19.ultra-High Performance of Concrete Application in Shear Key Connections of Precast Bridges - PR

Ultra-High Performance Concrete (UHPC)
Application in Shear Key Connections of Precast Bridges
Prasad Rangaraju, Ph.D., P.E.

GIAN Course
Professor
Glenn Department of Civil Engineering
Clemson University, USA
Advanced bridge design and construction
Advanced Bridge Design/Constr.
GIAN Lecture
Indian Institute of Technology Madras
July 22, 2016
IIT Madras
Chennai, TN
Acknowledgements
o Zhengqi Li (Jason), former PhD student at
Clemson University, Clemson, SC, USA
o Dr. Ben Graybeal, FHWA,

GIAN CourseTurner-Fairbank
Highway Research Center, McLean, VA,
USA.
July 22, 2016 Prasad Rangaraju, Clemson University Slide 2

Overview
o Background on US Infrastructure Condition
o Need for Innovative Materials/Methods
o What is UHPC?
GIAN Course
o Materials/Proportions/Mixing/Properties
o UHPC Application
Advanced in Bridge
bridge design andInfrastructure
construction
o Future Considerations/Research Needs

Condition of US Infrastructure
GIAN Course
Indian Institute of Technology Madras Source:

American Society of Civil Engineers (ASCE)
http://www.infrastructurereportcard.org/

Bridge Infrastructure in US
Nearly 10% of the USA's bridges (58,495

out of 609,539) were considered
structurally deficient
GIAN Coursein 2015 and in need
of repairs, according to the American
Advanced
Road andbridge design and
Transportation construction
Builders
Association.
(Source: ARTBA, 2015)

Accelerated Bridge Construction (ABC)
o Accelerated Bridge Construction (ABC) is an US FHWA Initiative that
promotes innovative planning, design, materials, and construction
methods to reduce the onsite construction time when building new
bridges or replacing and rehabilitating existing bridges.
o ABC improves:
o Site Constructability
GIAN Course
o Total project delivery time
o Work-zone safety for the traveling public
Advanced
o ABC reduces:
bridge design and construction
o Traffic Impacts
o Onsite construction time
o Weather-related time delays
o Key Material for ABC: Ultra-High Performance Concrete (UHPC)
Other names for UHPC
Generic Names
o Reactive Powder Concrete (RPC)
o Ultra-High Performance Fiber Reinforced Concrete
(UHPFRC)
o High PerformanceGIAN
Fiber Course
Reinforced Concrete (HPFRC)
Advanced
Commercial bridge
Products design and construction
o Examples- Ductal®, Densit®, CRC®, Cor-Tuf®, BSI®, etc.
o Proprietary compositions; expensive.
Definition of UHPC
o Ultra-high performance concrete (UHPC) is defined as a cementitious based
composite material with discontinuous fiber reinforcement, having
compressive strength above 21.7 ksi (150 MPa), pre-and post-cracking tensile
strength above 0.72 ksi (5 MPa), and enhanced durability [FHWA, June 2013].
Cement & Pozzolans Water

GIAN Course
Fine Aggregate High range
UHPC
(Fine Sand) water reducer
(Ground Quartz)
Indian Institute of Technology

Fibers Madras

Cementitious Material Characteristics
o Portland Cement:
o ASTM C150 Type I
o Moderate fineness (350 - 400 m2/kg)
o Average particle size of ~15 microns
o Low C3A content (< 8%)
o GIAN
Low Alkali content Course
(< 0.60% Na2Oeq. is preferred)
Advanced
o Pozzolans bridge design and construction
o Silica Fume is typically used, although others can be used:
Indian Institute
o 20% of Technology
to 25% mass replacement of cement Madras
o Low LOI content (preferably < 1% LOI)
Aggregates
o Fine quartz sand
o Clean material with no harmful contaminants
o Particle size ranging between 150 – 600 microns
o Considering the importance of optimized
gradation, twoGIAN Course
or more size fractions of fine
aggregate may be employed.
Advanced bridge
o Ground quartz (silicadesign
flour) and construction
o Average particle size - 5 to 10 microns
oIndian
Typical Institute of Technology
sand-to-cementitious Madras
materials ratio
between 1.25 to 1.50
Fibers for UHPC
o Typically steel fibers are used for UHPC, although
other fibers can be used (PVA, etc.) depending on
the purpose.
o Primary purposeGIAN Course

