Montana Department of Transportation Highways

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Montana Department of Transportation Highways
Engineering Conference-2007 Louis N.
Triandafilou, P.E.High Performance Structural
Materials EngineerFHWA Resource
CenterBaltimore, MD
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Topic Areas

• Definitions
• Benefits Advantages
• Project History
• Cost

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WHY USE HPC?
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What is HPC ?
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CHANGES FROM CURRENT PRACTICE

• Engineered or optimized concrete
• Durability specifications
• 0.6 - in diameter strand, typical for beam
  strengthsgt 10,000 psi
• Match-cured cylinders
• Internal concrete temperature

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CHANGES FROM CURRENT PRACTICE (continued)

• Dosage of high-range water reducer
• Concrete mix component compatibility
• AASHTO State design construction
  specifications
• Member transportation erection
• Teamwork partnering

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WHAT IS HPC FOR BRIDGES?
?

• Engineered concrete with
• Improved durability at normal strength
• Higher strengths, if needed in design
• Improved durability at high strength
• Consideration for performance of the specific
  
  member in its service
  environment

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Definition of HPC
HPC is concrete that meets special
performance and uniformity requirements that
cannot always be obtained using conventional
ingredients, normal mixing procedures, and
typical curing practices. (Charles Goodspeed,
Suneel Vanikar and Ray Cook)
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Definition of HPC

• These requirements may include the following
  enhancements
• ease of placement and consolidation without
  affecting strength,
• long-term mechanical properties,
• early high strength,
• toughness,
• volume stability, and
• longer life in severe environments.

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HPC Performance Characteristics
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HPC Performance Characteristics
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HPC Performance Characteristics
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BENEFITS OF HPC
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ADVANTAGES OF HPC

• 1. Longer Spans

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Longer Fewer Spans Piers
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ADVANTAGES OF HPC 1. Longer spans
2. Increased beam spacings
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ADVANTAGES OF HPC
1. Longer Spans 2. Increased
beam spacing 3. Shallower
members
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SHALLOWER INCREASED MEMBERS
ROADWAY CLEARANCES
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ADVANTAGES OF HPC 1.
Longer Spans 2. Increased Beam
Spacings 3. Shallower Members
4. Increased Durability
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Increased Longer Life Durability
Fewer Repairs
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DURABILITY

• Freeze - Thaw
• Rapid Chloride Permeability
• Abrasion Loss
• Carbonation Depth

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ADVANTAGES OF HPC 1. Longer Spans
2. Increased Beam Spacings 3. Shallower
Members 4. Increased Durability 5.
Improved Mechanical Properties
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• IMPROVED MECHANICAL PROPERTIES
• Compressive Strength
• Modulus of Elasticity
• Tensile Strength
• Bond

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States Utilization of HP Concrete

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Weighted Value Summary for Types of Distress
Experienced
Types of Distress
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Weighted Value Summary of Interest for HPC
Beneficial Attributes
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Colorado High Performance Concrete Showcase
Bridge
I-25 over Yale Ave. Denver, Colorado

• Box-Girder Bridge
• 34.1 m (112) Span
• Beam Concrete
• 69 MPa (10 ksi)
• Deck Concrete
• 37 MPa (5.3 ksi)

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Bridge Description
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Bridge Description
I-25/YALE AVE.
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HPC Advantage
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Design Requirements

• 10,000 psi Girders
• 0.6 Strands _at_ 2
• 5,000 psi Deck
• Durable Deck

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Substructure Details
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Substructure Details
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Completed Bridge
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New Hampshire High Performance Concrete Showcase
Bridge
Bristol, NH on NH Route 104

• 5 AASHTO Type III Girders
• 20 m (65) Span
• Beam Concrete 55 MPa (8 ksi)
• Deck Concrete 41 (6 ksi)
• 1.27 cm dia. (0.5 in) 270 ksi
• LoLax Strands

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General Plan
NEWFOUND RIVER
TO RTE 3A
65-0 C-C BRG
NH ROUTE 104
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Bridge Description

• Single Span I- girderBridge
• 19.8 m (65) Single
• Span
• 17.5 m (57.5) Width
• Single Span I Girder
• 5 AASHTO Type III
• Girders
• Concrete Deck

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HPC Advantage
7 Deck
fc6 ksi
8 Deck
fc10 ksi
Ref Castrodale et al., Fig. 1.1
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Bridge Construction
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Superstructure Deck Details

