Professional Documents
Culture Documents
High Performed Concrete Structures in Canada
High Performed Concrete Structures in Canada
A State-of-the-Art Review of
High Performance Concrete Structures
Built in Canada: 1990-2000
John A. Bickley
Denis Mitchell
This publication is intended for the use of professional personnel competent to evaluate
the significance and limitations of its content and who will accept responsibility for the
application of the material it contains. The Cement Association of Canada and the authors
disclaim any and all responsibility for application of the stated principles or for the
accuracy of the sources.
May 2001
ii
Executive Summary
In the search for durability, researchers in Canada and in other countries sought for
higher performance materials. Technology from other countries, notably France, Norway,
Japan and Germany, was incorporated into developments in Canada in the 1980s. High
Performance Concrete (HPC) was included in this research.
With the establishment of Concrete Canada (CC) in 1990, a co-ordinated and
concentrated programme of research commenced. In 1994, this programme expanded to
include demonstration projects to implement HPC technology on construction sites.
Technology Transfer was a primary goal of CC. Many seminars, workshops and
technology transfer days were held across Canada, by CC alone, in co-operation with
American Concrete Institute (ACI) Chapters, the Cement Association of Canada (CAC)
and its member companies, and for specific entities such as Provincial Highway
Departments and Cities.
Between 1990 and 2000, CC researchers published over 400 Papers in scientific journals.
It seemed appropriate, as the old millennium ended, to assess the practice in the use of
HPC in Canada over the past 10 years. The extent of its use, the varying specifications,
results, economics and problems encountered have been reviewed. Looking ahead, areas
for ongoing research and development have been identified.
The study demonstrates that, for those who have correctly implemented this technology,
HPC is the high quality concrete of choice for high strength, durability and optimum lifecycle costs.
iii
Preface
In 1990, as a Principal Investigator in the newly established and funded Network of
Centres of Excellence on High Performance Concrete, one of my main activities was to
lecture on this research programme and its objectives. At the time, the term High
Performance Concrete was virtually unknown. Now, ten years later, I am no longer
asked, "What is HPC?"
A perception that the use of HPC is now widespread led to the decision to produce this
review. It seemed timely, after a decade of the intensive development, promotion and
implementation of HPC, to step back and survey the extent of the use of this material
across Canada, the achievements, the problems encountered, and to suggest directions for
future practice.
The task turned out to be greater than I had envisaged. Despite my close involvement
with the implementation of this technology, I was surprised to find the extent and variety
of uses for this quality of concrete. As the pieces of the puzzle fell into place, a
comprehensive picture formed.
There are some inconsistencies in my classification of projects. For instance, the
Confederation Bridge is detailed in Chapter 4 on Precast Concrete Products. This
structure must be considered to be one of the most outstanding precast concrete projects
in the world. It seemed more appropriate to place it in Chapter 4 than in Chapter 3.
Similarly, some projects have incorporated more than one technology, i.e. Conventional
HPC and HPC using a Ternary cement. In such cases, the project is reported in the
chapter covering the more innovative technology.
With the help of Rico Fung of the Cement Association of Canada and Kevin Cail of
Lafarge Canada Inc., both of whom helped co-ordinate input from the cement companies
and monitored the progress of this report, a nation-wide net was cast for information. As
shown by the acknowledgements, many across the country provided me with
information. To all of them, I extend my sincere thanks.
This report is based on my own library and experience, and the input I received from the
many who helped. No doubt I have missed many projects, but the end result does
demonstrate that HPC is now a widely accepted construction material.
I hope that this review will contribute to the correct use of HPC, and that, overall, the
durability and serviceability of our structures will be improved.
John A. Bickley
Toronto, Spring 2001
iv
Acknowledgements
Particular thanks are due to Denis Mitchell for his chapter on design, Rico Fung and
Kevin Cail for their guidance and support, Don Hopkins and Joan Dawson for the
preparation of the manuscript for publication, my wife, Jean, for proof-reading; and to the
many, listed below, who supplied me with information.
Pierre-Claude Atcin, Universit de Sherbrooke; Vic Anderson, DELCAN; Herve
Bachelu, Saskatchewan Highways and Transportation; Beata Berszakiewicz, Ontario
Ministry of Transportation; Ken Bontius, Hatch Mott MacDonald; Don Brennan,
Department of Works, Services and Transportation Newfoundland and Labrador; Paul
Carter, Reid Crowther; Barry Charnish, Yolles Partnership Inc.; Mike Chung, City of
Toronto; Louis-Georges Coulomb, Ministre des Transports, Qubec; Martin Darby,
Lafarge Construction Materials; Savio DeSouza, AMEC; Walter Dilger, University of
Calgary; Sal Fasullo, DAVROC Testing Laboratories Inc.; James Fletcher, Nova Scotia
Power Inc.; Richard Gagn, Universit de Sherbrooke; Richard Golec, Pre-Con; Malcolm
Gray, AECL; Gilbert Haddad, Terratec; John Hart, Consultant; Jack Holley, Lafarge
Construction Materials; Dale Hollingsworth, Lafarge Construction Materials; Henri
Isabelle, Consultant; Harry Jagasia, UMA; Jan Jofriet, University of Guelph; Kamal
Khayat, Universit de Sherbrooke; Jana Konecny, Ontario Ministry of Transportation;
Ulrich Kuebler, Sky Cast Inc.; Francois Lacroix, Cement Association of Canada; Gord
Leaman, Jacques Whitford; Bill LeBlanc, Con-Force; Gene Lecuyer, Lafarge Canada
Inc.; Michel Lessard, Euclid Admixtures Canada; Wib Langley, Consultant; Bob Loov,
University of Calgary; Paul Lowe, Lafarge Construction Materials; Ron Lowther, BC
Ministry of Transportation and Highways; Yves Malier, ENPC, Paris and ENS Cachan;
P.K. Mehta, University of California, Berkeley; Mike Meschino, Yolles Partnership;
Grant Milligan, Quinn Dressel Associates; Rusty Morgan, AMEC; Richard Morin, Ville
de Montral; Robert Munro, Lafarge Canada Inc.; K Nasser, University of Saskatchewan;
Nikola Petrov, Universit de Sherbrooke; Michel Pigeon, Universit Laval; Tony Purdon,
SAR Transit JV; Gary Pyke, Nova Scotia Transportation and Public Works; Bob
Ramsay, UMA Group; Elizabeth Read, SEM; John Ryell, Trow Consulting Engineers
Ltd.; Phil Seabrook, Levelton Associates; Hannah Schell, Ontario Ministry of
Transportation; Fred Strang, Department of Transport, New Brunswick; Michael
Thomas, University of Toronto; Jean-Francois Trottier, Dalhousie University; Jim
Turnham, SAR Transit; Daniel Vezina, Ministere des Transport, Qubec; Gary Winch,
Lafarge Canada Inc.; Steve Zupko, Lafarge Canada Inc.
CONTENTS
Executive Summary.......
Preface
Acknowledgements
CHAPTER 1
CHAPTER 2
CHAPTER 3
CHAPTER 4
iii
vi
v
Introductions
Introduction...
Background and History...
1
1
Standards
National Standards for Structural Design.
CSA A23.3 and CSA S6 Bridge Code.
National Standards for Materials..
CSA A23.1 & 23.2
CSA A 3000..
CSA A 413
CSA S 438
4
4
19
19
19
20
20
Review of Bridges
General..
Alberta..
British Columbia..
Manitoba..
New Brunswick
Newfoundland and Labrador
Northwest Territories
Nova Scotia..
Ontario..
Prince Edward Island
Quebec..
Saskatchewan
21
21
27
30
31
33
34
34
37
45
47
51
58
60
63
63
64
64
65
67
67
vi
CHAPTER 5
70
71
Marine Applications
Hibernia Offshore Platform..
Grand Manan Wharf.
75
76
CHAPTER 7
Agricultural Applications...
79
CHAPTER 8
Shotcrete..
82
CHAPTER 9
Emerging Technologies
Self-Consolidating Concrete.
Reactive Powder Concrete
Use of Ternary Cements
High Performance Roller Compacted Concrete....
88
91
92
93
98
98
98
98
98
99
103
105
108
108
108
108
108
108
109
109
109
CHAPTER 6
CHAPTER 10
vii
Chapter 1
Introductions
Introduction
Mehta (1994) stated that his holistic model of concrete deterioration "provides a clear
justification why impermeability of concrete should be the first line of defence against
any of the physico-chemical deterioration processes described earlier. If adequate
attention in concrete making and processing is paid to hold the first line of defense, why
would one need epoxy-coated reinforcement for protection against corrosion, ASTM
Type V cement for protection against sulfate attack, and low-alkali cement or nonreactive aggregates for protection against expansion associated with the alkali-silica
reaction?" He went on to say "From the standpoint of life-cycle costs and conservation
of resources, the ecological implications of the foregoing proposition cannot be ignored
for too long".
In Canada, experience with concrete durability problems has led to a similar conclusion:
that the impermeability of the cover concrete is paramount. With ternary mixes and
available admixtures, high strength is relatively easy to achieve. The current fixation in
research and practice is the construction of durable structures. Owners are demanding an
extended service life and want reassurance prior to construction, that it will be achieved.
As a consequence, increasing effort is focusing on the development of predictive lifecycle models that can provide assurance of the specified service life, and can be used to
calculate life-cycle costs. This approach is particularly relevant since first costs for the
use of HPC are often higher than for conventional concrete. It is widely accepted that
life-cycle costs for HPC structures will be lower than those of similar structures using
conventional concrete.
It is now commonplace for construction contract specifications to require some form of
permeability test, and the trend is to carry out this test on samples taken from the finished
structure. The need to provide assurance of contract quality and the increasing use of
performance or end-result specifications highlights the need for quicker and more reliable
test procedures.
Continuing research and site implementation of the correct procedures are ongoing
construction industry objectives.
Background and History
Credit for the term "High Performance Concrete" must go to the French. It was coined in
1980 by Roger Lacroix and Yves Malier (Atcin, 1998). In 1986, the French project
"New Ways for Concrete" brought together 36 researchers from France, Switzerland and
Canada. Leading the Canadian group was Pierre-Claude Atcin. The research, findings
and field applications of all the members of this group formed the contents of the first
book published that was solely devoted to High Performance Concrete (Malier, 1990).
Towards the end of 1988, Pierre-Claude Atcin, assisted by Denis Mitchell and Michael
Collins, wrote the successful proposal for the Network of Centres of Excellence on High
Performance Concrete, funded under the Federal Government "Centres of Excellence
Programme".
This research programme started in 1990, and, in its second phase, starting in 1994, the
Network became known as Concrete Canada. The researchers who comprised Concrete
Canada were not the only Canadians researching and using HPC, however, they were the
pre-eminent and most active group in this field. By virtue of many publications in
scientific journals, a Newsletter sent to 7,000 persons world-wide, the organization of
technology transfer days and seminars, and the construction of demonstration projects,
Concrete Canada played the major role in establishing HPC as a widely accepted
construction material in Canada.
In the United States, the Strategic Highway Research Programme (SHRP) sponsored a
project on High Performance Concrete. In 1990, "High Performance Concretes", an
annotated bibliography, 1974-1989, was published as SHRP-C/WP-90-001.
The definition used by SHRP for HPC was as follows:
1. "It should meet one of the following criteria
a)
b)
c)
d)
2. It should also have a durability factor not less than 80 after 300 cycles of freezing and
thawing".
Many of the entries in this bibliography met the above criteria, but the authors of only
two of the 2204 publications included in this document used the term High Performance
in the titles of their Papers, and these were dated 1986 and 1987.
Since then the term has become a popular buzzword. In 1993, the American Concrete
Institute published the following definition:
"High-performance concrete (HPC) is defined as concrete which meets special
performance and uniformity requirements that cannot always be achieved by using only
the conventional materials and mixing, placing and curing practices. The performance
requirements may involve enhancements of placement and compaction without
segregation, long-term mechanical properties, early-age strength, toughness, volume
stability, or service life in severe environments".
In most applications, the water-cementing materials ratio will not exceed 0.40, but, as
will be noted later in this report, some truly high performance concretes do not meet any
of the above definitions. Cast-in-place HPC will normally contain silica fume. Precast
concrete may not, particularly where the main parameter needed is high strength.
In the decade 1990-2000, there has been an enormous amount of research on this subject,
and thousands of Papers have been published (Zia, 1997).
Major research programmes have been carried out in many countries in Europe, Asia,
Australasia, Japan and North America.
A unique feature of the Concrete Canada programme has been the use of demonstration
projects to effect the implementation of the correct use of HPC on construction projects.
Since 1990, many such projects have been carried out across Canada. The use of HPC
has recently spread rapidly. Most Provincial Highway Departments and some major cities
have adopted its use, or are in the process of doing so. As a result, many consultants are
specifying it, and, consequently, many contractors are winning contracts which contain
innovative features. This is resulting in some potential teething problems that are
discussed later.
REFERENCES
Mehta, P.K., "Concrete Technology at the Crossroads-Problems and Opportunities", Concrete Technology
Past, Present, and Future, ACI SP 144, 1994, pp. 1-30.
Atcin, P-C., " High-Performance Concrete", E & FN Spon, 1998, pp. 591.
Zia, P., "State-of-the-Art of HPC: An International Perspective", Proceedings PCI/FHWA International
Symposium on High Performance Concrete, New Orleans, October 1997, pp. 49-59.
Malier, Y., "Les Btons Haute Performance", Presse de L'Ecole National des Ponts et Chausses, 1990.
English Edition E & FN Spon, 1992.
Chapter 2
Standards
The Commentary to CSA S6 indicates that the minimum concrete strength limit
of 30 MPa was chosen to provide a minimum level of durability. The
Commentary also cautions designers about using concrete strengths greater than
85 MPa since special consideration of the structural response of this material
may be warranted.
c
Ec = 3300 fc + 6900
2300
1.5
(1)
(2)
This simpler expression is suitable for use with lower strength concretes and is
about 5% lower than that given in the 1999 ACI Code.
The CSA Standard also cautions designers that the modulus of elasticity of highstrength concrete is highly dependent on the properties of the aggregates used and
hence can vary in different regions of the country (Baalbaki et al, 1991). If the
modulus of elasticity is critical to the design, then a minimum value of Ec shall be
specified and shown on the drawings.
SPECIAL CONFINEMENT
CONCRETE COLUMNS
REQUIREMENTS
FOR
HIGH-STRENGTH
Studies on high-strength concrete columns (by Yong et al, 1988, Cusson and Paultre,
1994, Ibrahaim and MacGregor, and Polat, 1992), have indicated the need to
provide a greater degree of confinement to improve the ductility of high-strength
concrete columns. Furthermore, there is a tendency for splitting cracks to form in
high-strength concrete columns, resulting in premature spalling of the concrete cover
and a reduction in the capacity as discussed by (Collins et al, 1993).
12 times the diameter of the smallest longitudinal bars or the smallest bar in a
bundle;
36 tie diameters;
0.75 times the least dimension of the compression member; and
225 mm in compression members containing bundled bars.
(3)
(4)
These new stress block factors are more suitable for a wider range of concrete
strengths than those in the previous 1984 CSA Standard (CSA A23.3-84). The
stress block factors are intended to account for both the significant change in
shape of the stress-strain curves as the concrete strength increases and the
difference between the concrete cylinder strength and the in-situ strength of the
column concrete.
Fig. 2 illustrates the two analysis procedures for determining the factored flexural
resistance of members. Fig. 3 compares the factored moment resistances, Mr, using
the new stress block factors of the 1994 Standard, with those determined using stress
block factors of the 1984 CSA Standard, for a 400 mm by 600 mm deep beam singly
reinforced with 3 No. 30 bars. The two approaches are very similar for the case of
pure moment. This figure also illustrates that for this example, doubling the
concrete compressive strength results in only about a 6% increase in pure moment
capacity.
Maximum Axial Load Resistance
The maximum factored axial load resistance Prmax of compression members is
determined from the following expressions:
(a) for spirally reinforced columns:
Prmax = 0.85 Pro
(5)
(6)
where Pro is the factored axial load resistance at zero eccentricity defined as:
Pro = 1 c f c ( Ag - Ast - At - A p ) + s f y Ast + a Fy At - f pr A p
(7)
where
c
Ag
Ast
At
Ap
s
a
p
fpr
fy
Fy
=
=
=
=
=
=
=
=
=
The value of Prmax in the 1994 CSA Standard is a function of the stress block
factor, 1, which varies with the concrete compressive strength. Fig. 4 compares
the Prmax values calculated using the 1984 (similar to the 1999 ACI Code
approach) and 1994 CSA Standards for a 450 mm by 450 mm column containing
8 No. 20 bars. For this column, containing 1.2% steel, the new provisions give
about 4%, 9% and 13% lower capacities for concrete strengths of 30, 60 and
80 MPa, respectively.
10
Limit of c/d
Due to the change in the maximum strain at the extreme concrete compression
fibre from 0.003 to 0.0035 in the 1994 CSA Standard, the tension reinforcement in
flexural members shall not be assumed to reach yield unless:
c
700
d 700 + fy
(8)
where c is the depth of compression and d is the effective depth of the member.
When c/d exceeds this limit, the stress in the tension reinforcement must be
computed based on strain compatibility.
MINIMUM AMOUNT OF FLEXURAL REINFORCEMENT
The purpose of providing a minimum amount of flexural reinforcement is to ensure
a ductile flexural response. An insufficient amount of flexural reinforcement can
result in the flexural capacity being lower than the cracking moment, resulting in a
brittle response after cracking.
The 1994 CSA Standard gives three alternative approaches for satisfying the
requirements for minimum reinforcement as given below:
(1) At every section of a flexural member where tensile reinforcement is required
by analysis, minimum reinforcement shall be proportioned so that:
Mr 1.2 Mcr
(9)
where the cracking moment, Mcr, is calculated using the modulus of rupture, fr.
