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This work presents an experimental study to characterize the adhe- from very smooth to very rough. However, this analysis is
sion strength of concrete interfaces with conventional and light- very subjective as it does not provide a representation and
weight aggregate density. For this purpose, 75 specimens of slant quantification of the actual roughness profile sufficient for
shear (SS), 24 for pushoff (PS) and pulloff (PO) were performed. the calculation of parameters. Therefore, to obtain a reliable
For the SS test, a modified model was proposed inducing different
quantitative analysis of the surface roughness of a concrete
stresses at the interface of that traditional slant shear. The
interface some methods used in other sciences have been
substrates were manufactured with conventional density concrete
with a compressive strength of approximately 50 MPa, and for the applied in the concrete field.12-19 All these researches were
overlay and four lightweight concrete with percentages of 25, 50, motivated to determine roughness parameters and correlate
75, and 100% aggregate replacement. In the modified slant shear them with the bond strength of the interface, thus estimating
(MSS) substrates five types of roughness were performed: smooth, the real influence of the roughness, thus being possible to
as vibrated and three intentionally rough (R1, R2, and R3), and for evaluate the durability of the repair system.
the PS and PO tests only the ones: as vibrated (V) and the intention- The strength of the concrete-concrete interface has
ally rough (R2). An automatic roughness measuring method was been studied for normal strength concrete and currently
developed using a laser displacement sensor. Comparing experi- many researches have focused on ultra-high-performance
mental and theoretical results showed that they provide different concrete19-23 and self-consolidating concrete.24 Few studies
values for each type of test. For the MSS, Eurocode 2 and fib model
have evaluated the behavior of sand-lightweight concrete
codes can be used for these types of concrete interfaces, but for the
regarding the shear strength of interfaces.2,25,26 The study
PS they have proved to be very conservative.
presented here evaluates the adhesion strength of interfaces
Keywords: interface; pulloff; pushoff; roughness; shear strength; slant between normal and sand-lightweight concrete substrate/
shear. overlay, with different percentages of replacement of bulk
aggregate by lightweight and types of surface preparation.
INTRODUCTION There are many tests available to evaluate the strength of
With the development of lightweight concrete production the interface between the concrete substrate and the comple-
technology, it has become possible to produce structural ment. In general, they can be divided into three categories:
concrete with reduced density values by replacing normal direct tensile tests, direct shear tests and shear tests combined
aggregate with lightweight aggregates, while maintaining with compression. The slant shear test is the most widely
adequate mechanical performance and durability. Moreover, used laboratory test to estimate the interface strength.20,22,23,27
presenting advantages such as reduction of own weight, In general, the validity of the use of this test is sometimes
increase of span, ease in handling.1 Lightweight concrete subjective,4,21,28 being pointed out advantages and disad-
represents an interesting solution, not only for new struc- vantages, such as the possibility of representing real stress
tures, including pre-molded structures, but also to strengthen states of a structure and the fact that the rupture is highly
existing structures. In both cases, it will result in a composite conditioned by the orientation of the interface plane.29 The
element, which can be an interface between normal and resistance to the interface’s adherence, that is, the connec-
lightweight concrete or between lightweight concrete.2 The tion between the concrete-concrete layer obtained in the test
strength of the bond between a new concrete and an old one— depends, to a certain extent, on the chosen test configuration.
that is, the adhesion between a concrete-concrete layers is The sensitivity for the test configuration occurs due to the
a critical issue and of great importance when it comes to interaction of normal and shear stresses, the different stress
prefabricated elements or the repair of a structure. This states and distributions and possible effects of unintended
strength depends on several factors, such as: the compres- eccentricities. Above that, there is no direct conversion
sive strength of old concrete (substrate) and new concrete formula between tensile strength and shear stress, and the
(overlay),3 the moisture state of the substrate,4-9 the geom- dispersion of the available experimental results is enormous,
etry of the specimens,5 and the roughness of the substrate
surface causing an increase in the contact surface.8-11
The type of surface roughness at the interface influences ACI Structural Journal, V. 119, No. 1, January 2022.
