Low-Cycle Fatigue Testing of High-Performance Concrete Bonded Overlay–Bridge Deck Slab Systems

Plain and fibrous latex modified concrete and microsilica concrete overlays with acceptable laboratory strength and durability characteristics were installed on a full-scale prototype bridge deck for field performance evaluation. After 1?year of exposure to drying shrinkage, temperature variations, and freeze–thaw cycles, no cracking or debonding were observed in the overlays. The bond strengths at 28?days and at 1?year were acceptable for all overlay types due to the excellent curing and surface preparation using water-jet blasting. The prototype bridge was then statically tested before and after applying low-cycle fatigue loading simulating AASHTO HS20 truck service load, overload, and ultimate load. Minor bond strength deterioration at the maximum negative moment region and slight bridge stiffness degradation were observed after each load case. Significant enhancement in the bridge stiffness was observed after installation of the overlays. Also, the overlay with synthetic fibers showed better crack bridging action than the overlay with steel fibers.     

Evaluation of Composite Sandwich Bridge Decks with Hybrid FRP-Steel Core

A hybrid concept of composite sandwich panel with hybrid fiber-reinforced polymer (FRP)—steel core was proposed for bridge decks in order to not only improve stiffness and buckling response but also be cost efficient compared to all glass fiber-reinforced polymer (GFRP) decks. The composite sandwich bridge deck system is comprised of wrapped hybrid core of GFRP grid and multiple steel box cells with upper and lower GFRP facings. Its structural performance under static loading was evaluated and compared with the ANSYS finite element predictions. It was found that the presented composite sandwich panel with hybrid FRP-steel core was very efficient for use in bridges. The thickness of the hybrid deck may be decreased by 19% when compared with the all GFRP deck. The failure mode of the proposed hybrid deck was more favorable because of the yielding of the steel tube when compared with that of all GFRP decks.     

Effects of Fabrication Procedures on Fatigue Resistance of Welded Joints in Steel Orthotropic Decks

A common practice for the fabrication of steel orthotropic bridge decks in the United States is to use 80% partial joint penetration (PJP) groove welds between the closed ribs and deck plate. However, it is difficult to eliminate weld melt-through with the thin rib plates. Heat straightening after welding, sometimes combined with precambering, is used to meet the deck plate flatness requirement. To study the effects of both weld melt-through and distortion control measures on the fatigue resistance of the rib-to-deck plate welded joint, six full-scale two-span orthotropic deck specimens were subjected to laboratory testing. Specimens, 10 m long and 3 m wide with four closed ribs, were fabricated with and without weld melt-through and were heat straightened; three specimens were also precambered. To simulate the effect of repetitive truck traffic, each specimen was tested up to 8 million cycles. Test results showed that six cracks initiated from the weld toe outside the rib. Only one crack developed at the weld root inside the rib; this crack initiated from a location transitioning from the 80% PJP to 100% penetration weld. None of the cracks propagated through the deck plate thickness. Precambering was beneficial in fatigue resistance as two effectively precambered specimens did not experience cracking in the PJP welds.     

Evaluation of Effective Width and Distribution Factors for GFRP Bridge Decks Supported on Steel Girders

Glass fiber-reinforced polymer (GFRP) bridge deck systems offer an attractive alternative to concrete decks, particularly for bridge rehabilitation projects. Current design practice treats GFRP deck systems in a manner similar to concrete decks, but the results of this study indicate that this approach may lead to nonconservative bridge girder designs. Results from a number of in situ load tests of three steel girder bridges having the same GFRP deck system are used to determine the degree of composite action that may be developed and the transverse distribution of wheel loads that may be assumed for such structures. Results from this work indicate that appropriately conservative design values may be found by assuming no composite action between a GFRP deck and steel girder and using the lever rule to determine transverse load distribution. Additionally, when used to replace an existing concrete deck, the lighter GFRP deck will likely result in lower total stresses in the supporting girders, although, due to the decreased effective width and increased distribution factors, the live-load-induced stress range is likely to be increased. Thus, existing fatigue-prone details may become a concern and require additional attention in design.     

