Channel lining with fiber reinforced shotcrete

              ARIZONA DEPARTMENT OF TRANSPORTATION
REPORT NUMBER: FHWA-AZ--8902
CHANNEL LINING WITH
FIBER REINFORCED
SHOTCRETE
Final Report
Prepared by:
Dwiiht Metcatf
Douglas J. Latiin, P.E.
Arizona Transportation Research Center
206 South 1 7th Avenue
Phoenix, Arizona 85007
Prepared tor:
Arizona Department of Transportation
206 South 17th Avenue
Phoenix, Arizona 85007
in cooperation with
U.S. Department of Transportation
Federal Highway AdrMstratDn
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 do not necessarily reflect
the official views or policies of the Arizona Department of
Transportation or the Federal Highway Administration. This
report does not constitute a standard, specification, or
regulation. Trade or manufacturers' names which may appear
herein are cited only because they are considered essential
to the objectives of the report. The U.S. Government and
The State of Arizona do not endorse products or manufacturers.
Technkal Report Documentation Page
I
4. Title and SubW
CHANNEL LINING WITH FIBER REINFORCED SHOTCRETE
advantage over plain shotcrete. Therefore no spec
17. Key W d
Discrete Synthetic Fiber, Shotcrete, Pneumatic,
Plastic Shrinkage Cracking, Drying Shrinkage
Cracking, Stmndary Terrrperature Reinforcemmt
1. Report No. 3. Redplent's Catabg No.
FH WA-A24902
5. Report Date
JULY, 1992
6. Perlonning C)rgan(zabion Code
7. Author
Dwight Metcalf, Doug Lattin, P.E.
9. Pwfomiq Organlzstkn Nmno and Addma
ARIZONA TRANSPORTATION RESEARCH CENTER
206 S. 17TH AVENUE, MAIL DROP Q75R
PHOENIX, ARIZONA 85007
12.Sponsorhg~UwmandAdbers
ARIZONA DEPARTMENT OF TRANSPORTATION
206 S. 17TH AVENUE
PHOENIX, ARIZONA 85007
. .
rcation was devekped as part of this
18. W M b h StaSment
2. ~ m m e nAtcw eskn No.
8. P mOrgeniz abion Report No.
lo. Work Unit No.
1~.contractw~rant~o.
1 3 . m of Report 4 Perbd Covered
FINAL, 1989-92
14. ~ponborlnAgg ency code
Document is available to the U.S.
public thrwgh the National
Technical Idonnation Service,
15. Supplementary NoW
Prepared in cooperation with the U.S. Department of Transportation, Federal Highway Administration
Prepared by: Dwight Metcalf Reviewed by: Larry A. Scofield
16. AbsWact
The Arizona Department of Transportation (ADOT) has used bur brands of discrete synthetic fibers
in a drainage outfall channel lining as part of constnrction project ACI-10-3(270). The use of the fibers was
intended to test the constnrctibility and pedmnce of kur wmmercialty available fibers. If the fibers had
proven effective, a generic specification for synthetic fiber reinforced shotcrete would have been developed.
The drainage outfall channel is 500 ft bng and has a 140 ft hydraulic perimeter. Each fiber was
placed in a 50 ft bng sectkn ot the 5 inch thii Yning. The consbuction pmes was documented wilh video
tape and still photography. Slump measurements went taken before and aMr addition 04 fibers. Compressive
strengl h (ASTM C-42), llexural kughness (ASTM GI 01 8), and percent pemres#e voids (ASTM C-642) testing
were conduded on samples ad from 2x3' panels. Four panels were fabrkxW during the construction ot each
of the test sections. Shortly after construction, visible plastic and drying shrinkage cracks were painted. Each
test section was subsquently photographed and the lineal feet of cracks was determined. Beam and core
samples were extracted from the channel lining after two years of service and compared with panel samples
taken at the time of constnrdion and stored for two years.
Analysis of variance canied out at the 5% Signdikance level indicates that the addlion of fibers had
no effect on compressive sbewh, flexural toughness, or percent permeable voids. The beam samples used in
the flexural toughness testing did nd indicate any flexural toughness beyond first crack. Crack surveys
conducted shortly after construction and again after two years of service indicate that the lining is performing
satisfactorily.
This projed was conducted to test the corrstrudibili and performance of synthetic fibers used ai
manufacturers recommended dosages (1.6 bs/yd3 for three of the fibers and 1.0 Ibslyd3 for the other fiber).
The test results indicate that at the levels of reinforcement used for this project the fibers provide no measurable
TABLE OF CONTENTS
INTRODUCTION ..............................................................................................................1.
Background .............................................................................................................1.. .
Problem Definition ...................................................................................................-..2.. .
Synthetic Fiber Reinforcing ......................................................................................... 2
OBneclwEs . ................................................................................................................-.5.. ...
APPROACH ...................................................................................................................6.. ....
Experimental Plan ...................................................................................................6.. .....
Material Test Plan ........................................................................................................ 8
PROTECT LOCATION AND DESCRIPTlON .................................................................1 0
CONSTRUCIION. ............................................................................................................1. 0
Phase 1 ....................................................................................................................1.0.. ..
Phase 2 ......................................................................................................................1 0
Construction Equipment ......................................................................................1.2.
Activities ..........................................................................................................1.5.. .
Test Section D .................................................................................................... 15
Test Section C ................................................................................................... 16
Test Section B ...................................................................................................1 6
Test Section A .................................................................................................... 16
Control Section .................................................................................................. 16
Flooding ................................................................................................................... 16
MATEEUAL TEST RESULTS ............................................................................................. 17
Unaged Samples .......................................................................................................... 17
Aged Samples. .........................................................................................................-.2...0
EVALUATION OF CRACKING IN TEST SECTIONS .....................................................2.1
Crack Mapping ..........................................................................................................2.1..
Crack Measurements ..................................................................................................2..6
CONCLUSIONS AND RECOMMENDATIONS .......................................
REFERENCES .............................................................................................................2... 8
APPENDIX A: SPECIAL PROVISIONS AND CHANGE ORDER ................................. A- l
APPENDIX B: WORKPLAN ......................................................................................B..-..1.
APPENDIX C: SHOTCRETE MIX DESIGN ...............................................................C..-. 1
APPENDIX D: SHOTCRETE PUMP TECHNICAL SPECIFICATIONS ......................... Dl
LIST OF FIGURES
1. GABION LINED CHANNEL .................................................................................... 1
2 . FIBERMESH MAGNIFIED 20 TIMES ........................................................................... 3
3 . FIBER-LOK MAGNIFIED 20 TIMES ............................................................................ 4
4 . FORTA-CR MAGNIFIED 20 TIMES .............................................................................. 4
5 . NURLON MAGNIFIED 20 TIMES ................................................................................. 5
6 . EXPERIMENTAL LAYOUT .......................................................................................... 7
7 . SLUMP TEST ...........................................................................................................8.. ...
8 . MOLDED CYLINDERS. ................................................................................................9.
9. SHOTCRETE TEST PANELS ........................................................................................9.
10 . WET CURING OF FIRST APPLICATION OF SHOTCRETE ...................................... 11
1 1 . SURPACE OF FIRST APPLICATION OF SHOTCRETE ............................................. 11
12 . SHOTCRETE PUMP .................................................................................................. 12
13. FX'ITINGS USED ON SHOTCRETE PUMP ............................................................... 13
14 . SHOTCRETE NOZZLE ............................................................................................1 3
15 . ADDITION OF FIBERS TO SHOTCRETE TRUCK MIXER ....................................... 14
16 . WASHING OF FIBERS INTO SHOTCRETE TRUCK MIXER ................................... 14
17 . BENCHES USED TO APPLY SHOTCRETE .............................................................. 15
18 . FLOOD FOUR DAYS AFTER SHOTCRETE COMPLETION ..................................... 17
19 . INITIAL CRACK EVALUATION: TEST SECTION A ...................... . ...................... 22
20 . INITIAL CRACK EVALUATION: TEST SECTION B ........................................... 2 2
21 . INITIAL CRACK EVALUATION: TEST SECTION C ............................................ 23
22 . INITIAL CRACK EVALUATION: TEST SECTION D ........................................... 2 3
23 . APPARENT INCIPIENT CRACKING: TEST SECTION A ......................................... 24
24 . APPARENT INCIPIENT CRACKING: TEST SECTION B ......................................... 24
25 . APPARENT INCIPIENT CRACKING: TEST SECTION C ....................................... 25
26 . APPARENT INCIPIENT CRACKING: TEST SECTION D ....................................... 2 5
LIST OF TABLES
1. FIBER IDENT'FICATION ......................................................................................3.. .
2 . SUMMARY OF CONCRETE BEAM TEST RESULTS ............................................... 18
3 . MOLDED CYLINDER COMPRESSIVE STRENGTH RESULTS ................................ 18
4. 28-DAY PANEL COMPRESSIVE STRENGTH TEST RESULTS .............................. 19
5. SLUMP TEST RESULTS ..........................................................................................2..0..
6 . SUMMARY OF AGED SHOTCRETE BEAM TEST RESULTS .................................. 20
7 . AGED PANEL COMPRESSIVE STRENGTH TEST RESULTS .................................. 20
8 . EXTRACTED BEAMS TEST RESULTSFROM CHANNEL LINING ......................... 21
9. EXTRACTED CORES TEST RESULTS ..............................................................2..1
10 . ACWAL AND APPARENT INCIPIENT CRACKING ............................................... 26
I I . CRACK WIDTHS .....................................................................................................2..6. .
