Mechanistic Design Framework for Spalling Distress

Spalling is a distress form in concrete pavements that often manifests as the breakdown of the joint of a slab within 15 cm (6 in.) of the joint or crack and can occur at both longitudinal and transverse joints. Efforts have been under way at Texas A&M University to formulate mechanistic spalling models derived from data gathered in recent Texas Department of Transportation studies related to spall development. Extensive field studies have led to the establishment of a spalling mechanism consisting of a step-by-step process that can be characterized with engineering mechanics. These findings indicate that spalling is the result of damage initiated in the form of a shear delamination that is oriented parallel to and at a shallow depth below the surface of the pavement. Conditions necessary for formation of the delaminations include low interfacial strength between the aggregate and mortar and sufficient evaporation of pore water from the hydrating concrete, resulting in differential drying shrinkage near the pavement surface. Delaminations have been noted to initiate early in the life of the pavement and, once formed, extend later into spalls as a result of incompressibles, freeze-thaw cycles, traffic loading, and other such effects. A design framework for delamination formation and subsequent spalling development is presented in a practical format in which to mechanistically design concrete pavement systems relative to spalling distress.