Since 2006, research funded by the Texas Department of Transportation (TxDOT) has evaluated the use of coatings and sealers for mitigating expansion due to alkali-silica reaction (ASR) and/or delayed ettringite formation (DEF) in hardened concrete. The report herein includes a project summary of previous work in Phase I, led by Racheal Lute (2008) and Charles Rust (2009). The Phase II research, described in this thesis, established concrete exposure blocks and NCHRP 244 Series II testing as the cornerstones of characterizing coating effectiveness. The studies assessed coating system performance by examining the contribution of steel reinforcement, the effects of aggregate reactivity, the size limitations of treatments, and the impact of painted concrete substrates. Lastly, this thesis describes the preliminary results of a field study site of columns supporting a flyover, and a concrete exposure block site in Houston, Texas. Overall, the results are encouraging as several coatings have reduced expansion by lowering internal relative humidity.

Alkali-silica reaction (ASR) and delayed ettringite formation (DEF) deterioration have been a problem for the concrete infrastructure in the state of Texas and around the world in recent decades. A great deal of research into the causes and mechanisms of the deterioration has helped to prevent the formation of ASR and DEF in new construction, but the evaluation and maintenance of existing structures remains a problem. The goal of this research is to investigate the use of several nondestructive testing (NDT) methods to evaluate the level of ASR and DEF deterioration in a structural element. Based on the results, recommendations are made as to which NDT methods have the most potential to be incorporated into the evaluation process. / text

Alkali silica reaction (ASR) and delayed ettringite formation (DEF) are two causes of concrete deterioration. Both mechanisms cause expansion of concrete and thus extensive cracking. Most previous research on ASR and DEF focused on understanding the material science of the mechanisms. This dissertation adds to the smaller body of knowledge about ASR/DEF’s effect on the structural behavior of reinforced concrete columns. It compares the structural performance of ASR/DEF affected concrete columns to mechanically cracked columns, evaluates the relative performance of four different concrete repair methods for strengthening damaged columns, and describes how to model pre-existing cracks in the finite element program ATENA. Previous research on scaled columns used mechanically cracked concrete as an approximation of ASR/DEF cracking damage. These earlier column tests, by Kapitan, were compared to two columns affected by ASR/DEF. Due to a deficiency in original design of the actual columns modeled, all of these scaled column specimens failed in bearing during testing under biaxial bending. The ASR/DEF affected columns exhibited nearly identical performance (including bearing capacity) as Kapitan’s control specimen. Thus, with over one percent expansion due to ASR/DEF, there was no reduction in bearing capacity for these columns. Based on the bearing failure observed in these scaled column specimens, concrete repairs were designed to increase confinement of the column capital to address the bearing capacity deficiency. A series of bearing specimens was constructed, externally reinforced using four different strengthening schemes, and load tested. From this bearing specimen series, both an external post-tensioned repair and a concrete jacketing repair performed well beyond their designed capacities and are recommended for bearing zone confinement repair of similar ASR/DEF affected concrete columns. Further, this dissertation presents how Kapitan’s scaled column results were modeled using ATENA (a reinforced concrete finite element program). A technique for modeling the mechanical cracking was developed for ATENA. Once calibrated, a parametric study used the model to find that a 0.17-inch wide through-section crack in the scaled columnd (5/8 inches in the field) was the threshold that reduced capacity of the scaled column to the factored design load. / text

