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Suggested Citation:"Front Matter." National Academies of Sciences, Engineering, and Medicine. 2013. High-Performance/High-Strength Lightweight Concrete for Bridge Girders and Decks. Washington, DC: The National Academies Press. doi: 10.17226/22638.
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Suggested Citation:"Front Matter." National Academies of Sciences, Engineering, and Medicine. 2013. High-Performance/High-Strength Lightweight Concrete for Bridge Girders and Decks. Washington, DC: The National Academies Press. doi: 10.17226/22638.
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Suggested Citation:"Front Matter." National Academies of Sciences, Engineering, and Medicine. 2013. High-Performance/High-Strength Lightweight Concrete for Bridge Girders and Decks. Washington, DC: The National Academies Press. doi: 10.17226/22638.
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Suggested Citation:"Front Matter." National Academies of Sciences, Engineering, and Medicine. 2013. High-Performance/High-Strength Lightweight Concrete for Bridge Girders and Decks. Washington, DC: The National Academies Press. doi: 10.17226/22638.
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Suggested Citation:"Front Matter." National Academies of Sciences, Engineering, and Medicine. 2013. High-Performance/High-Strength Lightweight Concrete for Bridge Girders and Decks. Washington, DC: The National Academies Press. doi: 10.17226/22638.
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Suggested Citation:"Front Matter." National Academies of Sciences, Engineering, and Medicine. 2013. High-Performance/High-Strength Lightweight Concrete for Bridge Girders and Decks. Washington, DC: The National Academies Press. doi: 10.17226/22638.
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Suggested Citation:"Front Matter." National Academies of Sciences, Engineering, and Medicine. 2013. High-Performance/High-Strength Lightweight Concrete for Bridge Girders and Decks. Washington, DC: The National Academies Press. doi: 10.17226/22638.
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N A T I O N A L C O O P E R A T I V E H I G H W A Y R E S E A R C H P R O G R A M NCHRP REPORT 733 High-Performance/High-Strength Lightweight Concrete for Bridge Girders and Decks Tommy Cousins and Carin Roberts-Wollmann The Charles e. Via, Jr., DeparTmenT of CiVil anD enVironmenTal engineering Virginia polyTeChniC insTiTuTe anD sTaTe uniVersiTy Blacksburg, VA Michael C. Brown Virginia CenTer for TransporTaTion innoVaTion anD researCh Charlottesville, VA Subscriber Categories Bridges and Other Structures • Materials TRANSPORTAT ION RESEARCH BOARD WASHINGTON, D.C. 2013 www.TRB.org Research sponsored by the American Association of State Highway and Transportation Officials in cooperation with the Federal Highway Administration

NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM Systematic, well-designed research provides the most effective approach to the solution of many problems facing highway administrators and engineers. Often, highway problems are of local interest and can best be studied by highway departments individually or in cooperation with their state universities and others. However, the accelerating growth of highway transportation develops increasingly complex problems of wide interest to highway authorities. These problems are best studied through a coordinated program of cooperative research. In recognition of these needs, the highway administrators of the American Association of State Highway and Transportation Officials initiated in 1962 an objective national highway research program employing modern scientific techniques. This program is supported on a continuing basis by funds from participating member states of the Association and it receives the full cooperation and support of the Federal Highway Administration, United States Department of Transportation. The Transportation Research Board of the National Academies was requested by the Association to administer the research program because of the Board’s recognized objectivity and understanding of modern research practices. The Board is uniquely suited for this purpose as it maintains an extensive committee structure from which authorities on any highway transportation subject may be drawn; it possesses avenues of communications and cooperation with federal, state and local governmental agencies, universities, and industry; its relationship to the National Research Council is an insurance of objectivity; it maintains a full-time research correlation staff of specialists in highway transportation matters to bring the findings of research directly to those who are in a position to use them. The program is developed on the basis of research needs identified by chief administrators of the highway and transportation departments and by committees of AASHTO. Each year, specific areas of research needs to be included in the program are proposed to the National Research Council and the Board by the American Association of State Highway and Transportation Officials. Research projects to fulfill these needs are defined by the Board, and qualified research agencies are selected from those that have submitted proposals. Administration and surveillance of research contracts are the responsibilities of the National Research Council and the Transportation Research Board. The needs for highway research are many, and the National Cooperative Highway Research Program can make significant contributions to the solution of highway transportation problems of mutual concern to many responsible groups. The program, however, is intended to complement rather than to substitute for or duplicate other highway research programs. Published reports of the NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM are available from: Transportation Research Board Business Office 500 Fifth Street, NW Washington, DC 20001 and can be ordered through the Internet at: http://www.national-academies.org/trb/bookstore Printed in the United States of America NCHRP REPORT 733 Project 18-15 ISSN 0077-5614 ISBN 978-0-309-25888-3 Library of Congress Control Number 2013930599 © 2013 National Academy of Sciences. All rights reserved. COPYRIGHT INFORMATION Authors herein are responsible for the authenticity of their materials and for obtaining written permissions from publishers or persons who own the copyright to any previously published or copyrighted material used herein. Cooperative Research Programs (CRP) grants permission to reproduce material in this publication for classroom and not-for-profit purposes. Permission is given with the understanding that none of the material will be used to imply TRB, AASHTO, FAA, FHWA, FMCSA, FTA, or Transit Development Corporation endorsement of a particular product, method, or practice. It is expected that those reproducing the material in this document for educational and not-for-profit uses will give appropriate acknowledgment of the source of any reprinted or reproduced material. For other uses of the material, request permission from CRP. NOTICE The project that is the subject of this report was a part of the National Cooperative Highway Research Program, conducted by the Transportation Research Board with the approval of the Governing Board of the National Research Council. The members of the technical panel selected to monitor this project and to review this report were chosen for their special competencies and with regard for appropriate balance. The report was reviewed by the technical panel and accepted for publication according to procedures established and overseen by the Transportation Research Board and approved by the Governing Board of the National Research Council. The opinions and conclusions expressed or implied in this report are those of the researchers who performed the research and are not necessarily those of the Transportation Research Board, the National Research Council, or the program sponsors. The Transportation Research Board of the National Academies, the National Research Council, and the sponsors of the National Cooperative Highway Research Program do not endorse products or manufacturers. Trade or manufacturers’ names appear herein solely because they are considered essential to the object of the report.

The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished scholars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare. On the authority of the charter granted to it by the Congress in 1863, the Academy has a mandate that requires it to advise the federal government on scientific and technical matters. Dr. Ralph J. Cicerone is president of the National Academy of Sciences. The National Academy of Engineering was established in 1964, under the charter of the National Academy of Sciences, as a parallel organization of outstanding engineers. It is autonomous in its administration and in the selection of its members, sharing with the National Academy of Sciences the responsibility for advising the federal government. The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achievements of engineers. Dr. Charles M. Vest is president of the National Academy of Engineering. The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the services of eminent members of appropriate professions in the examination of policy matters pertaining to the health of the public. The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an adviser to the federal government and, on its own initiative, to identify issues of medical care, research, and education. Dr. Harvey V. Fineberg is president of the Institute of Medicine. The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy’s purposes of furthering knowledge and advising the federal government. Functioning in accordance with general policies determined by the Academy, the Council has become the principal operating agency of both the National Academy of Sciences and the National Academy of Engineering in providing services to the government, the public, and the scientific and engineering communities. The Council is administered jointly by both Academies and the Institute of Medicine. Dr. Ralph J. Cicerone and Dr. Charles M. Vest are chair and vice chair, respectively, of the National Research Council. The Transportation Research Board is one of six major divisions of the National Research Council. The mission of the Transporta- tion Research Board is to provide leadership in transportation innovation and progress through research and information exchange, conducted within a setting that is objective, interdisciplinary, and multimodal. The Board’s varied activities annually engage about 7,000 engineers, scientists, and other transportation researchers and practitioners from the public and private sectors and academia, all of whom contribute their expertise in the public interest. The program is supported by state transportation departments, federal agencies including the component administrations of the U.S. Department of Transportation, and other organizations and individu- als interested in the development of transportation. www.TRB.org www.national-academies.org

