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1
Rehabilitation of Longitudinal Joints
in Double-Tee Girder Bridges
Rehabilitation of Longitudinal Joints in Double-Tee Girder Bridges
Presenter
Mostafa Tazarv, PhD, PE,
Assistant Prof.
Research Team
Lucas Bohn, RA
Mostafa Tazarv, PhD, PE
Nadim Wehbe, PhD, PE
South Dakota State University
2Rehabilitation of Longitudinal Joints in Double-Tee Girder Bridges
Funding Agencies and Collaborators
• South Dakota Department of Transportation.
• Mountain Plains Consortium (MPC) -
University Transportation Center (UTC).
3
Current longitudinal joint detailing
Background
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
1'-11"
2"2"
2"
2"2"
#4 Bars D8 Wire Mesh
@ 4" OC T&B
12" Dia. 7-wire Strands
1"
COVER6"
5"
5"
D4 Wire @ 8" OC
4
➢ The current longitudinal joint detail for connecting adjacent
double-tee bridge girders exhibits poor serviceability and
strength performance
Background
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
5
➢ Fiber-reinforced cementitious concrete
➢ Made with very fine aggregates in size of dust
➢ Usually with 2% volumetric steel fibers
➢ Better durability than concrete
➢ More than 22,000 psi (150 MPa) compressive strength
➢ Significantly higher tensile strength and strain capacity
Courtesy: Dr. Graybeal of FHWA
Ultra-High Performance Concrete
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
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✓ 20 Rehabilitation Joint Detailing Alternatives.
✓ Testing of 13 Large-Scale Beams.
✓Detailed Finite Element Analysis.
✓ Testing of 40-ft Conventional Double-Tee Bridge.
✓Rehabilitation of the Conventional DT Bridge.
✓ Testing of Rehabilitated Bridge.
✓Recommendations.
Summary of Activities
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
7
Test Specimen and Setup
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
Load
Cell
N
W14x257 Column
S
HSS 12x6x1/2 Brace
Test Specimen
Two Double-Tee Girders40-ft Long, approx. 8-ft wide
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Testing Procedure
1. Fatigue testing of conventional DT – 250k cycles.
2. Monotonic testing of conventional DT to crack the joint.
3. Fatigue II testing of rehabilitated DT– 500k cycles.
4. Fatigue I testing of rehabilitated DT– 100k cycles.
5. Ultimate testing of rehabilitated DT to failure.
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
0
10
20
30
40
50
0 1 2 3 4 5
Actu
ato
r L
oa
d,
P (
kip
s)
Time (sec)
Fatigue II Fatigue I
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Instrumentation
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
SG-GA-L-28SG-GA-L-27SG-GA-L-32
ASG-GA-L-31
CSG-GA-L-19CSG-GA-L-17 CSG-GA-L-18
SG-GA-L-24SG-GA-L-23
SG - Strain Gauge
CsG - Concrete Strain Gauge
GA - Girder A
GB - Girder B
L - Longitudinal
➢ 34 Strain Gauges
➢ 14 LVDTs
➢ 4 String POTs
➢ 4 Load Cells
➢ 146-kip Actuator
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Proposed Testing Plan
1'-6"
1'-6"
40'
Not to Scale
LMC
LMC Continuous
Joint
Filler Material Plan
1'-10"
A
5'
UHPC Pocketed
Joint
UHPC
578
"
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
Pocket Detailing: UHPC filled pockets reinforced
with steel bars.
Continuous Detailing: LMC filled joint reinforced
with wire-mesh.
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Rehab after initial 200k Fatigue Testing
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
12
Rehab after initial 200k Fatigue Testing
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
13
Joint Pour w/ UHPC & LMC
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
14
Prior to Testing LMC Cracking
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
Girder A
Girder B
LMC Joint
Bridge U
ndern
eath
15
Fatigue Testing Video
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
16
Fatigue Results
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
K = 0.0029x + 103.1
95
100
105
110
115
0 100 200 300 400 500
Sti
ffn
ess
, K
(K
ip/i
n.)
Number of Cycles, N (x 1000)
Rehabilitated Specimen
Phase III, P = 21 kips
K = -0.0154x + 103.1
95
100
105
110
115
0 25 50 75 100
Sti
ffn
ess
, K
(K
ip/i
n.)
Number of Cycles, N (x 1000)
Phase IV, P = 42 kips
Rehabilitated Specimen
No stiffness degradation
after 0.5 million cycles of
AASHTO Fatigue II and 100k
cycles of AASHTO Fatigue I.
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Ultimate Testing Video
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
18
Cracks and Failure Mode
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
19
Rehabilitated Joints at Girder Failure
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
Minor cracks at the edge of
Pocket and Continuous joints
at girder failure.
20
Ultimate Test Results
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
0
100
200
300
400
500
600
0
20
40
60
80
100
120
140
0 1 2 3 4 5 6 7 8 9 10
Actu
ato
r L
oa
d,
P (
kN
)
Actu
ato
r L
oa
d,
P (
kip
s)
Midspan Deflection, Δ (in.)
