State-of-the-art Report On · E. Examples of successful projects F. Available resources (* FDDP =...
Transcript of State-of-the-art Report On · E. Examples of successful projects F. Available resources (* FDDP =...
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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 of
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 omitted)
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 open 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 outside 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 open 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
of the panel
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I-39/90 Bridge over 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 open channel,
one 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.
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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