Project No. 12-69 COPY NO. ___ GUIDELINES FOR DESIGN AND CONSTRUCTION OF DECKED PRECAST, PRESTRESSED CONCRETE GIRDER BRIDGES FINAL REPORT Prepared for National Cooperative Highway Research Program Transportation Research Board National Research Council R.G. Oesterle and A.F. Elremaily Construction Technology Laboratories, Inc. 5400 Old Orchard Road, Skokie, IL 60077 In Association with: Roy Eriksson, Eriksson Technologies, Inc. Chuck Prussack, Central Pre-Mix Prestress Co. Z. John Ma, University of Tennessee, Knoxville July 30, 2009 Project No. 12-69 GUIDELINES FOR DESIGN AND CONSTRUCTION OF DECKED PRECAST, PRESTRESSED CONCRETE GIRDER BRIDGES FINAL REPORT Prepared for National Cooperative Highway Research Program Transportation Research Board National Research Council R.G. Oesterle and A.F. Elremaily Construction Technology Laboratories, Inc. 5400 Old Orchard Road, Skokie, IL 60077 In Association with: Roy Eriksson, Eriksson Technologies, Inc. Chuck Prussack, Central Pre-Mix Prestress Co. Z. John Ma, University of Tennessee, Knoxville July 30, 2009 i ACKNOWLEDGMENT OF SPONSORSHIP This work was sponsored by the American Association of State Highway and Transportation Officials, in cooperation with the Federal Highway Administration, and was conducted in the National Cooperative Highway Research Program, which is administered by the Transportation Research Board of the National Research Council. DISCLAIMER This is an uncorrected draft as submitted by the research agency. The opinions and conclusions expressed or implied in the report are those of the research agency. They are not necessarily those of the Transportation Research Board, the National Research Council, the Federal Highway Administration, the American Association of State Highway and Transportation Officials, or the individual states participating in the National Cooperative Highway Research Program. ii TABLE OF CONTENTS Page LIST OF FIGURES ............................................................................................. VI AUTHOR ACKNOWLEDGEMENTS ................................................................ VIII ABSTRACT ........................................................................................................ IX EXECUTIVE SUMMARY ...................................................................................... 1 CHAPTER 1 ......................................................................................................... 3 PRELIMINARY ASSESSMENT ............................................................................ 3 1.1 DESIGN CRITERIA .................................................................................... 3 1.1.1 Design Specifications ................................................................... 3 1.1.2 Loads ............................................................................................. 3 1.1.3 Roadway Geometry ....................................................................... 3 1.2 SITE ASSESSMENT .................................................................................. 4 1.2.1 Accessibility of Site ...................................................................... 4 1.2.2 Vertical Clearance Requirements ................................................ 4 1.2.3 Water Crossing Issues (hydraulics, shoreline, etc.) .................. 4 1.2.4 Permitting and Environmental Issues ......................................... 5 1.3 COORDINATION WITH LOCAL PRECAST PRODUCERS AND CONTRACTORS .............................................................................................. 5 1.3.1 Availability of Product Types ....................................................... 5 1.3.2 Material Properties ........................................................................ 5 1.3.3 Prestressing Systems and Conventions ..................................... 6 1.3.4 Design Conventions ..................................................................... 6 1.3.5 Trucking Capabilities, Shipping Distance ................................... 6 1.3.6 Crane Availability and Rates ........................................................ 6 1.3.7 Preliminary Cost Estimates .......................................................... 7 CHAPTER 2 ....................................................................................................... 10 SYSTEM CONFIGURATION .............................................................................. 10 2.1 STRUCTURAL SYSTEM ......................................................................... 10 2.1.1 Continuity .................................................................................... 10 2.1.2 Girder Splicing ............................................................................ 11 2.1.3 Provisions for Future Redecking ............................................... 12 2.2 GIRDER SIZE AND SPACING ................................................................. 13 2.2.1 Selection of Girder Depth and Depth Limitations .................... 13 2.2.2 Weight Limitations ...................................................................... 13 2.2.3 Length Limitations ...................................................................... 14 2.3 DIAPHRAGMS ......................................................................................... 14 2.3.1 Concrete Diaphragms ................................................................. 15 2.3.2 Steel Diaphragms ........................................................................ 15 iii TABLE OF CONTENTS (continued) 2.4 JOINTS ..................................................................................................... 15 2.4.1 Longitudinal................................................................................. 15 2.4.2 Transverse ................................................................................... 16 2.5 BEARINGS ............................................................................................... 16 2.6 BARRIER AND RAILING SYSTEMS ....................................................... 16 2.6.1 Parapets ....................................................................................... 17 2.6.2 Post and Rails Barriers ............................................................... 17 2.7 PROVISIONS FOR BRIDGE WIDENING ................................................. 17 2.8 BRIDGE AND GIRDER GEOMETRY CONTROL .................................... 17 2.8.1 Girder Camber ............................................................................. 17 2.8.2 Bridge Skew ................................................................................ 19 2.8.3 Bridge Cross Slope ..................................................................... 19 2.8.4 Girder Asymmetry ....................................................................... 20 2.9 OVERLAYS .............................................................................................. 20 2.9.1 Water-Proofing Membrane ......................................................... 20 CHAPTER 3 ....................................................................................................... 34 FABRICATION AND CONSTRUCTION ............................................................. 34 3.1 GIRDER FABRICATION .......................................................................... 34 3.1.1 Forming ........................................................................................ 34 3.1.2 Prestressing ................................................................................ 35 3.1.3 Embedded Hardware .................................................................. 35 3.1.4 Concrete Placement .................................................................... 35 3.2 TRANSPORTATION ................................................................................ 36 3.2.1 Girder Stability ............................................................................ 36 3.3 ERECTION SCHEMES ............................................................................ 36 3.4 GIRDER INSTALLATION ........................................................................ 36 3.4.1 Girder Continuity Connections .................................................. 36 3.4.2 Conventional Weld Plate Joints ................................................. 37 3.4.3 Headed Bar Joints ....................................................................... 39 3.5 FUTURE RE-DECKING ........................................................................... 43 3.5.1 Deck Removal .............................................................................. 43 3.5.2 System Stability .......................................................................... 45 3.5.3 Placement of New Deck .............................................................. 46 CHAPTER 4 ....................................................................................................... 58 DESIGN THEORY AND PROCEDURES ........................................................... 58 4.1 MATERIAL PROPERTIES ....................................................................... 58 4.1.1 Concrete ...................................................................................... 58 4.2 SECTION PROPERTIES .......................................................................... 58 4.3 LOADS ..................................................................................................... 59 4.3.1 Temporary Construction Loads ................................................. 59 4.3.2. Live Load ...................................................................................