State-of-the-art Report On FULL-DEPTH PRECAST CONCRETE BRIDGE DECK - - PowerPoint PPT Presentation

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State-of-the-art Report On FULL-DEPTH PRECAST CONCRETE BRIDGE DECK - - PowerPoint PPT Presentation

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State-of-the-art Report On FULL-DEPTH PRECAST CONCRETE BRIDGE DECK PANELS (SOA -01-1911) Vince Campbell Former president of Bayshore Concrete Products Corporation, VA This presentation is developed by Sameh S. Badie, Ph.D., PE Associate

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State-of-the-art Report On FULL-DEPTH PRECAST CONCRETE BRIDGE DECK PANELS

(SOA -01-1911)

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Vince Campbell Former president of Bayshore Concrete Products Corporation, VA

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This presentation is developed by Sameh S. Badie, Ph.D., PE

Associate Professor George Washington University Washington DC, USA

Maher K. Tadros, Ph.D., PE

Professor Emeritus, University of Nebraska-Lincoln Founder, e.construct., USA, Omaha, Nebraska

for

Note: this presentation is a shortened version of a 2- hour training PCI class on Full Depth Precast Decks (Dec. 2011)

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Table of Contents

  • A. Introduction, Concept & Advantages
  • B. Component of the FDDP*
  • C. Details of the FDDP*
  • D. Miscellaneous issues
  • E. Examples of successful projects
  • F. Available resources

(* FDDP = Full-Depth Precast Concrete Deck Panels)

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10

Direction/Reinforcement

Transverse

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Table of Contents

  • A. Introduction, Concept & Advantages
  • B. Component of the FDDP*
  • C. Details of the FDDP*
  • D. Miscellaneous issues
  • E. Examples of successful projects
  • F. Available resources

(* FDDP = Full-Depth Precast Concrete Deck Panels)

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  • A. Introduction, Concept & Advantages
  • In 2001 FHWA launched a new initiative called

Accelerated Bridge Construction

  • The ABC objectives (motto) were:

Get in Get out Stay out High construction speed Low maintenance

  • FHWA Recommendation: Encourage using

prefabricated bridge elements, such as foundations, columns, girders and deck panels

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Full-Depth Precast Deck Panels (FDDP)

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Full Depth Precast Panels Do not Crack

  • Cracking of FDDP is substantially controlled

Because :

– Concrete is mature. It has already undergone most of its cement hydration temperature change, shrinkage and creep – The panels can be prestressed in the plant and post-tensioned at the site, creating two-way precompression.

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Fresh concrete Girder Fresh concrete shrinks because: 1. Temperature drops after the concrete sets (by as much as 80 degrees) εTemp. drop = α * ∆T = (6x10-6)(80) = 4.8x10-4 2. Loss of hydration water (by as much as 300 micro strains) εshrinkage = 3.0x10-4 Thus, total shrinkage strain, εtotal = 4.8x10-4 + 3.0x10-4 = 7.8x10-4 If concrete compressive strength, f’c = 1,000 psi at one day Modulus of elasticity, Ec = 57,000 (Sqrt 1,000) = 1,800 psi Tensile stress due to combined actions = εtotal * Ec = 1,400 psi Modulus of rapture = 7.5* Sqrt(f’c) = 237 psi Since the deck concrete is restrained by steel girders, it cracks Fresh concrete Girder

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FDDP Construction Speed High Shrinkage cracking Eliminated Hydration temperature cracking Eliminated Formwork Eliminated Maintenance cost Low Structural integrity Maintained Adaptability for continuous span bridges Yes Initial cost Relatively High Service life Long

Advantages

  • f

FDDP

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Table of Contents

  • A. Introduction, Concept & Advantages
  • B. Component of the FDDP*
  • C. Details of the FDDP*
  • D. Miscellaneous issues
  • E. Examples of successful projects
  • F. Available resources

(* FDDP = Full-Depth Precast Concrete Deck Panels)

