCuring.InJenson, O.,Lura,P.,&Kovler,K.(Ed),ProceedingsoftheInternationalRILEMConference VolumeChangesofHardeningConcrete:TestingandMitigation(pp.1120) RILEMPublicationsS.A.R.L. Crowl,DaleandSutek,Mike,ASurveyofHighPerformanceConcreteBridgeDecks,VolumeIV.District12OhioDOT,2002,24pages. Cusson,D.,Lounis,Z.,&Daigle,L.(2010).BenefitsofInternalCuringonServiceLifeandLifeCycleCostofHighPerformanceConcrete BridgeDecks ACase Study.Cement andConcreteComposites,32(5),33935. Delatte, N.,Mack,E.,andCleary,J.,EvaluationofHighAbsorptiveMaterialstoImproveInternalCuringofLowPermeabilityConcrete, FHWA/OH2007/06, State JobNumber134227,OhioDOT,March2007. Hair,L.,TheRoleofGreenInfrastructureinChangingStormwater Management Approaches,USEPAOfficeofWater, August2011,NRMCAInternational Concrete SustainabilityConference. Hoff,G.(2002).TheUseofLightweight FinesfortheInternalCuringofConcrete. Northeast Solite Corporation. Holm,T.A.,Ooi,O.S.,andBremner,T.W.,MoistureDynamicsinLightweight Aggregate andConcrete, TheodoreBremner SymposiumonHighPerformance Lightweight Concrete, Eds.J.P.Ries andT.A.Holm,Proceedingsofthe6thCANMET/ACIInternationalConferenceonDurabilityofConcrete, Thessalonica, Greece,167184,2003. Jones,B.W.,Roberts,J.W.,ExtendingtheServiceLifeofDecksandEliminatingtheCarbonFootprintwithInternalCuring,Proceedingsof8th International ConferenceonShortandMediumSpanBridges,NiagaraFalls,Ontarion Canada,August5,2010. Jones,B.W.,Yazdani,N.,Roberts,J.W.,SustainableConcrete BridgesUsingNew,StructuralDesignConceptswithHighPerformanceConcrete(HPC), Internal Curing(IC)andHighVolumeSupplemental Cementitious Materials(HVSCM), ACIFallConvention,Pittsburgh,Pennsylvania,October24,2010. Mack,E.C.,UsingInternalCuringtoPrevent ConcreteBridgeDeckCracking,M.S.Thesis,ClevelandState University,June2006.

17. 18. 19.

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Raoufi, K., and. Weiss J.

REFERENCES(contd)
20.Mather,B.,SelfCuringConcrete,WhyNot?,ConcreteInternational,23(1),4647,December2001. 21.Peled,A.,Castro,J.,Weiss,J.,AtomicForceMicroscopyExaminationsofMortarMadebyUsing WaterFilledLightweightAggregates,TransportationResearchRecordJournalofTRB,No.214,2010,pp 92101. 22.Powers,T.,Copeland,L.,&Mann,H.(1959).CapillaryContinuityorDiscontinuityinCementPastes. TheResearchBulletinofthePortlandCementAssociation,1(2),3848. 23.RILEM.(2007).InternalCuringofConcrete.(K.Kovler,&O.Jensen,Eds.)Paris:RILEMPublications S.A.R.L. 24.Roberts,J.W., CurrentandFutureTrendsintheApplicationofInternalCuringofConcrete,in Proceedingsofthe4th InternationalSeminar:Self Dessication andItsImportanceinConcrete Technology,Eds.B.Person,D.Bentz,andL.O.Nilsson,Gaithersburg,MD,197209,2005. 25.Roberts,J.W.,InternalCuringinPavement,BridgeDecks, andParkingStructures,usingAbsorptive AggregatetoProvideWaterToHydrateCementnotHydratedbymixingWater,Transportation ResearchBoard,WashingtonD.C.,TRBCommitteeA2E05,ConcreteMaterialsandPlacement Techniques, January13,2004. 26.Roberts,J.W.,Jones,B.W.,Hulsman,J.M., ImprovingtheDurabilityandEconomyofShortand MediumSpanBridgesthroughInternalCuring,7thInternationalConferenceonShortandMedium SpanBridges,Montreal,Canada,August2325,2006. 27.TheErlin Company,Supplementary Report,PetrographicExaminationsofaConcreteCore,January 14,2009. 28.Wei,Y,andHansen, W.,PresoakedLightweight FineAggregatesasAdditivesforInternalCuringin Concrete,ACIPuertoRico,SP2563,2007

ThankYou

Questions

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