(2) In lieu of (1) above, minimum reinforcement may be determined from:
As min =
0.2 fc
fy
(10)
bt h
11
Older codes (CSA A23.3-84 and ACI 318-83) typically required a minimum
reinforcement ratio that was a function of the yield strength of the reinforcement, but
was not a function of the concrete strength. The 1994 CSA Standard and the 1995
ACI Code make the minimum amount of reinforcement a function of not only fy, but
also f c to account for the higher cracking moment as the specified concrete strength
is increased. Fig. 5 shows the variation of the reinforcement ratio, , with increasing
compressive strength. With the 1994 CSA provisions, a smaller amount of
minimum reinforcement is required than previous code provisions for concrete
strengths below about 40 MPa. Larger amounts of minimum reinforcement are
required by the 1994 Standard for flexural members with concrete compressive
strengths above 40 MPa.
MINIMUM AMOUNT OF SHEAR REINFORCEMENT
The purpose of minimum shear reinforcement is to prevent brittle shear failures and
to provide adequate control of shear cracks at service load levels (Collins et al,
1993). The 1984 CSA Standard (CSA A23.3-84), like the 1983 ACI Code (ACI
318-83), required a minimum area of shear reinforcement equal to 0.35bws/fy (i.e.,
stirrups to carry 50 psi) which is independent of the concrete strength. As the
concrete compressive and tensile strengths increase, the cracking shear also
increases. This increase in cracking shear requires an increase in minimum shear
reinforcement such that a brittle shear failure does not occur upon cracking. The
1994 CSA Standard (CSA A23.3-94) makes the minimum amount of shear
reinforcement a function of not only fy, but also f c to account for the higher cracking
shear as the specified concrete strength is increased. Where shear reinforcement is
required, the minimum area of shear reinforcement shall be such that:
Av = 0.06 fc
bw s
fy
(11)
Figure 6 compares the 1994 CSA and the 1999 ACI required amounts of minimum
shear reinforcement. The CSA requirements provide a more gradual increase in the
required amount of minimum shear reinforcement as the concrete strength increases.
Tests carried out by (Yoon et al, 1996) on large beams with concrete strengths
varying from 36 MPa to 87 MPa indicated that the amount of minimum shear
reinforcement prescribed by the 1994 CSA Standard provides adequate control of
diagonal cracks at service load levels and provides reasonable levels of ductility.
CRACK CONTROL REQUIREMENTS FOR HIGH-STRENGTH CONCRETE
ELEMENTS
As discussed above, the amount of minimum reinforcement required for both flexure
and shear is a function of the concrete compressive strength, f c. An important design
issue is whether or not the amount of uniformly distributed reinforcement required in
12
disturbed regions is also a function of the concrete strength. These disturbed regions
include deep beams, corbels and regions near supports. The 1984 CSA Standard
A23.3 introduced the strut-and tie design procedure for these disturbed regions and
these requirements remain unchanged in the 1994 Standard. In the strut-and-tie
design procedure the tension ties and compressive struts are first designed and then
uniformly distributed horizontal and vertical reinforcement is added to control
cracking at service load levels. The CSA Standard requires a minimum amount of
uniformly distributed reinforcement corresponding to a reinforcement ratio of 0.002
in both the horizontal and vertical directions. This maximum spacing of this crack
control reinforcement is 300 mm. For bridge design (CSA S6, 2000 and AASHTO,
1994 and 2000), this minimum reinforcement ratio has been increased from 0.002 to
0.003. An important question to be answered is whether or not this minimum
reinforcement ratio should be a function of f c, in keeping with the philosophy for
minimum amounts of flexural reinforcement and shear reinforcement. Preliminary
experimental evidence from testing carried out in full-scale bridge pier caps
(Macleod et al, 1996) indicated the following:
a reinforcement ratio of 0.0018 was sufficient to control service load cracking for
13
(3) Use of Vertical Dowels - The third approach is to supplement the strength of
the weaker concrete, "sandwiched" between the upper and lower column, by
adding sufficient vertical dowels to enhance the capacity locally (see Fig. 7(c)),
or by adding spirals or hoops in this critical region to increase the confinement
and effective strength of the concrete in the slab region.
DEVELOPMENT LENGTHS OF REINFORCEMENT
The 1994 CSA Standard (CSA A23.3-94) has adopted the same approach as the
1995 ACI Code by limiting the maximum permissible value of the square root of f c
to 8 MPa when calculating development lengths. More research is needed on this
important topic since there is a tendency for more brittle bond failures in highstrength concrete members unless an adequate amount of transverse reinforcement is
provided (Azizinamini et al, 1993, Abrishami et al, 1995).
CONCRETE CAST IN CSA CERTIFIED PRECAST PLANTS
The 1994 CSA Standard employs material resistance factors rather than capacity
reduction factors when calculating the factored member resistance. For elements
produced in certified manufacturing plants, the concrete material resistance factor,
c, may be taken as 0.65, rather than 0.60. This increased value of c, reflects the
better quality control achieved in certified precast plants.
SEISMIC DESIGN
The "Special Provisions for Seismic Design" in the 1994 CSA Standard (CSA
A23.3-94) limits the specified compressive strength, f c, used in design to 55 MPa.
These special provisions contain the seismic design and detailing requirements for
ductile and nominally-ductile structural elements. This conservative approach was
deemed necessary by the code committee because of the lack of test results of highstrength concrete elements subjected to reversed cyclic loading. The 1995 New
Zealand Standard (NZS 3101:1995) limits the specified concrete compressive
strength to 70 MPa for ductile elements and elements of limited ductility. The 1999
ACI Code (ACI 318-95) does not have an upper limit on the specified concrete
strength for the design of ductile elements.
CONCLUSIONS
The 1994 CSA Standard (CSA A23.3-94) introduced special provisions for the
structural design of high-strength concrete members which have some significant
differences with the ACI Code (ACI 318-95). It is clear that more research is
required in many different areas in order to develop codes for the future. The
Canadian Highway Bridge Design Code (CSA S6, 2000) currently does not give any
additional benefit for the use of high-performance concrete in determining cover
requirements for different types of construction (prestressed and non-prestressed)
and for different exposure conditions. It is hoped that future research will take
account of the improved durability of high-performance concrete.
14
REFERENCES
Canadian Standards Association, "CSA A23.3-94 Design of Concrete Structures", Rexdale, 1994, pp. 199.
American Concrete Institute, Building Code Requirements for Structural Concrete (ACI 318-95) and
Commentary, Detroit, MI, 1999, pp. 391.
Canadian Standards Association, CSA S6, Canadian Highway Bridge Design Code, Rexdale, 2000, pp. 724.
Carrasquillo, R.L., Nilson, A.H., and Slate, F.O., "Properties of High Strength Concrete Subject to Short-Term
Loads", ACI Journal, V. 78, No. 3, May-June 1981, American Concrete Institute, Detroit, pp. 171-178.
Baalbaki, W., Benmokrane, B., Chaallal, O. and A tcin, P.-C., "Influence of Coarse Aggregate on Elastic
Properties of High-Performance Concrete", ACI Materials Journal, Vol. 88, No. 5, Sept.-Oct. 1991, pp.
499-503.
Yong, Y.K., Nour, M.G., and Nawy, E.G., "Behavior of Laterally Confined High Strength Concrete Under Axial
Loads", Journal of Structural Engineering, Vol. 114, No. 2, Feb. 1988, ASCE, pp. 332-351.
Cusson, D. and Paultre, P., "High Strength Concrete Columns Confined by Rectangular Ties", Journal of
Structural Engineering, Vol. 120, No. 3, Mar. 1994, ASCE, pp. 783-804.
Ibrahaim, H.H.H. and MacGregor, J.G., "Flexural Behaviour of High Strength Concrete Columns", Structural
Engineering Report No. 196, Dept. of Civil Engineering, University of Alberta, pp. 197.
Polat, M.B., "Behavior of Normal and High Strength Concrete Under Axial Compression", Master's thesis,
Department of Civil Engineering, University of Toronto, 1992, pp. 175.
Collins, M.P., Mitchell, D., and MacGregor, J.G., "Structural Design Considerations for High-Strength
Concrete", Concrete International, Vol. 15, No. 5, May 1993, American Concrete Institute, Detroit, pp. 2734.
Phan, L.T., "Fire Performance of High-Strength Concrete: A Report of the State-of-the-Art", NISTR 5934,
National Institute of Standards and Technology, Gaithersburg, Maryland.
Collins, M.P. and Mitchell, D., "Prestressed Concrete Structures", Response Publications, Montreal/Toronto,
1997, pp. 766.
Canadian Standards Association, "CSA A23.3-84 Design of Concrete Structures for Buildings", Rexdale, 1984.
American Concrete Institute, Building Code Requirements for Reinforced Concrete (ACI 318-83), Detroit, MI,
1983, pp. 111.
Yoon, Y.-S., Cook, W.D. and Mitchell, D., "Minimum Shear Reinforcement in Normal, Medium and HighStrength Concrete Beams", ACI Structural Journal, V. 93, N. 5, Sept/Oct, 1996, pp. 576-584.
AASHTO LRFD Bridge Design Specifications and Commentary, American Association of State and
Highway Transportation Officials, Washington, D.C. 1994 with updates in 2000, pp. 109.
MacLeod, G.D., Cook, W.D. and Mitchell, D., Full-Scale Tests of Bridge Pier Caps, Proceedings of
Graduate Student Seminars, Concrete Canada, Moncton, 1996, pp. 10.
Azizinamini, A., Stark, A., Roller, J.J. and Ghosh, S.K., "Bond Performance of Reinforcing Bars Embedded in
High-Strength Concrete", ACI Structural Journal, V. 90, No. 5, Sept-Oct 1993, pp. 554-561.
Abrishami, H.H., Cook, W.D. and Mitchell, D., "Influence of Epoxy-Coated Reinforcement on the Response of
Normal and High-Strength Concrete Beams", ACI Structural J., V92, N2, Mar/Apr. 1995, pp. 157-166. 16.
New Zealand Standard, NZS 3101:1995, "Concrete Structures Standard", Standards Council of New
Zealand, Wellington, New Zealand, pp. 264.
15
Figure 1
16
Figure 2
17
Figure 3
Figure 4
18
Figure 5
Figure 6
19
20
21
22
23
Chapter 3
General
It is in the bridge field that HPC has found the widest and earliest use. The following are
summaries of HPC use in the Provinces, in alphabetical order.
Alberta
As in other Provinces, durability problems with normal quality concrete led to efforts to
improve the serviceability of bridges. Alberta Transportation and Utilities (ATU) enlisted
the assistance of the University of Calgary to research a number of materials
improvements, some of which would meet today's criteria for HPC (Carter, 1998).
An excerpt from this reference summarizes well the philosophy driving changes in
Alberta practice:
"Analysis of primary highway bridge rehabilitation costs showed that after a
certain bridge condition level was reached, the rehabilitation costs increased
exponentially in relation to time. Bridge decks that were in poor condition
consumed more money than if they had been repaired a few years earlier. It was
concluded that most of the existing major bridges would benefit economically
from protection systems, and that new and less expensive protection systems that
were applied at the right time, and that were intended to keep the condition of the
bridges good, would be less expensive, produce better repair service life, and
result in a higher number of annual repairs than the current policy of focusing
repairs to bridges in bad condition.
During the 1980s some of the bridge management changes used high performance
materials. These included the use of fibres and supplementary cementing materials. Some
milestones of innovation were as follows:
In the 1990s research at the U of C investigated the use of superplasticizers and SCMs
with local materials to improve durability (Johnston, 1993).
24
During the 1990s, silica fume overlays became the preferred protection system. They
replaced membranes below asphalt paving on bridges. Recently, most overlays have
incorporated steel fibres. The lessons learned in the use of these high performance
overlays were summed up as follows (Carter, 1998):
"It is possible and practical to produce a consistent mix for silica fume concrete
on a large scale,
Superplasticizer is a must with silica fume mixes,
In general only compatible admixtures should be used,
Avoid cement/admixture compatibility problems by trial batching,
Silica fume concrete with its lack of bleed water and susceptibility to surface
crusting from evaporation should be placed and finished in low evaporation
conditions,
Prevention of cracking is a major concern in Alberta's climate,
Mild weather conditions are essential to preventing cracking,
Mix temperature is best in the range of 12C (ATU specifications call for
rejection if > 18C), for prevention of cracking and for keeping slump and air
retention properties to manageable levels,
Ice is needed for temperature control on many ATU pours,
Best time to pour is at night because hot decks absorb water from mix, making
finishing hard, night time pours do not conflict with the mix suppliers other
customers jobs,
Use of compatible retarder/superplasticizer combination has benefits,
Transit mix HPC can be used acceptably for pours within 1 hour travel time, and
this means most Alberta sites; dry truck batching is not as good as plant mixing,
Pre-bagged mixes are harder to work with than transit mix, partly because oven
dried aggregates create slump variability from batch to batch,
Today's pours are done with a workable, 120 mm slump,
Mono-monecular curing compound is recommended for use immediately after
texturing and prior to wet burlap placement to reduce surface cracking,
A second generation superplasticizer, when properly matched with an air
entraining agent, can meet the recognized requirements for air void spacing factor
(<0.23 mm),
Add superplasticizer after batching and mixing for 5 minutes; adding the
superplasticizer during batching can result in unmixed balls in the mix,
HPC can be used for bridge deck construction and replacement".
Developments were also made in the use of HPC for precast bridge girders, and these are
described in chapter 4 - Precast Concrete Products.
The following specification was used in a number of bridges:
25
Bridges constructed to this specification include the Fish Creek and Canyon Meadows
1995, Stoney Trail CPR 1997 and Ogden Road Overpass, Elevated Roadway at Calgary
Airport and Center Street in 1998.
Details of some other recent HPC bridges are as follow:
Bridge
Date
Stoney Trail
Centre Street rehabilitation
1997
1999
Anderson/McLeod
Interchange
Deerfoot Trail/ 22X
Interchange
Fish Creek LRT
2000
2000
2000
Components
C-I-p box girders
C-I-p deck
C-I-p barrier walls
C-I-p decks
C-I-p barrier walls
C-I-p decks
C-I-p barrier walls
C-I-p decks
C-I-p barrier walls
In 1999, the Province of Alberta adopted a specification for HPC in the form of Special
Provisions. In 1999, these provisions were used for two bridge deck overlays and for the
26
top slab of a box culvert. In 2000, they were used for three bridge deck overlays and for
the deck of the Sturgeon River Bridge. HPC is designated as Concrete-Class SF
(Modified). Key criteria for this concrete are as follows:
Penalty: $/m
Nil
20
40
60
80
100
130
180
240
rejected
Trial batches are to be made at least 35 days before concrete placement. A trial batch
placement of at least 3 m is required to simulate anticipated placing procedures.
Where stainless steel is used as reinforcement, it is specified to meet the requirements of
ASTM A955M-96 "Deformed and Plain Stainless Steel Bars for Concrete
Reinforcement" and shall be deformed, stainless steel Grade 316LN or 2205 Duplex and
strength Grade 420. Chairs or bar supports shall be non-metallic. Tie wire shall be Grade
316L stainless steel.
27
Comprehensive specifications were recently adopted for HPC by the Cities of Calgary
and Edmonton, and by Reid Crowther. Key criteria are listed in the following table:
Date
Cement: kg/m
Silica fume: %
W/c ratio:
Air: %
RCP: coulombs
Air void system
28-day strength
Decks/girders
Barrier walls
Scaling test
Calgary
January 2000
Min 360
Max 8
Max 0.37
5-8
Max 600
CSA A23.1*
Reid Crowther
August 2000
Min 340
Max 8
Max 0.37
5-8
700 +/- 35 %
CSA A23.1
Edmonton
November 1999
Min 340
Max 8
Max 0.37
5-8
Max 1000
-
50 MPa
40 MPa
0.4kg/m/30 cycles
50 MPa with
corrosion inhibitor
0.4 kg/m/30 cycles
50 MPa #
40 MPa #
0.4 kg/m/30 cycles
Decks and girders 40 MPa with fibres and either corrosion inhibitor or shrinkage
reducing admixture. For 50 MPa concrete. # 50 MPa for decks, abutment deck slabs
and approach slabs; 40 MPa for Barrier walls and medians. * Air void system limits can
be relaxed if 300 cycles of freezing and thawing tests to ASTM C 666 produce a
durability factor greater than 90%.
Curing with fog mist or evaporation retarder to start immediately after finishing. Curing
to continue for at least 5 days (3 days for overlays) with wet burlap covered with vapour
proof sheeting.
The City of Calgary requires tests in advance of construction to determine the cracking
potential of the proposed mix. Cracks over 0.2 mm in width in the structure are repaired.
A number of penalties are imposed for failures to meet specification requirements:
Strength
Air content
RCP
Unit
3.5-4.5 MPa below specification
> 4.5 MPa below specification
0.2 % outside limits
> 0.2 % outside limits
601-1200 coulombs
>1200 coulombs
Penalty: $/m
70
150 or remove
60
150 or remove
40
250 or remove
For overlays, a corrosion inhibitor is specified. The RCP value is given as 600 coulombs
plus a 20% tolerance. Consequently, the penalties shown in the above table are different,
only for RCP values, as follows:
750 - 1000 coulombs: $ 40/ m. > 1000 coulombs: $ 250 or remove.
28
The City of Edmonton adopted a specification for HPC in November 1999. Key criteria
are as follows:
Mix
Element
Air
%
Min
Cement
Kg/m
340
W/C
Ratio
Max
0.37
Max Slump
mm* mm
70
150
28 Day
Strength: MPa
Min
50
RCP:
Coulombs
Max
1000
HPC
All decks
5-8
1
and slabs
HPC Barriers and 5-8
340
0.37
70
150
40
NA
2
medians
All mixes contain 8% silica fume and a corrosion inhibitor. *Before superplasticizer,
after superplasticizer.
