Highway Concrete Pavement Technology Development and Testing Volume V:Field Evaluation of SHRP C-206 Test Sites (Bridge Deck Overlays)

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FOREWORD

Two types of concrete overlays (silica fume concrete (SFC) and latex–modified Type III portland cement concrete (LMC–III) were installed and tested as part of the Strategic Highway Research Program (SHRP) Project C–206: Optimization of Highway Concrete Technology—Bridge Deck Overlays. The two different overlay types were chosen for their ability to fill two different needs: use of SFC as a long-term, low-permeability overlay; and use of LMC–III as a high earlystrength concrete for use when traffic had to be restored after as little as 24 hours. This report summarizes the 5-year study to evaluate the long-term performance of the overlays. Evaluation and comparison of SFC and LMC–III overlays were performed at four locations. The test sites were in Ohio and Kentucky. Each location included SFC and LMC-III overlays on opposite directions of a bridge structure. All overlays were installed in 1992. This study evaluated the overlays each year between 1994 and 1998. All overlays had high initial bond strengths, and the bond strengths remained high over the study period when tested away from delaminations. The overlays were generally rated as good condition in 1998, after 6 years of service, though some individual sites were rated as fair due to extensive cracking. Though good performance was achieved from both SFC and LMC-III overlays, the service life of the overlays tended to vary based on the site location. Generally, cracking and delamination of the overlays tend to increase with time. Typically, all overlays should be inspected biannually for cracking and delamination and routine maintenance including consideration of crack and delamination repairs to extend the service life of the SFC and LMC–III overlays.

NOTICE

This document is disseminated under the sponsorship of the U.S. Department of Transportation in the interest of information exchange. The U.S. Government assumes no liability for its contents or use thereof. This report does not constitute a standard, specification, or regulation.

The U.S. Government does not endorse products or manufacturers. Trade and manufacturers’ names appear in this report only because they are considered essential to the object of the document.

Quality Assurance Statement

The Federal Highway Administration (FHWA) provides high-quality information to serve Government, industry, and the public in a manner that promotes public understanding. Standards and policies are used to ensure and maximize the quality, objectivity, utility, and integrity of its information. FHWA periodically reviews quality issues and adjusts its programs and processes to ensure continuous quality improvement.

Technical Report Documentation Page

Form DOT F 1700.7 (8-72) Reproduction of completed page authorized

SI (Modern Metric) Conversion Factors

TABLE OF CONTENTS

1. INTRODUCTION
2. SUMMARY OF TESTING TECHNIQUES
   • Visual Survey and Distress Mapping
   • Delamination Surveys
   • Copper/Copper Sulfate Half-Cell Potential Testing
   • Polarization Resistance (PR) Testing
   • Chloride Sampling And Testing
   • Shear Bond Testing
   • Inspection Schedule Description
3. INTERSTATE 270 (I—270) IN COLUMBUS, OH
   • Introduction
   • Visual Inspection
   • Delamination Survey
   • Half-Cell Potential Survey
   • Polarization Resistance (PR) Testing
   • Shear Bond Testing
   • Chloride Analyses
   • Sumary of I—270 Tests (Columbus, OH)
4. U.S. 52 IN NEW RICHMOND, OH
   • Introduction
   • Visual Inspection
   • Delamination Survey
   • Half-Cell Potential Survey
   • Polarization Resistance (PR) Testing
   • Core Testing
   • Chloride Analysis
   • Summary of U.S. 52 Test (New Richmond, OH)
5. I–265 OVER KY 22, JEFFERSON COUNTY, KY
   • Introduction
   • Visual Inspection
   • Delamination Survey
   • Half-Cell Potential Survey
   • Polarization Resistance (PR) Testing
   • Core Testing
   • Chloride Analysis
   • Summary of I–265 Over KY 22 (Jefferson County, KY)
6. U.S. 41 OVER KY 351, HENDERSON, KY
   • Introduction
   • Visual Inspection
   • Delamination Survey
   • Half-Cell Potential Survey
   • Polarization Resistance (PR) Testing
   • Core Testing
   • Chloride Analysis
   • Summary of U.S. 41 Test (Henderson, KY)
7. PROJECT SUMMARY

