FHWA-HRT-22-065: Design and Construction of UHPC-Based









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FHWA-HRT-22-065: Design and Construction of UHPC-Based

FHWA-HRT-22-065. MAY 2022 The Federal Highway Administration (FHWA) provides high-quality ... UHPC beam end repair on the Route 6/10 Interchange Bridge.


215277 FHWA-HRT-22-065: Design and Construction of UHPC-Based

Research, Development, and Technology

Turner-Fairbank Highway Research Center

6300 Georgetown Pike

McLean, VA 22101-2296

Design and Construction of

UHPC-Based Bridge Preservation

and Repair Solutions

FOREWORD

In 2021, ultra-high performance concrete (UHPC) for bridge preservation and repair (P&R) was rolled out as one of the innovative technologies in the Federal Highway Administration's Every Day Counts program. UHPC has been a proven solution in bridge construction for connections between prefabricated bridge elements and is an emerging solution for P&R that offers enhanced performance and improved lifecycle cost over traditional methods. UHPC repair solutions are long lasting and resilient, requiring less maintenance and fewer follow-up repairs than conventional methods. The information presented in this document provides background, context, and foundational knowledge to bridge owners and designers interested in using this innovative solution for preserving our Nation's highway bridges.

Cheryl Allen Richter, P.E., Ph.D.

Director, Office of Infrastructure

Research and Development

Notice

This document is disseminated under the sponsorship of the U.S. Department of Transportation (USDOT) in the interest of information exchange. The U.S. Government assumes no liability for the use of the information contained in this document. The U.S. Government does not endorse products or manufacturers.

Trademarks or

manufacturers" names appear in this report only because they are considered essential to the objective of the document.

Quality Assurance Statement

The Federal Highway Administration (FHWA) provides high-quality information to serve Government, industry, and the public in a manner that promotes public understanding. Standards and policies are used to ensure and maximize the quality, objectivity, utility, and integrity of its information. FHWA periodically reviews quality issues and adjusts its programs and processes to ensure continuous quality improvement. Recommended citation: Federal Highway Administration,

Design and Construction of

UHPC-Based Bridge Preservation and Repair Solutions (Washington, DC: 2022) https://doi.org/10.21949/1521867

TECHNICAL REPORT DOCUMENTATION PAGE

1. Report No.

FHWA-HRT-22-065 2. Government Accession No.

3. Recipient's Catalog No.

4. Title and Subtitle

Design and Construction of UHPC-Based Bridge Preservation and Repair Solutions 5. Report Date

May 2022

6. Performing Organization Code:

7. Author(s)

Zachary B. Haber, Andrew Foden, Michael McDonagh, Justin Ocel, Kevin Zmetra, Benjamin Graybeal 8. Performing Organization Report No.

9. Performing Organization Name and Address

Engineering Software Consultants

14123 Robert Paris Court

Chantilly, VA 20151

Rao Research and Consulting, LLC

1775 Tysons Blvd., 5th floor

Tysons, VA 22102

WSP USA

One Penn Plaza

2nd Floor, 250 W 34th Street

New York, NY 10119 10. Work Unit No.

11. Contract or Grant No.

693JJ319D000055

/ 693JJ320F000186

12. Sponsoring Agency Name and Address

Office of

Infrastructure Research and Development

Federal Highway Administration

6300 Georgetown Pike

McLean, VA 22101-2296 13. Type of Report and Period Covered

Final Report;

June 2020

-December 2021

14. Sponsoring Agency Code

HRDI-40

15. Supplementary Notes

16. Abstract

This report is intended for bridge owners, contractors, and their supporting professionals responsible for design,

construction, materials, and maintenance who are interested in including ultra-high performance concrete (UHPC) in their bridge preservation and repair (P&R) toolkit. This document aims to familiarize the reader with the material mechanical and durability properties of UHPC, along with common and emerging UHPC-based P&R

solutions. Most notably, the document contains design and construction recommendations for three promising and

fastest growing UHPC P&R applications: bridge deck overlays for rehabilitation, link slabs, and steel beam end

repair. These recommendations are limited in scope but provide valuable information for all owner agencies

considering the development of materials, construction, and design specifications. Lastly, much of the information

provided herein builds on previous UHPC design and construction documents published by the Federal Highway

Administration in Design and Construction of Field-Cast UHPC Connections (Report No. FHWA-HRT-19-011).

