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cHAPTER 4

DESIGN OF PRESTRESSED
CONCRETE BRIDGES

Done by: Hadeel Sameeh “Ahmed Hussien”


 4.1 lNTRODUCTlON

This chapter focuses on the design of prestressed


concrete short-to-medium span bridge superstructures,
with emphasis on bridge superstructures made of
precast prestressed concrete beams that are
composite with a cast-in-place (CIP) reinforced
Concrete slab.

The chapter will discuss non-composite beams, where


short examples shall be presented to illustrate
horizontal shear, bending, and vertical shear design of
such members.

The objective of the material covered herein is to


present a simplified and unified procedure for the
design of-prestressed concrete bridge superstructures
in accordance with the 2010 AASHTO LRFD Code.
The material covered in this chapter has been
adopted, either in whole or in part, from Reference 1:
Naaman, A. E., ’Prestressed Concrete Analysis and
Design (Fundamentals)”, 3rd edition, Techno Press
3000, 2012. Figures, charts, tables, text, examples, are
accordingly referenced throughout this chapter as
Ref.1. Almost all of the text material has been taken
directly from Ref. 1, with or without any modifications.

Although the review material presented in this chapter


primarily focuses on precast prestressed concrete
girders made composite with a cast in place. slab, the
procedure is still applicable to other types of girders,
such as post-tensioned concrete box girders, precast
pre-tensioned box beams, and cast in place post
tensioned deck slabs.
In effect, the provisions that apply to a composite
beam are generalized in the sense that if the
thickness of the CIP slab is rendered zero, the
provisions explained herein can be applied to regular
non-composite prestressed pre-tensioned or post-
tensioned beams.

Whenever possible, equations and examples


presented in this chapter are given in SI units.
Examples presented given using US English units will
be provided with SI equivalents at the end of each
individual calculation.
 4.2 DEFINITION OF COMPOSITE CONSTRUCTION AND ITS USE

This chapter mainly deals with precast prestressed concrete


beams made composite with a cast-in-place (CIP)
reinforced concrete slab to act as a single structural flexural
unit.

A prestressed concrete composite beam is defined as a


beam that is precast, pretensioned at a plant, then
transported to site, lifted in place and then integrated with a
CIP slab.

The integration takes place by tying both systems together at


the slab/beam interface using horizontal shear studs or
extended beam stirrups.
The new integrated beam/slab system is allowed to act as
a composite unit in counteracting flexural stresses, where
the beam carries tension without cracking, while the CIP
slab carries compression.

Fig. 4.1Extended Beam Stirrups Used to


Make the Top Slab Composite (Ref.1)
 4.2.3 Advantages of Precast pre-tensioned
Composite Beam Construction

The following are the main advantages for using


precast pre-tensioned composite beam construction
as opposed to using CIP post-tensioned beam
construction:

1) Time savings: Total construction time is reduced


when using precast pretensioned beams made
composite with CIP RC slabs. Since the beams are
cast in a plant the casting utilizes higher efficiency
rates, thereby accelerating the rate of casting,
curing, transporting, and final Lifting into permanent
position.
2) Higher QA/QC Procedures: Pre-tensioning and casting
concrete in plant is more cost-effective than post-
tensioning on-site due to the higher quality control
procedures employed in factory-produced beam
elements, where both higher mechanical properties and
better quality assurance procedures are achieved,
thereby reducing the delivery time and associated costs.

3) False Work Construction Savings: One of the main


advantages for using precast concrete composite beam
construction over the use of CIP post-tensioned beams is
the ability to use precast beams as means for supporting
the CIP slap formwork without the need for additional
scaffolding. In fact, construction time can be reduced
further through the use of stay-in-place precast (RC or
PC) concrete panels to support the CIP slab.
There are other advantages for using composite beam
construction over other types (e.g., such as single or
double tee beams with toppings). They include:

a) Load Distribution in the Lateral Direction: When securely tied to


the underlying precast pretensioned beam, the CIP slab provides
an effective means to distribute loads in the lateral direction
through the embedded shear studs or
stirrup extensions from the beam into the CIP slab.

b) Continuity of Spans over Interior Supports: When poured


continuously over the supports of precast units, the CIP
slab provides a continues system under
the application of superimposed dead plus live loads,
while self-weight of the
beam acts on the non-composite beam section.
Fig. 4.5- Precast Prestressed Bridge Girder Made Continuous for Superimposed
plus Live Loads (Ref. 1)
c) Increased stiffness of the composite beam under the
application of the superimposed load plus live loads,
especially once full composite action takes place after
the pouring of the CIP slab, will significantly be higher
than beams made with topping slab or simply
supported multi-span units. This Will have a significant
impact on reducing the downward long-term
deflections.
4. 3 SHORED VS. UNSHORED CONSTRUCTION

The various loadings affecting composite construction


can be separated into two groups: One involving the
precast beam alone; and another involving the
composite section.