HPC cannot be placed if the anticipated air temperature is expected to exceed 22C.
Temperature of concrete at discharge must be between 10C and 18C, using ice or liquid
nitrogen if needed to not exceed 18C.
Immediately after finishing fog misting, evaporation retarder or special curing
compounds shall be applied to the concrete surface.
Penalties are the same as the Calgary specification except for compliance with maximum
RCP values for which the penalties are as follows: 1001- 4000 coulombs: $40/m, > 4000
coulombs: $250/m or remove.
The Read Crowther specification contains the following key criteria:
Mix
Element
Admixtures
HPC 1
Air
%
Cement
Minimum
Kg/m
340
Deck, superstructure, CI
5-8
barriers, toppings
HPC 2 Barriers, toppings
Fibres, SRA 5-8
340
HPC 3 Barriers, toppings
Fibres, CI
5-8
340
CI: Corrosion inhibitor, SRA: Shrinkage reducing admixture.
Mix
W/C
Ratio
Max
0.37
Slump
mm mm
70
150
0.37
0.37
70
70
150
150
28 Day
Tendency to crack: Width (mm) x
RCP: Max
Strength: MPa
Length (m) per m of Surface Area*
Coulombs
HPC 1
50
Comparative evaluation: 0.25-0.35
700 +/- 35 %
HPC 2
40
Comparative evaluation: 0.25-0.35
700 +/- 35 %
HPC 3
40
Comparative evaluation: 0.25-0,35
700 +/- 35 %
*Cracking for the area under consideration will be determined by measuring the
estimated total crack length of cracks greater than 0.2 mm wide multiplied by the
average crack width of each crack and then divided by the area under consideration in
square metres, as defined by a perimeter 500 mm beyond the nearest crack under
consideration.
29
HPC will not be placed if the air temperature is anticipated to exceed 22C. Concrete
temperature, as delivered, shall be between 10C and 18C, and ice or liquid nitrogen
shall be used to ensure that the concrete temperature does not exceed 18C.
Curing with pre-wetted burlap shall begin no more than 30 minutes after final finishing,
and be continued for at least 7 days.
Penalties in this specification are as follows:
3.5 MPa to 4.5 MPa below
> 4.5 MPa below
Up to 0.2 % outside range
> 0.2 % outside range
1001-2500 coulombs
> 2501 coulombs
Strength
Air Entrainment
Permeability
$ 50/ m
$ 100/mor remove
$ 60/m
$ 150/mor replace
$ 250/m
No payment, plus acceptable
protection or replace
For cracking, as measured by the definition shown above, the penalties are as follows:
0 to 0.30
0.31 to 0.6
0.61 to 1.0
> 1.0
No deduction
$ 100/m plus specified repair
$ 200/m plus specified repair
No payment plus acceptable protection system or replace
British Columbia
As in other provinces, there was not suddenly a day when all concrete became HPC.
Requirements for high strength and durability became imperatives before 1990. The
Annacis Bridge is a case in point (Taylor et al, 1986). In order to meet strength, weight
and durability criteria, the deck was cast in a High-Strength HPC, it just was not called
HPC.
The precast panels used the following mix:
Type 10 cement: 425 kg/m3
Water-cement ratio: 0.19-0.24
Air content: 4-6 %
Compressive strength: MPa
At 16 hours: 40-50
At 56 days: > 75
The cast-in-place deck topping contained fly ash, had a water-cement ratio of 0.28, and
contained a superplasticizer. Compressive strength at 56 days averaged 63 MPa with a
standard deviation of 3.3 MPa.
Both these concretes would qualify as HPC but were not designated as such at the time.
30
A major rehabilitation project in 1999 was the deck overlay replacement on the Columbia
River Bridge at Revelstoke (Morgan, 2000) using a steel fibre reinforced HPC. The
original construction in 1959 was concrete infill to a metal T-grid deck surfaced with
asphalt. By the 1990's, the bonded concrete overlay that replaced the asphalt in the 1970's
had delaminated and spalled, resulting in potholes.
The existing concrete was removed to within 10 mm of the T-grid using high-pressure
water jets. The concrete mix was dry batched in Vancouver in 1600 kg bulk bin bags,
discharged into transit mixers near the site, water and admixtures added and the concrete
delivered after 30 minutes batching and mixing time. Travel and discharge time was 45
minutes to 1.5 hours.
Just prior to placement, a sand-cement bonding agent was scrubbed into the T-grid cells.
A Bidwell machine compacted and finished the overlay. The concrete was placed at
night, fog sprayed prior to covering with wet burlap and plastic sheeting for 3 days
followed by 4 days of wet curing.
The concrete mix design was as follows:
Material
Type 10 cement
Silica fume
Coarse aggregate
Fine aggregate
Water
Steel fibres
Water-reducing admixture
Superplasticizer
Corrosion inhibitor
Air-entraining agent
Proportions Kg/m
375
30
1010
750
135
50
1.2 l
4.0 l
10.0 l
0.2 l
Air content of the fresh concrete was 5-8%, slump 70 +/- 20 mm, water-cement ratio 0.35
and steel fibre content 0.64 % by volume.
The properties of the hardened concrete were as follow:
Compressive strength: MPa
3 days
7 days
28 days
Flexural strength and toughness at 7 days
Flexural strength: MPa
Toughness (ASTM c 1018)
JSCE SF-4 Toughness factor: MPa
Round determinate panel test
Absorbed energy at 40 mm
31
35
55
68
4.8
Level III to level IV
2.7
290 J
In view of the results obtained on this project, a similar specification and procedure was
used on the Laforme Creek Bridge in Revelstoke in 2000.
The SkyTrain Millennium Line Project is a 20.4 km extension of the existing LRT line.
The 16 km elevated guideway is comprised of 5,675 precast HPC segments, and used
135,000 m of HPC. It is the largest precast segmental construction contract undertaken
in North America. The use of segmental construction allowed for different spans.
The segments were cast in a facility in Port Moody established for the project. The 17
month construction time mandated a one day cycle for most segments resulting in a 14
hour strength requirement of 18 MPa. Where segments were to be erected within 48
hours of casting, a 35 MPa strength was required prior to stressing.
The project specification was for a 100-year service life with "required maintenance no
greater than ordinarily required for similar structures". The specification for the contract
was independently evaluated. This review took a holistic view by asking two basic
questions:
a) What are the mechanisms that could cause deterioration of the reinforced concrete
construction prior to the 100 year design service life? and
b) How does the specification address these potential deterioration mechanisms, so
as to provide a structure which meets the required service life?
Deterioration mechanisms evaluated and considered in the concrete mix designs
included: frost damage, de-icing salt scaling, chloride ion and carbonation induced
corrosion, alkali-aggregate reactivity, and cracking due to drying shrinkage and thermal
stresses.
The criteria adopted for the segment concrete were as follows:
Specified 28-day strength:
Type 10 cement:
Flyash:
Air content:
Maximum aggregate size:
Target water-cementitious ratio:
Maximum water-cementitious ratio:
40 MPa*
378 kg/m
42 kg/m
6%
14 mm
0.32
0.36
32
A build-up rate of 0.032 kg/m was determined. RCP values of 2,600 coulombs were
obtained from 28 day lab cured test cylinders, but 800 coulombs at 365 days were
obtained from cores taken from a discarded concrete segment which had been field cured.
Quality control was excellent with coefficients of variation generally between 4 and 6%
and as low as 3%. Of 13,000 loads of concrete delivered, only two had to be rejected.
Temperature probes in each segment form monitored the temperature of the hydrating
concrete. These data, converted to maturity values, correlated closely to compressive
strength, enabling form removal times to be determined accurately. The data also
facilitated the fine-tuning of the mix designs.
Manitoba
Up to 1998, the following bridges used HPC:
Manitoba Highways
Bridge
Component
75 mm overlay
75 mm overlay
Superstructure
75 mm overlay
100 mm overlay
Plum River
Assiniboine River Floodway
Little Saskatchewan River
Assiniboine River Bridge
Boine River
All concrete contained 8% silica fume and met a 35 MPa 28 day strength requirement.
City of Winnipeg
Bridge
Norwood Bridges, North &
South
Charleswood
LaSalle River, North & South
Component
140 mm deck lift
75 mm overlay
75 mm overlay
All concrete contained 8% silica fume and met a 35 MPa 28 day strength requirement.
Key criteria in the current Manitoba concrete specifications are as follow:
Manitoba
Cement
10 SF
Cement content: kg/m
340
Silica fume content: %
8
Water-cement ratio
0.37 max
Rapid chloride permeability
1000 coulombs max
Air: %
5-8
28-day strength: MPa
45
Allowable cracking width (mm) x length (m) per square metre
of surface area: 0.25 to 0.35
33
New Brunswick
During the last five years, over 150 HPC structures have been constructed in New
Brunswick. A review of test data from 25 HPC projects showed average coulomb values
were 730 while for 4 projects using normal strength concrete with Type 10 cement, the
average coulomb value was 4024. No value is specified, but values less than 1000 are
expected for the specified concrete prior to the addition of a corrosion inhibitor. A value
of 1500 coulombs is expected after the addition of the corrosion inhibitor. The
reinforcement is uncoated and the decks are waterproofed and paved.
The following summary of New Brunswick experience is based almost verbatim on a
presentation made by Fred Strang of the New Brunswick Department of Transportation at
the ACI Convention in Toronto in October 2000 (Strang, 2000).
High Performance Concrete - Specifications and Mix Design
The Department specifications are method based. The specifications are as follows:
Construction Methods
Goals
The goals this department is striving to meet are as follows:
The department has had success meeting these goals following the practices
described below:
Placing
Place the concrete at night. At night there is less evaporation of water from
the surface of the concrete because the relative humidity is higher and there
is less wind. The temperature is also lower at night. This prevents rapid
drying of the surface. The concrete properties such as air and slump remain
more consistent.
34
The sooner the screeding operation is performed after the concrete is placed,
the easier the concrete will be to work with and to finish.
Finishing
Success with a bullfloat has been limited. This concrete is sticky and will
pull and tear. The bullfloat can be used but additional hand finishing is
usually necessary.
Concrete with slumps between 125 mm and 150 mm seem to finish the best.
Concrete with slumps over 150 mm does not produce such a good finish.
New Brunswick decks have a 3% crown.
The majority of surface imperfections such as aggregate tears and ridges are
finished with the hand trowel. The closer the finisher is behind the screed
machine the easier it is to finish.
The area beyond the screed rails that is finished entirely by hand is more
prone to problems with meeting the surface tolerance requirements.
It is easier to finish the concrete under the screed rails when the rails are
raised. The screed rails are removed when the concrete is still plastic and the
voids are filled with fresh concrete. The use of shorter lengths of screed rail
pipe allows the filling and finishing of the voids in a timely manner.
comb
polymer
(Ethylene
Misting
The timing of when to mist and how much to mist is important. It will
change with the time of day and other weather conditions.
As the placing operation progresses, the misting is heavier and becomes the
transition to water curing (which is continued for a minimum of 7 days
using a burlap or non-woven geotextile fabric).
Surface Finish
A delay in finishing the plastic concrete will result in voids in the surface.
Trying to remove these voids, by working water into the top surface, is
unacceptable.
35
Water/Cement Ratio
Slump
RCP: coulombs
Air content: %
Air void system:
Spacing factor: m
Specific surface: mm/mm
Superstructure
45 MPa at 28 Days 40 MPa at 28 Days
0.36 max
0.37 max
as per mix design* as per mix design*
1000 max
1000 max
6+/- 1 %
6+/-1 %
230 max
25 min
230 max
25 min
* Maximum slump after addition of superplasticizer shall be 230 mm. The mix design
shall state the slump before and after the addition of superplasticizer and appropriate
tolerances.
Type 10E-SF cement or Type 10 plus silica fume is specified, and the silica fume content
must be 7-10% by mass of cement. Cementitious content for all superstructure concrete is
420 kg/m. Air content for severe exposure (decks, curbs, endblocks, barriers and grade
separation columns) shall be 7+/-1%.
With regard to curing, decks are floated, straight edge and broom finished, and then
coated with evaporation retardant. The concrete is then kept moist for at least 7 days at a
temperature of at least 10C.
The penalty for failure to meet strength requirements is: $ (Adjusted concrete price) = $
(Bid price) - $ (10 (Specified strength-Tested strength)).
36
Northwest Territories
The department of Transportation specification for cast-in-place concrete was revised in
January 2000. Class SF concrete contains 7.5% silica fume and meets a specified 28 day
strength of 35 MPa. Minimum cement content is 350 kg/m and maximum water-cement
ratio 0.38. Where fibre is added, the requirements are the same. Air void system
requirements are as per CSA A23.1. Temperature at the time of discharge must be
between 10 and 18C. Curing is by the placing of filter fabric or burlap on the finished
surface as soon as the surface will not be marred as a result. A fine water spray is then
applied and the concrete wet cured for at least 7 days.
For bridge deck repairs, requirements are similar with the following exceptions: cement
content: minimum 360 kg/m, 10% silica fume, 60 kg/m steel fibres. Curing by wet
burlap is carried out for a minimum of 3 days.
Penalties for lower than specified strengths are as follow:
New construction:
28 Day Compressive Strength
35 MPa and above
34 to 35 MPa
33 to 34 MPa
32 to 33 MPa
31 to 32 MPa
30 to 31 MPa
29 to 30 MPa
28 to 29 MPa
27 to 28 MPa
Below 28 MPa
Penalty: $/m
Nil
15
30
45
60
80
110
150
200
Reject
Penalty: $/m
Nil
25
50
100
Reject
Repairs:
37
Nova Scotia
In 1996, Concrete Canada received a request from the Deputy Minister of the Department
of Transportation and Public Works (NS TPW) for assistance in the design and
construction of a bridge in HPC.
Separate meetings were held to discuss design and construction, and a pre-tender
workshop was held for bidders. An industry committee consisting of representatives from
NS TPW, Dalhousie University, CPCA, the Atlantic Provinces Ready Mixed Concrete
Association, Concrete Canada, Jacques Whitford and Lafarge developed the special
provisions for HPC (Bickley, 1998).
A preconstruction test programme was carried out at Dalhousie University, (Trottier,
1997). Extensive tests were made on suitable locally available aggregates. Six trial mixes
were then made, and tested for strength at ages up to 91 days, modulus of elasticity, air
void system, scaling resistance and rapid chloride permeability. The early creep of one
mix was determined.
The bridge is a two span 215 mm thick continuous deck 70.59 m long and 8.85 m wide
on three 1900 mm bulb tee girders per span. Uncoated reinforcing steel was 400 MPa
grade to CSA G30.12-78. Prestressing strand was 16 mm nominal 1860 MPa grade to
ASTM 415 or CSA G279.
The specified strength for all cast-in-place concrete in the bridge was 60 MPa, and 65
MPa for the girders. The design in HPC allowed a wider spacing of girders with a
consequent reduction in cost. The use of HPC resulted in the elimination of
waterproofing and paving and the use of uncoated reinforcing steel.
Prior to construction, an economic analysis was made to compare costs for alternative
designs (Fletcher, 1997).
The results were as follows:
Construction Costs Life Cycle Costs
Normal strength bridge
$484,697
$578,827
HPC bridge-paved
$470,317
$525,070
HPC bridge- exposed deck
$444,815
$454,587
As a result of the extensive pre-construction testing, the contract document gave the
bidders the option of using the mix developed at Dalhousie or, after carrying out
equivalent testing, proposing an alternative mix. The successful contractor chose to use
the proven mix, which was as follows:
kg/m
Type 10E-SF cement (low alkali)
Class F fly ash
Will-Kare fine aggregate
Will-Kare coarse aggregate
Water
Micro-Air
Daratard 17 and/or WRDA-82
WRDA 19
*To be adjusted as necessary
38
450
30
690
1045
144 mL/100 kg of cement
350*
250*mL/m3
5000*
39
The specified slump of 190 +/- 30 mm for the deck was found to be too high, about 150
mm being more suitable. In future, slump would be determined by site trials. As all
superplasticizer was added on site, control of slump was considered possible.
The deck was placed in mild weather. The temperature, 24 hours after placing, was 8-12
C, and it was 40 hours before the hydration induced temperature rise started. Peak
temperature was 23C.
Neither fog misting, nor evaporation retarder, was used for curing. Curing compound was
applied immediately after finishing at twice the rate suggested by the manufacturer. The
second application was at 90 to the first. Saturated burlap sheets were applied as soon as
the surface could withstand their application. If a catwalk is required in future for fog
misting, an extra man will also be needed. Insulation was used on the deck for curing.
A 9 m long 0.25 mm wide crack occurred over one pier. There was slight separation at
the expansion joints. These cracks were filled by gravity with a low viscosity epoxy.
The trial slab was thought to be helpful for contractors handling HPC decks for the first
time, and this provision should be kept for two years. On this contract, the trial slab cost
$8,000, considerably less than the $18,000 reported for a bridge in Ontario.
The pre-bid workshop was considered useful for bidders and their suppliers to become
aware of new and non-standard clauses.
The deck pour, planned for 6 hours, took 11-12 hours due to reduced loads and the time
taken for travel and testing. Overall variation of strength test results was, according to
ACI 214 criteria, poor. Air void systems and RCP results were excellent. The owner was
satisfied that a durable structure had been achieved.
At the time of construction, four corrosion probes were installed in the deck and two in
the parapet. Initial readings of corrosion, current densities, and half-cell potentials, taken
six months after the deck was cast, showed the steel to be passive (Hansson and
Marcotte, 1998). Further readings will be taken in 2002. Annual half-cell surveys by the
owner have shown no corrosion activity.
Ontario
As early as 1992, at least one transportation project with special durability requirements
used HPC (Hart et al, 1997), but this was a special use in tunnel segments which did not
affect the general acceptance of HPC.