Over the last decade, a number of reinforced concrete bent caps within Houston, Texas have exhibited premature concrete damage (cracking, spalling and a loss of material strength) due to alkali-silica reaction (ASR) and/or delayed ettringite formation (DEF). The alarming nature of the severe surface cracking prompted the Houston District of the Texas Department of Transportation to initiate an investigation into the structural implications of the premature concrete damage. Specifically, an interagency contract with the University of Texas at Austin charged engineers at Ferguson Structural Engineering Laboratory to: 1. Establish the time-dependent relationship between ASR/DEF deterioration and the shear capacity of affected bridge bent caps. 2. Develop practical recommendations for structural evaluation of in-service bridge bent caps affected by ASR and/or DEF. To accomplish these objectives, six large-scale bent cap specimens were fabricated within the laboratory. Four of the specimens (containing reactive concrete exposed to high curing temperatures) represented the most severe circumstances of deterioration found in the field. The remaining two specimens (non-reactive) provided a basis for the comparison of long-term structural performance. All of the specimens were subjected to a conditioning regimen meant to foster the development of realistic ASR/DEF-related damage. Resulting expansions were characterized over the course of the study through a carefully-planned monitoring program. Following a prolonged exposure period, three of the six bent cap specimens (representing undamaged, mild, and moderate levels of deterioration) were tested in shear. Observations made over the course of each test captured the service and ultimate load effects of ASR/DEF-induced deterioration. Six shear-critical spans were tested prior to this publication: three deep beam and three sectional shear tests. The remaining six shear spans (contained within the remaining three specimens) were retained to establish the effects of severe deterioration through future shear testing. Subsequent analysis of the expansion monitoring and shear testing data provided much needed insight into the performance and evaluation of ASR/DEF damaged bent structures. The results ultimately formed a strong technical basis for the preliminary assessment of a damaged bent structure within Houston, Texas. / text

A combined experimental and analytical program was conducted to investigate the effects of Alkali-Silica Reaction (ASR) and Delayed Ettringite Formation (DEF) on D-regions in reinforced concrete (RC) bridge bents. Four large-scale RC specimens, which represent cantilever and straddle bents in Texas bridges in each specimen, were constructed. The first specimen represented the unexposed control specimen, while the other three were conditioned in the field with supplemental watering to promote ASR/DEF and served as the exposed specimens. The control and two exposed specimens with various levels of ASR/DEF, after eight months and two years of field conditioning, were load tested to failure. The last specimen remains in field with additional exposure to promote ASR/DEF and will be load tested in future studies. The width and length of preload-induced cracks and developing cracks that initiated in the exposed specimens and grew over time, indicating concrete expansion due to ASR/DEF mechanisms, were measured. Petrographic analysis results of concrete cores extracted from the exposed specimens after their load testing confirmed the formation of ASR gel and minimum accumulation of ettringite. The structural testing results showed that the failure mechanism in all three tested specimens was due to a brittle shear failure in the beam-column joint. However, slightly greater stiffness, strength, and ductility were observed in the exposed specimens as a result of the activation of the reinforcing steel in the specimens due to the expansion of the concrete primarily from ASR, which effectively prestressed and confined the core concrete. Sectional analysis and Strut-and-Tie Modeling (STM) of the experimental specimens were applied. Three-dimensional nonlinear Finite Element Analyses (FEA) were also conducted to numerically simulate the overall structural performance, internal response, and out-of-plane behavior of the experimental specimens. The effects of varying constitutive relations of the concrete in tension on models of the specimens were compared with the measured experimental response. A method to mimic ASR/DEF effects on exposed specimens was proposed and incorporated into the FEA approach. As a result, forces that prestress and confine the core concrete were effectively applied through the reinforcing steel prior to subsequent structural loading. The three-dimensional FEA approach was able to simulate the out-of-plane behavior of the beam-column joint and the proposed method yielded comparable results with the measured overall and internal behavior of specimens.

