Alkali-Silica Reaction Guidance For Recycled Aggregate in Concrete

Aggregate Research Programme/Final Report
Alkali-Silica Reaction Guidance for Recycled Aggregate in Concrete
This report summarises the outcomes of a comprehensive research project investigating the effect of recycled aggregates (RAs) on the risk of alkali-silica reaction (ASR) in concrete carried out over 4.5 years.
Project code: MRF 108-001 Research date: August 2008 - January 2009
ISBN: 1-84405-411-X Date: January 2009
Front cover photograph: Processing of recycled aggregates (Courtesy of Commercial Recycling, Wimbourne)
WRAP and the University of Dundee believe the content of this report to be correct as at the date of writing. While steps have been taken to ensure accuracy, WRAP cannot accept responsibility or be held liable to any person for any loss or damage arising out of or in connection with this information being inaccurate, incomplete or misleading. For more detail, please refer to WRAPs Terms & Conditions on its web site: www.wrap.org.uk
Published by Waste & Resources Action Programme
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Contents
1.0 Introduction ................................................................................................................................ 5 1.1 Background ....................................................................................................................... 5 1.2 Overall Aim and Objectives of the Project ............................................................................. 5 Experimental Programme ........................................................................................................... 5 2.1 Phase 1: Classification of RA Components using Rapid Tests .................................................. 6 2.2 Phase 2: Concrete Expansion Tests (BS 812-123, 38oC) ......................................................... 7 2.3 Phase 3: Unsheltered External Exposure Site Tests ................................................................ 7 2.4 Phase 4: Optical Microscopy Assessment .............................................................................. 7 Test Materials and Assessment Methodologies ......................................................................... 7 3.1 Materials ........................................................................................................................... 7 3.1.1 Concrete Constituents ............................................................................................ 7 3.1.4 Laboratory-Produced RAs........................................................................................ 8 3.1.5 Site-Produced RAs ................................................................................................. 10 3.2 Test Methods .................................................................................................................... 10 3.2.1 Bulk Oxide Analysis ............................................................................................... 10 3.2.2 RA Alkali Release (RILEM/CANMET) ........................................................................ 10 3.2.3 Mortar Expansion (ASTM C1260) ............................................................................ 12 3.2.4 Concrete Expansion Tests (BS 812-123, carried out at 38oC and 60oC) ....................... 12 3.2.5 Unsheltered External Exposure Site Tests and Optical Microscopy Assessment ............ 13 Phase 1: Classification of RA Components Using Rapid Tests................................................. 14 4.1 RA Alkali Release (RILEM/CANMET) .................................................................................... 14 4.2 Mortar Expansion (ASTM C1260)......................................................................................... 14 4.3 Concrete Expansion Tests (BS 812-123, carried out at 60oC) ................................................. 21 4.3.1 Reactivity ............................................................................................................. 21 4.3.2 Alkali Release ....................................................................................................... 27 Phase 2: Concrete Expansion Tests (BS 812-123, 38oC) ......................................................... 29 5.1 Reactivity ......................................................................................................................... 29 5.1.1 Fine RA ................................................................................................................ 29 5.1.2 Coarse RA ............................................................................................................ 29 5.2 Alkali Release .................................................................................................................... 29 5.3 Additional Tests................................................................................................................. 34 5.3.1 Demolition Materials .............................................................................................. 34 5.3.2 High Expansion / High Alkali Release Materials ........................................................ 34 5.3.3 Combination with High Reactivity Aggregates .......................................................... 34 Phase 3: Unsheltered External Exposure Site Tests ................................................................ 40 Phase 4: Optical Microscopy Assessment ................................................................................ 41 Conclusions and Practical Implications.................................................................................... 55 References ................................................................................................................................ 57
2.0
3.0
4.0
5.0
6.0 7.0 8.0 9.0
ASR Testing on Recycled Aggregates 2
Executive Summary
This report describes the work of an investigation carried out to examine the influence of recycled aggregate (RA) on damaging alkali-silica reaction (ASR) in concrete. The experimental programme was carried out in 4 phases. Phase 1 was concerned with identifying, by rapid tests, RAs with a tendency to (i) release alkalis in concrete, which may contribute to damaging ASR and (ii) exhibit reactive properties. A range of materials, including masonry units, concrete, plaster, road planings and demolition waste were collected and examined for these effects using the RILEM/CANMET (alkali release) and ASTM C1260 mortar (aggregate reactivity) test methods. The alkali release tests indicate that for the range of materials, greatest alkali release occurred in masonry units (clay bricks and concrete blocks). Alkali release from concrete was less than that of the masonry units by typically more than 50%. Demolition waste (concrete and bricks), while giving similar effects to recently produced material, generally released less alkali. Slate and plasterboard released least alkali of the RAs tested. The reactivity tests, carried out with the RAs in mortar, indicate that all materials exhibited expansions of < 0.1 %, (ie innocuous, according to the standard), thereby suggesting little reactivity and risk of damaging ASR. A selection of materials from these tests, including masonry units, concrete, mortar, road planings and demolition waste were used in concrete to replace sand or gravel in a low reactivity aggregate combination (North Fife sand and gravel) and examined for reactivity, in terms of expansion, using the BS 812-123 test (high alkali content, 7.0 kg/m3), but at a temperature of 60oC. The results indicate that in almost all cases over the 12 week test period, expansions of less than 0.07% were obtained. The exception to this was road planings, which had expansions more than double those of the other materials tested. Tests under similar conditions on concrete with an alkali content of 5.4 kg/m3 using RA to replace sand in a normal reactivity aggregate combination (Trent Valley sand and gravel) were carried out to examine the effect of alkali release from RA. These were designed to establish whether the RA reactivity and their alkali release would give greater expansion than the normal reactivity aggregate combination. In all cases, except for road planings, the RAs gave lower expansions than this, with all expansions being less than 0.11% at 12 weeks. A chemical test to examine for ASR gel in road planing specimens, although inconclusive, suggested that the high expansion may not have been due to ASR. In Phase 2, parallel expansion tests, on the same concretes used in Phase 1, were carried out for reactivity and alkali release using the BS 812-123 method at 38oC for more than 3 years (186 weeks). The results of these tests showed general agreement with the 60oC tests in terms of the expansion rankings of the test concretes. It was noted that the road planings gave similar expansions to the other concretes for both reactivity and alkali release tests in this case. In the reactivity tests at 52 weeks, all concretes had expansions of less than 0.06% indicating low reactivity. There were only minor increases in these in the 100+ weeks that measurements were continued for thereafter. In the alkali release tests, the control concrete (with the normal reactivity aggregate combination) and that with recycled concrete aggregate previously showing signs of ASR in service (Montrose Bridge concrete) gave greatest expansions of 0.13 and 0.10% at 52 weeks, respectively. The other concretes had expansions of 0.07% or less at this time. Only minor increases in expansion were noted with these concretes in the test period thereafter. In Phase 3, expansion tests were carried out on large blocks (500 x 250 x 200 mm) at a local unsheltered external exposure site, with bricks, road planings and RCA as fine aggregate. These indicate insignificant expansions at 3 years for both reactivity and alkali release test concretes. In Phase 4, optical microscopy was carried out on small cores taken from Phase 2 samples exhibiting greatest expansions, and all of those from Phase 3, to examine for the presence of alkali-silica gel and associated damage. These indicate that the maximum rim thickness for alkali-silica gel observed around aggregate particles was 14 m, with most samples giving rims of < 10 m. The microscopy suggests insignificant effects with regard to concrete damage caused by ASR. Overall, the results indicate that RAs can contribute alkali to concrete, which was greatest with masonry units. The RAs when tested in concrete replacing sand or gravel in a low reactivity aggregate combination were found to give low reactivity. Greatest expansions tended to occur with materials containing reactive aggregates, or which have shown signs of ASR in their previous applications, e.g. in recycled concrete aggregate. The combination of alkali release and the reactivity of the RAs when replacing fine aggregate in a normal reactivity aggregate combination gave less expansion than the control (normal reactivity aggregate combination) concrete.
Acknowledgements
The Authors would like to acknowledge the advice given in the early part of the project (Phase 1) by representatives of the following organisations, Waste and Resources Action Programme, Brick Development Association Ltd, Castle Cement Ltd, Concrete Block Association, Davis Langdon LLP, Gifford and Partners Ltd, H + H Celcon Ltd, Quarry Products Association, RMC Materials (UK) Ltd and STATS Ltd (who were members of the Project Steering Committee). Mr P Livesey (Castle Cement Ltd) is thanked for his input and discussions in the preparation of this report.
1.0 Introduction
1.1 Background
The 2003 amendment to BS 8500-2 [1] introduced changes to the provisions to resist damaging alkali-silica reaction (ASR) in concrete, when recycled concrete aggregate (RCA) and recycled aggregate (RA) are used. The requirements with respect to RCA were relaxed, with its classification being changed from high reactivity aggregate to normal reactivity. In addition, a safe assumed alkali contribution from RCA was introduced. However with RA, the new provisions made it more difficult to use these materials. Indeed, the British Standards Institution (BSI) was unable to draft provisions for resistance to ASR with RA, given its very wide range of potential compositions. Consequently, BS 8500-2 [1] requires specifications to include: Reactivity classification of RA Alkali contribution from RA This may be possible when a particular source of RA is to be used, but it is a significant deterrent to the general use of RA. Moreover, as BS 8500-2 [1] does not contain a full specification for RA, it cannot be included in the permitted constituent materials for designated concretes. Coverage of the effect of RA on ASR in the literature is limited and there is little information on individual components. Furthermore, this also indicates differences in behaviour between studies. For example, it has been found that the use of bricks as fine aggregate, may suppress ASR due to their pozzolanic properties [2]. However, other work suggests that these components do not appear to reduce the risk of damage [3]. For RCA, it is usually the aggregate used in recycled concrete that is the main concern [4, 5]. Given the general lack of information and the obstacles highlighted above, there is a need to examine this issue and to provide appropriate guidance. The Concrete Technology Unit (CTU), University of Dundee, have carried out several research projects investigating the use of RCA and RA in construction [5 - 16]. This report describes a four phase investigation to examine the effect of recycled aggregate on the risk of ASR in concrete. In Phase 1, rapid tests to measure alkali release of RA materials and their reactivity (expansion) when used in mortar and concrete were carried out to provide an initial assessment of ASR risk. In Phase 2, parallel expansion tests on concrete using the British Standard method (BS 812-123 [17]) were made. Phase 3 involved expansion tests at an unsheltered external exposure site (large samples; 500 x 250 x 200mm) on selected concretes. Phase 4 used optical microscopy to examine for the presence of damaging alkali-silica gel in concretes tested in Phases 2 and 3. The practical implications of the research were also explored.
1.2
Overall Aim and Objectives of the Project
The main aim of this study was to examine, by experimental means, the risk of ASR in concrete for the range of RAs available, or likely to become available in concrete construction. The project objectives were as follows: i. To define the range of compositions of RA and identify whether they release alkalis within an alkali solution and/or exhibit expansion in a cementitious system. This was intended to establish materials that require detailed investigation. To test components that exhibit expansion, in concrete mixes, to determine the level of reactivity. To test components that release alkalis, in concrete mixes, to quantify their influence on the ASR process.
ii. iii.
iv. To develop guidance on the classification of different RAs and alkali limits in relation to damaging ASR.
2.0 Experimental Programme

