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1、<p>  A review of the experience of thaumasite sulfate attack by the</p><p>  UK Highways Agency</p><p>  Neil Loudon</p><p>  Highways Agency, SSR CE SDM Division, Heron House

2、, 49-53 Goldington Road, Bedford MK40 3LL, UK</p><p><b>  Abstract</b></p><p>  The paper summarises and reviews the UK Highways Agency experience of thaumasite sulfate attack.</p

3、><p>  Thaumasite sulfate attack was found in February 1998 in a number of bridge foundations and buried columns on the M5Motorway in Gloucestershire. The paper will highlight the investigation of these structu

4、res, and assess the implications of the resultsof the extensive testing undertaken at these sites, for other structures.</p><p>  Subsequent to the discovery of thaumasite in Gloucestershire the Highways Age

5、ncy participated in the Thaumasite Expert</p><p>  Group set up by the Minister for Construction. The report produced by the group influenced the development of the Agencies own</p><p>  guidanc

6、e. Investigations were undertaken nationally using risk based criteria, to determine whether the occurrence of thaumasite</p><p>  was a local phenomenon, or of more widespread concern. Concurrently guidance

7、 was also issued for managing and minimising therisks of thaumasite in new construction, and this culminated in the development of a new specification for buried concrete. There arealso implications for ground investigat

8、ions, and these will be discussed.</p><p>  The paper will also highlight the case study of the A1 Mally Gill Bridge in County Durham, where a markedly different set of</p><p>  circumstances ga

9、ve rise to thaumasite sulfate attack in a foundation.</p><p>  The Highways Agency has been involved with the development of improved guidance, as a result of the Expert Group Report, to</p><p>

10、  ensure that that there is a consistency of approach across the construction industry. The paper will acknowledge that there are still</p><p>  many unknowns, particularly the mechanism governing the occurr

11、ence of thaumasite and the speed of thaumasite production.</p><p>  A particular aspect of concern to the Highways Agency is the ongoing management of structures that are known to be or may be</p><

12、;p>  affected by thaumasite.</p><p>  What are the methods for investigation and testing and are there suitable methods for remote detection?</p><p>  Do we need to introduce new inspection r

13、egimes?</p><p>  What are the requirements for the repair of thaumasite affected structures?</p><p>  Mention will be made of some of the research in this area, particularly the trial of repaire

14、d concrete at Moreton Valence.</p><p>  The paper will summarise the lessons learnt so far from the thaumasite experience, the implications for the future management of</p><p>  structures in po

15、tentially higher risk areas, and identify research needs.</p><p>  Crown Copyright _ 2003 Published by Elsevier Ltd. All rights reserved.</p><p>  Keywords: Thaumasite; Structures; Highways Agen

16、cy</p><p>  1. Background</p><p>  In early 1998, in the course of other maintenance and</p><p>  bridge strengthening works, unusual concrete deterioration</p><p>  wa

17、s found to have occurred in the foundations</p><p>  and buried columns on a couple of bridges on the M5</p><p>  Motorway in Gloucestershire. Subsequent investigations</p><p>  pro

18、ved that the observed defects were the result of</p><p>  thaumasite sulfate attack, and the Highways Agency</p><p>  were faced with a number of immediate questions.</p><p>  How s

19、erious was the attack?</p><p>  Were there structural implications?</p><p>  How many bridges were affected?</p><p>  Was it a local problem, or national?</p><p>  What

20、 were the costs?</p><p>  How do we undertake repairs or other remedial action?</p><p>  Were there any faults in the original design and construction?</p><p>  Were there implicati

21、ons for new construction?</p><p>  What were the implications beyond the Highways</p><p>  Agency interests?</p><p>  Do we need to carry out any research?</p><p>  095

22、8-9465/$ - see front matter Crown Copyright _ 2003 Published by Elsevier Ltd. All rights reserved.</p><p>  doi:10.1016/S0958-9465(03)00146-X</p><p>  Cement & Concrete Composites 25 (2003)

23、1051–1058</p><p>  www.elsevier.com/locate/cemconcomp</p><p>  This paper covers the responses to some of these</p><p>  questions, and summarises the current situation, and</p&g

24、t;<p>  identifies other issues for the future.</p><p>  2. Tredington-Ashchurch Bridge</p><p>  Thaumasite sulfate attack was first observed in early</p><p>  1998 on a High

25、ways Agency structure in the substructure</p><p>  of the Tredington-Ashchurch Bridge, an overbridge</p><p>  carrying a local road over the M5 Motorway situated</p><p>  between Ju

