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July 2011 NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM Responsible Senior Program Officer: Waseem Dekelbab Research Results Digest 355 SUMMARY OF CAST-IN-PLACE CONCRETE CONNECTIONS FOR PRECAST DECK SYSTEMS This digest summarizes key findings from NCHRP Project 10-71 "Cast-in- Place Concrete Connections for Precast Deck Systems," conducted by the University of MinnesotaTwin Cities and the University of Tennessee Knoxville. The digest was prepared from the project final report (pub- lished as NCHRP Web-Only Document 173: Cast-in-Place Concrete Connections for Precast Deck Systems) authored by Catherine French, Carol Shield, Z. John Ma, David Klaseus, Matthew Smith, Whitney Eriksson, Peng Zhu, Samuel Lewis, and Cheryl E. Chapman. INTRODUCTION and new bridge construction. For many deficient bridges in the United States on the The aging highway bridge infrastruc- waiting list for replacement, it is imperative ture in the United States is subjected to that new bridge construction be as econom- increasing traffic volumes and must be con- ical as possible and yet be long lasting and tinuously renewed while simultaneously nearly maintenance free. accommodating traffic flow. Speed of con- The focus of the research was to develop struction, especially for the case of bridge recommended design and construction replacement and repair projects, is a critical specifications and examples for the design issue. Disruption of traffic and inconve- and construction of durable cast-in-place nience to motorists, not to mention major (CIP) reinforced concrete connections for safety issues arising from detours, has precast deck systems. These connections encouraged the development of rapid con- were to emulate monolithic construction struction methods. The issue of construction and consider issues including durability speed, combined with higher labor costs and and fatigue, while increasing speed of con- more variable quality control associated with struction. The typical sequence of erecting on-site concrete casting, construction and bridge superstructures in the United States motorist safety issues, political pressures, is to erect the precast prestressed concrete or C O N T E N T S and environmental concerns, has paved the steel beams, place either temporary form- Introduction, 1 way for further increase in the use of precast work or stay-in-place formwork such as PCSSS, 2 elements. steel or concrete panels, place deck rein- Longitudinal and Transverse Joints Depending on the specific site con- forcement, cast deck concrete, and remove in DBT and Full-Depth Precast ditions, the use of prefabricated bridge formwork if necessary. This project focused Panel on Girder Systems, 16 systems can minimize traffic disruption, on systems that reduce the need to place and References for PCSSS Portion of Study, 31 improve work-zone safety, minimize impact remove formwork, thus accelerating on-site to the environment, improve constructabil- construction and improving safety. References for Longitudinal and Transverse Joints In DBT ity, increase quality, and lower life-cycle The three systems considered to accom- And Full-Depth Precast Panel on Girder System Portion costs. This technology is applicable and plish these objectives were identified during of Study, 31 needed for both existing bridge replacement a 2004 Prefabricated Bridge Elements and