1. Report No.
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`2. Government Accession No.
`
`3. Recipient’s Catalog No.
`
`Technical Report Documentation Page
`
`FHWA/TX-02/1852-1
`4. Title And Subtitle
`
`Structural Lightweight Concrete Prestressed Girders and Panels
`
`7. Author(s)
`
`D. B. Thatcher, J. A. Heffington, R. T. Kolozs, G. S. Sylva III,
`J. E. Breen, and N. H. Burns
`
`9. Performing Organization Name and Address
` Center for Transportation Research
` The University of Texas at Austin
` 3208 Red River, Suite 200
` Austin, TX 78705-2650
`12. Sponsoring Agency Name and Address
`
` Texas Department of Transportation
` Research and Technology Implementation Office
` P.O. Box 5080
` Austin, TX 78763-5080
`
`15. Supplementary Notes
`
`5. Report Date
`
`September 2001
`Revised January 2002
`
`6. Performing Organization Code
`
`8. Performing Organization Report No.
`
`Research Report 1852-1
`
`10. Work Unit No. (TRAIS)
`11. Contract or Grant No.
`
` Research Project 0-1852
`
`13. Type of Report and Period Covered
`
`Research Report (9/99-8/01)
`
`14. Sponsoring Agency Code
`
`
`
`Project conducted in cooperation with the U.S. Department of Transportation, Federal Highway Administration,
`and the Texas Department of Transportation.
`
`16. Abstract
`
`$7 6/4368 /436/7 8/ 97/7 30 1 4/6036+2-/ 18;/18 -32-6/8/ (cid:21)0- ን 

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`4+2/7
`
`
`79+6304/682/288/6+896/32+44-+8323018;/18-32-6/8/2,6.1/+44-+832771:/2
`$/6/79872.-+8/+
`29,/63079--/7709+44-+8327+7;/+7+0/;-+98327
`$/./:/34/2830

47+2.

47/797213-+
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`"/79872.-+8/.8+8

47;+7+1./4/2.+,/+9
`
`'36+,8308//7;+7+./59+8/&+2.+7/6/730,/+7/-8327&2-9.2173/496437/091-321/78/./,/67&
`;/6/79--/7709-+7892./64+28-32.8327
`
`
`'/2+44/.246/8/2732/.16./67&8/86+270/6/218036W(2786+2.7;+70392.83,/

4/6-/28321/68+28/#$
`6/596//28
`/:/34/28/2187&3/28-+4+-8/7&+2.3+.(./0/-832-96:/7;/6/:/67+683837/30236+;/18
`-32-6/8/16./67
`18;/18-32-6/8/97/246/-+78./-4+2/72.-+8/.8/86+270/6/218307+/6786+2.7;+7+./59+8/
`
`$/ 09 -+-9+8/. 98+8/ 3/28 -+4+-8 30 16./67 ;8 18;/18 -32-6/8/ ./- 4+2/7 ;+7 ./:/34/.
`  #9- 4+2/7
`-39. ,/ 97/. 28/6-+21/+, ;8 236+;/18 -32-6/8/ 4+2/7 9721 -966/28 ./712 6/596//287 +7 321 +7 8/ 0/96+
`8/27/786/778792./609../-3+.+6/7+870/.
`
`
`$/ 6/4368 6/-3/2.7 8+8 #$ -+21/ 8/ 3./ 036 -+-9+821 ./:/34/28 /218 036 46/786/7721 786+2. 83 +2
`/46/7732 -328+221 8/ -32-6/8/ 3.997 30 +78-8
`  $7 ;39. +/ 8 +44-+,/ 83 ,38 236+;/18 +2.
`18;/18-32-6/8/
`09896/6/4368;.7-977/-323-+2+770+-8367
`
`
`17. Key Words
`
`18. Distribution Statement
`
`lightweight concrete bridges, pretensioned
`girders, pretensioned deck panels, transfer
`length, development length, lightweight
`concrete mix design
`
`No restrictions. This document is available to the public
`through the National Technical Information Service,
`Springfield, Virginia 22161.
`
`19. Security Classif. (of report)
`
`20. Security Classif. (of this page)
`
`21. No. of pages
`
`22. Price
`
`
`
`Unclassified
`
`
`
`Unclassified
`
`208
`
`Form DOT F 1700.7 (8-72)
`
`Reproduction of completed page authorized
`
`Metromont Ex-1014, p.1
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`
`

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`Metromont Ex-1014, p.2
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`Metromont Ex-1014, p.2
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`

