5... FEATURE Bonded concrete toppings Tips for bonding topping slabs with precast concrete construction By Charles H. Raths, S.E., and Kurt R. Hoigard, P.E. ince the inception of precast concrete products, concrete topping slabs from 2 to 4 inches thick have been used with structural precast concrete members. ‘Typically, the intended purpose of the additional concrete is to produce composite behavior of the topping slab with the precast member. The most common composite topping slab systems are constructed with precast concrete members, such as hollowcore, solid planks, and tees, and rely on bond only. Unfortunately, planned composite topping slabs are not always successful where bonding is the sole means used to structurally connect the topping slab to the precast concrete component. The write ate aware of major projects | where specified topping slab composite ystems failed 10 develop the required long-term | bonding, resulting in systemic disbonding throughout the project. The topping slab bond failures — on a parking garage, two stadiums, and a penal faclity — required expensive reme- dial work to remave and replace the topping slab and could have been avoided ifthe design- cs and contractors had increased knowlege | on factors influencing topping slab bonding. ‘Topping slab disbonding, when it ocr it is often the result of generalized specifications, awing notes, and plan details that do not cealy define a “composite” condition; lack of specific requiremens forthe precast concrcie ‘member (or substate) top surface finish; inad- ‘quate of omitted topping slab pre-placement procedures; incomplete material specifications for the topping sab concrete; and insufficient or omitted presaipive stepbystep methods for placing the planned compete topping slab. Also, bonding failures can result from contractors nat following specifications andjor using poor construction practices. An | auddional problem facing the bonded-topping- slab precast concrete jem i the common use of divided design responsibilty. The actual designer of the composite gjstem is typically not the project architet or stctural engineer but rather is the precast concrete supplier engineer, who has no contol over any of the concrete topping slab requirements orinte- sation ofthe topping slab and precast concrete units with other aspects of the planned construcion, All of these various evens too often result in the constuction of a bonded topping slab system being an uncontoled activity and will be discussed below Bonded systems Bonded roping labs ae wsed for both struc ‘url and functional reasons. Figure 1 illusrates bonded composite condons: One stctural reason forhaving a bonded system isto make the topping slab a par ofthe sucural cos setion through composite behavior By using 2 bonded composite sytem, addtional superimposed load capacity can be developed without nesting larger precast concete members ot additonal Teinforcement. An aed benefit of the compote sem i an incase in esl sess which recs shor and longterm defections and undesinble bration response. In aditon, a bonded oping sab asi in dlstibining concentrated. ads on a. gien fret cone member ajacent mene Anober impo ofa bonded concrete floor or wo se iw at a a stil diaphragn The oping sa, acing gether veh dhe pect conc unit, pods til structural diaphragm that wansmits in-plane Intra ods o shea val oc moment ames Bonding. of the topping sab diaphragm prevents localized topping dab upd buck Ting deplcement area of compeson ot shear loading, Insta appiation of the topping sab provides a convenient meas 1 ‘make connections between the diaphragm and oer Intra load resting clement Common nes ae astro he ea td ‘resisting element into which coarsely threaded ‘oka plc and then encased topping Sab conc Sometimes prcecing ears insead of inser and coanely headed rods se mplajed forthe load rane omnecion. In addkion to the stucural benef conarte opin abs fee sed fo funcional benef suchen enter sucres expose tothe cements where the toying provides both drainage profes and water Proting The ws of tpn st for water Drooling require complete surance that the topping slab wil be compote, sine ditoning would pov water with apa vay between the topping a and the tps fc ofthe precast conte bat, Moore i topping lap dbonting oc cpl leads tothe deopment of exes cad in the oping sah, lionng aoa water 0 pene no the open nef he pres Conaete top sce Pea conte hte rember ae mos Hil tbe pees Prestige camber that ca infuence ‘he dranage profile and may equ somec ‘hetopping a ohavea eateries than the nomial design ve EIRP aucuneSlab disbonding Disbonding of the topping slab from the recast concrete member can lead toa variety of “unwanted problems. which can create the need for expensive and inconvenient remedial work. Some of the problems resulting fom Alsbonding inciude the following: los of fecal capacity due tothe decease in the cross section depth + cation of hollow sounds fiom footsteps oF tuffc fom the interface gap between the topping slab and the precast concrete; ‘development of excessive topping slab shrinkage cracks; + cutlng ofthe topping sab at rads (pain lay at cade locations above precastio.pre cast member joint); «* development of reflective cracks in flooring ‘materials that are adhered tothe topping slab; + Tos of rebar or mesh engagement within the topping slab where the reinforcement has Tie of no concete cover at the topping slab Dottom (paniculaly where reinforcement is, placed too dose 10 of ditely upon the precast concrete unit top surface): ‘leakage Unrough the topping slab cracks, which permits water migration via the lisbonded interface 1 eas below the foot ‘roof stem: ‘consion of topping slab reinforcement (sulting from improper cover atthe topping, slab botiom and water leakage); + comosion of precast concete embeds (when water is present in the disbonded interface); and + damage from freeze thaw to the topping slab bottom and the precast concrete top surface the disbonded interface). This is a serious problem for non-airentained topping sab and precast concrete member. Substrate surfaces | roughened surface is FEATURE: CONCRETE the precast concrete member top surface at the time of ex sion, or sometime later by mechanical Jy scaifying the already hardened top surface Photo 1. illus rates the smooth top surface of an extruded — precast: prestressed concrete hhllowcore member Usualy precast con caete