Designing and Testing of Concrete Bridge Decks Reinforced with Glass FRP Bars

In addition to their high strength and light weight, fiber-reinforced polymer (FRP) composite reinforcing bars offer corrosion resistance, making them a promising alternative to traditional steel reinforcing bars in concrete bridge decks. FRP reinforcement has been used in several bridge decks recently constructed in North America. The Morristown Bridge, which is located in Vermont, United States, is a single span steel girder bridge with integral abutments spanning 43.90 m. The deck is a 230 mm thick concrete continuous slab over girders spaced at 2.36 m. The entire concrete deck slab was reinforced with glass FRP (GFRP) bars in two identical layers at the top and the bottom. The bridge is well instrumented at critical locations for internal temperature and strain data collection with fiber-optic sensors. The bridge was tested for service performance using standard truck loads. The construction procedure and field test results under actual service conditions revealed that GFRP rebar provides very good and promising performance.     

Finite-Element Modeling and Development of Equivalent Properties for FRP Bridge Panels

Fiber-reinforced polymer (FRP) composite materials are increasingly making their way into civil engineering applications. To reduce the self-weight and also achieve the necessary stiffness, sandwich panels are commonly used for FRP bridge decks. However, due to the geometric complexity of the FRP sandwich deck, convenient analysis and design methods for FRP bridge deck have not been developed. The present study aims at developing equivalent properties for a complicated sandwich panel configuration using finite-element modeling techniques. With equivalent properties, the hollowed sandwich panel can be transformed into an equivalent solid orthotropic plate, based on which deflection limits can be evaluated and designed. A procedure for the in-plane axial properties of the sandwich core has first been developed, followed by developing the out-of-plane panel properties for bending behavior of the panel. An application is made in the investigation of the stiffness contribution of wearing surface to the total stiffness of bridges with FRP panels. The wearing surface contribution is not usually accounted for in a typical design of bridges with traditional deck systems.     

Endurance of Deck-to-Deck Connections in Transverse Hardwood Glulam Decks

Dowel and stiffener beam deck-to-deck connections transfer shear and moment between hardwood glued-laminated (glulam) transverse deck panels in longitudinal timber bridges. The connections resist relative deflections between the deck panels and aid in the prevention of reflexive cracking of the bituminous wearing surface at panel joints. Cyclic loading can reduce the stiffness of some types of deck-to-deck connections resulting in shortened service life. The performance of dowel and stiffener beam deck-to-deck connections for hardwood glulam transverse panel bridge decks was evaluated during cyclic laoding. Five tests were conducted with steel dowel connected deck panels, and five tests were conducted with glulam stiffener beam connected deck panels. Each connection was subjected to 1,000,000 load cycles. Degradation of connector stiffness with increasing number of load cycles was determined. Stiffener beam connections had better cyclic load response than the steel dowel connections. Steel dowel connections experienced approximately 20% degradation of stiffness after 1,000,000 load cycles. Most stiffener beam connections experienced little to no stiffness degradation after 1,000,000 load cycles; the smaller stiffener beam experienced 14% degradation after 1,000,000 load cycles. All connections remained within the limits of deflection criteria established in the 1994 AASHTO LRFD Bridge Design Specifications.     

