Cracking is a major problem with newly placed concrete decks. These decks tend to develop full depth, transverse cracks and partial depth longitudinal cracks within a few months of the concrete being placed. A literature review showed that several other states had experienced similar problems. A review of data from Ohio bridge decks showed weak correlations between deck cracking and slump, time of year when the deck was placed, shrinkage, chloride permeability and compressive strength, but there was no clear relationship between cracking and any of these properties. Data also suggested that using a coarse aggregate with an absorption> 1% may help mitigate deck cracking but will not always stop it. As part of this study, 3 bridge decks were instrumented. One was a standard class "S" concrete deck and the other two were high performance concrete. The class "S" deck showed only hairline cracking after 1 year, but transverse cracking occurred in the HPC decks. Instruments were placed in the decks to monitor strains. From the data, it appears that cracking is caused by several factors. High heat of hydration caused the plastic concrete to expand. When the concrete sets and cools, tensile stressed develop. Further tensile stresses develop through drying shrinkage. Restraining the deck against normal thermal movement contributes to additional tensile stress. Autogeneous shrinkage, where high heats of hydration cause water evaporation during hydration, and plastic shrinkage may cause more tensile stress. Recommendations for mitigating cracking include using lower cement contents, adding pozzolans and retarders, using slightly higher water/cement ratios, using larger aggregates, taking steps to limit shrinkage and eliminating restraints.

In Phase I, the research team contacted each of 16 participating states to gather information about concrete and concrete material tests. A preliminary suite of tests to ensure long-term pavement performance was developed. The tests were selected to provide useful and easy-to-interpret results that can be performed reasonably and routinely in terms of time, expertise, training, and cost. The tests examine concrete pavement properties in five focal areas critical to the long life and durability of concrete pavements: (1) workability, (2) strength development, (3) air system, (4) permeability, and (5) shrinkage. The tests were relevant at three stages in the concrete paving process: mix design, preconstruction verification, and construction quality control. In Phase II, the research team conducted field testing in each participating state to evaluate the preliminary suite of tests and demonstrate the testing technologies and procedures using local materials.

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This manual provides guidance on evaluating the condition of the concrete in a structure, relating the condition of the concrete to the underlying cause or causes of that condition, selecting an appropriate repair material and method for any deficiency found, and using the selected materials and methods to repair or rehabilitate the structure. Guidance is also included on maintenance of concrete and on preparation of concrete investigation reports for repair and rehabilitation projects. Considerations for certain specialized types of rehabilitation projects are also given.