Design and Construction of Deck Bulb Tee Girder Bridges with UHPC Connections (2022)

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2022 N A T I O N A L C O O P E R A T I V E H I G H W A Y R E S E A R C H P R O G R A M NCHRP RESEARCH REPORT 999 Design and Construction of Deck Bulb Tee Girder Bridges with UHPC Connections Eric Steinberg Kenneth Walsh Waleed Hamid Alexander Chlosta Caleb Slyh Ohio University Athens, OH Richard Miller Bahram Shahrooz Abdullah Haroon University of Cincinnati Cincinnati, OH Reid Castrodale Castrodale Engineering Consultants, PC Concord, NC Chuck Prussack Oldcastle Precast Spokane, WA Subscriber Categories Bridges and Other Structures • Construction • Design Research sponsored by the American Association of State Highway and Transportation Ofcials in cooperation with the Federal Highway Administration

NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM Systematic, well-designed, and implementable research is the most effective way to solve many problems facing state departments of transportation (DOTs) administrators and engineers. Often, highway problems are of local or regional interest and can best be studied by state DOTs individually or in cooperation with their state universities and others. However, the accelerating growth of highway transporta- tion results in increasingly complex problems of wide interest to high- way authorities. These problems are best studied through a coordinated program of cooperative research. Recognizing this need, the leadership of the American Association of State Highway and Transportation Officials (AASHTO) in 1962 ini- tiated an objective national highway research program using modern scientific techniques—the National Cooperative Highway Research Program (NCHRP). 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Published research reports of the NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM are available from Transportation Research Board Business Office 500 Fifth Street, NW Washington, DC 20001 and can be ordered through the Internet by going to https://www.mytrb.org/MyTRB/Store/default.aspx Printed in the United States of America NCHRP RESEARCH REPORT 999 Project 18-18 ISSN 2572-3766 (Print) ISSN 2572-3774 (Online) ISBN 978-0-309-68703-4 Library of Congress Control Number 2022938457 © 2022 by the National Academy of Sciences. National Academies of Sciences, Engineering, and Medicine and the graphical logo are trade- marks of the National Academy of Sciences. All rights reserved. COPYRIGHT INFORMATION Authors herein are responsible for the authenticity of their materials and for obtaining written permissions from publishers or persons who own the copyright to any previously published or copyrighted material used herein. Cooperative Research Programs (CRP) grants permission to reproduce material in this publication for classroom and not-for-profit purposes. Permission is given with the understanding that none of the material will be used to imply TRB, AASHTO, FAA, FHWA, FTA, GHSA, NHTSA, or TDC endorsement of a particular product, method, or practice. It is expected that those reproducing the material in this document for educational and not-for-profit uses will give appropriate acknowledgment of the source of any reprinted or reproduced material. For other uses of the material, request permission from CRP. NOTICE The research report was reviewed by the technical panel and accepted for publication according to procedures established and overseen by the Transportation Research Board and approved by the National Academies of Sciences, Engineering, and Medicine. The opinions and conclusions expressed or implied in this report are those of the researchers who performed the research and are not necessarily those of the Transportation Research Board; the National Academies of Sciences, Engineering, and Medicine; the FHWA; or the program sponsors. The Transportation Research Board does not develop, issue, or publish standards or speci- fications. The Transportation Research Board manages applied research projects which provide the scientific foundation that may be used by Transportation Research Board sponsors, industry associations, or other organizations as the basis for revised practices, procedures, or specifications. The Transportation Research Board; the National Academies of Sciences, Engineering, and Medicine; and the sponsors of the National Cooperative Highway Research Program do not endorse products or manufacturers. 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e National Academy of Sciences was established in 1863 by an Act of Congress, signed by President Lincoln, as a private, non- governmental institution to advise the nation on issues related to science and technology. Members are elected by their peers for outstanding contributions to research. Dr. Marcia McNutt is president. e National Academy of Engineering was established in 1964 under the charter of the National Academy of Sciences to bring the practices of engineering to advising the nation. Members are elected by their peers for extraordinary contributions to engineering. Dr. John L. Anderson is president. e National Academy of Medicine (formerly the Institute of Medicine) was established in 1970 under the charter of the National Academy of Sciences to advise the nation on medical and health issues. Members are elected by their peers for distinguished contributions to medicine and health. Dr. Victor J. Dzau is president. e three Academies work together as the National Academies of Sciences, Engineering, and Medicine to provide independent, objective analysis and advice to the nation and conduct other activities to solve complex problems and inform public policy decisions. e National Academies also encourage education and research, recognize outstanding contributions to knowledge, and increase public understanding in matters of science, engineering, and medicine. Learn more about the National Academies of Sciences, Engineering, and Medicine at www.nationalacademies.org. e Transportation Research Board is one of seven major programs of the National Academies of Sciences, Engineering, and Medicine. e mission of the Transportation Research Board is to provide leadership in transportation improvements and innovation through trusted, timely, impartial, and evidence-based information exchange, research, and advice regarding all modes of transportation. e Board’s varied activities annually engage about 8,000 engineers, scientists, and other transportation researchers and practitioners from the public and private sectors and academia, all of whom contribute their expertise in the public interest. e program is supported by state transportation departments, federal agencies including the component administrations of the U.S. Department of Transportation, and other organizations and individuals interested in the development of transportation. Learn more about the Transportation Research Board at www.TRB.org.