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Components of the FDDP

Precast panels Shear pockets Shear key Transverse joints Overlay (may be

  • mitted)

Longitudinal joint Pockets for splicing longitudinal reinforcement Leveling bolts

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Table of Contents

  • A. Introduction, Concept & Advantages
  • B. Component of the FDDP*
  • C. Details of the FDDP*
  • D. Miscellaneous issues
  • E. Examples of successful projects
  • F. Available resources

(* FDDP = Full-Depth Precast Concrete Deck Panels)

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Panel-to-Girder Connection

A positive connection between the precast panels and the supporting girders is required to create a composite deck-girder system

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Concrete Girders

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Concrete Girders

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NEW CONSTRUCTION WITH COIL INSERTS AND COIL BOLTS

Concrete Girders

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NEW CONSTRUCTION WITH PROJECTING DOUBLE HEADED STUD

Concrete Girders

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Live Oak Bridge, TX

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Concrete Girders

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Steel Girders

I-39/90 Bridge over Door Creek, MacFarland, Wis

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Types of Shear Pockets

FDDP with individual Open shear pockets I-39/90 Bridge over Door Creek, MacFarland, Wis

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FDDPs with continuously

  • pen channels for PT and

composite connection

Skyline Bridge, Omaha, Nebraska

NCHRP 12-41

NUDECK System

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FDDPs with individual hidden shear pockets

Live Oak Bridge, TX

NCHRP 12-65

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Spacing Between Shear Pockets

S = 2 ft ASSHTO LRFD S = 4 ft NCHRP 12-65

  • Wis. DOT

I-39/90 Bridge over Door Creek, MacFarland, Wis S

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Panel-to-Panel Transverse Connection

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Male-Female (Tongue/Groove) Shear Key

Cracking, spalling & leakage were observed. Due to elevation adjusts and fabrication tolerances , the tongue/groove detail did not provide 100% match. Bloomington Bridge, Indiana State Highway Commission

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Female-to-Female Shear Key

Bulb Shape (NCHRP 12-41)

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Female-to-Female Shear Key

More flexible detail with higher level of mechanical interlocking capacity Diamond Shape (NCHRP 12-41)

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Leveling Bolts

Live Oak Bridge, TX

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Overlapping U-bars

Notes

  • Extending bars
  • utside the panels
  • Bending diameter vs

the panel thickness

  • Use U-shape bars

separate from panel reinforcement

Bill Emerson Memorial Bridge, Missouri DOT

Splicing Longitudinal Reinforcement Case 1: Reinforcing Bars, No PT

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Using HS Spirals

NCHRP 12-41

2" 6" + 1/4" ** 3 3/4" 4 1/8" #7 splice bar, 2'-2 1/2" long 2'-3" 4" OD, 1" pitch, 27" long, 1/4" diameter wire

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Using Open Steel Tubes

NCHRP 12-65

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Live Oak Bridge, TX

Notes

  • Alignment of slots
  • Tight fabrication tolerance
  • Durability was enhanced by minimizing

the exposed surface area of the grout (using hidden shear pockets and the

  • pen steel tube detail for splicing the

longitudinal reinforcement)

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Using Closed Steel Tubes

(NCHRP 12-65)

Notes

  • Tilting panels during

installation

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Splicing Longitudinal Reinforcement Case 2: Longitudinal Post Tensioning

longitudinal PT is distributed over the width

  • f the panel
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I-39/90 Bridge

  • ver Door Creek,

McFarland, Wis.

