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Concrete Durability Design
Minnesota Concrete CouncilMinnesota Concrete Council
ConcreteConcrete A Changing IndustryA Changing Industry
ByBy
,,
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Acknowled ements Design and Control of Concrete MixturesDesign and Control of Concrete Mixtures,,
thth
,, ,,
20022002
,,
Committee Report, 2008Committee Report, 2008
StructuresStructures, ACI 362, Committee Report 1997, ACI 362, Committee Report 1997
u uu u Photos from archives of WJEPhotos from archives of WJE
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Outline DurabilityDurability DefinitionsDefinitions
What structures require durabilityWhat structures require durability
durabilitydurability a concre e m x ure an cur nga concre e m x ure an cur ng
conditions affect durabilityconditions affect durability
How can concrete be designed forHow can concrete be designed for
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Concrete
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Ob ective
Describe issues that cause concreteDescribe issues that cause concrete
durability problemsdurability problems
taken to provide durability to concretetaken to provide durability to concrete
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Definition of Concrete Durabilit Concrete DurabilityConcrete Durability
Concrete fit for the purpose for which itConcrete fit for the purpose for which itwas intended, under the conditions towas intended, under the conditions to
w c e concre e s expec e o ew c e concre e s expec e o e
exposed, and for the expected life duringexposed, and for the expected life during ..
Adam Neville CI July 2000Adam Neville CI July 2000
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Definition of Concrete DurabilitACI 201.2RACI 201.2R Guide to DurableGuide to Durable
oncre eoncre eDurability of hydraulic cement concrete isDurability of hydraulic cement concrete is
determined by its ability to resistdetermined by its ability to resist
weathering action, chemical attack,weathering action, chemical attack,a ras on, or any ot er process oa ras on, or any ot er process o
deteriorationdeterioration
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CI 201 Deterioration Modes Freezing and thawingFreezing and thawing
AlkaliAlkali--aggregate reaction (AAR)aggregate reaction (AAR)
Corrosion of embedded metalsCorrosion of embedded metalsAbrasionAbrasion
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Steel Reinforcin
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Structure T es Structure types needing to be durableStructure types needing to be durable
Bridge decksBridge decks Bridge piers, especially when in salt waterBridge piers, especially when in salt water
Parking structuresParking structures
PavementsPavements
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Service Life Ex ectationsAspects having direct bearing onAspects having direct bearing on
ura yura y Nature of the projectNature of the project
Type of structureType of structure
Expected service lifeExpected service life
Exposure conditionsExposure conditions
Consider as ects concurrentl to assessConsider as ects concurrentl to assess
levellevel ofof durabilitydurability
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Attack Mechanisms Freezin and thawinFreezin and thawin
CarbonationCarbonation
CrackingCracking LeakingLeaking
A re atesA re ates
Chemical attackChemical attack
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Makin Concrete Durable There are two fundamental ways toThere are two fundamental ways to
ma e concre e ura ema e concre e ura eAddress the properties of the concreteAddress the properties of the concrete
Provide protective systems external to theProvide protective systems external to the
concreteconcrete
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Concrete Mixture Pro erties BasicBasic Admixture andAdmixture and
emenemen
Coarse aggregateCoarse aggregate Air entrainingAir entraining
Fine aggregateFine aggregate
WaterWater
a er re ucersa er re ucers
Other cementitiousOther cementitious
Mixing/PlacingMixing/Placing ma er a sma er a s
Corrosion inhibitorsCorrosion inhibitors
ur ng reg mesur ng reg mes
