A U.S. Department of Transportation University Transportation Center. State of the Art Practices of Mass Concrete A Literature Review

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1 A U.S. Department of Transportation University Transportation Center State of the Art Practices of Mass Concrete A Literature Review February 5, 2014

2 Mass Concrete Overview

3 Mass Concrete Overview ACI Definition: Any volume of concrete with dimensions large enough to require that measures be taken to cope with generation of heat from hydration of the cement and attendant volume change to minimize cracking 1. Cement hydration is a very exothermic process. 2. Placement of large amounts of concrete results in storing heat within the core, resulting in Adiabatic Temperature Rise (ATR). 3. Mass concrete is considered for a structure where the least dimension is 3 ft (1 m) or greater. 4. Controlling both maximum core temperature and surface/core temperature differential are critical to preserving quality.

4 Cement Hydration Cement (C 3 S, C 2 S, C 3 A, C 3 AF) + Water > C S H + CaOH + heat Proper cement compound proportions in a cement mix is required to control the heat of hydration in the reaction Cement mixes with reduced tricalcium silicates and calcium aluminates effectively control heat during hydration Cement Compound Specific Heat of Hydration (cal/g) C 3 S 120 C 2 S 62 C 3 A + CŜH 2 (Gypsum) 320 C 3 AF 100 Values courtesy of Cannon (1986)

5 Heat of Hydration in Cements Cement blends have been developed to control temperatures in hydrating concrete. Image courtesy of ACI 207.1R

6 Supplementary Cementitious Materials (SCMs) SCMs offer a means of reducing heat of hydration through cement replacement. FLDOT study indicates peak temperature reductions of 0.1% to 26.1% compared to Ordinary Portland Cement (OPC) concrete Cement Source Placing Temperature % Reduction in Peak Temperature after 14 days 25% Fly Ash 35% Fly Ash 50% Slag 70% Slag A 73 o F B 73 o F Average for Cements A & B A 95 o F B 95 o F Average for Cements A & B Chini & Parham, 2005

7 Mix Design: SCMs No. Cement Type Heat of Hydration at 100% Hydration (cal/g) 1 Type I Cement Type I Cement + 15% Class C Fly Ash Type I Cement + 25% Class C Fly Ash Type I Cement + 35% Class C Fly Ash Type I Cement + 45% Class C Fly Ash Type I Cement + 15% Class F Fly Ash Type I Cement + 25% Class F Fly Ash Type I Cement + 35% Class F Fly Ash 95 9 Type I Cement + 45% Class F Fly Ash Type I Cement + 30% Ground Granulated Blast 113 Furnace Slag 11 Type I Cement + 50% Ground Granulated Blast Furnace Slag 112 ACI Materials Journal, Heat of Hydration Models for Cementitious Materials, Title no. 102 M04

8 Aggregates in mass concrete Coefficient of Thermal Expansion 10-6 / C 10-6 / F Aggregate Granite Basalt Limestone Dolomite Sandstone Quartzite Marble Lower thermal expansion protects concrete from thermally induced volume changes that can lead to cracking Lower thermal conductivity also protects concrete from thermal gradients that can lead to cracking Image courtesy of FHWA

9 Issue 1: Thermal Cracking

10 Adiabatic Temperature Rise (ATR) Cement hydration causes a rise in internal concrete temperature. Temperature differentials may result in surface tension. Shocking the surface with cold water/air can lead to cracks. Thermal cracking Trapped heat from Cement reaction Restrained concrete

11 Reducing Thermal Cracking Surface tension is typically discouraged in concrete design Typically ~10%f c can be lower during curing stages Concrete elements designed with large (Volume) : (Surface Area) ratio are more susceptible to thermal cracking Tabulating temperature differentials as a function of curing time is recommended Current specifications call for T < 35 F ACI 207.1R 96 f t = 1.7 f c 2/3 (psi) Controlling initial temperature and using cements with low heat of hydration also help reduce potential for thermal cracking

12 Issue 2: Delayed Ettringite Formation

13 Delayed Ettringite Formation (DEF) High initial placement temperatures and poor temperature control can lead to entrapped sulfates and aluminates. Once temperatures recede, sulfates/aluminates precipitate and react with monosulfate hydrates to form Ettringite Trapped heat from Cement reaction causes monosulfates to remain unreacted in aggregate Ettringite C 3 A 3CaSO 4 32H 2 O Naturally forming Expansive material Image Courtesy of Rob Lavinsky (commons.wikimedia.org)

14 ATR and Delayed Ettringite Formation (DEF) DEF is a long term adverse effect resulting from high internal curing temperatures Threshold internal peak temperature of 160 F widely accepted Ettringite is a naturally forming EXPANDING material within concrete. When concrete is properly cured, ettringite can easily be found intertwined within the concrete matrix. When ettringite forms as a result of entrapped sulfates and aluminates, it causes internal stresses that have deleterious effects on concrete durability

15 Delayed Ettringite Formation (DEF) DEF 90 days after curing DEF 255 days after curing Images courtesy of Yang et. al (1999) DEF 365 days after curing