C O O P E R A T I V E R E S E A R C H P R O G R A M S AUTHOR ACKNOWLEDGMENTS The research reported herein was performed under NCHRP Project 18-15 by Virginia Tech (VT), the Virginia Center for Transportation Innovation and Research (VCTIR), and PE Structural Consultants, Inc. At VT, the principal investigator was Tommy Cousins and the co-principal investigator was Carin Roberts-Wollmann. Major contributions to the project were made by Ben Cross, Bernie Kassner, Jana Scott, and Jon Marston. The hard work of Chinmay Damle, Brett Farmer, and Dennis Huffman is also gratefully acknowledged. At VCTIR, the research was performed under the direction of Michael Brown, with significant contribu- tions from Brenton Stone. At PE Structural Consultants, Inc., the design examples and parametric studies were performed by Nestor Rubiano, under the direction of Lisa Powell. The assistance of all these indi- viduals is gratefully acknowledged. CRP STAFF FOR NCHRP REPORT 733 Christopher W. Jenks, Director, Cooperative Research Programs Crawford F. Jencks, Deputy Director, Cooperative Research Programs Amir N. Hanna, Senior Program Officer Andrea Harrell, Senior Program Assistant Eileen P. Delaney, Director of Publications Hilary Freer, Senior Editor NCHRP PROJECT 18-15 PANEL Field of Materials and Construction—Area of Concrete Materials Bijan Khaleghi, Washington State DOT, Tumwater, WA (Chair) David Hohmann, HDR Engineering, Inc., Austin, TX (formerly with Texas DOT) Hossein Ghara, Louisiana DOTD, Baton Rouge, LA Jose A. Lopez, Plainsboro, NJ (formerly with New Jersey DOT) Ric Maggenti, California DOT, Sacramento, CA Vicki R. Stewart, Maryland State Highway Administration, Hanover, MD Maher K. Tadros, University of Nebraska–Lincoln, Omaha, NE Benjamin A. Graybeal, FHWA Liaison Frederick Hejl, TRB Liaison

F O R E W O R D By Amir N. Hanna Staff Officer Transportation Research Board This report presents proposed changes to the AASHTO LRFD bridge design and construction specifications to address the use of lightweight concrete in bridge girders and decks. These modified specifications will provide highway agencies with the informa- tion necessary to develop comparable designs of lightweight and normal weight concrete bridge elements for use in evaluating alternatives and selecting the alternative that will yield economic benefits. The material contained in the report should be of immediate interest to state bridge engineers and others involved in the design and construction of concrete bridges. Use of high-strength prestressed concrete girders and high-performance bridge decks has become accepted practice by many state highway agencies because of the associated technical and economic benefits. These girders and decks are generally manufactured with concrete made with natural normal weight aggregates. Use of manufactured lightweight coarse aggregate, such as expanded shale, slate, and clay, to produce lightweight concrete offers the benefit of reducing the weight of the superstructure, leading to reductions in the size of girders, substructure, and foundations. These size and weight reductions facilitate shipping, handling, and construction or replacement of bridge elements and thus result in economic benefits. Recent advances in high-performance/high-strength lightweight concrete have had limited application in bridge construction because of the lack of design and construction guidelines and concerns about material properties and their impact on performance. Thus research was needed to (1) address the factors that significantly influence the design, constructibility, and performance of high-strength prestressed concrete bridge girders and high-performance bridge decks and (2) propose appropriate changes to the AASHTO LRFD bridge design and construction specifications to adequately address the use of lightweight concrete for these applications. Under NCHRP Project 18-15, “High-Performance/High-Strength Lightweight Concrete for Bridge Girders and Decks,” Virginia Polytechnic Institute and State University (Virginia Tech) conducted a review of the use of lightweight concrete in bridge decks and girders and executed an experimental investigation to evaluate the performance of specimens and bridge beams made with lightweight concrete mixtures. Based on the findings of the literature review and the experimental investigation, the research proposed changes to the AASHTO LRFD bridge design and construction specifications, primarily to the equations for estimating modulus of elasticity, modulus of rupture, and creep. The research also presented examples that considered proposed changes to illustrate the change in prestressing steel requirements of typical bridge girders if lightweight concrete is used

