Evaluation of a High Performance Concrete Box Girder Bridge
Andreas Greuel
Graduate Research Assistant University of Cincinnati Cincinnati, Ohio
T. Michael Baseheart, Ph. D.
Associate Professor of Civil Engineering University of Cincinnati Cincinnati, Ohio
Bradley T. Rogers
Engineer LJB, Inc.
As part of the FHWA (Federal Highway Administration) High Performance Concrete Bridge Program, two full-scale truckload tests of Bridge GUE-22-6.57 were carried out. The main objectives of these tests were to investigate the static and dynamic response of the high performance concrete (HPC) structure. A secondary objective was to investigate the load transfer between the box girders through experimental middepth shear keys. The structure was loaded using standard Ohio Department of Transportation (ODOT) dump trucks. A model test of the bridge was conducted as well. It was found that the bridge behavior is well predicted using simple models. The bridge behaves as a single unit and all girders share the load almost equally. The dynamic behavior of the bridge is typical for comparable structures.
Dayton, Ohio
Richard A. Miller, Ph. D.
Associate Professor of Civil Engineering University of Cincinnati Cincinnati, Ohio
Bahram M. Shahrooz, Ph. D.
Associate Professor of Civil
Engineering
University of Cincinnati
Cincinnati, Ohio
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located on US Route 22, a heavily traveled two-lane highway near Cambridge, Ohio. in that the Ohio box girder has only a 5 in. (127 mm ) thick bottom flange rather than the 5.5 in. (140 mm) flange used in the AASHTO box. As a result, the Ohio box can accommodate only a single, full layer of 23 strands in the bottom flange and a partial layer of four strands and several layers of two strands in the webs. If the bridge were designed using the largest Ohio box (B42-48, see Fig. 3), standard 5500 psi (39 MPa) concrete and 0.5 in. (13 mm) diameter strands, the maximum span of the girder would be 110 ft (33.5 m). If the steel area is increased by using 0.6 in. (15 mm) diameter strand, the girder could easily span the required length. However, the larger strand he use of high performance concrete (HPC) can lead to more economical bridge designs be-
T
The new bridge replaced a 70 ft
(21.4 m) single span, steel stringer bridge with a concrete deck. The hydraulic requirements required the span of the new bridge to be increased to 115.5 ft (35.2 m ). Note that the bridge was originally designed as a threespan, noncomposite, adjacent box girder system using normal strength concrete [5500 psi (35 MPa)] and 0.5 in. (13 mm) diameter strands [see Fig. 1(b)]. cause the designer can often eliminate girder lines, use shallower sections or extend the span of a section and eliminate the need for intermediate supports. While the use of HPC can lead to lower initial costs through elimination of piers or girder lines, the high durability of HPC can also lead to lower long-term costs because of reduced maintenance and a longer bridge life. Despite the above advantages, as designers use longer and shallower spans with fewer girders, the structures become more flexible. This leads one to question whether the structures will deflect or vibrate excessively or if the greater flexibility will affect the load distribution between adjacent box girders.
Normally, a span of 115.5 ft (35.2 m) would not be too long for a box girder. However, the Ohio box girder (see Fig. 3) differs from the AASHTO standard
Fig. 1(a).
In 1998, the Ohio Department of Transportation (ODOT) constructed a HPC, adjacent box girder bridge. In this bridge, a preliminary design for a three-span bridge was converted to a single-span design [see Figs. 1(a) and 1(b)]. Prior to construction, researchers at the University of Cincinnati (UC) formulated the high performance concrete mixes which would be used and conducted several tests on prototype girders.
HPC single-span design.
The prototype test results showed the simple span box girders to be sufficiently strong and ductile. These tests confirmed that girder behavior was predictable using linear elastic theory prior to cracking and a strain compatibility approach for the ultimate behavior. Satisfied with prototype girder performance, ODOT let the contract for the bridge construction, yet, there were still questions as to how the actual bridge would behave.
