Professional Documents
Culture Documents
2R-98
Many highway bridges become functionally obsolete due to inadequate Chapter 2—General design considerations, p.
width before they become structurally deficient. Because widening is 345.2R-4
almost always more economical than complete replacement, there is a need 2.1—General
to make available the results of research and field experience pertaining to 2.2—Selection of structure type
the widening of bridges. This guide discusses many problems unique to the
widening of concrete bridges and bridges with concrete decks. The primary
focus of this document is on bridge decks. Substructure issues, however, Chapter 3—Design and construction details, p.
also are raised and discussed. The effects of differential movements 345.2R-6
between the existing and new portions, including movements due to traffic 3.1—General
on the existing structure during construction, are discussed. General rec- 3.2—Concrete removal
ommendations are made pertaining to the choice of structure type, design 3.3—Refinishing exposed areas of the deck
details, and construction methods and materials.
3.4—Traffic-induced vibrations and deflections
3.5—Avoidance of damage due to dead load deflections
Keywords: bridge decks; bridges (structures); bridge widening; concrete
3.6—Closure placement details
construction; deflection; formwork (construction); reinforced concrete;
reinforcing steels; substructures; superstructures; traffic vibrations. 3.7—Substructure details
345.2R-1
345.2R-2 ACI COMMITTEE REPORT
taken to avoid damaging any reinforcing steel that is to remain 3.3—Refinishing exposed areas of the deck
in place. The following are suggested specification provisions: Concrete exposed by rail, curb, or sidewalk removal can
When portions of a bridge are to be removed, the removal be too rough to serve as a riding surface (Fig. 3.1). Unless a
operations should be performed without damage to any por- concrete or bituminous overlay is to be placed, the area must
tion of the structure that is to remain in place.Existing rein- be refinished. The degree of refinishing, which can vary
forcement that is to be incorporated in the new work should from minor patching to a complete leveling course (Fig. 3.2),
be protected from damage and should be cleaned thoroughly should be specified in the contract documents.
of all adhering concrete material before being embedded in Refinishing can consist of simply grinding off a few high
new concrete. spots or filling in local depressed areas with concrete repair
Before beginning the removal of a portion of a monolithic patches. If the surface is too rough and requires extensive
concrete element, a saw cut should be made, taking care to grinding or patching, it is generally better and more eco-
avoid the reinforcing steel, to a true line along the limits of nomical to mill off the entire surface to a depth of at least 3/4
removal on all faces of the element that will be visible in the in. (19 mm) below the adjacent deck and place a concrete
completed work. overlay (Loveall, 1992; Flynn, 1992). In either case, the
Removal can be done by waterjetting (hydrodemolition), recommendations in ACI 546.1R should be followed in
which removes concrete efficiently without damaging the re- patching or overlaying the deck surface.
inforcement or introducing microcracking or other damage
into the remaining concrete (Weyers, 1993; American Con- 3.4—Traffic-induced vibrations and deflections
crete Institute, 1980). There has been a widely held view that once concrete is
Reinforcing dowels exposed during the rail, curb, or side- placed, consolidated, and finished, it should not be disturbed
walk removal should be cut off below the finished surface and until it has gained sufficient initial strength. This view has led
the recess filled with a nonshrink grout (ASTM C1107-97). to concerns about permitting traffic on bridge decks during con-
When dowels are in a patch or overlay area, they should be crete-placing operations. Traffic-induced vibrations are quite
cut off at the bottom of the overlay or patch. noticeable to human senses, and therefore understandably raise
345.2R-8 ACI COMMITTEE REPORT
concerns among those involved in repair or widening of con- 1950s and 1960s. This damage was noted in decks connect-
crete structures. However, several reports (Transportation ing to existing structures carrying traffic. Such damage has
Research Board, 1981; Furr, 1981; Deaver, 1982; Arnold, now been found to be related to the use of high-slump (more
1980; Whiffen, 1971; Harsh, 1983; Silfwerbrand, 1992; than 4 in. (100 mm)) concrete that probably contained excess
Concrete Repair Digest, 1997) found that vibration in bridg- water. Similar damage was not noted in subsequent work
es due to highway traffic is not as harmful as theorized. In when the slump was reduced. Although no research has been
fact, it can actually be beneficial. In situations where the done to examine the effects of using high range water reduc-
forms and reinforcing steel are supported by the same struc- ing admixtures in concrete used to widen bridges, use of such
tural members, experience and research have shown that concrete should reduce the chance for delaminations because
damage due to traffic-induced vibrations is very rare. In the water to cement ratio is typically lower than that of con-
these cases, fresh concrete reinforcement and forms are in crete without the admixture.