The experimental programme was divided into four main phases, carrying out (i) rapid tests to examine alkali release and reactivity of RA materials, (ii) BS 812-123 [17] concrete tests on RA materials, (iii) unsheltered external exposure site tests on selected concretes and (iv) optical microscopy to examine for the presence of alkali-silica gel in the concretes tested during (ii) and (iii).
Initially a search of the literature was carried out to identify available RAs for testing and to obtain information on their composition, in particular the presence of reactive silica and likelihood of alkali release. A range of materials were obtained thereafter for testing including concrete, bricks, blocks and demolition waste. Initial alkali release and mortar reactivity experiments were carried out on these, in order to identify which materials were likely to represent a risk in relation to ASR and required further investigation. The reactivity of various RAs was examined by using these to replace fine or coarse aggregate components in a low reactivity (aggregate) combination in BS 812-123 [17] concrete mixes (high alkali content). The test procedure described in this standard was also followed, but at an elevated temperature (60oC), with expansion measurements carried out for 12 weeks. The alkali contribution of the various RAs was considered using the same exposure conditions and test procedure, but with RA replacing fine aggregate in a normal reactivity (aggregate) combination. In this case, the alkali level in concrete was sufficient to cause measurable ASR expansion (for the normal reactivity combination aggregate) and the test would determine whether the alkali release / reactivity of the RA increased this. A parallel set of concrete tests (reactivity and alkali release) was carried out using BS 812-123 [17] test conditions (38oC). Further work using these tests with additional material samples was initiated to address some of the issues raised in the earlier data generated. In addition, large-scale test specimens were cast with selected materials (covering both reactivity and alkali release concretes described above) for exposure at a local external site. Optical microscopy was also carried out to examine for alkali-silica gel in the 38oC and external exposure tests. The different phases of the experimental programme are described in greater detail below.
2.1
Phase 1: Classification of RA Components using Rapid Tests
To ensure the study was comprehensive, attempts were made to include all available RAs being used, or likely to be used in concrete construction in the near future. Reference to the literature, AggRegain Website and discussions with the steering committee members, lead to the formulation of the following list of materials for inclusion in the project: Concrete (including that containing reactive aggregates) Bricks (clay and calcium silicate) Lightweight concrete blocks Masonry units containing waste materials Road (asphalt) planings Mortar Plasterboard Slate Material samples were obtained from both (i) recently manufactured products and (ii) locally demolished structures/elements. On receipt, the RA samples were crushed to the required size for the various tests and for determination of their bulk oxide composition using X-ray fluorescence spectrometry (XRFS). Alkali release was examined using the RILEM/CANMET test [18], which provides a measure of alkali release in alkali solution, i.e. corresponding to the pore fluid chemistry of concrete. Alkali-silica reactivity was assessed using the ASTM C1260 standard [19], which is a rapid test to assess ASR risk of aggregate. These tests and conditions were selected in order to enable a rapid assessment to be made. Testing of RA in concrete followed the BS 812-123 method [17], but at 60oC, with expansion tests up to 12 weeks. It was intended that testing would focus on RA components used during the RA alkali release / mortar reactivity tests in Phase 1, where results suggested potential ASR risk. The RAs were used both as fine and coarse aggregate, with a Na2Oeq in concrete of 7.0 kg/m, controlled by the cement content. Tests with different RA levels (as fine aggregate) to examine if there was a pessimum proportion of reactive material were also carried out. The aggregate combination used (components of which RA replaced) in the control concrete was of low reactivity (North Fife sand and gravel) [4]. Similar concrete tests at 60oC were carried out to establish alkali contributions from RA components and their influence on ASR. The aggregate combination (the sand of which RA replaced) in the control concrete in these tests was of normal reactivity (Trent Valley sand and gravel). A Na2Oeq in concrete of 5.4 kg/m, controlled by the cement content, sufficient to cause measurable expansion ([20] was used, with alkali contributions from RA ignored in this calculation. If alkali was released from RA, the expansion would be greater than the control, assuming it was of similar reactivity.
2.2
Phase 2: Concrete Expansion Tests (BS 812-123, 38oC)
Given there can be limitations associated with high temperature testing with regard to ASR behaviour in practice [21], test series were initiated using the industry accepted BS 812-123 method [17] at 38oC and high humidity. This work used the same materials and mixes as for the reactivity and alkali release tests made at 60oC and involved periodic measurements of expansion for up to approximately 3.5 years (186 weeks, ie beyond the 52 weeks required by the standard [17] or 104 weeks for greywacke aggregates as per BRE Digest 330 [4]) to examine for any long-term effects. As data was generated, further tests were set up to address some of the issues that these raised. This included testing of, (i) demolition materials from 4 sites to examine the effect of RA material variability (as fine and coarse aggregate in concrete), (ii) further RA samples for those showing high reactivity (expansion) / alkali release in the earlier tests including, road planings and brick and (iii) combinations of RA samples showing similar effects to (ii) in the earlier tests, including, road planings, brick and recycled concrete, with aggregate likely to have high reactivity (borosilicate glass) as fine aggregate.
2.3
Phase 3: Unsheltered External Exposure Site Tests
In addition to the tests at 38oC, large concrete samples (500 x 250 x 200 mm) were also cast with selected RA materials (road planings, bricks and RCA) using reactivity and alkali release concrete mixes (as above). These had fixed reference studs attached for expansion testing and were located at a local unsheltered external exposure site. Tests on these were continued for up to 3 years.
2.4
Phase 4: Optical Microscopy Assessment
Optical microscopy was carried out on small cores removed from the test concretes to assess for the presence of alkalisilica gel and cracking. The concretes considered were (i) those exposed to 38oC exhibiting greatest expansions at the conclusion of testing (Phase 2) and (ii) all externally exposed samples (Phase 3).
3.0 3.1
Test Materials and Assessment Methodologies Materials
3.1.1
Concrete Constituents
Portland Cement (PC) Two Portland cements (PCs) were obtained for inclusion in the test programme. For the ASTM C1260 mortar tests, PC with a Na2Oeq of 0.6% (low alkali; PC1) was used. For the concrete tests, PC with a Na2Oeq of 1.0% (high alkali; PC2) was used, thus allowing the alkali content to be readily controlled in the test mixes. The physical and chemical properties of these materials are given in Table 1. Natural Aggregates Two natural aggregates were used for the concrete tests during the experimental programme and were chosen to provide low and normal reactivity aggregate combinations, according to BRE Digest 330 [4]. These were a North Fife gravel (10 and 20 mm) and sand, classified as low reactivity and a Trent Valley gravel (10 and 20 mm) and sand, classified as normal reactivity. Table 2 gives the physical and chemical properties of these materials. Borosilicate Glass Borosilicate glass, from laboratory waste and household glassware was used in selected test mixes as a fine aggregate. This was treated at a processing plant and its physical and chemical properties are also given in Table 2.
Table 1 Physical and chemical properties of Portland cements used (manufacturers data) PORTLAND CEMENT
Physical Properties
Fineness, m/kg Loss-On-Ignition, % by mass Particle Density, kg/m Compressive Strength, N/mm 28 day Setting Time, min Initial Soundness, mm
PC1 350 0.9 3140 59.5 125 0.6
PC2 360 2.5 3150 52.0 130 1
Chemical Properties
Bulk Oxide, % by mass SiO2 Al2O3 Fe2O3 CaO ClNa2Oeq Bogue Composition, % by mass C2S C3S C3A C4AF 20.8 5.0 2.9 63.5 0.0 0.6 19.0 55.0 8.3 8.9 21.3 4.9 3.3 65.0 0.1 1.0 15.0 61.0 7.0 10.0
3.1.4
Bricks
Laboratory-Produced RAs
Commercial bricks from four sources (3 clay (Brick 1, 2 and 3) and a calcium silicate) were used. Bricks 1 and 3 were obtained locally, while Brick 2 and the calcium silicate brick were sourced from national suppliers. Blocks/Bricks Containing Waste Concrete blocks containing incinerator bottom ash aggregate (IBAA), as a total replacement of lightweight aggregate, were obtained from a national supplier. Lightweight Concrete Blocks Recently manufactured (aerated) lightweight concrete blocks were obtained from a national supplier. These blocks had a density of 620 kg/m and a 7-day compressive strength of 4.0 N/mm. Mortar A mortar (Designation 1) was produced in the laboratory using mixes given in the BS 5628 [22]. The mortar was mixed, using PC1, cured to 28 days in water at 20oC before crushing. This was only used selectively in the concrete tests. Plasterboard A recently produced gypsum plasterboard was obtained for use as fine aggregate in the alkali release and mortar reactivity tests. This is subsequently referred to as plaster.
Table 2 Properties of test aggregates AGGREGATE COMBINATION Normal Reactivity* Low Reactivity* Sand 10 mm 20 mm Sand 2.63 0.5 0.6 ---100 99 84 70 56 36 7 1 1 78.5 8.4 3.3 1.9 1.9 --0.6 --1.5 1.4 0.1 0 10 mm 20 mm
PROPERTY
Borosilicate Glass Sand 2.42 n/t
Physical Properties
Shape, visual Surface texture, visual Particle density Water absorption, % Lab. dry to SSD Oven dry to SSD Oven dry to 10 min 2.65 0.4 0.6 Rounded Smooth 2.65 2.64 0.6 0.2 ---100 21 6 0.6 -----93.6 3.5 1.4 0.3 0.0 0.0 0.2 0.1 0.8 0.0 0.1 0 0.6 0.2 100 86 3 1 0.3 0.2 ------92.5 5.1 0.5 0.4 0.1 0.0 0.3 0.2 0.7 0.2 0.1 0 Rounded Smooth 2.59 2.59 1.3 1.0 --100 93 17 1 1 -----68.7 12.6 4.9 2.9 2.9 --0.8 --1.8 2.4 0.1 0 1.2 1.0 100 92 45 9 2 2 1 1 ----63.7 15.0 5.0 4.6 3.2 --0.9 --1.5 2.2 0.1 0
Grading, % passing by mass

37.5 mm 20 mm 14 mm 10 mm 6.3 mm 5 mm 2.36 mm 1.18 mm 600 m 300 m 150 m 75 m ---100 99 96 84 78 72 22 1 -91.5 5.8 0.5 0.2 0.5 0.0 0.2 0.0 1.2 0.0 0.1 0
Bulk Oxide Composition, % by mass