Experimental Study on Prefabricated Concrete Bridge Girder-to-Girder Intermittent Bolted Connections System

This paper reports on a new bridge deck slab flange-to-flange connection system for precast deck bulb tee (DBT) girders. In prefabricated bridge system made of DBT girders, the concrete deck slab is cast with the prestressed girder in a controlled environment at the fabrication facility and then shipped to the bridge site. This system requires that the individual prefabricated girders be connected through their flanges to make it continuous for live load distribution. The objectives of this study are to develop an intermittent bolted connection for DBT bridge girders and to provide experimental data on the ultimate strength of the connection system. This includes identifying the crack formation and propagation, failure mode, and ultimate load carrying capacity. In this study, three different types of intermittent bolted connection were developed. Four actual-size bridge panels were fabricated and then tested to collapse. The effects of the size and the level of the fixity of the connecting steel plates, as well as the location of the wheel load were examined. The developed joint was considered successful if the experimental wheel load satisfied the requirements specified in North American bridge codes. It was concluded that location of the wheel load at the deck slab joint affected the ultimate load carrying capacity of the connections developed. Failure of the joint was observed to be due to either excessive deformation and yielding of the connecting steel plates or debonding of the embedded studs in concrete.     

Girder Differential Deflection and Distortion-Induced Fatigue in Skewed Steel Bridges

The prevalence of fatigue cracking in steel bridge girders due to out-of-plane web distortion motivates development of procedures to evaluate the effects of distortional fatigue. In a previous study sponsored by the Minnesota Department of Transportation (Mn/DOT) the frequency and magnitude of distortional stresses on a typical skewed, steel bridge with staggered, bent-plate diaphragms were assessed. The results revealed a diaphragm deformation mechanism that causes distortional fatigue in the girder web gap, leading to simple, accurate estimates of fatigue stress if bridge properties and differential vertical deflection between girders are known. In the present study, linear finite element models are used to represent composite steel bridges and identify bridge parameters that influence relative deflection of adjacent girders. Parameters found to have a significant effect on differential deflection include girder spacing, angle of skew, span length, and deck thickness. These results are incorporated in a simple procedure that is intended for use in management schemes for skewed, steel-girder bridges, with staggered, bent-plate diaphragms, susceptible to web gap distortional fatigue.     

Characterization of a Low-Profile Fiber-Reinforced Polymer Deck System for Moveable Bridges

Moveable bridges in Florida typically use open steel grid decks due to weight limitations. However, these decks present rideability, environmental, and maintenance problems, as they are typically less skid resistant than a solid riding surface, create loud noises, and allow debris to fall through the grids. Replacing open steel grid decks with a lightweight fiber-reinforced polymer (FRP) deck can improve rideability and reduce maintenance costs, simultaneously satisfying the strict weight requirement for such bridges. In this investigation, a new low-profile, pultruded FRP deck system successfully passed the preliminary strength and fatigue tests per AASHTO requirements. Two two-span deck specimens were tested, one with the strong direction of the deck placed perpendicular to the supporting girders, whereas the other had a deck placed with 30° skew. This paper also describes a simplified finite-element approach that simulates the load–deformation behavior of the deck system. The results from the finite-element model showed a good correlation with the deflection and strain values measured from the tests.     

Service Load Effective Compression Flange Width in Fiber Reinforced Polymer Deck Systems Acting Compositely with Steel Stringers

This paper reports on the field study of a steel stringer-fiber reinforced polymer (FRP) deck composite bridge in Pennsylvania. The objective of the study is to assess the effective compression flange width in the FRP deck and floor systems when they act compositely with underlying steel girders at service conditions. The research results reported herein support the notion of employing a design approach, for both interior and exterior girders of a composite floor system, that is philosophically consistent with current practice related to steel girders acting compositely with concrete decking. It appears from the results presented herein that FRP decks and floors acting compositely with underlying steel girders exhibit an effective width that is close to the actual girder spacing for interior beams, and approximately one-half this value for exterior beams.     

