Post-Tensioned Box Girder Design Manual
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Post-Tensioned Box Girder Design Manual June 2016 This page intentionally left blank. 1. Report No. 2. Government Accession No. 3. Recipient’s Catalog No. FHWA-HIF-15-016 XXX XXX 4. Title and Subtitle 5. Report Date Post-Tensioned Box Girder Design Manual June 2016 Task 3: Post-Tensioned Box Girder Design Manual 6. Performing Organization Code XXX 7. Author(s) 8. Performing Organization Report No. Corven, John XXX 9. Performing Organization Name and Address 10. Work Unit No. Corven Engineering Inc., XXX 2864 Egret Lane Tallahassee, FL 32308 11. Contract or Grant No. DTFH61-11-H-00027 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered Federal Highway Administration XXX Office of Infrastructure – Bridges and Structures 1200 New Jersey Ave., SE Washington, DC 20590 14. Sponsoring Agency Code HIBS-10 15. Supplementary Notes Work funded by Cooperative Agreement “Advancing Steel and Concrete Bridge Technology to Improve Infrastructure Performance” between FHWA and Lehigh University. 16. Abstract This Manual contains information related to the analysis and design of cast-in-place concrete box girder bridges prestressed with post- tensioning tendons. The Manual is targeted at Federal, State and local transportation departments and private company personnel that may be involved in the analysis and design of this type of bridge. The Manual reviews features of the construction of cast-in-place concrete box girder bridges, material characteristics that impact design, fundamentals of prestressed concrete, and losses in prestressing force related to post-tensioned construction. Also presented in this Manual are approaches to the longitudinal and transverse analysis of the box girder superstructure. Both single-cell and multi-cell box girders are discussed. Design examples are presented in Appendices to this Manual. The document is part of the Federal Highway Administration’s national technology deployment program and may serve as a training manual. 17. Key Words 18. Distribution Statement Box girder, Cast-in-place, Multi-cell, Concrete, Top Slab, No restrictions. This document is available to the public Cantilever Wing, Web, Bottom Slab, Prestressing, Post- online and through the National Technical Information tensioning, Strand, Tendon, Duct, Anchorage, Losses, Friction, Wobble, Elastic Shortening, Creep, Shrinkage, Service, Springfield, VA 22161. Force, Eccentricity, Bending moment, Shear, Torsion, Joint flexibilities, Longitudinal analysis, Transverse analysis 9. Security Classif. (of this 20. Security Classif. (of this 21. No of Pages 22. Price report) page) 355 $XXX.XX Unclassified Unclassified SI* (MODERN METRIC) CONVERSION FACTORS APPROXIMATE CONVERSIONS TO SI UNITS Symbol When You Know Multiply By To Find Symbol LENGTH in inches 25.4 millimeters mm ft feet 0.305 meters m yd yards 0.914 meters m mi miles 1.61 kilometers km AREA in2 square inches 645.2 square millimeters mm2 ft2 square feet 0.093 square meters m2 yd2 square yard 0.836 square meters m2 ac acres 0.405 hectares ha mi2 square miles 2.59 square kilometers km2 VOLUME fl oz fluid ounces 29.57 milliliters mL gal gallons 3.785 liters L ft3 cubic feet 0.028 cubic meters m3 yd3 cubic yards 0.765 cubic meters m3 NOTE: volumes greater than 1000 L shall be shown in m3 MASS oz ounces 28.35 grams g lb pounds 0.454 kilograms kg T short tons (2000 lb) 0.907 megagrams (or "metric ton") Mg (or "t") TEMPERATURE (exact degrees) oF Fahrenheit 5 (F-32)/9 Celsius oC or (F-32)/1.8 ILLUMINATION fc foot-candles 10.76 lux lx fl foot-Lamberts 3.426 candela/m2 cd/m2 FORCE and PRESSURE or STRESS lbf poundforce 4.45 newtons N lbf/in2 poundforce per square inch 6.89 kilopascals kPa APPROXIMATE CONVERSIONS FROM SI UNITS Symbol When You Know Multiply By To Find Symbol LENGTH mm millimeters 0.039 inches in m meters 3.28 feet ft m meters 1.09 yards yd km kilometers 0.621 miles mi AREA mm2 square millimeters 0.0016 square inches in2 m2 square meters 10.764 square feet ft2 m2 square meters 1.195 square yards yd2 ha hectares 2.47 acres ac km2 square kilometers 0.386 square miles mi2 VOLUME mL milliliters 0.034 fluid ounces fl oz L liters 0.264 gallons gal m3 cubic meters 35.314 cubic feet ft3 m3 cubic meters 1.307 cubic yards yd3 MASS g grams 0.035 ounces oz kg kilograms 2.202 pounds lb Mg (or "t") megagrams (or "metric ton") 1.103 short tons (2000 lb) T TEMPERATURE (exact degrees) oC Celsius 1.8C+32 Fahrenheit oF ILLUMINATION lx lux 0.0929 foot-candles fc cd/m2 candela/m2 0.2919 foot-Lamberts fl FORCE and PRESSURE or STRESS N newtons 0.225 poundforce lbf kPa kilopascals 0.145 poundforce per square inch lbf/in2 *SI is the symbol for the International System of Units. Appropriate rounding should be made to comply with Section 4 of ASTM E380. (Revised March 