Within each group, two extreme loadings (a minimum


and a maximum loading) can be identified for the
purposes Of WSD.

The various loads that are part of the minimum and


maximum loadings will depend on whether the
composite beam is shored or unshored.
shored construction implies the use temporary supports or shores
under the precast beam and/or slab during slab pouring and
curing.

The shores are used to relieve the beam from supporting the
weight of the slab by itself.

After hardening the shores are removed, the weight of the slab is
released and the beam ( acting now compositely with the slab ) can
resist the weight of the slab plus any additional superimposed, live,
and impact loading.

Fig. 4.6 – Typical Shored vs. Unshored Construction in Bridges (Ref.1)


Unshored construction on the other hand, implies the use of
precast beams to carry their own weight plus the weight of the
slab during slab pouring and curing, and prior to reaching full
composite action.

Once composite action is achieved after the slab achieves full


strength (e.g., at 28 days), the composite beam is capable of
resisting any additional superimposed, live. plus impact loading .
In summary, shored construction involves resisting the weight of the
beam by the precast section (i.e., using beam cross-sectional
properties), while resisting all the weights that are in excess of the beam
self-weight using the composite section (i.e., using the composite cross-
sectional properties).

Unshored construction, on the other hand, involves resisting the


weight of the beam plus slab by the precast section, while
resisting any additional loadings using the composite section.
Let us define Mmin as the minimum moment applied on the
section which included the self-weight of the beam acting
under the effect of initial prestress, while define Mmax as the
moment including the sum of self-weight, superimposed,
additional dead, plus live loads, acting under the effect of the
final prestressing force.

In composite construction, whether shored or unshored, the


following total moment shall define the critical loading stages
and be used later in design:

Mmin = moment due to self-weight of the precast beam alone


acting under the effect of initial prestress

Mp = sum of external bending moments acting on precast


beam alone under the effect of effective prestress

Mc = sum of external bending moments (in excess of those


that are part of Mp) acting on the composite section under the
effect of effective prestress
 4.4 CROSS-SECTIONAL PROPERTIES AND TRANSFORMED
FLANGE WIDTH

When a monolithic beam with an infinitely wide flange is


subjected to a flexural Loading, the compressive stress on
the top fiber is not constant but varies across the flange due
to what is known as "shear lag“.
it would be too complicated to utilize a theoretical
solution using the actual stress distribution along the slab.
instead, a simplified approach is adopted in design
where the flange is assumed to have an equivalent width,
be, over which the flexural stress is assumed uniform in
the transverse direction.

In principle, the effective flange at a given section is


calculated in order to carry the same load as the
real flange. In theory, the effective flange width, being
simplified and represented as a rectangular stress
distribution in the transverse direction.

Also varies along the beam length. In practice, however,


the effective flange width is assumed constant throughout
the span length.
Here, the effective flange width in accordance with the
2010 AASHTO LRFD Code is obtained using a very
complicated and lengthy procedure} Hence and to
simplicity, a more conservative approach is presented in
this chapter based on the previous version of the AASHTO
Code, known as the AASHTO standard specifications.

Note that L is defined as the effective span length, and


maybe-taken as the actual span length for simply
supported beams, and the distance between the points of
permanent load inflection for
continuous beams, as appropriate for either positive or
negative moments.
When using I beams compositely with a CIP slab, the top
flange of the precast beam becomes the web of the
composite beam.

In order to distinguish the web of the composite beam


from the web of the precast beam, bw, the value of bw
shown in Fig. 4.8 and Table 4.1 can be replaced by bv,
defined as the width of the section at the interface with
the slab.
 4.4.1 - Assumptions and Definition of the Transformed
Flange Width

The following assumptions shall be employed in the analysis


and the design of composite beams:

1) A prestressed concrete composite beam is assumed to


behave elastically under the application of full service load.
2) Precast and composite beam sections shall be designed
uncracked under full service load.
3) The strain distribution along the entire section due to a
bending moment is assumed linear.
4) Full composite action between the precast beam and the
ClP slab shall occur after 28-days.
5) The stress in prestressing steel shall be assumed
constant along the beam length and equal to fpi (initial
prestressing stress at time of transfer prestressing force )
under the application of the self- weight of the precast
beam section, and fpe ( final prestressing stress after all
losses have taken place ) under the application of Mc
and/or Mp.
6) Stresses along the beam cross-section are assumed
linear and are calculated using Hooke's law.