In 1994, as part of Concrete Canada's implementation mandate, a combined MTO/CC
committee developed the design changes and special provisions needed for the
construction of the first bridge in Ontario to incorporate HPC. Prior to this, MTO had
investigated the use of HPC as a means of improving structural performance and service
life (Schell et al, 1997). In 1992 and 1993, MTO had used HPC in a bridge deck overlay
and a thin slab replacement. In 1995, two bridge decks were rehabilitated using HPC
overlays.
40
The first bridge built by MTO using HPC throughout most of the structure was on
Highway 20 over 20 Mile Creek (Bickley, 1996, Schell and Konecny, 2000). This single
span bridge, which had a cast-in-place deck on precast prestressed girders, used HPC in
the deck and barrier walls, abutments and wing walls. The design was not changed to
reflect the 60 MPa concrete used, the object being to investigate the durability of HPC
and its potential for use under routine contract conditions. To this end, the deck was not
waterproofed or paved and the reinforcement was uncoated. Three types of probes were
cast into the deck to measure corrosion activity of the reinforcing steel and corrosion
resistance.
A number of innovative constructability issues were dealt with in the construction of this
project. A mandatory pre-bid meeting for all potential bidders was held at which the
differences in the contract resulting from the decision to use HPC were presented and
discussed. Trial batches were required prior to submission of a proposed mix design. A
trial slab was constructed using the materials, plant and personnel intended for the deck.
Tests included in-place measurement of air void systems, temperature monitoring of the
deck, provision for insulating the deck to control temperature gradients and RCP tests on
cores from the deck.
The specified 28 day compressive strength was 60 MPa and Type 10E-SF cement content
450 kg/m.
Some finish problems occurred, but the test results on the hardened concrete were
excellent and the project was considered a success. A summary of test data is as follows:
Compressive Strength
28 Days
MPa
Number of tests: N
Mean strength: X
Standard deviation: s
Coefficient of variation: V
All Tests
Deck
23
77.5
4.77
6.15
12
80.1
4.20
5.70
28
823
191
12
758
135
632 - 1365
605 - 995
Air void data; Spacing factor: Before pumping: all data 0.144 mm, deck 0.142 mm
After pumping: all data 0.204 mm, deck 0.206 mm
Cover to top steel: mean 72.6 mm, standard deviation 7.2 mm.
The next prototype bridges were constructed during Phase 1 of Highway 407. This was a
69 km concrete highway with 127 bridges. In 1994, CC made presentations to the design
41
and construction team on the potential benefits of HPC for bridge construction.
Innovation committees were set up, including one to consider innovative bridge
construction. As a result, two of the bridges incorporated HPC (Bickley et al, 1997,
Jagasia, 1997). The first used HPC in the deck and barrier walls and the second also used
HPC in the precast prestressed CPCI 1900 girders. The reinforcement was uncoated, and
corrosion probes were cast into the exposed decks. The specification requirements were
similar to those on the Highway 20 bridge, except that a lower cement content was
specified and slag was incorporated into the mix to facilitate finishing.
Test data for the two decks were as follows:
28-day compressive strength: N = 7
mean 72.8 MPa
standard deviation 6.2 MPa
Rapid chloride permeability: mean 514 coulombs, range 403-672 coulombs
Spacing factor: mean 170 m, range 106-225 m
It was considered, by those involved, that these trial projects were successful.
Subsequently a CC/CAC committee developed input to an HPC specification that formed
the basis for the acceptance by MTO of HPC as an alternative material for bridge
construction. In May 1998, MTO issued Special Provision No. HPC May 1998. Since
then, approximately 60 MTO bridges have been constructed with HPC or are currently
under construction. The adoption of this technology by the MTO has led to some
consultants and cities following suit.
Based on the experience gained on trial and demonstration projects between 1992 and
1998, the 1998 specification introduced by MTO was an end result specification.. In this
specification, HPC was defined as follows:
42
concrete and the temperature difference within the concrete. The temperature of the
centre of the concrete must not fall below 10C or exceed 70C and the difference
between the centre and the surface must not exceed 20C.
As the presence of significant cracks would compromise the protection provided by the
HPC, they must be repaired as follows:
Decks waterproofed and paved: cracks wider than 1 mm
Exposed concrete decks: cracks wider than 0.3 mm
On the three prototype bridges (Highways 20 and 407), no cracks occurred during the
construction that were wide enough to need repair. This is attributed to the fog misting
after placing followed by 7 days wet curing, and control of temperature as described
above.
In keeping with other MTO end result specifications, bonuses and penalties are applied
based on the consistency of results. For compressive strength, the mean and standard
deviation are used to calculate the percent of results within permissible limits. A bonus
payment up to $5/m or penalties as great as $40/m may apply. Cracks are repaired at the
contractors expense and criteria for rejection of the work are detailed.
Air void determinations on cores are required to meet the following criteria:
Minimum air content: 3%
Average spacing factor: 250 m max
Maximum spacing factor: 300 m
In the event these criteria are not met, the concrete is removed or a remediation scheme
proposed by the contractor, may be accepted. The Ministry has worked with industry to
develop a payment adjustment formula for air void parameters that fail to meet the
specification requirements. This will be introduced in the near future.
For rapid chloride permeability results, a value of between 1000 and 2000 coulombs
results in a penalty of up to $25/m of concrete.
MTO has continued monitoring these three prototype bridges. Results to date show no
deterioration and the absence of any significant corrosion. Recent cracking described
later is the cause of some concern and will be watched. The monitoring is covered in
more detail in the section on Monitoring in Chapter 10.
43
The results obtained using the 1998 specification can be summarized as follows:
Strength: mean strengths from 51.8 MPa to 64.9 MPa. Standard Deviations from
about 3.5 MPa to 6 MPa
Air void parameters: Average air content: 5.9%, average spacing factor 0.150
mm. The specification requirements were met 98% of the time.
Rapid Chloride Permeability: averages 380 to 1267, with typical averages being
less than 600. High values were found to be due to improper testing. Mixes
containing slag averaged 380 to 557 coulombs at 28 days.
MTO experience to 2000 was summarized as follows (Schell and Konecny, 2000):
Field Issues
Curing - Although there was resistance, both from contractors and from MTO field staff
responsible for enforcement, to the introduction of fog misting and extended wet curing
of HPC, this appears to have been largely overcome. A number of contractors have
modified their deck finishing equipment to provide machine-mounted fogging systems
for deck placements. In some cases and, where it appears to work most effectively, these
are augmented by hand-held equipment. With this arrangement, stoppages of the
automatic equipment, or redirection of the mist by wind, can be compensated for, and
fogging maintained by the hand-held equipment. Consideration is being given to making
the presence of a hand-held fogging wand mandatory on site.
Finishing - Finishing of bridge deck surfaces has been an issue on several jobs, with
grinding of a rough or uneven deck surface necessary, in some cases, to produce a surface
smooth enough to receive the normal hot-applied waterproofing treatment. The Ministry's
current specification for finishing is aimed more at elimination of high and low areas than
dealing with roughness issues, and attention to this area is required. To some extent, this
appears to be a function of contractor experience as well as mix design. There appears to
be little transfer of experience from one job to the next, as the contractor moves from one
concrete supplier to the next. The use of trial slabs has, unfortunately, not provided the
intended effect of allowing the contractor to work out his finishing problems prior to
starting work on a structure.
Appropriateness of Mixes - Although the specification responded to industry's desire for
increased allowable replacement of cement by supplementary cementing materials, and
greater flexibility in types and amount of cement used, this does not appear to have been
exploited to any degree to date. Mixes are conservative, some more so than the original
trial work, with extremely high cement contents (450 to 480 kg/m) typical. Slag at the
25% replacement level, commonly used in conventional MTO concrete, is being used in
an increasing number of mixes, about half of those under the current specification, with
good results. No contractors have elected to utilize fly ash, or add additional Portland
cement, although the specification allows this.
44
It is hoped that as contractors and suppliers become more familiar with HPC and with the
performance characteristics of their mixes, that there will be more "customizing" and thus
optimization of mix designs. For example, there appears to have been no deliberate
attempt, to date, to develop mixes with superior finishing characteristics, although it is
certainly possible and is desirable from the contractor's viewpoint as well as the
ministry's.
Appearance - The appearance of MTO's HPC installations is not attractive. Colour of the
concrete is dark and blotchy in appearance. Decks are not visible because of
waterproofing and paving, but barrier walls and other components are. While this is not
expected to be detrimental to performance in any way, it is a factor in terms of overall
acceptance of the material.
Costs - Based on recent contract figures, a premium of between 0 and 20% of normal
costs is being paid for HPC. This is slightly less than the anticipated $60/m premium
based on assessment of costs related to special features such as trial batches and slabs,
and additional curing requirements.
City of Toronto
Since 1995, the City of Toronto has used HPC for concrete overlays and deck
replacements. Type 10E-SF cement is used. The following are some of the key criteria
from the City specification:
Slag is not used in rehabilitation contracts as there is a need to return the deck to service
within a few hours.
Fog mist is applied to the concrete during finishing. Pre-soaked burlap with a moisture
vapour barrier is placed on the overlay within 2 m of the finishing operation and kept wet
for a minimum of 7 days.
For bridge decks, a 19 mm limestone aggregate is used. Black reinforcing steel is used
and cover is specified as 80 mm 10 mm. It is reported that these stringent cover limits
have proven to be attainable. All decks are waterproofed and paved. The modest increase
in first cost is considered more than offset by better durability leading to a lower service
life cost.
To date, about 50 bridge decks and 20 overlays have been constructed with HPC.
45
A major City project involved seven new bridges over the Humber River at a cost of
$100 million. One was a pedestrian and cycle bridge forming part of the waterfront trail.
This elegant steel arch bridge has won acclaim for architectural merit. The post-tensioned
deck, comprised of only 200 m of silica fume concrete, was the only HPC used on this
project.
The other six bridges carry high volume traffic in and out of Toronto on the Gardiner
Expressway. The first of these bridges used traditional bridge deck concrete.
Subsequently a change to HPC was made for the remaining five bridges. Key criteria
from the specifications for the last five bridges were as follows:
Reinforcing steel: uncoated.
A trial slab 13 m wide by 10 m long by 250 mm thick was specified. This was to be
placed using the mix, plant, methods and personnel to be used on the bridge. Tests on
fresh and hardened concrete included cores taken from the trial slab to check compliance
with the specification.
At the time of the first HPC contract, the degradation of the in-situ air void system of
pumped mixes was a concern and the following clause was included in the contract
specification:
"Contractors should note that the site transportation and placing of high
workability mixes, particularly when pumps are used, can degrade the air void
system of the concrete. Contractors should ensure that the potential effects of the
site transportation and placing system proposed by them be taken into account by
them and their concrete supplier when designing mixes for this project".
Concrete properties were specified as follows:
Cement: 10E-SF
Silica fume content: 6-8%
28-day compressive strength: 45 MPa
Cementitious content: 355 kg/m minimum
Water-cement ratio: 0.40 maximum
RCP: 1000 coulombs maximum
Air content at end of pump: 6-8%
Air void system (on cores drilled from the structure)
Air content: 3% minimum
Average spacing factor: 230 m maximum
No individual test greater than: 260 m
Slump: 50 +/- 20 mm before addition of superplasticizer
180 +/- 40 mm after addition of superplasticizer
Maximum temperature of concrete as delivered: 25C
46
47
As a result of experience gained on bridge 201, over 40 bridges in the GTAA expansion
will be built with HPC, with many already underway or completed.
Another project at the GTAA incorporating HPC is the elevated roadway accessing the
new terminal. The specification is basically the MTO specification and pours of up to
3000 m of the 1 m. thick, post-tensioned deck were made starting in hot weather in the
summer of 1999. In order to meet the 70C maximum temperature, the 20C maximum
temperature gradient, and the maximum delivered temperature of 25C, a number of steps
were taken. In the concrete mix 24% of the 10E-SF cement was replaced with slag, a
retarder was used, the coarse aggregate was soaked with cold water and concreting took
place at night. In the first pour in June, a maximum temperature of 57-58C was reached.
In-situ test data were as follows:
Mean
Air content: %
Spacing factor: m
RCP: coulombs
6.7
134
512
Standard
Range No of
Deviation
Results
1.4
3.6-9.7
28
19
98-173
28
172
263-1053
28
Compression test results at 28 days were analyzed with the following results:
No of results: 100
Mean: 55.14 MPa
Standard deviation: 5.43 MPa
Coefficient of variation: 9.8%
Data from some other bridge projects were as follows:
Year
Component
1997
1997
1997
1997
1998
Deck
Overlay
Deck
Overlay
Deck
28-day strength:
MPa
Specified
Achieved
35
45.9
50
60.3
45
49
45
54.4
50
67.5
48
RCP:
Coulombs
575
423
720
378
Average slump
Range of slump
In the case of low 28 day results, additional strength specimens held for later age testing
at 56 days and, in the majority of cases, met the specified strength of 45 MPa. Some of
the low compressive strength results at 28 days were associated with elevated air
contents.
Pinette River Bridge (1996 to 1997)
An existing structure over the mouth of the Pinette River was replaced to correct
horizontal and vertical alignment of the bridge and roadway. The cast-in-place concrete
specifications for the project were generally based on those used for the Confederation
Bridge. All concrete was specified with a minimum 28 day compressive strength of 50
MPa using Type 10E-SF (low alkali) cement and Class F fly ash, 5 to 8 percent total air
content, and a slump after the addition of superplasticizer of 190 30 mm. The structure
consisted of two spans (versus the original three spans) of New Brunswick DOT Type 1
prestressed precast girders using conventional concrete having a specified 28 day
compressive strength of 40 MPa. The abutments and centre pier were founded on 500
mm diameter concrete pipe piles filled with 50 MPa cast-in-place concrete.
49
Average slump
Range of slump
For two sets of compressive strength specimens failing to meet the 28 day specified
strength, additional specimens cast and tested at 91 days exceeded the specified strength.
Qubec
Taking advantage of the pioneering research on HPC at Sherbrooke University and also
at the University of Laval, the Province of Qubec has been a leader in the use of HPC in
Canada. Organized by the Montreal office of the Canadian Portland Cement Association
(CPCA), the "Projet Voies Nouvelles du Bton (Project on New Directions for
Concrete)", launched in October 1990 and supported by Concrete Canada, CPCA, MTQ,
The City of Montreal, cement producers and structural engineers, provided a framework
for HPC projects.
As a result, the first bridges in Canada using concrete designated as HPC were built in
Qubec (Lessard et al, 1993, Malier and Larrard, 1993, Aitcin et al, 1998, Mitchell et al,
1993, Lessard, 1994, and Lachemi et al, 1994). The extensive data obtained, evaluated
and publicized, provided invaluable encouragement to others.
The first was a 17 m single span bridge at St Eustache, replaced in 1992. Due to the
advanced state of deterioration, it was replaced with 70 MPa HPC pretensioned channel
girders, placed side by side to eliminate the need for deck slab formwork. The deck was
cast in 30 MPa concrete. The 70 MPa was not needed structurally but was used to assure
long term durability.
The second replacement bridge, also in 1992, was a pedestrian bridge over a 6 lane
highway in Laval. The Z-shaped precast pretensioned girders were cast with 70 MPa air
entrained HPC. The girders were erected during one night to avoid traffic delays. The
girders were connected structurally by precast deck slabs with a latex concrete topping.
The third bridge was at Portneuf, in fall 1992 (Aitcin and Lessard, 1994). This was a
single span rigid frame comprising precast post-tensioned beams, a thin cast-in-place
deck and external prestress cables. The specified 28 day compressive strength was 60
MPa. Test results averaged 75.3 MPa with a standard deviation of 3.5 MPa and a
coefficient of variation of 4.6%. The average air content in-place was 5.4% with a
standard deviation of 0.8% and a coefficient of variation of 15%. The average spacing
factor of the air void system in the hardened concrete was 190 m with a standard
deviation of 33 m. and a coefficient of variation of 4.6%.
50
The fourth bridge was built in 1993 over Highway 50 near Mirabel. It was a two span
continuous structure comprising precast beams and a cast-in-place deck and external
prestress cables. Compared to a bridge of the same design made with conventional bridge
concrete, the cost was 5% less (Coulombe and Ouellet, 1995). The mean compressive
strength at 28 days was 80.7 MPa and the air content 6.3%.
By the end of 1997, a total of 12,065 cubic metres of HPC had been used by the MTQ in
14 bridges (Coulombe and Vezina, 1998). Most bridges used 60 MPa cast-in-place decks
on 60 MPa AASHTO precast, prestressed girders. Pumping concrete was not allowed, so
as to avoid degradation of the air void system. On all contracts, the specification
requirements for compressive strength, air content, slump and spacing factor were met. A
survey of two bare decks subjected to the direct action of de-icing salts were as follows:
Chloride ion content in the bare decks after 5 years: % by weight of concrete
Depth: mm
Portneuf
Mirabel
0-12.5
0.164
0.035
12.5-25
0.017
0.008
25-50
0.008
0.009
50-75
0.009
0.008
75-100
0.008
0.008
Test data from the first 13 bridges built by the MTQ from 1992 to 1998 were as follows
(Vzina,1997):
Test
Slump: mm
Air: %
Compressive
Strength: MPa
Spacing factor: m
Specific surface: in-1
Scaling: kg/m
RCP: coulombs
MPa
60
50
60
50
60
50
60
50
60
50
60
50
60
50
Mean
168
150
5.8
5.7
73.6
62.5
208
177
24.8
27.5
0.071
0.102
393
666
s
28
34
0.8
1.1
8.4
5.6
54
25
3.0
3.5
Min
130
90
4.5
4.5
56
50
157
125
19.9
21.1
0.03
0.019
165
205
Max
210
200
6.8
7.6
83
74
319
218
30.7
33.6
0.16
0.18
1237
1319
n
6
7
6
7
6
7
6
7
6
7
6
5
5
8
Notes: MPa is the 28 day strength specified, s is the standard deviation, n is the number
of bridges to which the data relate.
