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Precast Deck System with UHPC joints

Precast Deck System with UHPC joints. Why Precast decks? Faster construction Reduced cracking Better durability Better quality control. What are the negatives? Increased cost Complexity of design Complexity of construction Joint performance. Types of precast decks.

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Precast Deck System with UHPC joints

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  1. Precast Deck System with UHPC joints

  2. Why Precast decks? • Faster construction • Reduced cracking • Better durability • Better quality control

  3. What are the negatives? • Increased cost • Complexity of design • Complexity of construction • Joint performance

  4. Types of precast decks • Grouted joints and concrete overlay • Grouted joints, membrane and asphalt overlay • Grouted joints, post tensioning and concrete overlay • Grouted joints UHPC joints and concrete overlay • Grouted joints UHPC joints, membrane and asphalt overlay • Grouted joints UHPC joints, diamond ground no overlay

  5. What is UHPC UHPC is a type of concrete with ultra-high compressive strength, high ductility and other advanced mechanical properties. COMPRESSIVE STRENGTHS UP TO 30,000 psi (200 Mpa) FLEXURAL STRENGTHS UP TO 5,800 psi (40 MPa) OUTSTANDING DURABILITY VERY HIGH BOND STRENGTH RESISTANCE TO CORROSION, ABRASION, CARBONATION AND IMPACT

  6. Development Length Tests #4 BARS (BLACK & EPOXY) – 3” EMBEDMENT #5 BARS (BLACK & EPOXY) – 4” EMBEDMENT #6 BARS (BLACK & EPOXY) – 5” EMBEDMENT

  7. Joint Testing by FHWA for Strength Durability and Performance • 8” THICK PANEL - #4 EPOXY COATED HAIRPIN BARS • 8” THICK PANEL - #5 GALV. STRAIGHT BARS (6” LAP) • 8” THICK PANEL - #5 BLACK STRAIGHT BARS (6” LAP) • 8” THICK PANEL - #5 BLACK HEADED BAR (3 ½” LAP) • 6” THICK PANEL - #5 BLACK STRAIGHT BARS (6” LAP) • 6” THICK PANEL - #5 BLACK HEADED BARS (3 ½” LAP)

  8. UHPC Specification for NYSDOT Non-proprietary specification with material qualification and testing: • Shall meet NYDOT material qualification criteria • Compressive strength – As specified in the contract document • Shall meet pull out strength test Test Method No. NY 701-14E

  9. UHPC Specification for NYSDOT (Contd.) 4. Shall meet joint performance as tested by NYSDOT no degradation of joints or leakage through joints under cyclical loading. • Joints shall be stronger than precast deck panels. All test specimens are to be prepared and cured in the same manner as the joint fill in the field.

  10. UHPC Specification for NYSDOT Quality control during field application include: • Manufacturer’s technician shall be present and perform prescribed QC tests • Shall meet compressive strength requirement

  11. Practical Considerations • Pre-wetting of precast surfaces before joint fill • Consolidation settlement of UHPC and the need for overfill and grinding • Need for leak proof formwork • Mixing time issues • Strength gain issues • Specimen preparation for strength tests

  12. First precast deck system: Rte 23 over Otego Creek Installation of Precast Decks

  13. : Accelerated bridges deck replacements completed in 2012 • RTE 31 PUTNAM BROOK SINGLE SPAN 5 DAYS • I-690 WB CROUSE AVENUE SINGLE SPAN 3DAYS • I-690 EB CROUSE AVENUE SINGLE SPAN 3 DAYS • I-690 EB PEAT STREET SINGLE SPAN 3 DAYS • I-690 WB PEAT STREET SINGLE SPAN 3 DAYS • I-481 NB KIRKVILLE ROAD SINGLE SPAN 5 DAYS

  14. Accelerated Bridges deck replacements scheduled for 2013. • I-81 NB EAST CALTHROP AVENUE THREE SPAN 10DAYS • EB EAST CALTHROP AVENUE THREE SPAN 10DAYS • I-81 NB EAST CASTLE ST AVENUE THREE SPAN 10DAYS • I-81 SB EAST CASTLE ST AVENUE THREE SPAN 10DAYS • RTE 92 G OVER RTE 17 TWO SPAN 5 DAYS • RTE 12 SPRING BROOK SINGLE SPAN 3 DAYS • RTE 38 WILSON CREEK SINGLE SPAN 3 DAYS • RTE 10 WBSTER BROOK SINGLE SPAN 5 DAYS

  15. Construction Sequence in Photos of a three day deck replacement

  16. Any Questions?

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