synchronous movement. None of these reports was able to Limited laboratory research at the University of Michigan
identify any occurrences of damage for these conditions. (Arnold, 1980) also showed that high-slump concrete mix-
Therefore, special precautions, such as closing the bridge to tures are especially sensitive to segregation in the plane of
traffic in such situations, are generally not necessary. the reinforcing steel. In limited testing, the hydraulic pres-
The most effective way to reduce the amplitude of traf- sure applied through voids cast in the plane of the top mat of
fic-induced vibrations is to maintain a smooth structure ap- reinforcement were measured. The hydraulic pressure need-
proach and deck riding surface. Vehicle speed and weight ed to rupture concrete that had been subjected to continuous
restrictions have only a secondary effect on the magnitude of vibration during its early life, was reduced from 1600 to 800
traffic-induced vibrations. psi (11 to 5.5 MPa) when the slump of the concrete was
Traffic-induced vibrations can make the slipform method raised from 3 to 4 in. (75 to 100 mm).
of constructing concrete barriers or curbs very difficult, if b. Reinforcing details—The Texas Transportation Insti-
not impossible. Therefore, this method should be avoided. tute (Furr, 1981) found that reinforcing dowels extending
In situations where the vibrations are carried into freshly straight from old concrete and lapping with the new deck re-
placed concrete through reinforcing steel extending from the inforcing created in fresh concrete created no defects in the
existing bridge, damage to new concrete can occur (Silfwer- fresh concrete. However, they did find that when the dowels
brand, 1992; Concrete Repair Digest, 1997). Such damage is were bent at a right angle in a horizontal plane, voids devel-
avoidable through use of proper construction techniques, such oped between the dowels and fresh concrete, although these
as attaching the forms to the existing bridge, and traffic control. voids were not found to cause problems in the performance
When a reinforcing bar moves relative to the concrete, the of the deck. (Fig. 3.3).
displaced concrete will flow readily back and forth with the Good practice also requires that when deck closure place-
bar, as it is still plastic. As initial set begins, only weak, wa- ments are to be employed, the reinforcing bars or dowels ex-
ter-diluted grout flows back to surround the bar. Also, cracks tending from the existing concrete to the new should not be
can develop in the plastic concrete and fill with weak mate- connected to the reinforcing bars in the widening during con-
rial, along a horizontal plane with adjacent bars or along crete placement of the widening, but should be attached se-
sloping planes running from the bar to the surface of the curely to reinforcing bars in the new deck just before the
deck. This condition can result in a severe reduction in bond closure placement is made (Fig. 3.4).
to reinforcement and premature deck spalling. Similar dam- Some damage was observed in California (Shaw, 1974)
age can occur in new bridge decks, if live loads from workers when a single row of dowels was drilled and grouted into the
or equipment are allowed directly on poorly blocked-up re- face of the existing deck midway between the steel mats used
inforcing steel on the outside of a construction joint bulk- in the widening. This problem was solved when two rows of
head. For this reason, during placing and finishing dowels were used, one secured to each plane of steel in the
operations, workers and equipment near the perimeter of a new deck (see the left-side elevation in Fig. 3.4).
reinforced concrete deck should be restricted to planks or c. Forming details—When deck closure placements are em-
runways blocked-up from the forms, rather than bearing di- ployed, the forms for the widening should not be connected to
rectly on any reinforcing steel that extends through bulk- the existing bridge during placement of concrete for widening.
heads and into the concrete being placed. When the closure is placed, however, its supporting form
Although it would seem that any movement of reinforcing should be secured to both the old and the new structure.
steel extending from a structure carrying traffic into freshly Differential live load deflections or relative movements
placed concrete on a widening would result in the defects de- between the first girder of a widening and the adjacent girder
scribed, certain practices will generally eliminate such dam- of the existing bridge cause racking (shear stresses) in the
age. These practices should be employed on all deck closure new deck concrete and closure placement between the two.
placements or in other situations where concrete is placed At first consideration, it would seem that this action would
against an existing structural element carrying traffic, and in- also preclude the practice of connecting decks of widenings
clude the following: rigidly to existing bridges carrying traffic. Research done at
a. Use of moderate (2 to 3 in.) (50 to 75 mm) slump con- Texas A & M University (Furr, 1981), however, determined
crete—Surveys (Transportation Research Board, 1981) found the magnitude of the change in differential deflection due to
frequent delamination in bridge decks built or widened in the dynamic loading that would cause cracking in a 7 3/4 in. (200
GUIDE FOR WIDENING HIGHWAY BRIDGES 345.2R-9
mm) concrete slab. Field measurements of typical bridges in Although all of these measures have been used, items c
Georgia (Deaver, 1982) and Texas (Furr, 1981) showed that and d are most economical. They require only a short-term
deflections actually produced in deck slabs by traffic imme- restriction of traffic. These measures need be employed only
diately adjacent to the widening during concrete placement when very flexible structures are being widened.
and thereafter were only about one-fourth of this magnitude.