members with smooth surfces do not have open pores since the surface is dosed by the cement past latance. ‘A. purposely ree shown in Photo 2. This surface was produced with acommon ste! garden rake afer the sutace was slighty tif ‘ened, but before the concrete hardened. The roughened surface shown in Photo 2s similar to that produced for specimen testing of ond | seen (ee “Bonded surface testng®on page| 46 for more information on testing proce: dures), except for the depth of the groves is approimately5[8inch pealetosalley ‘maximum. Ci of the purpostly roughened terface argue that some of the aggregate and | pst projions wil come lose lesen the degree of topping sab bond. Ake aspect ofthe (eh am ec when te WIN | me = Figure Common precast concrete construction with slab topping. roughened substrate surface i that it allows the topping slab concrete to mechanically interlock swith the substrate to prevent dxbonding. Also, the interlock negates the lose surface panicle effect, Roughening the substrate a6 shown in Photo 2 increases the area ofthe topping slab contact surface by about one half ‘Scarifying a surface to provide a roughened top finish is shown in Photo 3. Scarfying increases the topping slab surface bonding area by one-quarter. Sandblasting the scarified cance exposes the surface’s pores as well as removes scrfVing dust. Open substrate surface | | Sues ofthe bonded topping Sab sub- | | statecn be made soo othe pues | | roughened profile, Smooth surfaces are most | ‘often produced by a precast concrete fabricator 2 pat ofits normal finishing methods. In fact, the extruded manufacturing process for most hollowcore slab units results in a smooth sur- | | face. Smooth finishes for other precast concrete ‘meer ar typically created by seeding and | Aloatng the precast concrete’ top surface a the time ofits production. A roughened top finish ‘an be fashioned by mechanically aking the | surface during fabrication, scoring or groovingFEATURE: CONCRETE Bonded surface testing ‘The American Concrete institu Building Code Requirements for Structural Concrete (ACI 318-02), Chapter 17 = Composite Concrete Flexural Members, provides the references upon which the composite design and contace surface roughness requirements are based, NW. Hanson’ research conducted in 1960, which was detailed inthe Pordand Cement Association’ Journal tied “Precast Prestressed Concrete Bridges: Horizontal Shear Connections” gves essen information Felatve tothe compote conc surface Specly designed direct shear push-ff est specimens were used by Hanson to evaluate both rough and smooth bonded pln concrete composite contact surfaces. Paush-off specimen rough contac surfces were made by scraping the surface ofthe specimen base (the substrate) with the edge ofa steel sheet creating depressions and peaks 3/-nch below and above the average level, which resulted in an approximate peak-to-depression height of 3/4 inch. No ateempt was made to smooth aggregate into the concrete paste. Hanson's rough surface diferent han the inceneonally roughened surface defined in ACI 318 Chapter 17, wich has undulations of 1/4 inch Except for the peatto-depression height of 34 inch, Hanson’ rough yy face snr to Fg 2. The sneth wee of te puo ‘specimens was created by troweling the base to a relatively smooth ¢ Cindton Ban radon oh pcr tw pre wa sched by cat pr prt pcr toe sh ay Ire wren Span cnr was rma meget he npr sng of 501580 poe pr sree troup snd snot tof pin er specie wee texed Te de det she arg fe oh omar re form 350 fo 55 ps Conieg the eto + aa tingle f+ get pop th th pecan rug mre bonded sar reg apely (nein at 9s ree eae hes et ae) 30s suo dbo sn pin ate moth bold eines a her ae ‘es agg om 9 0220p wh dee Tuten paren smcthand onde da shape of pt aoe ce tare pce ache et scr he cour ord mec yng lec cre lags or rapt ln bes ene Tethered te noe todd ser seg 2 & pores enhance topping slab bonding by drawing the topping slab concrete paste tentades into the pores, Construction practices Many construction factors and procedures can have a meaningfl effect upon topping slab.to-substrate bonding inchuding. proper ddeaning and preparation of the precast | ‘member substate and placing and curing ofthe | topping slab. For example, substrate surface Figure 2: Sketch ofan intentionally roughened composite concrete interface. leaning is essential if topping slab bond is to be achieved. ll loose debris saw dust and ditt require removal. Cleaning canbe accomplished by sweeping and vacuuming followed by the use of cilfive blown compressed air. In dition, surface contamination esultng from spills of consiuction materials, grease, oils paint, and similar substances must be fully emoved using appropriate chemicals ot abrasive basting. Bonded topping stems using hollowcore- ‘ype members should have joints about any individ: ual slab grouted, and the grout, should be level with | the members top | surface. This | decreases the occur rence of topping | stab cacking ateach slab keyway joint. Mesh and other reinforcements embedded in the topping slab should be supported on ‘continuous chats ot slab bolsters 10 thatthe reinforcing will be located atthe planned positions With required top and betiom conte cove. Toping sas Shoulda conan mh enforcement ta, sim, contol oping lb ck above or jut accent side and end ois of the peat conc sate Rates popes sae Ge emi an 1 | Uupperthird of the topping slab thickness" ‘counteracts curtng (which can occur at topping slab cracs) by providing moment resistance to the cuting deformation. ‘The subacute tecivng the toppings | stab nenis tobe comely preswetied prior to Placing the sab This weting should presi tere cot pce nd 9 for at east 12 hours pio to sab placement. Immediately before topping sla placement, the substrate should be in a saturated surfac Mp dry condition wit no standing wate Honding ‘ofthe topping dab ca be improved bythe use ofa grout scub coat When the topping sl conains mesh enforcing we ofshotree ia ‘more practical method of applying the grout scrub coat. Regards ofthe scrub coat appli tion, it is citical that the scrub coat. not y | alowed o prema dry om which would © | inhibi bonding of the topping slab. ‘The! tnping db on shoud hae igi vatercement ratio to minimize topping la | ‘to-substrate differential shrinkage. A low water- ein 35 | reds A, proper can of he topping {hb mniiza the ees of oping dads sue iftcal ge Te et siocoehe pags ha webu