SiO2 Al2O3 Fe2O3 CaO MgO P2O5 TiO2 SO3 K2O Na2O MnO Cl68.2 5.3 0.1 2.3 0.1 0.0 0.0 0.2 1.7 6.1 0.0 0
*In accordance with BRE Digest 330 [4], - not applicable, -- all passing / not passing, n/t particle size distribution not tested, --- not detected
Recycled Aggregate Concrete Concretes containing low (L) and normal reactivity (N) aggregate combinations were cast in the laboratory with PC1 and cured for 28 days in water at 20C before use. Different target (cube) strengths were considered, i.e. 25 and 50 N/mm2 (25N and 50N) to determine the effect of variable alkali (cement) content (25NN indicates 25 N/mm concrete with normal reactivity aggregate, etc). Concretes containing fly ash (FA, 30%) and ground granulated blastfurnace slag (GGBS, 50%) as additions, known to reduce the risk of ASR, were also examined (in 50 N/mm2 concrete, with the low reactivity aggregate combination).
3.1.5
Site-Produced RAs
Recycled Aggregates A range of materials were obtained from recently demolished structures/elements. All materials were crushed using a jaw crusher and graded to meet the requirements of the test being carried out, or mix they were being used in. In the case of the concrete tests, this was similar to the grading or size of the aggregate being replaced. Demolition Waste Samples of demolition waste were collected from two sites processing recycled material. Initially a total of five materials were obtained, namely, 3 concrete samples, including a lightweight concrete, and 2 brick samples. Concrete from Montrose Bridge (NE Scotland), built during the 1930s (recently demolished, and known to be suffering from ASR) was also used. Additional samples of RA were later sourced from four sites (Brechin, Dundee, Dundee - 1 and Bristol) for inclusion in the test programme. Road Planings Two road planings samples (Road Planings and Road Planings - 1) were obtained from a local supplier, which had been recovered (at different times) for recycling and sized to 5, 10 and 20 mm. No details of the material history or composition were available but the material came from the Tayside area and was likely to use local aggregate sources (most commonly crushed whinstone). Slate Roofing slate was obtained locally from recently demolished housing. This was used as fine aggregate in alkali release and mortar reactivity tests.
3.2
Test Methods
3.2.1
Bulk Oxide Analysis
The bulk oxide analysis of the RAs was determined using a Philips MagiX sequential fluorescence spectrometer (XRFS) with a Rhodium source (the instrument has 10 analysing crystals to cover all elements, with the mA/kV settings of the tube adjusted to best suit the range being analysed) coupled with an auto sampler. Each material was ball-milled and the fine powder compressed into a standard pellet for analysis. The bulk oxide analyses of all RA test materials are given in Table 3
3.2.2
RA Alkali Release (RILEM/CANMET)
The alkali release test used was a method developed by RILEM/CANMET [18], which is a procedure for evaluating the alkali contribution of components in concrete. As there was no information on aggregate grading, the materials for this test were graded as described in the ASTM C1260 Standard [19] for the ASR mortar expansion test (Table 5). A 25 g sample of each material was placed in a sealed container with 100 ml of either 1N potassium hydroxide (KOH) or 1N sodium hydroxide (NaOH) solution. The container was placed in an oven at a temperature of 80 oC for 14 days and agitated twice a day. At this time, the solutions were filtered and stored until testing. The K+ and Na+ concentrations of each solution were measured using atomic absorption spectrometry (AAS). This method enables concentrations of metallic species in solution to be determined.
Table 3 Bulk oxide composition of RA test materials MATERIAL Brick 1 Brick 2 Brick 3 Calcium Silicate Brick Lightweight Concrete Block IBA Block 25 NL Concrete 25 NN Concrete 50 NL Concrete 50 NN Concrete Demolition Concrete 1 Demolition Concrete 2 Demolition Brick 1 Demolition Brick 2 Demolition Lightweight Concrete Mortar Road Planings Road Planings -1 Slate Plaster Montrose Bridge Concrete Brechin Dundee Dundee -1 Bristol BULK OXIDE, % by mass MnO TiO2 K2O Na2O 0.1 0.2 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.0 0.1 0.1 0.6 0.1 1.0 1.1 1.0 0.4 0.9 0.9 0.5 0.6 0.8 0.4 1.3 0.7 1.3 1.0 3.4 2.3 3.6 2.2 2.1 1.6 1.1 1.4 1.6 1.2 2.2 2.0 1.1 1.3 1.5 0.5 1.8 0.5 0.7 1.1 0.6 1.1 1.2 0.5 2.4 1.5 0.2 0.2
CaO 2.9 0.6 2.6 20.8 19.8 39.9 38.1 30.9 27.9 38.8 10.5 16.4 3.0 1.5
Si2O3 56.7 57.0 57.9 53.2 35.2 24.9 41.7 41.1 45.2 40.8 52.7 55.7 57.5 39.9
Al2O3 17.0 21.0 16.8 6.7 17.7 9.8 6.2 7.6 8.3 4.3 14.8 10.7 20.8 17.2
Fe2O3 7.5 8.7 7.6 4.2 10.9 5.6 2.6 4.0 4.0 2.6 6.6 4.8 8.3 5.0
MgO 2.9 1.6 3.0 0.7 1.4 1.2 1.6 2.3 2.2 1.3 4.2 1.6 0.9 0.7
P2O5 0.2 0.2 1.2 0.1 0.3 0.6 0.1 0.1 0.1 0.1 0.3 0.2 0.1 0.1
Cl0.0 0.0 0.0 0.3 0.4 0.4 0.0 0.0 0.0 0.0 0.1 0.0 0.0 0.0
SO3 0.0 0.0 0.0 0.1 1.5 3.1 0.8 0.8 0.6 1.0 0.4 0.5 0.0 0.1
Na2Oeq 3.7 2.0 4.2 1.9 2.1 2.2 1.9 2.1 2.3 1.3 3.8 2.8 0.9 1.1
22.4 38.6 6.1 8.9 2.5 40.0 21.9 12.5 10.3 7.6 11.3
33.8 37.5 52.6 64.0 63.9 0.4 55.7 60.0 57.0 59.0 56.0
19.7 6.7 13.1 9.9 19.3 0.3 7.2 9.4 12.8 14.3 13.7
5.7 4.2 6.3 4.9 6.9 0.1 2.8 4.5 4.7 5.0 6.0
1.1 0.7 3.6 2.5 2.3 0.0 1.0 1.6 3.0 3.2 2.9
0.1 0.1 0.1 0.1 0.1 0.0 0.1 0.1 0.1 0.1 0.1
1.2 0.4 1.3 0.5 0.9 0.0 0.4 0.5 0.7 0.9 0.3
0.4 2.2 1.7 2.0 3.0 0.1 1.6 1.90 1.70 2.30 2.00
0.2 0.5 2.2 1.9 1.8 0.0 1.4 0.60 1.40 1.50 1.40
0.3 0.1 0.4 0.2 0.1 0.1 0.1 0.1 0.2 0.2 0.3
0.0 0.3 0.1 0.0 0.0 0.0 0.1 0.5 0.6 0.6 0.5
1.3 0.1 0.7 0.9 0.1 45.3 0.6 0.10 0.10 0.11 0.10
0.5 1.5 3.3 3.2 1.3 <0.1 2.4 1.9 2.5 3.0 2.7
3.2.3
Mortar Expansion (ASTM C1260)
Preparation of Materials Prior to mixing, the aggregate to be tested was crushed to achieve similar grading to that specified in ASTM C1260 [19], see Table 4 and dried in laboratory air (20C, 55% RH).
Table 4 Grading of aggregate used in RILEM/CANMET alkali release and ASTM C1260 mortar tests PARTICLES PASSING, % by mass 1.18 mm 600 m 65 40
4.75 mm 100
2.36 mm 90
300 m 15
150 m 0
Mix Proportions The proportions used for the mortar mixes to determine aggregate reactivity were those given in the standard, see Table 5.
Table 5 Batch proportions used in ASTM C1260 mortar tests BATCH QUANTITIES, g Aggregate 990 w/c RATIO 0.47
PC1 440
* De-ionised water
Water* 205
Casting of Test Specimens The mortar was prepared, as described in the standard, using a 5 litre capacity planetary mixer, and specimens cast into steel moulds (3 No. 25 x 25 x 300 mm for each mix) and cured for 24 hours, under a tentage of damp hessian and plastic sheeting at 20C, 95% RH, prior to demoulding. Test Procedure The ASTM C1260 test involves measuring the expansion of test specimens daily over a 16 day period: immersion in water at 80C for 1 day and 1N NaOH solution at 80C for a further 14 days. Expansion was calculated as that occurring during the 14 days in alkali solution.
3.2.4
Concrete Expansion Tests (BS 812-123, carried out at 38oC and 60oC)
Concrete Constituent Mix Proportions BS 812-123 [17] prescribes test concrete mixes on a percentage by volume basis, as follows, PC 22.2%; water 22.8%; sand 16.5%; 10 mm 16.5%; 20 mm 22.2%. These were used for both Phase 1 and 2, with the mix proportions determined by mass, by taking account of the particle densities of the constituents (including each of the RAs tested). As an example, the mix proportions used for the control mix are given in Table 6. In the case of alkali-release tests, the cement content (540 kg/m3) was fixed to give the required alkali content and the water content adjusted to maintain the w/c at the BS 812-123 [17] level. Thereafter, the aggregate contents were derived using the BRE Method for the design of normal mixes [23]. The mix proportions of the control mix for this are also given in Table 6.
Table 6 Mix proportions for concrete expansion tests (control concretes) MIX PROPORTIONS, kg/m MIX* Reactivity Alkali-release PC2 700 540 Water 20 mm 230 180 575 780 Aggregates 10 mm 430 395 Fine 435 505 0.33 0.33 7.0 5.4 w/c Na2Oeq
*Consistence Class S2 (small dosage of superplasticizer added as required to achieve workability)
Preparation of Test Specimens All aggregates/RA components in this stage of the work were used after oven drying at 105C to constant mass and cooling in a desiccator. Prior to use, the RAs were crushed to achieve similar size/grading to the material they replaced. Calculation of batch quantities involved adjustment to the water content to allow for absorption. As prescribed in the standard, for fine aggregate water absorption from oven-dry to saturated-surface dry (SSD) was allowed for, whilst for 10 and 20 mm aggregates the water absorbed in 10 minutes was used. Concrete was prepared, and 4 No. 75 x 75 x 300 mm prisms cast for each of the exposure conditions and cured (20C, 95% RH), as described in the standard. Specimens were demoulded 24 hours after casting, prior to preconditioning and initiation of testing. Expansion Measurements The BS 812-123 test involves periodically measuring expansion of the 75 x 75 x 300 mm specimens during storage in moist air at 38C (RH >95%). In this study, the tests were carried out according to BS 812-123, but with exposure temperatures of both 60C (Phase 1) and 38oC (as given in the Standard, Phase 2) used. Immediately after demoulding, length measurements of the concrete specimens were taken and they were wrapped in moist cloth and plastic sheeting (which was kept in place throughout the test) and then sealed in air-tight containers above water (RH > 95%). Initially, the specimens and containers were stored at 20C, prior to transfer at the age of 7 days to the 60C and 38 oC rooms. Initial expansion measurements were taken and then subsequent tests made at 1, 2, 4, 6, 8, 10 and 12 weeks for those at 60oC and weekly to 4 weeks and then at 13, 26, 39 and 52 weeks and at regular intervals thereafter for those in the 38oC exposure. In both cases, the specimens were located in a room at 20C for 24 hours, prior to testing length change. Immediately after testing, the specimens were returned to their containers and appropriate temperature control room for continued exposure. BRE Digest 330 [4] provides guidance on the interpretation of BS 812-123 [17] tests at 7.0 kg/m Na2Oeq (38oC) with regard to aggregate reactivity / expansion risk (based on 52 week expansion), see Table 7. The literature indicates that the onset of cracking on specimen surfaces may be noted when expansion exceeds a level of 0.05% [21].
Table 7 BS 812-123 Concrete prism test, suggested criteria for interpretation (BSI WG B/502/6/10) [4] Expansion for up to 12 months, % of initial length at 7 days > 0.20 0.10 to 0.20 > 0.05 to 0.10 0.05 Classification for the aggregate combination tested Expansive Possibly expansive Probably non-expansive Non-expansive Aggregate type Normal reactivity Normal reactivity Low reactivity Low reactivity
3.2.5
Unsheltered External Exposure Site Tests and Optical Microscopy Assessment
Details of the external exposure tests and optical microscopy assessment carried out on selected materials and samples are given in Sections 6.0 and 7.0, respectively.
4.0 Phase 1: Classification of RA Components Using Rapid Tests

