Bridge Decks and Overlays PDF
Preview Bridge Decks and Overlays
• ResearchR eport UKTRP-87-1 BRIDGED ECKSA ND OVERLAYS by JamesH . Havens AssociateD irector TheodoreH opwoodI I ChiefR esearchE ngineer and E. E. Courtney EngineerinTg echnologistI I January1 987 ResearRcehp ort UKTPR-87-1 BRIDGDEE CKASN DO VERLAYS by JameHs. H avens AssociaDtier ector TheodoHroep wood, II ChieRfe searEcnhg ineer a� E.E .C ourtney EngineerTienhcgn ologisItI KentucTkrya npsortatiRoens earPcrhgo ram ColleogfeE ngienering UniversoiftK ye ntucky inc ooperatwiiotnh TransportaCtaiboinn et Commonawletho fK entucky andt he FederHailg hwaAyd ministration U.SD.e patrmento fT ransportation Thec ontenotfst hisr eporrte flte tchev iewosf thea uthorwsh oa rer esponsifbolre the faandc ts thea ccuraocfyt hed atap resentheedr einT.h e cotnentdso n otn ecessarrielfyl te tcheo fficial viewso r policies Unoifv etrhseoi ftK ye ntkuyc, oft heF ederHailg hwaAyd ministraotni,n ort he KentucTkrya npsortatiCoanb inetT.h is repordto esn otc onstitau tset adnar,d specificna,t io orr egulation. The incluosfim oanun fcaturenra meos rt radneames aref ori dentificaptuiropno saensd a ren ott ob e considearse edn doermsetns. Januar1y9 87 TechniRceaplo Drotc umentaPtaigoen 1.R eporNto . 2.G overnmeAnct cessNioo.n 3.R ecipieCnatt'aslo Ngo . UKTRP-78-1 4.T itlaen dS ubtitle s.R eporDta te BridgDee ckasn dO verlays January1 987 6.P erformiOnrgg onzio tiCoond e B.P erformiOnrgg anizatRieopno rNto . 7.A uthosr)� Jas.H .H avensT,h eodoHroep wooIdI ,E .E .C ourteny UKTR-P87-1 9.P erformiOnrgg anizatNiaomne andA ddress 10.W orkU niNto .{ TRAJS) KenutckyT ranosrptatiRoensa erchP rgoram CollegoefE nginenegr i 11.C ontraocrtG ranNto . UniversoiftK ye ntucky KYHPR-82-88 LexingtoKne,n utcky4 0506-0043 13.T ypeo fR eporotn dP erioCdo vered· 12.S ponsoring AgNeanmceay n dA ddress KetnuckTyr anosprtatiCoanb inet Interim Depamretnto fH ighways FraknfortK,e ntuck4y0 622 14.S ponsoriAngge ncyC ode 15.S upplementNaortye s StudTyi tl:e SpeicallyC onstrucBtreidd ges Prepariendc ooperatwiiotnht heU ..S Depatrmenotf T ranpsortiaotn,F ederaHli hgway Admiinstrtaion 16.A bstract Ther eporptr esenat sh istoripcearls pectoifvt eh eT ranpsortation Cabniet'sb ridgdee kc constructainodn m aintenanecffeo rtsd irected towaridn creags birnidgdee ckd urbailtiy. Bridgdee ckcsr acki ns pecifpiact rtnest hatp rimaridleyp enudp on bridgdee signsN.o rmal dcercakc kgi insd uet ol oadn-diuceadnd thermal effectsE.a cht ypeo fc rackihnags a distinpcatt tern. One-hundraendd nineteeenx perimenbtraild ge doevcekr laywser e inspectedI.n cludweedr e9 membrabner idegs,8 7l atecxo ncreotvee rlays and2 3l ow-sluomvpe rlaysT.h eo verlahyasd b eenp laceodr igailnlyo n bothn ewa nde xistgi bnridgdee ckso n variourso utetsh roughotuhte sttae.M osto ft heo verlawyesr er ateidn g oodt oe xcellecnotn dtiion. Noneo ft heo verlmaeyt hodwass d iscernisbulpye ritoort heo thers. Thirty-fionutre graablu tmebnrti dgweesr ei npsectedN.e arlayl lo f thosber igdesa rei ng oodt ov eryg oodc onidtionO.n lyo neb ridghea da probml ecausebdy s ettmlenet. 