17. Key Words

Preservation, repair, rehabilitation,

maintenance, UHPC 18. Distribution Statement No restrictions. This document is available to the public through the National Technical Information Service, Springfield, VA 22161. http://www.ntis.gov

19. Security Classif. (of this report)

Unclassified 20. Security Classif. (of this page)

Unclassified 21. No. of Pages

86 22. Price

N/A

Form DOT F 1700.7 (8

-72) Reproduction of completed page authorized. ii

SI* (MODERN METRIC) CONVERSION FACTORS

APPROXIMATE CONVERSIONS TO SI UNITS

Symbol When You Know Multiply By To Find Symbol

LENGTH

in inches 25.4 millimeters mm ft feet 0.305 meters m yd yards 0.914 meters m mi miles 1.61 kilometers km AREA in 2 square inches 645.2 square millimeters mm 2 ft 2 square feet 0.093 square meters m 2 yd 2 square yard 0.836 square meters m 2 ac acres 0.405 hectares ha mi 2 square miles 2.59 square kilometers km 2

VOLUME

fl oz fluid ounces 29.57 milliliters mL gal gallons 3.785 liters L ft 3 cubic feet 0.028 cubic meters m 3 yd 3 cubic yards 0.765 cubic meters m 3 NOTE: volumes greater than 1,000 L shall be shown in m 3 MASS oz ounces 28.35 grams g lb pounds 0.454 kilograms kg T short tons (2,000 lb) 0.907 megagrams (or “metric ton") Mg (or “t")

TEMPERATURE (exact degrees)

°F Fahrenheit

5 (F-32)/9

Celsius °C

or (F-32)/1.8

ILLUMINATION

fc foot-candles 10.76 lux lx fl foot-Lamberts 3.426 candela/m 2 cd/m 2

FORCE and PRESSURE or STRESS

lbf poundforce 4.45 newtons N lbf/in 2 poundforce per square inch 6.89 kilopascals kPa

APPROXIMATE CONVERSIONS FROM SI UNITS

Symbol When You Know Multiply By To Find Symbol

LENGTH

mm millimeters 0.039 inches in m meters 3.28 feet ft m meters 1.09 yards yd km kilometers 0.621 miles mi AREA mm 2 square millimeters 0.0016 square inches in 2 m 2

Research, Development, and Technology

Turner-Fairbank Highway Research Center

6300 Georgetown Pike

McLean, VA 22101-2296

Design and Construction of

UHPC-Based Bridge Preservation

and Repair Solutions

FOREWORD

In 2021, ultra-high performance concrete (UHPC) for bridge preservation and repair (P&R) was rolled out as one of the innovative technologies in the Federal Highway Administration's Every Day Counts program. UHPC has been a proven solution in bridge construction for connections between prefabricated bridge elements and is an emerging solution for P&R that offers enhanced performance and improved lifecycle cost over traditional methods. UHPC repair solutions are long lasting and resilient, requiring less maintenance and fewer follow-up repairs than conventional methods. The information presented in this document provides background, context, and foundational knowledge to bridge owners and designers interested in using this innovative solution for preserving our Nation's highway bridges.

Cheryl Allen Richter, P.E., Ph.D.

Director, Office of Infrastructure

Research and Development

Notice

This document is disseminated under the sponsorship of the U.S. Department of Transportation (USDOT) in the interest of information exchange. The U.S. Government assumes no liability for the use of the information contained in this document. The U.S. Government does not endorse products or manufacturers.

Trademarks or

manufacturers" names appear in this report only because they are considered essential to the objective of the document.

Quality Assurance Statement

The Federal Highway Administration (FHWA) provides high-quality information to serve Government, industry, and the public in a manner that promotes public understanding. Standards and policies are used to ensure and maximize the quality, objectivity, utility, and integrity of its information. FHWA periodically reviews quality issues and adjusts its programs and processes to ensure continuous quality improvement. Recommended citation: Federal Highway Administration,

Design and Construction of

UHPC-Based Bridge Preservation and Repair Solutions (Washington, DC: 2022) https://doi.org/10.21949/1521867

TECHNICAL REPORT DOCUMENTATION PAGE

1. Report No.

FHWA-HRT-22-065 2. Government Accession No.

