Research Activities: 2012

Self-Consolidating Concrete for Connecting Precast Concrete Deck Panels and I-Girders

 Status Complete                 View Final Report: PDF
Sequential Number R328
Identification Number 00041168
Matching Research Agency

Nebraska Department of Roads and Precast Concrete Association via University of Nebraska-Lincoln

Principal Investigator

Kamal H. Khayat
Vernon and Maralee Jones Professor
Missouri University of Science and Technology
224 Engineering Research Lab
Rolla, MO 65409
(573) 341-6223

Student Involvement

One graduate student


Project Objective

The objective of this project is to experimentally investigate the effectiveness of using SCC to fill the gap between the precast concrete girder and precast deck soffit as well as the shear pockets in the deck panels. This includes developing a specific SCC mixture(s) for this special application and evaluating its flowability and pumpability in small–scale and full-scale laboratory settings. Sequence of pumping SCC as well as its quality control and quality assurance procedures will be investigated and presented to bridge owners/contractors.

Both a concrete-based mixture and a mortar-based mixture will be developed and fully tested for fresh and hardened properties affecting the fast bridge construction methodology. The robustness of these mixtures to changes of temperature, water content, and superplasticizer content will also be determined. This investigation is crucial for the success of such a great system and for avoiding any problems that might occur due to the unfamiliarity of the involved parties with these new developments.


Project Abstract
Existing precast concrete deck systems are either partial depth or full-depth with open channels/pockets that require cast-in-place concrete and deck overlay. There operations negatively affect the quality and speed of construction, which are the main goals of using precast deck systems.  The Kearney East Bypass in Kearney, NE is the first bridge project that uses the latest developments in full-depth precast concrete deck systems for precast/prestressed concrete girder bridges. These developments include using full-depth full-width deck panels with covered individual pockets at 4 ft spacing eliminating the need for deck overlay or exposed cast-in-place concrete. Self-consolidating concrete (SCC) is vital to the success of the new deck system to fill the deck pockets and the large gap between the deck soffit and precast concrete girders without the need for expensive commercial grouts. A research project titled “Implementation of Precast Deck Panel NUDECK” is currently being conducted at the University of Nebraska – Lincoln (UNL) and sponsored by Nebraska Department of Roads (NDOR) to address design and detailing of the new deck system to be implemented in the Kearney Easy Bypass by the end of 2013. However, the constructability of the developed deck system needs to be investigated to improve its competitiveness against cast-in-place concrete decks.

Relationship to other Research/Projects

This is a stand alone project.


Transportation-Related Keywords

Fast bridge construction, Grouting, Pumping, Self-consolidating concrete, Q/C&Q/A

Technology Transfer Activities

Final report will be published on website of the NUTC. Two publications are expected out this research that will be submitted to The TRB Record and other leading journals. The work will be presented at the 2014 CIES Conference.


Project Deliverables

Task #1: Review the literature of grouting materials currently used/specified by various transportation agencies for precast concrete deck systems and determine their performance requirements.

Task #2: Develop SCC and mortar mixtures that satisfy the performance requirements determined in task #1.

Task #3: Investigate the production and placement of optimized SCC and mortar mixtures.

Task #4: Develop draft specifications for pumping SCC in precast concrete deck applications.

Task #5: Erect the 60 ft long specimen consists of one I-girder, three typical panels, and two end panels.

Task #6: Demonstrate to bridge owners, producers, contractors, and pumping suppliers in a full-scale setting the procedures of pumping SCC in the 60 ft long specimen.

Task #7: Document the presented construction procedures through videos and photos and prepare final specifications that document the recommended practice in implementing SCC in the precast deck system applications.


Anticipated Benefits

This investigation is essential for the success of a newly proposed method of fast bridge deck system that can enable faster and more cost-effective assembley of bridge girder and deck elements


Project Start Date: 01/01/2013
Project End Date: