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RECOMMENDATIONS FOR THE CONNECTION BETWEEN FULL-DEPTH PRECAST BRIDGE DECK PANEL SYSTEMS AND PRECAST I-BEAMS
RECOMMENDATIONS
FOR THE CONNECTION
BETWEEN FULL-DEPTH PRECAST
BRIDGE DECK PANEL SYSTEMS
AND PRECAST I-BEAMS
FINAL
CONTRACT REPORT
VTRC 07-CR17
http://www.virginiadot.org/vtrc/main/online_reports/pdf/07-cr17.pdf
DON P. SCHOLZ
Graduate Research Engineer
JOSEPH A. WALLENFELSZ
Graduate Research Engineer
CINTIA LIJERON
Undergraduate Research Assistant
CARIN L. ROBERTS-WOLLMANN, Ph.D., P.E.
Associate Professor
Via Department of Civil and Environmental Engineering
Virginia Polytechnic Institute & State University Standard Title Page - Report on Federally Funded Project
1. Report No.:
2. Government Accession No.
3. Recipients Catalog No.
FHWA/VTRC 07-CR17



4. Title and Subtitle:
5. Report Date:
Recommendations for the Connection Between Full-Depth Precast Bridge
Deck Panel Systems and Precast I-Beams
June 2007

6. Performing Organization Code


7. Author(s):
Don P. Scholz, Joseph A. Wallenfelsz, Cintia Lijeron, and
Carin L. Roberts-Wollmann

8. Performing Organization Report No.
VTRC 07-CR17
9. Performing Organization and Address:
10. Work Unit No. (TRAIS)
Virginia Transportation Research Council

530 Edgemont Road
11. Contract or Grant No.:
Charlottesville, VA 22903

79867
12. Sponsoring Agencies' Name and Address:
13. Type of Report and Period Covered
Virginia Department of Transportation
Federal Highway Administration Final Contract
1401 E. Broad Street
400 North 8th Street, Room 750
14. Sponsoring Agency Code
Richmond, VA 23219
Richmond, VA 23219-4825

15. Supplementary Notes



16. Abstract
Precast bridge deck panels can be used in place of a cast-in-place concrete deck to reduce bridge closure times for deck
replacements or new bridge construction. The panels are prefabricated at a precasting plant providing optimal casting and curing
conditions, which should result in highly durable decks. Precast panels can be either full-depth or partial-depth. Partial-depth
panels act as a stay-in-place form for a cast-in-place concrete topping. This study investigated only the behavior of full-depth
precast panels.

The research described in this report had two primary objectives. The first was to develop a performance specification for
the grout that fills the haunch between the top of the beam and the bottom of the deck panel, as well as the horizontal shear
connector pockets and the panel-to-panel joints. Tests were performed using standard or modified ASTM tests to determine basic
material properties on eight types of grout. The grouts were also used in tests that approximated the conditions in a deck panel
system. Based on these tests, requirements for shrinkage, compressive strength, and flow were established for the grouts. It was
more difficult to establish a test method and an acceptable performance level for adhesion, an important property for the strength and
durability of the deck panel system.

The second objective was to quantify the horizontal shear strength of the connection between the deck panel and the beam
prestressed concrete beams. This portion of the research also investigated innovative methods of creating the connection. Push-off
tests were conducted using several types of grout and a variety of connections. These tests were used to develop equations for the
horizontal shear strength of the details. Two promising alternate connections, the hidden pocket detail and the shear stud detail,
were tested for constructability and strength.

The final outcome of this study a set of recommendations for the design, detailing, and construction of the connection between
full-depth precast deck panels and prestressed concrete I-beams. If designed and constructed properly, the deck panel system is an
excellent option when rapid bridge deck construction or replacement is required.
17 Key Words
18. Distribution Statement
Full-depth precast bridge deck panels, grout performance
specification, deck panel girder connection, horizontal shear
strength
No restrictions. This document is available to the public through
NTIS, Springfield, VA 22161.
19. Security Classif. (of this report)
20. Security Classif. (of this page)
21. No. of Pages
22. Price
Unclassified
Unclassified
78

Form DOT F 1700.7 (8-72)
Reproduction of completed page authorized

FINAL CONTRACT REPORT

RECOMMENDATIONS FOR THE CONNECTION BETWEEN FULL-DEPTH
PRECAST BRIDGE DECK PANEL SYSTEMS AND PRECAST I-BEAMS

Don P. Scholz
Graduate Research Engineer

Joseph A. Wallenfelsz
Graduate Research Engineer

Cintia Lijeron
Undergraduate Research Assistant

Carin L. Roberts-Wollmann, Ph.D., P.E.
Associate Professor

Via Department of Civil and Environmental Engineering
Virginia Polytechnic Institute & State University



Project Manager
Rodney Davis, Ph.D., P.E., Virginia Transportation Research Council








Virginia Transportation Research Council
(A partnership of the Virginia Department of Transportation
and the University of Virginia since 1948)

In Cooperation with the U.S. Department of Transportation
Federal Highway Administration

Charlottesville, Virginia

June 2007
VTRC 07-CR17

Contract Research Sponsored by
the Virginia Transportation Research Council
ii

NOTICE

The project that is the subject of this report was done under contract for the Virginia
Department of Transportation, Virginia Transportation Research Council. 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 official views or policies of the
Virginia Department of Transportation, the Commonwealth Transportation Board, or the Federal
Highway Administration. This report does not constitute a standard, specification, or regulation.

Each contract report is peer reviewed and accepted for publication by Research Council
staff with expertise in related technical areas. The contractor performs final editing and
proofreading of the report.















Copyright 2007 by the Commonwealth of Virginia.
All rights reserved.

iii
ABSTRACT
Precast bridge deck panels can be used in place of a cast-in-place concrete deck to reduce
bridge closure times for deck replacements or new bridge construction. The panels are
prefabricated at a precasting plant providing optimal casting and curing conditions, which should
result in highly durable decks. Precast panels can be either full-depth or partial-depth. Partial-
depth panels act as a stay-in-place form for a cast-in-place concrete topping. This study
investigated only the behavior of full-depth precast panels.

The research described in this report had two primary objectives. The first was to
develop a performance specification for the grout that fills the haunch between the top of the
beam and the bottom of the deck panel, as well as the horizontal shear connector pockets and the
panel-to-panel joints. Tests were performed using standard or modified ASTM tests to
determine basic material properties on eight types of grout. The grouts were also used in tests
that approximated the conditions in a deck panel system. Based on these tests, requirements for
shrinkage, compressive strength, and flow were established for the grouts. It was more difficult
to establish a test method and an acceptable performance level for adhesion, an important
property for the strength and durability of the deck panel system.

The second objective was to quantify the horizontal shear strength of the connection
between the deck panel and the beam prestressed concrete beams. This portion of the research
also investigated innovative methods of creating the connection. Push-off tests were conducted
using several types of grout and a variety of connections. These tests were used to develop
equations for the horizontal shear strength of the details. Two promising alternate connections,
the hidden pocket detail and the shear stud detail, were tested for constructability and strength.

The final outcome of this study a set of recommendations for the design, detailing, and
construction of the connection between full-depth precast deck panels and prestressed concrete I-
beams. If designed and constructed properly, the deck panel system is an excellent option when
rapid bridge deck constru