Concrete Box Beam Risk Assessment and Mitigation: Volume 1—Evolution and Performance

Adjacent box beam bridges have a history of poor long-term performance including premature deterioration and failures. Leaking joints between box beams allow chloride-laden water to migrate through the superstructure and initiate corrosion. The nature of this deterioration leads to uncertainty of the extent and effect of deterioration on structural behavior. Due to limitations in previous research and understanding of the strength of deteriorated box beam bridges, conservative assumptions are made for the assessment and load rating of these bridges. Furthermore, the design of new box beam bridges, which can offer an efficient and economical solution, is often discouraged due to poor past performance. The objective of this research is to develop recommendations for inspection, load-rating, and design of adjacent box beam bridges. The research is presented in two volumes. Volume 1 focuses on the evolution of box beam design in Indiana to understand the lack of performance and durability. The Indiana Department of Transportation (INDOT) standards and bridge design manuals were reviewed to track the historical development of box beam bridges in the State. Two timelines were produced tracking important updates to box beam design. Adjacent box beam bridges within INDOT’s bridge database were also analyzed. Superstructure ratings were compared with bridge age as well as bridge characteristics to highlight possible causes for deterioration. Analyzing the INDOT inventory, data shows that the condition of adjacent box beam bridges may be affected by location, type of wearing surface, and the use of deck membranes. Six bridges were then inspected to identify common deficiencies and specific problems. Exterior beams and beams within the wheel load path tend to have higher levels of deterioration. Furthermore, leaking joints between beams leads to corrosion of reinforcement, ultimately resulting in spalling, fracture of prestressing strands, and loss of structural capacity. Volume 2 focuses on evaluating the capacity of deteriorated adjacent box beams, the development of improved load rating procedures, and new box beam design. Through a series of bridge inspections, deteriorated box beams were identified and acquired for experimental testing. The extent of corrosion was determined through visual inspection, non-destructive evaluation, and destructive evaluation. Non-destructive tests (NDT) included the use of connectionless electrical pulse response analysis (CEPRA), ground penetrating radar (GPR), and half-cell potentials. Deteriorated capacity was determined through structural testing, and an analysis procedure was developed to estimate deteriorated behavior. A rehabilitation procedure was also developed to restore load transfer of adjacent beams in cases where shear key failures are suspected. Based on the understanding of deterioration developed through study of deteriorated adjacent box beam bridges, improved inspection and load rating procedures are provided along with design recommendations for the next generation of box beam bridges

Concrete Box Beam Risk Assessment and Mitigation: Volume 2—Evaluation and Structural Behavior

Adjacent box beam bridges have a history of poor long-term performance including premature deterioration and failures. Leaking joints between box beams allow chloride-laden water to migrate through the superstructure and initiate corrosion. The nature of this deterioration leads to uncertainty of the extent and effect of deterioration on structural behavior. Due to limitations in previous research and understanding of the strength of deteriorated box beam bridges, conservative assumptions are made for the assessment and load rating of these bridges. Furthermore, the design of new box beam bridges, which can offer an efficient and economical solution, is often discouraged due to poor past performance. The objective of this research is to develop recommendations for inspection, load-rating, and design of adjacent box beam bridges. The research is presented in two volumes. Volume 1 focuses on the evolution of box beam design in Indiana to understand the lack of performance and durability. The Indiana Department of Transportation (INDOT) standards and bridge design manuals were reviewed to track the historical development of box beam bridges in the State. Two timelines were produced tracking important updates to box beam design. Adjacent box beam bridges within INDOT’s bridge database were also analyzed. Superstructure ratings were compared with bridge age as well as bridge characteristics to highlight possible causes for deterioration. Analyzing the INDOT inventory, data shows that the condition of adjacent box beam bridges may be affected by location, type of wearing surface, and the use of deck membranes. Six bridges were then inspected to identify common deficiencies and specific problems. Exterior beams and beams within the wheel load path tend to have higher levels of deterioration. Furthermore, leaking joints between beams leads to corrosion of reinforcement, ultimately resulting in spalling, fracture of prestressing strands, and loss of structural capacity. Volume 2 focuses on evaluating the capacity of deteriorated adjacent box beams, the development of improved load rating procedures, and new box beam design. Through a series of bridge inspections, deteriorated box beams were identified and acquired for experimental testing. The extent of corrosion was determined through visual inspection, non-destructive evaluation, and destructive evaluation. Non-destructive tests (NDT) included the use of connectionless electrical pulse response analysis (CEPRA), ground penetrating radar (GPR), and half-cell potentials. Deteriorated capacity was determined through structural testing, and an analysis procedure was developed to estimate deteriorated behavior. A rehabilitation procedure was also developed to restore load transfer of adjacent beams in cases where shear key failures are suspected. Based on the understanding of deterioration developed through study of deteriorated adjacent box beam bridges, improved inspection and load rating procedures are provided along with design recommendations for the next generation of box beam bridges

Load Distribution of Adjacent Prestressed Concrete Box Beam Bridges

One of the most common bridge types is the adjacent prestressed concrete box beam bridge because the system is economical and simple to build; over 43,000 are currently in service within the US. However, they are highly susceptible to strand corrosion and concrete deterioration which can result in early loss of load capacity. Therefore, an experimental program sponsored by the Indiana Department of Transportation (INDOT) was initiated to determine the behavior of deteriorated beams and develop recommendations for load rating and design of this bridge type. Displacement sensors were installed on a bridge in service to measure its deformation under load. Modifications of the bridge condition were made in phases. These phases included the initial condition, removal of the asphalt layer, cutting of the shear keys (beam joint), and construction of a concrete deck. The bridge used in this project was constructed of seven adjacent box beams, with a length of forty feet. Finally, after comparing the results, the change in load distribution was evaluated to determine how much the shear keys contribute to this, and if the addition of a concrete deck was an appropriate rehabilitation solution for the structure

Evaluation and Structural Behavior of Deteriorated Precast, Prestressed Concrete Box Beams

Adjacent precast, prestressed box beam bridges have a history of poor performance and have been observed to exhibit common types of deterioration including longitudinal cracking, concrete spalling, and deterioration of the concrete top flange. The nature of these types of deterioration leads to uncertainty of the extent and effect of deterioration on structural behavior. Due to limitations in previous research and understanding of the strength of deteriorated box beam bridges, conservative assumptions are being made for the assessment and load rating of these bridges. Furthermore, the design of new box beam bridges, which can offer an efficient and economical solution, is often discouraged due to poor past performance. Therefore, the objective of this research is to develop improved recommendations for the inspection, load rating, and design of adjacent box beam bridges. Through a series of bridge inspections, deteriorated box beams were identified and acquired for experimental testing. The extent of corrosion was determined through visual inspection, non-destructive evaluation, and destructive evaluation. Non-destructive tests (NDT) included the use of connectionless electrical pulse response analysis (CEPRA), ground penetrating radar (GPR), and half-cell potentials. The deteriorated capacity was determined through structural testing, and an analysis procedure was developed to estimate deteriorated behavior. A rehabilitation procedure was also developed to restore load transfer of adjacent beams in cases where shear key failures are suspected. Based on the understanding of deterioration developed through study of deteriorated adjacent box beam bridges, improved inspection and load rating procedure are provided along with design recommendations for the next generation of box beam bridges