Iowa State University Capstones, Theses and Graduate Theses and Dissertations Dissertations 2011 Laboratory testing of Ultra High Performance Concrete deck joints for use in accelerated bridge construction Douglas Robert Hartwell Iowa State University Follow this and additional works at:https://lib.dr.iastate.edu/etd Part of theCivil and Environmental Engineering Commons Recommended Citation Hartwell, Douglas Robert, "Laboratory testing of Ultra High Performance Concrete deck joints for use in accelerated bridge construction" (2011).Graduate Theses and Dissertations. 10420. https://lib.dr.iastate.edu/etd/10420 This Thesis is brought to you for free and open access by the Iowa State University Capstones, Theses and Dissertations at Iowa State University Digital Repository. It has been accepted for inclusion in Graduate Theses and Dissertations by an authorized administrator of Iowa State University Digital Repository. For more information, please [email protected]. Laboratory testing of Ultra High Performance Concrete deck joints for use in accelerated bridge construction by Douglas R. Hartwell A thesis submitted to the graduate faculty In partial fulfillment of the requirements for the degree of MASTER OF SCIENCE Major: Civil Engineering (Structural Engineering) Program of Study Committee: Jon M. Rouse, Major Professor Terry Wipf Kejin Wang Iowa State University Ames, Iowa 2011 Copyright © Douglas R. Hartwell, 2011. All rights reserved. ii TABLE OF CONTENTS LIST OF TABLES .............................................................................................................. iv LIST OF FIGURES .............................................................................................................. v ACKNOWLEDGEMENTS ............................................................................................... viii ABSTRACT ........................................................................................................................ ix CHAPTER 1. INTRODUCTION ..........................................................................................1 Problem Statement .....................................................................................................1 Research Goals and Objectives ..................................................................................1 Arrangement of the Thesis .........................................................................................2 CHAPTER 2. BACKGROUND ............................................................................................3 Project Background .........................................................................................................3 Second Strategic Highway Research Program ..........................................................3 Bridge Description ...................................................................................................3 Relevant UHPC Material Background .............................................................................6 Material Background and Characteristics .................................................................7 Current Bridge Applications.....................................................................................9 CHAPTER 3. METHODS ................................................................................................... 13 Research Design ............................................................................................................ 13 UHPC Abrasion Testing ................................................................................................ 13 Mixing and Casting UHPC Cylinders ..................................................................... 14 Abrasion and Compressive Strength Tests .............................................................. 16 Joint Constructability Testing ........................................................................................ 18 Designing and Constructing Intersecting Joint Formwork ...................................... 18 Mixing and Casting Intersecting Joint Specimen .................................................... 20 Transverse Joint Strength and Serviceability Testing ..................................................... 23 Designing and Constructing Full-Scale Transverse Connection Specimen .............. 24 Casting the Transverse UHPC Joint ....................................................................... 27 Instrumentation for the Transverse Module-to-Module Connection Specimen ........ 28 Calculating Testing Load Levels ............................................................................ 32 Conducting Service Level Static Testing ................................................................ 33 Conducting Service Level Testing with Connection Retrofit .................................. 35 Conducting Ultimate Moment Capacity Testing ..................................................... 37 CHAPTER 4. RESULTS & DISCUSSION ......................................................................... 38 Material Property Tests .................................................................................................. 38 UHPC Quality Control Tests .................................................................................. 38 UHPC Strength Tests ............................................................................................. 38 HPC Strength Test ................................................................................................. 41 Flexural Strength Test ............................................................................................ 42 UHPC Abrasion Testing ................................................................................................ 43 Abrasion Test Results ............................................................................................ 