26、nctions 9 and 10 in Gloucestershire. At about</p><p>  the same time similar, but less severe defects, were also</p><p>  found in Grove Lane Bridge foundations, also on the</p><p>

27、  M5, but further south, between Junctions 12 and 13.</p><p>  Tredington-Ashchurch is a four span overbridge with</p><p>  a reinforced concrete deck. Supporting columns are</p><p>

28、;  sited in the central reserve and verges, and extend through</p><p>  placed fill for about 5 m to reinforced concrete spread</p><p>  footings. The bridge was built about 30 years ago, to the

29、</p><p>  applicable contemporary Ministry of Transport standards</p><p>  and specifications. Regular structural inspections</p><p>  and testing of the concrete elements above gro

30、und have</p><p>  not indicated any observable signs of distress to the</p><p>  bridge in the intervening period.</p><p>  Planned strengthening work to the columns of the</p>

31、;<p>  bridge necessitated excavation of some of the backfill</p><p>  surrounding the concrete supports, and in the course of</p><p>  this work site staff observed some unusual deterior

32、ation</p><p>  in the exposed concrete. This indicated that some of the</p><p>  concrete surfaces had turned to a _mushy’ consistency,</p><p>  and of _warty’ appearance with evide

33、nce of expansion of</p><p>  the residual material. This was unexpected to the say the</p><p>  least, and potentially extremely serious. Diagnosis was</p><p>  first made by our Ma

34、intenance Agents, Gloucestershire</p><p>  County Council/Halcrow and later confirmed by the</p><p>  Building Research Establishment (BRE) as thaumasite</p><p>  sulfate attack, af

35、ter initial concrete samples had been</p><p><b>  analysed.</b></p><p>  Further excavation of the backfill ensued to completely</p><p>  expose the buried columns and t

36、he top surface of</p><p>  the foundations, entailing extensive temporary works to</p><p>  provide the necessary support. A large programme of</p><p>  investigation was initiated,

37、 including extensive concrete</p><p>  sampling, and soil and groundwater testing, backed up</p><p>  by a thorough laboratory testing regime, and analytical</p><p>  work to correl

38、ate soil conditions with concrete defects.</p><p>  The objective was to determine the precise causes of the</p><p>  deterioration, and to see if parameters could be found</p><p> 

39、 that would assist future identification of affected structures</p><p>  and their investigation.</p><p>  Other papers at the conference will deal with the</p><p>  Tredington-Ashc

40、hurch case study in much more detail,</p><p>  however suffice to say that it transpired that a number of</p><p>  critical factors in combination had occurred (listed</p><p>  belo

41、w), which were significant in terms of the deterioration</p><p>  that occurred, and particularly in relation to the</p><p>  severity of the thaumasite sulfate attack:</p><p>  (a)

42、 use of limestone aggregates in the concrete;</p><p>  (b) use of sulfate and sulfide bearing materials for backfilling</p><p>  around the foundations and buried columns</p><p>  (

43、the soil excavated to construct the foundations contained</p><p>  iron pyrites (sulfides) which started to oxidise</p><p>  after exposure to the atmosphere, and added to the</p><p&g

44、t;  reservoir of available sulfates);</p><p>  (c) groundwater movements;</p><p>  (d) physical disposition of the structure (deep foundations</p><p>  and slender concrete elements

45、);</p><p>  (e) construction regime, particularly the excavation of a</p><p>  large hole through undisturbed ground which was</p><p>  subsequently backfilled with the excavated ma

46、terials</p><p>  and created a _sump’ around the buried columns;</p><p>  (f) leaking motorway drainage;</p><p>  (g) relatively cold conditions.</p><p>  These factors

47、 are illustrated in Fig. 1.</p><p>  When the deterioration was first observed, a decision</p><p>  was taken to close the local road carried by the bridge,</p><p>  on safety groun

48、ds, until such time as the extent and</p><p>  nature of the problem could be determined. Subsequently</p><p>  the defects were found to be surface effects, with</p><p>  a sound c

49、entral core of concrete remaining. Assessment</p><p>  of the structure showed that the road could be safely</p><p>  reopened whilst the investigations continued.</p><p>  Based on

50、 the information available at the time, and</p><p>  the need to undertake the planned strengthening work</p><p>  on the columns against vehicular impact, it was decided</p><p>  t

51、hat the columns should be removed. This decision was</p><p>  reached after considerable deliberation, and assessment</p><p>  of costed options, but was influenced by the lack of</p><

52、;p>  available information on how to repair structural elements</p><p>  affected by thaumasite. There was also uncertainty</p><p>  as to whether the concrete deterioration had</p>&l

53、t;p>  _stabilised’ or was continuing. In the event the most effective</p><p>  strategy was the complete removal of the bridge</p><p>  columns. A system of temporary propping was introduced&

