Report temperature control during construction to improve the long term performance of portland cement concrete pavements

FINAL COPY Technical Report Documentation Page Government Accession No Report No FHWA/TX-05/0-1700-2 Title and Subtitle Temperature Control During Construction to Improve the Long Term Performance of Portland Cement Concrete Pavements Recipient’s Catalog No.: Report Date May 2002 Performing Organization Code Author(s) Anton K Schindler, Terry Dossey, and B F McCullough Performing Organization Report No 0-1700-2 Performing Organization Name and Address 10 Work Unit No (TRAIS) Center for Transportation Research The University of Texas at Austin 3208 Red River, Suite 200 Austin, TX 78705-2650 11 Contract or Grant No Research Study 0-1700 13 Type of Report and Period Covered: 12 Sponsoring Agency Name and Address Technical Report, September 2001 through Texas Department of Transportation August 2004 Research and Technology Implementation Office 14 Sponsoring Agency Code P.O Box 5080 Austin, TX 78763-5080 15 Supplementary Notes Project conducted in cooperation with the Texas Department of Transportation and the Federal Highway Administration 16 Abstract The study developed mitigation techniques to control the in place temperature development of early-age concrete Longer lasting PCC pavements will be produced if the assumptions made during design are achieved in the field This study proposes a method to integrate the design assumptions to the construction process by means of an end-result temperature control specification A general hydration model for cementitious materials and a model to predict the temperature gain in hardening concrete is developed and calibrated The temperature prediction model was calibrated for field conditions with data collected from seven concrete paving projects The model accounts for different pavement thicknesses, mixture proportions, cement chemical composition, cement fineness, amount of cement, mineral admixtures, material types, climatic conditions, and different construction scenarios The temperature prediction model will enable the development of performance based specifications to guard against premature concrete failures This model will further provide the designer, contractor, and specification developer with the means to evaluate and quantify the effect of most of the various complex interactions that affect the concrete temperature development during early-ages A model to predict initial and final setting of hardening concrete is presented, and calibrated, with data collected under laboratory and field conditions The effects of concrete temperature, different cements, and mineral admixtures on the initial and final times are characterized Finally, an innovative temperature control specification is presented, which encourages contractor innovation and focuses on material selection for the particular location and environmental conditions This approach accounts for the impact of modern paving materials, and will ensure improved concrete performance under hot weather placement conditions 17 Key Words 18 Distribution Statement PCC, Concrete Pavements, temperature control, hydration, No restrictions This document is available to the public through the performance-based specifications National Technical Information Service, Springfield, Virginia 22161; www.ntis.gov 19 Security Classif (of report) Unclassified 20 Security Classif (of this page) Unclassified 21 No of pages 538 Form DOT F 1700.7 (8-72) Reproduction of completed page authorized 22 Price  TEMPERATURE CONTROL DURING CONSTRUCTION TO IMPROVE THE LONG TERM PERFORMANCE OF PORTLAND CEMENT CONCRETE PAVEMENTS by Anton K Schindler Terry Dossey and B Frank McCullough Research Report Number 0-1700-2 Research Project 0-1700 Improving Portland Cement Concrete Paving Conducted for the TEXAS DEPARTMENT OF TRANSPORTATION in cooperation with the Federal Highway Administration by the CENTER FOR TRANSPORTATION RESEARCH Bureau of Engineering Research THE UNIVERSITY OF TEXAS AT AUSTIN May 2002 iv DISCLAIMERS The contents of this report reflect the views of the authors, who are responsible for the facts and the accuracy of the data presented herein The contents not necessarily reflect the official views or