Behavior of Reinforced Concrete Bridge Decks on Skewed Steel Superstructure under Truck Wheel Loads

This paper focuses on the behavior of skewed concrete bridge decks on steel superstructure subjected to truck wheel loads. It was initiated to meet the need for investigating the role of truck loads in observed skewed deck cracking, which may interest bridge owners and engineers. Finite-element analysis was performed for typical skewed concrete decks, verified using in?situ deck strain measurement during load testing of a bridge skewed at 49.1°. The analysis results show that service truck loads induce low strains/stresses in the decks, unlikely to initiate concrete cracking alone. Nevertheless, repeated truck wheel load application may cause cracks to become wider, longer, and more visible. The local effect of wheel load significantly contributes to the total strain/stress response, and the global effect may be negligible or significant, depending on the location. The current design approach estimates the local effect but ignores the global effect. It therefore does not model the situation satisfactorily. In addition, total strain/stress effects due to truck load increase slightly because of skew angle.     

Construction and Testing of an Innovative Concrete Bridge Deck Totally Reinforced with Glass FRP Bars: Val-Alain Bridge on Highway 20 East

The Val-Alain Bridge, located in the Municipality of Val-Alain on Highway 20 East, crosses over Henri River in Québec, Canada. The bridge is a slab-on-girder type with a skew angle of 20° over a single span of 49.89?m and a total width of 12.57?m. The bridge has four simply supported steel girders spaced at 3,145?mm. The deck slab is a 225-mm-thick concrete slab, with semi-integral abutments, continuous over the steel girders with an overhang of 1,570?mm on each side. The concrete deck slab and the bridge barriers were reinforced with glass fiber reinforced polymer (GFRP) reinforcing bars utilizing high-performance concrete. The Val-Alain Bridge is the Canada’s first concrete bridge deck totally reinforced with GFRP reinforcing bars. Using such nonmetallic reinforcement in combination with high-performance concrete leads to an expected service life of more than 75?years. The bridge is well instrumented with electrical resistance strain gauges and fiber-optic sensors at critical locations to record internal strain data. Also, the bridge was tested for service performance using calibrated truckloads. Design concepts, construction details, and results of the first series of live load field tests are presented.     

Performance of Overlays Placed Over Sealed Decks under Static and Fatigue Loading

In order to enhance the effectiveness of portland cement overlays placed over existing bridge decks, the deck may be sealed with an acceptable sealer before placing the overlay. The main purpose for such a treatment of the deck is to seal the existing cracks, and prevent penetration of chlorides into the deck if the overlay cracks. The presence of a sealer at the deck-overlay interface is expected to reduce the available bond strength. The reported research was carried out to investigate the performance of overlays placed over sealed bridge decks, examine the level of bond strength, and develop simple yet effective means to restore the bond strength as much as possible. Test results indicate that the sealer reduces the available bond strength by as much as 50%. Up to 85% of the bond strength can be restored if sand is broadcast over the sealer while it is curing or if the dried sealed surface is lightly sanded. These observations were validated through fatigue loading and loading to failure of a one-third-scale subassemblage of a steel stringer bridge.     

Dynamic Analysis of Steel Curved Box Girder Bridges

The impact of seven three-span continuous single box girder bridges, with overall span lengths ranging from 76.2 to 213.36 m (250–700 ft), due to vehicles moving across rough bridge decks is analyzed. The box girder is divided into a number of thin-walled beam elements. Both warping torsion and distortion are considered in the study. The analytical vehicle is the HS20-44 truck included in the American Association of State Highway and Transportation Officials specifications and simulated as a nonlinear vehicle model with 11 degrees of freedom. Truck parameters include the body, suspensions, and tires. The bridge deck surface is assumed to be good and was simulated using a stochastic process (power spectral density function). The analytical results show that the impact factors of torque and distortional torque for the curved single box girder bridges could be very high, while those of the other responses are generally less than that of corresponding straight box girder bridges. The proposed impact equations can be used in the design of continuous curved single box girder bridges.     