51
Criteria for HPC mixes from the MTQ Standard 3101 are as follows:
TYPE
Compressive strength at 28 days: MPa
XIIIA
50
XIIIB
60
360
0.37
5-14
4-7
180
yes
380
0.35
5-14
4-7
180
yes
For cast-in-place concrete Type 10E-SF, for prestressed precast beams Type 30 + 7 10% silica fume or Type 30E-SF. Water-cement ratio includes silica fume as cement.
In 1995, the deck of the Jacques-Cartier Bridge in Sherbrooke was reconstructed between
August and November with 1,800 m of 60 MPa air entrained HPC (Blais et al, 1996). In
hot weather, ice was used and, in cold weather, hot water to maintain delivery
temperatures of 18C maximum in hot weather, and 22C in cold weather. The high early
development of strength accelerated the construction and it was estimated that this saved
$150,000 just in the reduced times that drivers had to use a 3 km detour. This does not
include significant savings in user delay costs.
During the rehabilitation of the Benjamin-Moreau Bridge in 1996 (A tcin, 1998), the
opportunity was taken to investigate whether or not the degradation of air void systems
during pumping could be mitigated. High-slump HPC was used in the reconstruction of
the parapet wall. The wall was divided into four sections and different pumpline
configurations and pressures were used in each section (See figures 1-4).
The results were as follows:
1
Fresh concrete
Slump: mm
Air content: %
Hardened concrete
Compressive strength: MPa
Spacing factor: m
Air content: %
Scaling: kg/m
Length change: mm
Durability factor: %
165
5.0
100
4.0
195
5.5
170
2.6
200
4.2
170
2.8
220
5.1
130
2.1
76.4
205
4.8
0.01
0.025
99
78.7
395
3.6
0.01
0.025
100
70.3
195
5.3
0.01
0.025
99
81.9
485
2.3
0.01
0.025
98
76.4 82.5
220
450
3.7
2.8
0.01 0.02
0.025 0.025
100
99
73.3 78.6
215
470
4.6
2.3
0.02 0.02
0.010 0.030
98
98
It was not possible, from the above data, to determine a systematic way of reducing the
degradation of the air void system during pumping. Despite the degradation of the air
void system in all configurations, the durability of all the resulting concrete was
excellent.
The City of Montreal is a leader in the optimum utilization of HPC. In 1994, a mix
containing silica fume and specified to meet a 40 MPa strength was used on the
Wellington Bridge. The test results were approximately 50 MPa at 28 days. Between
1996 and 1997, three projects used HPC based on specifications developed jointly by the
City of Montreal and Sherbrooke University. The Henri-Bourassa-Albert-Hudon and
Henri-Bourassa-Merien overpasses used 50 MPa HPC in the structural sidewalks,
gradient walls, columns, parapet and central wall. The Rodolphe-Forget overpass was
made entirely with 50 and 60 MPa HPC.
Subsequently, HPC was used on the Chabanal and Peel-de la Commune enclosed
passageways.
To date, HPC has been used in the repair of about 25 structures. On some, a Ternary
cement has been used and these are described in Chapter 9.
During the above period, the City staff worked with concrete experts from industry,
suppliers and MTQ to develop a specification for HPC. A first edition was produced in
June 1998 and a second edition in January 2000 (Morin and Campeau, 2000). This
specification is a stand-alone document covering materials and methods of construction.
It is one of the most developed City specifications for HPC in Canada to date.
Some requirements of interest are as follows:
Notes are provided for guidance on the effects of pumping on temperature, slump
and air content.
Cement is Type 10E-SF except where concrete dimensions are large enough to
cause problems due to heat of hydration. In such cases, Type 20 cement with a
maximum heat of hydration of 350 J/g at 7 days is specified.
Maximum temperature of concrete on delivery: 5-22C for components less than
750 mm thick, 5-20C for components greater than 750 mm thick.
Maximum internal temperature: 70C.
Maximum spacing factor determined on standard test specimens: 230 m before
pumping, 325 m after pumping.
Maximum RCP value: 1000 coulombs at 28 days unless a later age is specified.
Maximum scaling loss: 500 g/m after 56 cycles using BNQ test 2621-90.
53
An important aspect of the use of HPC is the control of shrinkage cracking. Autogenous
shrinkage is of particular concern in HPC, but most data available to date have been
generated by laboratory experiments. The opportunity was taken by the City, in cooperation with the University of Sherbrooke, to instrument two components of a CNR
viaduct in Montreal during construction (Nikola et al, 2000).
Thermocouple equipped vibrating strain gauges were placed in a column and in the deck.
The column was 5m high and 1.2 m in diameter. The deck was 1.3 m thick and contained
1370 m of concrete.
W/B
Ratio
0.38
Binder
Type
kg/m3
10SF
390
Deck
0.38
10BA
Entrained
Air %2
8.4
450
5.9
f1 c
Curing Conditions
MPa
50/52 Sealed quasi adiabatic
conditions
40/40 7 days wet curing
54
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Reactive Powder Concretes, Sherbrooke, August 1998, Vol 4, pp. 81-90.
Vezina, D., "Experience du Ministere des Transports du Quebec Avec le Beton Haute Performance (1992 A
1997)", Proceedings ACI Quebec and Eastern Ontario Chapter seminar, December 1997, pp. 89-98.
Blais, F.A., Dallaire, E., Lessard, M. and A tcin, P-C., "The Reconstruction of the Bridge Deck of the
Jacques-Cartier Bridge in Sherbrooke (Qubec) Using High-Performance Concrete", Proceedings
CSCE Annual Conference, Edmonton, May/June 1996, Vol llb, pp. 501-508.
Aitcin, P-C, "Yamaska Bridge: Air-Void Stability and Finishing Field Trials for Pumped HPC", Concrete
Canada Report, 1995.
Morin, R. and Campeau, A., "Devis Technique Normalis Pour Le Bton Haute Performance (BHP),
3VM-20, Ville de Montral, Janvier 2000.
Petrov, N., Morin, R., Bonneau, O. and A tcin, P-C., "In-Situ Shrinkage in High-Performance Concrete
Structures", Proceedings RILEM International Workshop on Shrinkage of Concrete-Shrinkage 2000,
Paris, October 2000.
56
57
58
Jack Clark
SkyTrain Extension
Vancouver, BC
59
60
61
Chapter 4
Precast Concrete
Confederation Bridge
The pre-eminent example of the use of precast HPC is the Confederation Bridge (Holley
et al, 1999 and Langley et al, 1997). At 13 km, it is one of the longest multi-span bridges
in the world. With spans up to 250 m and girders weighing 7500 tonnes, it is an
outstanding example of the potential for the use of precast concrete. Designed for a
service life of 100 years in a freeze-thaw marine environment, protection of the uncoated
steel in the superstructure is provided solely by the concrete.
The following are extracts from the first referenced paper:
"Most of the bridge components, including the main girders and support piers, were
fabricated on land at one of two precast facilities situated either side of the bridge. Seven
different types of concrete were required to provide various combinations of the
following properties:
A blended low-alkali 10E-SF cement ground to significantly finer limits (89.7% passing
a 45 m sieve) than required by CSA A 362 was used. An extensive preconstruction
testing programme included the following tests:
62
30
55
60
450
0.34
1000
14-10
5 to 8
230
260
180+/-40
0.06
30
40
35
28
400
300
130
0.4
1000
5 to 8
4 to 7
230
260
180+/-40
500 to 600
0.06
Mix proportions for the main classes of concrete and typical trial mix test results were as
follows:
Concrete Class
C3-2 Ice-Shield
A1
A1-F5
453
0.33
435
46
0.31
329
130
0.31
507
58
0.25
309
103
0.4
220
170
6
158
210
150
6.2
191
220
190
7
162
200
200
7
163
220
200
6
N/A
26.3
25.7
7.7
38.9
68.3
73.5
68.5
76.7
56
64.7
79.4
92.1
19
34
52
Note: A1-F5 was mix A1 modified with 10% fly ash to reduce the loss of air during
pumping.
63
A1
Freezing and Thawing: RDF%
300 cycles
99
99
500 cycles
100
100
Salt scaling: mass loss g/m
50 cycles
36
34
100 cycles
112
448
Rapid chloride permeability: coulombs
28 days
450
475
91 days
300
225
Chloride ion penetration: 91 days - mm
0-13mm
0.082 0.166
13-25mm
<0.002 <0.002
100
100
100
100
278
591
66
102
780
260
315
235
0.2
0.013
0.068
<0.002
The maximum concrete temperature allowed during hydration was 70C and the
maximum temperature gradient was 20C/m.
The factors resulting in the successful placement of 450,000 m of HPC on this project
were described as follows:
"This exceptional performance was made possible by applied concrete technology,
rigorous material testing, high standards and quality control, and solid partnering
between the producer and the general contractor working together to solve
unexpected problems encountered during the placement of large quantities of high
performance concrete".
Bridges
The use of HPC in precast prestressed concrete bridge girders has been shown to result in
technical and economic benefits. In Alberta, it has been shown that the 20 hour transfer
strength can be met and a 60 MPa 28 day strength achieved at lower material cost and
without the traditional use of accelerated curing (Johnston, 1989).
On the Highway 407 project, two bridges were constructed of HPC. For the second, the
CPCI 1900 precast prestressed girders were cast with 60 MPa HPC. The transfer strength
was 48 MPa and oversize 0.5 inch strand (13.08 mm diameter) was used to reduce the
number of strands. By these means, the number of girders required were reduced from 4
to 3, a saving of about $30,000 (Jagasia, 1997, Bickley et al, 1997).
A study of HPC girder costs (Hassanain and Loov, 1998) for a two span continuous slab
on girder 3 lane bridge using CPCI 1400 girders showed that, as the concrete strength
was increased, the total superstructure costs decreased. Each span was 28 m. For
instance, an increase in the compressive strength of the girders from 43.4 MPa to 72.1
64
MPa decreased the superstructure cost from $163/m to $130/m where low transportation and erection costs prevailed. Where transportation and erection costs were high,
the costs were, respectively, $252/m and $183/m. As on Highway 407, the reduced cost
resulted from the need to use fewer girders with the HPC alternative.
A study of the economics of high strength concrete in spliced prestressed girders (Lounis
and Mirza, 1998) showed similar trends. A study of AASHTO-PCI bulb-tee 72 girders
with spans of 45, 50 and 55 m, and concrete strengths of 40, 50, 60 and 70 MPa showed
increases in maximum permissible girder spacings. Again, this permits the use of fewer
girders.
In both of the last two studies cited, there was a maximum concrete strength beyond
which no additional benefit accrued, or at which the strength was unattainable or release
strengths could not be achieved.
Test data for precast components for four bridges in Ontario were as follows:
Dundas Street
45
30
Yes
7
202
26.8
50
nil
203
25.5
5.3
0.4
5.7
1.2
4.6
0.3
71
5.2
-
60.2
1.8
-
63.4
1.9
711
151
On the fourth bridge project, the initial mix used tended to flash set. This problem was
solved by the use of retarders.
The test data for the double tees were as follows:
Before retarder
After retarder
Number of
results
60
103
Mean 28 day
strength: MPa
58.3
75
Standard
Deviation: MPa
5.4
7.3
The coefficient of variation of the results before and after adding a retarder were similar,
showing that the mix was the problem, not the level of quality control.
65
In 1998, bulb tees were used on Highway 14 and Whitemud Freeway overpass. Release
strength was 35 MPa at 12 hours. Type 30SF cement was used. Bulb tees were also used
on the Highway 3 bridge over Local Road G/S near Monarch. Release strength was 38
MPa and 28 day strength was 65 MPa. Span was 33.5 m. The concrete contained 10%
silica fume.
Data from two recent Alberta projects were as follows:
Anderson Road
Interchange
Trapezoidal
Girders
450
22.5
0.28
yes
no
Calgary Airport
Parkade
3660 wide Double Tees
100 mm thick flange
380
31
0.32
yes
yes
80
40
6
150
600
65
30
6
130
505
Performance
Average 28 day strength: MPa
Average 16 hour strength: MPa
Average air content: %
Slump: mm
RCP at 28 days: coulombs
No
24
18
24
24
Type
Channel
"
"
"
Span: Metres
12
12
8
12
All contained 8% silica fume, and met a 40 MPa 28 day strength requirement.
For the Main Street Bridge over the Assiniboine River, the City of Winnipeg used 26
post-tensioned precast trapezoidal box girders in phases 1 and 2. Specified strength at 28
days was 60 MPa. The concrete contained 8% silica fume.
Type 10E-SF cement has been used in the manufacture of prestressed bridge girders in
New Brunswick and Nova Scotia since 1995 (Thomas et al, 1998).
66
430
172
0.40
125
4.0
37.9
65.4
2.76
30.2
58.0
36.8
61.4
4.23
Concrete Pipe
Type 10E-SF cement is used in the production of concrete pipe, storm drains, box
culverts and concrete manholes for use in aggressive environments.
In 1997, silica fume concrete pipe was used in the Mixed Cargo Terminal Project at
Belledune, New Brunswick.
It was also used in the Cave Creek Collector Upgrade Sewer in Ottawa, in a high chloride
environment. A 50-year life was specified, and the use of 10E-SF cement proved to be
the most cost-effective alternative. The pipe was dry cast with 455 kg/m Type 10E-SF
cement containing 7.5% silica fume, a w/cm ratio of 0.23 and an air content of 5-7%.
Typical properties of this pipe were as follows (Smith, 1996):
Max absorption: %
Max RCP: coulombs
28-day strength: MPa
Type 10
5.0
2500
50
Apart from the improved physical properties, the surfaces of the pipe were smoother than
normal production pipe.
67
68
The second contract was the segments for the Sheppard Line Subway in Toronto. These
segments for a 5.2 m diameter tunnel were more typical in size than those of the St Clair
tunnel. Key requirements from the contract specification were as follows:
69
Research at the University of Calgary (Dilger and Rao, 1996) established principles for
the design of suitable mixes and spinning and curing regimes. These principles allow the
design of concrete mixes with high strength, lower weight and very good durability.
Building on this research, a test programme was carried out by The University of Calgary
and Sky Cast Inc. of Guelph (Dilger et al, 1998). The research demonstrated that a
properly proportioned mix could be fully consolidated without segregation and
prestressed within 6 to 8 hours. The durability and strength characteristics of the
optimized concrete mixes were determined for all critical parameters.
Subsequently, tests were initiated by Sky Cast Inc. and carried out by an independent
laboratory in 1999 to confirm the strength and durability of production poles.
Some of the properties of a production pole were as follows:
Test Result Specified
Resistance to Freeze-thaw
ASTM C 666, Procedure A
Relative Dynamic Modulus: %
Length Change: %
92.2
0.002
90 min
0.035 max
0.72
0.80 max
231
1000 max
0.65
no limit
2.2
0.185
3.0 min
0.3 max
65.8
72.1
73.5
50
All of the above acceptance criteria are Ontario specified, except strength which is the
requirement in the CSA Standard A 14-00 Concrete Poles.
The above results characterize a high strength very durable pole with an expected service
life of more than 35 years. The study showed that twice as much cover would be needed
if HPC were not used.
70
Parking Structures
Test data for a parking structure in Brampton, Ontario using precast beams and double
tees was as follows:
Plant 1 Plant 2
40
40
30
10SF
yes
yes
33
16
178
15.2
209
6.2
5.5
0.35
5.4
0.7
64
3.4
623
180
60
3.9
1148
197
Precaster Experience
A precaster with plants in British Columbia, Alberta, Saskatchewan and Manitoba
summarizes experience with HPC for precast concrete as follows:
71
REFERENCES
Holley, J.J., Thomas, M.D.A., Hopkins, D.S., Cail, K.M. and Lanctot, M-C., "Custom HPC Mixtures for
Challenging Bridge Design", Concrete International, Vol 21, no 9, September 1999, pp. 43-49.
Langley, W.S., Gilmour, R.A., Turnham, J., Forbes, G. and Mostert, T., "Quality Management Plan for the
Confederation Bridge", ACI SP 171, pp. 73-96.
Johnston, C.D., "Silica Fume Concrete for High-Strength Precast Prestressed Highway Bridge Girders",
Proceedings of The Third International Conference on Fly Ash, Silica Fume Slag and Natural
Pozzolans in Concrete, Norway, 1989, ACI SP 114, pp. 1077-1100.
Jagasia, H.K., "Design and Construction of High Performance Concrete Bridges on 407 Express Toll
Route", Proceedings PCI/FHWA International Symposium on High Performance Concrete, New
Orleans, October 1997, pp. 533-542.
Hassanain, M.A. and Loov, R.E., "Design Optimization of Precast Girder Bridges Made With HighPerformance Concrete", Proceedings PCI/FHWA Symposium on High Performance Concrete, New
Orleans, August 1998, pp. 1-12.
Lounis, Z. and Mirza, M.S., "High Strength Concrete in Spliced Prestessed Concrete Bridge Girders",
Proceedings PCI/FHWA Symposium on High Performance Concrete, New Orleans, August 1998, pp.
39-48.
Bickley, J.A., Berzakiewicz, B., Carter, K., Pianca, F. and Raven, R. "Construction, Testing and Monitoring
of Highway 407 High-Performance Concrete Structures B22A and B22C at Levi's Creek in
Mississauga", Concrete Canada Report, August 1997.
Smith, M.,"Silica Fume Used to Extend Service Life of Pipe", Concrete Pipe Journal, Vol II, October 1996,
pp. 8-9.
Hart, A.J.R., Ryell, J. and Thomas, M.D.A., "High Performance Concrete in Precast Tunnel Linings:
Meeting Chloride Diffusion and Permeability Requirements", PCA/FHWA International Symposium on
High Performance Concrete, New Orleans, October, 1997, proceedings, pp. 294-307.
