Design and Performance of Cost-Effective Ultra High Performance Concrete for Bridge Deck Overlays

The main objective of this research was to develop a cost-effective ultra-high performance concrete (UHPC) for bonded bridge deck overlays. The high durability and mechanical properties of such repair material can offer shorter traffic closures and prolong the service life of the bridge deck. The UHPC was optimized using supplementary cementitious materials (SCMs), proper combinations of sands, and adequate selection of fiber types and contents. Packing density studies included paste, sand, and fiber combinations. The robustness of optimized UHPC mixtures to variations of mixing and curing temperatures was examined. The efficiency of various shrinkage mitigation approaches for reducing autogenous and drying shrinkage of optimized UHPC mixtures was evaluated. This included the use of CaO-based and MgO-based expansive agents, shrinkage-reducing admixture, and pre-saturated lightweight sand. Test results indicate that the optimized UHPC mixtures exhibited relatively low autogenous shrinkage and drying shrinkage. All tested UHPC mixtures exhibited high mechanical properties and excellent frost durability. The use of 60% lightweight sand led to a significant reduction in autogenous shrinkage from 530 to 35 με. The optimized UHPC mixtures were cast as thin bonded overlays of 25, 38, and 50 mm (1, 1.5, and 2 in.) in thickness over pavement sections measuring 1 × 2.5 m2 (10.7 x 27 ft2). Early-age and long-term deformation caused by concrete, humidity and temperature gradients, as well as cracking and delamination were monitored over time. Test results indicate that there was no surface cracking or delamination in UHPC overlays after more than 200 d of casting. After laboratory investigations, a life cycle cost analysis (LCCA) was determined for the selected concrete mixtures with different mixture compositions and performance characteristics. Results indicate that, based on both deterministic and probabilistic results, UHPC overlay with minimum 25 mm (1 in.) thickness is a more cost-effective option compared with other commonly used materials, such as latex-modified concrete and conventional bonded concrete overlays.

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  • Corporate Authors:

    Missouri University of Science and Technology, Rolla

    Department of Civil, Architectural and Environmental Engineering
    1401 N Pine Street
    Rolla, MO  United States  65409

    Missouri University of Science and Technology, Rolla

    Center for Infrastructure Engineering Studies
    Rolla, MO  United States  65409

    Missouri Department of Transportation

    Construction and Materials Division
    Jefferson City, MO  United States  65102

    Federal Highway Administration. Office of Transportation Operations

    Washington, DC   
  • Authors:
    • Khayat, Kamal H
    • Valipour, Mahdi
  • Publication Date: 2018-4


  • English

Media Info

  • Media Type: Digital/other
  • Edition: Final Report
  • Features: Figures; References; Tables;
  • Pagination: 121p

Subject/Index Terms

Filing Info

  • Accession Number: 01670960
  • Record Type: Publication
  • Report/Paper Numbers: cmr 18-006
  • Contract Numbers: TR201704
  • Created Date: May 29 2018 4:05PM