of the fibers is to bridge cracks and
improve confinement of primary reinforcement in the
Advanced bridge
cementitious matrix.design and construction
oIndian Institute
Fiber type, geometryof Technology
and volume fractionMadras
are
important considerations depending on application.
Steel fibers
o Typical steel fibers used in UHPC
have:
o Nominal diameter of 0.2 mm (0.008 inch)
o Nominal length of 12.7 mm (0.5 inch)
o Average yield strength of 3160 MPa
o
GIAN Course
Average tensile strength of 3270 MPa
o Young’s Modulus of Elasticity of 205 GPa
oIndian
Typical Institute
fiber dosage of
used in UHPC is a
Technology Madras
minimum of 2% by volume.
Typical Stress-Strain Plot of Fiber
GIAN Course

Source: FHWA-HRT-14-084

Chemical Admixtures
o High-range water reducers (HRWR)
o Polycarboxylic ethers (PCE) are preferred compared to
more conventional HRWRs.
o Dosage level of 1% to 1.5 % by weight of cementitious
materials.
GIAN
o Important to establish theCourse
compatibility of the HRWR and
cements.
Advanced bridge
o Upper limit design
on HRWR is and
important to construction
limit flow and setting
time.
oIndian Institute of Technology
Set Accelerators Madras
o Shrinkage Reducing Admixtures
Typical Proportions of UHPC
GIAN Course

Typically, w/c ratio << 0.25; sand/cementitious ratio ~ 1.25 – 1.50
Fiber content~ 2% by volume.
Mixing Process for UHPC
3 min
GIAN Course

Typical mixing time needed for UHPC can range from 10 to 20 minutes
16
Mixing of UHPC
Lab Scale
Large Scale
in Field
GIAN Course

Small Scale
in Field Source: FHWA-HRT-14-084

Self-Consolidating Nature of UHPC
GIAN Course


Performance-Based Material Specs for UHPC
GIAN Course


Typical properties of Field UHPC
GIAN Course


Typical properties of Field UHPC
GIAN Course


Typical Construction Specifications for UHPC
o Surface preparation of precast concrete to ensure
adequate bond with UHPC
o Adequately sealed formwork to prevent leakage
and providing an air-vent for adequate
consolidation ofGIAN
UHPC Course
o Avoiding vibrations at early ages to prevent
Advanced
debonding. bridge design and construction
o Limit pours to small volumes/segments to prevent
Indian Institute
excess horizontal of Technology
movement Madras
and segregation of
fibers.
Surface preparation of precast concrete
GIAN Course

• Adequate surface roughening – Ex: sand blasting
• Adequate saturation of the roughened surface

