A literature review concerning the objectives of the project was completed. A significant number of published papers, reports, etc., were examined to determine the effectiveness of full depth precast panels for bridge deck replacement. A detailed description of the experimental methodology was developed which includes design and fabrication of the panels and assembly of the bridge. The design and construction process was carried out in cooperation with the project Technical Review Panel. The major components of the bridge deck system were investigated. This includes the transverse joints and the different materials within the joint as well as composite action. The materials investigated within the joint were polymer concrete, non-shrink grout, and set-45 for the transverse joint. The transverse joints were subjected to direct shear tests, direct tension tests, and flexure tests. These tests exhibited the excellent behavior of the system in terms of strength and failure modes. Shear key tests were also conducted. The shear connection study focused on investigating the composite behavior of the system based on varying the number of shear studs within a respective pocket as well as varying the number of pockets within a respective panel. The results indicated that this shear connection is extremely efficient in rendering the system under full composite action. Finite element analysis was conducted to determine the behavior of the shear connection prior to initiation of the actual full scale tests. In addition, finite element analysis was also performed with respect to the transverse joint tests in an effort to determine the behavior of the joints prior to actual testing. The most significant phase of the project was testing a full-scale model. The bridge was assembled in accordance with the procedures developed as part of the study on full-depth precast panels and the results obtained through this research. The system proved its effectiveness in withstanding the applied loading that exceeded eight times the truck loading in addition to the maximum negative and positive moment application. Only hairline cracking was observed in the deck at the maximum applied load. Of most significance was the fact that full composite action was achieved between the precast panels and the steel supporting system, and the exceptional performance of the transverse joint between adjacent panels.

A bridge with precast bridge deck panels was built at the Virginia Tech Structures Laboratory to examine constructibility issues, creep and shrinkage behavior, and strength and fatigue performance of transverse joints, different types of shear connectors, and different shear pocket spacings. The bridge consisted of two AASHTO type II girders, 40 ft long and simply supported, and five precast bridge deck panels. Two of the transverse joints were epoxied male-female joints and the other two transverse joints were grouted female-female joints. Two different pocket spacings were studied: 4 ft pocket spacing and 2 ft pocket spacing. Two different shear connector types were studied: hooked reinforcing bars and a new shear stud detail that can be used with concrete girders. The construction process was well documented. The changes in strain in the girders and deck were examined and compared to a finite element model to examine the effects of differential creep and shrinkage. After the finite element model verification study, the model was used to predict the long term stresses in the deck and determine if the initial level of post-tensioning was adequate to keep the transverse joints in compression throughout the estimated service life of the bridge. Cyclic loading tests and flexural strength tests were performed to examine performance of the different pocket spacings, shear connector types and transverse joint configurations. A finite element study examined the performance of the AASHTO LRFD shear friction equation for the design of the horizontal shear connectors. The initial level of post-tensioning in the bridge was adequate to keep the transverse joints in compression throughout the service life of the bridge. Both types of pocket spacings and shear connectors performed exceptionally well. The AASHTO LRFD shear friction equation was shown to be applicable to deck panel systems and was conservative for determining the number of shear connectors required in each pocket. A recommended design and detailing procedure was developed for the shear connectors and shear pockets.

The frequent use of precast concrete panels has been used to decrease the construction time for bridges. Cracking often occurs at the transverse connections of these panels, resulting in corrosion, and decreased bridge life. Previous laboratory testing of these connections was performed at Utah State University for the Utah Department of Transportation to determine maximum shear and moment capacities, cracking behavior, and cracking loads for five different connections. Two connections are Utah Department of Transportation standard connections. These connections are post tensioned and welded tie connection using shear studs. A different type of welded tie connection using rebar was also tested, along with two prototype connections using a curved bolt to apply post tensioning. As part of this research finite element models were created using ANSYS software to confirm the tested results, and provide models for future analysis. Moment-deflection and shear force-deflection curves were created using the results from the laboratory testing, and were compared with the results from the finite element analysis. The finite element models produced similar behavior and cracking loads when compared to the laboratory results. The curved bolt connections were found to be a good way of applying post tensioning.