policies of the Federal Highway Administration or the Texas Department of Transportation This report does not constitute a standard, specification, or regulation There was no invention or discovery conceived or first actually reduced to practice in the course of or under this contract, including any art, method, process, machine, manufacture, design or composition of matter, or any new and useful improvement thereof, or any variety of plant, which is or may be patentable under the patent laws of the United States of America or any foreign country NOT INTENDED FOR CONSTRUCTION, BIDDING, OR PERMIT PURPOSES B Frank McCullough , P.E (Texas No 19924) Research Supervisor v ACKNOWLEDGEMENTS The author would like to express their gratitude to the Texas Department of Transportation (TxDOT) for their support, without which this study would not have been possible The assistance and guidance of George Lantz, the TxDOT project director is appreciated The members of the project monitoring committee members have all provided valuable contributions to this project These members included: Dr Moon Won, Gray Graham, Gerald Lankes, Jim Hunt, David Head, Thomas Saenz, Dr German Claros, Angela Batiz, Charles Gaskin, James Kosel, Susan Chu, Ned Finney (Jobe Concrete), Dennis Warren (ACPA), Gene Marter (ACPA), and Mark Brown (Zachary Construction) Part of this study required laboratory and field work Special thanks to the many individuals at the Construction Materials Research Group whom contributed Without the help supplied by Mike Rung, Kerry Rothenbach, and Dave Figurski much of this work would not have been possible, and to those individuals we would like to extend our sincere gratitude The contribution of the following individuals is appreciated: Dave Whitney, Sherian Williams, Cruz Carlos, Patricia "Pat" Campbell, Marie Martinez, Zeeshan Arshad, Moses Ogolla, Guy Dudley, Zack Pannier, and Oliver Salgado Research performed in cooperation with the Texas Department of Transportation and the U.S Department of Transportation, Federal Highway Administration vi Executive Summary Findings from past research efforts have demonstrated that the concrete temperature development during the first 24 to 72 hours has a major impact on long-term pavement performance The development of excessive portland cement concrete (PCC) temperatures may result in reduced pavement performance These factors emphasize that concrete temperature control during construction in hot weather conditions is essential to improve the durability of PCC pavements The primary objective of this study is to develop mitigation techniques to control the in place temperature development of early-age concrete, as this will improve the performance of PCC pavements constructed under hot weather conditions Longer lasting PCC pavements will be produced if the assumptions made during design are achieved in the field This study proposes a method to integrate the design assumptions to the construction process by means of an end-result temperature control specification During this study, a general hydration model for cementitious materials and a model to predict the temperature gain in hardening concrete is developed and calibrated The temperature prediction model was calibrated for field conditions with data collected from seven concrete paving projects The model accounts for different pavement thicknesses, mixture proportions, cement chemical composition, cement fineness, amount of cement, mineral admixtures, material types, climatic conditions, and different construction scenarios The temperature prediction model will enable the development of performance based specifications to guard against premature concrete failures This model will further provide the designer, contractor, and specification developer with the means to evaluate and quantify the effect of most of the various complex interactions that affect the concrete temperature development during early-ages A model to predict initial and final setting of hardening concrete is presented, and calibrated, with data collected under laboratory and field conditions The effects of concrete temperature, different cements, and mineral admixtures on the initial and final times are characterized Finally, an innovative temperature