2003) Visit http://www.fhwa.dot.gov/publications/convtabl.cfm for a 508 compliant version of this table. This page intentionally left blank. Post-Tensioned Box Girder Design Manual June 2016 Preface This Manual contains information related to the analysis and design of cast-in-place concrete box girder bridges prestressed with post-tensioning tendons. The Manual is targeted at Federal, State and local transportation departments and private company personnel that may be involved in the analysis and design of this type of bridge. The Manual reviews features of the construction of cast-in-place concrete box girder bridges, material characteristics that impact design, fundamentals of prestressed concrete, and losses in prestressing force related to post- tensioned construction. Also presented in this Manual are approaches to the longitudinal and transverse analysis of the box girder superstructure. Both single-cell and multi-cell box girders are discussed. Design examples are presented in Appendices to this Manual. The document is part of the Federal Highway Administration’s national technology deployment program and may serve as a training manual. Preface i Post-Tensioned Box Girder Design Manual June 2016 This page intentionally left blank. ii Post-Tensioned Box Girder Design Manual June 2016 Table of Contents Chapter 1 – Introduction ...........................................................................................................1 1.1 Historical Overview .............................................................................................................1 1.2 Typical Superstructure Cross Sections ............................................................................... 2 1.3 Longitudinal Post-Tensioning Layouts ................................................................................ 3 1.4 Loss of Prestressing Force ................................................................................................. 6 1.5 Post-Tensioning System Hardware .................................................................................... 6 1.5.1 Basic Bearing Plates ....................................................................................... 6 1.5.2 Special Bearing Plates or Anchorage Devices ................................................. 7 1.5.3 Wedge Plates ..................................................................................................8 1.5.4 Wedges and Strand-Wedge Connection .......................................................... 8 1.5.5 Permanent Grout Caps .................................................................................... 8 1.5.6 Ducts ...............................................................................................................9 1.5.6.1 Duct Size...........................................................................................9 1.5.6.2 Corrugated Steel Duct ....................................................................... 9 1.5.6.3 Corrugated Plastic ........................................................................... 10 1.5.6.4 Plastic Fittings and Connections for Internal Tendons ..................... 11 1.5.6.5 Grout Inlets, Outlets, Valves and Plugs ........................................... 11 1.5.7 Post-Tensioning Bars Anchor Systems .......................................................... 11 1.6 Overview of Construction ................................................................................................. 12 1.6.1 Falsework ...................................................................................................... 12 1.6.2 Superstructure Formwork .............................................................................. 13 1.6.3 Reinforcing and Post-Tensioning Hardware Placement ................................. 15 1.6.4 Placing and Consolidating Superstructure Concrete ...................................... 15 1.6.5 Superstructure Curing.................................................................................... 16 1.6.6 Post-Tensioning Operations .......................................................................... 17 1.6.7 Tendon Grouting and Anchor Protection ........................................................ 19 Chapter 2 – Materials .............................................................................................................. 20 2.1 Concrete ..........................................................................................................................20 2.1.1 Compressive Strength ................................................................................... 20 2.1.2 Development of Compressive Strength with Time ......................................... 21 2.1.3 Tensile Strength ...........................................................................................