Questions from the Field is a selection of questions NPCA Technical Services engineers received from calls, emails and comments on blogs or magazine articles on precast.org.
If you have a technical question, contact us by calling (800) 366-7731 or visit precast.org/technical-services.
Paul writes:
What factors could cause bugholes? How does aggregate gradation affect bugholes?
NPCA Technical Services engineers answered:
There are many different variables that could affect the surface finish of hardened concrete and cause bugholes. For conventional wet-cast concrete, the consensus is that the primary culprit is improper vibration, but that’s true even with self-consolidating concrete. The rapid placement of SCC could lead to entrapped air and, if procedures to remove the air aren’t in place, bugholes could form. Try to slow down the placement of fresh SCC into the form to see if this provides beneficial results. Also, you may need to reevaluate where the concrete is being placed in the form. The concrete may be getting pushed too far and trapping air on tricky corner sections or in areas with heavy reinforcement congestion. Other factors, including not properly applying form release agent, could also promote bughole development.
Your suggestion of aggregate gradations certainly can contribute to surface defects, including bugholes. The Portland Cement Association states, “Mix design can also be considered a significant contributor to bughole formation. Mix designs vary widely in their use of aggregate type, size, and grading and their use of admixtures and air-entrainment.”
PCA also states, “Workable, flowing mixtures are easier to place and consolidate and therefore reduce the risk of bughole formation. Concrete with an optimally graded aggregate that avoids excessive quantities of fine aggregate, properly proportioned cement content, and any admixture that provides increased flow, workability, or ease of consolidation contributes to bughole reduction.”
Another item to look into is the gradation of the fines. Very fine sands tend to hold more water, increase bleed water and add to the potential for trapped water, all of which could lead to bugholes. Also, sands that are very coarse without uniform gradation have been known to trap more air and, consequently, form bugholes. The best solution is to set up trial mixes to optimize the best results.
Jason writes:
Is there a specification regarding the exposed ends of supporting reinforcement in precast concrete? For example, exposed longitudinal ends in a precast concrete pipe.
NPCA Technical Services engineers answered:
Yes, there are provisions that address these situations. ASTM C76, “Standard Specification for Reinforced Concrete Culvert, Storm Drain, and Sewer Pipe,” Section 8.2, “Longitudinal Reinforcement,” (and the equivalent U.S. transportation standard AASHTO M170) states, “Each line of circumferential reinforcement shall be assembled into a cage that shall contain sufficient longitudinal bars or members to maintain the reinforcement in shape and in position within the form to comply with permissible variations in 8.1. The exposure of the ends of longitudinals, stirrups, or spacers that have been used to position the cages during the placement of the concrete shall not be a cause for rejection.”
Similar language can be found within the standards for precast concrete manholes and box culverts. The industry and owners recognize through decades of in-ground performance that these minimal areas of exposure have not shown to provide durability concerns or increased corrosion conditions. Forensic review of buried pipe or other precast products shows the oxide formation on these small steel ends is skin deep. It is believed the pH conditions of the surrounding concrete prohibit continued corrosion.
With respect to pipe and manholes which may be exposed to highly corrosive effluent conditions such as sanitary sewage or other special waste, it is considered a best practice to use non-corrosive spacers (coated steel or plastic) on the effluent side of the formwork. However, even in this case their exposure or presence is not a cause for rejection,per the standard or accepted production practices.
Leave a Reply