The full-width, full-depth precast panel system is very convenient for rehabilitation of deteriorated decks as well as for new bridge construction. The horizontal shear strength at the interface between the two interconnected elements is of primary importance in order to provide composite action. The strength of the bond between the two precast members should be high enough to prevent any progressive slip from taking place. Flexural strength, shear strength and deflection characteristics all depend on the satisfactory performance of the interface to provide composite action. However, the case when both of the interconnected elements are precast members bonded by means of grout, is not currently addressed by ACI or AASHTO. This is the main impetus for this project. A total of 36 push-off tests were performed to develop a method for quantifying horizontal shear strength and to recommend the best practice for the system. Test parameters included different haunch heights, different grout types, different amount and different type of shear connectors. Two equations, for uncracked and cracked concrete interfaces, are proposed to be used in horizontal shear design when the precast panels are used. Predictive equations are compared with available methods for the horizontal shear strength of the precast panel system. Conclusions and recommendations for the optimum system are made. / Master of Science

The Texas Department of Transportation (TxDOT) uses precast, prestressed concrete panels (PCPs) as stay-in-place formwork for most bridges built in Texas. The PCPs are placed on the top flanges of adjacent girders and topped with a 4-in. cast-in-place (CIP) slab. This thesis is directed towards identifying and quantifying the serviceability implications of reducing the deck reinforcement across the interior spans of CIP-PCP decks. The goal of this research is to understand how the PCPs influence cracking and crack control in the CIP slab and to make recommendations to optimize the top mat reinforcement accordingly. Several tests were conducted to evaluate the performance of different top mat reinforcement arrangements for ability to control crack widths across PCP joints. The longitudinal reinforcement was tested using a constant bending moment test, a point load test, and several direct tension tests. Because of difficulty with the CIP-PCP interface during the longitudinal tests, direct tension tests of the CIP slab only were used to compare the transverse reinforcement alternatives. Prior to testing, various top mat design alternatives were evaluated through pre-test calculations for crack widths. Standard reinforcing bars and welded wire reinforcement were considered for the design alternatives. During this study, it was found that the tensile strength of the CIP slab is critical to controlling transverse crack widths. The CIP-PCP interface is difficult to simulate in the laboratory because of inherent eccentricities that result from the test specimen geometry and loading conditions. Furthermore, the constraint and boundary conditions of CIP-PCP bridge decks are difficult to simulate in the laboratory. Based on the results of this testing program, it seems imprudent to reduce the longitudinal reinforcement across the interior spans of CIP-PCP decks. The transverse reinforcement, however, may be reduced using welded wire reinforcement across the interior spans of CIP-PCP decks without compromising longitudinal crack width control. A reduced standard reinforcing bar option may also be considered, but a slight increase in longitudinal crack widths should be expected. / text

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Full-depth precast deck panels are a promising alternative to the conventional cast-in-place concrete deck. They afford reduced construction time and fewer burdens on the motoring public. In order to provide designers guidance on the design of full-depth precast slab systems with their full composite strength, the horizontal shear resistance provided at the slab-to-beam interface must be quantified through further investigation. Currently, all design equations, both in the AASHTO Specifications and the ACI code, are based upon research for cast-in-place slabs. The introduction of a grouted interface between the slab and beam can result in different shear resistances than those predicted by current equations. A total of 29 push off tests were performed to quantify peak and post-peak shear stresses at the failure interface. The different series of tests investigated the surface treatment of the bottom of the slab, the type and amount of shear connector and a viable alternative pocket detail. Based on the research performed changes to the principles of the shear friction theory as presented in the AASHTO LRFD specifications are proposed. The proposal is to break the current equation into two equation that separate coulomb friction and cohesion. Along with these changes, values for the coefficient of friction and cohesion for the precast deck panel system are proposed. / Master of Science

The use of full-depth precast concrete bridge deck panels is becoming more and more attractive to transportation authorities throughout the country. In comparison to conventional cast-in-place decks, precast decks are of higher quality, allow for the bridge to be opened to traffic in less time and are easier to maintain, rehabilitate, and replace. This ultimately results in lower costs for transportation authorities and less disruption for the motoring public. Unfortunately, the use of precast deck panel systems is hindered by the lack of design standardization and information regarding the performance of such systems. This research focuses on a key element of the system, the mortar or grout, which is used to connect the precast panels to the bridge girders by filling the space in the horizontal shear pockets and the haunches. Several essential mortar characteristics were identified and investigated in order to create a specification that indicates required performance criteria for mortars. This specification can be used to determine whether particular mortars or grouts are suitable for use in a full-depth precast concrete bridge deck panel system. / Master of Science

Throughout the United States accelerated bridge construction is becoming increasingly popular to meet growing transportation demands while keeping construction time and costs to a minimum. This research focuses on eliminating the need to form full-depth concrete bridge deck overhangs, accelerating the construction of concrete bridge decks, by using full-depth precast prestressed concrete deck panels. Full-depth precast overhang panels in combination with cast-in-place (CIP) reinforced concrete are experimentally and analytically investigated to assess the structural performance. Experimental loaddeformation behavior for factored AASHTO LRFD design load limits is examined followed by the collapse capacity of the panel-to-panel seam that exists in the system. Adequate strength and stiffness of the proposed full-depth panels deem the design safe for implementation for the Rock Creek Bridge in Fort Worth, Texas. New failure theories are derived for interior and exterior bridge deck spans as present code-based predictions provide poor estimates of the ultimate capacity. A compound shear-flexure failure occurs at interior bays between the CIP topping and stay-in-place (SIP) panel. Overhang failure loads are characterized as a mixed failure of flexure on the loaded panel and shear at the panel-to-panel seam. Based on these results design recommendations are presented to optimize the reinforcing steel layout used in concrete bridge decks.