• 23 cm (9 in.) Deck
• 7.6 cm (3 in.) Clear Cover (top)
• 3.8 m (12.5 ft.) Span (c-c girders)
• No Wearing Course

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Substructure Details
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Ohio High Performance Concrete Showcase Bridge
Guernsey County on US Route 22

• ODOT B42-48 Box Beams
• 35.20 m (115.5) Span
• Beam Concrete
• 68.9 MPa (10 ksi)

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Bridge Description
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Cross Section
115.5
Elevation
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HPC Advantage
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Bridge Construction
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Bridge Construction
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Superstructure Details
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Completed Bridge
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Nebraska High Performance Concrete Showcase
Bridge
Sarpy County 120th Street

• NU 1100 Girders
• 22.9 m (75) Span
• Beam Concrete
• 83 MPa (12 ksi)
• Deck Concrete
• 55 MPa (8 ksi)

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Bridge Description
Substructure design is the same for both bridges.
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Bridge Description Conventional Concrete
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Bridge Description HPC
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Deck Mix Design

• Criteria
• Compressive Strength at 56 days 8,000 psi
• Chloride Permeability at 56 days x lt 1800
• Coulombs (in accordance with AASHTO T277)
• Air Content 5.0 lt x lt 7.5

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Bridge Construction
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Substructure Details
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Completed Bridge
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Virginia High Performance Concrete Showcase
Bridge
Route 40 over Falling River

• AASHTO Type IV
• 4-24.4 m (80) Spans
• Beam Concrete
• 55 MPa (8 ksi)
• Deck Concrete
• 27.5 MPa (4 ksi)
• Strand Diameter
• 13 mm (0.5 in)

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Bridge Description
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8.5
TYPE IV (8,000 psi)
10-4
(TYPICAL)

• AASHTO Type IV Girders
• 4-24.4 m (80) Spans
• 13.4 m (44) Width
• Total Length 97.6 m (320)

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HPC Advantage
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8.5
TYPE IV (8,000 psi)
10-4
(TYPICAL)
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TYPE IV (6,000 psi)
6-11
(TYPICAL)
TRANSVERSE SECTION
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Girder Fabrication - Concrete
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Deck/Substructure Concrete
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HPC BRIDGES IN VIRGINIA
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BENEFITS OF HPC
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Completed Bridge
Route 40 Bridge over Falling River
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CONCLUSIONS
(based on Virginias first 7 HPC bridges)

• Low permeability and high strength
• concrete can be obtained in the field with
• locally available materials
• Use pozzolans or slag, low W/CM
• Follow proper construction practices
• control retardation and temperature for high
• early strengths

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Puerto Rico
First two bridge projects in summer 2000
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Victor Rojas Bridge
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Victor Rojas Bridge
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Specification Highlights

• Concrete ranges from 3000-7000 psi
• Max. w/c ratio 0.45
• Minimum cement content 450-600 lbs./cy
• Mandated use of silica fume
• 5 minimum
• 10 maximum
• Permeability for all classes
• 2000 coulombs _at_ 28 days
• If gt2000 coulombs, 0.50/coulomb/yd penalty
• gt2500 coulombs rejection

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Specification Highlights

• No concrete placement if evaporation rate is, or
  is expected to exceed, 0.20 lbs./sf./hr.
• Curing
• 7 days wet burlap OR
• Curing compound
• Mandated epoxy rebars

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Delaware
Utilizing HPC criteria in design ASR
specifications LMC Vs. Silica fume overlay (bid
option)
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Specifications
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COMPLETED PROJECTS

• Bridge 356 on SR 10
• First Micro-Silica Overlay Contract
• Seaford Bridges
• Four Different Overlay Materials
• Latex-Modified Concrete
• Micro-Silica Modified Concrete
• Concrete with Fly Ash
• Concrete with Corrosion Inhibitor
• 389A on K389 Bridge 8G on K10
• Bridge

Utilized HPC specs for entire structure
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Types of Cost Estimates

• Project Cost Estimate
• Square Foot Cost
• Square Foot Superstructure Cost
• Square Foot Substructure Cost
• Preliminary Quantity and Unit Price