16 Delayed Ettringite Formation (DEF) Images courtesy of CMC, Inc. concrete.com/delayed%20ettringite.htm

17 Reducing or Eliminating potential for DEF Proper mix, placement and temperature control design is critical Mixes should consider low Heat of Hydration cements, low cementitious content, use of SCMs, cooled aggregates, cold water (or ice chips) Formwork should be insulated to prevent excessive heat loss (differential temperatures) Thermal Control plan should outline methods to mitigate peak temperature and temperature differentials Maintain peak temperature below 160 F

18 Summary of Recommendations

19 Recommendations Cements 1. ACI recommends cements that consist of a max 58% C 3 S + C 3 A or limiting heat of hydration to 70 cal/g 2. Use Type II Cements to reduce heat of hydration. This results in slower heat buildup and lower peak Temperature 3. Select proportioning of cementing material used in design mix no greater than that needed to satisfy design strength. 4. ACI states that using ASTM option for Type II cement (70 cal/g), and limit content to 235 LB/CY, temperature rise can be limited to 35oF (ACI 207.1R 13 Subsection 2.8.2)

20 Recommendations SCMs 1. Use SCMs, mainly Class F Fly Ash or Ground Granulated Blast Furnace slag to further reduce heat of hydration. 2. Silica Fume is not recommended, as it increases heat of hydration. 3. NJDOT currently does not allow use of Grade 80 slag. It s low activity index is ideal to retard reaction and reduce heat generation in concrete. Re adoption of Grade 80 slag for Mass Concrete application only, could provide another option.

21 Recommendations Aggregates 1. Use aggregates with low thermal conductivity (10 6 / o F) Granite 4.3 Basalt 4.4 to 4.6 Limestone Shading and/or chilling/cooling aggregates helps control the temperature gradient and minimizes volumetric changes in the concrete.

22 Recommendations Thermal Control Plan 1. Each concrete component must be accounted for in terms of heat of hydration 2. Timing of forms/insulation must coincide with modeled time to thermal normalization. 3. Thermal modeling can be used to predict the element s behavior, 4. Including cooling pipes, insulation or other means to maintain thermal control can be determined via modeling 5. Monitoring the element should also include concrete maturation. Tables can be developed to provide a more stringent control over thermal differentials

23 Recommendations Thermal Control Plan 6. Temperature differentials cause surface tensions (leading to cracks). Controlling core temperatures during curing is critical to prevent cracking. 7. It is critical to maintain core temperatures below 160 F and control thermal differentials below 35 F Corrective actions: For thermal induced cracks Sealants Coatings More comprehensive repairs DEF May not be visible for months or years after construction Generally pervasive May require replacement

24 Recommendations Thermal Control Plan 8. Duration of temperature control should be considered. 15 days may not be sufficient to allow temperature to normalize Modeling should guide removal of insulation or other protective measures (cooling pipes) to ensure temperatures achieve ambient balance 9. Consider developing tables for differential temperature thresholds based on concrete maturation. Modeling can assist in developing tables 10. Place concretes at temperatures ranging between 50 F (preferred) and 70 F (Max)

25 Thank you! Andrés M. Roda, P.E. Research Manager Center for Advanced Infrastructure and Transportation (CAIT) Rutgers, The State University of New Jersey 100 Brett Road Piscataway NJ List of literature references provided at the end of this presentation.

26 References (1 of 3) 1. ACI Code 207.1R 13 Mass Concrete 2. ACI Code 207.2R 02 Effect of Restraint, Volume Change, and Reinforcement on Cracking of Mass Concrete 3. ASTM C150 Standard specification for Portland Cement 4. Gajda, J., Mass Concrete: How do you handle the heat?, PCA 5. Kurtis, K, Portland Cement Hydration, Georgia Institute of Technology 6. Folliard, K., et al., Preventing ASR/DEF in New Concrete: Final Report, FHWA/TX 06/ , June ACI 207.1R 96, November Chini, A., Parham, A., Adiabatic Temperature Rise of Mass Concrete in Florida, BD 529, February 2005

27 References (2 of 3) 9. Breitenbücher, R. (1990). Investigation of thermal cracking within the cracking frame. Materials and Structures, (23), Chini, A. R., Muszynski, L. C., Acquaye, L., & Tarkhan, S. (2003, February). Determination of the maximum placement and curing temperatures in mass concrete to avoid durability problems and DEF 11. Siler, P., Kratky, J., & De Belie, N. (2011). Isothermal and solution calorimetry to assess the effect of superplasticizers and mineral admixtures on cement hydration. Journal of Thermal Analysis and Calorimetry. 12. Ramlochan, T., Zacarias, P., Thomas, M. D., & Hooton, R. D. (2003). The effect of pozzolans and slag on the expansion of mortars cured at elevated temperature Part I: Expansive behaviour. Cement and Concrete Research, 33(6),

28 References (3 of 3) 13. Pongsak Choktaweekarn; Somnuk, T. (2010) Effect of aggregate type, casting, thickness and curing condition on restrained strain of mass concrete. Songklanakarin Journal Of Science & Technology, 32(4), Quality Assurance Sample, Essroc Cement Co. Plant #1 Nazareth, PA, dated October 18, PCA, Concrete Technology Today, Vol. 18/Number 2, July Diamond, S. (1996). Delayed ettringite formation Processes and problems. Cement and Concrete Composites, 18(3), doi: / (96) Riding, K. A., Poole, J. L., & Schindler, A. K. (2008). Quantification of effects of fly ash type on concrete early age cracking. ACI Materials Journal, 105(2),

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