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Archived: Construction of the Iowa Highway 60 Precast Prestressed Concrete Pavement Bridge Approach Slab Demonstration Project

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Archived: Construction of the Iowa Highway 60 Precast Prestressed Concrete Pavement Bridge Approach Slab Demonstration Project Construction of the Iowa Highway 60 Precast Prestressed Concrete Pavement Bridge Approach Slab Demonstration Project PUBLICATION NO. FHWA- IF -07 -034 JULY 2007 Archived Notice This document is disseminated under the sponsorship of the U.S. Department of Transportation in the interest of information ex­ change.The U.S. Government assumes no liability for the use of the information contained in this document.This report does not constitute a standard, specification, or regulation. The U.S. Government does notArchived endorse products or manufacturers.Trademarks or manufacturers’ names appear in this report only because they are considered essential to the objective of the document. Quality Assurance Statement The Federal Highway Administration (FHWA) provides high-quality information to serve Government, industry, and the public in a manner that promotes public understanding. Standards and policies are used to ensure and maximize the quality, objectivity, utility, and integrity of its information. FHWA periodically reviews quality issues and adjusts its programs and processes to ensure continuous quality improvement. Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. Recipient's Catalog No. FHWA-IF-07-034 4. Title and Subtitle 5. Report Date Construction of the Iowa Highway 60 Precast Prestressed Concrete Pavement July 2007 Bridge Approach Slab Demonstration Project 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report David K. Merritt, Alberto J. Miron, Richard B. Rogers, Robert Otto Rasmussen No. 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) The Transtec Group, Inc. 6111 Balcones Dr. 11. Contract or Grant No. Austin, Texas 78731 DTFH61-05-C-00035 12. Sponsoring Agency Name and Address 13. Type of Report and Period U.S. Department of Transportation Iowa Highway Research Board Covered Federal Highway Administration Iowa Department of Transportation Final Report 1200 New Jersey Avenue, SE, HIPT-20 800 Lincoln Way March 2005—September 2006 Washington, DC 20590 Ames, IA 50010 14. Sponsoring Agency Code HIPT-20 15. Supplementary Notes Contracting Officer's Technical Representative: Sam Tyson, FHWA Office of Pavement Technology 1200 New Jersey Avenue SE, HIPT-20 / E73-440, Washington, DC 20590 E-mail: [email protected], Phone: 202-366-1326 16. Abstract Reconstruction of bridge approach slabs that have failed due to a loss of support from embankment fill consolidation or erosion can be particularly challenging in urban areas where lane closures must be minimized. Precast prestressed concrete pavement is a potential solution for rapid bridge approach slab reconstruction which uses prefabricated pavement panels that can be installed and opened to traffic quickly. To evaluate this solution, the Iowa Department of Transportation constructed a precast prestressed approach slab demonstration project on Highway 60 near Sheldon, Iowa in August/September 2006. Two approach slabs at either end of a new bridge were constructed using precast prestressed concrete panels. This report documents the successful development, design, and construction of the precast prestressed concrete bridge approach slabs on Highway 60. The report discusses the challenges and issues that were faced during the project and presents recommendations for future implementation of this innovative construction technique. 17. Key Word 18. Distribution Statement precast pavement, precast prestressed concrete pavement, No restrictions. bridge approach, prestressed pavement, rapid construction 19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. No. of Pages 22. Price Unclassified ArchivedUnclassified 102 Form DOT F 1700.7 (8-72) Reproduction of completed page authorized i Archived ii TABLE OF CONTENTS Executive Summary..................................................................................................................... ix CHAPTER 1. INTRODUCTION.................................................................................................1 The Problem...............................................................................................................................1 FHWA Demonstration Projects .................................................................................................1 Benefits of Precast Prestressed Concrete Pavement ..................................................................3 Rapid Construction ..............................................................................................................3 Improved Durability and Performance ................................................................................4 Reduced Slab Thickness ......................................................................................................5 Extended Construction Season ............................................................................................5 Benefits of PPCP for Bridge Approach Slabs......................................................................5 Report Objectives.......................................................................................................................6 CHAPTER 2. KEY FEATURES OF PRECAST PRESTRESSED CONCRETE PAVEMENT...................................................................................................................................7 Prestressed Pavement.................................................................................................................7 Full-Depth Panels.......................................................................................................................7 Keyed Panel Joints.....................................................................................................................7 Base Preparation ........................................................................................................................7 Grouting .....................................................................................................................................8 Construction Process..................................................................................................................8 CHAPTER 3. IOWA HIGHWAY 60 DEMONSTRATION PROJECT................................11 Project Scope ...........................................................................................................................11 Location .............................................................................................................................11 Demonstration Project Goals .............................................................................................11 Partnering and Project Coordination........................................................................................12 Project Layout..........................................................................................................................12 Roadway Geometry ...........................................................................................................12 Integral Bridge Abutment ..................................................................................................14 Precast Panel Layout Options ............................................................................................14 Selected Precast Panel Layout ...........................................................................................16 CHAPTER 4. DESIGN................................................................................................................21 Design Considerations .............................................................................................................21 Slab Bridging .....................................................................................................................21 Traffic Loading ..................................................................................................................21 Bridge and Approach Slab Movement...............................................................................21 Highway 60 PPCP Design .......................................................................................................22 Traffic Loading ..................................................................................................................22 Initial Flexural Design .......................................................................................................22 Final FlexuralArchived Design.........................................................................................................23 Transverse Prestress...........................................................................................................24 Slab Movement Analysis ...................................................................................................24 CHAPTER 5. PANEL FABRICATION....................................................................................27 Procedure .................................................................................................................................27 iii Tolerances................................................................................................................................27 Panel Details ............................................................................................................................27 Keyways.............................................................................................................................27
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