Precast Concrete Elements for Accelerated Bridge Construction

357 Pages·2009·11.25 MB·English

Precast Concrete Elements for
Accelerated Bridge Construction
Volume 1-1. Laboratory Testing of Precast
Substructure Components: Boone County Bridge
Volume 1-2. Laboratory Testing of Full-Depth
Precast, Prestressed Concrete Deck Panels: Boone
County Bridge
Volume 1-3. Field Testing of a Precast Concrete
Bridge: Boone County Bridge
Final Report
January 2009
Sponsored by
the Iowa Highway Research Board (IHRB Project TR-561),
the Iowa Department of Transportation (CTRE Project 06-262),
and
Boone County, Iowa, through the Federal Highway Administration’s
Innovative Bridge Research and Construction Program
Iowa State University’s Center for Transportation Research and Education is the umbrella organization for the following centers and programs: Bridge Engineering Center (cid:129) Center for Weather Impacts on Mobility
and Safety (cid:129) Construction Management & Technology (cid:129) Iowa Local Technical Assistance Program (cid:129) Iowa Traffi c Safety Data Service (cid:129) Midwest Transportation Consortium (cid:129) National Concrete Pavement
Technology Center (cid:129) Partnership for Geotechnical Advancement (cid:129) Roadway Infrastructure Management and Operations Systems (cid:129) Statewide Urban Design and Specifications (cid:129) Traffic Safety and Operations
About the Bridge Engineering Center
The mission of the Bridge Engineering Center is to conduct research on bridge technologies to
help bridge designers/owners design, build, and maintain long-lasting bridges.
Disclaimer Notice
The contents of this report refl ect the views of the authors, who are responsible for the facts
and the accuracy of the information presented herein. The opinions, fi ndings and conclusions
expressed in this publication are those of the authors and not necessarily those of the sponsors.
The sponsors assume no liability for the contents or use of the information contained in this
document. This report does not constitute a standard, specifi cation, or regulation.
The sponsors do not endorse products or manufacturers. Trademarks or manufacturers’ names
appear in this report only because they are considered essential to the objective of the document.
Nondiscrimination Statement
Iowa State University does not discriminate on the basis of race, color, age, religion, national
origin, sexual orientation, gender identity, sex, marital status, disability, or status as a U.S.
veteran. Inquiries can be directed to the Director of Equal Opportunity and Diversity,
[phone].
GENERAL ABSTRACT
Precast Concrete Elements for Accelerated Bridge Construction
Precast concrete elements and accelerated bridge construction techniques have the potential to
improve the health of the U.S. highway system. In precast bridge construction, the individual
components are manufactured off-site and assembled on-site. This method usually increases the
components’ durability, reduces on-site work and construction time, minimizes traffic disruption,
and lowers life-cycle costs. Before widespread implementation, however, the benefits of precast
elements and accelerated bridge construction must be verified in the laboratory and field.
For this project, precast bridge elements and accelerated bridge construction techniques were
investigated in the laboratory and at three bridge projects in Iowa: in Boone County, Madison
County, and Black Hawk County. The objectives were to evaluate the precast bridge elements,
monitor the long-term performance of the completed bridges, and evaluate accelerated bridge
construction techniques.
The results of these investigations are presented in three volumes, as described below; this
volume is Volume 1.
Vol. 1-1. Laboratory Testing of Precast Substructure Components: Boone County Bridge
1-2. Laboratory Testing of Full-Depth Precast, Prestressed Concrete Deck Panels:
Boone County Bridge
1-3. Field Testing of a Precast Concrete Bridge: Boone County Bridge
In 2006, a continuous four-girder, three-span bridge was constructed that included precast
abutments, pier cap elements, prestressed beams, and precast full-depth deck panels. All of
the precast elements performed well during strength testing and were set quickly and
smoothly during construction, and the completed bridge experienced very small
displacements and strains when subjected to live loads.
Vol. 2. Laboratory Testing, Field Testing, and Evaluation of a Precast Concrete Bridge:
Madison County Bridge
In 2007, a two-lane single-span bridge was constructed that had precast box girders with
precast abutments. The elements performed well during laboratory load transfer and
strength testing, and the completed bridge performed well in terms of maximum deflections
and differential displacements between longitudinal girder joints.
Vol. 3. Laboratory Testing, Field Testing, and Evaluation of a Precast Concrete Bridge:
Black Hawk County
In 2007, two precast modified beam-in-slab bridge (PMBISB) systems were constructed,
each of which included precast abutment caps, backwalls, and deck panels. Various deck
panel configurations transferred load effectively during laboratory testing, and all precast
elements met expectations. The completed bridges experienced very low induced stresses
and met AASHTO deflection criteria, while the PMBSIB system effectively transferred
load transversely.

