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Durability Provisions For Vicroads Structural Concrete: F. Andrews-Phaeoonos, Mieaust.
Durability Provisions For Vicroads Structural Concrete: F. Andrews-Phaeoonos, Mieaust.
STRUCTURAL CONCRETE
This paper presents an overview of the durability provisions in Section 610 (July 1993
version). Areas covered include concrete cover, grade, class and designation, exposure
classification, minimum compressive strength, minimum cementitious material content,
PAPER NO. 27
maximum water/cementitious material ratio and use of blended cement as an alternative to
ordinary portland cement. Concrete mix design, consistency of concrete prior to placing,
practical on-site curing requirements based on minimisation of evaporative moisture losses
from all freshly placed and unprotected concrete, and formwork removal times are also
discussed.
PAPER NO. 27
1. INTRODUCTION
There are many ways to produce good concrete work for a given set of conditions. This
paper serves as a record of the VicRoads' approach to providing durability provisions in
its standard QA Bridgework Specification, Section 610 - "Structural Concrete" (I). These
provisions contain a number of important initiatives which should ensure that the desirable
standards of concrete durability will be achieved.
Durability of concrete is a vast and complex topic. Both the complexity and difficulty of
ensuring durability have resulted in the ongoing and c0stly remedial and rehabilitation
works being carried out on concrete structures in many parts of the world. Hence, the
need to design, specify and construct durable and cost-effective concrete structures has
been in the forefront of concrete technology and worldwide attention in recent years.
Tremendous advances have been made in the science of concrete technology. In spite of
this, working with concrete is still very much an art. Like any art, its mastery involves
the mastery of both theory and practice.
2. BACKGROUND
The publication of the AUSTROADS Draft Bridge Design Code March 1991, in particular
Section 5.4 - Design for Durability, was the impetus and stimulus behind the investigations
carried out on durability of concrete. Prior to this, durability as a concrete property was
not explicitly provided for as a requisite bridge design or specification requirement. In
effect, the new '92 AUSTROADS Bridge Design Code(1) (hereafter referred to as the
Code) has challenged and changed the way an old familiar construction material like
concrete is looked at and thought about.
Through a series of discussions and literature reviews, a number of internal reports lJ•4•5l on
concrete durability were prepared. The major findings of the investigations were presented
in a seminar to the concrete industry groups prior to their implementation into Section 610
(July 1992 version) as first stage interim measures. In this version, use of blended cement
was subject to approval on merit; where proposed, full documentation on concrete
performance characteristics and construction techniques together with reasons for its use
were to be provided.
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Adequate curing is essential to good durable concrete. An internal investigation report(7)
on curing of cast-in-place concrete has been prepared with a view to practical
implementation of curing requirements into the Specification. The report emphasised the
importance of a theoretical and practical understanding of the fundamental concrete mix
parameters and the physical structure and volumetric composition of the hydrated cement
paste through the application of basic concrete technology. This has resulted in the
adoption of new curing regimes and form work removal times in the Specification.
3. BASIC PRINCIPLES
The basic principles underpinning the durability provisions in Section 610 are summarised
as follows:
3. Select and specify the relevant levels of durability and strength requirements
with respect to exposure classifications and in-service conditions.
The durability provisions will be subject to ongoing review. Changes can be made twice
yearly in February and July as up-to-date knowledge and information dictate. It is also
intended that the performance and effectiveness of the Specification are to be monitored
and reviewed on an ongoing basis. In particular, a research project is proposed to evaluate
the performance and sensitivity of SCMs concrete with respect to the specified curing
regimes in the Specification. Existing consultative and education processes with the
concrete industry and VicRoads construction personnel on the provisions of Section 610
will be maintained and expanded as required.
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4. SECTION 610, AUSTROADS, AS 3600(1), AS 1379(')
Design for durability, in accordance with the Code, is now an integral part and the first
step in the structural concrete bridge design process. The aim is to ensure that a concrete
structure has the ability to withstand the expected physical and chemical wear and
deterioration throughout its intended life without the need for undue maintenance.
However, the Code warns that 'Durability is a complex topic and compliance with these
(Code) requirements may not be sufficient to ensure a durable structure'.
I Description
I AUSTROADS I AS3600
I
Nom. Design Life (yrs.) 100 40-60
EC A, Bl, B2, C, U AI-2, BI, B2, C, U
Cover - Nominal cover specified. - Nominal cover
- 5 to 20 mm > AS 3600. implied.