Fig. 1(b). Original, three-span design.
To try to answer these questions, the UC research team tested the bridge during and after construction. This paper summarizes the result of destructive and nondestructive testing of prototype girders and of nondestructive testing the completed bridge structure.
BRIDGE DESCRIPTION
Bridge GUE-22-6.57 is a 115.5 ft
(35.2 m) long prestressed, noncomposite, adjacent box girder bridge [see Fig. 1(a)]. The cross section of the bridge is shown in Fig. 2. The structure is
Fig. 2. Cross section of HPC bridge.
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This bridge utilizes an experimental shear key at middepth of the cross section. This shear key configuration was found to be less susceptible to cracking.1 After tying adjacent girders together with non-prestressed threaded rods located transversely through diaphragms at the ends and quarter points of the bridge (see Fig. 4), the shear keys are grouted. Note that in this configuration, only the shear key itself was to be grouted. The area above the middepth shear key was filled with sand and a sealant was applied to the top of the joint to further guard against leakage (see Fig. 5).
Fig. 3. Ohio B42-48 section.
MATERIAL PROPERTIES
The first task for the UC research team was developing a mix design which would produce extremely durable concrete that had high release and ultimate strengths. To make the girder span the required 115.5 ft (35.2 m), it was determined that the concrete would need a minimum compressive strength of 10 ksi (70 MPa ). For durability, a rapid chloride permeability of less than 1000 coulombs was desired. The mix was designed using the materials which the precaster had available. Normally, Type I cement is used for HPC, but the precaster usually used Type III and it was not economically desirable to change to Type I. generates a greater prestressing force and, therefore, high strength concrete is required. Another reason for using HPC is that it has a high durability. Adjacent box girders have shear keys cast between the girders to transfer shear between adjacent girders. Shear keys of adjacent box girder bridges tend to crack, and subsequently, allow water from the bridge surface to leak between the sides of adjacent box girders. Leakage can cause serious damage to the tendons and reinforcement when water and deicing chemicals penetrate the concrete. Leakage is a major problem with adjacent box girder bridges, so HPC with its high durability is an ideal choice for this type of structure.
To improve durability and strength, a water to cementitious material ratio (w/c+p) of less than 0.3 was chosen and microsilica was added to the mix. The precaster did not have a silo available to store the microsilica, so it was batched from bags. To avoid having to weigh the microsilica separately, the mix was designed using single bag increments of 25 lb (11.3 kg). This is why there is an unusual percentage (11.8 percent) for the microsilica. Because of the low w/c+p ratio and presence of microsilica, a water reducer was required both to provide enough workability and to defloculate the cement particles so the microsilica would be able to fit in between them and densify the mix. The fine aggregate was natural river sand. A No. 8, partially crushed, river gravel (3/8 in. or 10 mm max.) was used as the coarse aggregate. Because the aggregate was only partially
Fig. 4. Installing tie rods.
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Fig. 5.
Middepth shear key and tie rods.
strain gauges were placed between the strands at approximately 1 ft (3 m) intervals from each end of the girder prior to casting. After the girder had cured and the strands were cut, the measured strain was used to determine that somewhere between 35 in. and 48 in. (0.89 and 1.2 m) the transfer was complete. This means that the transfer length
was between 60D and 80D (where D
is the strand diameter). The AASHTO Standard Specifications2 use a transfer length of 50D, the AASHTO LRFD Specifications5 use a transfer length of 60D while a transfer length of 80D has been suggested in the literature.6 The prototype girders were subjected to destructive testing. Each girder was supported on neoprene pads such that the test span was 115.5 ft (35.2 m) and loaded with two-point loads placed crushed, the aggregate/paste bond did not appear to be particularly good and this appeared to limit the concrete strength. Making the specified strength required a high cement content. The specified strength could have been obtained with lower cement contents and/or higher w/c+p ratios with the use of a better aggregate (e.g., crushed limestone). the research team could verify the behavior of the girders. An in-depth discussion of the prototype fabrication and destructive testing can be found in a previous work.4 For completeness, a summary is presented here. One area explored was the transfer length for 0.6 in. (15 mm) diameter strand when used with HPC. To measure transfer length, vibrating wire
Thirteen trial mixes were investigated.2 The final mix proportions are shown in Table 1. During fabrication of the prototype and final bridge girders, test cylinders and modulus of rupture beams were cast and later tested to determine the concrete properties. Table 2 provides a list of the measured concrete properties.