V
o
lu
m
Volume 1-1. Laboratory Testing
e
1
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1
of Precast Substructure
Components: Boone County
Bridge

Technical Report Documentation Page
1. Report No. 2. Government Accession No. 3. Recipient’s Catalog No.
IHRB Project TR-561
4. Title and Subtitle 5. Report Date
Precast Concrete Elements for Accelerated Bridge Construction: Laboratory January 2009
Testing of Precast Substructure Components, Boone County Bridge
6. Performing Organization Code

7. Author(s) 8. Performing Organization Report No.
Terry J. Wipf, F. Wayne Klaiber, and Samantha Hockerman CTRE Project 06-262
9. Performing Organization Name and Address 10. Work Unit No. (TRAIS)
Bridge Engineering Center
Iowa State University 11. Contract or Grant No.
2711 South Loop Drive, Suite 4700

Ames, IA 50010-8664
12. Sponsoring Organization Name and Address 13. Type of Report and Period Covered
Iowa Highway Research Board Final Report
Iowa Department of Transportation 14. Sponsoring Agency Code
800 Lincoln Way
Ames, IA 50010
15. Supplementary Notes
Visit www.ctre.iastate.edu for color PDF files of this and other research reports.
16. Abstract
In July 2006, construction began on an accelerated bridge project in Boone County, Iowa that was composed of precast substructure
elements and an innovative, precast deck panel system. The superstructure system consisted of full-depth deck panels that were
prestressed in the transverse direction, and after installation on the prestressed concrete girders, post-tensioned in the longitudinal
direction.
Prior to construction, laboratory tests were completed on the precast abutment and pier cap elements. The substructure testing was to
determine the punching shear strength of the elements. Post-tensioning testing and verification of the precast deck system was
performed in the field. The forces in the tendons provided by the contractor were verified and losses due to the post-tensioning
operation were measured. The stress (strain) distribution in the deck panels due to the post-tensioning was also measured and analyzed.
The entire construction process for this bridge system was documented. Representatives from the Boone County Engineers Office, the
prime contractor, precast fabricator, and researchers from Iowa State University provided feedback and suggestions for improving the
constructability of this design.

17. Key Words 18. Distribution Statement
accelerated bridge construction—Boone County, Iowa—field testing—laboratory No restrictions.
strength testing—precast concrete abutments, pier caps, deck panels—prestressed
concrete girders
19. Security Classification (of this 20. Security Classification (of this 21. No. of Pages 22. Price
report) page)
Unclassified. Unclassified. 200 NA

P C E
RECAST ONCRETE LEMENTS FOR
A B C :
CCELERATED RIDGE ONSTRUCTION
LABORATORY TESTING OF PRECAST SUBSTRUCTURE

COMPONENTS, BOONE COUNTY BRIDGE

Final Report
January 2009

Co-Principal Investigators
Terry J. Wipf, Director, Bridge Engineering Center
Center for Transportation Research and Education, Iowa State University

Brent M. Phares, Associate Director, Bridge Engineering Center
Center for Transportation Research and Education, Iowa State University

F. Wayne Klaiber, Professor, Department of Civil, Construction, and Environmental Engineering
Iowa State University

Research Assistant
Samantha Hockerman

Authors
Terry J. Wipf, F. Wayne Klaiber, and Samantha Hockerman

Sponsored by
the Iowa Highway Research Board (IHRB Project TR-561)
and Boone County, Iowa,
through the Federal Highway Administration’s
Innovative Bridge Research and Construction Program

Preparation of this report was financed in part
through funds provided by the Iowa Department of Transportation
through its research management agreement with the
Center for Transportation Research and Education (CTRE Project 06-262).

Center for Transportation Research and Education
Iowa State University
2711 South Loop Drive, Suite 4700
Ames, IA 50010-8664
Phone: [phone]
Fax: [phone]
www.ctre.iastate.edu