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Water to Cementitious Ratio w/cm plays defining role for concretew/cm plays defining role for concrete
ura yura y Generall the lower the w/cm ratio theGenerall the lower the w/cm ratio the
better the performancebetter the performance
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Water to Cementitious Ratio
precast / prestressed concrete
ive
Strengt
cast-in-place concrete
Compress
. . . . . . . . .Water - Cementitious Ratio
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Mixin Extended mixingExtended mixing
Higher concrete temperaturesHigher concrete temperatures
Add water to restore slumpAdd water to restore slump
Impacts air void pore size distributionImpacts air void pore size distribution
Reduces concrete strengthReduces concrete strength
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Placin and Consolidation Excessive free fallExcessive free fall
Reduces the entrained air contentReduces the entrained air content Pum in chan es air contentPum in chan es air content
Vibration durationVibration duration
ncrease v ra on re uces a r con enncrease v ra on re uces a r con en
Reduced vibration leaves voidsReduced vibration leaves voids
Good vibration reduces permeabilityGood vibration reduces permeability
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Inade uate Vibration - Hone combin
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A re ates - Po out
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A re atesAlkaliAlkali--silica reaction (ASR)silica reaction (ASR)
Involves chemical reaction between alkaliInvolves chemical reaction between alkalisource (cement) and reactive silicasource (cement) and reactive silica
s ceous aggrega ess ceous aggrega es
Can manifest itself in 5 to 20 yearsCan manifest itself in 5 to 20 years
nterna tear ng crac ng o t e concretenterna tear ng crac ng o t e concrete
matrix)matrix)
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Alkali-silica Reaction ASR
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Alkali-silica Reaction ASR
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Alkali-silica Reaction ASR
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Alkali-silica Reaction ASR
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Alkali-silica Reaction ASR
Silica gel in microcrack
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A re atesAlkaliAlkali--carbonate reaction (ACR)carbonate reaction (ACR)
Involves certain argillaceous dolomiticInvolves certain argillaceous dolomitic
limestoneslimestones
Chemical reaction between alkali sourceChemical reaction between alkali source
(cement) and certain calcium(cement) and certain calcium--magnesiummagnesiumcar onate roc s o om tescar onate roc s o om tes
Not a significant issue in U.S. exceptNot a significant issue in U.S. except
VirginiaVirginia
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A re ate Evaluation Petrographic examination ASTMPetrographic examination ASTM
Laborator testinLaborator testin
Mortar Bar Test ASTM C 227Mortar Bar Test ASTM C 227
Quick Chemical Test ASTM C 289Quick Chemical Test ASTM C 289
oncre e r sm es soncre e r sm es s
Essentially, measure expansionEssentially, measure expansion
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Prism Tests
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Reducin ASR in Concrete Use nonreactive aggregatesUse nonreactive aggregates
Use low alkali cementUse low alkali cement, ,, ,
Use lithium compoundsUse lithium compounds
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Concrete Mixture Pro erties BasicBasic Admixture andAdmixture and
emenemen
Coarse aggregateCoarse aggregate Air entrainingAir entraining
Fine aggregateFine aggregate
WaterWater
a er re ucersa er re ucers
Other cementitiousOther cementitious Mixing/PlacingMixing/Placing ma er a sma er a s
Corrosion inhibitorsCorrosion inhibitors
ur ng reg mesur ng reg mes
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Air EntraininAir entraining is the most importantAir entraining is the most important
aspec , nex o w cm, or en anceaspec , nex o w cm, or en ance
durability in concretedurability in concrete
Air entraining essential in freezingAir entraining essential in freezing
