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UHPC Waffle Slab Project

Develop a durable UHPC waffle slab bridge deck with innovative splice connection detail for lightweight and strong construction in Wapello County, Iowa. Partnership with FHWA, Coreslab, Iowa State University.

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UHPC Waffle Slab Project

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  1. UHPC Waffle Slab Project FHWA HfL Tech Partnerships Grant Project Team Coreslab Structures (Omaha), Inc.  Prime Iowa DOT Iowa State University Wapello County, Iowa Lafarge North America, Inc.

  2. UHPC Waffle Slab Project Concept: Develop a UHPC two-way ribbed bridge deck panel which meets all design requirements, is lighter than a conventional deck, and is more durable Develop a simple splice connection detail which engages the short development lengths provided by UHPC to create a strong, durable joint

  3. Waffle Slab Project • Highways for Life funding • Grant awarded to Coreslab Structures (Omaha) • Two phases • Phase I – Development, casting, and testing of two waffle panels • Phase II – Casting of waffle panels and construction of bridge in Wapello County, Iowa

  4. Waffle Slab Project • Proposed system developed jointly by Coreslab, Iowa State University, Wapello Co, and Iowa DOT • Proposed system builds on prior work by FHWA and others • Panels fabricated by Coreslab, Omaha • 8 in. panels cast up side down • For texture, form liners were used for production panels. • Joints will be field-cast with UHPC

  5. Waffle Slab Test Panel Preliminary Design

  6. Typical Web Detail

  7. Typical Transverse Joint Detail

  8. ISU Testing Summary • Cast integrally with two prestressed beams supplied by Coreslab

  9. Punching Shear Test Ultimate Load 155 kips

  10. Testing Completed and Approved by FHWA Fatigue testing Ultimate strength tests Joint between panels Waffle panel Skid resistance Production Panels Cast Summer 2010

  11. Bridge Design • 33’-2 wide by 60’-0 single span prestressed concrete beam bridge (30’-0 Roadway) • 5 beam cross section spaced 7’-4 • Iowa B-beam (39 in. deep 9 in web) • Individual panels 8’-0 x 16’-2 ¾ tied at the centerline of roadway • Total 14 precast panels for project • Field casting of joints using UHPC

  12. Bridge Deck Cross Section

  13. Panel Placement

  14. Joint Casting

  15. Future Work • UHPC prestressed concrete pile • Project Sac Co 10-18-11 letting replacement UHPC pile, integral abutment • Composite UHPC/HPC panels • Testing at ISU bond between mixes

  16. Acknowledgment • Iowa Department of Transportation • Norm McDonald, Gary Novey, Ahmad Abu-Hawash, Ping Lu, Ken Dunker, Steve Fisher, Thayne Sorenson • County Engineers • Brian Moore, County Engineer, Wapello Co. • Brian Keierleber, County Engineer, Buchanan Co. • Bridge Engineering Center (ISU) • Dr. Wipf, Dr. Sritharan, Dr. Sriram, Doug Wood, Dr. Phares, Dr. Fanous, Dr. Rouse, Brian Degen and Isaac Couture

  17. Acknowledgment • FHWA • Joey Hartmann, Ben Graybeal, FHWA Turner-Fairbanks Highway Research Center • Julie Zirlin, FHWA Highways for Life • Coreslab Structures of Omaha, Nebraska • Todd Culp, John Heimann • Lafarge North America - Vic Perry, Kyle Nachuk • MIT • Dr. Ulm • Prestressed Services, Lexington, KT • Chris Hill

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