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`RESEARCH REPORT 1852-1
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`STRUCTURAL LIGHTWEIGHT CONCRETE
`
`PRESTRESSED GIRDERS AND PANELS
`
`
`D. B. Thatcher, J. A. Heffington, R. T. Kolozs, G. S. Sylva III,
`J. E. Breen, and N. H. Burns
`
`
`
`
`
`
`CENTER FOR TRANSPORTATION RESEARCH
`
`B U R E A U O F E N G I N E E R I N G R E S E A R C H
`
`T H E U N I V E R S I T Y O F T E X A S A T A U S T I N
`
`
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`
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`S E P T E M B E R 2 0 0 1
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`R E V I S E D J A N U A R Y 2 0 0 2
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`Metromont Ex-1014, p.3
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`Metromont Ex-1014, p.4
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`Metromont Ex-1014, p.4
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`

`

`
`
`
`
`
`
`
`
`STRUCTURAL LIGHTWEIGHT CONCRETE
`
`PRESTRESSED GIRDERS AND PANELS
`
`by
`
`
`
`D. B. Thatcher, J. A. Heffington, R. T. Kolozs,
`G. S. Sylva III, J. E. Breen, and N. H. Burns
`
`Research Report 1852-1
`
`Research Project 0-1852
`
`
`PRESTRESSED STRUCTURAL LIGHTWEIGHT CONCRETE BEAMS
`
`conducted for the
`
`Texas Department of Transportation
`
`
`
`in cooperation with the
`
`U.S. Department of Transportation
`Federal Highway Administration
`
`
`
`
`
`by the
`
`CENTER FOR TRANSPORTATION RESEARCH
`BUREAU OF ENGINEERING RESEARCH
`THE UNIVERSITY OF TEXAS AT AUSTIN
`
`
`
`
`
`September 2001
`
`Revised January 2002
`
`iii
`
`Metromont Ex-1014, p.5
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`

`

`Research performed in cooperation with the Texas Department of Transportation and the U.S. Department of
`Transportation, Federal Highway Administration.
`
`ACKNOWLEDGEMENTS
`
`We greatly appreciate the financial support from the Texas Department of Transportation that made this
`project possible. The support of the project director, Thomas Rummell (BRG), program coordinator,
`Michael O'Toole (BRG), and program advisor, Joe Roche (CST), is also very much appreciated. The
`authors also greatly appreciate the enthusiastic participation of Dr. Ramon L. Carrasquillo in the early
`stages of the project.
`
`DISCLAIMER
`
`The contents of this report reflect the views of the authors, who are responsible for the facts and the
`accuracy of the data presented herein. The contents do not necessarily reflect the view of the Federal
`Highway Administration or the Texas Department of Transportation. This report does not constitute a
`standard, specification, or regulation.
`
`
`
`
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`
`
`
`
`
`
`
`
`NOT INTENDED FOR CONSTRUCTION,
`
`PERMIT, OR BIDDING PURPOSES
`
`
`
`J. E. Breen, Texas P.E. #18479
`
`N. H. Burns, Texas P.E. #20801
`Research Supervisors
`
` iv
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`Metromont Ex-1014, p.6
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`