REFERENCES
1. Ame,ican Society for Testing Materials, "Standard Specifications for Fiber Reinforced
Concrete ,md Shotcrete", ASTM C116-89, 1989.
2. Pananese, William C., 'F~ber Good for the Concrete Diet 7". Civil Engineering, May 1992.
3. Zellers, 6:obert C., "High Volume Applications of Collated Fibrillated Polypropylene Fiber"
Fiber Reinforced Cements and Concretes: Recent Developments 1989.
4. Neville, A.,U., bperties of Concrete, Longman Scientific and Tcxhical, 1981.
APPENDIX A: SPECIAL PROVISIONS AND CHANGE ORDER
ARIZONA DEPARTMENT OF TRANSPORTATION
ADVERT1 SEMENT FOR BIDS
BID OPENING: FRIDAY, JUNE 9, 1989 AT 11:OO A.M.
PROJECT NO: ACI10-3(270)
TRACS NO: lOMA 149 H 0128 05C
TERMINI : PHOENIX-CASA GRANDE HIGHWAY
LOCATION : East Tunnel Outfall Modification
ROUTE NO. DISTRICT ITEM NO.
1-10 1 463
The location and description of the proposed work and the
representative items and approximate quantities are as follows:
The proposed work is located in the City of Phoenix South of
University Drive, between 19th and 20th Streets. Major cross streets are
16th Street and University Drive, approximately one mile south of
Interstate 10 and the 16th Street Traffic Interchange. The work consists
of modifying the outfall channel and includes consolidating the dumped
riprap, removing debris from the surface of existing gabions and dumped
riprap and applying shotcrete to the bottom and sides of the existing
channel and additional project related work.
Pipe, Reinforced Concrete, 24" L.Ft. 120
Headwall Each 1
Concrete Curb, Precast (Roughness Control Device) Each 224
Shotcrete (First Application) Sq.Yd. 7,970
Shotcrete (Second Application) Sq.Yd. 10,450
Force Account Work (Channel Surface Preparation) L.Sum 1
Construction Survey and ~ayout L. Sum 1
The number of working days specified for the completion of the work
is -6 0 .
The Arizona Department of Transportation hereby notifies all
bidders that pursuant to this advertisement for bids, Disadvantaged
Business Enterprises will be afforded full opportunity to submit bids in
response to this solicitation and will not be discrimated against on the
grounds of race, color, sex, or national origin in consideration for an
award.
The minimum goals for participation by Disadvantaged Business
Enterprises in the work, as a percentage of the total amount bid, shall
be -0.
HNTB
02/03/89
REV: 05/0 3/89
A C I 10-3(270)
10 MA 149 H0128 05C
SPECIAL PROVISIONS
ARIZONA PR03ECT ACI 10-3(270)
10 MA 149 H0128 05C
EAST TUNNEL OUTFALL MODIFICATION
PROPOSED WORK:
The proposed work is located in the City of Phoenix south of
University Drive, between 19th and 20th Streets. Major cross
streets are 16th Street and University Drive, approximately one mile
south of Interstate 10 and the 16th Street Traffic Interchange. The
work consists of modifying the outfall channel and includes
consolidating the dumped riprap, removing debris from the surface of
existing gabions and dumped rip rap and applying shotcrete to the
bottom and sides of the existing channel and additional project
related work.
PROJECT DESIGNATION:
All references on the project plans to Project I 10-3(270) shall be
changed to read Project ACI 10-3(270).
Page 1 of 27
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ACI 10-3 (270
10 MA 149 H0128 05C
ITEM 9120001A - SHOTCRETE (First Application):
ITEM 91200018 - SHOTCRETE (Second Application):
Description:
Shotcrete shall conform to the requirements of Section 912 for the
wet mix process except as modified by these special provisions.
General :
Shotcrete shall be applied in two separate applications. The
purpose of the first application is to fill the voids between the
rocks in the gabions to a minimum depth of 9 inches and the voids in
the riprap at the bottom and ends of the channel to a minimum depth
of 18 inches. The second application shall have a minimum thickness
of 5 inches.
Materials:
Materials shall conform to the requirements of Subsection 912-2
except for the following:
Reinforcement:
Reinforcing shall be a collated fibrillated, twisted bundle,
polypropylene fibrous reinforcement and shall contain chemically and
alkali inert, virgin polypropylene.
The fibrous reinforcement shall have the following physical
characteristics:
Characteristic Requirement Test Method
Specific gravity: 0.91
Tensile strength: 70 ksi pinimum
Modulus of elasticity: 0 . 7 0 ~ 1 0 psi
ASTM D-792
ASTM D-1682
ASTM C-469
Fiber length: as recommended by the manufacturer.
Certificates of Compliance will be required in accordance with
Subsection 106.05.
Page 21 of 27
HNTB
02/03/59
REV: 05/03/89
ACI 10-3(270)
10 MA 149 ti0128 05C
Surface Sealant:
Surface sealant shall be a waterproofing material of the penetrating
type that contains no added chlorides or sodium compounds, is
organic, non-toxic, resists chemical attack and conforms to the
following:
*Ph sical P roperty Result -Test Method 1752 9 psi ASTM C-452
Tensile Strength 3322 16 psi @ 100% RH ASTM C-190
1182 6 psi @ 50% RH
Flexural Strength 472+ 24 psi ASTM C-580
* Permeability 2.63 x lo\-10 + 5%
CM/Sec (1 coat) CRD-48-7 3
* Tested at water heads of 4612 it. (200 psi! for surface water-proofing.
The contractor shall obtain from the manufacturer, for submittal to
the Engineer, SEM photographic proof showing penetration into a
substrate which has received application of the waterproofing
material.
Certificates of Compliance will be required in accordance with
Subsection 106.05.
Joint Sealant:
Joint sealant shall consist of styrene butadiene styrene black
polyer cross-linked with bitumen. It shall have an elongation
greater than 2000 percent and retain flexibility at temperatures
down to -25 degrees C. The joint sealant shall be resistant against
rodents, roots, salt solutions, diluted acids, and shall be stable
against aggressive water.
-The joint sealant shall conform to the following:
Ph sical Pro eft Result
Viscositv approximate
Test Method
AsTMDZ170
viscosity @ 160' C. 3000 approximate
Tensile strength and
elongation (25O C, 50 cm/min
elongation speed)
Modulus 300% - K~/c~: 0.85 .04 ASTM D2523
Modulus 500% - Kp/Cm 1-32 .07
Puncture elongation - percept 22002 110 ASTM Dl708
Puncture resistance - Kp/Cm 10.5+ 0.5
Olinsis resistance 3 day, SO0 C
with B-80 used as impregnating
fluid mm 0.35 0.015 ASTM Dl370
Stain test, 18 hrs, 100° C 6-7 ASTM Dl328
Page 22 of 27
HNTB
02/03/89
REV: 05/03/89
ACI 10-3(270)
10 HA 149 H0128 OSC
The contractor shall furnish the Engineer with three sample strips
of cured joint sealant material 1"x6"~1/2~'t hick. Strips shall be
able to be extended 400 percent by hand without fracturing. Follow
extenstion, the material shall have the recovery and memory to
return to the original configuration within 5 minutes.
Certificates of Compliance will be required in accordance with
Subsection 106.05.
Construction Requirements:
Construction requirements shall conform to the requirements of
Subsection 912-3 except for the following:
First Application:
The first application of shotcrete shall be premixed non-reinforced
mortar and shall consist of not less than 6.0 sacks of portland
cement per cubic yard, fine aggregate and water mixed to a desired
consistency, generally to a slump that will provide the penetrations
specified above for gahions and riprap.
The material may be mixed at a central mixing plant or at the
project site. If mixing is done at the project site, the mixer
shall be capable of thoroughly mixing the specified materials in
sufficient quantity to maintain continuous placing of the mortar.
Second Application:
The second application of shotcrete shall not be placed until the
entire first application of shotcrete has been completed.