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Freezing and Thawing
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Air Entrainment
No air entrainment
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D-Crackin
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D-Crackin
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Concrete Scalin
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Good Deicer Rapid ice melting rateRapid ice melting rate
Minimal scalingMinimal scaling
crackingcracking
n ma me a corros on po en an ma me a corros on po en a
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Deicin or Anti-icin DeicingDeicing -- an effort to remove ice froman effort to remove ice from
sur aces a er ce ex s ssur aces a er ce ex s s
AntiAnti--icinicin -- a surface treatmenta surface treatment
applied prior to ice formation;applied prior to ice formation;
bond between ice and surfacebond between ice and surface
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Deicin Chemicals Chloride saltsChloride salts
Sodium chlorideSodium chloride -- NaClNaCl
Calcium chlorideCalcium chloride -- CaClCaCl22
Magnesium chlorideMagnesium chloride -- MgClMgCl22
Potassium chloridePotassium chloride -- KClKCl
Phosphate saltsPhosphate salts
ono so um p osp a eono so um p osp a e -- aa 22 44
Mono calcium phosphateMono calcium phosphate Ca(HCa(H22POPO44)H)H22OO
Mono potassium phosphateMono potassium phosphate -- KHKH22POPO44
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Deicin ChemicalsAcetatesAcetates
Calcium magnesium acetateCalcium magnesium acetate -- CMACMA
Potassium acetatePotassium acetate -- KCKC22HH33OO22
BenzeneBenzene
,,
Synthetic ureaSynthetic urea
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Deicin Chemicals Concentrations in concrete of 2Concentrations in concrete of 2 4 %4 %
cause mos amagecause mos amage
Lower percentages not as damagingLower percentages not as damaging
Higher percentages of some deicersHigher percentages of some deicers --
damagingdamaging ConversionConversion
--
equivalent to 0.5equivalent to 0.5 1.0 molality1.0 molality
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Scalin Mechanism
Water freezes in capillary poresWater freezes in capillary pores
ce crys a s ormce crys a s orm
Develop hydraulic pressuresDevelop hydraulic pressures
If available pore space is less thanIf available pore space is less than
required for all the water (criticalrequired for all the water (criticalsaturation), excess is driven off bysaturation), excess is driven off by
pressure of expansionpressure of expansion
If pressure exceed tensile strength ofIf pressure exceed tensile strength ofconcrete, local cracking occursconcrete, local cracking occurs
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Scalin Mechanism - Deicers
Concrete is further damaged by deicingConcrete is further damaged by deicing
Increase in the osmotic pressureIncrease in the osmotic pressure
Deicing agent magnifies the pressures inDeicing agent magnifies the pressures in
the concretethe concrete Increases the potential for surface scalingIncreases the potential for surface scaling
Deicer salt scaling generally thought to beDeicer salt scaling generally thought to be
physical rather than chemicalphysical rather than chemical
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Salt Scalin
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Deicin Rate
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Summar
Very low concentrationsVery low concentrations small effect onsmall effect on
Very high concentrationsVery high concentrations cause longcause long--
erm sca ngerm sca ng
ObjectiveObjective keep water and salt (chlorides)keep water and salt (chlorides)outout
Make concrete tighterMake concrete tighter
Low w/cm not the answerLow w/cm not the answer Add supplementary cementitious materialsAdd supplementary cementitious materials
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Summar
NaClNaCl -- least expensiveleast expensive
os amag ng o re n orc ng s eeos amag ng o re n orc ng s ee
CMACMA -- more expensivemore expensive Can chemically damage concreteCan chemically damage concrete
Does not induce corrosion of reinforcing steelDoes not induce corrosion of reinforcing steel
Use beet juice?Use beet juice?