Special Class Concrete - For EC Bl & above. - Usage not specified.
- w/c , c/c, cement type. - c/c, cement type.
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5. DURABILITY PROVISIONS IN SECTION 610
All concrete covers are specified as minimum covers with zero negative tolerances. The
values of these minimum covers are generally consistent with and satisfy the Code's
specified nominal values less the negative tolerance allowances therein.
Concern has been expressed about the practicality and difficulty of implementing the
Code's abstract 'nominal cover' concept in the field. Nominal cover is not a quantity that
is directly measurable and used on site. It has to be thought through with both negative
and positive tolerances to achieve the end result and may be more prone to mistakes in
implementation on the actual jobs, whereas the existing 'minimum cover' approach in
bridge construction is a well tried and accepted method that has proved to be reliable.
All VicRoads' structural concrete is specified as special class performance concrete (32
MPa or higher) in accordance with Appendix C, Clause C4.2 of AS 1379. Normal class
concrete (25 MPa) is not used because it does not afford the user the opportunity to control
the quality of the concrete (with respect to maximum W/C ratio, minimum C/C or cement
type) as only strength (f J, slump and maximum nominal aggregate size can be specified.
As well, for normal class 25 MPa concrete, where the water/cement ratio can be 0.65 or
higher, it appears that a long period of continuous moist curing is required (greater than
6 months)(lo.11) to achieve capillary discontinuity. Further, 'the importance of eliminating
continuous capillaries is such that this might be considered a necessary condition for a
concrete to be classified as "good"' Neville (1981)(10).
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5.4 Concrete Designation
The basis for acceptance or rejection of concrete is the specified minimum 28 day
compressive strength as measured by testing of site-sampled test cylinders. This is in spite
of the many limitations of the standard test to 'prove' the potential quality of as-cast
concrete. Table 3 below is reproduced from Table 610.051 in Section 610.
Minimum Compressive
Strength (MPa)
Concrete
Grade 3 7 28
days days days
VR330/32 15 24 32
VR400/40 18 30 40
VR450/50 23 40 50
VR470/55 25 45 55
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The 3 and 7-day compressive strengths are also specified in order to ensure that both
portland cement and SCMs concretes are designed with comparable rate of strength
development for durability considerations. Documentary evidence of previous performance
and relevant test results complying with the minimum compressive strength requirements
given in Table 3 are to be submitted by the contractor as part of the concrete mix design
submission. In the absence of documentary evidence the contractor is required to
undertake trial mix(es).
The values of minimum compressive strength given in Table 3 are those shown in Table
5.16.1.2 of the Code, except for concrete grade VR470/55 and the 7-day value for
concrete grade VR450/50. The 55 MPa concrete has been introduced to especially cater
for the manufacture of some of the VicRoads standard precast concrete bridge beams.
Cementitious Water/Cementitious
Concrete
Material Content Material Ratio
Grade
(min) (kg/m 3) (MPa)
These two performance parameters are the most difficult to resolve. The different
requirements between the '92 AUSTROADS Code and AS 3600 and among the various
State Road Authorities have added to the difficulty. Nevertheless, there is an intimate
relationship between the water content (generally in the range 180 ± 20 litres/m3 , with or
without the use of chemical admixtures), c/c or C/C, w/c or W/C ratio, target slump or
strength, impermeability and the applied curing regimes. In simple and practical terms,
the properties of concrete can be said to depend in the first instance entirely on the
water/cement or cementitious material ratio. The lower the w/c or W/C ratio (within
limits) the better the properties of well-eompacted standard concrete mixes.
The numerical values of C/C and W/C adopted either conform to or exceed the Code's
recommended minimum requirements (Le. 320/0.56, 390/0.46 and 450/0.40 for 32, 40
and 50 MPa concrete respectively). The minimum C/C are about 10% less than
VicRoads' previous (c/c) provisions (Le. 380132, 450/40 and 500/50 respectively). A
W/C ratio of no greater than 0.50 for 32 MPa concrete is considered to be the minimum
requirement to obtain a relatively impermeable cover concrete with the limited curing
periods generally specified and encountered on site.
