The present research project investigates monitoring concrete precast panels for bridge decks that are reinforced with Glass Fiber Reinforced Polymer (GFRP) bars. Due to the lack of long term research on concrete members reinforced with GFRP bars, long term health monitoring is important to record the performance and limit states of the GFRP decks and bridge as a whole. In this research, data is collected on concrete strains, bridge deflections, vertical girder accelerations, as well as initial truck load testing and lifting strains.

Accelerated bridge construction (ABC) using full-depth precast deck panels is an innovative technique that brings all the benefits listed under ABC to full fruition. However, this technique needs to be evaluated and the performance of the bridge needs to be monitored. Sensor networks, also known as health monitoring systems, can aid in the determination of the true reliability and performance of a structure by developing models that predict structure behavior and component interaction. The continuous monitoring of bridge deck health can provide certain stress signatures at the onset of deterioration. The signatures are vital to identify type of distress and to initiate corrective measures immediately; as a result, bridge service life increases and eliminates costly repairs This project focused on the continuous monitoring and evaluation of the structural behavior of the Parkview Bridge full-depth deck panels under loads using the sensor network installed. Special attention was placed on the durability performance of the connections between precast components. However, after careful evaluation of the designs and construction process, it was identified that the transverse joints between deck panels are the weakest links, in terms of durability, in the system. Analysis of sensor data and load test data showed that the live load effect on the bridge is negligible. The dominant load is the thermal. Using three years of data from the sensors, stress envelopes were developed. These envelopes serve as the basis for identifying the onset of bridge deterioration. A detailed finite element model was developed, and the model was first calibrated using load test data. However, due to the dominance of thermal loads, it was required to calibrate the model using stresses developed in the structural system due to thermal loads. This was a great challenge due to a lack of sensors along depth of the bridge superstructure cross-section. A few models were identified that are capable of representing the thermal gradient profile from 12 p.m. to 6 p.m. in a summer day. The FE model was calibrated using sensor data and the thermal gradient profile of the specific duration. Construction process simulation with the calibrated model shows that all the joints between the panels are in compression, as expected at the design. Stress signatures were developed simulating the debonding of a transverse joint between panels. The signatures show a distinct pattern than what is observed from a bridge without distress. Hence, the onset of deterioration can be identified from the sensor data to make necessary maintenance decisions. The proposed signatures are applicable only during noon to 6 p.m. on a summer day, and development of deterioration models for the rest of the time requires development of new thermal models. Further, the stresses vary drastically following onset of joint deterioration; hence, identification of exact physical location of the sensors is required for fine-tuning the models.

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.