ULTRA HIGH PERFORMANCE CONCRETE

Transcription

1 ULTRA HIGH PERFORMANCE CONCRETE 1

2 Buchanan County Iowa 259 Bridges over 20 3 Pin-connected Trusses constructed Henry Ford started mass production of the Model T in

3 Many of our bridges are old 3

4 Our System Cannot meet Today s Demands 4

5 TAHD Trailboss LowPro 5

6 We Have NOT kept up with Modern Agriculture POSTING FOR SEMI Loaded Semi 6

7 Postings Do Not Work unless I am there. 7

8 The world and our economy relies on Food 8

9 It was posted at 8 Tons. They did not care before 9

10 They always made it before, axle weights are an issue 10

11 The Bridge does NOT Discriminate 11

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14 Build Less Expensive Bridges Report No. KS FINAL REPORT December 2014 Guardrail and Bridge Rail Recommendations for Very Low-Volume Local Roads in Kansas Ronald J. Seitz, P.E. Tod Salfrank Kansas Department of Transportation Bureau of Local Projects Division of Operations Bureau of Research 14

15 Timber String/multi-beam or girder 32 x 23.3 (0ºSkew) Built 1899 SR=30 Scour=5 Last Insp: Jan 2015 Next Insp: Jan 2016 (12 mo cycle) 15

16 Dr. Joh, Mr. Keierleber, Dr. Kim,Mr. Davis, Dr. Koh 16

17 No piling in the abutment May,

18 The Initial PI beam Design Design Guidelines - University of New South Wales, France, and Japan Development of PI section by Dr Ulm at MIT Testing of UHPC and PI section (Turner-Fairbanks) I-Beam Testing by Turner-Fairbanks & Iowa State University Experience Wapello Co. project Discussions with Dr. Graybeal (FHWA) and Vic Perry (LaFarge North America) 18

19 Preliminary PI Girder Test Beam 20

20 UHPC Design Data Modulus of elasticity final = 7,500 ksi Compressive strength at release = 14.5 ksi Compressive strength final = 21.5 ksi Tensile strength ~ 1.20 ksi 21

21 PI Girder Developed by MIT/FHWA Optimized section No Mild Steel NEEDED Integral Deck 4-71 ft sections tested by Turner-Fairbanks Laboratory, FHWA 22

22 Improving Transverse Strength and Lateral Distribution Worked w/ existing forms initially Thickening deck Providing ribs Post-tensioning High strength rods Strands Addition of steel diaphragm 23

23 Final Section New detail 24

24 Jakway Park Bridge

25 UHPC Material (Positive) Self Consolidating High compressive strength (30 ksi) Dense low permeability Low creep post-cured High durability Fibers post-cracking strength 27

26 Mix Design of K-UHPC Constituents lb/yd^3 (kg/m^3) Conventional Concrete UHPC K-UHPC Conventional Concrete Aggregate 1739 (1032) 42.70% % by weight UHPC K-UHPC Sand 1429 (848) 1462 (867) 35.10% 35.30% Cement 600 (356) 1329 (789) 14.70% 32.10% Water 300 (178) 311 (184) 7.40% 7.50% Superplasticizer 31 (18) 0.70% 16.3mm fiber 66 (39) 1.60% 19.5mm fiber 131 (78) 3.20% Defoamer 1 (0.5) 0.02% SRA 13 (8) 0.30% Pre-mix* 797 (473) 19.30% Total 4068 (2413) 4142 (2457) 100% 100% 28

27 Hawkeye UHPC Bridge 29

28 Mixing Proportions and Process Mixing orders SC180 KICT MIX Total (lb/5.5 CY) Location Mixing instruction 1 Pre-mixing binder 4,386 County 2 Cement 7,310 Ready Mix Plant Mix for 10 min 3 Dry Sand 8,041 Ready Mix Plant Mix for 5 min 4 Water 1,710 Ready Mix Plant 5 SRA 73 County 6 Defoamer 5 County 7 Superplasticizer 140 County Rotate at 10 RPM and move to cou nty shop After adding all liquid additives, mix for 5 min at 10 RPM then, Mix for 5 min at Maximum speed 8 Steel Fiber (0.63 inch long) 362 County Add for 7 min at 10 RPM 9 Steel Fiber (0.78 inch long) 723 County Add for 13 min at 10 RPM, then mix for 2 min at maximum speed 30

29 Alex Building the forms (Dr. Joh, Dr. Ryu, Haena) May 19,

30 County Constructed Forms JUNE 23,

31 2008 Placing UHPC into trucks in Canada UHPC

32 Placing the K-UHPC into trucks K-UHPC JUNE 23,

33 Placing Super plasticizer in 2008 UHPC

34 Placing the Admixtures in K-UHPC K-UHPC JUNE 23,

35 Placing Steel Fibers in Canada UHPC

36 We used a better method K-UHPC 38

37 We added a second vibrator K-UHPC JULY 16,

38 Pouring UHPC in Canada UHPC

39 Pouring the K-UHPC Beams K-UHPC JUNE 23,

40 Curing UHPC beams in Canada UHPC

41 The Steam Curing Machine. K-UHPC 43

42 Steam Curing in our yard K-UHPC August 6,

43 Loading the Beams Drive Sign in August 25, 2015 UHPC pictures 8 items TITLE LAST MODIFIED _ jpg Oct _ jpg Oct _ jpg Oct _ jpg Oct _ jpg Oct _ jpg Oct _ jpg Oct _ jpg Oct 4 Loading Loading Loading Loading Loading Loading _ jpg _ jpg Open Extract Open with 8 of 8 items Zoom in 45

