Bridge Engineering/Construction Ultra High Performance Concrete (UHPC)

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Laurence Walton
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1 Bridge Engineering/Construction Ultra High Performance Concrete (UHPC) Ductal UHPC Paul White, PE, P. Eng. Bridge Engineering Manager, UHPC/Ductal U.S. LafargeHolcim October, 2016

Superplasticizer Organic fibers Water w/c ratio less than 0.

2 UHPC Premix/Constituents Premix Blend of cement, silica sand, quartz flour and silica fume Largest aggregate less than 1 mm Superplasticizer Organic fibers Water w/c ratio less than 0.25 Fibers Steel (structural) Organic (architectural) Metallic fibers 2

Properties of UHPC Compressive Strength 140 to 225 MPa (20,000 to 33,000 psi) Flexural Strength 20 to 50 MPa (3,000 to 7,000 psi) Organic fibers Ductility Greater capacity to deform and

3 Properties of UHPC Compressive Strength 140 to 225 MPa (20,000 to 33,000 psi) Flexural Strength 20 to 50 MPa (3,000 to 7,000 psi) Organic fibers Ductility Greater capacity to deform and support flexural and tensile loads even after initial cracking Abrasion Resistance Similar to natural rock Metallic fibers Impermeability Almost no carbonation and penetration of chlorides 3

4 UHPC Matrix Conventional Concrete 4000 psi High Performance Concrete 10,000 psi Ultra High Performance Concrete 21,000 psi 4

5 Impermeability & Longevity US Army Corp, Exposure Site Treat Island, Maine August 14, 2002 EXPOSURE: 500 freeze/thaw cycles and 4500 wet/dry cycles in saturated sea water

6 Ductility Greater capacity to deform and support flexural and tensile loads even after initial cracking! Flexural Strength Equivalent Stress (MPa) Ductal HPC Deflection (mm) 6

7 Ductility Steel Fibers Bridging the Crack - Ductility h 7

8 UHPC Connections Cyclic Loading (Fatigue): 2000 to 16,000 pounds for 8,900,0000 cycles 2000 to 21,300 pounds for 5,200,000 cycles No leakage through the joint 8

9 Design Details 9

10 Design Aids French Association Civil Engineering First Came Out 2002 Revised Part 2 in June 2013 to be Consistent with the Euro Code 10

11 Design Aids 11

12 Design Aids 12

13 Design Aids 13

14 Design Aids 14

Field Batching of UHPC UHPC may be mixed in any

optimization but best performance is achieved in

15 Field Batching of UHPC UHPC may be mixed in any type of mixer with proper mixer adjustments and optimization but best performance is achieved in high shear mixers. Most precast plant mixers work fine. 0.2 yd 3 batches (0.8 m3 per hour) 0.65 yd 3 batches (2.6 yd 3 per hour) 6 yd 3 batches 15

16 Casting 16

17 Quality Control Slump Flow Mini-slump cone Flow 7ʺ to 10ʺ Compressive Strength 3ʺ x 6ʺ Cylinders Ends cut to length and machined to <0.5 o Material supplier provides on-site QA/QC for all projects. 17

18 High Early Strength UHPC for ABC 18

19 Applications Precast deck panel connections Link slabs Beam connections Beams Pier elements Precast substructure connections Bridge rehabilitation, repair and retrofit Thin bonded overlays 19

Precast Concrete Connections Engineering With UHPC 3 Dia Port For Placing UHPC 3 Dia Corrugated Pipe Sleeve Around Reinforcing Steel Precast

20 Precast Concrete Connections Engineering With UHPC 3 Dia Port For Placing UHPC 3 Dia Corrugated Pipe Sleeve Around Reinforcing Steel Precast Concrete Pier Cap * Precast Concrete Column * UHPC Collar Form and Pour Through 3 Port Shown is One of Many Types of Possible Connections 20

21 Engineering with UHPC As Built 21

22 UHPC Field Connections For Full-Depth Precast Deck Panels 22

23 Typical Concrete Panel Joint Details 23

24 UHPC Field Cast Joints for Live-Load Continuity UHPC Joint Fill Side-by-side Boxes Pier Threaded Inserts c/w High Strength Bolts * Courtesy of Hatch Mott McDonald & Ministry of Transportation Ontario

25 Side-by-Side Box Girder UHPC Field Connections UHPC Straight Bars with off-set laps! * Courtesy of Ministry of Transportation of Ontario

26 Abutment to Pile Connections for ABC Precast Abutment Plan View UHPC Field Cast Fill Precast Piles * Courtesy of Delcan & Ministry of Transportation Ontario Section

27 Pulaski Skyway, New Jersey/New York 27

28 Pulaski Skyway, New Jersey/New York 28

29 Pulaski Skyway, New Jersey/New York 29

30 Pulaski Bridge UHPC Details Typical Shear Connector Details 30

31 Pulaski Bridge UHPC Details Typical Transverse Joint Details 31

32 Nipigon Bridge UHPC Details 32

33 Nipigon Bridge UHPC Details Phase 1 Construction - Westbound 33

34 Typical Joint Details Nipigon Bridge UHPC Details 34

35 Nipigon Bridge UHPC Details Typical PBES/UHPC Portion Completed 35

36 Deck Bulb-Tee UHPC Field Connections * Courtesy of NY State Department of Transportation 36

37 Deck Bulb-Tee UHPC Field Connections * Courtesy of MassDOT 37

38 UHPC Field Connections For UHPC Waffle Deck Bridge Panels 38

39 Hodder Avenue Underpass, Thunder Bay, ON 39

40 Hodder Avenue Underpass 40

41 Hodder Avenue Underpass 41

42 Mission Bridge Pier Retrofit, Mission, BC 42

43 Mission Bridge - Pier Retrofit 43

44 Mission Bridge - Pier Retrofit 44

45 Mission Bridge - Pier Retrofit 45

46 CN Rail - Column Jacketing, QC 46

47 CN Rail - Column Jacketing 47

48 CN Rail Column Jacketing 48

49 Q & A 49

Applications of Ultra High Performance Concrete and Prefabricated Concrete Elements in Accelerated Bridge Construction

Applications of Ultra High Performance Concrete and Prefabricated Concrete Elements in Accelerated Bridge Construction 2018 Virginia Concrete Conference March 2, 2018 Bardia Emami, PE Outline Projects