The objectives of Phase 1 of the experimental programme were to carry out tests to identify, by rapid means, RA materials that may represent a risk in terms of ASR. These tests: i. ii. iii. established the levels of alkali released from RAs following the method developed by RILEM/CANMET [18]. determined the level of reactivity of the various RAs using the rapid mortar expansion ASTM C1260 test method [19]. examined reactivity of various materials and the influence of their alkali contribution with regard to ASR in concrete at 60oC and high humidity
4.1
RA Alkali Release (RILEM/CANMET)
The sodium (Na+) and potassium (K+) concentrations for each of the test materials and the alkali released in terms of Na2Oeq using the RILEM/CANMET test [18], by atomic absorption spectrometry are given in Table 8. The alkali released is also compared in Figures 1 to 4 for bricks and blocks, concrete, demolition waste and the range of other materials tested respectively. For the various materials, released alkali levels increased in the following general order, slate, plaster, road planings, concrete, bricks and blocks. With the exception of calcium silicate brick (which released alkali levels of around 0.15% Na2Oeq by mass), the RAs releasing greatest alkali were recently produced bricks and blocks, which were between 0.47% and 0.61% Na2Oeq by mass. Bricks from demolition waste had alkali contents of 0.21% and 0.40% Na2Oeq by mass. These were lower than those recently produced, suggesting differences in compositions and/or production techniques, or possible leaching of alkalis during service. The alkalis in the bricks may be due to quantities of sodium or potassium present, which are likely to be in the form of potassium or sodium sulfate. The alkalis in the lightweight concrete blocks will be mainly sourced from the Portland cement. Concretes recently produced in the laboratory (PC) and from the demolition waste had alkali contents of between approximately 0.15 and 0.20% Na2Oeq by mass. Differences between low and high strength concretes were minor and there were essentially no differences between concretes containing low and normal reactivity aggregates. In line with their coverage in guidance documents [4], the alkali release of GGBS concrete was lower than that of the others, while perhaps surprisingly, given its known alkali contribution to concrete [20], the FA concrete was higher (at 0.27% Na2Oeq). The alkali levels of the demolition concrete were slightly lower than those of the laboratory produced materials, again possibly reflecting constituent material differences or leaching during service. The results of the other materials indicate similar alkali release levels for road planings to those of concrete, suggesting that Portland cement may have been used as a filler in the material. The slate and plaster had the lowest levels of the materials tested of 0.1% Na2Oeq by mass or less. Comparisons of the total Na2Oeq from XRF tests and those from the RILEM/CANMET [18] alkali release tests are also given in Table 8. The results indicate that the clay bricks (both recently produced and from demolition waste), lightweight and IBAA blocks gave the highest relative alkali release, in most cases, in excess of 20%. The recently produced concretes were generally between 10 and 15%, while those of the demolition waste concretes were around 5%. The calcium silicate brick, slate and road planings all released less than 10% of their total alkali contents.
4.2
Mortar Expansion (ASTM C1260)
The results obtained from the mortar expansion ASTM C1260 [19] tests to 14 days are given in Figures 5 to 8. A comparison between the 14 day results for all materials is given in Table 9 and Figure 9, where the various classes for quantifying the risk of ASR, according to the ASTM C1260 test method standard are shown. It should be noted that with this test the alkali content of the solution used is relatively high, such that variations in alkali release between materials
Table 8 Alkali release results for RAs using RILEM/CANMET test method MATERIAL Brick 1 Brick 2 Calcium Silicate Brick Lightweight Concrete Block IBAA Block FA Concrete GGBS Concrete 25 NL Concrete 25 NN Concrete 50 NL Concrete 50 NN Concrete Demolition Concrete 1 Demolition Concrete 2 Demolition Brick 1 Demolition Brick 2 Demolition Lightweight Concrete Road Planings Slate Plaster
- not tested, -- total Na2Oeq < 0.1% (see Table 3)
K 0.61 0.51 0.06 0.33 0.38 0.08 0.05 0.11 0.10 0.10 0.12 0.07 0.07 0.23 0.38 0.04 0.02 0.06 0.07
CONCENTRATION, % by mass of solids Na Na2Oeq % of Total Na2Oeq 0.11 0.61 16.3 0.05 0.47 23.4 0.09 0.16 8.2 0.16 0.47 22.7 0.22 0.60 27.7 0.16 0.27 0.05 0.10 0.09 0.20 10.8 0.08 0.18 9.0 0.09 0.19 8.7 0.08 0.20 15.5 0.08 0.15 4.0 0.06 0.14 5.0 0.02 0.21 22.8 0.07 0.40 38.3 0.04 0.08 16.7 0.10 0.15 4.6 0.02 0.07 5.7 0.03 <0.10 --
1.0
0.8
ALKALI RELEASE, % by mass of solids
0.6
0.4
0.2
0.0 Brick 1 Brick 2 Calcium Silicate Brick Lightweight Concrete Block IBAA Block
Figure 1 Alkali release of bricks and blocks using RILEM/CANMET test method
1.0
0.8
0.6
0.4
0.2
0.0 FA Concrete GGBS Concrete 25 NL Concrete 25 NN Concrete 50 NL Concrete 50 NN Concrete
Figure 2 Alkali release of recycled concretes using RILEM/CANMET test method
1.0
0.8
0.6
0.4
0.2
0.0 Demolition Concrete 1 Demolition Concrete 2 Demolition Brick 1 Demolition Brick 2 Demolition Lightweight Concrete
Figure 3 Alkali release of demolition waste using RILEM/CANMET test method
1.0
0.8
0.6
0.4
0.2
0.0 Road Planings Slate Plaster
Figure 4 Alkali release of other RA materials using RILEM/CANMET test method
is unlikely to influence the results and significant expansions will reflect the presence of reactive components in the aggregates. In line with expected behaviour, there was a gradual increase in expansion for the various mortars with time (Figures 5 to 8). However, in most cases, by the end of the test period, the expansion development appeared to level off. In addition, for all RAs, expansions measured by 14 days were all less than 0.06%, indicating that they were all in the innocuous region, according to ASTM C1260, suggesting low risk of ASR. Comparisons between bricks and blocks indicate that greatest expansions were recorded in Brick 1 and 2, with expansions of around 0.05%. The calcium silicate brick gave an expansion of 0.036%, while the lightweight concrete and IBAA blocks gave expansions of 0.022 and 0.039%, respectively. The expansions of the demolition bricks were slightly lower than those of the recently produced bricks. The results obtained for the tests on recycled concrete indicate that these gave a similar range of expansions to those noted for the masonry units. In this case, least expansion was obtained in the FA and GGBS concretes of around 0.025%. Little difference was found in the tests between low and high strength concretes and between concretes with normal and low reactivity aggregate combinations. The latter is slightly surprising, but may reflect variations in quantities of aggregate/paste present in the mortars following crushing to the required grading, between samples. Indeed, reference to the bulk oxide composition in Table 3 indicates that CaO is higher and SiO2 lower than would be expected, based on the concrete mix proportions and hence that the concretes (used as RAs) may be paste rich. This suggests that the characteristics of the concrete and crushing method may influence the composition of RA and potentially, therefore, impact on ASR. The demolition concretes fell within the range of results for those produced in the laboratory. As with the alkali release tests, the road planings gave similar type expansions to those of the recycled concrete as aggregate. Slate and plaster were at the lower end of the expansions measured for the range of materials examined.
0.20 0.18 0.16
Exposure, 80 C 1N NaOH
EXPANSION, % of initial length
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0 2 4 6 8 TIME, days Brick 1 Brick 2 Calcium Silicate Brick Lightweight Concrete Block IBAA Block 10 12 14 16
Figure 5 Expansion development of mortar containing bricks and blocks (ASTM C1260 test method)
0.20 0.18 0.16
Exposure, 80oC 1N NaOH
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0 2 4 6 8 TIME, days 25NL Concrete 25NN Concrete 50NL Concrete 50NN Concrete PFA Concrete GGBS Concrete 10 12 14 16
Figure 6 Expansion development of mortar containing concrete (ASTM C1260 test method)
0.20 0.18 0.16
Exposure, 80 C 1N NaOH
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0 2 4 6 8 TIME, days Demolition Concrete 1 Demolition Concrete 2 Demilition Brick 2 Demolition Brick 1 Demolition Lightweight Concrete 10 12 14 16
Figure 7 Expansion development of mortar containing demolition waste (ASTM C1260 test method)
0.20 0.18 0.16
Exposure, 80oC 1N NaOH
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0 2 4 6 8 TIME, days Plaster Road Planings Slate 10 12 14 16
Figure 8 Expansion development of mortar containing other RAs (ASTM C1260 test method)
Table 9 14 day ASR expansion test results (ASTM C1260 test method) 14 DAY EXPANSION, % of initial length 0.050 0.053 0.036 0.022 0.039 0.025 0.024 0.053 0.053 0.045 0.048 0.030 0.036 0.032 0.046 0.044 0.036 0.023 0.028
MATERIAL Brick 1 Brick 2 Calcium Silicate Brick Lightweight Concrete Block IBAA Block FA Concrete GGBS Concrete 25 NL Concrete 25NN Concrete 50 NL Concrete 50 NN Concrete Demolition Concrete 1 Demolition Concrete 2 Demolition Brick 1 Demolition Brick 2 Demolition Lightweight Concrete Road Planings Slate Plaster
0.30
14 DAY EXPANSION, % of initial length
0.25
Potentially deleterious*
0.20
0.15
Further testing required*
0.10
Innocuous*
0.05
0.00
te NN De te m Co ol nc iti on re De te Co m nc ol re iti on te 1 Co De nc re m te ol De iti 2 on m De ol Br iti m ick on ol iti 1 Li on gh tw Br ick ei gh 2 tC on cr Ro et ad e Pl an in gs ick oc k Bl oc k et e te te nc re nc re nc re Br ick Br ick nc re Sl at e Pl as t Br nc r Bl er 1 2 lic at e
te
Co
Co
Co
Co 50
nc re
IB A
NN
NL
Si
GG B
Co
ciu m
25
25
NL
FA
Ca l
* ASTM limits at 14 days
Li
gh
tw
ei g
ht
Figure 9 Comparative behaviour of RAs using ASTM C1260 test method
50
Co
4.3 4.3.1
Concrete Expansion Tests (BS 812-123, carried out at 60oC) Reactivity
It was initially intended, in the planning of the test programme, that results from the early tests of Phase 1 would be used to identify materials that represent a risk in terms of alkali release and expansion with respect to ASR. However, it was clear that there were only small differences between materials for both tests. It was, therefore, decided that, with the exception of slate and plaster, samples of the other material types examined would be considered in the expansion tests carried out on concrete. The main objective of this part of the work was to examine the reactivity of RA in concrete. Details of the materials tested during this work are given in Table 10. In all cases, the alkali content of the test concretes was 7.0 kg/m3, controlled through the cement content. The majority of the tests included RA as fine aggregate. In these concretes the following RAs were used, Brick 1, 50 NN concrete, Montrose Bridge concrete, lightweight concrete blocks, IBAA blocks, demolition waste, mortar and road planings. These replaced all of the fine aggregate (in the low reactivity aggregate combination) of the control concrete. Tests using RAs to examine the effect of (i) RA as coarse aggregate, using, Brick 1, 50 NN concrete and demolition waste (i.e. replacing coarse aggregate in the (low reactivity aggregate combination) control concrete), and (ii) RA content (as fine aggregate) using Brick 1 and IBAA blocks (i.e. replacing different portions of fine aggregate (in the low reactivity aggregate combination) control concrete)
Table 10 RA materials used in Phase 1 concrete reactivity tests (7.0 kg/m3 Na2Oeq concrete) RA CONTENT OF AGGREGATE FRACTION, by mass 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 25% 50% 25% 50%
RECYCLED AGGREGATE*
RA as FINE aggregate (combined with coarse aggregate)

