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This study evaluates the strength and long-term performance of CFRP prestressed panels in a bridge deck, compare the behavior of bridge decks designed with the empirical and conventional methods of AASHTO, and a new limit-state design, and examinne the influence of lap splices between precast panels on deck cracking.
Following development of rectangular prestressed, precast concrete panels (PCP) that could be used as stay-in-place formwork adjacent to expansion joints in bridge decks, the Texas Department of Transportation (TxDOT) initiated a research effort to investigate the use of PCP units at skewed expansion joints. The fabrication of trapezoidal PCP units was studied and the response of skewed panels with 45° and 30° skew angles was obtained. The panels were topped with a 4 in. thick cast-in-place (CIP) slab to complete the bridge deck. Specimens with 45° skew performed well under service and overload levels. The deck failed in diagonal shear at loads well over the design level loads. However, two 30° specimens failed prematurely by delamination between the topping slab and the PCP. The cause of the delamination was insufficient shear transfer capacity between the PCP and CIP topping slab. For the specimens tested at a square end, the failure mode was punching shear at high loads for all specimens. The surface condition of the PCP was specified to have a "broom finish" and the panel was to have a saturated surface dry (SSD) condition so that PCP units would not leach moisture from the CIP topping slab. Neither of these conditions was satisfied in the two panels that failed prematurely. Although the panels were specified to have a broom finish, the panel surface had regions that were quite smooth. The objective of this research project was to reinvestigate the response of 30° PCP at an expansion joint following specified procedures for finish and moisture conditions. One specimen was constructed with a rectangular panel placed between two 30° skewed panels. These panels had a much rougher surface texture than the previously tested panels that failed in delamination. The skewed ends of the specimen were subjected to monotonically increasing static loads at midspan of the panel ends. The panels failed in diagonal shear and the response of the tested specimen confirmed that the panel surface roughness, and not the skew angle, caused delamination with the previously tested specimens. While TxDOT does not currently specify a minimum panel surface roughness, a surface roughness of approximately 1/4 in. is required in some codes for developing composite action. In addition, wetting the panels to a SSD condition prior to placement of the topping slab further enhances shear transfer between the topping slab and the PCP.
A literature review concerning the objectives of the project was completed. A significant number of published papers, reports, etc., were examined to determine the effectiveness of full depth precast panels for bridge deck replacement. A detailed description of the experimental methodology was developed which includes design and fabrication of the panels and assembly of the bridge. The design and construction process was carried out in cooperation with the project Technical Review Panel. The major components of the bridge deck system were investigated. This includes the transverse joints and the different materials within the joint as well as composite action. The materials investigated within the joint were polymer concrete, non-shrink grout, and set-45 for the transverse joint. The transverse joints were subjected to direct shear tests, direct tension tests, and flexure tests. These tests exhibited the excellent behavior of the system in terms of strength and failure modes. Shear key tests were also conducted. The shear connection study focused on investigating the composite behavior of the system based on varying the number of shear studs within a respective pocket as well as varying the number of pockets within a respective panel. The results indicated that this shear connection is extremely efficient in rendering the system under full composite action. Finite element analysis was conducted to determine the behavior of the shear connection prior to initiation of the actual full scale tests. In addition, finite element analysis was also performed with respect to the transverse joint tests in an effort to determine the behavior of the joints prior to actual testing. The most significant phase of the project was testing a full-scale model. The bridge was assembled in accordance with the procedures developed as part of the study on full-depth precast panels and the results obtained through this research. The system proved its effectiveness in withstanding the applied loading that exceeded eight times the truck loading in addition to the maximum negative and positive moment application. Only hairline cracking was observed in the deck at the maximum applied load. Of most significance was the fact that full composite action was achieved between the precast panels and the steel supporting system, and the exceptional performance of the transverse joint between adjacent panels.
Continuous longitudinal and transverse U-bar joint connections between flanges of the decked bulb-Ts (DBTs) or between precast panels for accelerated bridge construction are investigated. The procedure for selecting durable closure pour (CP) materials for the connections is discussed firstly. The accelerated construction is quantified as two categories: overnight cure and 7-day cure of CP materials. Candidate materials are selected first based on literature review as well as tests of compressive strength and flow and workability. Then, performance criteria for selecting durable CP materials for both categories are developed based on durability tests of selected candidate materials. These durability tests include freezing-and-thawing durability, shrinkage, bond, and permeability tests. To investigate the longitudinal U-bar joint details, four pairs of full-scale slabs connected by a U-bar detail with one of the selected CP materials, overnight cure and 7-day cure, were tested. The loading demand necessary in the slab testing is determined based on the maximum forces in the longitudinal joint from an analytical parametric study. Static and fatigue tests under four-point flexural loading and three-point flexural-shear loading were conducted. Test results were evaluated based on flexural capacity, curvature behavior, cracking, deflection and steel strain. The transverse U-bar joint details are investigated to provide negative moment continuity in the multi-span bridges. Four full-scale specimens connected by a U-bar detail with one of the selected CP materials, overnight cure and 7-day cure, were tested. Static and fatigue tests under tension loading were conducted. The loading demand necessary in the beam testing is determined based on the maximum forces in the transverse joint from an analytical study. Test results were evaluated based on tension capacity, cracking, displacement and steel strain. Based on the test results, the developed longitudinal and transverse U-bar joint details are viable connection systems.
TRB's National Cooperative Highway Research Program (NCHRP) Synthesis 319: Bridge Deck Joint Performance presents the state of the practice on commonly used expansion joint systems in bridges by summarizing performance data for each system type and by providing examples of selection criteria and design guidelines.