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`TABLE OF CONTENTS
`
`
`
`CHAPTER 1: INTRODUCTION AND BACKGROUND .....................................................................1
`
`1.1 LIGHTWEIGHT CONCRETE USE IN PRESTRESSED CONCRETE GIRDERS ...........................................1
`
`1.2 LIGHTWEIGHT CONCRETE MATERIAL ..............................................................................................1
`
`1.3 CONCRETE STRENGTH......................................................................................................................1
`1.3.1 Normal Strength Concrete ................................................................................................................... 1
`1.3.2 High Performance Concrete................................................................................................................. 2
`
`1.4 USE OF HIGH PERFORMANCE LIGHTWEIGHT CONCRETE .................................................................2
`
`1.5 BACKGROUND ..................................................................................................................................2
`1.5.1 Lightweight Concrete Background ...................................................................................................... 3
`1.5.2 Deck Panels Background ..................................................................................................................... 3
`1.5.3 Development Length Background ....................................................................................................... 3
`
`1.6 OBJECTIVES ......................................................................................................................................4
`
`1.7 SCOPE OF PROJECT ...........................................................................................................................5
`
`1.8 ORGANIZATION OF REPORT..............................................................................................................5
`
`CHAPTER 2: LITERATURE REVIEW ..................................................................................................7
`
`2.1 GENERAL RESEARCH ON HIGH-STRENGTH LIGHTWEIGHT CONCRETE ............................................7
`2.1.1 Martinez Morales (1982) [50].............................................................................................................. 7
`2.1.2 Shideler (1957) [70] ............................................................................................................................. 8
`2.1.3 Zhang and Gjørv (1993) [81] ............................................................................................................... 8
`2.1.4 Burg, Cichanski, and Hoff (1998) [23] ................................................................................................ 8
`2.1.5 Nilsen and Aïtcen (1992) [59].............................................................................................................. 9
`2.1.6 Zhang and Gjørv (1991) [80] ............................................................................................................... 9
`2.1.7 Mircea, Ioani, Filip, and Pepenar (1994) [53]...................................................................................... 9
`2.1.8 Reichard (1967) [64].......................................................................................................................... 10
`
`2.2 PERFORMANCE OF LIGHTWEIGHT CONCRETE IN PRESTRESSED MEMBERS ...................................10
`2.2.1 Lightweight Aggregate Bridge Construction and Performance in Europe......................................... 10
`2.2.2 Lightweight Concrete Bridge Performance in United States ............................................................. 11
`2.2.3 Lightweight Concrete Bridge Performance in Texas ......................................................................... 13
`
`CHAPTER 3: MIX DESIGNS .................................................................................................................15
`
`3.1 FIRST ITERATION ............................................................................................................................15
`3.1.1 Decisions on Materials....................................................................................................................... 15
`3.1.2 Initial Variables.................................................................................................................................. 16
`3.1.3 Procedures.......................................................................................................................................... 18
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`Metromont Ex-1014, p.7
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`3.1.4 Initial Results ..................................................................................................................................... 20
`
`3.2 SECOND ITERATION........................................................................................................................26
`3.2.1 Modification of Variables .................................................................................................................. 27
`3.2.2 Procedures.......................................................................................................................................... 31
`3.2.3 Results................................................................................................................................................ 32
`
`3.3 THIRD ITERATION ...........................................................................................................................37
`3.3.1 Modification of Variables .................................................................................................................. 37
`3.3.2 Procedures.......................................................................................................................................... 39
`3.3.3 Properties ........................................................................................................................................... 39
`
`CHAPTER 4: 6000 PSI MIX FIELD TRIALS......................................................................................43
`
`4.1 MIX PROPORTIONS .........................................................................................................................43
`
`4.2 PROPERTIES ....................................................................................................................................43
`4.2.1 Workability ........................................................................................................................................ 43
`4.2.2 Mechanical Properties........................................................................................................................ 45
`4.2.3 Creep and Shrinkage .......................................................................................................................... 47
`
`4.3 JOBSITE PERFORMANCE .................................................................................................................50
`4.3.1 Workability ........................................................................................................................................ 50
`4.3.2 Compressive Strength ........................................................................................................................ 52
`4.3.3 Tensile Strength ................................................................................................................................. 53
`
`CHAPTER 5: NOMINAL 8000 PSI MIX FIELD TRIALS .................................................................55
`
`5.1 MIX PROPORTIONS .........................................................................................................................55
`
`5.2 PROPERTIES ....................................................................................................................................55
`5.2.1 Workability ........................................................................................................................................ 55
`5.2.2 Mechanical Properties........................................................................................................................ 56
`5.2.3 Creep and Shrinkage .......................................................................................................................... 59
`
`5.3 CASTING YARD PERFORMANCE .....................................................................................................60
`5.3.1 Workability ........................................................................................................................................ 60
`5.3.2 Compressive Strength ........................................................................................................................ 63
`5.3.3 Flexural and Split Cylinder Tensile Strength ..................................................................................... 64
`
`CHAPTER 6: CONCLUSIONS FOR THE MIX DESIGN PORTION OF THE PROJECT .........67
`
`6.1 SUMMARY ......................................................................................................................................67
`
`6.2 CONCLUSIONS ................................................................................................................................67
`6.2.1 6000 psi Mix ...................................................................................................................................... 67
`6.2.2 Nominal 8000 psi Mix ....................................................................................................................... 68
`
`6.3
`
`IMPLEMENTATION ..........................................................................................................................68
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`Metromont Ex-1014, p.8
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`