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Examples

• Square Foot Cost
• P.S. Girder Bridges - 80 to 140 feet spans
• Water Crossing with Pile Footings 55 - 100
  /SF
• Water Crossing w/ Spread Footings 50 - 90 /SF
• Dry Crossing with Pile Footings 50 - 90 /SF
• Dry Crossing with Spread Footings 45 - 80 /SF

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Example

• Unit Prices
• Steel reinforcing bars 0.35 -
  0.50/lb.
• Epoxy coated rebars 0.45 -
  0.70/lb.
• Concrete for bridge deck 350 - 500/cy
• Concrete for substructure 250 - 350/cy
• P.S. Girders (60' to 100) 100 - 115
  /LF
• P.S. Girders (100' to 150) 110 - 135 /LF

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Types of Cost Estimates

• Contract Cost Estimate
• Materials
• Equipment
• Labor
• Overhead
• Profit

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Example

• Concrete Cost
• Normal Mix (5.5 sack)
• 5.0 sack 55.00
• 0.50 sack 2.30
• Total 57.30 x 770 cy 44,121
• HPC Mix (5.0 sack, fly ash, mid-range
  plasticizer)
• 5.0 sack 55.00
• 80 lbs. Fly ash 2.00
• Mid-range plasticizer 3.76
• Total 60.76 x 770
  cy 46,785

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Example

• Pump Cost
• Normal Mix
• 30 cy/hour _at_ 4" slump
• 770 cy/30 cy per hour 25.7
  hrs
• 25.7 hours x 95.00/hour 2,442
• 770 cy x 2.00/cy pump cost 1,540
• 8 pours x 50/pour mobilization 400
• Total 4,382

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Example (continued)

• HPC Mix
• 34.5 cy/hour at 5" to 7" slump
• 770 cy/34.5 cy per hour 22.3 hrs
• 22.3 hours x 95.00/hour 2,119
• 770 cy x 2.00/cy pump cost 1,540
• 8 pours x 50/pour mobilization 400
• Total 4,059

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Example (continued)

• Placing Labor Cost
• Normal Mix
• Concrete placed at a 4" slump requires 3 persons
• 3 persons x 40/hour
  120/hr
• 120/hour x 25.7 hours 3,084
• HPC Mix
• Concrete placed at 5-7" slump requires 2
  persons
• 2 persons x 40/hour
  80/hr
• 80/hour x 22.3 hours 1,784

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Example (continued)

• Sacking Cost
• Normal Mix
• 20,738 sq. ft. x 1.00/sq. ft. 20,738
• HPC Mix
• 20,738 sq. ft. x 0.50/sq. ft. 10,369

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Example (continued)

• Summary
• Normal Mix HPC Mix
• Concrete Cost 44,121 46,785
• Pump Cost 4,382 4,059
• Placing Labor 3,084 1,784
• Sacking 20,738 10,369
• Total 72,325 62,997
• Savings 9,328 12.11/cy

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HPC Cost Data
State
Bridge
Deck
Beam
Substructure
Square Foot Cost
Length
Main
Width
Strength
Cost
Strength
Cost
Strength
Cost
Superstr
Total
(Feet)
Span(Ft.)
(Ft.)
psi.
/Unit
psi.
/Unit
psi.
/Unit
/SF
/SF
Alabama
gt600
81-120
33-40
Delaware
81-120
81-120
49-56
10/sf
35/sf
630/cy
64
197
Florida
26
49
Maryland 125/cy (50 increase)
Kentucky
301-400
81-120
49-56
363/cy

Nebraska
181-240
80
gt77
511/cy
720/cy
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New
Hamp.
80
80
57-68
545/cy
255/lf
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New York
80-600
80-180
26-77
21/sf
Nevada 415/cy (30 increase materials)
Ohio 514/cy
Tennessee
39
Texas
9/sf
115/lf
413/cy
15-32
24-47
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Virginia
Washington
241-300
121-180
33-40
10,000
153/lf
26
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Vermont 150-250/cy increase
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SummaryImproved Mechanical Properties

• Compressive Strength
• Modulus of Elasticity
• Tensile Strength
• Bond

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Summary Increased Durability

• Decreased Permeability
• Resistance to Freeze - Thaw damage
• Resistance to Abrasion
• Resistance to Scaling

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Summary

• Think cost savings! Think HPC!
• Design Flexibility
• Long Service Life
• Low Life-Cycle Cost

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The End