Thomas, M.D.A. and Matthews, J.D., "Chloride Penetration and Reinforcement Corrosion in Fly Ash
Concrete Exposed to a Marine Environment", Third CANMET/ACI International Conference on
Performance of Concrete in a Marine Environment, ACI SP-163, 1996, pp. 317-338.
DeSouza, S.J., Hooton, R.D. and Bickley, J.A., "A Practical QC test Programme for HPC in Precast Tunnel
Liners", ACI SP 191, 2000, pp. 99-114.
Dilger, W.H. and Rao, S.V.M.K., "Design of High Performance Concrete Mixtures for the Commercial
Production of Spun-Cast Poles", Proceedings CSCA 1 st Structural Specialty Conference, Edmonton,
June 1996, pp. 509-521.
Dilger, W.H., Kuebler, U. and Wang, M., "High Performance Concrete for Spun-Cast Utilities Poles", In
Publication
72
73
Chapter 5
Buildings
High Strength HPC has found favour in the construction of tall buildings and structures.
In Toronto and Calgary, a number of large high-rise buildings have been built with 70
and 85 MPa concrete.
Recent Buildings with High-Strength Concrete (Bickley, 1999 and Lafarge 2000) are:
Building
Location
Scotia Plaza
Toronto
Bay Adelaide Center Toronto
BCE Place Phase 1
Toronto
BCE Place Phase 2
Toronto
Simcoe Place
Toronto
Millenium Tower
Calgary
Bankers Hall 2
Calgary
TCPL Tower
Calgary
Pantages Place
Toronto
Year
1988
1991
1992
1993
1994
1998
1999
2000
2000
70
85
70
85
85
85
80
85
85
Starting with Scotia Plaza, a logical approach was developed to ensure the achievement
of the specified high strengths by these HPC mixes (Ryell and Bickley, 1987). Ternary
mixes were used in all the Toronto buildings. Initially, undensified silica fume was added
separately. This proved to be difficult to mix uniformly, and a special batching sequence
had to be developed to overcome the mixing problem. Subsequently, Type 10E-SF
cement was available for the later projects. Innovative procedures employed on these
projects included nitrogen cooling of concrete in hot weather, in-place testing for early
form removal, as early as 11 hours after casting, and pre-construction mockups to
investigate thermal problems with large sections.
A high degree of quality control was achieved on all these projects as shown in the
following tables (Ryell and Fasullo, 1993):
Projects using 70 MPa
Concrete
No of tests
Mean strength: MPa
Standard deviation: MPa
Coefficient of variation: %
74
Bay Adelaide
93
95.2
5.8
6.1
At the time Scotia Plaza was under construction, the use of silica fume in Canada on tall
buildings was in its infancy. There was also concern to establish the long term properties
of silica fume concrete. Cores were taken from a typical column at ages of 1, 2 and 7
years to confirm the mechanical properties of the concrete in situ (Bickley et al, 1991 and
1994). Further long-term in-situ data was obtained by casting and instrumenting an
experimental column in a high-rise concrete building in Montreal (Aitcin et al, 1985 and
Aitcin et al, 1990).
The high early strength properties of HPC have also been utilized to reconstruct busy
entrances to a fast food restaurant overnight and have them back in service next morning
(Lessard et al, 1994).
Parking Structures
The current edition of CSA S 413-94 does not allow for the use of HPC in nonprestressed
components. Where prestressed concrete is used, there are options to use "low
permeability concrete". For cast-in-place components, this type of concrete can be used
in conjunction with a membrane for bonded tendons, with a membrane or epoxy-coated
bars or corrosion inhibitor for unbonded tendons or bonded tendons in non-metallic
ducts. For precast concrete, low permeability concrete can be used with epoxy coated top
bars, with corrosion inhibitor and with a sealer. All the last three systems listed can be
used with uncoated welded steel wire fabric.
Low permeability concrete is defined as concrete having a maximum water-cement ratio
of 0.40 and an average coulomb rating of 1500 after standard curing for 28 days. (Where
slag or fly ash are incorporated in the mix, the test may be made at ages up to 91 days.)
This type of concrete would qualify as HPC.
Despite the limitations of CSA S 413, HPC, meeting more stringent specifications, has
been used in the construction of cast-in-place concrete parking structures. One example is
the parking structure built as part of the Sheppard subway line project at the Don Mills
Station and Fairview Mall.
The relevant TTC specification requirements for this project were as follows:
Fog curing was specified prior to finishing and applying saturated burlap for 7 days.
75
The contractor expressed concern about fog misting because the deck area at each level
was 54 m x 54 m, and the practicality of doing it during the winter. The opportunity was
taken to carry out comparative trials on the upper level during construction. The
contractor was advised to use a commercial power washer with a misting hose. By
elevating this hose on the upwind side of the structure, a fog mist was reasonably applied
to the whole surface.
Three adjacent areas of the placement were chosen for tests:
Zone 1: Fog misting only
Zone 2: Fog misting plus evaporation retarder
Zone 3: Evaporation retarder only
The placing and finishing was witnessed, and a representative of the supplier instructed
the placing crew on the use of the evaporation retarder. After the surface had hardened,
sorptivity tests were made and cores taken from each of the test areas.
A summary of test results is as follows:
Sorptivity
RCP tests:
Tests
coulombs
0.5
mm/min
Top
Middle
Densities: kg/m
Top
Middle
Fog misting
0.032
0.031
0.032
185
185
190
240
240
250
2410
2400
2400
2415
2415
2400
Fog misting +
Evaporation retarder
0.029
0.031
0.029
185
170
190
235
215
215
2400
2430
2395
2400
2405
2420
Evaporation retarder
0.036
0.036
0.039
175
195
190
200
245
230
2395
2385
2385
2380
2380
2375
Test cylinders
280
230
265
2415
2450
2455
There is very little difference between the test results for sorptivity or RCP for any of the
three curing regimes. Sorptivity tests on the three lower levels, which it is understood
were not fog cured, gave values of 0.061 mm/min0.5. Based on these few results, it would
appear that fog curing and evaporation retarder produce similar sorptivity results, while
the absence of either results in significantly higher sorptivity.
76
Other cores tested at the University of Toronto gave an average resistivity of 87,467 ohm
cm, with a range of 75,337 to 104003. Diffusion values ranged from 0.53-3.08 x 10-12
with an average of 1.48 x 10-12. Bulk diffusion values at 90 and 365 days, respectively,
were 1.65 and 0.96 x 10-12. RCP values were similar to those in the above table.
HPC was used in the repair of a parking garage in Kitchener in 1998. The specified 28
day strength was 35 MPa and test results exceeded 40 MPa. The RCP value obtained was
565 coulombs.
REFERENCES
Bickley, J.A., "North American Trends in the Development of High-Strength Concrete", Proceedings 5 th
International Symposium on High Strength/High Performance Concrete, Sandefjord, Norway, June
1999, pp. 1-13.
Lafarge, Private communication.
Ryell, J. and Bickley, J.A., "Scotia Plaza: High Strength Concrete for Tall Buildings", Proceedings
Utilization of High Strength Concrete, Stavanger, Norway, June 1987, pp. 641-654.
Bickley, J.A., Ryell, J., Rogers C. and Hooton, R.D., Some Characteristics of High Strength Concrete:
Canadian Journal of Civil Engineering, Vol. 18, No. 5, 1991, pp. 885-889.
Bickley, J.A., Ryell, J., Rogers C. and Hooton, R.D., Some Characteristics of High Strength Concrete: Part
2, Canadian Journal of Civil Engineering, December 1994, Vol. 21, No. 6, pp. 1084-1087.
A tcin, P-C, Laplante, P. and Bedard, C. "Development and Experimental Use of a 90 MPa (13,000 psi)
Field Concrete", ACI SP 87, 1985, pp. 51-70.
A tcin, P-C, Sarkar, S.L. and Laplante, P. "Long Term Characteristics of a Very High Strength Field
Concrete", Concrete International, Vol 12, no 1, January 1990, pp. 40-44.
Lessard, M., Dallaire, E., Blouin, D. and Aitcin, P-C., "High-Performance Concrete Speeds Reconstruction
for McDonalds", Concrete International, September, 1994.
77
78
Chapter 6
Marine Applications
After some initial concrete work with a temporary batch plant, a permanent plant was
installed for the base concreting. This consisted of two 2 m twin axle high shear mixers
with separate materials feed trains to each. Similar 2.5 m mixers were used in the batch
plant for the deep water construction. Provision was made for the heating and cooling of
concrete.
Type 10 cement containing blended silica fume at 8.5 +/- 0.5% was used having an Na 2O
equivalent of 0.72%. High dosages of superplasticizer were used to produce concrete
with slumps of 220-240 mm that was pumpable over large distances and placeable in
reinforcement densities averaging 611 kg/m.
The one-year design compressive strength of the concrete was 69 MPa. An extensively
equipped laboratory was built on site. Test cylinders 100 mm in diameter by 200 mm
were used and ends were ground before testing.
79
81.7
3.1
83.5
2.5
Tests were also made for creep, drying shrinkage, water permeability, in-situ strength, air
void parameters, freeze-thaw resistance (ASTM 666 Procedure A) and chloride ion
permeability. All test data confirmed the high quality of the concrete reflecting the high
level of quality control exercised throughout the project.
Grand Manan Wharf
As no suitable construction facilities existed on this small island, the new wharf was
formed from four massive concrete caissons cast in Saint John and towed 100 km to
Grand Manan (Hopkins et al 2000).
Three of the caissons were 30 m long by 14.6 m wide by 15.5 m high. The fourth was
slightly smaller. Exterior walls were 500 mm thick and the cells were separated by 300
mm thick walls. After the casting of the bases the walls were slipformed, at rates of 160
to 185 mm/hr. all the concrete was placed by pump. The almost 6000 m of concrete was
placed in just over four weeks in 1999.
Key specification criteria were as follows:
The use of silica fume had, in the past, caused finish problems in slipformed concrete,
and the contractor for this project had concerns in this regard. The use of a non-chloride
accelerator in the mix lubricated the concrete interface with the slipform. The mix was
slipformable at about 3.5 hours.
80
To meet the New Brunswick DOT's cold weather and curing requirements, the caissons
were enclosed in insulated tarpaulins. Low-pressure steam provided a 100% humidity for
7 days of curing and kept the concrete above the 10C minimum temperature specified.
Compressive strengths were 53.5 MPa.
REFERENCES
Hoff, G.C., "The Hibernia Offshore Platform-A Major Canadian Use of High Performance Concrete",
Proceedings International Symposium on High-Performance and Reactive Powder Concretes,
Sherbrooke, August 1998, Vol 4, pp. 29-56.
Hopkins, D.S., Strang, F., Woytowich, W., Ballantyne, T. and Thomas, M.D.A., "The Wharf That Floated",
ACI Atlantic Chapter Conference, St. Johns, Nfld. 2000.
81
82
Chapter 7
Agricultural Applications
HPC has been used in agricultural buildings where the impermeability of HPC provides
durability against the aggressive agents from the animals and feed. Used in swine
nurseries, HPC reduced infections by inhibiting the growth of harmful bacteria, which
normally breed in the pores of conventional concrete. The result was heavier pigs and
higher profits to the breeder (Gagn et al, 1994).
60 MPa HPC was also used for the floor slab of a poultry smokehouse.
In recent years there have been many large pig-breeding factories established on
farmland. In these facilities, the pigs live on precast slats above a lower level where
wastes are collected. Previously the precast slats were made with conventional concretes
and these had a short service life in the aggressive environment.
Research has been carried out which confirms that precast slats made with HPC provide
significantly longer service life than the quality of concrete usually used (Idriss et al,
2001). Two series of tests were made to determine the time to corrosion of steel
reinforcement in mortar specimens exposed to hydrogen sulphide.
In the first series, the specimens were subjected to impressed voltage and electrochemical
potential tests. For the impressed voltage tests, 95.5 mm diameter cylinders 200 mm long
were cast with a 11.3 mm diameter 400 MPa reinforcing bar in the middle. After 28 days
wet curing, the specimens (three replicates) were immersed in a solution of 2000 ppm of
H2S for a year. The reinforcement was then connected to a 40-volt direct current to make
it anodic with respect to an external cathode, which was connected to the negative pole of
the DC source. The time to develop a longitudinal crack was noted.
For the electrochemical potential tests, specimens 100 mm by 100 mm by 30 mm thick
were cast with an 11.3 mm diameter reinforcing bar in the middle. Five stainless steel
wires were attached to the reinforcing bar, three of which protruded from the specimen.
The other two were attached at the ends of the bar outside the test specimen. The
specimens were wet cured for 28 days. The specimens (three replicates) were immersed
in H2S for 650 days and half-cell readings taken every 10 days starting at day 60. Once
the readings indicated active corrosion, the specimens were tested to determine the
concentration of sulphides that initiated corrosion.
Mix
Type 10 w/c ratio 0.55
Type 10SF w/c ratio 0.35
Failure time
Tc min
Susceptibility to
Corrosion, A-1min-2
165
62.5
36,000
86.3 x 10-6
83
In the second series of tests, diffusion tests were made on specimens immersed in H2S
and epoxy coated on all but one surface. The time to reach the threshold value for
corrosion in the Type 10E-SF 0.35 w/c ratio mix was more than eight times as long as in
the Type 10 0.55 w/c ratio mix.
From these tests, it was concluded that the life of slats made with the Type 10E-SF mix
would be double that of slats made with conventional concrete.
In Ontario, all the precast concrete producers use HPC for farm applications. In addition
to slats, other HPC products are manger feeder bottoms, kennel floors and bunker silos.
REFERENCES
Gagn, R., Chagnon, D. and Parizeau, R., "Utilization of High-Strength Concrete in the Agricultural
Industry", Concrete Canada Technology Transfer Workshop, Sherbrooke University, October 1994.
Idriss, A.F., Negi, S.C., Jofriet, J.C. and Hayward, G.L., "Corrosion of Steel Reinforcement in Mortar
Specimens Exposed to Hydrogen Sulphide, Part 1: Impressed Voltage and Electrochemical Potential
Tests", In publication, Journal of Agricultural Engineering Research.
Idriss, A.F., Negi, S.C., Jofriet, J.C. and Hayward, G.L., " "Corrosion of Reinforcing Steel in Mortar
Specimens Exposed to Hydrogen Sulphide, Part 2: Diffusion Tests", In publication, Journal of
Agricultural Engineering Research.
84
85
86
Chapter 8
Shotcrete
In 1993, a study was made of four dams in British Columbia, which had previously been
repaired with shotcrete (Heere et al, 1996). Recommendations for repair were made based
on current high performance shotcrete technology.
In 1995, the multiple arches Littlerock Dam in California was repaired using silica fume
steel fibre reinforced air-entrained shotcrete (Forrest et al, 1995), and Canadian
technology. The shotcrete was used, as part of a seismic upgrading, to stiffen the arches
of the dam.
87
The good practice measures taken to ensure a competent repair were as follows:
88
HPC Shotcrete has been used in the repair of many marine structures including an oildrilling platform (Morgan, 1997). Wet-mix shotcrete with a specified 28-day strength of
80 MPa and a direct tensile bond strength of 2 MPa was used.
In BC, the Ministry of Transportation and Highways has used fibre-reinforced HPC
shotcrete to stabilize creek beds and protect bridge piers and abutments from scour.
In BC, an historic building, the Vancouver Block, was rehabilitated using HPC shotcrete
(Chan and Morgan, 2000). Wind-driven rain had penetrated the walls and caused severe
deterioration of the masonry walls and corrosion of the structural steel.
In 1997/98, at a cement plant in Bath, Ontario, a cement storage silo with a capacity of
68,000 tonnes was constructed of high performance shotcrete. The dome is 55 m in
diameter and 29 m high. An inflatable form was attached to the foundation ring beam.
After inflation, the interior was sprayed with polyurethane insulation and reinforcing steel
fixed. The concrete was then sprayed on the inside in a single layer. Wall thickness varies
from 0.51 m at the base to 0.15 m at the top of the dome. The inflatable form remains in
place as permanent waterproofing.
The wet mix shotcrete used had the following proportions:
Water reducing and air entraining admixtures produced the desired set characteristics, a
slump of 100 to 125 mm and an air content of 5-8%. The low rebound of 12% was
attributed to the use of silica fume and a low coarse aggregate content in the mix. Test
panels were made and cored. A summary of test data is as follows:
Concrete Cylinders Concrete Cores
7 days
28 days 7 days 28 days
No of tests
Mean strength: MPa
Standard deviation: MPa
Coefficient of variation: %
89
43.1
3.43
8.0
89
55.8
4.68
8.4
12
32.9
6.85
21.0
24
43.9
5.35
12.0
A major use of high performance shotcrete is the support of rock in tunnels, particularly
in mines. A comprehensive review of this application was produced by an admixture
supplier's underground construction group (Melbye, 1996). The need for the correct
specification and application of specifications for shotcrete resulted from conflict
between specifiers and contractors (Wood, 1992). The need for preconstruction
qualification testing and ongoing QC testing during construction was emphasized. Two
case histories are given in detail.
89
Components
Cement
Silica fume
Aggregate (blended)
Steel fibres
Accelerator
Superplasticizer
Water reducer
Air entraining agent
Water
Characteristic
Uniaxial compressive
strength: MPa
8 hr (accl.)
1 day
3 day
7 day
28 day
Flexural strength: MPa
7 day
28 day
Toughness index
I5
I10
Boiled absorption: %
Voids volume: %
Accelerated set: min
Aggregate gradation
Dry Mix
kg/m % of dry
Materials
420
19
50
2.2
1670
75.5
60
2.7
13
0.6
Test Method
Wet Mix
kg/m
% of dry
Materials
420
18.1
40
1.7
1600
68.9
60
2.6
13
0.6
6 litres
0.3
2 litres
0.1
if required
180
7.7
Minimum Required
ASTM C42
"
"
"
"
5
10
20
30
40
ASTM C1018
"
4
6
ASTM C1018
"
ASTM C 642
"
ASTM C 403
"
ACI 506R-90
3.5
5
8 max
17 max
Initial: 10
Final : 30
1,2 or 3
Note: The standards quoted in the above table have all been updated since 1992.