54、lt;/p><p>  to allow the columns to be cut up and removed,</p><p>  and a new foundation and supports cast on top of the</p><p>  existing foundation.</p><p>  Alongside t

55、he continuing site investigation work, records</p><p>  of the structure were inspected, and also available</p><p>  geotechnical information. It was evident that the design</p><p>

56、  of 30 years ago had been undertaken in accordance with</p><p>  the standards and specifications of the time, based on</p><p>  the contemporary soil survey. This had duly taken account</p&

57、gt;<p>  of the prevailing soil conditions in regard to the</p><p>  occurrence of sulfates. However at that time there was</p><p>  no requirement to consider sulfides, and so in compari

58、son</p><p>  to the rules developed in 1999 in response to the</p><p>  discovery of thaumasite, may have underestimated the</p><p>  influence of sulfates by 2–3 classes (based on

59、BRE Di-</p><p>  1052 N. Loudon / Cement & Concrete Composites 25 (2003) 1051–1058</p><p>  gest 363 [1]). Clearly this was very significant, but no</p><p>  fault could be atta

60、ched to the design or construction</p><p>  process of 30 years ago.</p><p>  Whilst work was taking place at Tredington-</p><p>  Ashchurch Bridge, a further maintenance contract a

61、t</p><p>  Grove Lane Bridge further south on the M5 Motorway,</p><p>  revealed similar signs of thaumasite deterioration in</p><p>  buried concrete, although evidently not as sev

62、ere or as</p><p>  widespread. In this case after initial investigation, conventional</p><p>  concrete repairs were conducted, after removal</p><p>  of the contaminated concrete.&

63、lt;/p><p>  3. DETR Expert Group</p><p>  When the concrete deterioration was first discovered</p><p>  in the motorway bridges, it was immediately apparent</p><p>  that

64、the thaumasite attack was very serious, and there</p><p>  were potential implications for all new construction as</p><p>  well as existing buildings and civil engineering structures.</p>

65、<p>  The Highways Agency briefed the Department of</p><p>  the Environment Transport and the Regions (DETR)</p><p>  and Government Ministers. It also transpired that BRE,</p>&l

66、t;p>  through Dr. Norah Crammond and other colleagues,</p><p>  had been investigating thaumasite related concrete deterioration</p><p>  for nearly 10 years, though the results of this</p

67、><p>  research had not been published, and the current edition</p><p>  of BRE Digest 363 [1], made only passing reference.</p><p>  A decision was taken at Ministerial level to set u

68、p a</p><p>  National Expert Group under the chairmanship of</p><p>  Professor Les Clarke of University of Birmingham, with</p><p>  a remit to investigate thaumasite and report ba

69、ck within</p><p>  six months. This was a very tight constraint, but it was</p><p>  decided that it was essential to provide authoritative</p><p>  guidance at the earliest opportu

70、nity to allay public and</p><p>  industry concerns. The Expert Group was derived from</p><p>  a wide cross section of industry and the author was also</p><p>  seconded to represe

71、nt the Highways Agency.</p><p>  After considerable discussion and deliberation a report</p><p>  entitled “The Thaumasite Form of Sulfate Attack:</p><p>  Risks, Diagnosis, Remedia

72、l Works and Guidance on</p><p>  New Construction“ [2] was produced and published in</p><p>  January 1999. As such, it was a significant achievement</p><p>  to publish a very deta

73、iled report in such a short timescale,</p><p>  and represented a collaborative and very constructive</p><p>  approach by all the participants, although it</p><p>  was apparent th

74、at there were differing views on many</p><p>  aspects, and especially the detailed and complex chemistry</p><p>  involved in thaumasite. It was also apparent that</p><p>  many of

75、 the construction industry representatives, had</p><p>  understandable concerns about the commercial implications</p><p>  for their own sector of the market.</p><p>  The report d

76、ealt with the nature and risk of thaumasite</p><p>  and sulfate attack, inspection and testing requirements,</p><p>  structural assessment, remedial works, and a specification for new works, a

77、nd it is particularly with this last section I was involved. However the report as a whole provided authoritative guidance and recommendations for both new works, and for clients and property owners managing structures a

78、nd buildings.</p><p>  The report itself set out _guidance’ in areas where only limited research and case studies had been undertaken,but _recommendations’ where more reliable and well documented information

79、 was available. It was acknowledged that not all the answers were known. In particular there was much debate surrounding the mechanisms for occurrence of thaumasite, and the timescales over which it occurred, and in this

80、 area further research was essential. Consequently some caution had to be exercised in the detai</p><p>  One aspect of major importance, particularly as regards new construction, was the need to strike the