17.K eyW ords 18.D istribuSttiaotne ment bridged,ec kc,o ncretper,e stressed, Unlimitweidt,ha pprovoaflt he temperatucrrea,c kinfgl,xe urec racking,K enutckyT ranosprtatiCoanib net overlayisn,t egraablu tmenmte,bm ranes, latexes 19. SecuriCtlyo ssi(fo.ft his report) 20. SecuriCtlyo ssi(fo.ft hipsa ge) 21.No ,o fP ages 22.P rice Unicassiife d Unclassified 72 FormD OTF 1700.IB7- 271 Reproductoifco onm pletpeadg ea uthorized TABLE OF CONTENTS Introduction. .. .. 1 • .. .. .. • • .. .. .. .. .. • .. .. • .. .. .. .. .. .. .... .... •.. ..• •• .... .... .. • .. .. • Epoyx-CoateRde inforcSitnege. .l.................... ..1. .. FailuroefsM asonrCyo aitng.s................8. .......... Stay-i-nPlacFeo rsm..................................... .. ............................ 16 ExperimenDtekac lF eatur.e.s.................19. ............ SegmentBarli dsg..e......... .. .. .................................................... .. ..2 0 SteelC orrosion-CMoentthroo.dl.s . ..............44. ....... MicriolsicaC oncr.et....e.. ............................................ .. ............ 45 FailuroefsA lumuimn Nut.s.. .............. .................. ...... .. ......... 47 .. Summarayn dC oncliuosn.s.. .. . ................................... .. .. .... .5..1.. Overlay..s .. 51 .. .. .. .. .. .. .. .. .. .. •.. ..• .... .. .. • .. .. • • • .. .. .. .. .. • .. .. . • • • • . • • . • Epoxy-CoaRteeidn forcSitnegle. ............5.1 ........ Bried gDeck.s .. 52 . • • • • • • . • • • • • • .. • • • • • .. • • • • . • . • • • • . • .. . • • Interga-lAbutmeBnrti dg.es...............52. .......... MasonrCyo aitng.s. . .. . . .....................5.2. ........ SegmentaBlr igde.s........................5..3. ........ Weatehrign andG alvaniSzetedel B ridsg.e........5.3 ... References 53 • • . • • • • . • • • . . • • • • . • . • •••.•••••••••••.••••••.. Appednix:M asonrCyo aitngS urvey 57 . • • ••••.••••.•••••.••• EXECUTISVUEMMA RY A chronoloofg ayd vanciensb rigde-dke cconstructainodmn a intenance in Kentuckiys presenteTdh.e I-64 brigdesb etweeLne xingtaonnd Fraknforeta chh add iffegr ienxpemreintadle kc feautre.s BridgoensU S 119, Harlan-bCeulrman,d are expeirmentaflr omt he standpto ionf ovelraymenotn newb ridg.e sThosea nda largenu mebr of overlayed brigdesw ered esginatedl ong-teerxmp eirmentaslt ructures and were monitordeudr intgh ec oursoef t hiss tud.y Reserachd urintgh ep eriod from1 970-19f8o0c useodn imprvoementisn durabiitlyo f brid-gdeeck concreteD.e veplmoentawlo rkw as conducteodn latexc oncretaen d concreutsei gn supewra terre dcuer.s Initiaplr otectieofnf ortesn tailepdr esveartioonf deteraitoerd concredteec ksu singp enetrtasn,s eal,s lacqruse, epoxyr esi,n setc. Allo ft hosper oveddi sapptoiinn.g Kentuckwya s a pioneeirn thed eveolpmenotf latexo velraysa nd fisrtu sedl atemxo rta(r91 69-73f)o rd eckr ehalbiitaotni. In1 973t,h e TranpsortatiCoanb inestw itchteod a concreftoer mulaf romt hem ortar typem itxure.T he TransportatCiaobni neatl soe xeprmientedw ith mebmranoev elraysa t ther equesotf theF ederHailg whayA dmisntiration on nine briddguersi ntgh e mid1-97'0s. Low-lsumpc oncretbee came feasibalned c ompettiiv,e butw asr equirteod b e placeadt a slihgtly greatetrh ickness than colnactreextd eu e to its lowerc hloride impeerambilitIyn.t hem id1 906'sK,e ntucskpy eciicfatoinsr equired use of ClasAsA concreatned i nt he ear1l9y7' 0si ncreasceodn crectoev er overt het