The paper concluded that the complex installation of brittle layers of shotcrete and wire
mesh could be replaced with a single pass of steel fibre reinforced silica fume shotcrete.
An outstanding example of the application of high performance shotcrete in the mining
industry is Incos Stobie mine in Sudbury (O'Hearn et al, 1998). A number of extensive
90
in-situ trials were made to confirm that steel fibre reinforced silica fume shotcrete could
safely replace the use of traditional shotcrete plus wire mesh reinforcement and rock
bolts. The trials also served to optimize the wet mix that was used.
The final proportions per m were as follow:
A high degree of quality control was exercised during construction. Analysis of the
results showed not only that the high performance shotcrete system was cheaper and
easier to install than traditional shotcrete systems, but the safety margin of the finished
installation was better.
REFERENCES
Morgan, D.M., "New Developments in Shotcrete for Repairs and Rehabilitation", Proceedings, Advances
in Concrete Technology, Athens, May 1992, pp. 699-739.
Heere, R., Morgan, D., Banthia, N. and Yogendran, Y., "Evaluation of Shotcrete Repaired Dams In British
Columbia", Concrete International, Vol 18, no 3, March 1996, pp. 24-29.
Forrest, M.P., Morgan, D.R., Obermeyer, J.R., Parker, P.L. and LaMoreaux, D.D., "Seismic Retrofit of
Littlerock Dam", Concrete International, Vol 17, no 11, November 1995, pp. 30-36.
Morgan, D.R., Rich, L. and Lobo, A., "About Face-Repair at Port of Montreal", Concrete International,
Vol 20, no 9, Septenber 1998, pp. 66-73.
Morgan, D.R., Bremner, T.W. and Gilbride, P., "Repair of Berth Faces at the Port of Saint John, New
Brunswick", Concrete Canada Technology Transfer Day, University of Moncton, August 1996, pp.6172.
Morgan, D.R., "Shotcrete Repair of Infrastructure in North America", Beton-Instandsetzung '97, Igls,
Austria, January 1997, pp. 21-37.
Chan, C. and Morgan, D.R., "Infrastructure Repair and Rehab: Shotcrete: Spraying on the Solution", CE
News, March 2000, pp. 66-71.
Hopkins, D.S., Cail, K., Robert, N. and Thomas, M.D.A., "World's Largest Dome for Cement Storage Silica
Fume Shotcrete", Canadian Society for Civil Engineering, Proceedings Annual Conference, Regina,
June, 1999, pp. 117-133.
Melbye, T.A., "Sprayed Concrete for Rock Support", MBT International Underground Construction group,
Switzerland, 1994.
Wood, D.F.,"Specification and application of fibre reinforced shotcrete", Rock Support in Mining and
Underground Construction, Kaiser and McCreath, Editors, Balkerma, Rotterdam, 1992, pp. 149-156.
OHearn, B., Buksa, H. and Walker, S., "Stobie signals shotcrete success", Engineering and Mining
Journal, August 1998.
91
92
Chapter 9
Emerging Technologies
Self-Consolidating Concrete
This type of concrete, originally invented in Japan, was developed in Canada at the
University of Sherbrooke and has been used in a number of new and rehabilitation
projects in Canada (Khayat, 2000).
Self-consolidating concrete (SCC) is a class of HPC based primarily on the properties of
the concrete during placement. Properly proportioned and controlled, this concrete will
flow significant distances inside formwork, consolidate to normal density without the
application of compactive effort, resist the segregation of coarse aggregate from the paste
and produce high quality finishes. Experience has shown that a high degree of QC is
required, but there are benefits, especially where access is difficult, where the noise of
vibration is undesirable and where labour savings for placing, compacting and finishing
can be achieved. The high quality finish possible, with virtually no "bug holes" makes it
particularly suitable for architectural quality exposed finishes.
The first full-scale application of this technology in a new building was at the Canadian
Centre for Technology at the National Research Council campus in Ottawa in 1999. The
basement walls for a three-unit residence were cast using this technique (Khayat et al,
2000).
After a laboratory development programme at Sherbrooke University and the casting of
two prototype walls in Toronto, the installation in Ottawa was made without any
problems with the concrete. The following were the test results on the fresh and hardened
concrete.
Concrete Mix Design and Fresh Concrete Properties
kg/m
Cement
Silica Fume
Slag
Water
Sand
Coarse Aggregate
VMA
l/m
Superplasticizer
Set retarder
Air entrainer
3.0-4.0
1.04
0.65
Slump flow: mm
Fresh air content %
Unit weight: kg/m
Concrete temp: C
630-650
5.2
2245
22
215
16
215
203
665
855
3.5
93
Slump flow: mm
Fresh air content: %
Filling capacity: %
Compressive strength: MPa
7 days
28 days
RCP at 56 days: Coulombs
Air void system
Air content: %
Spacing factor: m
4.9
5.4
Truck Load
3
4
640 +/- 10
5.2
85
34.2
46.7
540
34.8
43.1
5.4
300
36.2
43.2
560
90
34.6
45.9
33.2
50.7
4.7
265
SCC has been used in a number of rehabilitation contracts. On the Webster parking
structure in Sherbrooke, the soffit and sides of a reinforced concrete beam supporting a
slab was repaired with SCC. Holes 100 mm in diameter were drilled through the slab on
one side of the beam and the concrete was placed through these. The concrete had to flow
down the entry side of the beam formwork, under the soffit and up the other side, as well
as along the length of the beam. Small holes were drilled on the opposite side of the beam
to allow air to escape as the form filled. An additional innovation was the use of a ternary
cement.
At the Beauharnois Dam, an L-shaped slab and beam element with restricted access was
rehabilitated with SCC. A mobile mixer was used for the production of the concrete. This
necessitated special modifications to both the batching sequence and mixing.
A reaction wall built at the University of Sherbrooke used 240 m of SCC. An
underground drainage conduit in Shawinigan was successfully repaired using 130 m of
SCC. The Quebec Ministry of Transport has completed eight repair projects, and the City
of Montreal and the Montreal Metro have each completed one.
An example of the use of self-consolidating concrete in Montreal is the repair to 200 m of
parapet walls on McDougall Road on Decarie Blvd. Access was only possible from the
side to be repaired. The cross-section of the repair is shown on page 96. A total of 200 m
of 50 MPa SCC was used, and all test results exceeded 50 MPa. Research carried out by
the City over the last two years indicates greater tensile creep for SCC, resulting in a
reduced tendency to crack.
A project at the Toronto International Airport expansion that used a self-consolidating
HPC was the New Passenger Terminal (Meschino and Ryell, 2000). The pipe columns
supporting the roof are 31 m high. They had to be filled with concrete and contained
significant reinforcement. Evaluation of the various options for filling these columns
94
resulted in a decision to fill them from the bottom, provided a suitable mix could be
developed which could be pumped at a pressure the pump could handle.
A mix was developed based on the technology used for self-compacting concrete. The
mix contained 450 kg/m of cementitious material, 10 mm of uncrushed pea gravel. a
superplasticizer and a self-levelling admixture. A slump flow of 650-700 mm was used as
the acceptable range of workability. After field trials of the proposed mix, the first
column was successfully used as a trial. The filling process for the 12 m of concrete
takes about 15 minutes and pumping is smooth without high pressures. Four cores were
taken from the trial column at the top, bottom and two intermediate levels. Mean strength
was 44.0 MPa and the cores were seen to be uniform in quality with no segregation or
voids.
Lafarge has developed a proprietary version of this type of concrete with the name
"Agilia".
The first use of this concrete was in the massive columns to the first four floors of the
Wall Centre in Vancouver, a 48 storey building (Concrete Products, 2000). The decision
was based on the successful demonstration casting of five columns in the underground
parking area. The 8 ft. square columns, which were stripped after as little as 18 hours,
attained compressive strengths in excess of 70 MPa. Prior to proposing the use of SCC,
an extensive test programme was carried out for Lafarge by AMEC. In this programme,
the mechanical properties of SCC were compared to those of a conventional 50 MPa mix.
The results were summarised as follows:
From the test results, it can be concluded that Lafarge's Agilia self-compacting concrete
demonstrates the following characteristics:
Agilia has also been used on projects at the ICT building at the University of Calgary
using 50 MPa concrete in columns, core walls and stairways, and at the Calgary Eaton
Centre.
95
Property
Compressive strength
Flexural strength
Modulus of Elasticity
Fracture Toughness
Freeze-thaw, ASTM C 666 A
Salt Scaling
Carbonation depth: 36 d in CO2
Abrasion
Unit
80 MPa
RPC
MPa
MPa
GPa
10 J/m
RDF
g/cm
mm
-12
10 m/s
80
7
40
<1
90
80
2
275
200
40
60
30
100
<10
0
1.2
In 1994, small-scale feasibility trials in the use of RPC were conducted at the University
of Sherbrooke and at a precast plant (Bonneau et al, 1996). The successful completion of
these trials resulted in a decision to build a pedestrian and bicycle bridge in the City of
Sherbrooke in 1996 (Aitcin and Richard, 1996).
The design is a lightweight space truss consisting of precast segments assembled on site.
The bridge has a span of 70 m and a deck width of 4.2 m. The deck is 30 mm thick,
stiffened with 70 mm high transverse ribs 1.7 m apart, and was cast in RPC with fibre.
A low-heat type of reactive powder concrete has been developed at the laboratories of the
Atomic Energy of Canada Limited (Gray and Shelton, 1998) to meet needs for mass
pours for nuclear reactor foundation mats and for underground containment of nuclear
wastes.
96
Three high performance mixes were compared. Mix proportions were as follows:
Portland Cement
Silica fume
Fly ash
Silica fume
Superplasticizer
Fine aggregate
Coarse aggregate
Water
W/CM
Temperature: C
rise
maximum
100 day strength MPa
43
66
128
23
53
96
The low temperature rise would reduce temperature gradients. Cooling costs
would be reduced.
This HPC should be more durable than standard HPC.
Workability is good.
Early age curing needs careful attention.
Inert filler replaces cement that would not hydrate in practice.
The use of less cement is environmentally beneficial.
Caterpillar Tractor
Equipment Yard
Howe Avenue
Street Paving
Criteria
80-year design life
low permeability
f1c: 60 MPa
High Resistance to
surface abrasion
f1c: 56 MPa
Heavy traffic
durability
97
Mix Characteristics
Cement: 450 kg/m
w/c: 0.34
Cement: 430 kg/m
w/c 0.37
Cement: 410 kg/m
w/c: 0.38
In Montreal, repairs to the Notre Dame - St Augustin overpass and the Saint Michel
Quarry snow dumping pier used a ternary cement based on the successful use of this
cement in sidewalk construction in 1998 (Bissonette and Morin, 2000). The ternary
cement consisted of Type 10 cement with 6% silica fume and 25% fly ash. On the
overpass, the columns were made of 35 MPa HPC and the deck of 50 MPa HPC. On one
side, the sidewalks and parapets were made with conventional 50 MPa HPC and on the
other side with 50 MPa HPC using the ternary cement. By using closely spaced joints, a
crack free structure was obtained.
A similar ternary cement was used to repair 9 kilometres of Autoroute 13. The new
reinforced concrete pavement used 48,000 m of concrete.
High Performance Roller Compacted Concrete
Until recently, RCC paving was a relatively low-grade material used for the construction
of logging roads and storage areas not subjected to high impact or abrasion loading.
Research at Laval University has established improved concrete mix design procedures
(Marchand, et al, 1997). These are based on obtaining the optimum packing of the
various sizes of particles, and the addition of silica fume to the mix in a binary 10E-SF
cement.
In the Province of Quebec approximately one hundred projects have been completed
using High Performance Roller Compacted Concrete (HPRCC). The first, in 1995, was a
25,000 m storage yard for Noranda Minerals in Rouyn-Noranda. Up to October 1997
more than 240,000 m of HPRCC pavement had been constructed, using over 67,000 m
of this concrete.
In 1996, the largest project till then was a 87,000 m log yard at Domtar Papers in
Windsor, Quebec. Built in 7 weeks using a pug-mill mixer, the contractor produced
26,000 m3 of concrete at a rate of 90 m3/hour. Compaction was by an ABG Titan highdensity paver for top lift and a conventional Cedar Rapids asphalt paver for the bottom
lift. The pavement thickness was 300 mm.
In order to cope with 75 tonne log handlers, the specification required minimum 7 day
strengths of 40 MPa in compression and 5 MPa in flexure. The mix designed to meet
these requirements is shown in the following table.
Mixture Composition
Type 10SF Water
Fine
Coarse
Cement
Aggregate Aggregate
kg/m
kg/m
kg/m
kg/m
295
103
774
1347
* Per kg of binder
98
Water
Reducer
ml/kg*
4
Laboratory tests made prior to construction and field tests made during construction are
shown in the following table.
Laboratory
No of specimens
Field
No. of specimens
Compressive Strength
MPa
3 days
7 days 28 days
39.2
45
52.8
2
2
2
34.6
114
40.1
110
Flexural Strength
MPa
3 days
7 days 28 days
6.2
6.7
78.1
2
2
2
6.1
77
7.1
93
8.7
4
A chemical compound was used for curing using double coverage in two directions and
the amount recommended by the manufacturer was doubled. Experience has shown that
premature drying of HPRCC will reduce its resistance to abrasion and scaling.
In 1995, a 25,000 m2 slag dumping area was built for Noranda mines in Rouyn-Noranda.
Slag transporters weighed 90 tonnes and contained molten slag at 800C. After cooling,
the slag was dumped onto the RCC area. In addition, the area was traversed all day by a
D-9 bulldozer. The specification for this project called for compressive strengths of 50
MPa at 7 days and 62 MPa at 28 days. Minimum flexural strengths 5.1 MPa at 7 days and
9.4 MPa at 28 days were called for. Field test specimens reached 55 MPa at 7 days. The
mix used was as shown in the following table:
Type 10SF
Cement:
359
kg/m
Coarse
Fine
Aggregate Aggregate
1270
846
Water
127
Using a continuous flow pugmill, the paving was completed in 10 days. The 8,000 m of
RCC was placed at rates up to 1,800 m per day. Compaction was by ABG Titan Pavers,
and the two lifts totalled 360 and 450 mm.
Because of the increasing interest by the City of Montreal in the potential use of RCC in
their road system, a programme was carried out to optimize mixes (Reid et al, 2000). The
use of lower binder content was investigated to reduce drying shrinkage and the
incidence of cracking. Since the RCC would be paved with asphalt, a high quality finish
was unnecessary. A test section was built in Montreal in 1998. As a result of the success
of this trial, a 9000 m section of boulevard was built in 1999, followed in 2000 by a
23,000 m snow depot.
99
REFERENES
Khayat, K.H., Private Communication, November, 2000.
Trudel, G.A., Bergeron, G. and Khayat, K.H., "Use of Self-Consolidating Concrete in Highly Restricted
Areas for Rehabilitation of Underground Drainage Conduit", Presented at ACI Fall Convention,
Toronto, October 2000.
Khayat, K.H., Bickley, J.A. and Lessard, M., "Performance of Self-Consolidating Concrete for casting
Basement and Foundation walls", ACI Materials Journal, May-June 2000, Vol.97 no 3, pp. 374-380.
Meschino, M.and Ryell, J., "Bottom-Up Construction of 31 Meter High Reinforced Concrete-Filled Steel
Columns for the Greater Toronto Airports Authority New Terminal Building", Presented at the ACI
Convention, Toronto, October 2000.
Perry, V., "Industrialization of Ultra-High Performance Ductile Concrete", Symposium on HighStrength/High-Performance Concrete, University of Calgary, November, 1998.
Bonneau,O., Poulin, C., Dugat, J., Richard, P. and Aitcin, P.C., "Reactive Powder Concrete: From Theory
to Practice", Concrete International, Vol 18, no 4, April 1996, pp. 47-49.
Aitcin, P.C. and Richard, P., "The Pedestrian/Bikeway Bridge of Sherbrooke", Proceedings 4th
International Symposium on Utilization of High-Strength/High-Performance Concrete, Paris, 1996, pp.
1399-1406.
Adeline, R., Lachemi, M. and Blais, P., "Design and Behaviour of the Sherbrooke Footbridge",
Proceedings International Symposium on High-Performance and Reactive Powder Concretes,
Sherbrooke, August 1998, Volume 3, pp. 89-97.
Gray, M.N.and Shelton, B.S., "Design and Development of Low-Heat, High-Performance Reactive Powder
Concrete", Proceedings, International Symposium on High-Performance and Reactive Powder
Concretes, Sherbrooke, August 1998, pp. 203-230.
Langley, W.S., Private Communication, November 2000.
Bissonette, B. and Morin, R., "Exprimentation d'un ciment ternaire pour la reconstruction du passage
suprieur Notre-Dame/St Augustin Mon tral", 7e Colloque sur la progression de la recherche
qubcoise sur les ouvrages d'art, Universit Laval, Quebec, Mai 2000.
Marchand, J., Gagne, R., Ouellet, E. and Lepage, S., "Mixture Proportioning of Roller Compacted
Concrete-A Review", Proceedings Third CANMET/ACI International Conference, Auckland, New
Zealand: Advances in Concrete Technology, ACI SP 171, 1997, pp. 457-486.
Reid, E. and Marchand, J., "High-Performance Roller Compacted Concrete Pavements: Applications and
Recent Developments", Proceedings Canadian Society for Civil engineering 1998 Annual Conference,
Halifax.
