Feasibility of Sprayable Engineered Cementitious Composites Using Natural Sand and Low Fiber Content: Effect of Hybrid Fiber System, Silica Fume, and Air-Entraining and Shrinkage-Reducing Admixtures

Deterioration of corrugated steel culverts (CSCs) is a significant problem for the Virginia Department of Transportation and other U.S. transportation agencies. Spray-on lining using shotcrete engineered cementitious composites (ECCs) is a promising structural repair strategy for deteriorated CSCs. This study evaluates the feasibility of practical sprayable ECCs using natural silica sand and low fiber content, while forgoing the use of commonly utilized calcium sulfoaluminate cement to allow for delivery of the materials via ready-mixed concrete trucks. Aspects of the compositional space evaluated include the effect of a hybrid polyvinyl alcohol/polyethylene fiber system, silica fume (SF), shrinkage reducing admixture (SRA), and air-entraining admixture (AEA) on the properties of the composites. Experimental results suggested that the development of the proposed materials is feasible, because flow characteristics associated with shotcrete ECCs and ECC-like tensile ductility were achieved in the fresh and hardened state, respectively. Notwithstanding, further mixture optimization may be required for satisfactory field performance, which should be assessed through field testing. Generally, the use of the hybrid fiber system tended to improve the strength and ductility of the composites, especially when coupled with the use of SF. Furthermore, SF was effective at mitigating the strength loss associated with the incorporation of AEA and SRA, and meaningfully improved surface resistivity. SF also tended to reduce the mixture’s flow, whereas the contrary occurred with the use of SRA and AEA. SRA contributed to the reduction in drying shrinkage at early ages. However, the effect of SRA in reducing shrinkage was negligible at later ages.