opm ato fr einforgc sitnee.l Benefiotfst hosree queimrents weren otw idelrye cognibzeecda useep oxy-coarteebda rwse rep romotbeyd theF ederHailg whayA dministrasthioornt tlhye rfetaer.M illingm achines ando veralyp averism provdeedc ko velrayinpgr acti.c es An attendafnitn idngo ft hiss tud,y madduer ign thes urveoyf r igid concreotvee rylsa, ist hee xistenocfe s pecifdieckc crakc patterfnosr eachs tyleo f bridagned decks ystem.T hosec rakcs are due to temperataunrded ekc flexureef ftesc. Naturadlek c crackasr e caubsye d diffreenceisn t hermaelx painosnb ewteenr einforcsitnege aln dc oncrete. Load-diuncecdr acksa res pecifaincd a rer ecogniazsew do rkincgr acks. Someb ridgtey pe(se .,g c.ontuionuss teeIl- bema typea)p peatro b em ore pronteo d ekc crakcign thano thetry pe(se .,g .prestsreeds concIrete beamt yep). Thata ppeartso be relatetdo thset infefss of the superrsutcturaen d deck. heaOvni ltyr vaeledr odas,l oad-induced crackimnagy b e sevree.T hee ffecotf c rackinogn d eckd uralbiityh as notb eend etmeirned. Deckt extugr inbyt iinngh asb eena ssocida wtietha numebr of probmlse includiingre rgularg roovin,g roughd eck,s ovelray pull crakcin,g anda ggregaptuel lo uts.O nev iablael etrnatifvoer itnigni s to ws garoovienst ot hec ompleteddek c oro verlay. Masisve overaly debondifnagi lurehasv eo ccurreidn freqtuleyn. Partiadelb ongd iinsc omomn. Oftent,h ati sa ssociawtietdhf aliureo f theu ndelryindge ck. Inspectioof n thmeem rban-etreatberdi dgerse vealeeidg hto f the nineb ridgweesr ei ng ood ciotnidonV.i sible sudrifsatcreei snsc luding blsitres and seamc racksd idn ot appeart o havea ffectetdh eir perfmoarnec. Resiisvtittye stosn twoo f thosber idgeisn dicattehde memrbanewse reg radualdleyt eraitoirgn. Twenty-eiogfh tth e 3D8o wl ateoxv erlawyesr er ateedx cell,e n5t werer atedg oo,d and 5 werej udgepdo or. The pooro verlayhasd delmaiantionsa nds pallinMgo.s to f the 4R9e ichholladt eox verlays werep lacesde verayle arsl ater than thoev eryDlosaw. Forty-one Reichhoolvde rlawyesr ep laceodn i n-servbircei dgesT.w enty-eiogfh t thoswee rer ated exce, l1l5ew netrej udged tgoo o,bd ea nd5 werer ated fairt op oor.L owerr atingfso rt heR eichlhdoo verlaayrse a ttruitbed to extenvsei use odne ckst hatw erem ore deteraitoder thant hosoen whicDho wo verlawyesr eu se.d The2 3e xperimenltoawl-l sumpo verlays generalpleyr fmoerda sw ella s thel ateoxv erylsa.N ineo ft hoswee re ratede xcelleanntd 1 4 werer atedg ood.L ow-lsumpo verladyisd not cracaks e xtensivaesll ya teoxv erlsa.y Thir-tsiyxo ft he4 6e xistiinngt egraablu tmebnrti dgienst hes tate were insepde.c Tthreeo f thosber idgewse reo f reinforced-concrete dec-kgirdetry pec onsrtucteidn th1e9 70,' sFour inteagbruatlm ent bridgceosn sutcrtde in tmhied t ol ate1 970'usse dp recsat,p restressed I-beamsO.f the3 9e xistgi nintegraablu tmebnrt idgecso nstrucitne d the1 98'0s, 33 usedp reacs,t prestresIs-ebdem a girders;f ive used preacstp,r estresbsoexd- bme gairderasn;do neu seds teeIl- bemas. Bride ginspectiaonndss u bsequreenvti eowf D ivisioofnM aintenance SturcturIen vetnorya ndA pparisaRle oprtsi ndicattehda t nearloyf all thes tructurweesr ei ng ood vteor yg oodc odnitionT.h eb ridgdee kcs containveedr yf ew crakcs. Theo nlyp rolbem