Table 1. Concrete mix proportions.
- Material
- Lb per cu yd
- kg/m3
- 497
- Cement
Microsilica Water
846
- 100
- 58.7
- 262
- 145
Fine aggregate Coarse aggregate
Air
- 927
- 544
GIRDER PROPERTIES
The girders are standard ODOT B42-48 box girders (see Fig. 3) and were designed using the provisions of the AASHTO Standard Specifications.3 The ODOT require bridges to be designed for an HS-20 loading, but this bridge was designed using the HS-25 loading to allow for future increases in traffic loads. Because of the experimental aspect of the bridge, the engineer added a few extra strands for additional safety. Thirty 0.6 in. (15 mm) diameter strands were used in the bottom flange with two additional strands placed in the top flange to control tension at release.
1774
6 percent
1042
6 percent
Admixtures
Air entrainer
- Ounces per cu yd
- l/m3
0.81 1.08 7.84
21
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- Retarder
- High range water reducer
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Table 2. Average concrete properties.
Compressive strength at release* Compressive strength at 56 days‡ Modulus of elasticity at 56 days‡ Modulus of rupture at 56 days§
Split strength at 56 days†
8 ksi (56 MPa)
11.8 ksi (80 MPa)
5800 ksi (40000 MPa)
1250 psi (8.6 MPa) 620 psi (4.3 MPa)
0.1 percent
DESTRUCTIVE TESTING OF
PROTOTYPE GIRDERS
Prior to the fabrication of the actual bridge girders, two prototype box girders were cast and tested. This was done so that the precaster could gain more experience in placing HPC and so that
Shrinkage after one year§
Creep coefficient after one year** Rapid chloride permeability at 56 days
2.1
360 coulumbs
* 6 x 12 in. cylinders - bed cured. † 6 x 12 in. cylinders - moist cured. ‡ 6 x 6 x 14 in. beams - moist cured. § 3 x 3 x 11.25 in. prisms - 28 days moist cure
** 6 x 12 in. cylinders - test started at 1 day (i.e., at release of prestressing force)
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Fig. 6. Testing the prototype girder.
47.25 ft (14.4 m) from each support (see Fig. 6). Loads were applied such that the deflection of the girder under the load points increased in 0.05 in. (1.3 mm) increments. The first cracks in both girders appeared when the applied load at each point was approximately 42 kips (187 kN). Counting self weight, the total cracking moment was 3570 kip-ft (4840 kN-m). This value was larger than the 3155 kip-ft (4280 kN-m) cracking moment predicted using the provisions of the AASHTO Standard Specifications. Note that in calculating the cracking moment, a loss of prestressing force of 20 percent was assumed. This loss value was calculated from the provisions of the AASHTO Standard Specifications. One reason for the difference between the calculated and measured values of the cracking moment is that the modulus of rupture was taken as higher modulus of rupture. If the measured modulus of rupture of 1250 psi (8.6 MPa) is used, the calculated cracking moment becomes 3525 kip-ft (4780 kN-m), which is very close to the measured value. The use of the higher modulus of rupture is important since the provisions of the AASHTO Standard Specifications require that φ Mn > 1.2 Mcr, where Mn is the nominal moment, Mcr is the cracking moment and φ is the capacity reduction factor. If Mcr is underestimated, the design may not be conservative. The girders were loaded to approximately 80 kips (356 kN) at each load point. Again, accounting for self weight, the applied moment was 5320 kip-ft (7220 kN-m). This exceeded the ultimate moment of 5130 kip-ft (6960 kN- m), calculated using the provisions of the AASHTO Standard Specifications. Under this load, the girder had a very large deflection of 24 in. (61 m) at the midspan. This corresponds to a deflection of L/58, where L is the span.