44 Transporting the Beams August 25,

45 August 25,

46 Standard Slab Construction August 25,

47 Not all the joints were perfect. August 25,

48 Highway Departments Have old Signs SEPTEMBER 2,

49 Limited Finish Work SEPTEMBER 2,

50 Curing the joints. SEPTEMBER 4,

51 Completed Joints SEPTEMBER 23,

52 Long waits for SL-1 Barrier Rail Posts OCTOBER 1,

53 Minimal soil exposure OCTOBER 1,

54 Reseeded with Hydromulcher OCTOBER 7,

55 We have a small footprint 57

56 Lessons Learned Follow the Mixing instructions, Mix the Premix and the Portland cement prior to the sand Have superplasticizer available to add as needed. High density and high viscosity create pressures we are not accustom to. (uplift pulled the screws through the 2x4 s) Post tensioning is simple and easy 58

57 Design and Construction of Hawkeye UHPC Bridge 59

58 Hawkeye UHPC Bridge 52 ft. long 32 ft. 4in. Wide Five Crossbeams 60

59 Hawkeye UHPC Pi-girder 52 ft. long, 5 ft. 4.5in. wide and 2ft. 4in. Deep 61

60 Hawkeye UHPC Pi-girder 62

61 Fundamental Properties of K-UHPC Conventional Concrete K-UHPC Compressive Strength, psi (MPa) Flexural Strength, psi (MPa) Tensile Strength, psi (MPa) Elastic Modulus, ksi (GPa) 3,046 5,802 (21-40) (2-4) 26,106-29,007 ( ) 4,351 6,527 (30-45) TABLE 1 Property Comparison of Different Types of UHPC (2-5) 3,046 5,076 (21-35) Vf=2%: 2,320 (16) Vf=1.5%: 2,030(14) 6,237-7,252 (43-50) 63

62 Hawkeye UHPC Bridge (K-UHPC) Jackway Park Bridge (DUCTAL) Bridge Dimensions L= 52 (15.85m), W= 32-4 (9.852m) Area=1,679 ft 2 (156m 2 ) L = 50 (15.24m), W= 25 (7.62m) Area=1,249 ft 2 (116m 2 ) Girder Height 2-4 (711mm ) 2-9 (838mm) Girder width & number (1.64m) & Six Girders 8-4 (2.54m) & Three Girders Slab Thickness 4 (100mm) 4.1 (105mm) UHPC Weight / Volume of Girder 1) 32,372 lbs. / 205 ft 3 (144kN / 5.8m 3 ) 47,659 lbs./ 300 ft 3 (212kN / 8.5m 3 ) UHPC Weight / Volume 1,518 ft 3 (0.90 ft 3 /ft 2 ) of Bridge 2) (43m 3 (0.276 m 3 /m 2 ) ) Cross Section of Bridge 3) UHPC 918 ft 3 (0.73 ft 3 /ft 2 ) (26m 3 (0.224m 3 /m 2 ) ) Steel Diaphragm (Difficult to assemble, Conventional concrete joint) Types of Prestressing 4) Post-Tensioning (14 Strands/Girder) Pre-Tensioning (22 Strands/Girder) Type connection between Girders 5) shear ball Connection (UHPC Field Pour) + Transverse Post-Tensioning shear key (Steel) + Grouted Pockets 64

63 Post-tensioning Seven 0.6- in. dia. longitudinal strands at the bottom of each of twelve flanges (300 kips) Three 0.6- in. dia. transverse strands in the middle of each of five crossbeams (105.5 kips) Aug 25, 2015 Sept 9, 2015 Longitudinal Post-tensioning Transverse Post-tensioning 65

64 Accelerated Bridge Construction (ABC) August 25,

65 Laboratory Testing of field Samples 6 samples from each truck was collected (12 samples from each girder Total of 72 sample) They were kept in the same curing condition as the girders July 6, 2015 July 9,

66 Compressive Strength Test 68

67 35,000 Compressive Strength of K- UHPC Field Samples COMPRESSIVE STRENGTH (PSI) 30,000 25,000 20,000 15,000 10,000 25,015 22,633 22,925 22,453 20,481 21,691 30,315 27,40626,256 27,349 28,859 29,350 28,264 28,378 28,635 29,000 28,225 26,423 26, ,511 25,580 25, ,086 23,820 5,000 0 DAY 7 DAY 18 DAY 28 DAY 58 Second Girder-truck1 Second Girder-truck2 Third Girder-truck1 Third Girder-truck2 Fourth Girder-truck1 Fourth Girder -truck2 Fifth Girder - truck 1 Fifth Girder - truck 2 Sixth Girder -truck 1 Sixth Girder - truck 2 69

68 Laboratory Mix Test Prior to Construction 70

69 Mixing K-UHPC in Laboratory Drum Mixer 71

70 Samples Cured Under Water at 72 F 72

71 Compressive Strength Results Compressive Strength 30,000 22,583 25,299 26,208 25,000 19,356 16,576 Compressive Strength (psi) 20,000 15,000 10,000 12,740 C1 C2 C3 Average 5,000 0 Day 1 Day 2 Day 4 Day 7 Day 14 Day 28 73

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73 Installed Wireless Strain Gauge Sensor

74 National News Coverages DENNIS MAGEE Falls Courier The Associated PressFinance & Commerce Targeted News Service KansasCity.com Belleville News Democrat Sacramento Bee Bradenton Herald Beaufort Gazette Myrtle Beach Sun News San Luis Obispo.com Raleigh News & Observer Macon Telegraph Kentucky.com Ledger-Enquirer 76

75 +KWWL+-Eastern+Iowa+Breaking+News+Weather+Closings.mp4 77

76 Any Questions Visit lactiowa.org 78