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Construction of the Iowa Highway 60 Precast Prestressed Concrete Pavement Bridge Approach Slab Demonstration Project

July 2007
FHWA-IF-07-034

TABLE OF CONTENTS

• Technical Report Documentation Page
• Executive Summary
• Chapter 1. Introduction
  • The Problem
  • FHWA Demonstration Projects
  • Benefits of Precast Prestressed Concrete Pavement
    • Rapid Construction
    • Improved Durability and Performance
    • Reduced Slab Thickness
    • Extended Construction Season
    • Benefits of PPCP for Bridge Approach Slabs
  • Report Objectives
• Chapter 2. Key Features of Precast Prestressed Concrete Pavement
  • Prestressed Pavement
  • Full-Depth Panels
  • Keyed Panel Joints
  • Base Preparation
  • Grouting
  • Construction Process
• Chapter 3. Iowa Highway 60 Demonstration Project
  • Project Scope
    • Location
    • Demonstration Project Goals
    • Partnering and Project Coordination
  • Project Layout
    • Roadway Geometry
    • Integral Bridge Abutment
    • Precast Panel Layout Options
    • Selected Precast Panel Layout
• Chapter 4. Design
  • Design Considerations
    • Slab Bridging
    • Traffic Loading
    • Bridge and Approach Slab Movement
  • Highway 60 PPCP Design
    • Traffic Loading
    • Initial Flexural Design
    • Final Flexural Design
    • Transverse Prestress
    • Slab Movement Analysis
• Chapter 5. Panel Fabrication
  • Procedure
  • Tolerances
  • Panel Details
    • Keyways
    • Post-Tensioning
    • Anchor Sleeves
    • Expansion Joint
    • Reinforcement
    • Lifting Anchors
  • Mixture Design
  • Finishing and Curing
  • Handling and Storage
  • Trial Assembly
  • Panel Repairs
  • Fabrication Issues and Challenges
    • Post-Tensioning Ducts
    • Pocket Reinforcement
    • Formwork
    • Panel Damage
• Chapter 6. Approach Slab Construction
  • Pre-Construction Meetings
  • Base Preparation
  • Panel Installation
    • Procedure
    • Joint Epoxy
    • Temporary Post-Tensioning
  • Post-Tensioning
  • Grouting
    • Tendon Grouting
    • Underslab Grouting
  • Finishing and Tie-in
    • Longitudinal Joint
    • Pocket Filling
    • Bridge Abutment Anchor
    • Expansion Joint
    • Diamond Grinding
  • Construction Issues and Challenges
    • Panel Placement
    • Post-Tensioning
    • Grouting
  • Instrumentation and Monitoring
    • Bridge Instrumentation
    • Approach Slab Instrumentation
    • Showcasing Workshop
• Chapter 7. Project Evaluation and Recommendations for Future Projects
  • Project Layout
  • Design
    • Design Procedures
    • Design Details
  • Panel Fabrication
  • Construction
    • Base Preparation
    • Panel Installation
      
    • Post-tensioning
    • Grouting
  • Post-Construction Evaluation
  • Project Cost
• Chapter 8. Summary and Recommendations
  • Summary
  • Recommendations for Future Implementation

References

Acknowledgments

Appendix A: Project Plans From the Iowa Department of Transportation

Appendix B: Agenda From IADOT/FHWA Showcasing Workshop

LIST OF FIGURES

• Figure 1. Illustration. Flowchart for the overall PPCP construction process.
• Figure 2. Illustration. Location of the Iowa precast pavement demonstration project.
• Figure 3. Illustration. Situation Plan for the Highway 60 bridge and precast approach slabs.
• Figure 4. Illustration. Schematic layout of full-width panels with variable thickness.
• Figure 5. Illustration. Schematic layout of partial width panels with uniform thickness.
• Figure 6. Illustration. Selected precast panel and post-tensioning tendon layout.
• Figure 7. Illustration. Selected precast panel layout.
• Figure 8. Illustration. Longitudinal joint at the centerline of the approach slab.
• Figure 9. Illustration. Approach slab Abutment Panels.
• Figure 10. Illustration. Approach slab Base Panels.
• Figure 11. Illustration. Approach slab Joint Panels.
• Figure 12. Equation. Load combination used to calculate total load.
• Figure 13. Equation. Equation used to calculate flexural capacity of the approach slab.
• Figure 14. Equation. Equation used to calculate yield strength of the prestressing steel.
• Figure 15. Illustration. Transverse keyway dimensions for the precast panels.
• Figure 16. Illustration. Keyway dimensions for the longitudinal joint.
• Figure 17. Illustration. Post-tensioning tendon gasket detail
• Figure 18. Photo. Placement of concrete for an abutment panel.
• Figure 19. Photo. Application of the light broom texture to the panel surface.
• Figure 20. Photo. Curing tent being lowered to cover a precast panel after casting.
• Figure 21. Photo. Precast panels stored at the fabrication plant.
• Figure 22. Photo. Trial assembly of precast panels at the fabrication plant.
• Figure 23. Photo. Damaged panel corner after trial assembly.
• Figure 24. Photo. Damaged keyway after trial assembly.
• Figure 25. Photo. Battered keyway after removal from forms.
• Figure 26. Photo. Keyway after completion of grinding.
• Figure 27. Photo. Grading and compaction of the aggregate base material.
• Figure 28. Photo. Installation of Panel 1A at the south bridge abutment.
• Figure 29. Photo. Finished approach slab prior to final post-tensioning.
• Figure 30. Photo. Application of joint epoxy during panel installation.
• Figure 31. Photo. Temporary post-tensioning used to pull panels together.
• Figure 32. Photo. Inserting the longitudinal strands into the approach slab.
• Figure 33. Photo. Inserting the transverse strands into the approach slab.
• Figure 34. Photo. Grouting of the post-tensioning tendons.
• Figure 35. Photo. Rod and level were used to check for slab lifting during the underslab grouting operation.
• Figure 36. Photo. Filling of the longitudinal joint (photo by Iowa State University).
• Figure 37. Illustration. Abutment anchor detail for PPCP approach slabs.
• Figure 38. Photo. Dowels for the EF expansion joint prior to its installation in the precast panels.
• Figure 39. Photo. Diamond grinding the south approach slab.
• Figure 40. Photo. Joint between south approach slab and bridge abutment.
• Figure 41. Photo. Minor joint spall that occurred during panel installation.
• Figure 42. Photo. Slight misalignment of transverse post-tensioning ducts at the longitudinal joint.
• Figure 43. Photo. Vibrating wire strain gage mounted in the precast panel during fabrication.
• Figure 44. Photo. Presentations were provided by those involved in the Highway 60 project.
• Figure 45. Photo. Site visit during installation of the precast approach slab.
• Figure 46. Photo. Finished north approach slab prior to opening to traffic

LIST OF TABLES

• Table 1. Factored Design Moments for Highway 60 Approach Slab
• Table 2. Flexural Capacity of Various Prestressing Configurations
• Table 3. Predicted Movements at the Ends of the Approach Slabs
• Table 4. Table of Panel Tolerances From the Project Plans

More Information

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Contact

Sam Tyson
Office of Asset Management, Pavement, and Construction
202-366-1326
E-mail Sam