LIST OF FIGURES

• Figure 1. Schematic drawing of polarization resistance test setup
• Figure 2. Photograph showing test section on I–270 northbound (1995)
• Figure 3. Photograph showing test section on I–270 southbound (1995)
• Figure 4. Histogram of half–cell potentials for I–270 NB SFC test section for 1994 and 1997
• Figure 5. Equipotential map of half–cell potentials for I–270 NB (silica fume–modified concrete)
• Figure 6. Histogram of half-cell potential readings for the I–270 southbound LMC–III test section for 1994 and 1997.
• Figure 7. Equipotential map of half–cell potentials for I–270 southbound (latex–modified concrete)
• Figure 8. Cumulative frequency diagram for I–270 (NB and SB) for years 1994 and 1997
• Figure 9. Photograph showing the eastbound deck of U.S. 52 over Raymond Run in Columbus, OH. The overlay is latex-modified.
• Figure 10. Photograph of westbound travel lane of U.S. 52 over Raymond Run in Columbus, OH. The overlay is latex-modified
• Figure 11. Photograph showing westbound passing lane of U.S. 52 over Raymond Run in Columbus, OH. The overlay is silica fume concrete
• Figure 12. Histogram of half-cell potential readings for U.S. 52 eastbound travel lane LMC in 1994 and 1997
• Figure 13. Histogram of half-cell potentials for U.S. 52 westbound travel lane LMC in 1994
• Figure 14. Histogram of half-cell potentials for U.S. 52 westbound passing lane SFC in 1997
• Figure 15. Equipotential map of half-cell potentials for eastbound travel lane U.S. 52 in 1997 (latex-modified concrete)
• Figure 16. Equipotential map of half-cell potentials for westbound passing lane of U.S. 52 in 1997 (silica fume concrete)
• Figure 17. Photograph of I–265 northbound lanes with latex-modified overlay
• Figure 18. Photograph showing I–265 southbound lanes with silica fume concrete overlay
• Figure 19. Histogram of half–cell potential readings for I–265 southbound SFC test section
• Figure 20. Histogram of half–cell potential readings for the –265 northbound LMC test section
• Figure 21. Equipotential maps of half–cell potentials of the three southbound spans SFC of the I–265 test section in 1997
• Figure 22. Equipotential maps of half–cell potentials of the three northbound spans LMC of the I–265 test section in 1997
• Figure 23. Photograph of northbound test section of U.S. 41 (latex-modified concrete overlay)
• Figure 24. Photograph of southbound test section of U.S. 41 (silica fume concrete overlay)
• Figure 25. Photograph showing typical cracking found in the northbound deck of the U.S. 41 test section LMC
• Figure 26. Photograph showing typical cracking associated with the southbound test section of U.S. 41 SFC
• Figure 27. Histogram of half-cell potential readings for U.S. 41 southbound in 1994 SFC
• Figure 28. Histogram of half-cell potential readings for U.S. 41 southbound in 1997 SFC
• Figure 29. Histogram of half-cell potential readings for U.S. 41 southbound SFC in 1994 and 1997
• Figure 30. Histogram of half-cell potential readings for U.S. 41 northbound LMC in 1994
• Figure 31. Histogram of half-cell potential readings for U.S. 41 northbound LMC in 1997
• Figure 32. Histogram of half-cell potential readings for U.S. 41 northbound spans in 1994 and 1997
• Figure 33. Cumulative frequency diagram for U.S. 41 (NB and SB) for years 1994 and 1997
• Figure 34. Equipotential maps of half-cell potentials for the three spans of the southbound test section of U.S. 41 in 1997 SFC
• Figure 35. Equipotential maps of half-cell potentials for the three spans of the northbound test section of U.S. 41 in 1997 LMC

