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An Innovative Design Concept For Improving The Durability of Concrete Bridges
An Innovative Design Concept For Improving The Durability of Concrete Bridges
Johannes Berger*
Sebastian Bruschetini-Ambro
Johann Kollegger
DOI: 10.1002/suco.201100022
Introduction
Research programme
The research project Prestressed concrete bridges without reinforcing steel, sealing and pavement was initiated
in order to improve the durability of concrete bridges. To
achieve more durable concrete bridges, it is suggested that
concrete bridges should be built with the following characteristics:
The bridge is prestressed and has no mild steel reinforcement.
The prestressing steel is arranged in plastic ducts and is
also fully encapsulated in plastic at the anchorages.
There is no longer a need for sealing because there is no
reinforcement in the structure that is endangered by
corrosion.
There is no longer a need for a pavement to protect the
membrane. It is proposed to build the pavement with
high-quality concrete in a composite form with the
structure as the upper part of the bridge.
The edge beam is an integral part of the structure.
Bridges with short spans can also be designed as integral
bridges.
During construction, the economic advantage of the project consists of savings with regard to construction materials, i.e. neither reinforcing steel nor insulation, expansion
joints or edge beams are needed. Considering the future
savings in operation and maintenance, as well as the unlimited lifetime, the bridge will show a superior economic
performance compared to conventional bridge structures.
2.1
Large-scale tests
Large-scale tests were performed to obtain practical values for the serviceability, ductility and loadbearing capacity of this structural system, see Fig. 1. The design of the
specimens was inspired by the Egg-Graben Bridge. The dimensions were 15.3 0.63 0.5 m (L W D) and the effective span of the continuous beam was 7.5 m. Forces
were applied at distances of 2.5 m from the intermediate
support. For prestressing, a post-tensioning system with
plastic ducts and fully encapsulated anchorages was used.
Each tendon consisted of 7 strands of 150 mm2, grade
1570/1770. The specimen was concentrically prestressed
with straight tendon guidance and was deviated over the
final 1.5 m. The reinforcing bars were arranged to prevent
2011 Ernst & Sohn Verlag fr Architektur und technische Wissenschaften GmbH & Co. KG, Berlin Structural Concrete 12 (2011), No. 3
155
J. Berger/S. Bruschetini-Ambro/J. Kollegger An innovative design concept for improving the durability of concrete bridges
Span 1
7.5m
Span 2
2.5m
2.5m
7.5m
C30/37
0.50
Cross Section
0.08 0.34 0.08
Structural System
0.315 0.315
0.63m
700
600
Load [kN]
500
1st Crack
Span
400
300
1st Crack
Intermediate support
200
100
0
0
10
15
20
25
Displacement [mm]
Span 1
Span 2
splitting tensile stress in the anchorage area of the tendons. Grade C30/37concrete was used.
The company that later carried out the prestressing
work for the bridge was also involved in the production of
the specimens in order to gain experience at a very early
stage of the project with regard to the construction
process and the installation of a measuring system (electrically isolated tendons) for monitoring the corrosion protection. A detailed description of the tests and test results
can be found in [1].
156
slope due to the redistribution of the internal forces because of the cracked section at the intermediate support
area. The load was then increased until the first cracks
were visible in the span area, which took place at a force
of 420 kN. After that, the load-deflection relationship was
not linear any more because of the cracks, and a greater
increase in deformation occurred. The last load level
reached was F = 656 kN, with a maximum deflection of
umax = 21 mm, which corresponds to a ratio of l/357.
The achievement of the ultimate capacity was announced by the appearance of cracks (bending shear
cracks), spalling in the concrete compression zone and by
the rapid growth in deformations for an insignificant increase in load.