Rebar embedment length in UHPC
GIAN Course


Other detailing considerations with UHPC
GIAN Course

Typical Connection Details
GIAN Course

Typical c/s of precast deck panel
GIAN Course

Typical Shear Key Connections in Bridges
GIAN Course

UHPC

Typical Shear Key Connections in Bridges
GIAN Course

UHPC Source: FHWA-HRT-14-084

Connection between Deck and Steel Girder
GIAN Course

UHPC Source: FHWA-HRT-14-084

Connection between Deck and Concrete Girder
GIAN Course

UHPC

Link-slab UHPC connection
GIAN Course

UHPC

Field Installations
GIAN Course

Superstructure prepared for Deck Installation
GIAN Course


Transport and Placement of Deck Panel
GIAN Course


Installation of Deck Panel with Integral Barrier
GIAN Course

Deck level connections between precast panels
GIAN Course

Deck assembly before UHPC
GIAN Course

Field mixing of UHPC
GIAN Course

Field Placement of UHPC in Shear Keys
GIAN Course

Surface Profiling of Finished Deck
GIAN Course

After Grinding, Grooving and Striping of the Deck
GIAN Course

Field UHPC Installations
o As of 2015, over 40 bridges in the US have used
UHPC connections with prefabricated bridge
elements successfully.
GIAN Course
o Efforts are now focused on developing guidelines
for UHPC formulations using local materials to make
Advanced
UHPC more bridge design
economical, and
expand theconstruction
use of UHCP
and promote Accelerated Bridge Construction
using prefabricated
Indian Institute concrete elements. Madras
of Technology

Future of UHPC
o UHPC is increasingly being specified in
bridge construction.
o However, existing test methods do not
adequately characterize UHPC.
GIAN Course
o New test methods for UHPC are being
developed,
Advanced evaluated
bridge designand standardized.
and construction
o New materials are being explored to
Indian Institute
develop of Technology
UHPC to make Madras
it more economical.

GIAN Course
Questions?
prangar@clemson.edu

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Ultra-High Performance Concrete (UHPC)

Application in Shear Key Connections of Precast Bridges

Prasad Rangaraju, Ph.D., P.E.

o Dr. Ben Graybeal, FHWA,

Indian Institute of Technology Madras

July 22, 2016 Prasad Rangaraju, Clemson University Slide 2

July 22, 2016 Prasad Rangaraju, Clemson University Slide 3

Advanced bridge design and construction

Indian Institute of Technology Madras Source:

July 22, 2016 Prasad Rangaraju, Clemson University Slide 4

Nearly 10% of the USA's bridges (58,495

July 22, 2016 Prasad Rangaraju, Clemson University Slide 5

Cement & Pozzolans Water

Indian Institute of Technology

July 22, 2016 Prasad Rangaraju, Clemson University Slide 8

o Primary purposeGIAN Course

Advanced bridge design and construction

Indian Institute of Technology Madras

July 22, 2016 Prasad Rangaraju, Clemson University Slide 13

Advanced bridge design and construction

Indian Institute of Technology Madras

Advanced bridge design and construction

Indian Institute of Technology Madras

Advanced bridge design and construction

Indian Institute of Technology Madras

July 22, 2016 Prasad Rangaraju, Clemson University Slide 17

Advanced bridge design and construction

Indian Institute of Technology Madras

July 22, 2016 Prasad Rangaraju, Clemson University Slide 18

Advanced bridge design and construction

Indian Institute of Technology Madras

July 22, 2016 Prasad Rangaraju, Clemson University Slide 19

Advanced bridge design and construction

Indian Institute of Technology Madras

July 22, 2016 Prasad Rangaraju, Clemson University Slide 20

Advanced bridge design and construction

Indian Institute of Technology Madras

July 22, 2016 Prasad Rangaraju, Clemson University Slide 21

Advanced bridge design and construction

Indian Institute of Technology Madras

July 22, 2016 Prasad Rangaraju, Clemson University Slide 23

Advanced bridge design and construction

Indian Institute of Technology Madras

July 22, 2016 Prasad Rangaraju, Clemson University Slide 24

Advanced bridge design and construction

Indian Institute of Technology Madras

July 22, 2016 Prasad Rangaraju, Clemson University Slide 25

Advanced bridge design and construction

Indian Institute of Technology Madras

Advanced bridge design and construction

Indian Institute of Technology Madras

July 22, 2016 Prasad Rangaraju, Clemson University Slide 27

Advanced bridge design and construction

Indian Institute of Technology Madras

July 22, 2016 Prasad Rangaraju, Clemson University Slide 28

Advanced bridge design and construction

Indian Institute of Technology Madras

July 22, 2016 Prasad Rangaraju, Clemson University Slide 29

Advanced bridge design and construction

Indian Institute of Technology Madras

July 22, 2016 Prasad Rangaraju, Clemson University Slide 30

Advanced bridge design and construction

July 22, 2016 Prasad Rangaraju, Clemson University Slide 31