Girder A Girder B First Cracking Peak Load Failure
Rehabilitated Specimen
Phase V
Strength I LS
Service I LS
Peak Load
P = 113.9 kips
Girder Cracking
P = 53.8 kips
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Ultimate Test Results
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
0
20
40
60
80
100
120
140
160
0 500 1000 1500 2000 2500
Actu
ato
r L
oa
d,
P (
kip
s)
Strain, με (microstrain)
P3-T-1 P3-T-2 P3-T-3 P3-T-4
P4-T-5 P4-T-6 P4-T-7 P4-T-8
Rehabilitated Specimen
Phase V
A
P3B P4P1 P2
SG-P4-T-6SG-P4-T-5
N
SG-P3-T-3SG-P3-T-4
SG-P4-T-7SG-P4-T-8
S
SG-P3-T-2SG-P3-T-1
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Evaluation
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
0.85
0.9
0.95
1
1.05
1.1
1.15
0 100 200 300 400 500
Norm
ail
ized
Sti
ffn
ess
Number of Cycles, N (x 1000)
Rehabilitated DT Continuous DT Conventional DT
Fatigue II, P = 21 kips
0.75
0.8
0.85
0.9
0.95
1
1.05
1.1
1.15
0 20 40 60 80 100
Norm
ail
ized
Sti
ffn
ess
Number of Cycles, N (x 1000)
Rehabilitated DT Continuous DT Conventional DT
Fatigue I, P = 42 kips
Grouted Key
38"
14" X 1" X 5"
WELD PLATE
UHPC
1'-038
"
3"3" 318
"
#4 Bars @
4" OC T&B
D8 Wire @ 4" OC
5"
1"
COVER
Rehabilitated Detailing New Constr. Continuous Detailing
(Konrad, 2014)
Conventional Detailing
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Evaluation
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
Grouted Key
38"
14" X 1" X 5"
WELD PLATE
UHPC
1'-038
"
3"3" 318
"
#4 Bars @
4" OC T&B
D8 Wire @ 4" OC
5"
1"
COVER
Rehabilitated Detailing New Constr. Continuous Detailing
(Konrad, 2014)
Conventional Detailing
0
100
200
300
400
500
600
0
20
40
60
80
100
120
140
0 1 2 3 4 5 6 7 8 9 10
Actu
ato
r L
oad
, P
(k
N)
Actu
ato
r L
oad
, P
(k
ips)
Midspan Deflection, Δ (in.)
Rehabilitated DT Continuous DT Conventional DT
Strength I LS
Service I LS
Girder A
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Evaluation
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
Cost estimate for: 40-ft long by 30.6-ft wide double-tee
girder bridge having 8 girders and 7 long. Joints.
➢ Pocket joint rehabilitation cost is 28% of that of replacement.
➢Continuous joint rehabilitation cost is 57% of that of replacement.
Table 8-1 Rehabilitation vs. Replacement Cost for 40-ft Double-Tee Bridges
Type Item Cost
Replacement
Girder Material and Fabrication $79, 040
Girder Demolition, Removal, and Construction
$15,000
Crane Mobilization $20,000
Total $114,040
Rehabilitation Pocket Joint $31,685 (or 28% of Replacement)
Continuous Joint $64,856 (or 57% of Replacement)
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Conclusions
➢ Both pocket and continuous rehabilitation methods
are viable solutions to rehabilitate Double-Tee
bridges. Only UHPC should be used for field
applications.
➢ The pocket joint rehabilitation method is the most
cost effective solution.
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
26
Comments/Questions
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
https://sites.google.com/people.unr.edu/mostafa-tazarv/research/rehab-of-dt-bridges
27
Recommendations
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
G5
G6Max. 5 ft
Min. 18 in.
No more than 2 ft
Length
Min. 18 in.
B
UHPC Pocket Joint
Midspan
Min.
5.5 in. A
UHPC
(2) Cont. #4 Bars#4 Bars @
4" OC Long. & Trans.
638
"
1"Min.
3-in.
UHPC Pocket
Min.
3-in.
D8 Wire @ 4" OC
5"318
"
1"
COVER
(2)
Co
nt.
#4
Ba
rs
318
"
Min.
5.5-in.
1"5"
Min. 2.5-in.
UHPC Key
1"
COVER
Section A – Shear key Detailing Section B - Pocket Joint Detailing
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Recommendations
➢Preparation
1. 1-in. Saw-cut around perimeters.
2. Hammer-chip at 45 degree slope, 20 degrees
between pockets:
a. 30-lb chippers for first 2.5 inches.
b. 15-lb chippers around reinforcement.
3. Hydro-demolition shall be permitted as an alternative.
4. Joint surface shall be sand-blasted and pre-wetted
for 24 hours prior to pouring.
5. Formwork shall be water tight and installed from top
of bridge.
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders
29
Recommendations
➢Pocket Detailing
1. UHPC filled square pockets with minimum side
dimensions of 18 inches. Spacing shall not exceed 5
ft c/c.
2. UHPC filled continuous key with a minimum width of
5.5 inches.
3. Pockets reinforced with four Gr. 60 No. 4 bars each
direction. Continuous key reinforced with two Gr. 60
No. 4 longitudinal bars.
4. Minimum lap-splice of 3 inches between pocket
reinforcement and exposed wires.
Rehabilitation of Longitudinal Joints in Double-Tee Bridge Girders