7) One of the two materials comprising the composite


beam section (i.e., either the Slab or the precast beam,
since both might have different mechanical properties)
shall be transformed into the other in order to
systematically calculate the stresses at the extreme top
and bottom fibers of the slab, the precast non-composite
beam, and the composite beam.

8) Constant effective prestressing force, F, under the effect


of Mc or Mp (in practice, the force in the prestressing steel
under the effect of Mp will be somewhere in between Fi
and F).
Point (7) above basically states that either the slab or the
precast beam is transformed , into the other since two
different materials having different modulus of elasticity
values are involved in casting them. This is done using
the concept of transformed section , which in this
chapter shall be applied to the cast in place slab.
The concept essentially transforms the slab into a
fictitious slab having the same concrete mechanical
properties as the precast beam, thereby allowing the
designer to treat the composite section as one unit.
Fig. 4.9a – Effect of Transforming Material B into Equivalent Material A (Ref. 1)
In order to convert the section into a single homogeneous
material, either be or hf transformed into an equivalent
length.
However, and in order to maintain the same compressive
force in the slab and the same centroid for that force, the
slab depth , hf shall be kept the same, but a new
"transformed” Width shall be established.
Therefore, the slab section of depth hf and width be is
transformed into an equivalent section having the same
depth hf and a transformed width btr
where btr is given by:

Where:
Eq. 4.1 ensures that, under bending, the total compressive
force in the actual slab of width be is the same as the
force in the transformed slab of width btr and having the
same modules of elasticity as the precast beam.

For a series of composite beams, fig 4.9b shows be and


btr with respect to beam spacing S.
4.4.2- Cross Sectional Properties of the Composite Section

The use of the transformed flange width, btr leads to a


fictitious slab having the same Strength and elastic modulus
as the precast beam. Consequently, the composite section
can also be considered transformed into an equivalent
monolithic (i.e., non-composite) section having the same
strength and modulus as the precast beam.

Its geometric properties are determined and directly used for


flexural design in the same manner as monolithic non-
composite sections, with a slight adjustment to the
procedure as shall be shown herein.
Let b = btr. Then the area of the composite section, Acc,
can be expressed as follows:

Where, Ac is the cross-sectional area of the precast beam.

Since now Acc and btr are both known quantities, the
remaining cross-sectional properties of the composite
section can be computed according to established
procedures.
4.5 INTERFACE SHEAR (I.e., HORIZANTAL SHEAR)

 4.5.1 - Evaluation of Horizontal Shear

Full composite action between the CIP slab and


the precast beam is a key to utilizing the full
potential of the composite beam. When the CIP
slab and the ·beam are not connected, the slab
slides with respect to the beam and the system
acts as if two separate elements are used.
However, if sufficient shear resistance is
provided between the CIP slab and the beam,
the slip between the two elements can be
prevented.
Sufficient shear guarantees a good connection between
the two element in order to achieve full composite
action in flexure. This can be achieved using
combination of the Following actions:

 Intentionally roughening the precast beam extreme


top fiber.
 Providing an artificial bonding agent to be applied at
the extreme beam top Fiber.
 Extending the shear stirrups in the beam into the CIP
slab, and
 Using shear studs that are welded to the precast
beam top steel cage Reinforcement
Horizontal shear acting at the interface between the
precast beam and the CIP slab is typically generated by all
the factored load acting on the composite section.
The various loadings that are incorporated n this shear force
are independent on whether the construction is shored or
unshored.

In order to understand the derivations at ultimate nominal


strength, let us first derive the equations assuming linear
elastic and uncracked section analysis. Then the Horizontal
shear stress vh can be expressed as follows:
Where:
ASHTO provisions separate the contribution of concrete
and that of reinforcement to the interface shear
resistance.
Interface shear is used as a general term and is essentially
the same as the horizontal shear at the interface between
a precast concrete and a CIP slab.
When the required area of interface shear
reinforcement in girder slab design exceeds the
design required to satisfy vertical (transverse) shear
requirements, additional reinforcement must be
provided to satisfy interface shear requirements.
Unlike vertical shear reinforcement, the additional
interface shear reinforcement needs only to extend
into the girder a sufficient depth to develop its yield
strength. Generally, all reinforcements present where
interface shear transfer is considered should be fully
developed on both sides of the interface.
When the required area of interface shear reinforcement is
less than that required to satisfy vertical shear
reinforcement, no additional action is needed, provided all
the shear reinforcement is extended into the slab. Of
course, the shear reinforcement is assumed to be fully
developed on both sides of the interface.