LIST OF TABLES

• Table 1. Mix proportions for LMC-III and SFC overlays (lb/yd3)
• Table 2. Number and areas of delaminations ( I–270 northbound SFC)
• Table 3. Number and areas of delaminations (I–270 southbound LMC)
• Table 4. Cumulative percent of half–cell potentials for I–270 NB in 1994 (silica fume–modified)
• Table 5. Cumulative percent of half–cell potentials for I–270 NB in 1997 (silica fume–modified)
• Table 6. Cumulative frequency of half–cell potentials for I–270 SB in 1994 (latex–modified)
• Table 7. Cumulative frequency of half–cell potentials for I–270 SB in 1997 (latex–modified)
• Table 8. Corrosion rate testing on I–270 northbound SFC (1994)
• Table 9. Corrosion rate testing on I–270 southbound LMC (1994)
• Table 10. Results of polarization resistance testing at I–270 (1997)
• Table 11. Shear bond testing of cores from I–270 (1994)
• Table 12. Shear bond testing of cores from I–270 (1997)
• Table 13. Results of chloride content testing of cores from I–270 (1994)
• Table 14. Results of chloride content testing of cores from I–270 (1998)
• Table 15. Potentials more positive than –250mV (Cu/CuSO4) (percent of measurements)
• Table 16. U.S. 52 concrete proportions and characteristics
• Table 17. Number and areas of delaminations LMC (eastbound passing U.S. 52)
• Table 18. Number and areas of delaminations LMC (westbound travel U.S. 52)
• Table 19. Number and areas of delaminations SFC (westbound passing U.S. 52)
• Table 20. Cumulative frequency of half-cell potentials for U.S. 52 EB travel in 1994 LMC
• Table 21. Cumulative frequency of half-cell potentials for U.S. 52 EB travel in 1997 LMC
• Table 22. Cumulative frequency of half-cell potentials for U.S. 52 for WB travel in 1994 LMC
• Table 23. Cumulative frequency of half-cell potentials for U.S. 52 for WB passing in 1997 SFC
• Table 24. Corrosion rate testing on U.S. 52 eastbound travel lane, LMC-III (1994)
• Table 25. Corrosion rate testing on U.S. 52 westbound travel lane, LMC-III (1994)
• Table 26. Results of polarization resistance testing at U.S. 52 (1997)
• Table 27. Shear bond testing of cores from U.S. 52 (1994)
• Table 28. Shear bond testing of cores from U.S. 52 (1997)
• Table 29. Results of chloride content testing of cores from U.S. 52 (1994)
• Table 30. Results of chloride content testing of cores from U.S. 52 (1998)
• Table 31. Potentials more positive than –250mV (Cu/CuSO4) (percent of measurements)
• Table 32. I–265 concrete proportions and characteristics
• Table 33. Number and areas of delaminations, southbound I–265 SFC
• Table 34. Number and areas of delaminations, northbound I–265 LMC
• Table 35. Cumulative frequency of half–cell potentials for I–265 for SB travel lane, SFC (1994)
• Table 36. Cumulative frequency of half–cell potentials for I–265 for SB travel lane, SFC (1997)
• Table 3. Cumulative frequency of half–cell potentials for I–265 for NB travel lane, LMC (1994)
• Table 38. Cumulative frequency of half–cell potentials for I–265 for NB travel lane, LMC (1997)
• Table 39. Corrosion rate testing on I–265 southbound in 1994 SFC
• Table 40. Corrosion rate testing on I–265 northbound in 1994 LMC
• Table 41. Results of polarization resistance testing at U.S. 52 (1997)
• Table 42. Shear bond testing of cores from I–265 (1994)
• Table 43. Shear bond testing of cores from I–265 (1997)
• Table 44. Results of chloride content testing of cores from I–265 (1994)
• Table 45. Results of chloride content testing of cores from I–265 (1998)
• Table 46. U.S. 41 over KY 351 concrete proportions and characteristics
• Table 47. Number and area of delaminations (U.S. 41 southbound SFC)
• Table 48. Number and area of delaminations (U.S. 41 northbound LMC)
• Table 49. Cumulative frequency of half-cell potentials for U.S. 41, SFC (SB travel lane 1994).55
• Table 50. Cumulative frequency of half-cell potentials for U.S. 41, SFC (SB travel lane 1997).57
• Table 51. Cumulative frequency of half-cell potentials for U.S. 41, LMC (NB travel lane 1994)
• Table 52. Cumulative frequency of half-cell potentials for U.S. 41, LMC (NB travel lane 1997)
• Table 53. Corrosion rate testing on U.S. 41 southbound, SFC (1994)
• Table 54. Corrosion rate testing on U.S. 41 northbound
• Table 55. Results of polarization resistance testing at U.S. 41 (1997)
• Table 56. Shear bond testing of cores from U.S. 41 (1994)
• Table 57. Core Testing Results from U.S. 41 Henderson, KY (1997)
• Table 58. Results of chloride content testing of cores from U.S. 41 (1994)
• Table 59. Results of water-soluble chloride content testing of cores from U.S. 41 (1998)
• Table 60. Results of acid-soluble chloride content testing of cores from U.S. 41 (1998)
• Table 61. Potentials more positive than –250mV (Percent of measurements)
• Table 62. Summary of all test sites