Reid, E., Marchand, J. and Ouellet, E., "Mechanical Behaviour and Frost Durability of Low Binder
Content Roller-Compacted Concrete", US Army, Air Force and Navy Transportation Systems
Workshop, San Diego, February 2000.
100
HPC
Self-Consolidating Concrete
101
Pedestrian-Bikeway Bridge
Sherbrooke, PQ
102
103
On most contracts, the concrete supplier or precast concrete company takes responsibility
for the mixture design. Where the Owner takes this responsibility, it can limit the
supplier's ability to use his expertise, and may, on occasion, result in the imposition of a
less than optimum mix.
Many specifications require trial mixes and often specify the lead time by which the data
are to be available. Generally insufficient time is allowed for trial mixes.
Testing
Slump - Practice with regard to specifying slump varies, with most specifiers stating
limits. In the field it has been found that the use of superplasticizers empowers the
contractor to use whatever slump is optimum for the placing conditions. (Cross falls and
gradients on bridges determine what slump is practical.) The choice of slump is best left
to be decided in the field. This would be in line with the requirements of CSA A 23.12000.
Air Content - In the earlier part of the decade, 1990-2000, the degradation of air void
systems in these very workable mixes between the discharge of the concrete by the
supplier and final compaction in place was a major concern. This was particularly true of
pumped concrete. It gradually became fairly wide practice to require confirmation of the
in-situ air void system. This created liability concerns between the supplier and
contractor. Some specifications had a clause added to try to ensure that the contractor
discussed this issue with the concrete supplier prior to finalizing a contract for the supply
of concrete. Two responses resulted. The air void systems at the point of discharge were
improved to allow for degradation, and admixture companies developed air-entraining
agents that produced more stable air voids. Today, the specification of in-situ air void
parameters should not be a cause of concern to either the supplier or the contractor.
Philosophically, all tests to determine the quality of concrete should be made on samples
taken from the structure. It is the structure that the Owner buys.
There remain concerns on the part of concrete suppliers in particular that the standard of
reliability of testing for these parameters needs to be more reliable, with less variability
between test laboratories. Restricting testing to named technicians with proven skill
would be one desirable measure. In addition, the 2000 edition of CSA A 23.1 has
tightened the limits on the magnification used in the test. This must now be between 100
and 125.
Rapid Chloride Permeability - This is the most widely used test to confirm that a
concrete mix has low permeability to chloride ions. While it is not a direct measure of
permeability, it has been shown to be a reliable index of the permeability and diffusion
coefficients of concrete made with slag, fly ash and silica fume (Bridge Views,
November/December 2000). Adding calcium nitrite raises the conductivity of the pore
solution. It is practice to test such mixes before the calcium nitrite is added. Ingredients
that are conductive, such as steel fibres or aggregates containing iron, will also negate the
test results.
104
On many contracts the test has been made on specimens cast from samples fabricated
from the concrete at the point of discharge. There is an increasing practice to test cores
taken from new construction to confirm in-situ quality. Where this is done early in the
life of the concrete, and before it is contaminated, the results can be compared to preconcreting tests. Like air void determinations on cores taken from the structure, this
approach provides assurance that the concrete in place meets the owner's durability
requirements. The usual test age is 28 days after casting. Where the concrete contains
SCMs, specifications increasingly recognize the possible need to test specimens at later
ages, instead of or in addition to, tests at 28 days.
An important issue in the test procedure is the curing history of the test specimens. The
permeability of HPC containing SCMs improves with age, particularly if the concrete is
saturated throughout the pre-test period. If the test specimens are cured in water or in a
fog room until the test age, the improvement in impermeability may not reflect that of the
structure. With silica fume mixes, the difference may be insignificant, but this is an area
that warrants further research and standardization.
As this survey shows, the predominant coulomb value specified is 1000. Some
jurisdictions that initially specified 600 have changed to 1000. Some others specify 700
+/- 35%. This survey shows that very few test results have exceeded 1000. At this value it
is felt that the concrete is very durable. Where test results have exceeded the 1000
coulomb value, the result has been attributed to poor testing or the choice of an unsuitable
mix. From extensive published test data from many contracts, it is clear that the concrete
industry can consistently meet a 1000 coulomb maximum requirement for cast-in-place
concrete. It is possible that a lower value could be specified for particularly severe
exposure conditions, but a raison d'tre would be needed to justify a lower value.
Where this parameter is a performance issue, penalties are levied by some Provincial
Highway Departments and Cities for failure to meet the maximum value specified. The
MTO, for instance, applies the following penalties:
Pa = (C-1000) /40 where Pa = price reduction in $ per m per lot and C = average
RPC of a lot.
Some other Highway Departments and Cities also impose penalties as detailed above in
this report.
Some specifications are silent on any adjustment of price due to failure to meet the
maximum value specified. It is possible that, as more experience is gained in the use of
this test, other mechanisms will be developed to deal with a failure to meet this aspect of
the specification.
105
In practice, there is some evidence that the variability of the test is significantly less than
ASTM C 1202 would suggest. On Bridge 201 at Pearson Airport (Bickley and Fung,
2000) the difference between the results of two laboratories testing cores from the deck
was as follows:
Parameter
Number of tests
Range
Average
Average of all tests
Lab 1
4
546 to 829
658
Lab 2
8
411 to 697
553
588
Despite the widespread use of this test without apparent difficulty in applying it, a faster
test is considered desirable. The age at which the test is started is at least 28 days and
sometimes later if slag or fly ash is included in the mix. The test takes about two days to
condition the specimens and determine the coulomb value. Results are thus not available
until at least 30 days after the concrete, to which the test specimens relate, has been
placed.
As the trend to performance specifications spreads, the need for faster and more reliable
tests will increase. This need is being addressed by an FHWA contract (Stanish et al.
2000). As a result, it is likely that a new test will be proposed for standardization in the
near future. It will require considerable promotion to change practice from the current
widespread use of the RCP test.
Diffusion - The permeability of concrete to chloride ions can be determined by diffusion
tests. Using current techniques, this test takes 120 days from the time the test specimens
are 28 days old. It is an expensive test. It is not really a practical quality control test.
Recent attempts to replace it have focussed on the use of a modified ISAT test combined
with established diffusion values. In one application, usable quality control test results
were obtained at an age of 14 days (DeSouza et al, 2000).
Scaling - A minority of authorities specifies testing for scaling resistance. The scaling
resistance of HPC is good (A tcin, 1998). Where significant percentages of
supplementary cementing materials are used, there are reservations about the reliability of
standard scaling tests to predict in-service performance, which has been better than would
be predicted by the test.
Compressive Strength - Most specifications evaluate test results for compliance in
accordance with CSA A 23.1. A number of jurisdictions have mechanisms to penalize
contractors based on the consistency with which the specified strength is met, but no
bonus for good performance.
The MTO in end-result, or performance, specifications provides for a bonus for the
production of concrete meeting strength requirements with good consistency. A
comparison of the level of quality control of prescription and end-result contracts was
made in 1991 (Bickley, 1991). The performance of the concrete on end-result contracts,
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where bonuses could be won, was superior to that on prescription contracts. Perhaps,
there is a moral here.
For high-strength concretes to be consistently delivered, an extensive and detailed preconcreting programme is necessary (Ryell and Bickley, 1987). Where the recommended
procedures have been followed, the results have been a high level of QA and QC and
excellent compliance with specified requirements (Ryell and Fasullo, 1993). ACI
Committee 363 "High-Strength Concrete" has produced a document (ACI 363, 1998)
which provides guidance on quality control and testing for high-strength concrete
projects. There have recently been two projects where the advice in the above three
references was not followed. The result was extensive failure of test results to reach the
specified high strengths, with significant costs as a result.
While most high-strength concrete buildings have used the concrete in the inside of
buildings, high strength is sometimes used in structures exposed to the elements. Where
this results in a requirement for air-entrained high-strength concrete, the effect of
entrained air on strength must be considered. Each 1% of air will reduce the strength of a
concrete by about 5% (Aitcin, 1998), so a 6% air content will result in a loss of strength
of about 20% allowing 2% for entrapped air.
It may be impractical to achieve a very high strength air entrained concrete. In such
instances, it is even more essential to follow the best advice on preconstruction testing
and QC during construction. Advice on mix design for such critical mixes is available
(Aitcin, 1998).
Two approaches have been used to address the need for air entrainment in HPC exposed
to freezing and thawing.
Research at the University of Sherbrooke established that the air void system required to
make HPC resistant to freezing and thawing can be significantly inferior to the criteria in
our National Standards (Aitcin, 1998).
Most specifications cite or copy the provisions in CSA A 23.1-94, Section 14. In the
MTO Special Provisions for HPC, issued in 1998, the requirements for the air void
system, and the revised provisions in Section 14 of CSA A 23.1-00 are summarized
below.
CSA A 23.1-00
MTO Special
Provisions, May 98 Conventional Concrete
Spacing factor: average m
250
230
Spacing factor: max m
300
260
Hardened air content: %
3
3
* Where specified in HPC specifications, the number has been 3%.
Parameter
HPC
250
300
-*
On a recent contract requiring very high strength concrete, the requirement for airentrainment made it impractical to achieve the specified strength. Current belief is that
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mixes with water-cementitious ratios of 0.30 and above require air entrainment, and those
under 0.25 do not. In between these two values, the need is uncertain. In the case
described, the mix had a water-cementitious ratio of 0.27. Tests were made on the mix
without air-entrainment and after over 400 cycles of freeze-thaw tests to ASTM C 666
procedure A, the relative durability factor was over 90%. The contract proceeded using
the non air-entrained mix.
It is noted that the specifications of several of the Highway Departments and Cities
reviewed above allow acceptance on the basis of ASTM C 666 tests where the specified
air void systems cannot be met. This approach is generally approved on HPC bridge
contracts in the USA.
Constructability
Trial Slabs - The use of trial slabs, as specified in the MTO special provisions for HPC,
has proven to be useful. Constructing a length of deck with the materials, plant and
personnel that are to be used in the contract, often highlights potential problems. These
trial slabs are expensive to construct, possibly in the range of $10,000 to $20,000. It is
reasonable, in accordance with MTO policy, to waive this requirement where a contractor
has recent prior experience of HPC.
Placing and Compacting - HPC is usually placed at high or relatively high slumps.
Vibration is still needed to ensure full compaction.
When the deck of Bridge 201 at Pearson Airport was finished, the finishing machine left
a narrow strip at each side of the deck, which had to be hand finished. This is the normal
situation when finishing bridge decks. The only way to avoid this is to mount the
finishing machine on rails supported outside the edges of the deck. This is expensive and
may present structural problems. After the finishing of the deck, sorptivity tests were
made on the deck. These tests showed that the sorptivity of the hand-finished edges was
significantly higher than the rest of the deck. This raises the concern that these edges may
be more permeable to chloride intrusion than the rest of the deck. It was suggested in the
report on Bridge 201 (Bickley and Fung, 2000), that the use of a hand held plate vibrator
to compact and finish the upper layer of the edges might be a solution to this problem.
Finishing Probably, the most controversial aspect of the use of HPC is in the finishing
of bridge decks. The use of superplasticizers enables high quality to be achieved with
high slumps. On occasion, where a range is specified, the slump may be too high for the
crossfalls and gradients that occur on some bridges. A wide range of slumps can be
achieved by the use of superplasticizers without compromising the quality or strength of
the concrete. Therefore, the contractor should choose the appropriate slump for the job
conditions.
Mixes containing silica fume are more difficult to finish than conventional bridge deck
concrete. Finishing can be improved by the use of slag or fly ash. The greater the
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Monitoring
The prime imperative for the use of HPC is the assumption that structures constructed
with it will have an enhanced service life. Durability will be better, life cycle costs less,
intervals between rehabilitation longer, and repairs less costly. These assumptions are
based mainly on the rational testing of HPC durability parameters and extrapolations
using life cycle prediction models.
All current life cycle prediction models use assumptions that are, in the main, educated
guesses. What is missing are long term field performance data to support these
assumptions.
Perceived performance to date confirms the assumptions, but the volume and duration of
the supporting data is not yet adequate. The prime barrier to more extensive monitoring is
a real difficulty in obtaining funding. As a result, the amount of data available is not
extensive.
Corrosion Monitoring - The use of HPC in structures exposed to the elements is based on
the assumption that corrosion of the reinforcement will not be initiated for a long time.
On some of these projects, a probe with elements at increasing cover depths has been
used (Hansson et al, 2000). This configuration allows the ingress of chlorides to be
monitored by the development of corrosion activity at different levels. The owner is thus
given advance warning of impending corrosion and the data can be used to predict time
to corrosion for the reinforcement in the structure.
Hereunder is a compilation of Concrete Canada corrosion monitoring projects reported:
Exposure
Marine
Structure
1994
1997
1997
1998
Replacement deck
Deck of new HPC segmental structure
1998
Deck
1996
1997
1999
1997
Bridges
1994
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The Highway 20 bridge and one of the two Highway 407 demonstration bridges were
instrumented by MTO. Access to the latter has precluded a full monitoring programme.
For the Highway 20 bridge, annual surveys have been made in the five years since
completion.
During the construction of this bridge, four clusters of three types of corrosion probes
were installed in the deck:
Visual Inspection
Delamination survey
Cover survey
Half-cell survey
Linear polarization, by 3LP and GECOR procedures
Resistivity, by four-point resistivity probe
Chloride ion profiles
Review of data from the embedded probes
The full results will shortly be published by the MTO. To date, the results of the survey
show that the structure has performed very well. There are some recently developed long
fine cracks, but the steel has remained in a passive state. No physical damage is apparent.
Thermal Effects - The dimensions of the components of the Confederation Bridge were
such that thermal studies were undertaken before and during construction (Dilger, 2000).
Data included temperature measurements across a cold joint of two segments of a box
girder. The data showed a temperature difference between the two segments at the time
of hardening of 18C. This difference would result in tensile stresses in the concrete as
the temperature between the segments equalized.
The structure was instrumented with over 250 temperature sensors located at six sections.
Movement at expansion joints and strains are monitored as is solar radiation using
pyrometers. Freeze-thaw cycles occurred almost every day during February and March
1998, confirming the severe nature of the environment at the bridge location. This
monitoring is expected to continue for ten years after the completion of the bridge.
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For non-massive structures, such as most bridge decks, a maximum concrete temperature
of 70C and a maximum gradient between the centre and surface of the concrete of 20C
have been found to be effective in avoiding significant cracking. While temperaturestress relationships can be investigated using a number of available computer
programmes, the practical advice given in Table 18 of CSA A23.1-2000 has been found
to be reliable on most typical construction contracts.
REFERENCES
Isabelle, H.L., "Development of Canadian and American Specifications for Silica Fume", International
Workshop on Condensed Silica Fume, Montreal, 1987, CANMET Compilation of Papers.
Thomas, M.D.A., Cail, K. and Hooton, R.D., "Development and Field Applications of Silica Fume Concrete
in Canada: A Retrospective", Canadian Journal of Civil Engineering, Vol. 25, No. 3, June 1998, pp.
391-400.
Bickley, J.A. and Fung, R., "Optimizing the Economics of High-Performance Concrete", Cement
Association of Canada, 2000.
Bickley, J.A.,"Directions in Concrete Research", MTO research and development branch, report MAT-9109, September 1991.
Ryell, J. and Bickley, J.A.,"Scotia Plaza: High Strength Concrete for Tall Buildings" Proceedings:
Utilization of High Strength Concrete, Stavanger, Norway, June 1987, pp. 641-654.
Ryell, J. and Fasullo, S., "The Characteristics of Commercial High Strength Concrete in the Toronto
Area", Presented at the 1993 CPCA/CSCE Structural Conference, Toronto, May 1993.
ACI 363.2R-98, "Guide to Quality Control and Testing of High-Strength Concrete".
A tcin, P-C, "High-Performance Concrete", E & FN Spon, 1998, pp. 591.
Tazawa, E.,Ed, "Autogenous Shrinkage of Concrete", Proceedings of the International Workshop,
Hiroshima, June, 1998, E & FN Spon, 1999, pp. 411.
HPC Bridge Views, Issue no 12, November/December 2000, pp. 2-4.
DeSouza, S.J., Hooton, R.D. and Bickley, J.A., "A Practical QC Test Programme for HPC in Precast
Tunnel Liners", ACI SP-191, 2000, pp. 99-114.
Hansson, C.M., Seabrook, P.T. and Marcotte, T.D., "In Situ Corrosion Monitoring Using Embedded
Probes: Why? What? How? And-so what?" Presented at the ACI Convention, Toronto, October 2000.
Wang, M., Dilger, W.H. and Langley, W.S., "Curing of High Performance Concrete-An Overview",
Proceedings PCI/FHWA Symposium on High Performance Concrete, New Orleans, August 1997, pp.
283-293.
Dilger, W.H., "Temperature Effects in Concrete and Composite Bridges", Keynote paper, Proceedings of
the Workshop on Research and Monitoring of Long Span Bridges, Hong Kong, April 2000, pp. 1 -13.
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The finishability of HPC for bridge decks needs to be improved. The manufacturers of
finishing machines should undertake a new look at this issue. Designers of concrete
mixes should optimize mixes for finishability.
Curing
The three rules for successful HPC are curing, curing and curing. Curing must be done by
the book, and supervision must enforce curing specifications. Fog curing after finishing,
followed by 7 days wet curing, has proven to be effective. The effectiveness of
evaporation retarders as an alternative to fog curing warrants further research.
Service Life Predictions
The accuracy of the service life and cost life-cycle predictive models available would be
much enhanced by data obtained by monitoring new structures. For reliable and accurate
predictions of service life and life cycle costs much more monitoring data are needed.
Summary
The last 10 years have seen an increasing use of HPC. Many authorities are convinced
that long term durability and lower life cycle costs result. Certainly, these are the benefits
to be expected. If they are to be realized consistently, the enforcement of state-of-the-art
specifications is essential.
Printed in Canada
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