The test was stopped at this point for safety reasons. Fig. 7 shows a load versus midspan deflection graph for one of the prototype girders. Also plotted is the behavior predicted using a computer program called RESPONSE.7 For a given moment, RESPONSE generates curvature and strain values for the cross section by strain compatibility. Deflections are found by first choosing an applied load level, plotting the moment diagram for the total moment (dead load plus applied load), and then using the result of this analysis to plot a curvature diagram. The curvature can then be double integrated to find the deflection. Load versus strain behavior is available directly from the RESPONSE results. Clearly, the girder deflection behavior is well predicted. A graph of load versus extreme fiber compressive strain (see Fig. 8) also shows good agreement between the analysis and experiments up to a strain of 0.002 (where the test was stopped).
- 7.5
- (in psi units), or 750 psi (5.3
MPa). However, HPC has a
- Fig. 7. Load versus deflection for prototype girder.
- Fig. 8. Load versus top compressive strain for prototype girder.
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Table 3. Loss of prestressing force – prototype girder.
Measured losses of prestressing force were determined experimentally on the prototype girders. The girders were loaded to cracking and then unloaded. When unloaded, the prestressing force causes the cracks to close. Clip gauges were placed across the closed cracks so that the crack opening could be measured when the girder was reloaded. When the girder is reloaded, the tensile stress from the applied moment relieves the compressive stress caused by the prestressing force and eventually overcomes it, causing the crack to open. Theoretically, the load at which the crack just begins to open (as measured by the clip gauges) corresponds to a zero stress state. Knowing the applied moment which causes a state of zero stress at a known point on the girder, it is possible to back-calculate the effective prestressing force. The measured values are shown in Table 3. Calculated values of the loss of prestressing force, from two different methods, are also presented. One method of calculating the loss of prestress is that given in the PCI Design Handbook8 and the other is the method given in the AASHTO Standard Specifications.2 The calculated values of loss of prestressing force are final values, which assume a large amount of time has passed and all of the creep, shrinkage and relaxation of the strands has occurred. The prototype girders were only 6 to 9 months old at the time of testing, so an exact comparison cannot be made. However, at 6 to 9 months, approximately 80 percent of the time-dependent deformations have occurred. With this in mind, the data in Table 3 suggest that the calculated values of loss of prestressing force are reasonable.
- Girder 1
- Girder 2
Crack 1
- PCI
- AASHTO
- Crack 1
- Crack 2
- 17 percent
- 18 percent
- 17.5 percent
- 18 percent
- 20 percent
lems occurred during the fabrication of the girders and only minor adjustments to the usual fabrication process were needed to accommodate the use of HPC. Most of these accommodations centered around the fact that HPC tends to be sticky, does not move well under vibration and has a high rate of slump loss. The workers simply needed to use greater care in the method and rate of placement to prevent cold joints or voids. Girder camber was measured at release and at various times while the girders were in storage. At release, the girders showed a camber of about 1/8 in. (3 mm), but growth in storage began immediately. Before the girders were shipped to the construction site, they had cambered up an average of 1.5 in. (38 mm). This behavior is in reasonable agreement with a predicted value of 1.66 in. (42 mm), which was calculated using elastic theory and accounting for time-dependent effects by using the multipliers given in the PCI Design Handbook. initial prestressing force. The calculated loss due to elastic shortening was approximately 6 percent.