MS No. S-2020-525.R3, doi: 10.14359/51733007, received June 9, 2021, and
the cohesion, friction and bond strength between the concrete reviewed under Institute publication policies. Copyright © 2022, American Concrete
Institute. All rights reserved, including the making of copies unless permission is
layers.8,9 Roughness is usually evaluated only qualitatively obtained from the copyright proprietors. Pertinent discussion including author’s
by visual observation of the substrate surface and classified closure, if any, will be published ten months from this journal’s date if the discussion
is received within four months of the paper’s print publication.
besides the great variety of parameters related to the type of Table 2—Mechanical properties of steel used in
concrete and the surface preparation factors. stirrups-shape transverse reinforcement
Due to the difficulty of performing some bonding tests Yield strength fy, Modulus of elasticity
routinely there is an interest from some researchers,30 in Steel type Ø, mm MPa E, GPa
defining conversion factors between different tests and,
CA-50 8 570 247.83
mainly, in using traction test data obtained from tests as
pull-off and splitting test to estimate the shear strength of the
EXPERIMENTAL INVESTIGATION
interface. This problem is highly sensitive to failure modes
Materials
and should be taken into account primarily in test configu-
In the production of the concrete a Brazilian type V port-
rations that allow for interface failure rather than material
land cement (high early strength cement31) as the main
failure (substrate or overlay).
binder. The conventional coarse aggregates for the produc-
However, to better represent stress transfer in structures
tion of concrete was of the basalt type, from crushing of the
subjected to bending and shear stress, a modified slant shear
mines in Campos dos Goytacazes, RJ, with specific mass
specimen has been proposed, which induces a different
of 2.73 g/cm3 and unit mass of 1.58 g/cm3. As lightweight
stress state than the traditional slant shear commonly found
aggregates, the expanded clay, was used in two sizes:
in reinforced or prestressed concrete elements. In this case,
CINEXPAN 0500, used as a fine aggregate and CINEXPAN
the specimen is subjected to axial forces with an eccen-
1506, used as a coarse aggregate. Table 1 presents the values
tricity, causing normal and tangential variable stresses
of the specific mass and the unit mass in the dry and loose
along the slanted interface. Pushoff and pulloff tests were
state, the latter calculated according to ABNT,32 the specific
also performed to determine shear and tensile strength at the
mass of the lightweight aggregates CINEXPAN 0500 was
interface between normal and lightweight concrete, respec-
determined by the method prescribed by ABNT,33 while
tively. In addition, to characterize these interfaces, a simple
CINEXPAN 1506, following the prescriptions of ABNT34
and efficient system was developed that allowed measuring
Natural quartz sand from the Paraíba do Sul River was used
the roughness without requiring contact with the surface,
in the city of Campos dos Goytacazes, RJ, with a specific
being easy to use, fast to perform and suitable for use in situ
mass equal to 2.63 g/cm3 and a unit mass in the loose and
and in the laboratory.
dry state equal to 1.54 g/cm3. Fumed silica was used with
specific mass calculated according to ABNT35 equal to 2.20
RESEARCH SIGNIFICANCE
g/cm3. A third-generation high-range water-reducing admix-
Although many researchers have addressed the
ture (HRWRA) was used. This additive has a chemical
concrete-concrete interface strength for different types and
base of modified carboxylic ether, acting as dispersant of
strengths of concrete. Specifically between concretes with
cementitious material, propitiating HRWRA and high water
normal strength and density, and currently between these
reduction.
and ultra-high performance concretes. The interfaces of
Ribbed bars were used for the PS test, according to
conventional and sand-lightweight concrete have not been
Brazilian specifications,36 with 8 mm nominal diameter (ϕ),
explored very much and there are no published works
were used to produce stirrup-shaped transverse reinforce-
with concrete manufactured with different percentages of
ment, as well as 4.2 mm plain bars and 8 mm bars were
replacements of the conventional for lightweight aggregate.