50NN Concrete Brick 1 Lightweight Concrete Block Road Planings Mortar IBAA Block Demolition Waste Montrose Bridge Concrete Control 50NN Concrete Brick 1 Demolition Waste Brick1 Brick1 IBAA Block IBAA Block
RA as COARSE aggregate (combined with fine aggregate)
RA as FINE aggregate (combined with a mix of coarse and fine aggregate)
* RA combined as indicated with coarse or fine aggregate (or a mix of these) of the low reactivity aggregate combination (North Fife sand and gravel)
Fine RA The results showing the expansion development obtained for the range of materials in the 60oC exposure using RA at 100% of the fine aggregate are given in Figure 10, whilst the 12 week results from these tests are plotted in Figure 11. The results indicate that in all cases there was an increase in expansion with time, but at a gradually reducing rate.
0.20 0.18
0.16 0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0
Exposure: 60oC, RH > 95% Alkali content, 7.0 kg/m Low reactivity aggregate Fine aggregate replacement
8 TIME, weeks
10
12
14
Control Demolition
Road Planings IBAA Blocks
Brick 1 Lightweight Concrete Blocks
50NN Concrete Montrose Bridge Concrete
Figure 10 Expansion development for concrete containing RA as FINE aggregate (60oC - reactivity test)
0.20 0.18
12 WEEK EXPANSION, % of initial length
0.16 0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 Control 50NN Concrete Lightweight Concrete Block Road Planings Demolition Waste Montrose Bridge Concrete Brick 1 IBAA Block
Figure 11 12 week expansion for concrete containing RA as FINE aggregate (60oC - reactivity test)
The expansion ranking for the materials at 12 weeks, lowest to highest was Brick 1, IBAA block, demolition waste, control, lightweight concrete block, Montrose Bridge concrete, 50 NN concrete and road planings. In the majority of cases, the concretes exhibited expansions of less that 0.07% compared to their initial length, by the conclusion of the tests. The exception to this was the road planings, which had expansions more than double those of the other concretes. It is unclear whether the high expansion of road planings was caused by ASR, or some other effect. For example, road surface courses can comprise greywacke aggregates or similar, which may be susceptible to ASR. The test temperature could also have influenced the volume stability of the aggregate, although high expansions were not observed in the ASTM C1260 tests. In order to examine this further, it was decided to use a chemical test method on one of the road planing test specimens to establish the presence of ASR products or not. The technique used was the dual staining method described by Guthrie and Carey [24], where the abundance and distribution of potassium and calcium (chemically distinct ASR gel products) is identified. One of the ASR test prisms was sawn in half and then rinsed with de-ionised water. It was then treated with the staining solutions in the following sequence: rinse - sodium cobaltinitrate treatment rinse rhodamine B treatment - rinse After rinsing, stained regions can be observed (yellow potassium, and pink calcium) and are normally concentrated at the paste / aggregate interfaces and cracks if ASR is occurring. The results of this test indicate minor yellow staining and uniform distribution of pink staining. While not conclusive, these suggest that ASR is unlikely to be occurring. Overall the results indicate that (with the exception of road planings) IBAA blocks, Brick 1 and demolition waste all had lower expansions than the control, while those containing normal reactivity aggregate (50NN concrete), lightweight concrete block and that with aggregate known previously to have exhibited ASR (Montrose Bridge concrete) were only 0.01 to 0.02% higher. Coarse RA The expansion results from tests on selected materials carried out with 100% replacement of coarse aggregate with RA are given in Figures 12 and 13. The results are similar to those obtained for the corresponding tests with fine RA, in terms of expansion development with time, and ranking of the various materials. This is despite greater quantities of (coarse) RA in these concretes. The results suggest that little or no effect of particle size in relation to ASR damage. RA Content The results obtained on selected RAs (Brick 1 and IBAA blocks) tested to examine the effect of aggregate content in concrete and whether there is a pessimum proportion with respect to ASR are given in Figures 14 and 15. The 12 week results are compared in Figures 16 and 17. The data indicate, for both materials, that the low expansions found for the tests with 100% RA were also noted for the 25 and 50% levels tested, and these were essentially indistinguishable at the different RA levels, suggesting that there is no pessimum proportion.
0.20 0.18 0.16
Exposure: 60 C, RH > 95% Alkali content, 7.0 kg/m Low reactivity aggregate Coarse aggregate replacement
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0 2 4 6 TIME, weeks Control Brick 1 50NN Concrete Demolition Waste 8 10 12 14
Figure 12 Expansion development for concrete containing RA as COARSE aggregate (60oC - reactivity test)
0.20 0.18 0.16
Exposure: 60oC, RH > 95% Alkali content, 7.0 kg/m Low reactivity aggregate Coarse aggregate replacement
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 Control 50NN Concrete Demolition Waste Brick 1
Figure 13 12 week expansion for concrete containing RA as COARSE aggregate (60oC - reactivity test)
0.20 0.18 0.16
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0 2 4 6 8 10 12 14
TIME, weeks Control 25% Brick 50% Brick 100% Brick
Figure 14 Expansion development for concrete containing different levels of Brick 1 as FINE aggregate (60oC - reactivity test)
0.20 0.18 0.16
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0 2 4 6 TIME, weeks 8 10 12 14
Control
25% IBAA Block
50% IBAA Block
100% IBAA Block
Figure 15 Expansion development for concrete containing different levels of IBAA as FINE aggregate (60oC - reactivity test)
0.20 0.18 0.16
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 Control 25% Brick 1 50% Brick 1 100% Brick 1
Figure 16 12 week expansion for concrete containing different levels of Brick 1 as FINE aggregate (60oC - reactivity test)
0.20 0.18 0.16
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 Control 25% IBAA Block 50% IBAA Block 100% IBAA Block
Figure 17 12 week expansion for concrete containing different levels of IBAA as FINE aggregate (60oC - reactivity test)
4.3.2 Alkali Release

This work was concerned with establishing alkali contributions from RA to the ASR process. Details of the materials tested during this part of the work are given in Table 11. In all cases, tests used RA to replace the fine aggregate of the normal reactivity aggregate combination control. The alkali content of the test concretes was 5.4 kg/m3 controlled through the cement content, which related work has shown [20] is sufficient to cause measurable expansion due to ASR with the aggregate combination being used. Therefore, any alkali contribution from the RA, should lead to increased expansions compared to the control, assuming it has similar reactivity to the aggregate it replaces.
Table 11 RA materials used in Phase 1 concrete alkali release tests (5.4 kg/m3 Na2Oeq concrete) RA CONTENT OF AGGREGATE FRACTION, by mass 100% 100% 100% 100% 100% 100% 100% 100% -
RECYCLED AGGREGATE*
RA as FINE aggregate (combined with coarse aggregate)

50NN Concrete Brick 1 Lightweight Concrete Block Road Planings Mortar IBAA Block Demolition Waste Montrose Bridge Concrete Control
combination (Trent Valley gravel)
* RA combined as indicated with coarse aggregate of the normal reactivity aggregate
The results obtained from the tests to examine the influence of alkali release from the RAs on the expansion due to ASR are given against time in Figure 18. A comparison of the 12 week results is made in Figure 19. The results indicate that the general behaviour, noted previously in Section 4.3.1 of increasing expansion with time was also noted. While in some cases, expansion rates reduced with exposure period, in others, particularly those at higher expansion levels, it remained approximately constant during the 12 week test period, suggesting expansion would continue beyond the conclusion of the tests. The concrete showing greatest expansion was (as with the reactivity tests) that of road planings. The expansion ranking for the other materials from lowest to highest was Brick 1, demolition waste, 50 NN concrete, IBAA block, Montrose Bridge concrete, mortar, lightweight concrete block and the control, which was just lower than that of the road planings. The expansions noted were, in the main, slightly greater than in Phase 1, reflecting the combination of RAs with normal reactivity coarse aggregate (albeit with a lower alkali content). With the exception of the control, road planings and lightweight concrete block, which had expansions of between approximately 0.11% and 0.14% at 12 weeks, in the majority of cases, expansions at the test conclusion were less than 0.08%. The results therefore suggest that the combined effect of alkali release and reactivity of the RAs used (excluding road planings) gave less expansion than that of the (normal reactivity aggregate combination) control concrete mixes.
0.20 0.18
0.16 0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0
Exposure: 60oC, RH > 95% Alkali content, 5.4 kg/m Normal reactivity aggregate Fine aggregate replacement
2 Control 50NN Concrete
8 TIME, weeks
10 Brick 1 IBAA Blocks
12
14
Road Planings Demolition Mortar
Lightweight Concrete Blocks
Montrose Bridge Concrete
Figure 18 Expansion development of concrete containing RA as FINE aggregate (60oC - alkali-release test)
0.20 0.18
0.16 0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00
Control
50NN Concrete
Lightweight Concrete Block
Road Planings
Demolition Waste
Brick 1
IBAA Block
Mortar
Figure 19 12 weeks expansion of concrete containing RA as FINE aggregate (60oC - alkali-release test)
5.0 Phase 2: Concrete Expansion Tests (BS 812-123, 38oC)