J. Berger/S. Bruschetini-Ambro/J. Kollegger An innovative design concept for improving the durability of concrete bridges
2.50m
2.50m
Span 2
Span 1
Moment [kNm]
800
MRm = 673 kNm
600
1st Crack
Intermediate support
100
200
6
10
12
0
200
1st Crack span
800
Strain []
Span 1: Concrete-C
Span 1: Tendon-C
Span 1: Tendon-T
Span 2: Concrete-C
Span 2: Tendon-C
Span 2: Tendon-T
800
600
Moment [kNm]
elastic relationship
100
1st Crack
Intermediate support
0.020
0.015
0.010
200
0.000
0
0.005
0.005
0.010
0.015
0.020
200
1st Crack span
400
elastic relationship
600
MRm = 673 kNm
800
Curvature [m1]
Span 1
Intermediate support
Span 2
157
J. Berger/S. Bruschetini-Ambro/J. Kollegger An innovative design concept for improving the durability of concrete bridges
Client:
Province of Salzburg
Contractor:
Tensioning:
Research:
Concept:
Planning
team
2.1.4 Moment-curvature
The moment-curvature relationship is shown in Fig. 5,
and knowledge of the stiffness can be gained from this relationship. The curvature of the cross-section at the intermediate support progressed linearly until the first crack
appeared and corresponds well with the calculated elastic
moment curvature = M/EI (Ec = 33 000 N/mm2). After
the appearance of the first crack, a significant drop in
stiffness is noticeable. Again, in the fully cracked state, a
nearly constant stiffness EI(II) can be observed; however, it
amounts to just 1/9 of the stiffness of the uncracked crosssection. The maximum curvature is max;support =
0.0195 m1. The relationship in the two spans is not completely identical. In the uncracked state, span 2 shows a
greater curvature than span 1. After the first cracks have
occurred, a contrasting behaviour can be observed.
2.2
The construction of crack-free concrete bridges with corrosion-resistant reinforcement can be accomplished according to the system described. The omission of reinforcing steel is regulated by standards such as EC2 [2, 3], and
the requirements of this structure regarding serviceability,
ductility and loadbearing capacity could be demonstrated
experimentally. It was also shown that by using prestressing only without further reinforcement, ductile behaviour
at the ultimate limit state can be achieved. The announcement of the failure by deformations, large crack widths
and, finally, through spalling of the concrete in the compression zone as required in the design of reinforced concrete structures, was sufficiently demonstrated by the tests.
The comparison of the ultimate load reached experimentally with the calculated ultimate load show that the calculations with mean values of material strengths are in good
accordance with the experimental values.
Construction
design:
Project data
Duration:
Sept 2007 Dec 2009
Bridge length: 50.68 m
3.1
Bridge design
Construction
Egg-Graben Bridge
158
3.2
3
Structural
calculations:
J. Berger/S. Bruschetini-Ambro/J. Kollegger An innovative design concept for improving the durability of concrete bridges
3.3
Analysis [5]
The design of the bridge was carried out with the loads according to Eurocode, taking into consideration the individual effects of dead load, wind load, temperature effects,
unusual effects and traffic loads on bridges, as regulated
by the Austrian Standard NORM EN 1991-2 [6]. The relevant forces for the design of the bridge resulted from
varying effects with regard to road traffic. Load model 1
(LM1) was used as the traffic load. Loading due to special
vehicles was not considered.
Due to the complex geometry, the forces were calculated using a finite element program in a 3D model. The
3D model corresponds to the actual geometry of the
bridge, only the transverse gradient was neglected. To verify the results, a 1 m strip of the bridge was analysed with
a program for the design of frame structures. Determina-
159
J. Berger/S. Bruschetini-Ambro/J. Kollegger An innovative design concept for improving the durability of concrete bridges
160
3.4
Construction work for the substructure began in the autumn of 2008. The unweathered rock was found 8 m below ground level and so extensive excavation work was required. The foundation consisted of a reinforced concrete
slab (L W D = 15.0 /5.0 2.0 m) on the rock. The
work for the falsework of the arch began the following
spring. During the concreting of the arch, the region
where the intersection of the arch with the superstructure
takes place was omitted. The intersection was cast simultaneously with the superstructure. In the steep region of
the arc, from the foundation to the rising wall, a wall formwork was used and filled with self-compacting concrete.