43 iii Joint Constructability Testing ........................................................................................ 50 Constructability Test Results .................................................................................. 51 Transverse Joint Strength and Serviceability Testing ..................................................... 56 Results Terminology .............................................................................................. 56 Service Level Static Test Results ........................................................................... 57 Service Level Fatigue Test Results ......................................................................... 68 Connection Retrofit Test Results ............................................................................ 78 Ultimate Capacity Test Results .............................................................................. 93 CHAPTER 5. CONCLUSIONS ........................................................................................ 104 UHPC Abrasion ........................................................................................................... 104 Joint Constructability ................................................................................................... 105 Transverse Joint Strength and Serviceability ................................................................ 106 WORKS CITED................................................................................................................ 110 APPENDICES .................................................................................................................. 113 Appendix A: Steel Fabrication Plans............................................................................ 114 Appendix B: Instrumentation Locations & Labeling .................................................... 120 iv LIST OF TABLES Table 3.1. Specimen Curing and Testing Matrix ..................................................................14 Table 3.2. Abrasion Testing Specimen UHPC Mix Design 1 (0.58 ft³ Batch).......................15 Table 3.3. Abrasion Test Specimen UHPC Mix Design 1 (0.40 ft³ Batch) ...........................15 Table 3.4. Constructability Test Specimen UHPC Mix Design 2 (5.11 ft³ Batch) .................20 Table 3.5. HPC Mix Proportions .........................................................................................26 Table 4.1. Joint Constructability – UHPC Quality Control Test Results ...............................38 Table 4.2. Joint Strength & Serviceability – UHPC Quality Control Test Results ................38 Table 4.3. Joint Strength & Serviceability – HPC Flexural Strength ....................................43 Table 4.4. Abrasion Specimen Identification Matrix ............................................................44 Table 4.5. 2-Day Abrasion Test Results ...............................................................................45 Table 4.6. 4-Day Abrasion Test Results ...............................................................................46 Table 4.7. 7-Day Abrasion Test Results ...............................................................................47 Table 4.8. 28-Day Abrasion Test Results .............................................................................48 Table 4.9. Row 1, Top-of-Deck Strain Accrual ....................................................................72 Table 4.10. Row 1, Bottom-of-Deck Strain Accrual.............................................................73 Table 4.11. Row 2, Top-of-Deck Strain Accrual ..................................................................74 Table 4.12. Row 2, Bottom-of-Deck Strain Accrual.............................................................75 Table 4.13. Row 3, Top-of-Deck Strain Accrual ..................................................................76 Table 4.14. Row 3, Bottom-of-Deck Strain Accrual.............................................................77 v LIST OF FIGURES Figure 2.1. Existing US Highway 6 Bridge over Keg Creek .................................................. 4 Figure 2.2. Bridge Plan View ............................................................................................... 4 Figure 2.3. Bridge Deck Cross Section ................................................................................. 5 Figure 2.4. Precast Deck Modules ........................................................................................ 5 Figure 2.5. Completed SHRP 2 Project R04 Demonstration Bridge ...................................... 6 Figure 2.6. UHPC I-Girder Bridge - Wapello County, Iowa .................................................10 Figure 2.7. PI Girder Bridge - Buchanan County, Iowa ........................................................11 Figure 2.8. UHPC Deck Closure Joints ................................................................................12 Figure 3.1. Lancaster Products Mixer ..................................................................................15 Figure 3.2. Diamond Cut and Rough Top Surface Finishes ..................................................16 Figure 3.3. Rotating Cutter Head .........................................................................................16 Figure 3.4. ASTM C944 Test Setup .....................................................................................17 Figure 3.5. UHPC Deck Joint Details ..................................................................................19 Figure 3.6. Intersecting Joint Specimen Formwork ..............................................................19 Figure 3.7. Acrylic Glass Vertical Bulkhead ........................................................................20 Figure 3.8. Placement of Transverse UHPC Joint ................................................................22 Figure 3.9. Plywood Top Forms ..........................................................................................23 Figure 3.10. Module-to-Module Transverse Connection Detail ............................................24 Figure 3.11. Prefabricated Deck Module Construction .........................................................25 Figure 3.12. Completed Deck Module .................................................................................26 Figure 3.13. Transverse UHPC Deck Joint Detail ................................................................27 Figure 3.14. UHPC Joint Preparation and Placement ...........................................................28 Figure 3.15. Connection Instrumentation Locations, Plan View ...........................................29 Figure 3.16. Connection Instrumentation Locations, Section View ......................................30 Figure 3.17. Embedded Bonded Strain Gages in HPC Deck ................................................31 Figure 3.18. Surface Mounted Strain Gages on Top of Deck................................................32 Figure 3.19. Test Specimen Free Body Diagram ..................................................................33 Figure 3.20. Lubricated Steel Bearing Plates .......................................................................34 Figure 3.21. Load Frame for Service Level Testing .............................................................34 Figure 3.22. Load Test Setup ...............................................................................................35 Figure 3.23. Connection Retrofit Detail ...............................................................................36 Figure 3.24. Connection Retrofit Installed ...........................................................................36 Figure 3.25. Actuators for Ultimate Moment Capacity Testing ............................................37 Figure 4.1. Compressive Strength of UHPC Mix Design 1 (Abrasion Testing) ....................39 Figure 4.2. Compressive Strength of UHPC Mix Design 2 (Joint Constructability) ..............40 Figure 4.3. Compressive Strength of UHPC Mix Design 2 (Strength & Serviceability)........41 Figure 4.4. Compressive Strength of HPC (Joint Strength & Serviceability) ........................42 Figure 4.5. Abrasion Testing – Percentage Mass Loss vs. Strength ......................................49 Figure 4.6. Section of Transverse Joint (1)...........................................................................53 Figure 4.7. Section of Transverse Joint (2)...........................................................................53 Figure 4.8. Joint Intersection Specimen ...............................................................................54 Figure 4.9. Stay-in-Place Acrylic Bulkhead .........................................................................55 Figure 4.10. Removable Acrylic Bulkhead ..........................................................................55 vi Figure 4.11. Proposed Placement Plan .................................................................................56 Figure 4.12. Deck Surface Terminology Photograph ...........................................................56 Figure 4.13. Deck Surface Terminology Diagram ................................................................56 Figure 4.14. Applied Moment vs. Actuator Displacement ....................................................57 Figure 4.15. Top-of-Deck Surface Mounted Strain Gages over the Joint Interface ...............58 Figure 4.16. Selected Surface Mounted Strain Gages Adjacent to the Joint Interface ...........59 Figure 4.17. Joint Interface Opening ....................................................................................60 Figure 4.18. Embedded Strain Gage Location and Identification..........................................61 Figure 4.19. Row 1, Top-of-deck Embedded Strain Gages (Static) ......................................62 Figure 4.20. Row 2, Top-of-deck Embedded Strain Gages (Static) ......................................63 Figure 4.21. Row 3, Top-of-deck Embedded Strain Gages (Static) ......................................64 Figure 4.22. Row 1, Bottom-of-Deck Embedded Strain Gages (Static) ................................65 Figure 4.23. Row 2, Bottom-of-Deck Embedded Strain Gages (Static) ................................66 Figure 4.24. Row 3, Bottom-of-Deck Embedded Strain Gages (Static) ................................67 Figure 4.25. Row 1, Top-of-Deck Embedded Strain Gages (1,000,000 cycles) ....................68 Figure 4.26. Row 2, Top-of-Deck Embedded Strain Gages (1,000,000 cycles) ....................69 Figure 4.27. Row 3, Top-of-Deck Embedded Strain Gages (1,000,000 cycles) ....................70 Figure 4.28. Full Depth Cracking in Precast Deck ...............................................................71 Figure 4.29. Row 1, Top-of-Deck Strain Accrual .................................................................72 Figure 4.30. Row 1, Bottom-of-Deck Strain Accrual ...........................................................73 Figure 4.31. Row 2, Top-of-Deck Strain Accrual .................................................................74 Figure 4.32. Row 2, Bottom-of-Deck Strain Accrual ...........................................................75 Figure 4.33. Row 3, Top-of-Deck Strain Accrual .................................................................76 Figure 4.34. Row 3, Bottom-of-Deck Strain Accrual ...........................................................77 Figure 4.35. Top-of-Deck Surface Mounted Strain Gages over Interface (60k Retrofit) .......79 Figure 4.36. Row 1, Top-of-Deck Embedded Strain Gages (60k Retrofit)............................80 Figure 4.37. Row 2, Top-of-Deck Embedded Strain Gages (60k Retrofit)............................81 Figure 4.38. Row 3, Top-of-Deck Embedded Strain Gages (60k