used for auxiliary reinforcement. The mechanical properties
The development of a simple and reliable automatic process
of the steel used as a transverse reinforcement are shown in
for the measurement of roughness allowed the quantification
Table 2.
of the roughness of the studied surfaces. The evaluation of
the resistance of interfaces subjected to shear and compres-
Concrete proportioning
sion stresses using a modified slant shear model allowed the
For the experimental characterization of the strength of
evaluation of the interface in stress gradients different from
the interfaces with concrete of different ages, the following
the traditional model. This simulates parts of reinforced or
concrete were defined: one normal strength concrete (NSC)
prestressed concrete structures with this stress distribution
with normal density and four sand-lightweight concrete
and, finally, the results of this study showed that the use of
(SLW) with substitutions of conventional coarse aggregate
this type of concrete is feasible and relevant for structural
for lightweight aggregate in the proportions of 25, 50, 75,
applications.
and 100%, named SLW-25%, SLW-50%, SLW-75%, and
Details of specimens
Three types of tests were performed to characterize the
resistance of the interfaces: (MSS), (PS), and (PO). In the
Fig. 1—Tools manufactured to perform roughness R1, R2,
SS type specimens, NSC was used in the substrate and five
and R3.
types of concrete were used in the overlay: NSC, SLW-25%,
SLW-50%, SLW-75%, and SLW-100%. The mechanical and lightweight aggregate, roughness R2 and the corresponding
physical properties of concrete are presented in Table 4. test type MSS.
The interface condition of the substrate for all specimens For the formwork of the straight slant shear (SSS) type of
was smooth (S), as vibrated (V) and three intentionally specimens, polyvinyl chloride (PVC) tubes with an internal
rough conditions named R1, R2, and R3, with roughness of diameter of 140 mm and a height of 280 mm were used.
5, 7.5, and 15 mm, respectively. These was cut at an angle of inclination of 45 degrees in
The values adopted for roughness were based on ABNT37 equal parts, serving as a form for producing the specimen
indications, which suggest for intentionally rough surfaces, substrate. Cylinders with a height of 280 mm were also
with a minimum roughness of 5 mm in 30 mm. Therefore, it produced for later concreting of the overlay. Place this inside
was also chosen to use tools capable of providing roughness and obtain the straight cylindrical specimen (traditional slant
around that suggested by the code. Figure 1 shows the tools shear), then this SSS was cut using a professional cutting
manufactured to obtain this roughness. saw, with an angle of inclination of 15 degrees with respect
For the SS test, specimens were made with the five combi- to the horizontal, in the upper and lower parts, with the aim
nations of roughness (S, V, R1, R2, and R3), with three of obtaining a MSS, thus having an angle of 30 degrees with
replicas each, totaling 75 specimens. For the PS and PO, respect to the vertical (Fig. 2(a)), angle recommended by
only the roughness (V and R2), with four types of concrete different researchers.20,22,23,27
of the overlay, except NSC, totaling for both types of tests 24 For the PS test, the formwork was produced to allow a
specimens. Each specimen was given the following nomen- non-monolithic condition along the shear plane and so that
clature: numbering of the replica, type of concrete of the the shear plane was totally exposed to allow the preparation
substrate, type of concrete of the overlay, type of roughness of its surface when the substrate was concreted, after this
of the interface and finally the type of test corresponding to first face, it was introduced into the form and the concreting
it. For example: Specimen 1-NSC-100-R2-MSS, represents of the overlay was performed (Fig. 2(b)). For the PO test,
replica number 1, produced with NSC substrate, overlay metal formwork with dimensions of 150 x 150 x 500 mm
with sand-lightweight concrete with 100% substitution of were used, being divided into three equal parts, resulting in
Casting of specimens
In Fig. 4 a sequence of the manufacturing process of the
specimens is shown. The cast specimens of the MSS, PS and
PO tests using a vibrating needle, obtaining a good compac- Fig. 3—PS specimen’s reinforcement details. (Note: Units in
tion. The smooth interface (S) was made with a wood form- mm; 1 mm = 0.0394 in.)
