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Publication Number: FHWA-HRT-05-056
Date: October 2006

Compilation and Evaluation of Results From High-Performance Concrete Bridge Projects, Volume I: Final Report

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Table of Contents

FOREWORD

In 1993, the Federal Highway Administration (FHWA) initiated a national program to implement the use of high-performance concrete (HPC) in bridges. The program included the construction of demonstration bridges throughout the United States. In addition, other States have implemented the use of HPC in various bridge elements. The construction of these bridges has provided a large amount of data on the use of HPC.

The first part of this project involved collecting and compiling information from each joint State-FHWA HPC bridge project and other HPC bridge projects. The compilation is available on a CD-ROM and includes information on the benefits of HPC, costs, structural design, specified concrete properties, concrete mix proportions, measured properties, associated research projects, sources of data, and specifications. Information from 19 bridges in 14 States is included. A summary of the compiled information is provided in this final report.

The second part of this project involved a review of the American Association of State Highway and Transportation Officials (AASHTO) Standard Specifications for Transportation Materials and Methods of Sampling and Testing, the AASHTO Standard Specifications for Highway Bridges, the AASHTO Load and Resistance Factor Design (LRFD) Bridge Design Specifications, and the AASHTO LRFD Bridge Construction Specifications for provisions that directly impact the use of HPC. The detailed review is included in this report.

The third part of the project involved developing proposed revisions to the AASHTO specifications where sufficient research results exist to support the revisions. Proposed revisions to 15 material specifications, 14 test methods, 30 articles of the standard design specifications, 17 articles of the LRFD design specifications, and 16 articles of the LRFD construction specifications are included in this report. These proposed revisions were submitted to the appropriate AASHTO technical committees for consideration for adoption into the relevant specifications.

Also in the third part of this project, a new material specification for combined aggregates and a new test method for slump flow are proposed. In addition, proposed revisions to the FHWA definition of HPC are included.

The fourth part of the project involved developing specific recommendations for needed research where sufficient results do not exist to support needed changes in the specifications. Six research problem statements related to concrete materials and four research problem statements related to structural design are recommended. These research problem statements have been submitted to the appropriate Transportation Research Board technical committees for prioritization and funding recommendations.

Gary L. Henderson
Director, Office of Infrastructure
Research and Development

NOTICE

This document is disseminated under the sponsorship of the U.S. Department of Transportation in the interest of information exchange. The U.S. Government assumes no liability for its contents or use thereof. This report does not constitute a standard, specification, or regulation.

The U.S. Government does not endorse products or manufacturers. Trade and manufacturers' names appear in this report only because they are considered essential to the object of the document.

QUALITY ASSURANCE STATEMENT

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.

Technical Report Documentation Page

1. Report No.

FHWA-HRT-05-056

2. Government Accession No.

3. Recipient's Catalog No.

4. Title and Subtitle

Compilation and Evaluation of Results From High-Performance Concrete Bridge Projects, Volume I: Final Report

5. Report Date

October 2006

6. Performing Organization Code

7. Author(s)

H.G. Russell, R.A. Miller, H.C. Ozyildirim, and M.K. Tadros

8. Performing Organization Report No.

9. Performing Organization's Name and Address

Henry G. Russell, Inc.
720 Coronet Road
Glenview, IL 60025

10. Work Unit No. (TRAIS)

11. Contract or Grant No.

DTFH61-00-C-00009

12. Sponsoring Agency's Name and Address

Federal Highway Administration
6300 Georgetown Pike
McLean, VA 22101-2296

13. Type of Report and Period Covered

Final Report
November 1999–February 2003

14. Sponsoring Agency's Code

15. Supplementary Notes

Contracting Officer's Technical Representative (COTR): Joseph L. Hartmann, HRDI-06

16. Abstract

In 1993, the Federal Highway Administration (FHWA) initiated a national program to implement the use of high-performance concrete (HPC) in bridges. The program included the construction of demonstration bridges throughout the United States. In addition, other States have implemented the use of HPC in various bridge elements. The construction of these bridges has provided a large amount of data on the use of HPC.

The first part of this project involved collecting and compiling information from each joint State-FHWA HPC bridge project and other HPC bridge projects. The compilation is available on a CD-ROM and includes information on the benefits of HPC, costs, structural design, specified concrete properties, concrete mix proportions, measured properties, associated research projects, sources of data, and specifications. Information from 19 bridges in 14 States is included. A summary of the compiled information is provided in this final report.