The contractor shall determine the mix proportions and shall furnish
concrete for pneumatic placement which contains a minimum of 7 sacks,
of portland cement per cubic yard of concrete and which attains a
minimum 28-day compressive strength of 3,000 psi. fine aggregate
and coarse aggregate shall conform to the requirements of Subsectioa
912-2.02. The total mix shall contain, by weight, 15 to 20 percent
coarse aggregate.
If ready-mixed concrete is used, it shall conform to the
requirements of ASTM C 94.
Fibrous reinforcement shall be added to the mix for the second
application at the time of batching in an amount of 1.6 + Ibs. per
cubic yard of concrete as directed by the Engineer anci.~y a method
recommended by the manufacturer to assure a uniform and complete
dispersion of the fibers. The contractor shall provide the services
of a qualified technical representative of the manufacturer to
assist the contractor in proper batching and mixing of materials.
Page 23 of 27
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A C I 10-3(270)
10 HA 149 H0128 05C
In no case shall the slump be greater than four inches for the
second application. Slump will be measured prior to the
introduction of the fiber into the concrete mix.
Fibrous reinforced concrete shall be placed in accordance with the
requirements of Section 912 and as directed by the Engineer. Tined
rakes will not be allowed as a means of moving the fibrous concrete.
The ready mix discharge chute shall be raised approximately 12
inches above the pump grate or screen as directed by the Engineer at
the time of discharging concrete.
Testing:
First Application:
The contractor shall first apply the shotcrete to the gabions and
riprap at the south end of the channel as a test area at an exact
location designated by the Engineer. The ~ngineer will then examine
the test area to determine that the required penetration has been
attained. If the required penetration has not been attained then
the Engineer will direct the contractor to adjust the mix and repeat
the test.
Second Application:
Tests to determine the physical quality of the shotcrete for the
second application will be performed by the Engineer periodically
during the work as required. Test panels and cores shall be
prepared by the contractor.
Test panels at least 12 inches square and as thick as the structure
being constructed shall be prepared by yunnincj shotcrete mix on a
piece of plywood form. Cores shall be taken from the panels for
compressive strength tests and for visual examination. Cores shall
have a minimum diameter of three inches and a length to diameter
ratio of at least one. Test panels shall be cured in the same
manner as the production work.
Cares shall be obtained and tested in accordance with the
requirements of AASHTO T 24. The cores will be tested for a minimum
compressive strength of 3,000 psi at 28 days.
The cut surfaces of the test specimens will be carefully examined
for soundness and uniformity of the material and shall be free from
laminations and sand pockets.
Construction Joints:
Construction joints shall be in accordance with the details shown on
the project plans and these special provisions.
Page 24 of 27
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REV : 0 5/0 3/8 9
ACI 10-3(270)
10 MA 149 HOl28 05C
A construction joint shall be placed at the end of each days
operations or every 200 f e e t , whichever is Less. The contractor may
either construct transverse construction joints that are continuous
and coincidental across the entire section of channel or he may
construct longitudinal construction joints on each of the sloped
sides of the channel a minimum of 3 feet vertically from the bottom
of ?.he channel. If the longitudinal joints are constructed, the
location of transverse joints do not have to coincide; however, the
longitudinal joints shall be continuous from beginning to end of the
channel.
The contractor shall submit a written plan to the Engineer for
approval showing the method he plans to use in determining the
location of construction joints. Once the plan is approved, the
contractor shall not deviate from the plan unless approval in
writing is obtained from the Engineer.
The surface sealant and the joint sealant shall be prepared and
applied at a time and in a manner recommended by the manufacturer
and as approved by the Engineer. The contractor shall provide the
services of a qualified technical representative of the manufacturer
during the process of sealing joints.
The concrete (shotcrete) surface shall be clean, structurally sound
and free of all contaminates including curing compounds, form
release agents, dust, dirt and oil coatings just prior to applying
the surface sealant and the joint sealant.
Curing:
The surface of the first shotcrete application shall be kept
continuously moist immediately after placement by means of either a
water spray or fog system for a minimum of seven days. The use of
membrane forming curing compound or sheeting will not be allowed.
The surface of the second application of shotcrete shall be kept
continuously moist for at least seven days, beginning immediately
after placement by means of either a water spray or fog system
capable of being applied continuously or by liquid membrane-forming
compound or by polyethylene sheeting conforming to the requirements
specified in ASTM C 171.
If polyethylene sheeting is used, it shall be white opaque and
adjoining sheets shall overlap at least 12 inches and the laps
secured to provide an airtight and windproof joint. If liquid
membrane-forming compound is used it shall be Type I conforming to
the requirements of ASTM C 309 and the application rate shall be 100
square feet per gallon.
Page 25 of 27
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REV: 05/03/89
ACI 10-3(270)
10 MA 149 H0128 OSC
Method of Measurement and Basis of Payment:
The method of measurement and the basis of payment will be in
accordance with Subsections 912-4 and 912-5 except that the surface
area for measurement will be the separate area of the first and
second applications and the contract price shall include the cost of
fibrous reinforcement and having a manufacturer's representative
present during batching and applying the second application of
shotcrete and during the sealing of construction joints.
ITEM 9240010 - FORCE ACCOUNT WORK (Channel Surface Preparation):
The work under this item consists of preparing the surface of the
existing outfall channel and riverbed rip-rap for the application of
shotcrete and includes, but is not limited to, removing mud and
debris, resetting gabions, consolidating riprap and removing
projecting portions of rock to obtain a reasonably uniform surface.
Payment for channel surface preparation will be made on a Force
Account Basis in accordance with Subsection 109.04.
GEOTECHNICAL INVESTIGATION REPORT:
A copy of a geotechnical investigation report is available for
prospective bidders to review at Contracts and Specifications
Services, 1651 West Jackson Street, Room 121-F, Phoenix.
Page 26 of 27
PROJECT NO. ACI 10-3(270)
10 MA 149 H0128 O5C
BIDDING SCHEDULE
1
2
3
7
5
6
7
ITEM NO.
2060001
2070001
4-
601.m
9010001
9080114
15
16
17
ITEM DESCRIPTION
SH(rrCRFTE: 0VE.T MISTIbG
FURNISH W'lER SUPPLY
DUST PALLIATIVE
PIPE, REINFORCED CONCRETE, CLASS V, 24"
Hf3UXAK.L (C14.30) (DOUBLE)
MOBILIZATION
CONCRETE CURB, PRECAST (Roughness Control Device')
"
A
UNIT
OUTFALL
L.SUM
M-GU.
L.FT.
EACH
L.SUM
EACH
QUANTITY
CHANNEL
1
500
120
1
1
224
UNIT PRICE
8.00
AMOUMT
4,000.00
I
ARIZONA DEPARTMENT OF TRANSPORTATION PAGE -/ O F -j e
DIVISION OF HIGHWAYS
SUPPLEMENTAL AGREEMENT
Change Order
Force Account Work Request
H.PT * - 7 7 - - - 3 - Project No. -@pfm12805C ' Fund Code Y/ 1 7 &- - -... .-% .. NO. 1 ' . . t-
Name of Project East Tunnel O u t f all Modificat i~~,~,,,~,,, L-.R. R.. Hensler.__Inc-r 'G
DESCRIPTION AND REASON
REDUEST : Tcl c r e a t e I t e r n No. 31?0002R, Shotcr-et.e (F i bey-
Reinf or-ced) ( S p e c i a l ) , as a basis of ~avrnerrt f clr c o n s t r u c t ~ Y I D
f o c r r d i f f ererlt t y p e s c ~ f f i br-ous r e i rlf o r c e d s h u t cret e i rr
accctr-dance with t h e a t t a c h e d olarl and specif i c a t iclrrs
( R t t a c h r n e n t s 1 R 2 ) . R d d i t i o n a 3 l y , a 259x2eJ' secticlvl of steel
t - e i n f or-ced s h o t c r e t e 1 irlirtg w i 11 t ~ e c o n s t r c ~ c t e d i n l ie1.r uf
f i b r o u s r e i r l f c t r r e d s h o t crete i n a c c c ~ r d a r r c e w i t h a t t a c h e d plan
a n d s ~ e cfi i cat i clrls ( F l t t a c hme n t s 1 8 2). M a t e r i a 1 test irrg w i 1 l
be perforrned as clcrt 1 i r ~ e d i n R t t a c h t n e r ~ t 3. e
REQSON r T h i s chanpe w a s reqt-rested by t h e RZ. T r a n s . R e s e a r c h Cerrter t c l
asses5 t h e p e r f c ~ r r f l a r ~ cce~ fr nul t i p l e f i b e r t y p e s , d e v e l c t ~ ea
p e r ~ e r i c ccwltract s p e c i f i c a t ic~rl fclr s y r r t h e t ic f i b e r
rei rlf ctrcerflev~t arrd d e t errni ne r o e t hods f o r d e t e r r n i r ~ i r s g c c c n t r a c t
cornr3l i arrce curl f u t u r e p r c l ~ e c t s .
