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PRESTRESSED
CONCRETE
FOR
BRIDGE
DECKS
JULY
1970
NUMBER
17
M.J.
GUTZWILLER
R.H
LEE
C.F.
SCHOLER
Technical Paper
PRECAST, PRES TRESSED CONCRETE FOR BRIDGE DECKS
J. F. McLaughlin, Director
TO:
H.
7-k-lk
Project No.:
C-36-56N
Respectfully submitted,
Harold L. Michael
Associate Director
HLM:ms
cc
F.
W.
w.
w.
M.
G.
L. Ashbaucher
L. Dolch
H. Goetz
L. Grecco
J. Gutzwiller
K. Hallock
M.
R.
V.
M.
E.
R.
E.
H.
E.
L.
M.
D.
Harr
Harrell
Harvey
Hayes
Mikhail
Miles
C. F. Scholer
M. B. Scott
W. T. Spencer
H. R. J. Walsh
K. B. Woods
E. J. Yoder
http://www.archive.org/details/precastprestressOOgutz
Technical Paper
PRECAST, PRESTRESSED CONCRETE FOR BRIDGE DECKS
by
M. J. Gutzwiller
R. H. Lee
C.
F.
Sender
Research Engineers
Conducted by
Joint Highway Research Project
Engineering Experiment Station
Purdue University
in cooperation with the
and the
U. S. Department of Transportation
Subject to Change
Purdue University
Lafayette, Indiana
July 16, 1970
Not Reviewed By
Indiana State Highway Commission
or the
Bureau of Public Roads
Abstract
University under the auspices of the Indiana State Highway Department and the
Bureau of Public Roads has demonstrated the feasibility of using precast, prestressed concrete slabs for deck replacement.
tensioned in the longitudinal direction with cables strung through preformed slab
ducts.
A thin rubber pad placed in the joints between slabs minimizes stress
to the supporting beams using spring clips and bolts screwed into preset anchors
in the concrete.
Laboratory research has dealt with the behavior of several joint shapes,
with a flat key-type joint selected for field use.
used provides adequate longitudinal slip resistance between the slab and the supporting beams.
little shear transfer between loaded units and the adjacent unloaded slabs.
An
initial set of repeated load tests to simulate wheel passage over a joint showed
distress at the joint, indicating the need for careful attention to joint detailing
and forming.
joint detail withstood ten million cycles of repeated load application and showed
no adverse effects.
Two field installations are planned for the Spring of 1970, one as a re-
placement deck for a heavily traveled bridge and the other on a newly installed
bridge
Introduction
The problem of concrete bridge deck spalling on many of our newer as well as
Furthermore the cost of repairs to highway agencies and cost of delays to the
durability of concrete bridge decks and greatly reduce the time required for
replacement of deteriorated bridge decks
A New Concept
The origin of this concept is directly related to the spalling of bridge
decks.
The Joint Highway Research Project at Purdue University, with the Indiana
State Highway Commission, has long been concerned with the durability of concrete.
Tne Indiana Highway Commission, and most other highway agencies, have through the
Their lack of success in this case is often dramatic and always obvious
When we consider the problem we find that several conditions exist on bridge
decks which are seldom found elsewhere.
environment are frequently the worst ever accepted for placing concrete.
What
may have been excellent concrete when mixed may be subject to unanticipated delays
between mixing and placement.
concrete on bridge decks all too often involve hand labor, poor finishing techniques, high wind, extreme temperatures and questionable curing.
It is smaL"
wonder that the product resulting from placing concrete in forms in the sky is not
concrete that the idea of taking the concrete to the environment rather than the
precast plant to obtain the highest quality of concrete and of steel placement.
It is well to realize that simply because the product is manufactured in a
Proper
Feasibility
The initial planning for this research project started in early 1967 with it
developing into an approved HPR research project in cooperation with both the
Indiana State Highway Commission and the Bureau of Public Roads in October 1967.
The initial feasibility study soon showed that the project had promise and that
Among the many questions which require an answer for the utilization of this
concept are:
What shape should the joints be?
What about joint material, both a sealer and one through which the post-
TYPICAL TEST
SECTION
o',
".