detectweads realtiev settlement thoef abeunttms( and posbsliyp ier)s on oneb ridgteh at causesdom e dekc crakcin.g Newd eckc oncreatded iitves( mic-rsoili,c saupewra terre duecr,s and calicumn itriteh)a veb eeni nevsitgateadn ds how opmsiref orp rdoucign strongearn dm ored urablceo ncretthea n tChlea sAsA concreptree sently usedi n bridgdee ck.s Micro-silaidcdai tiveensh ancset rengtwhe,a r resitsacne,a nd relativiem permielaibyt to chlodrei.s Superw ater reudcres allwo low waterm-ecnetr atioisn concree,t whichy ields imporved fer-ehteazw resisntcae. Calcmi u ntiritei s a corrosion inhbiitoarn dm ayb e useda s an altrenatteo epoxy-coarteeidn forgc in stee.l Threter iablr idgdee ckhsa ve bpeelna ceudsi ngt hosmeat erilas. Overlahyasv eb eena majosru ccessA.bo u2t ,000o verlahyasv eb een placed doenc ktsh ato ft enc ontaibna dlyd eterioractoendce rte.L ess thant enp rmeaturoev erlafya iulresh aveb eene xperiencOevde.r lays havee xetndedt hes erviclei veos f allo f those kdse,ac ndt hath as resultiend a singiifcantm aintenanscavei ngsf ort heT ransportation Cabient. The virtuaalb sencoef probmlse withi ntegraablu tmenbtr idges warrantthse icro ntuiendu se. Furthedre velopmaenndti nvsetigantsi aoppeadre sirabrleel atetdo bridge-kd eccrackingp robmlse, dekc texturinagn,d necwo ncrete additivfeosrd eckasn do verylsa. INTRODUCTION Thisr eporptr ovidae sb riefr evwi eof bridge-daencdk o verlay advacne,s surverye porotns o verlaaynsd i ntegraablu tmebnrti degs,a nd analysoefsb rigde-dke ccrakcingi nK entkuyc. A recenrte porptr esented thef irsptr leiminaarnya lysoifsb rideg-dekc crakc patter(n1s.) Over tyheea rst,h ep erfmoarncea ndd urabiloift yc oncrebtrei dge deckhsa veb eenm ajorc oncer.n sThe earpleyr fmoarnceo f interstate concrete brdiedcgkesp rovedd ispapoingt iannd promptecdh agne.s Earlideerc kc oncrewtaes o ftent oop oruos.I ns omec asesr,e inforg cin steewla sc losteo t hes urfa(cein suffiiecntc ove)r,p rompticnogr rosion and concsrpeatlel i. nAgsa resulotf t hosea ndo theprr obmlse, bridge dekc scaliwnags c ommon.I ncreasuesdeo fd eicisnagl tfsr omt he1 96s0 ' onwaredx acerbattheedr ateo f dekc deterioratBieogni.n niinng t he 1960'sa, s erieosf progrievsest ehcnologiciamplr oveenmtsi n concrete deckd esi,g nconsutcrtion,m aterlisa,a ndm aintenawnecree i nstiutted (Tabl1e) .T hosec hangewse rei netndedt o increatshee q ualitayn d enduranocfeb ridgdee ck.s Whilteh eya ddressveadri oufsa ctorresl ated to dekc durabilitym aiannetdn anec,t hosceh angeasl lh ada poistvie effecitn improdveikcn gp erofrmanc.e Unofrutnateyl,t hef actt hatt hey weren ot instiuttedu nifromly( due to the difrfeenta geso f the TransportaCtaiboinn et faomfi blryi dgehsa)s m adei t dififcultt o properlqyuna tifyi ncreasiens dekc qualitayn d durabiligtayi ned througihn dividcuhaalgn es. DECKC ONSUTCRTION Beforteh eu seo ff ulwl-idtfhi nsihinmga chin,e wsoodetne pmlateosn piper ailwse res ett og radaen dt hec oncrewtaes s creedmeadnu allbyy sawing a 2b obayr adc 6r oss thteo pso f theg radbeo ar.d sThe,n the templabtoea rdwse rer emoveadn dt hec oncrewtaes f loatteodt hef inal grad.e Fillinogf voidsre mainianfgt erre movaolf theb oard(sa nd pieps)w as rarely atdoep qrueavteend te terioraotfit ohnec oncree.t Bride-gdecfki