CDST :
-X tern No. Desct-1 o t I c1r1 B-rlt. i t v U1~i-t-1 >r cg. Firn>yrl_t:
3210 ilOZR Shot crete +1 L. SI-rm $5,€ 50.00 +B5, 65~:)Oi.l
(Fi b e r Reinf orced)
"cia",
G DEC 22'89
TOTAL DIFFERENCE
CIWICOUNTY ENGR
PLUS
$ 5,650.00 '
For Valuable Consldcrallon, It Is mulually agrted that the matter detalled above shall be done and payment nude as shown henln lor a
Supplemental Agmrment Change Order. all In accordance wllh ?he tennr ol the contracl For wok k i n g pcdmed ar a Supplemental
Agreement Force Account Request, ~IMpI ayment shall be made Ihe Standard Speclllutlonr and Its rupplemcntr upon
cornpletlon of u l d work.
MINUS
$
1 f
Approved for R. R. Hensler , Inc.
CONTRACTOR
I
BY
.... .: " . : --- r':i;,;2;-:.1 ,-;!. !<- -,-, ;
CHEcKEo /2-/U-89
ARIZONA DEPARTMENT OF TRANSPORTATION
CHANGE ORDER OR FORCE ACCOUNT WORK REPORT
Chmge Older -y~~---,---??,
To accompany 1 ' ha].^^ wi: ACI-10-3 ( 2 7 ~ j z .CO DE
4147 '
\ FD[dl)(W)L#W)C04#rt j
Addltlonal pertinent lnfonnation not contained In tha transmitted document. R E C E I E
U.N.T.B.
Doug L a t t i n , Fl r i z o r l a Tr a n s ~ c ~ r t a t i o rRte search Se c t i o r~. reauested t h i s
chwrqe order CTI July 15. 1383. @
Dar, Lance, F \ s s is t ant Dl s t r ic t J E r r q i r~eer - , bras cr i r~atc t ed C I ~ I J u l ! / 31, 1963
and concurred. .
P r i c l r aporc*val w a s g r ' a r r t e d at the project level clr~ Flugust 2. 1363..
Dlrcussed With Federal Highway Admlnlrlratlon. Date
F . H . W . A . A R E A E N C R , Explain Thelr Comlnents.
P h i 1 E l e -v 1 .- Rrea E n o i r r e e r . F. H. W. Q. . w a s cor~tactedc 8r1 JLI?Y3 1. 1383 artd
gave his terlbative
~e ReS- m u - ' Date
I /
Dlrtrlct En~lneer'r Commnnts:
I
ENGINEER ROADSIDE DEVELOPMENT
CHIEF RIGHT OF WAY AGENT
RIGHT OF WAY APPRAISALS 1 1
RIGHT OF WAY PLANS
LEGAL
ASST. DIR. ADMIN. SERV.
*Fully explain on separate sheet. /(original copy only to be attached to Change Order, F.A.W.R., or F ~ s c aVl ariance Report.
Use additional sheets if necessary.)
7.10-0701 R l l l l U A-12
91ZONA DEPARTMENT OF TRANSPORT 10N
OFFICE MEMO
August 2 , 1989
TO: DANPOWELL
" D i s t r i c t Engineer
FROM: MICHAEL J. HARRINGTON
Resident Engineer
RE: ACI 10-3 (270)
East Tunnel O u t f a l l Modification
Change Order No. 1 Authorization
This confirms t h a t authorization was granted by the Resident Engineer for
Change Order No. 1 to reimburse the Contractor for a d d i t i o n a l work t o be
performed on the East Tunnel O u t f a l l Modification. The performance of
m u l t i p l e f i b e r types w i l l be assessed SQ t h a t a g e n e r i c c o n t r a c t s p e c i f i -
cation f o r s y n t h e t i c f i b e r s and a method f o r e s t a b l i s h i n g compliance on
f u t u r e p r o j e c t s can Lie developed. Four 50' t e s t s e c t i o n s w i l l be con-s
t r u c t e d with four d i f f e r e n t types of f i b e r . In a d d i t i o n , a 20' x 20'
s e c t i o n w i l l be reinforced ~ $ t h reinforcing s t e e l and t h e s h o t c r e t e i n
t h i s control s e c t i o n w i l l n o t contain any fibrous reinforcement.
The t o t a l cost of t h i s change order w i l l be $5,600.00.
Doug L a t t i n of Arizona Transportation Research Section requested t h i s change
order on July 15, 1989.
Dan Lance, Assistant D i s t r i c t I Engineer was contacted on July 31, 1989
and concurred.
P h i l Bleyl, Area Engineer f o r the FHWA was contacr on July 31, 1989 and
gave h i s t e n t a t i v e approval.
Approved :
ONE ENGR. , .
MJH: SAX : dm
xc: Chief Deputy S t a t e Engineer
Highmy Operations DATE RECEIVED
F i e l d Reports Services
Larry Scofield (Az. Trans. Research Center) P.U G 2 1. 1989
FHWA
P r o j e c t F i l e (a610 CO #1) Field Reports Branch
FIR1 ZO' DEPRRTMENT OF TRFSNSPDRTFI' N
RES , SNT ENOINEER9 S COST RNFILYb-LI
RND ADDITIONAL JUSTIFICQTION
[ X I Change Order No. 1 ' P r o j e c t No. RCI-10-3 (270) '
C 3 Force Flccount Work Request No. Fund Code
Resident Eng frreerl s indrperldent cast OP price analysisr
1 ) -RE-D.U-CE. D- - R-ER- D. Y- .M. I -X LOR-D--S :
I n c ~ r d e r tcu have a gclod m i x rrith t h e f i b e r added cur~ s i t e . Ready rnix l o a d s
had t o be reduced frorfl 9 cys. to 7 cys.
The c o n t r a c t o r has beer1 o r d e r i n g 3 c y s . p e r t r u c k f c ~ rt h e f ir-st and s e c o n d
appl i c a t iclr~ of s h o t c r e t e . Theref ore, add it i o n a l t r i p s w i 11 have to be
rnade t o s e c u r e t h e sarfle p r o d u c t i o n r a t e . On t h e a v e r a g e t h e cclrltractctr
purnps 1 l C 1 cyc. p e r day. T h e r let i r ~ c r e a s ei n t r i p s w i l l be:
1 10 - 1-13 12 - 16 4 a d d i t iclrral t r i p s
3 7
No a d d i t i o n a l t r u c k s w i l l be ir~vchlved. However, f o u r e x t r a batches a r e
needed. C a l r n a t quoted an e x t r a 63.50 per cubic yard fclr t h e e x t r a b a t c h e s
and the t r i p s .
(447 + 10% mixer w a s t e ) x 63.50 = $1.72Z.OC) J
FIBER PLRCEMEE
Twct pclrflps w i l l be u t i l i z e d , and two l a b o r e r s w i l l be needed t o p l a c e the
fiber i r ~t h e rnixe r t r u c k s .
L a bur = 311.OO/Hr
S u r c h a r a e = E O X x S 1 1 . 0 0 = 3 2 . 2 O / H r
I nscrrance = 15% x 8 1 1 . 0 0 = 3 1.65/!ir
F r i n g e s --
TOTRL
Fo~.rr days w i 11 be needed tl=l p l a c e t h e test sect iclrts.
48 Hc~urs x $17.62/Hr x 2 L a b o r e r s = 31,631,5? J
S t e e l : 400 F t x 0.668 Lb/Ft x 0.20 %/Lb = 3 53.44
L a bum-- = 315. O / H r
S u r c h a r g e = 2OSC x $15. C)O = $ 3. C)O/Hr
I nsl.\rance = 13% x 815.00 = r6 2.25/Hr
F r i n g e s - $ 2.77 /"r
TOTRL $23.02
23.02 x 3 H r s = $63.06
Ft -~rnisha r ~ dp l a c e r e b a r = 363.06 + 5553.44 = Bl Z E . 5 0 - /
A-14
RRIZOIn,DEPRRTMENT OF TRRNSPORTRT W
COST RNRLYSIS
Qddition of f i b e r on the p r o j e c t s i t e , a d j u s t m e n t of slump and testing and
reduced miner lards will result i n rcduced pumping efficiency.
Loss o f eff i c i e r ~ c y = 2 cy r e d u c t i o n i n r n i x e r l c a ? = 22%
9 cy of norm~l mixer l o a d s
T h i s lctsc, of e f f i c i e r l c y wil 1 b e rnade LIP by w c ~ r k i r ~tgw cl a d d i t i o n a l h o u r s
e a c h day t o f i n i s h each test section.