Numerous cases of premature concrete deterioration due to alkali-silica reaction and/or delayed ettringite formation have developed within highway infrastructure in the state of Texas over the past two decades. Although experimental research and in-situ load testing on an international scale has indicated that moderate levels of deterioration are unlikely to pose a threat to structural safety, the discovery of reinforcing bar fracture in Japan due to ASR-related expansion has called into question the integrity of heavily damaged structures. A two-part experimental program was conducted at The University of Texas at Austin relating to ASR/DEF-induced reinforcing bar fracture. Work conducted under TxDOT Project 0-6491 included the fabrication and monitoring of four concrete specimens. Methods were employed to simulate a fracture of the transverse reinforcement within the time frame of the study and the applicability of various NDT monitoring techniques to detect bar fracture was evaluated. Furthermore, a number of reinforcing bar samples were tested and analyzed to investigate (1) the development of reinforcing bar cracking due to the bending operation and (2) the progression of cracks after application of an expansive opening force on bars with 90° bends. Research findings and conclusions form a preliminary assessment on the potential for reinforcing bar fracture within affected infrastructure in Texas. / text

Alkali-silica reaction (ASR) and delayed ettringite formation (DEF) are expansive reactions that can lead to the premature deterioration of concrete structures. Both have been implicated in the deterioration of numerous structures around the world, including many transportation structures in Texas. As a result of considerable research advances, ASR and DEF are now avoidable in new construction, but evaluating and managing the existing stock of structures damaged by these mechanisms remains a challenge. While the published guidance for evaluating structures is very effective at diagnosing the presence of ASR and DEF, there remain significant weaknesses with respect to the evaluation of structural safety and serviceability and nondestructive testing (NDT) is a minor component of the evaluation process. The research described in this dissertation involved a wide range of tests on plain and reinforced concrete at multiple scales. This included small cylinders and prisms, larger plain and reinforced concrete specimens in outdoor exposure, full-scale reinforced concrete beams, and core samples from the outdoor exposure specimens and full-scale reinforced concrete beams. Nondestructive test methods were applied at all scales, and the full-scale beams were also tested in four-point flexure to determine the effects of ASR and DEF on flexural strength and serviceability. Severe expansions from ASR and DEF did not reduce the strength of the full-scale beams or result in excessive deflections under live loads, despite significant decreases in the compressive strength and elastic modulus measured from core samples. Most NDT methods were found to be effective at low expansions but had difficulty correlating to larger expansions. Two promising NDT methods have been identified for future research and development, and guidance regarding existing test methods is offered. / text

Premature concrete deterioration due to alkali-silica reaction (ASR) and delayed ettringite formation (DEF) is a significant problem all over the world. In cases where these mechanisms were not initially prevented, mitigation is critical to halt expansion and cracking. The main objectives of the research presented herein were to study the effect of ambient relative humidity (RH) on rates of concrete expansion, to determine RH thresholds below which expansion due to ASR and/or DEF may be suppressed, and to evaluate coatings intended to lower the internal RH of concrete and thus minimize future potential for damage. Results from testing showed that the RH threshold for ASR was below 82%, the RH threshold for DEF was below 92%, and the RH threshold for combined ASR and DEF could be about 83% for the materials tested. Furthermore, it was shown that some coatings are effective in reducing ASR- and DEF-related expansion by lowering the internal RH of concrete. / text