control specification is presented, which encourages contractor innovation and focuses on material selection for the particular location and environmental conditions This approach accounts for the impact of modern paving materials, and will ensure improved concrete performance under hot weather placement conditions vii viii Table of Contents List of Tables xiii List of Figures xv Introduction 1.1 Background 1.2 Research Approach 14 1.3 Report Scope and Outline 18 Literature Review 21 2.1 Background on Cementitious Materials Composition and Hydration 22 2.1.1 Cement Composition 22 2.1.2 Mineral Admixtures 26 2.1.3 Hydration of Cement 28 2.2 Factors that Influence Concrete Hydration 32 2.2.1 Cement Type 32 2.2.2 Water-Cement Ratio 36 2.2.3 Mineral Admixtures 39 2.2.4 Chemical Admixtures 42 2.2.5 Member Thickness 43 2.3 Mitigation Measures: Current Practice 43 2.3.1 Discussion of Current Mitigation Practices 47 2.4 Summary and Conclusions 48 Modeling of Early-Age Behavior, and Temperature Development 51 3.1 Overall Modeling Concept 51 3.2 Modeling the Hydration of Cement Based Materials 53 3.2.1 Equivalent Age Maturity Method 53 3.2.2 Activation Energy Values Recommended in Literature 59 3.2.3 Ultimate Heat of Hydration Modeling 64 3.2.4 Methods to Determine the Degree of Hydration Development 66 3.2.5 Modeling the Degree of Hydration Development 70 3.2.6 Physical Interpretation of the Degree of Hydration Formulation 74 3.2.7 Ultimate Degree of Hydration 76 3.2.8 Modeling the Heat Generations and the Associated Temperature 78 ix 3.3 Temperature prediction and heat exchange with the environment 83 3.3.1 Conduction .84 3.3.2 Convection .87 3.3.3 Solar Absorption 93 3.3.4 Irradiation 94 3.3.5 Finite Difference Heat Transfer Method 102 3.4 Fresh Concrete Temperature Prediction Models 105 3.5 Initial and Final Set Modeling 106 3.6 Development of Early-Age Thermal Stresses 107 3.6.1 Background to Creep Models 109 3.6.2 Selection of Creep Model 110 3.6.3 Double Power Law (Bazant and Panula, 1978) 111 3.6.4 Triple Power Law (Bazant and Chern, 1985) 113 3.6.5 Extended Triple Power Law (Bazant and Chern, 1985) 113 3.6.6 Implementation of Proposed Creep Model 116 3.6.7 Sample results from the Proposed Creep Model 119 3.7 Summary and Concluding Remarks 121 Experimental Program .123 4.1 Phase I: Field Work 123 4.1.1 Data Collection Plan 124 4.1.2 Mixture Proportions and Materials for the Field Sites 128 4.1.3 Data Collected at Each Field Site 129 4.2 Phase II: Materials Characterization .156 4.2.1 Testing Plan 156 4.2.2 Laboratory Tests Performed 159 4.2.3 Laboratory Testing Results 165 4.3 Phase III: Concrete Hydration under Controlled Conditions 173 4.3.1 Small Concrete Specimens 173 4.3.2 Materials, Mixing and Curing 174 4.3.3 Presentation of Results 175 4.4 Summary and Concluding Remarks 176 General Hydration Model for Cementitious Materials .179 5.1 Model Development Approach 181 5.2 The Temperature Sensitivity of Cementitious Materials 182 5.2.1 Relationships between Concrete Properties and Maturity 183 x 502 APPENDIX G PavePro Layout and Results 503 (Version 1.01 - March 2002) Concrete Temperature Management Program Developed by: The Center for Transportation Research Anton K Schindler, M.S.E B Frank McCullough, Ph.D., P.E The University of Texas at Austin 3208 Red River, Suite 102 Austin, Texas, U.S.A 78705 Voice: (512) 232-3100 This program was develop under the sponsorship of TxDOT under Project 1700 The advice of the following individuals are greatly appreciated: Gary Graham, Dr Moon Won, George Lantz, Gerald Lankes, Ned Finney, David Head, Dr German Claros, Dr Robert Rasmussen, Dr George Chang, Mauricio Ruiz, and Gene Marter Figure G-1: PavePro - Title page 504 GENERAL INPUTS Section Definition Reliabiliy Pavement Thickness: 14.0 inch Subbase Thickness: 8.0 inch Subbase Type: 90% Prediction reliability level: Asphalt Concrete (HMAC) Perform Analysis Project Location and Construction Information Select City: Austin Month: August Construction Date: Day: 10 Construction Requirements CTE ≤ µε/°F CTE > µε/°F Maximum Concrete Temperature: 120 110 Maximum Axial Temperature Gradient: 25 25 °F / 24 hrs Maximum Vertical Temperature Gradient: 20 25 °F / 24 hrs °F Note: CTE = Coefficient of Thermal Expansion of 