^m
yl
TYPICAL
I.
'
CROSS -SECTION AT
TIE
FIGURE
DOWN
Can the necessary cables and cable ducts be placed within the depth of the
slab?
What about discontinuous support of the slabs on the girders - how important
is this and how can voids be filled with a load bearing material?
Laboratory
I nvestigations
Others* have made detailed studies of anchor pull out, loss of bolt torque
with loading and other factors involved with the rail to concrete fasteners.
It is anticipated that clips will be only lightly fastened until after the
slabs are post-tensioned and they will then be fastened securely by means of a
torque wrench.
investigation which indicates that the "flat" joint of Figure 2(a) was
superior to either a semi -circular joint of Figure 2(b) or circular sector
joint of Figure 2(c) insofar as minimizing stress concentrations due to
longitudinal loading.
beam was loaded with an HS 20-U1* live loading and subsequent deflection
calculation made to develop a deflection curve.
develop the required deflection of the laboratory test beam holding the joint
test specimen as shown in Figure 3.
The "flat" joint was tested under a kO psi post-tensioning stress, with
photoelastic studies to consider a joint material to reduce the stress concentrations in the joint.
Capillary
movement of water within the cloth proved to be considerable and the asbestos was
not considered further.
A l/l6 inch, V60 neoprene sheet proved to be the most promising material for
the purpose and is being used in the first field evaluation.
recommended for field application does not have contact along the upper and lower
7
.0.375'
<r
SJL
0.5"
(a)
Flat
Joint
0.5"
<>
(b)
Semicircular
Joint
0.5'
.25" R
->
Circular
(c)
FIGURE
2.
Sector
PHOTOELASTIC
Joint
MODELS
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portions, hence a polyurethane joint sealing will be used on this portion of the
joint in the field.
will not vary in width as do pavement joints so the sealing problem is much less
difficult.
plastic sleeves are to insure that corrosive water cannot attack the post-
tensioning cables.
Following the investigations of the joint shape and joint material the
first commercially constructed pretensioned slabs were made and used in a labo-
of a dual lane bridge in which the length of the slab (longest dimension) is 32
feet.
When the
For the 8-foot beam spacing 12-7/16 inch diameter 270 kip strands were
used at 6 inch spacing with 6 strands in the top and 6 in the bottom layers
For a 4-foot beam spacing the steel was reduced to 8-7/16 inch diameter 270 kip
strands with
**
allowing zero tension in the concrete under full dead load, live load and impact.
Slabs were 6 inches deep with 1-1/2 inch of cover above and below the center line
of the strands.
shown in Figure
Wood blocks were used between the forms forming the joints
insufficient to keep joint forms aligned which is absolutely essential -for the
successful use of these precast concrete bridge slabs.
FIGURE
4.
PRECAST
SLAB TEST
SETUP
10
FIGURE
5.
SPECIMENS
11
were not aligned we did use these slabs for a phase of our laboratory investigation.
They worked well for measurement of slip tests between the girders and
the concrete slabs and it was found that they readily met the AASHO requirements.
The next phase of the laboratory tests required that specimens be post-tensioned
6.
reality an unsatisfactory set of slabs and that such work would have to be
rejected in the field we continued to utilize these slabs within the laboratory.
They were subjected to repetitive loads wherupon it was found that severe spalling
occurred after a very few cycles of loading where the irregularities or "high
spots" caused severe stress concentrations.
adjusted to make up for any loss in the stress or post-tensioning stress due to
a failure of a concrete adjacent to the joints and continued testing produced no
separate days, the first day the operation was closely observed by a graduate
student, Mr. Jim Ford, who was present on this project.
struction and the subsequent cutting of the steel was not observed.
On the
unobserved prestressed slabs light cracking occurred near the ends of the
prestressing strand.
had not been obtained at the time that the prestressing was released, causing a
slippage at the strand.
the prestressing strand that was observed on either this set of slabs or a subsequent casting of three additional concrete slabs.
12
TESTING
ARRANGEMENT
SPALL AT CENTER
FIGURE
6.