USF completed a research study in 2005, which prioritized the replacement of 85 deteriorating composite precast deck panel bridges. This thesis re-evaluates the original recommendations in the wake of failures of two of these bridges in 2007. Since funding will not allow all identified bridges to be replaced, it was necessary to determine the most effective repair methods. To assess USF’s recommendations, a forensic study was undertaken in which the most current inspection and work program documents on the two failed bridges were reviewed and FDOT personnel interviewed. The best repair procedures were determined by reviewing repair plans, specifications, reports and site visits. The study found the two bridges that failed had been correctly prioritized by USF (No. 1 of 18 and No. 8 of 15). A new, accelerated repair method encompassing complete bay replacement was developed in a pilot project funded by the Florida Department of Transportation.

This thesis investigates the behaviour of UHPC as a fill material for precast deck panels subjected to negative bending. Two full-scale test specimens were constructed. The transverse joints between the panels, the shear pockets, and the deck haunches were all filled with UHPC. A total of four tests were performed including two static tests to failure and two fatigue tests, one of which was performed to failure. Testing consisted of a loading apparatus acting upwards on the deck soffit in an attempt to impose tensile stresses across the transverse joints, representing the conditions that a transverse joint in the negative moment region of a continuous bridge deck would experience. It was concluded that the transverse UHPC joint performed satisfactorily by transferring bending stresses and shear stresses across the joint from one panel to the adjacent panel. Overall, the test specimens displayed performance levels expected from conventional cast-in-place concrete deck alternatives. / February 2016

Full-depth precast concrete panels offer an efficient alternative to traditional cast-in-place concrete for replacement or new construction of bridge decks. Research has shown that longitudinal post-tensioning helps keep the precast bridge deck in compression and avoid problems such as leaking, cracking, spalling, and subsequent rusting on the beams at the transverse panel joints. Current design recommendations suggest levels of initial compression for precast concrete decks in a very limited number of bridge configurations. The time-dependent effects of creep and shrinkage in concrete and relaxation of prestressing steel complicate bridge behavior, making the existing recommendations for post-tensioning in precast deck panels invalid for all bridges with differing girder types, sizes, spacings, and span lengths. Therefore, the development of guidelines for levels of post-tensioning applicable to a variety of bridge types is necessary so designers may easily implement precast concrete panels in bridge deck construction or rehabilitation. To fulfill the needs described, the primary objective of this research was to determine the initial level of post-tensioning required in various precast concrete bridge deck panel systems in order to maintain compression in the transverse panel joints until the end of each bridge's service life. These recommendations were determined by the results of parametric studies which investigated the behavior of bridges with precast concrete decks supported by both steel and prestressed concrete girders in single spans as well as two and three continuous spans. The three primary variables in each parametric study included girder type, girder spacing, and span length. The age-adjusted effective modulus method was used to account for the ongoing effects of creep and shrinkage in concrete. Results from the Mathcad models used in the parametric studies were confirmed through comparison with results obtained from finite element models generated in DIANA. Initial levels of post-tensioning for various bridge systems are proposed based on the trends observed in the parametric studies. The precast decks of the simple span bridges with steel girders and the one, two, and three span bridges with prestressed concrete girders needed only 200 psi of initial post-tensioning to remain in compression under permanent and time-dependent loads throughout each bridge's service life. The precast decks of the two and three span continuous bridges with steel girders, however, needed a significantly higher level of initial compression due to the negative moments created by live loads. / Master of Science

Precast, prestressed concrete panels (PCPs) have been widely used in Texas as stay-in-place formwork in bridge deck construction. Although PCPs are widely popular and extensively used, Texas is experiencing problems with collinear cracks (cracks along the strands) in panels. One reason for the formation of collinear cracks is thought to be the required level of initial prestress. Currently, PCPs are designed assuming a 45-ksi, lump-sum prestress loss. If the prestress losses are demonstrated to be lower than this value, this could justify the use of a lower initial prestress, probably resulting in fewer collinear cracks. For this purpose, 20 precast, prestressed panels were cast at two different plants. Half of those 20 panels were fabricated with the current TxDOT-required prestress of 16.1 kips per strand, and the other half were fabricated with a lower prestress of 14.4 kips per strand based on initially observed prestress losses of 25 ksi or less. Thirteen of those panels were instrumented with strain gages and monitored over their life time. Observed losses stabilized after five months, and are found to be about 24.4 ksi. Even with the reduced initial prestress, the remaining prestress in all panels exceeds the value now assumed by TxDOT for design. / text