100% Saturated Hardened Concrete (Tex-428-A) Am arillo Lubbock Pa ving Zone IV W ichita Falls El Paso Abilene Midland Fort W orth D allas W aco Paving Z one III Lufkin Austin S an Antonio H ouston Beaum ont Paving Zone II Corpus Christi Laredo Brow nsville Paving Zone I Temporary Analysis Options Select Analysis Type: Design Version: Time of Placement: 10:00 AM Contruction Version (24 analysis every hour) * Note this box will not be part of the final construction version Errorcode = Figure G-2: PavePro - General Input screen 505 MIXTURE PROPORTION INPUTS Mixture Proportions Calculated Mixture Indices Cement Content: 517 lb/yd³ Sacks of cement / yd : 5.5 Water Content: 207 lb/yd³ Gallons of water / sack cement: 4.51 Coarse Aggregate Content: 1745 lb/yd³ Water / cement ratio: 0.40 Fine Aggregate Content: 1335 lb/yd³ Water / Cementitous ratio: 0.40 Air Content: % Fly Ash Content: lb/yd³ GGBF Slag Content: lb/yd³ hrs Mineral Admixtures Mixture Proportions Display Effect of Chemical Admixtures on Hydration Effect of admixture on initial set time at 70°F (21°C): 0% Note: Positive value retards hydration, Negative value accelerates hydration 20% 40% 60% Cement Water Coarse Agg Class C FA Class F FA GGBF Slag Figure G-3: PavePro - Mixture Proportions Input screen 506 80% 100% Fine Agg MATERIAL INPUTS Cement Properties Type I ASTM C150 Cement Type: Chemical Composition: Use default values User-defined: % C3S C2S C3A C4AF Free CaO SO3 MgO Total 63.3 12.1 10.2 5.5 1.0 2.9 1.4 96.4 Surface Area (Blaine Index): Use default value User-defined: 348 m /kg Fly Ash Definition ASTM C618 Fly Ash Type: Class C Fly ash CaO Content: Use default values 24.0 % User-defined: 25.0 % Note: Texas Class C fly ash: CaO ≈ 22-29% Texas Class F fly ash: CaO ≈ 9-15% East Coast Class F fly ash: CaO ≈ 2-5% Hydration Properties 1.0 Activation Energy:* 0.8 User-defined: * 45,000 Note: It is recommended to use the default option Adiabatic Constants: J/mol Degree of Hydration Use default value Use default values User-defined: 0.6 0.4 User selection Type I Default 0.2 τ (hrs) 15.2 β 0.706 αu 0.850 0.0 10 100 Concrete Equivalent Age (hours) Coarse Aggregate Type and Concrete Coefficient of Thermal Expanision Aggregate Type: Limestone Concrete Coefficient of Thermal Expansion: Use default value 4.4 εµ/°F User-defined: 5.0 εµ/°F Note: Coefficient of Thermal Expansion of 100% Saturated Hardened Concrete (Tex-428-A) Figure G-4: PavePro - Materials Input screen 507 1000 ENVIRONMENT INPUTS Environmental Input Options Data Generation Option: Automated Environmental Data Generator: This feature will generate default environemtal data based on the project location Average values are determined based on the historic data from the past 30-years (Data Source: NOAA) User Defined Daily Minumum and Maximum Environmental Values: Ambient Temperature: Minimum Maximum Relative Humidity: Wind Speed: Percent Cloud Cover: Day 65 °F 85 °F Day 60 °F 80 °F Day 65 °F 75 °F Daytime 50% 50% 50% Nighttime 50% 50% 50% Daytime mph mph mph Nighttime mph mph mph Daytime 20% 20% 20% Nighttime 20% 20% 20% Generate Data Note: This button will generate the hourly ambient temperatures below The hourly temperatures below can also be edited by the user Figure G-5: PavePro - Environmental Input screen 508 CONSTRUCTION INPUTS Fresh Concrete Temperature: Base Temperature Calculate from environmental conditions: User-defined: Calculate from environmental conditions: 100.0 °F White washed surface: No Calculate from raw material temperatures: Cementious materials: 80.0 Water: 80.0 °F Amount of Ice: 0.0 lb/yd³ Coarse aggregate: 80.0 °F Fine Aggregate: 80.0 °F °F User-defined at surface: Stage 1: Curing Method Stage 2: Curing Method (Optional) PCC age at Application: 0.5 hrs PCC age at Removal: 48 hrs Type: Double Coat Curing Compound Application Rate: Color: 12 Application Rate: ft2 / gallon ft2 / gallon Color: White Note: If the curing duration is less than 48 hrs, it will be assumed that a double coat curing compound is applied thereafter Material Type: Material Thickness: °F °F Estimated Concrete Temperature = Type: 100.0 inches Figure G-7: PavePro - Construction Input screen 509 Ambient Temperature (°F) 100 80 60 40 20 12 24 36 48 60 72 Time since Midnight of Day One (hours) Figure