Fl~trernarc = $16. / h r x 1 For-eman
Labclr = $ l l . / h r x 6 L a b o r e r s
NCIZ zelman .e sl5. / h r x 2 Nclzzelrner~
Purnp Operat u r = 313. / h r x 2 Operatcws
S u b t o t a l
T o t a l Labor Cost
E) €QUI PMENT :
Tow pickup 33. / h r
Cancret e Purn;, 135 c y / h r ) $45. / h r
Tot a1 Equi prnerlt Cclst 654. /hv
I r l c r e a s e d purnair~g c o s t = (54.00+216.77) /hr x E h r / d a y x 4 d a y s
5 ) CONSTRUCTION 3 O I T S :
Nc< ext ra j o i n t s w l l l be n e e d e d , 5ir1ce e a c h c c ~ r r t r olle d sect ion is e q u a l t o
a d a y ' s p r c l d u c t i o r ~ and w i l l be dorle i n the sarne day.
€ ) MRTER l RL TEST X NG :
S i x t e e n test panels a t least 3 feet by E f e e t and as t h i c k as t h e
strl-tct u r e b e i n g c o n s t r l - { c t e d s h a l l be p r e p a r e d . The s h c l t c r e t e o n the
p a r ~ e l s s h a l l be sawcut and cored, scl t h a t 2 bearns arlcl 4 c o r e s car1 be
t e s t e d f rclrtl each panel.
I
a) Panels:
1. Materials - 6100.00
2. S h c t t c r e t e 2 cy x $55./cy = 3110.00
1 Labor
Labclr = % l l . / h r
S u r c h a r g e ?<I% x $11. / h r = $ 1 . 6 5 / h r
I nscrrarlce 15% n B l l . / h r = t E . 2 5 / h r
F r i n ~ e s $E.77/hr x 1 Labcar = hZ3.-7Z!-h,r
Three h o u r s w i 1 1 be needed to cclrlst rcrct t h e p a v ~ e l s
6 1 7 , 6 2 / h r x 3 h r s = $52.86
T m t a l c ~ z l s t of p a r ~ e l s - $52. 66 + $1 11:). h r + Sl(:)il. = $262. BG
t) Cclrir~q = 64 c c t r e s x $ l O . / c o ~ e = 664C1.00
C) Saw i r ~ g = 32 bearns x 6 f t / bearn x $2.00 f t = g.,$64 . i)(;!
T o t a l cctst o f Material T e s t i r ~ c j 31,286. BE, J
7) FIBER: .n
The Depart rnerlt w i 11 s u p p l y t h e f i bey f car t h r e e of t h e test sect i o n s .
Cal rnat w i 1 l c r e d i t t h e cclrltractur 36. (5(:)/cy f c t r n c ~ ta dd i r ~ gt h e f i berrflesh t c l
the c o n c r e t e used i n t h e t h r e e test sections. The f o u r t h sect ictn w i l l
have f i b e r r n e s h i r ~i t , e x c e p t t h a t i t w i l l be a d d e d clr~ t h e j o b s i t e .
(357 cy + if:)% mixer waste) x $6. 0 i r = $2, 924. OC)
) R e d u c ~ d ready r l i i x 1 clad=
2 F i b e r la cement
3) F u r n i s h and place r e b a r
4 ) Operat ion
5 1 Eonst rctct i or1 J mint 5
6) Material t e s t i n g
S o t a 1 cost - 86,383. 04 x 15% o v e r h e a d a r ~ d p r o f i t = 88,037.40 /'
+Fi ber-1 ock, Nurlclr~ a r ~ d Fclrta f i bet-s w i 1 l be dclnat ed t o the Depart rnerlt by
the rnartuf a c t u r e r s .
.S_U?IMQRY OF CREDITS:
7 ) F i b e r 62,2E4.06
T o t a l cost f o r Change o r d e r No. 1 $8,037.34 - $2,224.00 =
+*5.el3.33 /"
PS: The c o n t r a c t o r 1 s ccl s t a r ~ a l y s i sd i d r~ct t i n c l u d e m a t e r i a l t e s t i n g ,
however, it i r ~ c l u d e d a cclst for- added j o i n t s . The Departrner~t
r ~ e g uita t e d wi t h t h e c c l n t r a c t o r t c ~d e d u c t t h e c o s t clf t h e c o n s t r u c t i c ~ n
j c l i r l t s ar~d ta deduct t h e c o s t of t h e f ibermesh for- t h r e e s e c t i c l r ~ s ctr~ly
i n s t e a d o f f 01-rr. T h e r ~ i a r ~ u f aucrte r of f i berrnesh ref us ed t o d c l r~a t et h e
f i b e r fclr test irlg purpclses. T h e r e f o r e , t h e Departrner~t deducted
83,242.84 f rorn t h e c a n t r a c t o r ' c t c l t a l cctst f cur t h e e x t r a jclint s and
added 8726.00 fclr the f iberrnech i n t h e f o r t h s e c t ion.
Th e c c ~ r l t r a c t c ~arq r e e d t a perfctrrn t h e wctrk f o r 35, 650. OU.4 4--
T h i s p r i c e is w i t h i n c ~ r ~pee r c e r ~ to f t h e Depa r tment s Cctst F l r ~ a l y s i s ,
t h e r e f o r e , i t is recc~rnrner~detdo a c ~ t h o r i n et h e work r e q u e s t e d i n Change
Order No. 1.
(Or-iginal cctpy t o be a t t a c h e d t o C. 0. or F. F1. W. R. fo!- t r a r ~ s r n i t t a l t o F i e l d
Reparts Branch only)
R. R. HENSLER. INC.
Mining Conmrcron Courruch
I US -ST MNL- DNVE
RYKr*x*RI-m5Os4
(047.) M7-,654
July 24, 1989
Arizona Department of Transportation
2015 E. Jefferson
Phoenix, AZ 85034
Atten: Mr. Mike Harrington
Resident Engineer
Subject: ADOT P r o j e c t ACI-10-3(270)
(H012805L)
Change Order No. 1 - Fiber
Gentlemen:
We have made t h e following a n a l y s i s of increased cost t o preform
the work as outlined i n your request. It is our understanding
the experimental f i b e r s w i l l be added by us on the j o b s i t e .
Added cost:
1. Increase i n mixer cycle time
2. Reducing mixer loads from 11 cu yds t o 7 cu yds t o f a c i l i t a t e
j o b s i t e mixing
3. Labor and scaffolding to add f i b e r
4. Increased pumping c o s t s
5. Cost of furnishing and placing reinforcing s t e e l f o r 20 f t .
by 20 f t . t e s t s e c t i o n
6. Increase estimated construction j o i n t by 180 l i n . f e e t
Cost Analysis:
1. Increased cycle time
a. Spot mixer a t f i b e r loading platform and add f i b e r t o
load -- 10 minutes
Mix i n f i b e r - 10 minutes
Total increased time per 7 cy load - 20 minutes
2. Reduced readymix loads from 11 cu yds t o 7 cu yds - 64%
reduction. This w i l l r e q u i r e approximately 63 a d d i t i o n a l
mixer t r i p s .
Arizona Department of Transportation
July 24, 1989
Page 2
Calmat has quoted an a d d i t i o n a l $3.25 per cubic yard to t h e j r
o r i g i n a l quote without f i b e r f o r readymix f o r Item 9120001B
s h o t c r e t e (second a p p l i c a t i o n ) .
q+' 7 -6fSr4-cubic ard + 10% mixer l o s s and waste =
&,+ I1 5% overhead & p r o f i t = cy ., $ /838.86
Calmat f i b e r c r e d i t $6.00 per c ~ i b i c yard
/ I . O O 2o%+lS'O/,
3. Labor - 2 men a t $ ~ 0 ; - 5 8 ' 7 - ~ 8l afb o r burden + 2.77 f r i n g e s
per hour. Estimated 6 - 8 hour days t o add f i b e r s ,
erzm dismantle s c a f f o l d f o r 2 men.
48 hours x 2 x 33;43 = $ .fij24r38 / 6 P L r Z
Plus 15% = 1%. L3 -22939 Z 53.73
Scaffold r e n t , d e l i v e r y & pickup o
c.____
Total
4. Increased pumping c o s t s :
Estimate l o s s of e f f i c i e n c y due t o t e s t i n g , spoting mixer,
a d j u s t i n g f o r charging f i b e r e t c . 2 hours per day f o r four
days equals 8 hours a d d i t i o n a l time.
Crew Cost:
//ber~oreman Q 16.00 per ?ouro= $ e&B /6.0a
2 - Nozzelmen @ $ff5i.f %P hour! 34.+ -p -3a.o~
2 - ELixer men @ $& per hour - *- . 2 d . 0 0
6 X- Laborers @ M per hour = -e3+ 66 ,oo
I / , 00
3/6-77 +~,+~2/6.77
$H6+9-+ 15% overhead & p r o f i t =
Total labor c o s t per hour $
E uipment:
I$ Foreman Pickup @ 8.64
1 Pump tow v e h i c l e @ 8.64
1 Concrete Pump, i n c . hose, nozzles e t c .
1 Air compressor 160 cfm
Hour1 y Equi pment Cost $ J;IL;42- 6 /, 53
Arizona Department of Transportation
July 24, 1989
Page 3
Tota pump crew c o s t per hour d $
x pump crews =
-Mk#.r-.