La Réaction Sulfatique Interne (RSI) est une pathologie du béton pouvant affecter les matériaux soumis à un échauffement au-delà de 65°C. Elle consiste en une formation d'ettringite dans le matériau durci et conduit à son gonflement. Il s'en suit une fissuration et une dégradation des performances mécaniques pouvant poser des problèmes d'intégrité structurelle à l'instar de la Réaction Alcali-Granulat (RAG) à laquelle elle est fréquemment couplée in situ. Lorsqu'un ouvrage est atteint, il convient de poser un diagnostic, évaluer son aptitude au service, prédire son évolution et mettre en uvre des méthodes de réparation. Ceci nécessite une compréhension fine des effets de la RSI à l'échelle microscopique et à l'échelle de l'ouvrage. De nombreuses études expérimentales et théoriques ont été menées pour déterminer les mécanismes mis en uvre et les paramètres influençant la RSI. Toutefois, la complexité des phénomènes rend délicate la transposition de ces connaissances à l'échelle de la structure. Les approches macroscopiques semblent donc plus adaptées à ce type de problème. Pour mettre au point ces approches, il est nécessaire de comprendre en détail les effets de la pathologie à l'échelle du matériau et de la structure. Cette thèse décrit les résultats d'une étude de laboratoire basée sur des essais sur éprouvettes pour caractériser les couplages entre les gonflements et l'humidité, la température et l'état de contraintes. Ces travaux ont également été l'occasion d'étudier les couplages entre RAG et RSI. En parallèle, des suivis dimensionnels et hydriques de poutres soumises à des conditions d'exposition à l'humidité contrôlées ont permis de constituer une base de données des effets structurels de la RSI. La confrontation de ces essais menés conjointement à l'échelle du matériau et de la structure fournit des données permettant de mettre au point des méthodes de re-calcul des ouvrages et de les valider en confrontant leurs prédictions aux résultats expérimentaux / Delayed Ettringite Formation (DEF) is a reaction that can affect concretes exposed to temperatures higher than 65°C. The corresponding formation of ettringite in the hardened material leads to swellings, cracking and decrease of the mechanical properties. Thus it gives serious concern in terms of structural integrity and serviceability. DEF is often coupled with Alkali-Aggregate Reaction (AAR) in the field. For a structure manager, it is necessary to be able to diagnose the reaction, to assess the serviceability of the structure, to predict its evolution and to repair it. To reach these objectives, it is necessary to understand DEF effects both at the microscopic scale and the structure scale. In the literature, a lot of theoretical and experimental researches have been reported and deal mainly with the chemo-physical mechanisms. These results emphasize the complexity of the microscopic features of DEF and thus can hardly be used to model its structural effects. Thus, macroscopic approaches seem to be more adapted. To develop such approaches, it is necessary to understand the effect of the deleterious process at the scale of the material and of the structure. In this context, this research proposes to quantify the couplings between DEF-induced swellings and moisture, temperature and mechanical loadings thanks to material tests on concrete cylinders. The couplings between DEF and AAR are as well investigated. Moreover the monitoring of dimensions and water content of concrete beams is also performed while being exposed to various controlled water supply conditions. The corresponding results provide a database useful to analyse quantitatively the mechanical effects of DEF (for the material and for the structures) and to validate the numerical models by comparing their predictions to the experimental behaviour

Cantilevered reinforced concrete columns with a lap splice of the longitudinal reinforcement near the base can induce high moment demands on the splice region when lateral loads are present on the structure. Code design specifications typically require a conservative splice length to account for these high moment demands and their consequences of bond failure. The required splice length is calculated as a function of required development length, which is a function of the bond between the reinforcement and the surrounding concrete, and a factor depending on the section detailing. However, the effects of concrete deterioration due to alkali silica reaction (ASR) and/or delayed ettringite formation (DEF) may weaken the bond of the splice region enough to overcome the conservative splice length, potentially resulting in brittle failure of the column during lateral loading. This thesis presents the following results obtained from an experimental and analytical program. * Fabrication of large-scale specimens of typical column splice regions with concrete that is susceptible to ASR/DEF deterioration * Measurement of the large-scale specimen deterioration due to ASR/DEF accelerated deterioration * Analytical model of the column splice region based on flexure theory as a function of the development length of the reinforcement and a factor to account for deterioration of the bond due to ASR/DEF * Experimental behavior of two large-scale specimens that are not influenced by premature concrete deterioration due to ASR/DEF (control specimens). This experimental data is also used to calibrate the analytical model. The conclusions of the research are that the analytical model correlates well with the experimental behavior of the large-scale control specimens not influenced by ASR/DEF. The lap splice region behaved as expected and an over-strength in the splice region is evident. To account for ASR/DEF damage, the analytical model proposes a reduction factor to decrease the bond strength of the splice region to predict ultimate performance of the region with different levels of premature concrete deterioration.