These results indicate that cracking is unlikely under normal 3.5—Avoidance of damage due to dead load
conditions. deflections
Surveys of rigidly connected deck widenings (Transporta- Two important facts should be recognized when consider-
tion Research Board, 1981; Furr, 1981; Deaver, 1982; Shaw, ing dead load deflection: (1) portions of the superstructure
1974) showed little evidence of distress due to differential widening should initially be built above the grade of the ex-
deflection caused by traffic. This is probably due to the fact isting structure to allow for dead load deflection; and (2) the
that, in addition to practices recommended previously, one deflected superstructure widening should meet the grade of
or more of the following measures were taken: the existing structure when the final connection is made be-
tween decks. If dead load deflection is not properly accom-
a. Diaphragms between adjacent girders or a rigid tempo-
modated, construction, maintenance, and traffic-safety
rary blocking system were used to equalize girder deflection
problems can occur.
until the deck slab gained sufficient strength. Sometimes the
forming system itself offers sufficient rigidity. When discussing dead-load deflections, it is necessary
to divide superstructures into two groups: 1) unshored
b. A smooth riding surface was maintained on the deck
construction, such as precast prestressed concrete girders or
and the approach roadway, and a good grade match was ob- steel girders, where the largest percentage of girder deflec-
tained where they join. tion occurs when the deck is placed, and 2) cast-in-place con-
c. Traffic speed, allowable loads, or both were reduced on crete superstructure construction where the deflection occurs
the existing bridge during and immediately after placing new when the falsework is released.
deck concrete. 3.5.1 Unshored construction—Sketches in Fig. 3.5 show
d. The traffic lane adjacent to the connecting joint was the different stages of simple-span precast or steel-girder de-
closed for a few days after placing new deck concrete. flection as the deck concrete is placed from one end of the
e. Temporary shoring was installed under the existing girder to the other. The concept is the same for continuous
bridge during this period. spans, but the design will change. Analysis of these sketches
345.2R-10 ACI COMMITTEE REPORT
Fig. 3.7—Widening slab bridges. Fig. 3.8—Vee groove splice details—welded option.
determined in accordance with ASTM E 1512. If sustained In addition, AASHTO LRFD Article 5.11.5.2.2 permits
loads are expected, the total displacement (initial plus creep) splices made with full mechanical connectors. Several types
should not exceed 0.03 in. (0.8 mm) when tested at 40 per- of mechanical connectors are available that meet the ACI
cent of the ultimate load, in accordance with the creep testing 318 criteria of development of at least 125 percent of the
procedure of ASTM E 1512. yield strength of the bar. AASHTO LRFD includes require-
The holes should be drilled by methods that do not shatter ments for maximum slip not included in ACI 318.
or damage the concrete adjacent to the holes. They should be Longitudinal reinforcing bars should be placed in the clo-
located at least 3 in. (75 mm) from the edge of the concrete and sure placement to distribute shrinkage cracks and minimize
be no more than 1/4 in. (6 mm) larger than the diameter of the their crack width.
dowels or as recommended by the manufacturer. The holes 3.6.3 Forms—Forms for the deck closure placement
must be free of dust and drilling slurry, and in a surface-dry should be supported from the superstructure on both sides of
condition before placing the grout or epoxy. The holes are then the closure. They then act as an articulated ramp to spread the
filled with grout or epoxy before the dowels are inserted. effect of any differential vertical movements over the widths
As an alternative to inclined holes, horizontal holes about of the closure. These forms should not be placed between old
3/ in. (20 mm) larger than the dowel can be drilled and the
4
and new structures until all other concrete in the widening
dowels bonded in place with nonshrink grout. The dowel is has been placed and the shoring released.