JOINT
SPACING
13
A second series of comme? cially cast prestressed slabs was made and proper
alignment of joints was obtained.
have undergone mere than 10 million cycles of simulated 18 thousand pound single
axle
Longitudinal Forces
The laboratory simulation of the deck system was subjected to longitudinal
forces tending to move the slab relative to the beam in order to measure friction
the joints and ensure that the entire deck moved as a unit.
units was measured by dial gages mounted at the corners of the slab units.
Oc-
Three test series were run, and total bolting force was variable in each
series.
The three series differed in the manner in which contact between the slab
Series
I -
The top flanges of the beams were leveled prior to the test
(compensating for the beam flange skew due to mill production tolerances).
Contact between slab and beam surface was essentially uniform.
Three support
11+
Series III - Support similar to Series II, except two beams at 8'-0" spacing
were used.
Total bolting force was found to have the greatest effect on longitudinal
slip force, rather than the actual arrangement of bolts to supply the force,
results of the tests are shown in Figure 7, which plots horizontal force at
slip versus total bolting force for each of the series.
ments providing the same bolting force give rise to the several sets of results
for the individual test series.
longitudinal force of five percent of the applied live load as specified by AASHO,
Vertical Loads
Static testing of the deck system under vertical loads was conducted with
the following variables:
Vertical loading:
0, 5, 10, 15 kips
Longitudinal prestress:
Bolting force:
0, 32, kQ kips
Beam spacing:
Figure 8 shows the loading arrangement used in the l+'-0" beam spacing
configuration.
Vertical loads were applied directly over the joint between the
center slabs, with circular steel plates and a neoprene pad providing pressure
distribution.
minimal
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18
Continuous support was supplied for the beams, such that the deflections
and strains were due to slab action alone.
Figure 9(a) shows the deflections of the specimen with k'-Q" beam spacing
due to the 5, 10, and 15 kip vertical loads applied, with a longitudinal prestress
of 3^ psi on the gross section and zero force in the tie-down bolts.
Figure 9(b)
gives similar results with a total tension force of U8 kips present in the tie-
down bolts.
Refer to
Figure 11(a) shows results when bolting force was zero, while Figure
noted during the tests was that increasing the level of post-tensionin
increased the deflections due to the applied load.
force
the fact that the post-tensioning cables were in contact with the member only at
the ends.
The member deflections did not bring the slab into contact with the
Figure 12 permitted simulation of a wheel load passing from one side of the joint
to the other, by varying the jacking loads on each side of the joint.
The
19
Point
(o)
Bolting
Force - Zero
Point
(b)
Vertical
Load Kty:
P 5.04
Bolting
*-
Force -
48 Kips
P 10.08 k
----
15.12 k
FIGURE
9.
20
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(o)
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Load
Ky:
Force
Bolting
P 5.04
k-*
Zero
P 10.08
--
Pl5.l2k-
Point
(b)
FIGURE
II.
Bolting
LONGITUDINAL
SPACING, 34
Force -
CENTERLINE
PSI
Kips
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repeated load was cycled at a rate of 250 cpm, with a maximum jack load of nine
Kips and a minimum load of one kip.
for only 32,000 cycles of load at which time a spall developed (Figure 6) at the
joint.
This spall was apparently due to a poor joint fit which has been described
previously.
were moved to provide U'-6" spacing, and another test was performed.
or joint deterioration occurred during two million cycles of loading.
teams
No cracking
Concrete
and the casting method was changed in order to provide a better joint fit.
second set of specimens made to the new specification have been made and tested
under ten million cycles of repeated loads with no apparent joint distress.
Field Tests
Two structures are intended to become an integral part of this project.
The
results of the laboratory tests were such that it seemed feasible to proceed with
several monitored prototypes and the performance of these structures will help
Structure
Blossom Creek.
2k
in the late forties and the deck has been patched several times.
Electric strain
gages are to be welded to several stringers and floor beams prior to removing the
old deck.
pretensioned slabs.
Strains will
then be monitored once again for the stringers and floor beams and also for the
slabs.
The behavior of the entire system will be closely observed over a period
will have
deck.
The traffic
under other than ideal conditions while the second structure is specifically
designed to receive the precast slabs as a deck.