5.1 Reactivity
5.1.1 Fine RA
The results showing the expansion development for the range of materials in the 38oC reactivity tests (Na2Oeq , 7.0 kg/m3), with RA replacing the fine aggregate of the low reactivity aggregate combination are given in Figure 20, whilst the 52 week results from these tests are compared in Figure 21. The results indicate gradual increases in expansion with time for all materials. It was noted that the ranking obtained at 52 weeks broadly followed that of the 60oC tests, (ie, least to highest Brick 1, IBAA block, demolition waste, control, road planings, lightweight concrete block, Montrose Bridge concrete and 50NN concrete). With the exception of Montrose Bridge concrete and 50NN concrete, the expansions at 52 weeks for all other materials (Brick 1, IBAA block, demolition waste, control, road planings and lightweight concrete block) were less than 0.05%, indicating that these materials are of low reactivity and non-expansive according to the BRE Digest 330 classification [4]. Montrose Bridge and 50NN concretes had expansions between 0.05 and 0.06% and were therefore in the low reactivity and probably non-expansive class [4]. The results also suggest that the effects noted at 60oC for road planings were probably not due to ASR. While, there was a general levelling off of results beyond 52 weeks, the changes in expansion with time indicate some differences between materials. Indeed, by 186 weeks the ranking order, least to highest was road planings, lightweight concrete block, 50NN concrete, control, IBAA block, Brick 1, Montrose Bridge concrete and demolition waste, and expansions were all between approximately 0.06% and 0.09%. While all still gave relatively low expansions, this indicates some differences in reaction rates between materials with time.
5.1.2 Coarse RA
The corresponding expansion results with coarse RA in concrete at 38oC are given in Figures 22 and 23. As noted for fine RA, these gave gradual increases in expansion over the test period. The ranking of the concretes in this case, from lowest to highest expansion was demolition waste, control, bricks and 50 NN concrete. All of the test concretes at 52 weeks were in the low-reactivity and non-expansive class according to BRE Digest 330 (< 0.05%) [4]. By the end of the test period all of the test concretes had expansions of between 0.05 and 0.08%, with 50NN concrete slightly higher. As noted at 60oC, similar results were obtained for the RA as fine and coarse aggregate.
5.2
Alkali Release
The corresponding tests carried out on concretes at 38oC to 52 weeks and beyond for alkali release are given in Figures 24 and 25. In this case, the control was that taken from a related study [20] with the same aggregates and alkali content (and similar mix proportions to those used in the current study). In these tests, the ranking from lowest to highest expansion was as follows, Brick 1, demolition waste, lightweight concrete blocks, road planings, IBAA block, 50NN concrete, Montrose Bridge concrete and the control. This indicates some difference compared to the corresponding tests at 60oC. Indeed, the road planings at 38oC gave expansions in the middle of the range for the RA materials and not significantly higher, as noted at 60oC. In this case at 52 weeks, Brick 1, lightweight concrete block and demolition waste all exhibited expansions of less than 0.05%, while, road planings, IBAA block, and 50 NN concrete were between 0.05 and 0.10 % and Montrose Bridge concrete marginally above 0.10% and the control 0.13%. The results from the tests at both temperatures indicate that expansions were less than that of the control. In the tests carried out to 186 weeks, the expansions for all materials, with the exception of Montrose Bridge concrete, were less than 0.10%. In order to examine the influence of alkali contribution from the RAs used, the RA alkali release (from Phase 1) was plotted against the expansions recorded at 60oC and 38oC at 12 and 52 weeks respectively and this is shown in Figure 26. The results indicate that there appears to be no noticeable effect of alkali release on expansion and those materials, which release alkali, do not when replacing fine aggregate in the normal reactivity combination increase this beyond that of the control concrete. The relationship between 60oC and 38oC testing regimes is shown in Figure 27 and indicates that while there is general agreement between these, the expansions do not have a strong correlation.
0.20 0.18
0.16 0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0
Exposure: 38 C, RH > 95% Alkali content, 7.0 kg/m Low reactivity aggregate Fine aggregate replacement
20
40
60
80
100
120
140
160
180
200
TIME, weeks
Control 50NN Concrete Lightweight Concrete Blocks Road Planings Demolition Waste Montrose Bridge Concrete Brick 1 IBAA Blocks
Figure 20 Expansion development for concrete containing RA as FINE aggregate (38oC reactivity test)
0.20 0.18
0.16 0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00
BS 812-123 52 week limit for low reactivity aggregate
Control
50NN Concrete
Road Planings
Demolition Waste
Brick 1
IBAA Block
Figure 21 52 week expansion for concrete containing RA as FINE aggregate (38oC reactivity test)
0.20 0.18 0.16
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0 20 40 60 80 100 120 140 160 180 TIME, weeks Control 50NN Concrete Demolition Waste Brick 1
Figure 22 Expansion development for concrete containing RA as COARSE aggregate (38oC reactivity test)
0.20 0.18 0.16
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 Control 50NN Concrete Demolition Waste Brick 1 BS 812-123 52 week limit for low reactivity aggregate
Figure 23 52 week expansion for concrete containing RA as COARSE aggregate (38oC reactivity test)
0.20 0.18
0.16 0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0
20
40
60
80
100
120
140
160
180
200
TIME, weeks
Control [20] Demolition Waste
Road Planings IBAA Blocks
Brick 1 Lightweight Concrete Blocks
50NN Concrete Montrose Bridge Concrete
Figure 24 Expansion development of concrete containing RA as FINE aggregate (38oC alkali-release test)
0.20 0.18
0.16 0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00
Control [20]
50NN Concrete
Road Planings
Demolition Waste
Brick 1
IBAA Block
Figure 25 52 week expansion for concrete containing RA as FINE aggregate (38oC alkali-release test)
0.20 0.18
0.16 0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 ALKALI RELEASED, % by mass of solids
Control, 38oC [20] Brick 1, 60oC IBAA Block, 38oC Demolition Waste, 60oC 50NN Concrete, 38oC Control, 60oC Lightweight Concrete Block, 38oC IBAA Block, 60oC Road Planings, 38oC 50NN Concrete, 60oC Brick 1, 38oC Lightweight Concrete Block, 60oC Demolition Waste, 38oC Road Planings, 60oC
Figure 26 Relationship between alkali release of RAs and 12 and 52 week expansion for RA as FINE aggregate in concrete (38oC and 60oC - alkali release tests)
0.20 0.18 0.16 0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00
EXPANSION AT 12 WEEKS (60OC), % of initial length
Alkali content, 5.4 kg/m Normal reactivity aggregate Fine aggregate replacement
Road Planings
0.00
0.02
0.04
0.06
0.08
0.10
O
0.12
0.14
0.16
0.18
0.20
EXPANSION AT 52 WEEKS (38 C), % of initial length
Figure 27 Relationship between concrete expansions for 38oC (52 week) and 60oC (12 week) test regimes
5.3
Additional Tests
5.3.1 Demolition Materials

In order to examine the effect of material variability of combined RAs, demolition material was obtained from four sites (Brechin, Dundee, Dundee -1 and Bristol) and used in reactivity tests. The concretes tested had a Na2Oeq of 7.0 kg/m, with RA used as both fine and coarse aggregate (replacing these in the low reactivity aggregate combination). The expansion development of these is shown in Figures 28 and 29 respectively. The results indicate that by 52 weeks, the majority of RAs had expansions less than the BRE Digest 330 [4] limit of 0.05% for non-expansive / low reactivity aggregates (Figures 30 and 31). By 130 weeks all specimens had expansions of less 0.08%. There was very little difference in behaviour between fine and coarse RAs in concrete, although the rankings changed slightly. The results also gave general agreement with those described above with the other RA materials.
5.3.2 High Expansion / High Alkali Release Materials

Additional samples of material exhibiting either high expansion or alkali release were obtained, (i.e. road planings and brick) and used as fine aggregate (replacing this in the low and normal reactivity aggregate combinations) in concrete with Na2Oeq of 7.0 kg/m and 5.4 kg/m. The results from these tests are shown in Figures 32 and 33. The tests with road planings indicate that at both alkali contents and aggregate combinations, the results were generally similar at around 0.05 to 0.06% at 52 weeks. By 104 weeks, expansions were between 0.06 and 0.08%, with the newer sample (Road Planings -1) giving slightly higher expansion in the 7.0 kg/m concrete. The tests with Bricks 1 and 3 in concrete with Na2Oeq of 7.0 kg/m and 5.4 kg/m indicate that while Brick 1 had expansions of around 0.025 and 0.03% at 52 weeks, Brick 3 was around 0.06%. While Brick 1 exhibited only minor changes at subsequent test ages, Brick 3 increased to levels of around 0.08% by 104 weeks. Chemically Brick 3 had a slightly higher alkali content than Brick 1, but the two bricks were otherwise similar. These differences in expansion between bricks are unlikely to have any practical significance.
5.3.3 Combination with High Reactivity Aggregates

In these tests coarse RA found in the earlier work to exhibit relatively high reactivity (expansions) or to release alkalis (i.e. road planings, brick and recycled concrete) were combined with fine aggregate (borosilicate glass) which in previous studies has given high expansions with respect to ASR [25]. These were tested in concrete with Na2Oeq of 7.0 kg/m and 5.4 kg/m with the coarse aggregate of the low and normal reactivity combinations also tested. The results from these tests are shown in Figures 34 and 35. These indicate that at 52 weeks all alkali contents / aggregate combinations gave expansions of between 0.05 and 0.08% by 52 weeks. For both tests the concrete containing the coarse aggregate of the low and normal reactivity combinations were similar and had higher expansions than the RAs considered. It also appeared that in considering the reactivity of the borosilicate glass, this lay somewhere between the North Fife and Trent Valley aggregates (and was not as reactive (expansive) as expected). It is apparent that between 52 and 104 weeks, there were further increases in expansion of about 0.02 to 0.03%, but all were 0.10% or less by 104 weeks.
0.20 0.18 0.16
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0 20 40 60 TIME, weeks Bristol Brechin Dundee Dundee -1 80 100 120 140
Figure 28 Expansion development of concrete containing demolition materials as FINE aggregate (38oC reactivity test)
0.20 0.18 0.16
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0 20 40 60 TIME, weeks Bristol Brechin Dundee Dundee -1 80 100 120 140
Figure 29 Expansion development of concrete containing demolition materials as COARSE aggregate (38oC reactivity test)
0.20 0.18 0.16
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 Bristol Brechin Dundee Dundee -1 BS 812-123 52 week limit for low reactivity aggregate
Figure 30 52 weeks expansion of concrete containing demolition materials as FINE aggregate (38oC reactivity test)
0.20 0.18 0.16
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 Bristol Brechin Dundee Dundee -1 BS 812-123 52 week limit for low reactivity aggregate
Figure 31 52 weeks expansion of concrete containing demolition materials as COARSE aggregate (38oC reactivity test)
0.20 0.18 0.16
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0 20 40 60 TIME, weeks Road Planings 0.20 0.18 0.16 Road Planings -1 80 100 120 140
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0 20 40 60 TIME, weeks Brick 1 Brick 3 80 100 120 140
Figure 32 Expansion development for high reactivity / high alkali release materials as FINE aggregate (38oC reactivity test)
0.20 0.18 0.16
Exposure: 38 C, RH > 95% Alkali content, 5.4 kg/m Normal reactivity aggregate Fine aggregate replacement
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0 20 40 60 TIME, weeks Road Planings 0.20 0.18 0.16 Road Planings -1 80 100 120 140
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0 20 40 60 TIME, weeks Brick 1 Brick 3 80 100 120 140
Figure 33 Expansion development for high reactivity / high alkali release materials as FINE aggregate (38oC alkali-release test)
0.20 0.18 0.16
Exposure: 38 C, RH > 95% Alkali content, 7.0 kg/m Glass aggregate Coarse aggregate replacement
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0 20 40 60 TIME, weeks Low Reactivity Aggregate 50NL Concrete Brick 3 Road Planings -1 80 100 120
Figure 34 Expansion development for glass FINE / RA COARSE aggregate concretes (38oC reactivity test)
0.20 0.18 0.16
Exposure: 38oC, RH > 95% Alkali content, 5.4 kg/m Glass aggregate Coarse aggregate replacement
0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0 20 40 60 TIME, weeks Normal Reactivity Aggregate 50NL Concrete Brick 3 Road Planings -1 80 100 120
Figure 35 Expansion development for glass FINE / RA COARSE aggregate concretes (38oC alkali-release test)
6.0 Phase 3: Unsheltered External Exposure Site Tests