work, the interface as vibrated (V) was the one obtained
interface to efforts from the demolding process. Then the
after the vibration and the intentionally rough interfaces,
same curing procedure as above was carried out and later
R1, R2, and R3, were produced after one hour of casting
they were stored in the laboratory until the day of the test.
the specimens, the roughness was performed in the direction
perpendicular to the shear application, for the MSS and PS
Roughness measurement
specimens. The substrate demolded occurred after 24 hours,
For the measurement of the interface roughness, an auto-
and then it was placed in curing immersed in water with lime
mated system was developed consisting of a high-perfor-
for 28 days.
mance distance laser displacement sensor, with a displace-
Before casting the overlay, the interface was cleaned, using
ment measurement range between 50 and 350 mm and a
an air compressor to remove impurities that could reduce the
manipulator table formed by two motors for the movement
adhesion of the new concrete layer and then humidified with
of the specimen, using the Arduíno® platform of free hard-
running water. After casting the overlay all, the specimens
ware electronic prototyping. A setup was developed that
were demolded with extreme care in order not to expose the
included a wooden base and a metal support, fixed to the
Realization of tests of 0.3 mm/s until rupture and performed at the civil engi-
Figure 7 presents the preparation, instrumentation and neering laboratory at UENF.
execution procedures of the MSS, PS and PO tests. The The PO test was performed according to ASTM C1583/
MSS type tests were performed on a universal mechanical C1583M-13,39 and consists of the extraction of a core of
testing machine and the PS type tests were performed using the concrete specimen by traction using an apparatus for
a hydraulic actuator controlled by a servo-hydraulic system, pulling out the company SOLOTEST®, designed to perform
with a 500 kN load capacity. Both at a load application speed adhesion tests with metal plates bonded on flat surfaces of a
substrate.
Fig. 8—Stress distribution τxy and σy: (a) SSS of group NSC-NSC; (b) MSS of group NSC-NSC; (c) SSS of group NSC-100%;
and (d) MSS of group NSC-100%.
Results from MSS, PS, and PO obtained in the PO test specimens, result of the division of
The calculation of the normal stress σu and tangen- the rupture load by the core area.
tial τu at the MSS test specimen interface was performed The MSS specimens showed two modes of rupture: cohe-
using Abaqus® V-6.0, with the model previously defined. sive and adhesive, the first occurred mainly on specimens
Each specimen was simulated considering the rupture with high interface surface roughness (R1, R2, and R3) and
load obtained in the test, considering the properties of the the adhesive was observed mainly on specimens with low
substrate and overlay materials (Table 6). Table 7 shows interface surface roughness (S and V), in the same way as it
the strength to pure adherence (τ0) at the interface, obtained occurred in the researchers.2,40 The type of cohesive rupture
in the PS test specimens, obtained from the division of the is common and undesirable in this type of test, because the
rupture load by the shear area (τ0 = P/Ac). Table 8 shows shear stress obtained is not the rupture stress of the spec-
the tensile strength of direct adherence of the interface (fti), imen. This depends primarily on the strength of the substrate
and overlay, the roughness of the interface and the type of the compression strength of the overlay decreased—that is,
specimen SS used, including the angle of the interface to the as concrete with greater substitution of lightweight aggre-
vertical. gates was used. In addition, the specimens exhibited higher
In the SS tests performed40 most of the specimens in strength values when the overlay concrete was equal to the
which high-strength concrete was used ruptured cohesively, substrate for the NSC-NSC.