nishimnagc hinweesr er equirfeodr a lln ewK entucky bridgceosn srtucteadft er1 926. At onet im,e itw asf eltt hatu seo fa rotarsyt ele-disikm pactifnign ishseurc ha s thKee llcyo pmactomri ght 1 TABL1E . CHRONOLOOGFY B RIDGE-KD IEMCPRVOEMENTS =================================================================== YEAR IMPREOMVENT 1956S pecifiaeird- eanitnrmenfto rd eckc oncrete 1962S pecififeuldl -wifditinhs hinmga chines 1962 Specifiliends eeoidl p rotevcet cioatgi n 1964S pecifimeebmdr anceu ring 1964I ncreasceodn crectoev eorv err einfcoermentto 2 inches 1965S pecifiteemdp lactlee arancchee cfko rf inishimnagc hines 1966S pecifCileads AsA concre(t6e. s6a csk ofc eemn,t maximuomf 5 gallonosf watpeerrs ack) 1967S pecifiteide -owdno fr einforcsitnege( l-8 foocte nters) 1968D ensceo ncreotvee rl,a CylarMke omriaBlr digeL,o uisville 1969 Specifiteemdp eratluirmei toantsif orh ot-weatchoenrc regt;i n nihgtitmec oncretpienmrgit tde 1975 Specifitehedu seo fe poxy-coarteeidn forcbianrgsi nt he upper mat 2 providbee ttecro ncrectoen solidaatnidot nh a,t couplewdi tht hes wirl finisphr ovided byc omatpchet or'dsi skw,o uldi mrpove tchoen crete deck.T heK ellcyo mpactwoarse mployoend o nlyo neb ride gin1 96a8n d fivei n1 972T.h irteberni dgoensI 64c ontaineexdp erimenfteaaltr ues, includiunsge othfe K elly pcaocmtoorn t wob ridgceosn strucitne1 d9 27. Thsoea ndo theerx preimentfaela turheasv eb eenr eportperde viou(s2l.y) Thel asti nspectsi coonnductoendt hosber idgreesv ealetdh at sevoefr al thosber idgehsa dv aryinagmo unts of dekc crakcs;b utt herwee ren o indicatioofns se verper ematudreec kd eteriora(tii..oen,s pallgi).n Bidweldle veloptehde f irsftu ll-wdithc oncertef inishimnagc hine. Itp osseds sear ealtively litgrhutsw si tha n undelrusn,g sawings creed floatL.a terv,i bratowresr ea ddetdo t he floaTthe.G omacCoo mpany subsequendtelvye lopae dp avemenfti nishimnagc hinwei tha spinning rollearn da uge(rF igurels a nd2 ).I tw asu sde forn ewd eckasn dl atex overylsa. Latre, the BidwelMlo delO F-400Ov erlaFyi nishewra s developteod handlloew -lsumpc oncre(tFei gu3re) .I t wasc apabloef singloer-d oubllea-neo velraymesn.t DECKM AINTENANCE Untitlh el ate1 95'0s,mo stm ajord ekc repaicrosn sistoefd f illing potholaensdd epressiaonndrs e surfacwiintgha sphaltciocn certe.W hile thatm ethopdr ovidae dt emporaprayt chi,t also rectoanitmnaienda nts and moisturteh ata tatckedt he underlgy idneck. The resulting deterioraptrioognr esusnesde enP.e hrapss omep rotectwiaosna chiveed, buta ccelerda tdeamage suwsapse cteDdu.r intgh att iem,u nderlayments ofa sphalrto ofgi wnerep rpoosde. Howveer,co nceranbso ubtl eedgi annd slippagdee terretdh eiru se. Conevntiaoln dekc overylmaent (balcktoppiwnagsu) s ualldyo nei nc onjunctwiiotnhr oadwary esurfac.i ng Someitmess econadn dt hird-generaastpihoanlo tv elraymenwtesr ep laced over briddegcek s( usuayl lafterr emovintgh e prveiousa sphalt ovelraymnet).E vent huoght hatw orkw asw idespretahde,r wea sa strong reluctantcoe b lackebnr idgdee cks sinccea usietpd o orn ightmtei visibiltiy. Initia,l nleyw aendxs itingb ridges twreeraet weidt hl inseeodi, l variouvsa rnissh,ea ndp enetrantto sp rotecthte mf romw atearn ds alt 3
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