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4. Construction methods concrete deck

The construction method, the way the concrete deck is applied, and the erection method, the way the deck is
connected to the main supporting steel structure, can greatly affect the construction cost, the construction speed
and functionality. That is why it is important for both methods to know what the advantages and disadvantages
are. In this connection, a range of attention points have to be considered, such as:

construction method
weather dependence; investment cost and labour intensity of usage of formwork; construction speed;
requirements regarding durability; connection steel supporting structure and concrete deck; temporary support
provisions; extra reinforcement for connecting prefab - in situ parts.

erection method
stress distribution: desired erection of the concrete deck

Often, preceding the application of the concrete deck, the entire steel structure, including dowels, is placed. Due
to the high labour cost versus material cost, it is desirable to aim at a low work intensive steel structure instead of
a structure that is optimal as to material use. The consequence is that the number of additional provisions, such as
cross frames and stiffening plates, is limited to a minimum. An extra advantage is that the total conservation
surface is reduced and inspection becomes easier. With regard to the application of the concrete roadway, the
following major construction methods can be distinguished:

a. in situ poured
b. use of prefab deck elements (full or half depth precast)
c. longitudinal sliding of concrete deck elements over steel girders

a. in situ poured concrete deck

Advantages are simple transport, simple adaptation of cross section shape, variances in sequence steel-concrete,
uniform shear connection over girder length, durable connection between steel upper flange and concrete deck,
and because the concrete deck forms one big unit, no extra reinforcement is required to have the various parts
working together, like the use of loop joints in case of precast decks. Disadvantages are the weather dependence;
in order words: no conditioned hardening, the required formwork construction and the relatively long
construction time: scaffolding, reinforcement and pouring at location.
The scaffolding can be:
1. temporary: used for many times
2. lost: used once only
3. permanent: scaffolding by using half depth prefab concrete elements

1. Temporary scaffolding construction: conventional construction

Fig. 33. Example of scaffolding using traditional timber beam / plate elements .

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Fig. 34. Example of scaffolding by using profiled sheets.

Tempory scaffolding construction: supported by the lower flange of the steel structure

Fig. 35. Example scaffolding supported by the

lower flange of the steel structure.

Tempory scaffolding construction: movable system

Fig. 36. Example scaffolding using a movable sytem.

The scaffolding is supported by the steel main construction. The simplest way of applying the concrete is the
method by which the roadway is poured in parts and the scaffolding is moved on every time.

2. Lost: scaffolding used once only

The usage cost of such a scaffolding are high and often support
provisions are required with a view to cantilevers and by the
dimension of the span between the main girders.

Fig. 37.
The use of profiled sheets which will not be removed after finishing
the concrete deck.

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3. Permanent: scaffolding by using half-depth prefab concrete

elements
The distance between the steel girders is bridged by for instance
prefab concrete deckpanels , that, apart from forming the scaffolding
also works together constructively. In other words, much additional
reinforcement is required to let the various parts cooperate
constructively .

Fig. 38.
Example of scaffolding by using prefab concrete elements.

Hoisting of prefab concrete deck panels

This construction method is used in case of great c.t.c. distances of the main girders and/or considerably
cantilevered decks. The spacing, taken up in the roadway elements match with the positions of the dowels on the
steel structure. After placing the elements, the steel-concrete connection is accomplished by curing the spacing
between the prefab elements with mortar free from shrinkage (having the same material properties like strength
and elasticity modulus as surrounding concrete)..

Fig. 39. Example on

connecting the prefab
concrete elements.

Advantages are the relatively short construction time, manufacturing in the shop, variances in the sequence of
placing the prefab elements and the sequence of connecting the steel-concrete.
Manufacturing in shop means good quality, improved working environment for the workers, reduced man-hours
outdoors and less trafic interference.
Disadvantages are the concentrated location of shear connections (so-called shear pockets), the reinforcement to
link-up the prefab elements, dimension tolerances and splice between steel and concrete.

Sliding of concrete roadway over steel girders

The roadway is pushed from land over the girders. The roadway elements can be supplied prefab or can be
poured conditioned near the abutment. The two most common variances are explained below.

Applying of the dowel connection in the spacings after

placing the concrete deck. Afterwards the spacings are
filled with mortar free from shrinkage.
Disadvantages here are that the dowels have to be fit at
the site and the concentrated load distribution between
steel-concrete.

Fig. 40.
Sliding of concrete deck panels; studs connected
afterwards.
Cross-section between Cross-section at spacing
spacings
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Fitting the dowel connection before sliding of the concrete deck.

The strength of the deck in transverse direction shear direction

is provided by concentrated reinforcements, placed in the part
between the spacings.

Fig. 41. studs

Sliding of concrete deck panels; studs connected already..

Cross-section between Cross-section at spacing

spacings

Both alternatives have the disadvantage that the sequence, in which the roadway is constructed, is difficult to
vary. and the connection steel-concrete can only be activated after the entire roadway has been placed.

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