With regard to the assembly, particular attention was
necessary when the reinforcement for the arch was laid
because the starter bars for the pier walls were made of
stainless steel (1.4571, BST 500). To avoid galvanic corrosion [7], contact between normal reinforcing steel and
stainless steel reinforcement had to be ruled out. Conventional reinforcing steel was used for the arch because no
direct penetration of water contaminated with chloride
was expected and the geometry of the arch was designed
in such a way that no tensile stresses occurred under dead
load. Further, the material costs were much lower compared with those of stainless steel. Self-compacting concrete was also used for the pier walls reinforced with stainless steel. Due to the very thin cross-sectional dimensions
of the arch, which were possible only because of the special geometry of the arch, an accuracy of 10 mm was
specified for the construction.
After completing the formwork for the superstructure, the anchor pockets, which had been produced at the
factory, were mounted. For the anchorage of the longitudinal tendons, placed in the structure area above each other,
it was necessary to deviate them at both abutments in order to accommodate the anchor heads. The plastic duct
sections 5 m long were connected by mirror welding. The
sensitivity of the plastic ducts with regard to the thermal
expansion behaviour needed special attention. The thermal expansion of the ducts could be controlled as soon as
an orthogonal grid of tendons was formed and the strands
were inserted. For the location and the installation of the
tendons at the proper level, supports made of fibre-cement
blocks (cut lengths) were arranged at each intersection between longitudinal and transverse tendon, see Fig. 8.
The maximum distance between the supports for the
ducts was 0.80 m according to the approval [8]. Since the
distance between longitudinal tendons was 0.63 m, and
0.50 m between transverse tendons, it proved to be advantageous to support every intersection between tendons. To
ensure a flat contact area between fibre-cement block and
duct, plastic half-shells were clipped to the ribbed duct.
The fibre-cement blocks were attached by plastic cable
ties. The cross-connection of the ducts formed a stable
mesh, see Fig. 9.
J. Berger/S. Bruschetini-Ambro/J. Kollegger An innovative design concept for improving the durability of concrete bridges
Fig. 10. Stainless steel reinforcement to control tensile splitting in anchorage zones
161
J. Berger/S. Bruschetini-Ambro/J. Kollegger An innovative design concept for improving the durability of concrete bridges
The impedance between the strands and the steel reinforcing bars is measured. As there is no reinforcing steel
located in the structure, an additional stainless steel reinforcing bar was installed to take measurements. For the
Egg-Graben Bridge, five measurements have been carried
out so far. On average, the length-normalized electrical
resistance amounts to Rl,mean = 7500 km (Rl,min =
6800 km, Rl,max = 10 000 km). Fluctuations in the results are due to changing environmental conditions such
as humidity, rainfall, temperature or season. The value requested by the client was set at Rl,reqd > 300 km (= high
electrical insulation). The very high values measured are
due to the tightness of the plastic ducts. An EIT measuring
box has been installed so that it is possible to carry out further measurements in the future.
Conclusion
3.5
The post-tensioning kit used allowed the longitudinal tendons to be run electrically isolated. Using a system with
compatible plastic ducts and an anchor with plastic ducts
provides an opportunity for non-destructive monitoring of
corrosion protection of tendons by measuring the electrical resistance [10]. The use of electrically isolated tendons
permits checking of the electrical insulation and the tightness of plastic ducts, and thus facilitates measurements
with regard to the condition of a tendon during its entire
service life.
A decrease in the resistance indicates the ingress of
moisture into the duct. This therefore amounts to monitoring the corrosion protection of the prestressing steel.
162
Acknowledgments
The field tests were performed within a research project
which is funded by:
sterreichische Forschungsfrderungsgesellschaft mbH
(FFG)
Vereinigung der sterreichischen Zementindustrie
(VZ)
Bundesministerium fr Verkehr, Innovation und Technologie (BMVIT)
Land Salzburg, Abteilung 6, Landesbaudirektion, 6/23
Brckenbau
Autobahnen- und Schnellstrassen-Finanzierungs-Aktiengesellschaft (ASFINAG)
BB Infrastruktur Bau AG, ES-Brckenbau und konstruktiver Ingenieurbau
ALPINE Bau GmbH
STRABAG AG, Sparte Hoch- und Ingenieurbau
Holcim (Wien) GmbH
Their support is gratefully acknowledged.
J. Berger/S. Bruschetini-Ambro/J. Kollegger An innovative design concept for improving the durability of concrete bridges
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