$ ++Hfi 3/0,82
x 8 hour s = V & ~ X~ h./e%&4
Increased pumping cost $ 3 + ~ & 2 ~ ~ 6 . ~ - 6
5. Furnish and place rebar on 12" C.C.E.V. i n 20' x 20' t e s t
s e c t i o n 4 fd&+?y. 6 , L L g /b/Ff X 0.~0//6.
-53Mr rebar F.O.B. j o b s i t e @ $120.00 + $ 33&;66- 3-3Y7'
Estimated c h a i r s & t -H+M
X hour i r o n worker $
p!&x x 3 L C.- #ZZ= '76.05
+ 15-2
/ 27% O/# --
$
6.
//,OfJ +z@k + l5-X
$ *+'6z u, 2 6 -
$ 6 0 ~ 7 8
/ / S o 0
+
1s. 4 Z$~Y&$
1/;7/7.8 8
Summary of a d d i t i o n a l c o s t f o r change order 8 1
I. Additional readymix c o s t -'"'..'",~38-95 '
2 . Ad d i t i o n a l c o s t t o add f i b e r 4~I %3. -€+ & ~ ? % - . . ~
3. Fiber c r e d i t from Calmat ar $6.00 per
cubic yard times 501 cubic yards ( 3 , 0 0 6 . 0 0 ) % , ~ 2 ~ : 0 0 )
4. Increased pumping c o s t 42 , ,n17 8 +. -&,4 L 8 6.56
5. Rebar c o s t . . 53832- ~ / C B . Y L
fl&fer ;-[ TC ~9:- i ,-,I I
1 *-. p a 7 % P ~IP~, ) a 4 a %7~9 . PR
c <-*tt)
Total added c o s t f o r C.O. C 1 $ d 7 k d F
Any c o s t incurred by delays during t h e t e s t i n g t h a t a r e not the
f a u l t of the c o n t r a c t o r w i l l be payed f o r as provided under
Section 109.04 Extra and Force Account.
We are concerned with both 90 minute time l i m i t and the temp-e
r a t u r e requirements f o r t h e readymix operation with the f i b e r
being added i n the f i e l d .
c--f~~L.ff-l q~r epe d t o
Arizona Department of T r a n s p o r t a t i o n
July 24, 1989
Page 4
It has been agreed t h a t t h e slump tests p r i o r t o adding t h e f i b e r
t o t h e mix during t h e r e s e a r c h period will f u r n i s h ADOT t h e i r
required data.
We r e q u e s t a two day time e x t e n t i o n f o r Change Order # 1.
S i n c e r e l y ,
R. R. Hensler, I n c .
Manager of Construction
APPENDIX B: WORKPLAN
ARIZONA DEPARTMENT OF TRANSPORTATION
HIGHWAYS DIVISION
206 South Seventeenth Avenue Phoenix. Ar~zona 85007
ROSE MOFFORD
Governor
CHARLES L MILLER
D~recror
THOMAS A BRYANT.II
Slate Enp~ncrr
ARIZONA TRANSPORTATION RESEARCH CENTER
Au y t 23 ,1989
Ed Wueste
Division Admhitrator
Federal Highway Administration
234 N. Central Avc., Suite 330
Phoeniw. Arizona 85004
Attn: Natc Banks
Dear Sir:
Tbt ATRC is currently documenting the construction of experimental project ,428902, Channel
Lining Wth Sy~tfhericF iber Reinfozed Sholcrerc. ATRC parlidpation was solicited by the FHWA in
early 1989 at which time the project had already bccn desipcd by a consultant using only one fiber
type. In July tbe ATRC initiated a change order on this project so that three other fiber types would be
included and a comparison muld be made.
Enclosed for your use is a copy of thc experimtntal project workplan which has been followed
thu far along with an iniLial FHWA form 1461 for each proprietary producl (A-D). Thc construction
report wiU follow within 120 days. Quesrions regarding project specifics should be addressed to Doug
Laxin of my staff.
Sincerely,
Frank R. ~ c ~ u ~ a ~ h
Assistant State Engineer
Il
Research Scclion
DJL
Enc. AZ8902 Detailed Workplan
Form 1461 for AZ-8902(A-D)
nlGHw&vS AERONAUTICES . M(jTOR VEHICLE PUSLIC TRANSIT ADLI INISTRATIVE SERVICES TR~NSPDRTATIONP ~ a N N ' N G
ARIZONA TRANSPORTATlON RESEARCH CENTER
EXPERIMENTAL PROJECTS PROGRAM
AZ-8902 DETAILED WOHKPLAN
CHANNEL LINING WITH SYNTHETIC
FIBER REINFORCED SHOTCRETE
I. PROBLEM STATEMENT
Drainage fsclltties are essential components of a highway system. The current and
forthcoming quantlty of new highway construction in Arizona motivated ADOT to publish a repon
in February of 1989 titled Channel Lining Design Guidelines. The conclusions of this report focus
on the use of welded wire fabric (WWF) or other secondary steel reinforcement in concrete
channel linings. Reinforcement of this nature is not expected to prevent cracking in a concrete
channel lining but is expected to hold cracks together once they are formed.
Shotcrete is concrete that is placed by projection onto a surface at high velocity. Channel
lining is one activity in which sholcrete reinforced exclusively wtth discontinuous discrete synthetic
fibers may have application. In such a situation the fiber would be used lo reduce formation of
early plastic shrinkage Cracks. Inclusion of fibers in the concrete mix can also result in a material
with increased toughness, lower permeability, higher flexural and compressive srrength, and
greater abrasion and fatigue resistance. The degree and manner in which these malerial
properties are affected depends upon the Type, length, strength, configuralion, and quantiry of the
fiber incorporated into the concrete mix.
In order to gain fmure consideration, synthetic fiber reinforced shotcrete linings must be
capable of controlling all cracking equal to or better Than channel linings with conventional
secondary steel reinforcemenr. Any claimed material property improvemenls must be confirmed
and not negated by excessive material and labor costs. Funhermore, the f i ~ e r re~ntorced
shorcrele musi nor present any fiber related consiruction problems.
11. OBJECTIVES
The primary objective of this project is to develop a generic specification for synthetic fibers
used in shotcrete and to es;ablish a resting program for verifying compliance with this
speciiication. Preliminary material and construction speciiications will be tested on ADOT project
AC1-10-3(270). This project involves moddying the East Papago Tunnel Oulfall channel by
applying a 5' thick fiber reinforced shotcrete lining. The channel ts approximalely 500' long wilh 2
130' cross section perimeter. four 50' test sections will be constructed using four difterenl fiber
brands. The fibers used will be FIBERMESH, FIBER-LOY FOATA, and NURLON as shown on me
anached Figure 1. An additional small control section will be included using a conventional steel
reinforced lining.
The variation between mmsured material propenies of shotcrete using different fiber types
and configurarions will be analyzed and compared with the control shotcrete. Material properties
to be measured are the slump of a given concrete mix betore and aher rhe addition of fibers. the 28
day compressive strength of the same mix with and without fibers, and the compressive strength.
flexural toughness, and percent perrnesble voids of beam and core samples enracled from
shotcrete panels.
Assessment of construction diflerences between dfflerenf fibers is another main objective.
Reporting will tocus on the abllny to place the different lypes of fiber on the channel without fiber
related constmction problems such as improper mixing, fiber balling, or plugging of the shotcrete
P""'P.
Earty field evaluations wlll be performed to determine H fiber reinforced shotcrete does in tact
minimize early plastic shrinkage cracking. The ditferent fiber materials and fiber geometries are
included in this project lo determine H these variables affect the ability ol a fiber to mltigate this
type of cracking. Funhermore, in the event that cracking does occur due 10 early plastic shrinkage
or any other cracking mechanism, the fibers wlll be expecled to inhibit further crack propagation.
The relative ablllty of dlnerent fibers lo achieve this goal wlll be substantialed by flexural toughness
tests and by detailed field monitoring over time.
Verification of ditlerent fiber material inenness in an alkali environment is research that may be
performed in the context of this channel lining project. If any fiber used on this project does
deteriorate this will be manifested by substandard performance. In addition, petrographic or other
laboratory anaiyses may be performed on field samples lo determine the degree to which the fiber
has deteriorated over lime.