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5.8 SCMs (Fly Ash. Ground Granulated Blast Furnace Slag. Silica Fume)
Much research information is available on SCMs. Most is highly specialised and job-
specific. In general, there are few disadvantages with these materials provided good mix
design procedures and the usual good construction techniques of placing, compactin~ and
curing are followed. Some limitations of these materials (compared to OPC concrete)
include physical/chemical material variability, slower early rate of strength gain, longer
setting times, extended formwork removal and curing times. However, in normal strength
concrete. judicious use of chemical admixtures, careful mix proportioning and construction
procedures can generally minimise these limitations.
As a first step, SCMs have been incorporated into Section 610 at moderate cement
replacement levels and only in single combination with portland cement. The minimum
mass of portland cement in concrete mixes containing either GGBF slag, fly ash or silica
fume is specified to be 60%. 75 % or 90% respectively of the total mass of cementitious
material in the concrete mix. The use of higher SCMs replacement levels for special
applications such as marine environments, chemical or sulphate attack, alkali aggregate
reaction etc. will be considered and specified on the bridge drawings and in the
construction specification on a case by case basis.
The contractor is required to submit as part of the mix design details the following:
Again. where documentary evidence on the performance of the concrete mix design is not
available. the contractor is required to undertake trial mix(es).
Section 610 requires that 'Each batch (truckload) of concrete delivered to site shall be
visually inspected to ensure consistency of concrete supply, and the estimated slump shall
be recorded on the identification certificate for the batch. Both the visual inspection and
slump estimate shall be carried out prior to any addition of a superplasticizer'.
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5.11 Curing
A chart for evaporation of freshly placed concrete is included in the Specification. When
the value of the rate of evaporation as determined from the chart exceeds 0.50 kg/or per
hour, the contractor is required to take precautions such as the application of an aliphatic-
alcohol based evaporative retarding compound or controlled fog spray to minimise
evaporative moisture losses. The contractor is also required to satisfy temperature limits
and other precautionary measures with regard to hot, cold and wet weather concreting.
GB 9 g
VR400/40 B2 GP 6 5
GB 8 7
VR450/50 C GP 5 5
VR470/55
GB 7 7
For concrete decks and slab., the period. of curing shall be extended by 2 day•.
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'An estimate of the required duration of curing is a complex problem'u.). It depends on
the water/cement or cementitious material ratio, the type and amount of cement or
cementitious material, SCMs additions, concrete temperature, exposure classification and
ambient conditions during and after curing. An analytical procedure(7) (based on OPC
concrete) undertaken to gain some insight into the problem is briefly outlined below:
The minimum curing periods/maturities provided in Table 5 are generally in line with
current international practices. As a comparison, these provisions exceed those specified
in Table 6.5 of BS 8110: Part 1 (1985)(i.e. from no special requirements to 3 to 7 days
for T > 10°C for OPC/SCMs concrete) or in Table d.l0 in CEB-FIP Model Code
1990(l4)(Le. 2 to 6 days for T > IOOC for OPC concrete and plus I to 2 additional days
for SCMs concrete). The curing periods are also generally in line with the major findings
of Ho (1992)(17) on the effectiveness of water-retaining curing techniques.
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The new minimum periods for removal of formwork and form work supports range from
1 day for sides of slabs and piles to 7 days (or achieving 7-day compressive strength,
whichever is the greater) for soffits of structural components such as beams, slabs,
cantilevers, crossheads etc. For SCMs concrete these periods have been increased by 1
day for soffit and high column/wall side forms, but excluding side forms for low columns
(less than 4 metres) and walls (less than 2 metres), or the sides of slabs and piles.
6. CONCLUDING REMARKS
7. REFERENCES
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14. "CEB-FIP Model Code 1990", Published by Thomas Telford Services Ltd. 1993,
pp 426-7.
15. Powers, T.C. (1947). "A Discussion of Cement Hydration in Relation to the
Curing of Concrete" , Pmc. 27th Ann. Meeting, Highway Res. Board , Washington.
16. van der Molen, J.L. (1979). "Performance-based Curing of Concrete", The Inst.
of Engineers Aust., National Conference Publication No. 79/9.
17. Ho, D.W.S. (1992). "The Effectiveness of Curing Techniques on the Quality of
Concrete", CSIRO Div. of Building, Construction and Engineering, TR 92/3.
18. "Recommended Practice: Durable Concrete", Concrete Institute of Australia,
February 1990, P 36.
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