3. Recipient's Catalog No.

4. Title and Subtitle

Design and Construction of UHPC-Based Bridge Preservation and Repair Solutions 5. Report Date

May 2022

6. Performing Organization Code:

7. Author(s)

Zachary B. Haber, Andrew Foden, Michael McDonagh, Justin Ocel, Kevin Zmetra, Benjamin Graybeal 8. Performing Organization Report No.

9. Performing Organization Name and Address

Engineering Software Consultants

14123 Robert Paris Court

Chantilly, VA 20151

Rao Research and Consulting, LLC

1775 Tysons Blvd., 5th floor

Tysons, VA 22102

WSP USA

One Penn Plaza

2nd Floor, 250 W 34th Street

New York, NY 10119 10. Work Unit No.

11. Contract or Grant No.

693JJ319D000055

/ 693JJ320F000186

12. Sponsoring Agency Name and Address

Office of

Infrastructure Research and Development

Federal Highway Administration

6300 Georgetown Pike

McLean, VA 22101-2296 13. Type of Report and Period Covered

Final Report;

June 2020

-December 2021

14. Sponsoring Agency Code

HRDI-40

15. Supplementary Notes

16. Abstract

This report is intended for bridge owners, contractors, and their supporting professionals responsible for design,

construction, materials, and maintenance who are interested in including ultra-high performance concrete (UHPC) in their bridge preservation and repair (P&R) toolkit. This document aims to familiarize the reader with the material mechanical and durability properties of UHPC, along with common and emerging UHPC-based P&R

solutions. Most notably, the document contains design and construction recommendations for three promising and

fastest growing UHPC P&R applications: bridge deck overlays for rehabilitation, link slabs, and steel beam end

repair. These recommendations are limited in scope but provide valuable information for all owner agencies

considering the development of materials, construction, and design specifications. Lastly, much of the information

provided herein builds on previous UHPC design and construction documents published by the Federal Highway

Administration in Design and Construction of Field-Cast UHPC Connections (Report No. FHWA-HRT-19-011).

17. Key Words

Preservation, repair, rehabilitation,

maintenance, UHPC 18. Distribution Statement No restrictions. This document is available to the public through the National Technical Information Service, Springfield, VA 22161. http://www.ntis.gov

19. Security Classif. (of this report)

Unclassified 20. Security Classif. (of this page)

Unclassified 21. No. of Pages

86 22. Price

N/A

Form DOT F 1700.7 (8

-72) Reproduction of completed page authorized. ii

SI* (MODERN METRIC) CONVERSION FACTORS

APPROXIMATE CONVERSIONS TO SI UNITS

Symbol When You Know Multiply By To Find Symbol

LENGTH

in inches 25.4 millimeters mm ft feet 0.305 meters m yd yards 0.914 meters m mi miles 1.61 kilometers km AREA in 2 square inches 645.2 square millimeters mm 2 ft 2 square feet 0.093 square meters m 2 yd 2 square yard 0.836 square meters m 2 ac acres 0.405 hectares ha mi 2 square miles 2.59 square kilometers km 2

VOLUME

fl oz fluid ounces 29.57 milliliters mL gal gallons 3.785 liters L ft 3 cubic feet 0.028 cubic meters m 3 yd 3 cubic yards 0.765 cubic meters m 3 NOTE: volumes greater than 1,000 L shall be shown in m 3 MASS oz ounces 28.35 grams g lb pounds 0.454 kilograms kg T short tons (2,000 lb) 0.907 megagrams (or “metric ton") Mg (or “t")

TEMPERATURE (exact degrees)

°F Fahrenheit

5 (F-32)/9

Celsius °C

or (F-32)/1.8

ILLUMINATION

fc foot-candles 10.76 lux lx fl foot-Lamberts 3.426 candela/m 2 cd/m 2

FORCE and PRESSURE or STRESS

lbf poundforce 4.45 newtons N lbf/in 2 poundforce per square inch 6.89 kilopascals kPa

APPROXIMATE CONVERSIONS FROM SI UNITS

Symbol When You Know Multiply By To Find Symbol

LENGTH

mm millimeters 0.039 inches in m meters 3.28 feet ft m meters 1.09 yards yd km kilometers 0.621 miles mi AREA mm 2 square millimeters 0.0016 square inches in 2 m 2