instead of normal weight concrete. These modified specifications will provide highway agencies with the information necessary to develop designs of lightweight concrete bridge elements that are comparable to those made with normal weight concrete to provide the basis for an equitable comparison. The attachments contained in the research agency’s final report provide elaborations and detail on several aspects of the research. Attachments A and B provide proposed changes to AASHTO LRFD bridge design and bridge construction specifications, respectively; these are included in the report. Attachments C through R are not published herein but are available by searching for NCHRP Report 733 on the TRB website.

C O N T E N T S 1 Summary 4 Chapter 1 Introduction 4 1.1 Background 4 1.2 Project Objectives and Scope 4 1.3 Research Plan and Methodology 5 1.4 Organization of the Project 6 Chapter 2 Findings 6 2.1 Materials Testing 7 2.2 Interface Shear Strength 8 2.3 Laboratory Beam Tests 8 2.4 Shear Tests 8 2.5 Time-Dependent Behavior of Lab-Cast and Full-Scale Beams 10 Chapter 3 Background and Research Approach 10 3.1 Mix Designs and Material Properties 23 3.2 Interface Shear Strength 33 3.3 Laboratory Beam Test Results and Analysis 40 3.4 Shear Performance of Full-Scale Beams 49 3.5 Time-Dependent Behavior of Lab-Cast and Full-Scale Beams 62 3.6 Design Examples 64 Chapter 4 Interpretation, Appraisal, and Application 65 Chapter 5 Conclusions and Suggested Research 65 5.1 Material Properties 65 5.2 Interface Shear Strength 65 5.3 Shear Tests 66 5.4 Transfer and Development Length Testing 66 5.5 Time-Dependent Behavior 66 5.6 Design Examples and Parametric Studies 66 5.7 Recommendations for Future Research 68 References 69 Attachment A Proposed Changes to AASHTO LRFD Bridge Design Specifications 80 Attachment B Proposed Changes to AASHTO LRFD Bridge Construction Specifications Note: Many of the photographs, figures, and tables in this report have been converted from color to grayscale for printing. The electronic version of the report (posted on the Web at www.trb.org) retains the color versions.

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TRB’s National Cooperative Highway Research Program (NCHRP) Report 733: High-Performance/High-Strength Lightweight Concrete for Bridge Girders and Decks presents proposed changes to the American Association of State Highway and Transportation Officials’ Load and Resistance Factor Design (LRFD) bridge design and construction specifications to address the use of lightweight concrete in bridge girders and decks.

The proposed specifications are designed to help highway agencies evaluate between comparable designs of lightweight and normal weight concrete bridge elements so that an agency’s ultimate selection will yield the greatest economic benefit.

The attachments contained in the research agency’s final report provide elaborations and detail on several aspects of the research. Attachments A and B provide proposed changes to AASHTO LRFD bridge design and bridge construction specifications, respectively; these are included in the print and PDF version of the report.

Attachments C through R are available for download below.

Attachments C, D, and E contain a detailed literature review, survey results, and a literature summary and the approved work plan, respectively.

Attachment C

Attachment D

Attachment E

Attachments F through M provide details of the experimental program that were not able to be included in the body of this report.

Attachment F

Attachment G

Attachment H

Attachment I

Attachment J

Attachment K

Attachment L

Attachment M

Attachments N through Q present design examples of bridges containing lightweight concrete and details of the parametric study.

Attachment N

Attachment O

Attachment P

Attachment Q

Attachment R is a detailed reference list.

Attachment R

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