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Water Reducers
w/cm concrete workablew/cm concrete workable
reduces the effectiveness of airreduces the effectiveness of air
entrainin a ents AEAentrainin a ents AEA Water reducers can cause slight increaseWater reducers can cause slight increase
Water reducers have no detrimentalWater reducers have no detrimental
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Su lemental Cementitious Materials
Fly ash (Type C)Fly ash (Type C)
Fly ash (Type F)Fly ash (Type F)
Silica fumeSilica fume Ground granulated blast furnace slagGround granulated blast furnace slag
(GGBFS)(GGBFS)
Natural pozzolansNatural pozzolansMetakaolin Calcined claMetakaolin Calcined cla
Calcined shaleCalcined shale
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Su lemental Cementitious Materials
Fly ash Class FMetakaolin
Silica fume
Metakaolin
SlagSlag
Fly ash - Class CFly ash - Class CCalcined shale
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Su lemental Cementitious Materials
, ,, ,
GGBFS)GGBFS)Adds a material that has cementingAdds a material that has cementing
ro ertiesro erties Reduces permeabilityReduces permeability
Fills the voids between cement particlesFills the voids between cement particles
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1,000X
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2,100X
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20,000X
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2,000X
C t P bilit
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Concrete Permeabilit
140
)
100
120
m/sec
x101
Maximum w/cm exposed to water
Maximum w/cm exposed
to freezin and thawin
80
m
eability(c
Maximum w/cm
exposed to deicing
40
cientofPer sa s, c em ca s,
salt water, seawater,
or salt spray
0
20
0.20 0.30 0.40 0.50 0.60 0.70 0.80
Coeffi
Water - Cementitious Ratio
P bilit M t
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Permeabilit Measurements
Two methods exist to assessTwo methods exist to assess
ASTM C 1202,ASTM C 1202, Electrical Indication ofElectrical Indication of
PenetrationPenetration -- Rapid Chloride PenetrationRapid Chloride Penetration
Test RCPTTest RCPTAASHTO T259,AASHTO T259, Resistance of Concrete toResistance of Concrete to
Chloride Ion PenetrationChloride Ion Penetration 9090--day pondingday ponding
testtest
R id Chl id P bilit T t
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Ra id Chloride Permeabilit Test
90 Da Pondin Test
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90 Da Pondin Test
Permeabilit Measurement
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Permeabilit Measurement
Chemical Attack
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Chemical Attack
CarbonationCarbonation
Acid attackAcid attack
Corrosion of embedded steelCorrosion of embedded steel
Carbonation
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Carbonation
Hardened concrete exposed to COHardened concrete exposed to CO22
COCO22
penetrates concrete and reactspenetrates concrete and reacts
with h droxideswith h droxides
Sulfate Attack
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Sulfate Attack
Sulfates in soil, usually, react with hydratedSulfates in soil, usually, react with hydrated
Chemical reactions cause internal pressureChemical reactions cause internal pressure srup s e cemen pas esrup s e cemen pas e
Internal compounds formedInternal compounds formed
r ng er ng e
GypsumGypsum
ruc e magnes um y rox eruc e magnes um y rox e
Thaumasite (forms in moist conditions)Thaumasite (forms in moist conditions)
Sulfate Attack
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Sulfate Attack
Sulfate Attack
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Sulfate Attack
Dela ed Ettrin ite Formation
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Dela ed Ettrin ite Formation
DEFDEF -- Deleterious formation of ettringiteDeleterious formation of ettringite
orm o su a e a acorm o su a e a ac
Ettringite is normal component of cementEttringite is normal component of cementhydrationhydration
Late formation causes expansion distressLate formation causes expansion distress Expansion causes crackingExpansion causes cracking prematurepremature
deteriorationdeterioration
Found in many precast productsFound in many precast products
Delayed Ettringite Formation
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y g
Ettringite is compoundEttringite is compound
that naturally formsthat naturally forms
when portland cementwhen portland cementse s upse s up
Formation delayed byFormation delayed by
high initialhigh initial
temperaturestemperatures
Requires moistureRequires moisture
Delayed Ettringite Formation
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y g
Examples
Delayed Ettringite Formation
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u u
microcrack
aggregate
Delayed Ettringite Formation
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About 160 oF is critical
Delayed Ettringite Formation
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Acid Attack