C O O P E R A T I V E R E S E A R C H P R O G R A M S CRP STAFF FOR NCHRP RESEARCH REPORT 999 Christopher J. Hedges, Director, Cooperative Research Programs Lori L. Sundstrom, Deputy Director, Cooperative Research Programs Waseem Dekelbab, Associate Program Manager, National Cooperative Highway Research Program Ahmad Abu-Hawash, Senior Program Officer Sheila A. Moore, Program Associate Natalie Barnes, Director of Publications Heather DiAngelis, Associate Director of Publications Claire Aelion-Moss, Editor NCHRP PROJECT 18-18 PANEL Field of Materials and Construction—Area of Concrete Materials J. P. Binard, Precast Systems Engineering, LLC, Exmore, VA Hussam Z. Fallaha, Virginia Department of Transportation, Richmond, VA Bijan Khaleghi, Washington State Department of Transportation, Tumwater, WA Leonard M. Ruminski, Idaho Transportation Department, Boise, ID Giri Venkiteela, New Jersey Department of Transportation, Trenton, NJ Benjamin A. Graybeal, FHWA Liaison Casey Soneira, AASHTO Liaison Stephen F. Maher, TRB Liaison

NCHRP Research Report 999 presents an evaluation of prestressed concrete deck bulb tee (DBT) girder bridges with ultrahigh-performance concrete (UHPC) connections. The eval- uation was based on extensive analytical and parametric studies along with experimental testing utilizing a three-girder bridge system. In addition to long-term performance, the study evaluated constructability, differential camber, live load distribution, continuity over supports, and thermal loading. The report presents a list of recommended design and construction spec- ification revisions for consideration by AASHTO in the next update of the AASHTO load and resistance factor design (LRFD) specifications. Implementation of the research findings could increase the use of accelerated bridge construction (ABC) techniques, thus improving safety and reducing public inconvenience during construction. The advantage of this bridge superstructure system is the speed of construction, since no separate decking is required. However, the performance of the connection between girders has been a primary concern. Based on the results of this study, the use of UHPC connections will address the performance concern and improve durability. A DBT girder system with durable UHPC connections will provide bridge owners with another superstructure option for ABC. Compared to other ABC superstructure systems, DBT girders can span greater distances, giving bridge owners the ability to minimize disruption to environmentally sensi- tive terrains. Under NCHRP Project 18-18, an Ohio University research team was asked to validate the concept of using DBT girders with UHPC connections and propose updates to the AASHTO LRFD Bridge Design Specifications and the AASHTO LRFD Bridge Construction Specifications to incorporate the use of UHPC connections. NCHRP Research Report 999 documents the entire research effort. F O R E W O R D By Ahmad Abu-Hawash Staff Officer Transportation Research Board

1 Chapter 1 Background 1 1.1 Introduction 1 1.2 Research Objective 2 1.3 Literature Review 30 Chapter 2 Analytical Approach and Results 30 2.1 Introduction 30 2.2 Bridge Models: Stage 1 42 2.3 Joint 3D FEM Models: Stage 2 52 2.4 Bridge 3D FEM Models: Stage 3 54 2.5 Summary of Analytical Results 56 Chapter 3 Experimental Testing 56 3.1 Introduction 56 3.2 Testing of Longitudinal Joint 96 3.3 Continuity Joint Testing 103 3.4 Summary of Experimental Testing 105 Chapter 4 Potential Modifications to AASHTO Specifications 105 4.1 Live Load Distribution Factors 108 4.2 Dynamic Load Allowance 108 4.3 Precast Deck Bridges 110 4.4 Bridge Composed of Simple-Span Precast Girders Made Continuous 111 4.5 References 111 4.6 AASHTO LRFD Bridge Construction Specifications 112 References A-1 Appendix A Cohesive Modeling Parameters B-1 Appendix B Traction-Separation Failure Model C O N T E N T S