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`6.4 RECOMMENDATIONS FOR FUTURE STUDY .....................................................................................69
`
`CHAPTER 7: TRANSFER AND DEVELOPMENT LENGTH BACKGROUND ...........................71
`
`7.1
`
`INTRODUCTION ...............................................................................................................................71
`
`7.2 BACKGROUND ................................................................................................................................71
`7.2.1 Lightweight Concrete......................................................................................................................... 71
`7.2.2 Bond Behavior ................................................................................................................................... 71
`
`7.3 LITERATURE REVIEW .....................................................................................................................73
`7.3.1 Use of Lightweight Concrete ............................................................................................................. 74
`7.3.2 Testing of Lightweight Concrete Beams............................................................................................ 74
`7.3.3 Use of Deck Panels ............................................................................................................................ 75
`7.3.4 Transfer and Development Length Studies ........................................................................................ 76
`
`CHAPTER 8: BEAM AND COMPONENT DESIGN AND CONSTRUCTION..............................81
`
`8.1
`
`INTRODUCTION ...............................................................................................................................81
`8.1.1 Nomenclature ..................................................................................................................................... 81
`8.1.2 Number of Beams .............................................................................................................................. 81
`8.1.3 Variables ............................................................................................................................................ 82
`
`8.2 DEVELOPMENT OF 20-FT DESIGNS .................................................................................................82
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`8.3 DEVELOPMENT OF 40-FT DESIGNS ................................................................................................84
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`8.4 LIGHTWEIGHT DECK PANEL DESIGN .............................................................................................87
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`8.5 MATERIAL PROPERTIES..................................................................................................................89
`8.5.1 Concrete ............................................................................................................................................. 89
`8.5.2 Prestressing Steel ............................................................................................................................... 90
`8.5.3 Reinforcing Steel ............................................................................................................................... 90
`
`8.6 FORMING, PLACEMENT, AND CURING OF CONCRETE ....................................................................91
`
`CHAPTER 9: TRANSFER LENGTH TESTING..................................................................................93
`
`9.1
`
`INTRODUCTION ...............................................................................................................................93
`
`9.2
`
`INSTRUMENTATION AND MEASUREMENT FOR DETERMINING TRANSFER LENGTH OF BEAMS .....93
`9.2.1 DEMEC Strain Measurements ........................................................................................................... 93
`9.2.2 Draw-In Measurements...................................................................................................................... 94
`
`9.3 DATA REDUCTION ..........................................................................................................................96
`9.3.1 DEMEC Strain Profile Smoothing..................................................................................................... 96
`9.3.2 Effect of Elastic Shortening on Draw-In Data ................................................................................... 97
`
`9.4 METHODS TO DETERMINE TRANSFER LENGTH..............................................................................98
`9.4.1 95% Average Maximum Strain.......................................................................................................... 98
`9.4.2 Slope-Intercept ................................................................................................................................... 99
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`Metromont Ex-1014, p.9
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`9.4.3 Strand Draw-In................................................................................................................................. 100
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`9.5 BEAM TEST RESULTS ...................................................................................................................100
`9.5.1 DEMEC Strain Measurement Results.............................................................................................. 100
`9.5.2 Draw-In Results ............................................................................................................................... 102
`
`9.6 DISCUSSION OF BEAM TEST RESULTS..........................................................................................104
`9.6.1 Comparison of Methods................................................................................................................... 104
`9.6.2 Comparison to Concrete Properties ................................................................................................. 104
`9.6.3 Comparison to Transfer Length Equations ...................................................................................... 106
`
`9.7 TRANSFER LENGTH IN LIGHTWEIGHT CONCRETE DECK PANELS [85] ........................................112
`9.7.1 Transfer Length Test Setup.............................................................................................................. 113
`9.7.2 Test Procedure ................................................................................................................................. 113
`9.7.3 Test Results...................................................................................................................................... 114
`9.7.4 Conclusion of the Panel Transfer Length Tests ............................................................................... 115
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`CHAPTER 10: DEVELOPMENT LENGTH TESTING ...................................................................117
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`10.1 INTRODUCTION .............................................................................................................................117
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`10.2 TEST SPECIMENS ..........................................................................................................................117
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`10.2.1 Concrete Mix.....................................................................................................................118
`10.2.2 Cross Section Details.........................................................................................................119
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`10.2.3 Prestressing Strands...........................................................................................................120
`10.2.4 Reinforcement ...................................................................................................................120
`10.2.5 Deck & Panels ...................................................................................................................122
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`10.3 TEST SET-UP .................................................................................................................................124
`10.3.1 General Layout ..................................................................................................................124
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`10.3.2 Loading Apparatus ............................................................................................................125
`10.3.3 Instrumentation..................................................................................................................128
`10.3.4 Data Acquisition Equipment .............................................................................................134
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`10.4 TEST PROCEDURE.........................................................................................................................135
`10.4.1 Loading..............................................................................................................................135
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`10.4.2 Cracking ............................................................................................................................135
`10.4.3 Failure Limit......................................................................................................................135
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`CHAPTER 11: DEVELOPMENT LENGTH TEST RESULTS .......................................................137
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`11.1 INTRODUCTION .............................................................................................................................137
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`11.2 TEST RESULTS ..............................................................................................................................137
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`11.2.1 Beam Properties ................................................................................................................138
`11.2.2 Initial Stiffness ..................................................................................................................140
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`Metromont Ex-1014, p.10
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`