regardless of the level of compression stress applied at the Noted that for the rough interfaces (R1, R2, and R3) there
interface and even for all the inclination angles considered was an increase in the strength of the interface with the
(20, 25, and 30 degrees). The authors affirmed that the cohe- increased roughness. However, it is observed in the results
sive rupture of the specimens with high strength overlay and that the order of magnitude between the rough interfaces did
the cracks propagated throughout the cylinder in the form not result in significant increases in the bonding capacity of
of vertical cracks, reaching the rupture before the interfacial the bond strength.
shear stresses reached the rupture strength of the interface. The values obtained from the interface’s adherence
The PS and PO specimens also showed forms of adhesive strength for each group were submitted to analysis of vari-
and cohesive rupture. Figure 10 shows the forms of rupture ance (ANOVA), complemented by Tukey’s test at a 5%
of the three tests performed. probability level.
Statistical analysis of the MSS specimens showed that the
Influence of roughness on strength of test NSC-NSC, NSC-75% and NSC-100% groups were statisti-
specimen interface MSS, PS, and PO cally equal, and for the NSC-25% group we obtained differ-
In Fig. 11 through 13, are plotted the adherence strength ences in mean values of the rough interface (R1) for smooth
values of the interfaces for the different types of roughness (S) and rough (R3), greater than 24.75% and 21.10%,
of the MSS and PS and PO specimens, respectively. respectively.
In general, the modified slant shear test specimens In the NSC-50% group, with interface as vibrated (V)
reduced the resistance values of the interface bond when significant differences were obtained with lower values in
Note: fctd is lowest tensile strength of concrete design; fcd is compressive strength of concrete; σn is normal stress at interface due to external loading; μ is coefficient of friction; and
ν is reduction coefficient of strength.
relation to all other series, of 29.30%, 30.65%, 31.29%, and Statistical analysis showed that the NSC-50% and
36.12%, when compared to interfaces S, R1, R2, and R3, NSC-100% groups did not present differences, not so, the
respectively. NSC-25 and NSC-75 groups presented higher values of
The results of the PS specimens were satisfactory in rela- 17.49% and 11.63%, respectively.
tion to the increase in roughness within the same group—that In the PO test bodies for the vibrated interface (V) there
is, there was an increase in shear strength when compared to were not differences between the groups, not so the rough
interface values as vibrated (V) with those of rough interface interface, where the group with higher tensile strength at the
(R2). interface was the NSC-25%, showed significant differences
Table 13—Summary of equations and parameters obtained from iteration of tangential and normal
stresses
Authors Roughness (τ/fct,sp)* c/fct,sp μ ϕ, degrees
Average (as vibrated) –0.73σ + 0.83 0.83 0.73 36.1
Present study
Average Rough (R2) –0.73σ + 0.96 0.96 0.73 36.1
As vibrated –0.07σ + 1.70 1.70 1.07 46.9
Harris et al.46
Rough (R2) –1.26σ + 1.45 1.45 1.26 51.6
As vibrated –1.36σ + 0.91 0.91 1.36 53.7
Costa et al.2
Rough (R2) –1.30σ + 1.40 1.40 1.30 52.4
Semendary et al.22 Rough (R2) –1.36σ + 1.22 1.22 1.36 53.7
As vibrated –1.34σ + 0.47 0.47 1.34 53.3
Zhang et al.47
Rough (R2) –1.36σ + 0.60 0.60 1.36 53.7
*
σ and fct,sp in MPa.
method may not be sufficient for a complete evaluation of The slopes of these curves are dependent on the type of
the interfacial interface strength. slant shear used and consequently the coefficient of friction
Figures 15 and 16 show a comparison between the interac- and the angle of friction. The values obtained in this research
tion curves obtained in the present study and those obtained were lower when compared to those obtained in the research
with data2,22,46,47 for interfaces such as vibrated (V) and evaluated. However, the angles of friction obtained here are
rough (R2), respectively. The data plotted in this analysis for approximately equal to that defined by the Mohr-Coulomb
the present study are the average values of all series evalu- failure criterion for concrete.
ated (NSC-25%, NSC -50%, NSC-75%, and NSC-100%).
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