In addition to the controlled tests carried out in the laboratory, further tests were initiated at an unsheltered external exposure. This provides a means of examining performance under real exposure conditions and of validating the results obtained under the conditions in the laboratory. Based on the results obtained from the RA alkali release tests and the 60oC tests of Phase 1, those RA materials most likely to influence ASR were selected for testing. These included road planings (which expanded most; road planings 1), bricks (which released most alkali; Brick 3) and a recycled concrete (50NL). The alkali contents of the test concretes were 7.0 kg/m3 and 5.4 kg/m3 and they were used to replace fine aggregate in low and normal reactivity aggregate combinations, respectively. Large concrete blocks containing these materials were cast and cured under wet Hessian and polythene sheeting, following demoulding, for a week, prior to exposure (Figure 36). Demec reference points were attached and used for measurement of expansion. The external exposure conditions (temperature and relative humidity) for the local area [26] are given in Figure 37. Under these, it should be recognised that the specimens will be subject to volume changes (shrinkage and expansion) in addition to any effects caused by ASR. Expansion measurements taken on these samples indicate little or no change in length between the reference points by 3 years. Visually, there was no sign of any damage on the concrete surfaces. The results to 3 years, therefore, show general agreement with the tests carried out on these material at 38oC, where the results for the combinations suggest that these were low reactivity, probably non-expansive [4].
Trowelled surface (uppermost at casting)
500
200
Specimen size, 500 x 250 x 200 mm
200 All dimensions in mm 250 Demec point
TEST FACE
Figure 36 Schematic of large concrete blocks and external ASR testing exposure
MEAN MONTHLY RELATIVE HUMIDITY, %
85 80 75 70 65 60 55 50
SCRI Data Relative Humidity SCRI Data Temperature Relative Humidity Temperature
Dundee Exposure Site Dundee Exposure Site Temperature = 12 3C 8% Relative Humidity = 70 Relative Humidity = 70 8% Temperature = 12 3C
Figure 37 Typical external exposure site conditions (SCRI: Scottish Crop Research Institute [26]) 45
Ju ne
Ju ly
Au gu st
Based on 12 month expansion results, samples were taken from a selection of the 38C test specimens (Phase 2) for optical assessment. Although the samples selected showed larger expansions than the others which were not tested, it should be noted that their expansions were still modest, at around 0.05% (Table 12). Samples were also taken from all of the specimens at the external exposure site for optical microscopy. Cores were taken and trimmed using diamond bladed machinery to obtain suitable size discs to be clamped in a grinder/polisher machine after gently vacuum drying and embedding in a dyed resin. The resin gives support to particles on the ground/polished surface and inhibits polishing powder from clogging voids/pores of the concrete. The various stages of sample preparation are shown in Figure 38. ASR leads to the formation of a pronounced siliceous rim around aggregates, which can be observed by optical microscopy. The deleterious effect of ASR correlates with the thickness of this layer, which in turn depends on the alkalinity of cement, moisture conditions and length of exposure. In a typical case, leading to noticeable damage in concrete, the thickness of the siliceous gel zone can be 100 m or more (Figure 39). Compared to this, the samples tested in the current study exhibited only very thin siliceous rims around some of the aggregate particles, generally not exceeding 10 m, with 14 m in the worst case. Images showing the maximum rim thickness for the samples tested in the study are given in Figures 40-61. In comparing the expansion values with the greatest (although relatively low) gel thicknesses found in the microscopic images, there was no simple correlation. For example, samples exposed to the external conditions may show aggregates with thicker siliceous rims than those in the 38C conditions. This discrepancy may be explained in part by local fluctuations of alkali content in concrete. The microscopic assessment can detect the thickness of the layer around the particles, but gives no information on when this occurred, or is occurring. In some cases where a relatively large siliceous rim is seen, but actual expansions are modest, it is possible that part of the ASR phenomenon had developed during the previous service of the RA, prior to inclusion in the test mixes.
Se p
7.0 Phase 4: Optical Microscopy Assessment

Ja br Fe
be r No ve mb er De c
rch
nu ar
ua r
Ap
Ma
t em
Ma
be
ril
40
Oc
to
Table 12 Sample details and maximum gel thickness observed during optical microscopy Concrete mix alkali content, kg/m Expansion, % of initial length (after x weeks) 0.072 (186) 0.083 (186) 0.077 (186) 0.098 (186) 0.066 (186) 0.051 (186) 0.065 (186) 0.163 (186) 0.083 (186) 0.096 (186) 0.060 (160) 0.054 (160) 0.083 (104) 0.072 (104) 0.105 (104) 0.094 (104) Observed maximum gel thickness, m
Sample
38C curing temperature

50 NN Concrete 50 NN Concrete Lightweight Concrete Blocks Lightweight Concrete Blocks Brick 1 Brick 1 Montrose Bridge Concrete Montrose Bridge Concrete Road Planings Road Planings Brechin (Coarse) Brechin (Fine) Road Planings -1 Road Planings -1 Glass Fine / Low Reactivity Coarse Glass Fine / Normal Reactivity Coarse 7.0 5.4 7.0 5.4 7.0 5.4 7.0 5.4 7.0 5.4 7.0 7.0 7.0 5.4 7.0 5.4 5 6 10 5 8 5 8 6 6 4 4 10 12 10 12 14
External exposure after 160 weeks

Road Planings -1 Road Planings -1 Brick 3 Brick 3 50 NL Concrete 50 NL Concrete 7.0 5.4 7.0 5.4 7.0 5.4 No change No change No change No change No change No change 12 10 8 6 12 10
Thus the risk of damaging ASR is low for the following reasons: Expansion potential of any susceptible aggregate has been reduced to some extent, Any susceptible aggregate is being diluted when used in making new concrete, Progression of ASR reaction is inhibited by the limited permeation of moisture through the existing siliceous layer around the susceptible aggregate particles.
Given the relatively low expansions and corresponding confirmation of low siliceous gel layer thicknesses, the microscopic study supports the macroscopic observation of satisfactory soundness and long-term volumetric stability from the expansion tests on concrete.
(a)
(b)
(c) (d)
Figure 38 Stages of sample preparation for optical microscopy assessment a) coring, b) trimming, c) embedding in resin, d) grinding/polishing
100 m
Figure 39 Typical ASR phenomenon (image taken during a previous CTU project, investigating the effects of glass cullet aggregate in concrete)
100 m
Figure 40 50 NN Concrete with 7.0 kg/m alkali content, stored at 38C for 186 weeks, gel thickness 5 m
100 m
Figure 41 50 NN Concrete with 5.4 kg/m alkali content, stored at 38C for 186 weeks, gel thickness 6 m
100 m
Figure 42 Lightweight Concrete Blocks with 7.0 kg/m alkali content, stored at 38C for 186 weeks, gel thickness 10 m
100 m
Figure 43 Lightweight Concrete Blocks with 5.4 kg/m alkali content, stored at 38C for 186 weeks, gel thickness 5 m
100 m
Figure 44 Brick 1 with 7.0 kg/m alkali content, stored at 38C for 186 weeks, gel thickness 8 m
100 m
Figure 45 Brick 1 with 5.4 kg/m alkali content, stored at 38C for 186 weeks, gel thickness 5 m
100 m
Figure 46 Montrose Bridge Concrete with 7.0 kg/m alkali content, stored at 38C for 186 weeks, gel thickness 8 m
100 m
Figure 47 Montrose Bridge Concrete with 5.4 kg/m alkali content, stored at 38C for 186 weeks, gel thickness 6 m
100 m
Figure 48 Road Planings with 7.0 kg/m alkali content, stored at 38C for 186 weeks, gel thickness 6 m
100 m
Figure 49 Road Planings with 5.4 kg/m alkali content, stored at 38C for 186 weeks, gel thickness 4 m
100 m
Figure 50 Brechin (Coarse) with 7.0 kg/m alkali content, stored at 38C for 160 weeks, gel thickness 4 m
100 m
Figure 51 Brechin (Fine) with 7.0 kg/m alkali content, stored at 38C for 160 weeks, gel thickness 10 m
100 m
Figure 52 Road Planings 1 with 7.0 kg/m alkali content, stored at 38C for 104 weeks, gel thickness 12 m
100 m
Figure 53 Road Planings -1 with 5.4 kg/m alkali content, stored at 38C for 104 weeks, gel thickness 10 m
100 m
Figure 54 Glass Fine / Low Reactivity Coarse with 7.0 kg/m alkali content, stored at 38C for 104 weeks, gel thickness 12 m
100 m
Figure 55 Glass Fine / Normal Reactivity Coarse with 5.4 kg/m alkali content, stored at 38C for 104 weeks, gel thickness 14 m
100 m
Figure 56 Road Planings -1 with 7.0 kg/m alkali content, external exposure, gel thickness 12 m
100 m
Figure 57 Road Planings -1 with 5.4 kg/m alkali content, external exposure, gel thickness 10 m
100 m
Figure 58 Brick 3 with 7.0 kg/m alkali content, external exposure, gel thickness 8 m
100 m
Figure 59 Brick 3 with 5.4 kg/m alkali content, external exposure, gel thickness 6 m
100 m
Figure 60 50 NL Concrete with 7.0 kg/m alkali content, external exposure, gel thickness 12 m
100 m
Figure 61 50 NL Concrete with 5.4 kg/m alkali content, external exposure, gel thickness 10 m
8.0 Conclusions and Practical Implications