111. IMPLEMENTATION
Specifications devel~peda nd refined during this project can be used on turure ADOT projects
where channel lining or similar activities are required. Besed on the findings of this research effon,
the applicability of the different liber fypes and configurations will be identifled in terms of design
objectives and distributed lo designers.
IV. WORKPLAN
1. Review literature on the use and control of fiber reinforced concrete, conventional
shotcrete, and fiber reinforced shorcrete. Compile an appropria~ec ollection of anicles and
a bibliography tor placement in the ATRC library.
2. Select a ~ ~ r o ~ r ifaibteers ID be included in this project so that the primary fiber materials
and fiber geometries can be compared.
3. fs tablish ap~ro~r ialtaeb oral on^ test ~roceduresto evaluate the qualiry of the Sn0lcrele
and tne efiects of tne fiber.
4. Establish field oualitv control ~rocedures1 0 be employed on this project so that the fiber
addition and the concrete mixing, testing, and sholcreting is perlormed in a uniform and
c~nsistenml anner.
5. Pre~area dditions and modifications to the construction documents as required for project
ACI-10-3(270). Both a change order to the special provisions and a diagram, Figure 1,
identifying test sections are necessary on this project.
6. Monitor and document all relevant phases of test section construclion. Primary emphesis
will be placed on identification of crit~cacl onstruction acliviiies that may affect the ability to
deliver the shotcrete to the channel surface in an acceptable manner. Mixing times.
pumping pressures, production rates, and equipment types will also be recorded.
7. Insure that all rnaterbl te$lina reouirements are satigid at the proper time, in the proper
location, and in the proper manner. All sample labels will be cross reterenced to AZ-8902
sample ID format. ID tormat is SECTION-TRUCK-SAMPLE. SECTION is the test section
d e s i g~t l o4n 0, C. D, or X as defined on Figure 1. TRUCK Is the truck sequence 1, 2, 3,
or 4. SAMPLE is the sample type and sequence defined below.
NI samples in parts (a) and (b) are to be obtained in accordance wtth AASHTO TI 41 with
the exception that the samples are trom the beginning portion of the loads by necessity.
All sampling methods are to be consistent.
(a) SLUMP: The following test shall be run and recorded by ADOT personnel in the field on
the malerial delivered by at least 4 randomly selected concrete trucks Der test section:
SO Slump test before fiber is added lo the concrete.
S1 Slump lest alter fiber is added to the concrete and mixed per fiber manufacturer
representative's recommendation.
One additional stump lest shall be performed on the control section material:
S* Control section slump test.
A cumulative rota1 of 32 slum^ tests will be conducted on the tesl section material andone
on the control section malerial. No additional testing or saving of the rnaterial used In
these tests is required.
(b) COMPRESSIVE STRENGTH: The following samples shall be fabricated and labelled by
ADOT personnel in the field using the material delivered by Ihe same 6 concrere trucks
selected in (2) above:
C01,COZ Two concrete cvlinder tesl s~ecimens tabricated in accoreance with tne
requirements of AASHTO 123 shall be takenprior to lne addilion of fibers to the
concrete.
Cll,C12 Two concrete cvlinder test s~ecimens fabricated in accordance with the
requirements 01 AASHTO T23 shall be taken atler fibor is added to the concrere
and mixed per f i ~ emr anuiacturer representative's recommendation.
One addirional concrete cvlinder set will be fabricated and labelled by ADOT personnel
using the material trom the control section:
CW1,C*2 Two concrete cvlinders test s~ecimens tabricated in accordance with the
requiremems ol AASHTO 123.
A cumulative total of 64 cvlinders fabricated trom test section malerial and 2 cvlinders
fabricalej trom the control section shall be tested for compressive strength in accordance
with the requirements of AASHTO T22 at 28 days.
(c) PANEL FABRICATION: The fdluwing specimens shalt be fabricated by the contractor
under supervision of ADOT personnel in the field using the material delivered by t h e m
4 concrete trucks sdected in fa) above:
PI 9ne ZW' mnel wlll be shot with shotcrete to a depth of approximately 5'. The
panel wlll be sawed as indicated in Figure 2 and will be cured in the same manner
as the channel tor 28 days.
Additional ~anelsw ill be fabricated trom the material delivered by the only truck delivering
lo the control section:
PC1,P*2 Two 2'a' ane el^ will be shot with shotcrete to a depth of approximately 5'. The
panel will be sawed as indicated in Figure 2 and will be cured in the same manner
as the channel for 28 days.
A curnutalive rolal of 16 ~anels will be fabricated trom the lesl section material and 2
panels fabricated trom the control section.
(d) PANEL TESTING: The following beam and core s~ecirnenss hall be obtained from each
panel fabricated in steD (cj above no more than 7 days prior to testing:
- FLEXURAL TOUGHNESS: Beams will be tested for flexural toughness in accordance
with the requirements of ASTM G1D18.
TI Two beams of dimensions 21Mx6"x5" for testing at 28 dass
T2 Two beams ol dimensions 21"x6'xS9 for resting at 2 vears
A cumulative total of 32 flexural touahness tes!s will be periormed on tesl seclion material
and 4 more on control sectlon material a: 2B days.
k cumulative total of 32 flexural louohnessrests will be pertormed on test section materral
and 4 more on conrrol section malerial a! 2 vears.
- COMPRESSIVE STRENGTH: Cores will be tested for compressive strenath ir,
accordance with the requirements of AASHTO T22.
Cl Two Cores with diameter 2.5' and he~gh5t " tor testing a1 28 davs
- ~7
C2 Two cores with diameter 2.5" and height 5'for testing a1 2 vears.
A curnulalive total of 32 com~ressive strenath tests will be performed on test section
material and 4 more on control section material at 28 davs.
A cumulative total of 32 com~ressive strenoth tests will be performed on test section
material and 4 more on control section material a1 2 vears.
- PERMEABiLITY: S c r a ~m aterial remainino aher testino beams and cores above will be
tested in accordance with ASTM CW2 for percent of permeable voios.
8. Comolialion and analvsis of all shon ierm test data will be included in the construction
repofi. An analysis ot variance will be performed on all test results to veriiy the validity of
the sampling program. inclusion of long rerm test data will not be possible until the final
repon.
9. Field evaluations will k scheduled for 1 month, 1 year. and 2 years from the time of
conslruction. Field evaluations will consist of documenting the number of cracks, type of
cracks, crack wMths, crack leng!hs, and vertical displacement across cracks. Crack maps
wlll be prepared for each section at each evaluation. All measurements will be analysed
over time to determine the degree to which crack growrh is inhlbiled.
10. Field sam~lesw ill be obtalned from a predetermined location aher 2 years. Field beams
and cores obtained at this time wlll be tested in exactly the same manner and at the same
time as the remaining panel samples which were obtained during construction. A
petrographic or similar analysis may be performed on the field samples at this time.
V. REPORTING
A cons1ruction repon will be prepared in accordance with ATRC procedures for repofling on
experimental projects and submitted to the FHWA wlthin 120 days atter completion of the last
construction activlt)~.
A technical summary, 1-2 pages in lengh, will also be prepared which summarizes the
findings and conclusions of the construction regon.
An irnpiementation repoR will be prepared within 120 days after submission of the
construction repon.
A final repon will be prepared in accordance with ATRC procedures for reporting on
experimental projects and submitted to the FHWA within 120 days of the last field evalualion. The
repon will delail all activities included in this experimental project and discuss the findings and
conclusions.
EAST TUNNEL OUTFALL ACI-10-3(270)
CHANNEL LINING MODIFICATIONS
. A 6
; I 1 3 1
I PROJECT
Sl'ATIONING I I I I I I
5+00 450 G too, t 50i 7tOOi + 50 8 + 00 +50 9+00 +SO 10+00
I-C
1
DESCRIPTION
COLLATED FlBnlLLATED POLYPnOPYLEFlE BUt4OLES
MONOFILAMENT POLYETttYLEEiE TERPIITtlALATE
MONOFILAMENT POLY PROPY LEN€ i ;
COLLATED FIBRILLATED POLYPROPYLENE TWISTED BUlJDLES
COt17f70L SECTION APPROXIMATELY 25' X 25'
114 BAnS @ 12"O.C. $OTI{ OlRECflOt~S
FIDEI1 LEflGTI1
112"
3!d"
314"
1 112"
I IIA
0
2
DOSAGE
1 .G l/lcy
1.0 Nlcy
1.6 "icy
1.6 lllcy
NIA
FIBER NAME
FlBERMESl 1
NUIILON
FIBEn-LOK
FOflTA
b11A
-TYPE
1
2
3
1
-
i
-
SECTION
A
, D
B
C
X
- - -
APPENDIX C: SHOTCRETE MIX DESIGN
:.. /
FIRST APPLICATION S' CRETE
Calmat of Arizona
06-Jul-89 PRODUCT CODE 3860
M i x Specifications
6.0 SACK SAND/CEMENT/FLY ASH/WATER
ADOT PROJECT: PHOENIX-CASA GRANDE HWY(EAST TUNNEL OUTFALL(ACIR-10-3(270:)
CONTRACTOR: RR HENSLER
PLANT: 32: 1801 E. UNIVERSITY DRIVE, PHOENIX, A:.