centered in the hole and the grout is then injected into the 3.6.4 Concrete—Specific requirements for concrete are
hole so that filling is accomplished outward from the base of necessary for encasing reinforcing steel that is subject to vi-
the hole. A gasket is used around the dowel at the face of the bration from external forces during the first few days after
hole to retain the grout while allowing the air to escape. placement (Furr, 1981; Arnold, 1980; Whiffen, 1971). This
3.6.2 Reinforcement—During placement of deck concrete applies to concrete for closure placements, and deck widen-
in the widening, reinforcing bars protruding from the new ings when closure placements are not used and traffic is al-
deck into the closure space should be kept completely free of lowed on the old bridge during construction. A minimum
contact with the existing reinforcing steel, concrete forms, or cement content of 564 lb/yd3 (330 kg/m3), a maximum of
attachments. 0.45 water-cementitious (w/c) ratio, and a maximum slump
During placement of deck closure concrete, the new and range of 1 to 3 in. (25 to 75 mm) should be employed.
existing transverse reinforcing steel within the closure High-early-strength cement (Type III), volume-adjusting types
should be connected securely together or to common longi- of cement (ASTM C1107-97), chloride-free proprietary
tudinal reinforcement, as in Fig. 3.4. high-early-strength cements, or Type I cements with non-
Reinforcing bars extending from the existing deck should chloride accelerators are sometimes used.
be straight rather than hooked, as in Fig. 3.3. Reinforcing 3.6.5 Time of placement—The timing of the placement of
bars extending from the existing deck that are too short to concrete for closure placements depends on the type of struc-
give sufficient development length can be extended by ap- ture. For steel girders or precast concrete girder bridges, clo-
proved mechanical connections or full-strength welds. Weld- sure placements can be made as soon as the full dead load is
ing can be used when the extension being welded is free from on the widening. For widenings consisting of more than one
restraint during the welding process to permit shortening of girder, the exterior railing need not be placed before closure.
the bar as the weld cools. For cast-in-place concrete construction, a delay after re-
The American Welding Society’s code (1992) contains moval of falsework should be provided to allow the relative-
recommended details for making welded splices in reinforc- ly rapid early dead load deflection to occur before the decks
ing steel and suggests making a chemical analysis of the steel are connected. The length of the delay period, along with the
to determine its weldability and gives procedures for welding width of the closure placement, should be engineered to ac-
splices if chemical composition is unknown. commodate the dead load deflection that will occur in the
GUIDE FOR WIDENING HIGHWAY BRIDGES 345.2R-13
low-slump concrete. This closure placement should be rein- Report, GDOT Research Project No. 7604, FHWA/GA-82/008, Georgia
forced with top and bottom mats of reinforcing bars that ex- Department of Transportation.
Dusel, J. P.; Stoker, J. R.; and Nordlin, E. F. (1979). “Development of a
tend out of both new and existing deck slabs. Such Rebar Dowel Anchorage System for Attaching the California Type 25 Barrier
reinforcement must all be tied together securely to minimize to Existing Bridges,” Report No. FHWA-CA-TL-69-16, CALTRANS, June.
differential movements and the resulting damage to the fresh Flynn, L. (1992). “Contract Drives Raleigh ‘Beltline’ Rubblization,”
closure concrete caused by vibrations from traffic. Such rein- Roads and Bridges, V. 30, No. 1, Jan.
forcing steel ties should not be made, however, until just be- Furr, Howard L., and Fouad, F. H. (1981). “Bridge Slab Concrete Placed
Adjacent to Moving Loads,” Research Report No. 266-1F, Study
fore the closure concrete is placed. Likewise, the connection 21-5-79-266, Texas Transportation Institute, State Department of High-
of diaphragms between the existing bridge and the widening, ways and Public Transportation, College Station.
and the installation of the forms for the closure placement, Harsh, S., and Darwin, D. (1983). “Effects of Traffic-Induced Vibrations
should not be done until just before the closure is placed. on Bridge Deck Repairs,” Project No. P-0255, Kansas Department of
Transportation.
“Interstate Rehab Called Biggest Job in Illinois” (1991). V. 226, ENR.
CHAPTER 5—REFERENCES Loveall, C. L. (1992). “Experience With a Thick Reinforced Overlay for
5.1—Recommended references Bridge Deck Rehabilitation,” Proceedings, Third International Workshop
The documents of the various standards-producing organi- on Bridge Rehabilitation, Technical University Darmstadt and the Univer-
zations referred to in this document are listed with their serial sity of Michigan.
designation. McMahon, J. E., and Womack, J. C. (1965). “Bridge Widening Prob-
lems,” Report No. 951120, HPR-1(2), DO422, California Division of
Highways.