Retrofit)............................82 Figure 4.39. Row 1, Bottom-of-Deck Embedded Strain Gages (60k Retrofit) ......................83 Figure 4.40. Row 2, Bottom-of-Deck Embedded Strain Gages (60k Retrofit) ......................84 Figure 4.41. Row 3, Bottom-of-Deck Embedded Strain Gages (60k Retrofit) ......................85 Figure 4.42. Top-of-Deck Surface Mounted Strain Gages over Interface (70k Retrofit) .......86 Figure 4.43. Row 1, Top-of-Deck Embedded Strain Gages (70k Retrofit)............................87 Figure 4.44. Row 2, Top-of-Deck Embedded Strain Gages (70k Retrofit)............................88 Figure 4.45. Row 3, Top-of-Deck Embedded Strain Gages (70k Retrofit)............................89 Figure 4.46. Row 1, Bottom-of-Deck Embedded Strain Gages (70k Retrofit) ......................90 Figure 4.47. Row 2, Bottom-of-Deck Embedded Strain Gages (70k Retrofit) ......................91 Figure 4.48. Row 3, Bottom-of-Deck Embedded Strain Gages (70k Retrofit) ......................92 Figure 4.49. Ultimate Capacity Moment vs. Deflection .......................................................93 Figure 4.50. Row 1, Top-of-Deck Embedded Strain Gages (Ultimate) .................................94 Figure 4.51. Row 2, Top-of-Deck Embedded Strain Gages (Ultimate) .................................95 Figure 4.52. Row 3, Top-of-Deck Embedded Strain Gages (Ultimate) .................................96 Figure 4.53. Row 1, Bottom-of-Deck Embedded Strain Gages (Ultimate) ...........................97 Figure 4.54. Row 2, Bottom-of-Deck Embedded Strain Gages (Ultimate) ...........................98 Figure 4.55. Row 3, Bottom-of-Deck Embedded Strain Gages (Ultimate) ...........................99 vii Figure 4.56. Interface Opening and Crack Propagation ...................................................... 100 Figure 4.57. Girder-Deck Interface .................................................................................... 101 Figure 4.58. UHPC Rupture (Top and Bottom-of-Deck) .................................................... 101 Figure 4.59. Bottom-of-Deck at Failure ............................................................................. 102 Figure 4.60. Exterior Hairpin Reinforcement (Opposite Sides) .......................................... 102 Figure 4.61. Bottom Flange Deformation .......................................................................... 103 Figure 4.62. Overall Specimen Deflection ......................................................................... 103 Figure A.1. Steel Frame 1 .................................................................................................. 114 Figure A.2. Steel Frame 2 .................................................................................................. 115 Figure A.3. Frame Details 1............................................................................................... 116 Figure A.4. Frame Details 2............................................................................................... 117 Figure A.5. Connection Details.......................................................................................... 118 Figure A.6. Fabrication Notes ............................................................................................ 119 Figure B.7. Bottom-of-Deck Surface Mounted Strain Gages .............................................. 120 Figure B.8. Top-of-Deck Surface Mounted Strain Gages ................................................... 121 Figure B.9. Embedded Strain Gages .................................................................................. 122 Figure B.10. Embedded Transverse Bar Gages & Steel Angle Gages................................. 123 Figure B.11. String Potentiometers .................................................................................... 124 viii ACKNOWLEDGEMENTS I would like to thank Dr. Matt Rouse for his guidance and assistance throughout my time at Iowa State University. I would also like to thank Dr. Terry Wipf for his time and contributions to my project and my thesis. Thank you to Doug Wood for his help in the structures lab setting up and running the data acquisition systems for multiple laboratory tests. Thanks to my civil engineering crew at Iowa State for their friendship and fellowship throughout my undergraduate and graduate career. Finally, I would like to thank my entire family, especially my parents and fiancé for their continued support throughout my education. ix ABSTRACT Accelerated bridge construction is one rapid renewal technique being investigated to address the needs of the United States’ aging infrastructure under the Second Strategic Highway Research Program (SHRP 2). SHRP 2 Project R04 aimed to develop standards and codes for accelerated bridge construction through the construction of a demonstration bridge. Several design details were important the rapid renewal aspect of the demonstration bridge, but the Ultra High Performance Concrete (UHPC) transverse full-depth deck joint over the pier was the focus of the laboratory testing due to its significance in the negative moment region tensile zone. Three suites of laboratory tests were conducted to evaluate the UHPC deck joints used in the demonstration bridge. Abrasion testing was completed to assess the abrasion resistance of the cast-in-place deck joints with respect to anticipated grinding operations, a constructability test was carried out to assess the placement procedure and feasibility of the longitudinal and transverse UHPC joint intersection detail, and strength and serviceability testing was completed to quantify the cracking moment and ultimate moment capacity of the transverse module-to-module connection detail over the bridge pier. Through this testing regiment, recommendations were developed for the demonstration bridge regarding construction and performance of the UHPC deck joints.