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Acid Attack
Some acids dissolve cement paste andSome acids dissolve cement paste and
Protection for portland cement concrete isProtection for portland cement concrete isno eas e w a m x uresno eas e w a m x ures
Need a protection system (coating/surfaceNeed a protection system (coating/surface
treatment)treatment)
ACI code does not cover externalACI code does not cover external
protection systemsprotection systems
Paste erosion by acid
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Corrosion of Embedded Steel
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ObjectiveObjective -- limit the ingress of chemicals thatlimit the ingress of chemicals that
Methodologies to limit corrosion by modifyingMethodologies to limit corrosion by modifying
Decrease diffusion rate into concreteDecrease diffusion rate into concrete
se c or e n or a m x uresse c or e n or a m x ures
Cathodic protectionCathodic protection
m na e crac ngm na e crac ng
Increase coverIncrease cover
Reduce the w/cm ratioReduce the w/cm ratio
rr i n f n l
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2+ -
Anode
Chloride and moisture ingress
Ch
2Fe(OH)2 +1/2O2 Fe2O3 + 2H2O
Fe2+ + 2OH- Fe(OH)2Fe3O4
Fe2O3
2OH- Fe3O42e -
Cathode area >> anode area
1/2O
2+ H
2O + 2e - 2OH-
Cathode
Diffusion
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Use supplemental cementitiousUse supplemental cementitious
ma er a sma er a s
Fly ashFly ash
Silica fumeSilica fume
GGBFSGGBFS
Natural pozzolans (Metakaolin)Natural pozzolans (Metakaolin)
Diffusion - Fl Ash
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Diffusion - SF & GGBSF
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Corrosion Inhibitor T es
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Calcium NitriteCalcium Nitrite
Organic Esters and aminesOrganic Esters and amines
AlkenlyAlkenly--succinic acidssuccinic acids
Corrosion Inhibitors
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Consequences of using inhibitorsConsequences of using inhibitors
Influence on freezin and thawinInfluence on freezin and thawin
resistanceresistance
Influence on inhibitin corrosionInfluence on inhibitin corrosion uncracked concreteuncracked concrete
Corrosion Inhibitors
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z w
Corrosion Inhibitors
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Corrosion and Chloride In ress
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Corrosion and Chloride In ress
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Crackin
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Cracking exists in reinforced concreteCracking exists in reinforced concrete
s ruc uress ruc ures
Crackin - Width
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ACI 318 Code
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ACI 318 Chapter 4ACI 318 Chapter 4 DurabilityDurability
equ remen sequ remen s
Exposure Categories and ClassesExposure Categories and Classes
Freezing and thawing (F)Freezing and thawing (F)
Sulfate (S)Sulfate (S)
Low permeability (P)Low permeability (P)
Corrosion rotection of steel reinforcin CCorrosion rotection of steel reinforcin C
Exposure Categories and Classes
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- z w Exposure category FExposure category F x er or concre ex er or concre e
Exposed to freezing and thawingExposed to freezing and thawing oss e exposure o e c ng c em ca soss e exposure o e c ng c em ca s
Four ClassesFour Classes
F0F0 Not exposed to freezing and thawing (fNot exposed to freezing and thawing (f--t)t)
F1F1 Occasionally exposed to moisture and fOccasionally exposed to moisture and f--tt
F2F2 Exposed to fExposed to f--t and continuous contact witht and continuous contact with
moisture before freezingmoisture before freezing
-- ont nuous contact w t mo sture,ont nuous contact w t mo sture, --t, ant, an
deicing chemicalsdeicing chemicals
Exposure Categories and Classes
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- u Exposure category SExposure category S
deleterious amounts of soluble sulfatedeleterious amounts of soluble sulfate
S0S0 Very low exposureVery low exposure
sulfate (moderate) [seawater]sulfate (moderate) [seawater]
sulfate (severe)sulfate (severe) S3S3 -- Structural member in contact with solubleStructural member in contact with soluble
sulfate : high sulfate content (very severe)sulfate : high sulfate content (very severe)
Exposure Categories and Classes
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- y Exposure category PExposure category P Concrete in contact with water where lowConcrete in contact with water where low
permeability is neededpermeability is needed
Two ClassesTwo Classes
P0P0 No s ecific ermeabilit neededNo s ecific ermeabilit needed
P1P1 Needed where water permeation intoNeeded where water permeation into
tank]tank]
Exposure Categories and Classes
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- Exposure category CExposure category C