Fatigue and Strength Evaluation of Two Glass Fiber-Reinforced Polymer Bridge Decks

The use of glass fiber-reinforced polymer (GFRP) bridge decks is appealing for applications where minimizing dead load is critical. This paper describes fatigue and strength testing of two types of GFRP decks being considered for use in the retrofit of an aging steel arch bridge in Snohomish County, Washington, where a roadway expansion is necessary and it is desirable to minimize the improvements to the arch superstructure. Each test used a setup designed to be as close as practicable to what will be the in situ conditions for the deck, which included a 2% cross slope for drainage. The fatigue testing consisted of a single 116 kN (26 kip) load applied for 2 million cycles, which corresponds to an AASHTO HS-25 truck with a 30% impact factor, and the strength testing consisted of multiple runs of a monotonically applied minimum load of 347 kN (78 kips). Results from the fatigue testing indicated a degradation of the stiffness of both deck types; however, the degradation was limited to less than 12% over the duration of loading. Further, the results showed both deck types accumulated permanent deck displacement during fatigue loading and one deck type used a detail with poor fatigue performance. That detail detrimentally impacted the overall deck performance and caused large permanent deck deformations. It was also found that degradation of composite behavior between the deck and girders occurs during fatigue loading and should be included in design.     

Performance of Coated Reinforcing Bars in Cracked Bridge Decks

The presence of cracks in bridge decks that are reinforced with epoxy-coated reinforcing (ECR) bars has raised some concerns among bridge and maintenance engineers in the state of Iowa. To study the effects of deck cracking on the performance of ECR bars, several concrete cores that contained reinforcing bars were collected from 80 bridges that are located in different counties throughout the state of Iowa. These samples were collected from cracked and uncracked areas of the bridge decks. Concrete powder samples were collected from these cores and were analyzed in the laboratory to determine the diffusion of the chloride in the bridge decks. This study revealed that no sign of corrosion was detected for the ECR rebars that were taken at the uncracked bridge deck locations. In addition, no delamination or spalling was observed for the bridge decks where bars in the core samples, which were taken at the cracked bridge deck locations, exhibited signs of corrosion. The collected ECR rebars samples were rated according to the degree of the corrosion that was observed on each bar. These ratings were used to develop condition/age relationships that were utilized to estimate the functional service life of bridge decks that are reinforced with ECR bars.     

Field Testing and Analysis of CRC Deck Girder Bridges

This paper presents findings of field tests and analysis of two conventionally reinforced concrete (CRC) deck girder bridges designed in the 1950s. The bridges are in-service and exhibit diagonal cracks. Stirrup strains in the bridge girders at high shear regions were used to estimate distribution factors for shear. Impact factors based on the field tests are reported. Comparison of field measured responses with AASHTO factors was performed. Three-dimensional elastic finite-element analysis was employed to model the tested bridges and determine distribution factors specifically for shear. Eight-node shell elements were used to model the decks, diaphragms, bent caps, and girders. Beam elements were used to model columns under the bent caps. The analytically predicted distribution factors were compared with the field test data. Finally, the bridge finite-element models were employed to compare load distribution factors for shear computed using procedures in the AASHTO LRFD and Standard Specifications.     

Erection of Cable-Stayed Bridges Having Composite Decks with Precast Concrete Slabs

For the construction of composite steel-concrete decks of cable-stayed bridges, methods of erection and analysis have to be applied that, upon completion of the deck, accurately yield the prescribed dead load configuration of the deck regarding geometry and forces. During deck erection, no unwanted bending moments should be locked into the composite sections when the concrete slab is connected to the steel substructure. Such locked-in moments would bend the deck, cause concrete creep that is difficult to predict, and introduce the risk of deviations from the desired deck alignment and the corresponding distribution of forces. This paper presents a simple and practical method of erection and erection analysis for composite decks with precast concrete slabs. A two-step tensioning procedure of the stay cables is proposed that minimizes the effects of unwanted locked-in moments, making it easy to predict the geometry of the erection stages and to yield the desired dead load configuration of the deck. The method was successfully applied for the erection of the Ting Kau bridge in Hong Kong, a cable-stayed bridge of 1,200 m in length having a composite deck with a precast deck slab.