81、correct balance between technical issues and commercial interests. To do this the Report had to deal authoritatively with the technical concerns without unnecessarily placing restrictions on the use of the constituent ma

82、terials to produce concrete. At the time it was published</p><p>  the Report acknowledged that the information was of an interim nature and would need to be updated as more evidence concerning thaumasite be

83、come available. It also sought to _minimise’ the risk of future occurrence,rather than the introduction of draconian measures to completely eliminate the risks.</p><p>  Key facets to the Report were the ide

84、ntification of a</p><p>  number of primary and secondary factors governing the</p><p>  occurrence of sulfate (these are referred to later in the</p><p>  paper) and the classifica

85、tion of thaumasite in affected</p><p>  structures:</p><p>  (a) _TSA’ for thaumasite sulfate attack where there is</p><p>  significant damage to the matrix of the concrete or</

86、p><p>  (b) _TF’ for thaumasite formation where thaumasite is</p><p>  present in pre-existing voids in the concrete, but</p><p>  there is no deterioration evident (a latent stage in&

87、lt;/p><p>  development of TSA).</p><p>  The Report also contained practical information on</p><p>  the requirements and methods for identification and testing of concrete and soils

88、in existing structures, to determine if thaumasite is present. Particularly important was the strong message to clients and designers of new structures to undertake a thorough soil survey as part of the design process. T

89、his has always been undertaken on road building projects and major civil engineering contracts, but less so on smaller works, and in</p><p>  the domestic property market.</p><p>  Chapter 9 of

90、the Report provided detailed specification</p><p>  requirements for new construction to minimise the risk of thaumasite sulfate attack, based on the approach already adopted in BRE Digest 363 [1], namely by

91、 classifying the sulfate conditions in the soil adjacent to the designed concrete, and by setting a series of restrictions and options for the concrete mixes for each classification. However this approach was extended to

92、 adopt a “package” of measures to deal with all ground</p><p>  classifications. It sought to leave as many options open</p><p>  to designers, and particularly to the contracting and concrete s

93、upply industries, and all such options were deemed to be equally effective. There was also a desire to keep all guidance and recommendations as simple as possible, and user friendly.</p><p>  The Report reco

94、mmendations consisted of detailed materials requirements for concrete mixes and this was allied to a risk based strategy based on different structural</p><p>  performance levels, depending on the required&l

95、t;/p><p>  service life and usage of the structure. There was an</p><p>  overarching assumption that the soil/ground water</p><p>  classification had been correctly assessed, and the

96、 recommendations</p><p>  in chapter 6 of the Report had been</p><p>  followed, and so consequently the concrete requirements</p><p>  were appropriate to the existing and anticipa

97、ted future</p><p>  ground conditions. The recommended concrete options</p><p>  followed on from this correct sulfate classification of the</p><p>  soils, with due allowance for a

98、ny sulfides present. Other</p><p>  related guidance involved consideration of the construction</p><p>  operations and the need, where appropriate, to provide additional drainage around structu

99、res, to avoid creating sumps, and where possible not to use reworked sulfate/sulfide bearing backfills.</p><p>  The concrete materials requirements embodied various</p><p>  controls on cement

100、content, and free water/cement ratios, but adopted a new classification of aggregates by defining different carbonate ranges depending on the amount of carbonate present in the fine and coarse aggregate fractions. In ter

101、ms of the structural performance level the philosophy adopted was one based on banding of structures into high, normal and low performance,</p><p>  representing a range from long service life structures to

102、low performance for short service life structures, and structures with massive buried concrete foundations or those with slender or critical buried elements. This recognized that thaumasite attack in reality was assumed

103、to be a relatively slow process, and may be insignificant for structures with only a short design life. More restrictive measures would be required when dealing with longer service lives for structures and critical/sensi

104、ti</p><p>  where structures had short anticipated service lives.</p><p>  Since there were a number of areas where the dearth</p><p>  of research data prevented authoritative reco

105、mmendations for materials, it was agreed that it would be prudent to adopt a _multi-layered’ protection approach, whereby a number of additional protective measures would be instigated, in addition to the material requir

106、ements, in appropriate situations. They would represent an important first line of defence and consisted of the adoption of surface protection and drainage requirements,</p><p>  as well as the choice of low

107、er carbonate range aggregates in certain circumstances.</p><p>  Overall the Expert Group Report provided a number of important messages. The number of structures potentially at risk was not thought to be la

108、rge, and the structural consequences not generally serious. The deterioration would generally provide early warning signs above ground where significant thaumasite sulfate attack was occurring below ground. There was als

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