INSTRUMENTATION OF THE GIRDERS
During the fabrication of the actual box girders for the bridge, a total of 69 internal sensors were embedded. A total of 57 vibrating wire strain gauges and 12 bonded foil strain gauges were embedded inside the girders. All the internal sensors were installed at midspan. Vibrating wire strain gauges were used to measure static truckload strains but are not capable of measuring dynamic events. In addition, temperature changes during curing and afterwards could be measured by thermistors in the vibrating wire gauges. The foil strain gauges measure instantaneous strains under traffic loading and can capture dynamic responses from moving trucks. Depending on the girder location, the number and layout of the embedded strain gauges were varied. This scheme allowed a reasonable and adequate number of sensors. All the girders had a single foil strain gauge near the middle of the bottom flange. As a minimum, two vibrating wire strain gauges were used in each girder – one in the top flange and one in the bottom flange.
Embedded strain gauges (see next section on Instrumentation) were read before and after detensioning and several times during girder storage. Using these readings, the strain change in concrete at strand level was calculated to be 580 microstrain at transfer. Thus, the loss at detensioning due to elastic shortening becomes 8.8 percent of the
The results of the prototype testing clearly showed that the girders were sufficiently strong and predictable. With the prototype girder testing complete, the girders for the actual bridge were fabricated.
FABRICATION OF THE BRIDGE
GIRDERS
The actual bridge girders were fabricated at Prestress Services, Melbourne, Kentucky. No major prob-
Fig. 9. Girder numbering for Phase I and Phase II.
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Additional sensors were installed in some of the girders to measure the distribution of strains and temperature gradient through the depth and across the width of the girders. Considering that Girders 4 through 9 (see Fig. 9) will resist most of the traffic loads, these girders were instrumented more heavily than the other girders. The vibrating wire strain gauges in the bottom flange were placed between the strands and gauges in the web were placed between the stirrups. To ensure adequate protection and long-term durability, the foil strain gauges were mounted onto auxiliary No. 4 mild steel reinforcement with adequate development length. These auxiliary bars were gauged in the laboratory. Durable adhesives, requiring oven curing, were used. Following the strain gauge manufacturer's recommended procedures, each gauge was protected from moisture. The strain-gauged bars were tied onto the bottom transverse reinforcement. The electrical wires to the internal sensors were numbered and routed to what would be the east end of the girder when the bridge was completed. At this location, a sufficient length of the electrical wire to connect the gauges to a data acquisition system at the bridge site was coiled and placed inside electrical boxes, which had been secured to the reinforcing cage. The end of each electrical wire was then taken out of the formwork. These electrical wire ends were then connected to a data acquisition system. The instruments were checked during fabrication to ensure no damage had occurred. Later, instruments were used to measure the heat of hydration during curing and monitor the response of the girders during detensioning. Prior to shipping the girders, the extra electrical cable was cut and the area around the electrical cable on the top flange was sealed. After the girders were placed, the instruments could be attached to the data acquisition system by accessing the wires through electrical boxes embedded in the bottom of the girders. removed and the channel in this area was widened. One-half of each new abutment, consisting of concrete filled tube piles, a pile cap and a beam seat, was constructed at each end. The first seven girders (see Figs.
2 and 9) were delivered and set on neoprene bearing pads. After the threaded rods were installed, the shear keys were grouted and the longitudinal joints were sealed. The top surface of the Phase I girders was covered with a waterproofing membrane and then a layer of asphalt. Traffic was then routed to the completed half of the new bridge. In Phase II, the other half of the old bridge was removed and the channel was widened. After constructing the remaining halves of the two abutments, Girders 8 to 12 (see Figs. 2 and 9) were sequentially put in place, installing and tightening the threaded rods along the way. However, only the shear keys between Girders 8 to 12 were grouted. The shear key at the construction joint between Girder 7 in Phase I and Girder 8 in Phase II was not grouted because of the constant movement of Girder 7 due to the traffic on Phase I half of the bridge. Without the shear key in place, the vertical displacements of Girder 7 due to the traffic load caused spalling on the bottom edge of Girder 8 where it contacted Girder 7. This occurred because there is a small amount of tension in the transverse rods which is used to pull the girders together during erection (but is not intended as a transverse post-tensioning).