Notes

  • Pocket is wide

enough to allow for splicing of the ducts

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Skyline Bridge Omaha, Nebraska Note: Continuously

  • pen channel,
  • ne line of

studs, visible strand for longitudinal PT NUDECK NCHRP 12-41

longitudinal PT is concentrated at girder lines

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Transverse joints must be grouted before the longitudinal PT tendons are tensioned

I-39/90 Bridge over Door Creek, MacFarland, Wis

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Special end panel is required for anchorage of the PT strands

  • PT done with a small jack,

borrowed from UNL Lab

  • Contractor worker was

trained by UNL technician

  • Anchorage plate was locally

fabricated

Skyline Bridge, Omaha, Nebraska

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Longitudinal PT ducts are grouted

I-39/90 Bridge over Door Creek, MacFarland, Wis

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Grout shear pockets and haunches

I-39/90 Bridge over Door Creek, MacFarland, Wis

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Panel-to-Panel Longitudinal Connection

It is recommended to create the connection in a positive moment area

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Panel to Panel Longitudinal Connection

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Panel to Barrier Connection

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Panel-to-Barrier Connection

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Table of Contents

  • A. Introduction, Concept & Advantages
  • B. Component of the FDDP*
  • C. Details of the FDDP*
  • D. Miscellaneous issues
  • E. Examples of successful projects
  • F. Design Example
  • G. Available resources

(* FDDP = Full-Depth Precast Concrete Deck Panels)

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How to Handle Skew

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Building Grout Barriers for Transverse Connections

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Grout Barriers for Haunches

(between the Deck and the Girders)

Using wood forms

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Grout Barriers for Haunches Using steel angles

Skyline Bridge, Omaha, Nebraska

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Grout Barriers for Haunches Using compressible material

Live Oak Bridge, TX

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Overlay Options

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  • The least expensive option is Option “f”.

Provide an extra “wearing surface” thickness. Use standard roadway profiling grinders to smooth out the surface

  • Provide extra protection of the reinforcement.
  • Discoloration due at grouted joints and pockets

may be objectionable by some owners.

Overlay Options

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Table of Contents

  • A. Introduction, Concept & Advantages
  • B. Component of the FDDP*
  • C. Details of the FDDP*
  • D. Miscellaneous issues
  • E. Examples of successful projects
  • F. Design Example
  • G. Available resources

(* FDDP = Full-Depth Precast Concrete Deck Panels)

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  • The list include information on about 60

projects about: Location (state, county), Year Completed, Girder Type, Rehab/New, Span Length, Skew………….

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Table of Contents

  • A. Introduction, Concept & Advantages
  • B. Component of the FDDP*
  • C. Details of the FDDP*
  • D. Miscellaneous issues
  • E. Examples of successful projects
  • F. Design Example
  • G. Available resources

(* FDDP = Full-Depth Precast Concrete Deck Panels)

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Table of Contents

  • A. Introduction, Concept & Advantages
  • B. Component of the FDDP*
  • C. Details of the FDDP*
  • D. Miscellaneous issues
  • E. Examples of successful projects
  • F. Design Example
  • G. Available resources

(* FDDP = Full-Depth Precast Concrete Deck Panels)

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Available Resources

PCI (www.pci.org)

  • State-of-the-art Report On Full-depth Precast

Concrete Bridge Deck Panels, PCI Report No. SOA - 01-1911 (2011)

  • Full Depth Deck Panels Guidelines For Accelerated

Bridge Deck Replacement Or Construction, PCI Report No. PCINER-11-FDDP, 2nd edition (2011)

  • PCI Journal Papers (30+ papers, 1970s-2011).

Citation of many of these papers is provided in the SOA report.

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Available Resources

NCHRP reports (http://www.trb.org/NCHRP/NCHRPProjects.aspx)

  • M. Tadros et al., “Rapid Replacement of Bridge

Decks,” NCHRP 12-41, Report # 407 (1998)

  • S. Badie & M. Tadros, “Full-Depth, Precast-Concrete

Bridge Deck Panel Systems,” NCHRP 12-65, Report # 584 (2008)

  • C. French et al., “Evaluation of CIP Reinforced Joints

for Full-Depth Precast Concrete Bridge Decks,” NCHRP 10-71, Web only document 173 (2011)

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Available Resources

Miscellaneous

  • DOT Reports
  • Journal papers:
  • ASCE Bridge Journal,
  • ACI Structural Journal,
  • Concrete International…..
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Thank You………..

Please Note: The full length (120 Minute) PCI Class on FDDP will be available in December of 2011