Alkali release tests indicate for the range of RAs that the greatest alkali release was obtained from masonry units (clay bricks and concrete blocks). The exception to this was calcium silicate bricks, which were lower. The alkali release of concrete was generally less than that of the masonry units by more than 50%. Demolition waste, while showing similar effects to those of recently produced material, generally released slightly less alkali. Slate and plasterboard released the lowest quantity of alkali for the range of RA materials tested. ASTM C1260 tests carried out on mortars containing the RA materials indicate that all were within the innocuous region (expansion < 0.1% at 14 days), suggesting little reactivity and risk of ASR for the RA materials. BS 812-123 tests at 60oC and 38oC, examining the reactivity of both fine and coarse RAs, replacing sand or coarse fractions in a low reactivity aggregate combination, indicate that in almost all cases over the 12 and 52 week test periods, expansions of less than 0.07% were obtained, suggesting (using the BRE Digest 330 [4] for the 38oC/52 week tests) that as with the ASTM tests, these materials are likely to be low risk with respect to damaging ASR. Although there was a steady increase in expansion with time, by 186 weeks, the expansions (at 38oC) were all less than 0.10%. The cause of the high expansion observed for road planings at the high temperature appears to relate to the test exposure conditions. There appeared to be little effect of aggregate size and no pessimum proportions for the RAs tested. Expansions at 104 weeks, even in concretes with 7.0 kg/m3 Na2Oeq, did not significantly exceed 0.08% expansion suggesting that all would pass the criterion for greywacke (slowly expanding) aggregates at 5.0 kg/m 3 Na2Oeq. BS 812-123 tests on fine RA at 60oC (at an alkali content of 5.4 kg/m3 Na2Oeq) replacing sand in a normal reactivity aggregate combination indicate that all but one of the RAs had lower expansions than those of the control concrete and ranged from between 0.03% and 0.15% at 12 weeks (with road planings exhibiting the highest expansion). Tests at 38oC indicate that all RAs were less than that of the control concrete (0.13%) and Montrose Bridge concrete was the only other RA greater than 0.10% at 52 weeks. The results suggest that the combination of alkali release and reactivity of the RAs when replacing fine aggregate in a normal reactivity aggregate combination concrete gave less expansion that the control (normal reactivity aggregate combination) concrete.
Further tests on combined RA from UK demolition sites and with additional material samples for those that suggest high reactivity and alkali release, and aggregate combinations with potentially highly reactive aggregate (borosilicate glass) confirmed the findings of the other tests carried out. Tests on selected RA samples as fine aggregate (bricks, road planings and recycled concrete aggregate) at an unsheltered external exposure site using different alkali contents (7.0 kg/m3 and 5.4 kg/m3) and aggregate combinations (with low and normal reactivity coarse aggregate respectively) indicate little or no expansion by 3 years. Optical microscopy of a selection of the 38oC and external exposure test concretes indicates that the greatest rim thickness of ASR gel observed was 14 m, with most samples giving rims of < 10 m. These corroborate the findings of the expansion tests. In addition, none of the samples exhibited signs of the typical cracking that would accompany damaging ASR. Overall, the results indicate that RAs can contribute alkali to concrete, which was greatest with masonry units. The RAs when tested in concrete replacing sand or gravel in a low reactivity aggregate combination were found to give low reactivity. Greatest expansions tended to occur with materials containing reactive aggregates, or which have shown signs of ASR in their previous applications, e.g. in recycled concrete aggregate. The combination of alkali release and the reactivity of the RAs when replacing fine aggregate in a normal reactivity aggregate combination concrete gave less expansion than the control (normal reactivity aggregate combination) concrete.
9.0 References
1. 2. 3. 4. 5. 6. 7. BRITISH STANDARDS INSTITUTION. BS 8500-2. Concrete - Complementary British Standard to BS EN 206-1 Part 2: Specification for constituent materials and concrete, 2002. (Current Edition: 2006). TURANLI, T, BEKTAS, F and MONTEIRO, P J M. Use of ground clay brick as a pozzolanic material to reduce the alkali-silica reaction, Cement and Concrete Research, Vol.33, 2003, pp 1539-1542. BEKTAS, F, WANG, K and CEYLAN, H. Effect of crushed clay aggregate brick on mortar durability. Construction and Building Materials, Vol 23, No 5, 2009, pp 1909 -1914. BUILDING RESEARCH ESTABLISHMENT. BRE Digest 330, Part 2. Alkali-silica reaction in concrete - detailed guidance for new construction, BRE, Watford, 2004, 12pp. CONCRETE TECHNOLOGY UNIT. DTI/Industry Funded Project, (1999-2001), entitled, Resolving application issues with the use of recycled concrete aggregates. Final Report CTU/1601, 2001, 170pp CONCRETE TECHNOLOGY UNIT. DTI/Industry Funded Project, (1995-1998), entitled, Recycled concrete aggregate for use in BS 5328 Designated Mixes. Final Report CTU/498, 1998, 134pp. CONCRETE TECHNOLOGY UNIT. DTI/Industry Funded Project, (2001-2003), entitled, Demonstration project utilising coarse recycled concrete aggregates. Final Report CTU/2403, 2003, 109pp. CONCRETE TECHNOLOGY UNIT. DTI/Industry Funded Project (2000-2003), Realising a High-vale Sustainable Recycling Solution to Glass Cullet Surplus. Final Report CTU/2203, 2003, 120pp. CONCRETE TECHNOLOGY UNIT. DTI/Industry Funded Project, (2003-2005), entitled, Repackaging of previous research on the use of recycled materials and industrial by-products in concrete to facilitate sustainable urban development. Final Report CTU/3605, 2005, 30pp. CONCRETE TECHNOLOGY UNIT. DTI/Industry Funded Project, (2003-2005), entitled, Opportunities for creating medium value construction projects via demolition waste reconstitution. Final Report CTU/3705, 2005, 78pp. CONCRETE TECHNOLOGY UNIT. DTI/Industry Funded Project, (2003-2005), entitled, Oil drill cuttings for construction related value-added used. Final Report CTU/2405, 2005, 122pp. CONCRETE TECHNOLOGY UNIT. RMCEF/Industry Funded Project, (2004-2006), entitled, A guide to determining best practicable environmental options for recycling demolition waste. Final Report CTU/3806, 2006, 193pp. CONCRETE TECHNOLOGY UNIT. WRAP Funded Project (2004 2005), entitled, Recycled and secondary aggregates in foamed concrete. Final Report CTU/3405, STBC 13/13C, ISBN 1-84405-184-6, 2005, 66pp. CONCRETE TECHNOLOGY UNIT. WRAP Funded Project (2005 2007), entitled, Increasing the use of foamed concrete incorporating recycled and secondary aggregates. Final Report CTU/4207, AGG 79-0001, ISBN 1-84405347-4, 2007, 91pp. CONCRETE TECHNOLOGY UNIT. Investigation into EC aggregate test methods and their potential impact on recycled and secondary aggregates. Final Report CTU/4308, 2008, 54pp. CONCRETE TECHNOLOGY UNIT. Facilitating the wider use of coarse and fine recycled aggregates from washing plants. Final Report CTU/4508, 2008, 46pp. BRITISH STANDARDS INSTITUTION. BS 812. Testing aggregates - Part 123: Method for determination of alkalisilica reactivity. Concrete prism method, 1999. RILEM/CANMET. FOURNIER B and LU D, International Center for Sustainable Development of Cement and Concrete (ICON/CANMET), Canada & College of Materials Science and Engineering, Nanjing University of Technology, China, Test Method for Alkali Release, 2003. AMERICAN SOCIETY FOR TESTING AND MATERIALS. ASTM C1260. Standard test method for potential alkali reactivity of aggregates (mortar bar method), 1994.
8.
9.
10. 11. 12. 13. 14.
15. 16. 17.
18.
19.
20.
McCARTHY, M J, DHIR, R K, HALLIDAY, J E and WIBOWO A. Role of PFA quality and conditioning in minimising damaging ASR in concrete. Magazine of Concrete Research. Vol. 58, No. 1, 2006, pp 49-61. HOBBS, D W. Alkali-silica reaction in concrete. Thomas Telford, 1988, 183pp. BRITISH STANDARDS INSTITUTION. BS 5628. Code of practice for use of masonry Part 1, Structural use of unreinforced masonry, 2005. BUILDING RESEARCH ESTABLISHMENT. Design of normal concrete mixes. Report 331, 2nd Edition, Watford, UK, 1997, 46pp. GUTHRIE, G D and CAREY, J W A simple environmentally friendly and chemically specific method for the identification and evaluation of alkali-silica reaction. Cement and Concrete Research, Vol. 27, No. 9, 1997, pp 1407-1417. DHIR, R K and CUI, Y J. A study of the use of glass culler as sand, cement component and filler in concrete. Internal Report, University of Dundee, 2005. SCOTTISH CROP RESEARCH Institute, Private Communication, 2008.
21. 22.
23.
24.
25.
26.
Written by:
McCarthy, M J, Halliday, J E, Csetenyi, L J and Dhir, R K Concrete Technology Unit, Division of Civil Engineering University of Dundee
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Aggregate Research Programme/Final Report

Alkali-Silica Reaction Guidance for Recycled Aggregate in Concrete

ISBN: 1-84405-411-X Date: January 2009

Published by Waste & Resources Action Programme

The Old Academy 21 Horse Fair Banbury, Oxon OX16 0AH

Helpline freephone 0808 100 2040

6.0 7.0 8.0 9.0

ASR Testing on Recycled Aggregates 2

ASR Testing on Recycled Aggregates 3

ASR Testing on Recycled Aggregates 4

Overall Aim and Objectives of the Project

2.0 Experimental Programme

ASR Testing on Recycled Aggregates 5

Phase 1: Classification of RA Components using Rapid Tests

ASR Testing on Recycled Aggregates 6

Phase 2: Concrete Expansion Tests (BS 812-123, 38oC)

Phase 3: Unsheltered External Exposure Site Tests

Phase 4: Optical Microscopy Assessment

Test Materials and Assessment Methodologies Materials

ASR Testing on Recycled Aggregates 7

PC1 350 0.9 3140 59.5 125 0.6

PC2 360 2.5 3150 52.0 130 1

ASR Testing on Recycled Aggregates 8

Borosilicate Glass Sand 2.42 n/t

Grading, % passing by mass

Bulk Oxide Composition, % by mass

ASR Testing on Recycled Aggregates 9

Bulk Oxide Analysis

RA Alkali Release (RILEM/CANMET)

ASR Testing on Recycled Aggregates 10

ASR Testing on Recycled Aggregates 11

Mortar Expansion (ASTM C1260)

ASR Testing on Recycled Aggregates 12

*Consistence Class S2 (small dosage of superplasticizer added as required to achieve workability)

Unsheltered External Exposure Site Tests and Optical Microscopy Assessment

ASR Testing on Recycled Aggregates 13

4.0 Phase 1: Classification of RA Components Using Rapid Tests

RA Alkali Release (RILEM/CANMET)

Mortar Expansion (ASTM C1260)

ASR Testing on Recycled Aggregates 14

ALKALI RELEASE, % by mass of solids

ASR Testing on Recycled Aggregates 15

ALKALI RELEASE, % by mass of solids

0.0 FA Concrete GGBS Concrete 25 NL Concrete 25 NN Concrete 50 NL Concrete 50 NN Concrete

Figure 2 Alkali release of recycled concretes using RILEM/CANMET test method

ALKALI RELEASE, % by mass of solids

Figure 3 Alkali release of demolition waste using RILEM/CANMET test method

ASR Testing on Recycled Aggregates 16

ALKALI RELEASE, % by mass of solids

0.0 Road Planings Slate Plaster

Figure 4 Alkali release of other RA materials using RILEM/CANMET test method

ASR Testing on Recycled Aggregates 17

0.20 0.18 0.16

EXPANSION, % of initial length

0.20 0.18 0.16

Exposure, 80oC 1N NaOH

EXPANSION, % of initial length

ASR Testing on Recycled Aggregates 18

0.20 0.18 0.16

EXPANSION, % of initial length

0.20 0.18 0.16

Exposure, 80oC 1N NaOH