Slump range: 0.00 TO 4.50
Unit Weight: 142.93
Fineness Modulus: 2.75
Percent fine a g g r e g a t e : ~ 0 0 . 0 0 %
Weight V o 1 u m e
Weight per cubic yard: 3859.00 Total volume: 27.06
Water/Cement: G.796 Water/Cement: 9.001 (gls/sk)
Water/(C+P) : 0.660 Water/(C+P): 7.449 (gls/sk)
Specific
Material D u a n t i t y Weight Gravity Absorption Volume
_____^______-______-------------------------------------------------------
Cement 0.000 480.0 3.150 0.00 2.442
ASTM C150 TYPE 1/11 LA(ARIZ0NA PORTLnND CEMENT,RILLITO,AZ.)
Flyash 0.000 100.0 2.300 0.00 0.697
ASTM C-618 TYPE F (NAVAJO) PAGE, AZ.
Water 0.000 383.0 1.000 0.00 6.138
CiTY/WELL (POTABLE)
Fine A ~ g r e g a t e 0.000 2806.0 2.650 0.00 17.513
ASTM C33 (M4NUFACTURED)(SALT R1VER)AASHTO ~b-El
En trapped Air 0.010 0.0 0.900 0.00 0.270
0-3% &Tfl C-260 @ 2 OZ/PCY (WASTERBUILDERS NBVR-STD)
Admixture 0.000 0.0 0.000 0.00 0.000
ASTM C-494 TYPE A @ 2.5 Uz/CWT(MASiER9UILDERS 220N)
Calmat of Ariz~na 1
15-Jun-89 PRODUCT CODE 1073 PAGE 1
M i x Specifications
7.0 SK 20% 3/B" 3000PSI AT 28 DAYS
hDDT PROJECT: PHOENIX-CASA GRANDE HNY(EAST TUNNEL DUTFALL(RC1R-10-3I270))
CONTROCTOR: RR HENSLER
PLANT 32: 1801 E. UNIVERSITY DRIVE, PHOENIX,AZ.
Slump range: 1.00 To 3.00
Unit Weight: 146.59
Fineness Modulus: 2.75
Percent f i n e aggregate: 79.66%
Weight Volume
Weight per c u b i c yard: 3958.00 Total volume: 27.07
Water/Cement: 0.532 WaterICement: b.OOO (gls/sk)
Water/ (C+P) : 0.532 Water/(C+P): 6.000 ( g l 6 / ~ k )
Specific
Material Quantity Weight Gravity Absorption Volume
_-_________--__--__---------------------------------------&--------------
C e m e t~ 0.000 658.0 3.150 0.00 3.348
ASTM C-150 TYPE 1/11 LA(ARIZ PORTLhND CEMENT,RfLLITO,AZ.)
Water 0.000 350.0 1.000 0.00 5.609
CITY/WELL (POTABLE)
Fine Aggregate 0.000 2353.0 2.650 0.00 14.211
ASTM C33 (MANUFRCTURED)(SALT RIVER-AASHTD Mb-Bl)
Coarse Rggrecjate 0.000 600.0 2,650 0.00 3.62B
ASTM C33 SIZE #B ( 3 / B V ) ( S A L T RIVER-AASHTO N43-82)
E n t r a ~ p e d A i r 0.010 0.6 0.000 0.00 0.270
0-3% ASTM C-260 @ 2+- 2 OZ/PCY [MSVR STD)
Admixture 0.000 C. 0 0.000 0.00 0.000
ASTM C-494 TYPE A @ 2.5 OZ/CWT (16.5 OZ/PCY)(MB: 220N)
APPENDIX D: SHOTCRETE PUMP TECHNICAL SPECIFICATIONS
BALANCED HYDRAULICS..
- Volume output from 0 to 30 cubic
yards per hour (23 mlhr)
-
Designed to handle the larger
- and 1 " aggregate (25 mm)
- Concrete piston face pressure of
750 psi (52 bar)
- "Cushioned" hydraulic cylinders
means a smoother pumping stroke
Shotcrete, masonry block fill, slabs, -
footings, lightweight mixes
Reverse pumping.. .pistons am
reversed, not the concrete valve -
Full flow, cast steel Shuttle-Tube -
Reversible, hardened wear corn-ponents
for longer life and less -
maintenance
SPECIFICATIONS
PERFORMANCE
Volume Output 30 ydslhr (23 mlhr)
Maximum Aggregate Size 1 '/l inch (35 mm)
Minimum Concrete Slump 0 inch (0 mm)'
Vertical Pumping Height 200 ft (60 m)
Horizontal Pumping Distance 1000 f3 (300 rn)
Maximum Concrete Pressure 750 psi (52 bar)
'These figures will vary due to concrete mix design, line size, job-site conditions and engine
options.
E o g i n e d i e s e l 57 or 36 hp (42 or 26 kW)
-gas 65 hp (48 kW)
Concrete Cylinders 6 x 24 inch (150 x 610 mm)
Hydraulic Cylinders 3 x 24 inch (76 x 610 rnm)
Hyd. Oil Capacity 70 gallons (265 liters)
Hyd. Oil Cooler standard on all models
Pump Outlet Diameter 5 inch raised end (125 mm)
Hopper Height 4 3 inc h (1090 mm)
Hopper Capacity 10 cu ft (283 liters)
Brakes hydraulic surge type
VERSATILITY
. . - . - . - . . - . . . . . . . - . .
DIMENSIONS We curry a complete line of
. superior pumping accessuries
L x W x H 140 x 67 x 54 inch
-356 x 170 x 137 cm
and delivery systems for
all makes of pumps.
Weight 3500 Ibs (1588 kg)
--O- PTIONS j
Hopper remixer, engine cover (hood), Auto-Compy rear hydraulic out-riggers,
hopper vibrator, tiatz, Deutz or Wisconsin engines, Silent Pack
engines, electric motor, high pressure water pump, wireless remote
control, electric brakes, skid or truck mount.
1
1,IJ5j31,'5-' >lA.i.0z - J,l,J7'!3- C O.?,tF..
The optional Auto-Camp-eliminates destructive line surge ond
reduces hose wear. Now you can ploce '/zV minus aggregate
SMOOTH, even, continuous flow at the end of the hose.
pumping lorge aggregate mixes, simply bypass the Auto-mp"
and ottoch the larger 3" and 4" hoses.
The Shotcrete Advantage
A Mayco ST-30 s wing tube pump with
AUTO-COMP
MAYCO PUMP CORP.
4640 Sperry St., Los Angeles, CA 90039
(81 8) 507-3900 TELEX 292479
FAX (81 8) 244-4799
"MAKE IT A MAYCO"
Your Dealer:
'Specifications subject to change without notice.
0#00Nl-PM~*Crp
D-3
The Mayco series of s t r u c t u r a l concrete pumps a r e hydraulically
operated, trailer mounted pumps designed t o pump concrete mixes
through s t e e l pipes and f l e x i b l e discharge noses (placing l i n e ) .
The engine powers an hydraulic pump which d e l i v e r s o i l , under
pressure t o operate the system.
The c o n c r e t e v a l v e on t h i s s e r i e s a s h u t t l e - t u b e o r suing tube,
which provides a 4-way action i n feeding concrete i n t o the
concrete c y l i n d e r s and i n discharging t h e concrete i n t o the
placing l i n e .
Concrete is poured i n t o the hopper and as the s h u t t l e - t u b e is
a l i g n e d w i t h one concrete cylinder (B), the other concrete
cylinder (A) is on t h e s t r o k e , drawing concrete i n t o the
c o n c r e t e c y l i n d e r ( s e e f i g u r e 1 1. A piston cup or mud cup is
a t t a c h e d t o the nramn i n t h e hydraulic cylinder and serves as the
agent t o both draw concrete i n t o t h e concrete cylinder and t o
expel concrete through the s h u t t l e - t u b e i n t o the placing l i n e .
As the intake stroke is completed and c y l i n d e r A is f u l l y charged
with material, oylinder B w i l l have completed its discharge
stroke at the same time. Simultaneous with c y l i n d e r A now i n the
discharge stroke and cylinder B now on the i n t a k e s t r o k e (see
figure 1A), the shuttle-tube w i l l s w i n g over to cylinder A and
a l i g n itself and concrete w i l l continue t o flow through the
s h u t t l e - t u b e i n t o the placing l i n e . This process is continuously
repeated, at the desired volume l e v e l , u n t i l the job is
completed.