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`11.2.3 Cracking and Ultimate Moment and Load ........................................................................142
`11.2.4 Strand Elongation ..............................................................................................................142
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`11.2.5 Maximum Strain and Displacement ..................................................................................144
`11.2.6 Crack Patterns....................................................................................................................147
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`11.2.7 Strand Slip .........................................................................................................................150
`11.2.8 Failure Types.....................................................................................................................151
`11.2.9 Support Spalling ................................................................................................................153
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`11.3 DISCUSSION ..................................................................................................................................156
`11.3.1 Test Results .......................................................................................................................156
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`11.3.2 Support Spalling ................................................................................................................159
`11.3.3 Lightweight Deck Panels...................................................................................................160
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`CHAPTER 12: CONCLUSIONS FOR THE BEAM PORTION OF THE PROJECT..................161
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`12.1 INTRODUCTION .............................................................................................................................161
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`12.2 SUMMARY ....................................................................................................................................161
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`12.2.1 Lightweight Concrete ........................................................................................................161
`12.2.2 Transfer Length .................................................................................................................162
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`12.2.3 Development Length .........................................................................................................162
`12.2.4 Lightweight Panels ............................................................................................................163
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`12.3 CONCLUSIONS ..............................................................................................................................163
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`12.3.1 Transfer Length .................................................................................................................163
`12.3.2 Development Length .........................................................................................................164
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`12.3.3 Ultimate Moment Capacity ...............................................................................................164
`12.3.4 Recommendations .............................................................................................................164
`12.3.5 Future Study ......................................................................................................................165
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`Appendix A: Notation ..............................................................................................................................167
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`Appendix B: Mix Designs........................................................................................................................169
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`Appendix C: Test Results for Mixes ........................................................................................................173
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`Appendix D: Concrete Strain Profiles......................................................................................................179
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`References .................................................................................................................................................187
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`Metromont Ex-1014, p.12
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`Metromont Ex-1014, p.12
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`LIST OF FIGURES
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`Figure 3.1
`
`Aggregate Soaking in Tub Before Drying ..........................................................................18
`
`Figure 3.2
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`Concrete Mixer ...................................................................................................................19
`
`Figure 3.3
`
`Apparatus for Compressive Test.........................................................................................20
`
`Figure 3.4
`
`Compressive Strengths of Initial 6000 psi Mixes ...............................................................21
`
`Figure 3.5
`
`Compressive Strength of Repeated Mixes in Initial Series.................................................21
`
`Figure 3.6
`
`Compressive Strengths of 8000 psi Concrete Mixes ..........................................................22
`
`Figure 3.7
`
`Test Setup for Modulus of Elasticity ..................................................................................23
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`Figure 3.8 Modulus of Elasticity for 6000 psi Mixes in First Iteration................................................23
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`Figure 3.9 Modulus of Elasticity of 8000 psi Initial Concrete Mixes ..................................................24
`
`Figure 3.10
`
`Test Setup for Splitting Tensile Test ..................................................................................24
`
`Figure 3.11 Machine Used for Modulus of Rupture Tests.....................................................................25
`
`Figure 3.12
`
`Tensile Tests for Initial 6000 psi Mixes .............................................................................25
`
`Figure 3.13
`
`Tensile Properties for Initial 8000 psi Mixes......................................................................26
`
`Figure 3.14 Appearance and Maximum Size of Clodine Aggregate......................................................29
`
`Figure 3.15 Grading Curve for Clodine Aggregate................................................................................29
`
`Figure 3.16 Appearance and Maximum Size of Streetman Aggregate ..................................................30
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`Figure 3.17 Grading Curve for Streetman Aggregate ............................................................................30
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`Figure 3.18 Appearance and Maximum Size of Western Aggregate.....................................................31
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`Figure 3.19 Grading Curve for Western Aggregate ...............................................................................31
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`Figure 3.20 Drying of Aggregate on Screened Bed ...............................................................................32
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`Figure 3.21 Age-Strength Curves for 0.28 Water/Cement Ratio Mixes from Second Iteration Mix
`