The second part of this project involved a review of the American Association of State Highway and Transportation Officials (AASHTO) Standard Specifications for Transportation Materials and Methods of Sampling and Testing, the AASHTO Standard Specifications for Highway Bridges, the AASHTO Load and Resistance Factor Design (LRFD) Bridge Design Specifications, and the AASHTO LRFD Bridge Construction Specifications for provisions that directly impact the use of HPC. The detailed review is included in this report.

The third part of the project involved the development of proposed revisions to the AASHTO specifications where sufficient research results exist to support the revisions. Proposed revisions to 15 material specifications, 14 test methods, 30 articles of the standard design specifications, 17 articles of the LRFD design specifications, and 16 articles of the LRFD construction specifications are included in this report. In addition, a new materials specification for combined aggregates and a new test method for slump flow are proposed. Proposed revisions to the FHWA definition of HPC are also included.

The fourth part of the project involved the development of specific recommendations for needed research where sufficient results do not exist to support needed changes in the specifications. Six research problem statements related to concrete materials and four research problems related to structural design are recommended.

The appendixes for this volume appears in volume II:
Compilation and Evaluation of Results from High-Performance Concrete Bridge Projects, Volume II: Appendixes (FHWA-HRT-05-057).

17. Key Words

Bridges, cast-in-place concrete, high-strength concrete, high-performance concrete, precast concrete, prestressed concrete.

18. Distribution Statement

No restrictions. This document is available to the public through the National Technical Information Service, Springfield, VA 22161.

19. Security Classif. (of this report)

Unclassified

20. Security Classif. (of this page)

Unclassified

21. No. of Pages

178

22. Price

n/a

Form DOT F 1700.7 (8-72) Reproduction of completed page authorized

SI (Modern Metric) Conversion Factors

TABLE OF CONTENTS

Appendixes for this document appear in FHWA-HRT-05-057, Compilation and Evaluation of Results from High-Performance Concrete Bridges Projects Volume II: Appendixes

LIST OF TABLES

  1. HPC bridges included in the compilation
  2. Major features of the prestressed concrete girders
  3. Major features of the cast-in-place concrete decks
  4. Structural design considerations
  5. Specified concrete properties for prestressed concrete girders
  6. Specified concrete properties for cast-in-place concrete decks
  7. Concrete mix proportions for prestressed concrete girders
  8. Concrete mix proportions for cast-in-place concrete decks
  9. Measured structural concrete properties for prestressed concrete girders
  10. Measured structural concrete properties for cast-in-place concrete decks
  11. Measured durability properties for prestressed concrete girders and cast-in-place concrete decks
  12. Grades of performance characteristics for high-performance structural concrete
  13. Details of test methods for determining HPC performance grades
  14. Recommendations for the application of HPC grades
  15. Specified and measured durability characteristics for precast, prestressed concrete girders
  16. Specified and measured durability characteristics for cast-in-place concrete decks
  17. Specified and measured strength characteristics for precast, prestressed concrete girders
  18. Specified and measured strength characteristics for cast-in-place concrete decks
  19. Proposed grades of performance characteristics for high-performance structural concrete
  20. Recommendations for the application of HPC grades for new durability characteristics
  21. Summary of recommendations for durability characteristics
  22. Summary of recommendations for strength characteristics

Tables taken from AASHTO Standard Specifications for Highway Bridges, Sixteenth Edition, 1996, and the 1997, 1998, 1999, and 2000 interim revisions

  1. Table 8.32.3.2. Tension lap splices
  2. Table 9.16.2.2. Estimate of prestress losses

Tables taken from AASHTO LRFD Bridge Design Specifications, Second Edition,
1998, and the 1999, 2000, and 2001 interim revisions

  1. Table 5.9.4.1.2-1. Temporary tensile stress limits in prestressed concrete before losses, fully prestressed components
  2. Table 5.9.4.2.2-1. Tensile stress limits in prestressed concrete at service limit state after losses, fully prestressed components
  3. Table 5.9.5.3-1. Time-dependent losses in ksi
  4. Table 5.11.5.3.1-1. Classes of tension lap splices

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