Full-Depth Precast Concrete Bridge Deck Panel Systems (2008)

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TRANSPORTAT ION RESEARCH BOARD WASHINGTON, D.C. 2008 www.TRB.org 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 584 Subject Areas Bridges, Other Structures, and Hydraulics and Hydrology Full-Depth Precast Concrete Bridge Deck Panel Systems Sameh S. Badie THE GEORGE WASHINGTON UNIVERSITY Washington, DC A N D Maher K. Tadros UNIVERSITY OF NEBRASKA–LINCOLN Lincoln, Nebraska 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. 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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 584 Project 12-65 ISSN 0077-5614 ISBN 978-0-309-09914-1 Library of Congress Control Number 2007909932 © 2008 Transportation Research Board COPYRIGHT PERMISSION 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. Such approval reflects the Governing Board’s judgment that the program concerned is of national importance and appropriate with respect to both the purposes and resources of the National Research Council. The members of the technical committee selected to monitor this project and to review this report were chosen for recognized scholarly competence and with due consideration for the balance of disciplines appropriate to the project. The opinions and conclusions expressed or implied are those of the research agency that performed the research, and, while they have been accepted as appropriate by the technical committee, they are not necessarily those of the Transportation Research Board, the National Research Council, the American Association of State Highway and Transportation Officials, or the Federal Highway Administration, U.S. Department of Transportation. Each report is reviewed and accepted for publication by the technical committee according to procedures established and monitored by the Transportation Research Board Executive Committee and the Governing Board of the National Research Council. 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CRP STAFF FOR NCHRP REPORT 584 Christopher W. Jenks, Director, Cooperative Research Programs Crawford F. Jencks, Deputy Director, Cooperative Research Programs David B. Beal, Senior Program Officer Eileen P. Delaney, Director of Publications NCHRP PROJECT 12-65 Field of Design—Area of Bridges Michael M. Sprinkel, Virginia DOT, Charlottesville, VA (Chair) Michael D. Hyzak, Texas DOT, Austin, TX Ted L. Barber, New Mexico DOT, Santa Fe, NM Shriniuas B. Bhide, LEAP Software, Inc., Tampa, FL Kishor Doshi, STV Incorporated, New York, NY Mark A. Gaines, Washington State DOT, Olympia, WA Majid Madani, California DOT, Sacramento, CA A. Osimboni, Rhode Island DOT, Providence, RI Peter Smith, Fort Miller Co., Inc., Schuylerville, NY Benjamin Graybeal, FHWA Liaison Joey Hartmann, FHWA Liaison Frederick Hejl, TRB Liaison 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 by the Civil and Environmental Engineering Department, The George Washington University, Washington DC; Tadros Associates, LLC, Omaha, Neb.; and the Department of Civil Engineering, University of Nebraska-Lincoln. The George Washington University was the contractor for this study. The work undertaken at Tadros Associates, LLC, and the University of Nebraska-Lincoln was under individual subcontracts with The George Washington University. Sameh S. Badie, Assistant Professor of Civil Engineering, Civil and Environmental Engineering Depart- ment, The George Washington University, was the principal investigator. Coauthors of this report are Maher K. Tadros, The Charles J. Vranek Distinguished Professor of Civil Engineering, and Amgad F. Girgis, Research Assistant Professor, Department of Civil Engineering, University of Nebraska-Lincoln. The following individuals provided assistance during various phases of the project: Walter Mesia, Nghi Nguyen, Parul Patel, and Krissachai Sriboonma, graduate research students at The George Washington University; Karen A. Bexten, Senior Engineer and partner of Tadros Associates, LLC; and Carlos Encarna- cion and Yuri V. Jukarev, graduate research students, and Kelvin J. Lein, Senior Laboratory Technician, at the University of Nebraska-Lincoln.

This report provides recommended guidelines and AASHTO load and resistance factor design (LRFD) specifications language for design, fabrication, and construction of full- depth precast concrete bridge deck panel systems. Durable and rapidly constructed connec- tions between panels were also developed as part of this research. The report details the development of the guidelines, connection details, and recommended specifications. The material in this report will be of immediate interest to bridge designers. The impact of highway construction projects on the public is considerable. Increased travel times resulting from congested construction work zones and the resultant degradation in traf- fic safety are the most readily apparent consequences. Development of a totally precast bridge construction system offers one means of significantly reducing construction time, because forming, casting, and curing operations can be carried out at a remote location with less on- site impact on motorists. Considerable time can be saved on bridge construction projects through the use of precast bent caps, columns, parapets, abutments, and other components. Development of a full-depth precast concrete bridge deck panel system with a ride qual- ity suitable for high-speed, direct traffic contact would be a major achievement, comple- menting work being done elsewhere in developing a totally precast bridge construction system. Previous research has resulted in implementation of posttensioned and overlaid sys- tems for connection durability and ride quality. Issues that have been addressed include panel casting and placement tolerances, shear connections, vertical alignment, final grade adjustment, drainage, and parapet connections. The objectives of this research were to develop recommended guidelines and AASHTO LRFD specifications language for design, fabrication, and construction of full-depth precast concrete bridge deck panel systems and to develop durable and rapidly constructed connec- tions between panels. To reduce total deck construction time, full-depth precast concrete bridge deck panels that provide connection durability and ride quality without the use of posttensioning and overlays were developed. Connections suitable for simple and continu- ous spans and composite and noncomposite design were also developed and other connec- tion details that reduce construction time associated with precast decks were investigated. In addition, applications for steel and prestressed concrete superstructures were investigated and research to extend the 24 in. maximum shear connector spacing to 48 in. was performed. This research was performed by The George Washington University, the University of Nebraska-Lincoln, and Tadros Associates, LLC. The report fully documents the research leading to the recommended design, fabrication, and construction guidelines; specification language; and connection details. The appendices, available on the TRB website (http:// www.trb.org/TRBNet/ProjectDisplay.asp?ProjectID=354), contain the recommended guide- lines and proposed revisions to LRFD specifications language. F O R E W O R D By David B. Beal Staff Officer Transportation Research Board

C O N T E N T S 1 Summary 3 Chapter 1 Introduction 3 Problem Statement 3 Objective and Scope of the Research 4 Research Approach 4 Organization of the Report 4 Applicability of the Results to Highway Practice 5 Chapter 2 Background and Literature Review 5 Panel to Superstructure Connection 7 Transverse Panel to Panel Connection 10 Longitudinal Reinforcement 12 Grout Material 14 History of the Shear Connector Spacing Limits of the AASHTO LRFD Design Specifications 15 Summary of the Literature Review 17 Chapter 3 Research Results 17 Recommended Full-Depth Precast Concrete Bridge Deck Panel Systems 28 Panel to Panel Connection 53 Panel to Concrete Girder Connection 61 Panel to Steel Girder Connection 105 Guidelines for Design, Detailing, Fabrication, and Installation of Full-Depth, Precast Concrete Deck Panel Systems 105 Proposed Revisions to AASHTO LRFD Specifications 106 Chapter 4 Conclusions, Recommendations, and Suggested Future Research 106 Conclusions and Recommendations 107 Suggestions for Future Research 108 References 110 Appendices