American Association of State Highway and Transportation “Operation Bridgeguard” (1992). World Highways/Routes Du Monde, V.
Officials 2, No. 1, Nov.-Dec.
LRFD Bridge Design Specifications Precast/Prestressed Concrete Institute (1980). “Precast Prestressed Con-
crete Short Span Bridges (Spans to 100 Feet),” Chicago, Ill.
Reay, G. C., (1976). “Widening of Hutton Rudby Bridge,” Highway
American Concrete Institute Engineer (London), Mar., pp. 18-21.
117 Standard Specifications for Tolerances for Roberts, J. E. (1972). “Effects of Curing and Falsework Support Periods
Concrete Construction and Materials on Dead Load Deflections of Reinforced Concrete Slab Bridges,” Califor-
211.1 Standard Practice for Selecting Proportions nia Division of Highways.
Scordelis, A. C., and Seible, F. (1983). “Time-Dependent Behavior of a
for Normal, Heavyweight and Mass Concrete Skew Reinforced Concrete Box Girder Bridge,” Concrete International:
212.1R Guide for Use of Admixtures for Concrete Design & Construction, V. 5, No. 1, Jan., pp. 84-92.
221R Guide for Use of Normal Weight Aggregates Seible, F.; Priestley, M. J. N.; and Krishnan, K. (1991). “Bridge Super-
in Concrete structure Rehabilitation and Strengthening,” Transportation Research
Record No. 1290, Transportation Research Board.
304R Guide for Measuring, Mixing, Transporting Shaw, T. V., and Stewart, C. F. (1974). “Effectiveness of Attached Bridge
and Placing Concrete Widenings,” Report No. CA-DOT-ST-4165-1-74-2, California Division of
305R Hot Weather Concreting Highways.
306R Cold Weather Concreting Silano, L. G.; Swindlehurst, J.; and Parkinson, F. H. (1992). “Steel Struc-
tures,” Bridge Inspection and Rehabilitation: A Practical Guide, John
308 Standard Practice for Curing Concrete Wiley and Sons, Inc.
318 Building Code Requirements for Reinforced Silfwerbrand, J. L. (1992). “Influence of Traffic Vibrations on Repaired
Concrete Concrete Bridge Decks,” Proceedings, Third International Workshop on
343R Analysis and Design of Reinforced Concrete Bridge Rehabilitation, Darmstadt, Germany, pp. 416-474.
Soto, M. H., (1978). “Some Considerations in Widening and Rehabilita-
Bridge Structures
tion of Bridges,” Transportation Research Record 664, Bridge Engineer-
345R Guide for Concrete Highway Bridge Deck ing, V. 1, Transportation Research Board, Washington, D. C.
Construction Sprinkel, M. M. (1985). “Prefabricated Bridge Elements and Systems,”
435.1R Deflections of Prestressed Concrete Members NCHRP Synthesis 119, Transportation Research Board, Washington, D. C.
435.2R Deflections of Reinforced Concrete Flexural Transportation Research Board (1981). “Effects of Traffic-Induced Vi-
Members brations on Bridge Deck Repairs,” NCHRP Synthesis of Highway Practice
No. 86, Washington, D. C.
5.2—Cited references “Thirteen Tips for Better Bridge Widening” (1997). Concrete Repair
American Concrete Institute (1980). Guide for Repair of Concrete Digest, Addison, Ill., Oct./Nov., pp. 248-251.
Bridge Superstructures, 546.1R, Farmington Hills, Mich. U.S. Department of Transportation (1988). Manual for Uniform Traffic
American Society for Testing and Materials (1993) Test Methods for Control Devices for Streets and Highways, FHWA.
Testing Bond Performance for Adhesive-Bonded Anchors, E1512. Weyers, R. E.; Prowell, B. D.; Sprinkel, M. M.; and Vorster, M. (1993).
American Welding Society (1992). Structural Welding Code—Reinforc- “Concrete Bridge Deck Protection, Repair, and Rehabilitation Relative to
ing Steel, D1.4-92. Reinforcement Corrosion: A Methods Application Manual,” National
Arnold, C. J. (1980). “Concrete Bridge Decks: Does Structural Vibration Research Council, Washington, D. C.
Plus Excess Water Form the Fracture Plane,” Research Laboratory Section, Whiffen, A. C., and Leonard, D. R. (1971). “Survey of Traffic-Induced
Michigan Department of Transportation. Vibrations,” Report LR418, Transport and Road Research Laboratory,
Deaver, R. W. (1982). “March 1982 Bridge Widening Study,” Final England.