G-6: PavePro - Ambient temperature review graph 130 Concrete Temperature (°F) 120 110 100 90 80 70 60 12 24 36 48 Concrete Age (Hours) Top Mid Bot Air Temp Figure G-8: PavePro – Predicted temperature history 510 Final Set 130 Concrete Temperature (°F) 120 110 100 90 80 70 60 12 24 36 48 Concrete Age (Hours) Average Slab Temperature Air Temp Zero-Stress Condition Final Set: ASTM C403 Figure G-9: PavePro – Average slab temperature and location of the zero-stress condition Temperature (°F) 70 80 90 100 110 120 130 0 hrs hrs Depth from Surface (inch) hrs hrs 12 hrs 18 hrs 24 hrs 30 hrs 10 36 hrs 12 Final Set PCC/SB 14 Figure G-10: PavePro – Predicted temperature distribution 511 512 APPENDIX H Special Provision to Item 360 515 CTR Project 1700 - DRAFT 02/20/02 TxDOT Maximum In-Place Temperature Control Limits SPECIAL PROVISION TO ITEM 360 CONCRETE PAVEMENT For this project, Item 360, “Concrete Pavement”, of the Standard Specifications, is hereby amended with respect to the clauses cited below and no other clauses or requirements of this Item are waived or changed hereby Article 360.8 Concrete Mixing and Placing, The following Subarticle is added: (6) Maximum In-Place Concrete Temperature During the period April 1st until October 31st, the maximum in place concrete temperature will be controlled and recorded over a minimum of days The Contractor shall develop a plan to assure that during the early-age hydration period, the in-place concrete temperature as measured at the mid-depth of the pavement shall not exceed the values listed in Table or The maximum in place temperature in Table or is determined by project location, as indicated by the Paving Zone shown in Figure 1, and by the Coefficient of Thermal Expansion (CTE) of the Hardened Concrete as tested in accordance with Tex-428-A Table provides a summary of the Paving Zones across the State of Texas A detailed plan, along with an analysis of the estimated in place concrete temperature development, shall be submitted to the Engineer for approval No concrete shall be placed until this plan is approved The plan may include a combination of the following: Reducing the fresh concrete temperature (The concrete temperature at the time of placement shall not exceed the limit specified in Article 360.8(3).) Scheduling of activities at times to lower the heat of hydration Selection of the cementitious materials to control the heat of hydration - Use of low heat cement, fly ash or GGBF slag The Contractor shall furnish and install temperature recording devices at a minimum frequency of two (2) per 1000 linear foot of concrete, or per paving day The time of the installation of the temperature recording devices will as be as determined by the Engineer Table 1: Current TxDOT Reinforcement Standards 516 Maximum In Place Concrete Temperature (°F) CTE > 6.5 CTE ≤ 5.0 5.0 < CTE ≤ 6.5 Paving Zone I 130 120 110 II III IV 130 130 122 115 110 105 105 100 na Table 2: New Grade 70 Reinforcement Standard Maximum In Place Concrete Temperature (°F) CTE > 6.5 CTE ≤ 5.0 5.0 < CTE ≤ 6.5 Paving Zone I II III IV 130 *na = not applicable Note: CTE = 130 130 130 120 130 130 120 120 Coefficient of Thermal Expansion of 100% Saturated Hardened Concrete (Tex-428-A) in 1x10-6/°F Table 3: Summary of Paving Zones cross the State of Texas Paving Zone Combined Districts Major Cities I Lower Coast / Lower Valley Corpus Christi, Laredo, Brownsville II East coast / Lower South III West, East, and Central Texas IV North Texas and Panhandle 517 Houston, San Antonio, Austin, Beaumont, Victoria Dallas, Forth Worth, El Paso, Waco, Lufkin, Abilene, Midland Amarillo, Lubbock, Wichita Falls Figure 1: Paving Zones in Texas 518 ... TEMPERATURE CONTROL DURING CONSTRUCTION TO IMPROVE THE LONG TERM PERFORMANCE OF PORTLAND CEMENT CONCRETE PAVEMENTS by Anton K Schindler Terry Dossey and B Frank McCullough Research Report. .. system; the effect of these materials on the concrete temperature, and ultimately the concrete performance, need to be quantified There are currently few tools available to the concrete industry to. .. pavement performance These factors emphasize that concrete temperature control during construction in hot weather conditions is essential to improve the durability of PCC pavements The primary