AASHTO's Interface shear design applies at a given section


in a similar way treated by the ACI. Moreover, in theory, the
shear friction procedure recommend by the ACI and
applicable to a whole segment of the beam [such as half
the span for a simply supported beam] should also be
applicable to AASHTO designs, provided the loads and the
resistance factors are taking according to AASHTO.
Although AASHTO uses a different notation, an attempt is
made in the following section to use notation consistent with
this text. In particular, the subscript i used for "interface" by
AASHTO is replaced in this section by the manuscript h
which stands for "horizontal" shear [as opposed to vertical
shear].
 4.5.2 GENERAL DESIGN APPROACH

Similar to the case of vertical shear and bending, the design


for horizontal shear transfer is based on ultimate strength
requirements, and must conform to the following relation:

Where:
Vuh = factored interface shear force due to the total load
based on the applicable strength and extreme events load
combination (see Tables 3.2 to 3.4), in kips or KN (Note:
AASHTO Code uses Vui)
Vnh = nominal interface shear force resistance; kips or kN
(Note: AASHTO uses Vni)
= strength reduction factor for shear as per AASHTO
Article 5.5.4.2.1, taken as 0.9 for normal weight concrete; and
0.7 for structural light weight concrete (i.e., sand lightweight
or all lightweight).
In cases where different weight concretes exist on
the two sides of an interface, the lower of the two
values of shall be used.

Note that in the AASHTO approach the value of an


ultimate effect such as bending or shear is
generally equal to the sum of factored loads
multiplied by a load modification factor, related to
ductility, redundancy, and operational importance
of the structure, and as per Eq. (3.5).
 4.5.3 Factored Interface Shear Per Unit Length
of interface, Vuh

The following factored horizontal shear stress may be


determined from:

Where:
The concrete area resisting horizontal shear per inch
length of interface is given by:

The horizontal I shear force across the interface, per unit


length (here, per inch), is then determined from:

From Eqs. (4.5) and (4.7), the following is obtained:


4.5.4 - Nominal Interface Shear Resistance Per Unit
Length, Vnh

According to AASHTO LRFD [Section A.5.8.4.1], the nominal


shear resistance at the interface between two types of
concrete surfaces cast at deferent times shall be taken as :

Where:

Fc’ =the smaller value of the compressive strength of the beam or slab, ksi
Pc represents the dead weight of the slab and other
permanent superimposed dead load, such as
asphalt. In case Pc is negative, then the force is in
tension and additional interface reinforcement shall
be provided as:
4.5.5 Minimum Interface Shear Reinforcement

The cross-sectional area of interface shear reinforcement


per unit length (in inches) should not be less than that
required by the following equation:

Where bvi is the width of the interface (in), fy is in ksi,


and Avf is in in2.
For beams and girders, the longitudinal spacing of
the rows of shear transfer bars, shall not exceed 24
inches {600 mm). Ties or dowel bars for horizontal
shear reinforcement may consist of simple bars or
wires, multiple leg stirrups, and vertical legs of
smooth or deformed welded wire fabric. Ties must be
fully anchored into all interconnected elements.

For the cast in place concrete slab on clean


concrete girder surfaces free of laitance, the
following provisions also apply:
The minimum interface shear reinforcement, Avf,
need not to exceed the lesser of the amount
determined from Eq. 4.11 and the amount needed to
resist 1.33 Vuh / as determined using Eq. 4.9.
The minimum reinforcement provisions specified above
shall be waived for girder/slab interfaces with surfaces
roughened to an amplitude of 0.25 inches (600 mm),
where the factored interface shear stress computed from
Eq 4.5 is less than 0.210 ksi (1.45 MPa), and all the
vertical (transverse) shear reinforcement required by the
provisions of article 5.8.2.5 (minimum shear
reinforcement) is :extended across the interface and
adequately anchored in the slab.

No particular mention is given by AASHTO as to whether


the limit of 0.210 ksi (1.45 MP& -is the same for lightweight
concrete. However, and to be on the safe side, it is
reasonable to assume that for lightweight concrete, the
limit should be 0.2101'. (ksi). Note that 'A= 0.85 for sand
lightweight concrete, and 'A= 0.75 for ·all lightweight
(sand and coarse aggregate) concrete.

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