and prestressing steel requiring protectionand prestressing steel requiring protection
Three ClassesThree Classes
C1C1 Exposed to moisture but no chloridesExposed to moisture but no chlorides
chlorides (deicing chemicals, brackish water,chlorides (deicing chemicals, brackish water,seawater, seawater spray) [parking decks,seawater, seawater spray) [parking decks,
bridge decks, piers]bridge decks, piers]
ACI 318 Re uirements
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Select concreteSelect concrete
exposure classexposure class
Cate or F
M i / 0 45M i / 0 45
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Maximum w/cm 4500 n ra ne a r con enn ra ne a r con en
or useor usesupplementalsupplemental
materialsmaterials
Cate or S
U lf t i t tU lf t i t t
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Use sulfate resistantUse sulfate resistant
Type IIType II
T e VT e V
Maximum w/cm ratioMaximum w/cm ratio
Minimum fMinimum f No chlorides allowedNo chlorides allowed
for S2 and S3for S2 and S3
Cate or P
Mi i l i tMi i l i t
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Minimal requirementsMinimal requirements
< 0.50< 0.50cc
Cate or C
Minim mMinim m ff > 5000 psi> 5000 psi
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MinimumMinimum ffcc> 5000 psi> 5000 psi
Maximum w/cm
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u u Low w/cm concrete effective in controllingLow w/cm concrete effective in controlling
Supplementary cementitious can reduceSupplementary cementitious can reducec or e ngress ra ec or e ngress ra e
Corrosion inhibitors can extend service lifeCorrosion inhibitors can extend service life
Heat curing below 160Heat curing below 160ooF can reduceF can reduce
ermeabilitermeabilit
Air entrainment necessary in freezingAir entrainment necessary in freezing
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External Protection Schemes
FHWA sponsored research 1992FHWA sponsored research 1992
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FHWA sponsored research 1992FHWA sponsored research 1992
ObjectiveObjective
Find costFind cost--effective coatin s or alternateeffective coatin s or alternate
materialsmaterials
Desi n life for infrastructure facilities: 75 toDesi n life for infrastructure facilities: 75 to100 years100 years
Corrosion of Reinforcin Bars
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Delaminations
lternate Reinforcin Bar T es
ASTM A 615 / A 706 blackASTM A 615 / A 706 black
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ASTM A 615 / A 706 blackASTM A 615 / A 706 black
poxy coa e arspoxy coa e ars
BendableBendable NonbendableNonbendable
Galvanized barsGalvanized bars
MetallicMetallic--clad barsclad bars
ZincZinc
CopperCopper
StainlessStainless
Metallic corrosion resistant bars (stainless)Metallic corrosion resistant bars (stainless)
Wettin and Dr in Re imes
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Effectiveness Rankin
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Effectiveness Rankin
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Effectiveness Rankin
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Zone Ma for Parkin Structures
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ACI 362 Precast
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Parkin Structure Desi n
Effective use of protective measuresEffective use of protective measures
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Effective use of protective measuresEffective use of protective measures
Good design measuresGood design measures
DrainageDrainageDetailing for crack controlDetailing for crack control
Proper coverProper cover
Proper finishingProper finishing
Proper curingProper curing
Parkin Structure Desi n
Effective use of protective measuresEffective use of protective measures
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Effective use of protective measuresEffective use of protective measures
Internal measuresInternal measures
Air entrainmentAir entrainmentCorrosion inhibitorsCorrosion inhibitors
Reduced permeabilityReduced permeability
Coated or special reinforcing barsCoated or special reinforcing bars
Parkin Structure Desi n
Effective use of protective measuresEffective use of protective measures
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Effective use of protective measuresEffective use of protective measures
External measuresExternal measures
SealersSealersProtective coatings (membranes)Protective coatings (membranes)
Traffic Bearin Membranes
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Summary Durable Concrete
u uAlternate reinforcing bar schemes canAlternate reinforcing bar schemes can
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gg
ex en serv ce eex en serv ce e
Need same type bar throughoutNeed same type bar throughout Epoxy coating effectiveEpoxy coating effective
Stainless for lon service life in crackedStainless for lon service life in cracked
concreteconcrete
in.)in.)
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Questions