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.

The durability of infrastructure components, such as prestressed concrete bridge beams, can be significantly affected by long-term deterioration associated with corrosion. Corrosion is a major concern for bridges in Virginia, due to the frequent use of deicing salts during the winter, as well as the number of structures in marine environments. The residual capacity of corrosion damaged prestressed I-beams and box beams needs to be accurately estimated to determine if damaged bridges need to be posted, and to help with making informed decisions related to repair, rehabilitation and replacement of damaged bridges. This report presents the results of testing of six corrosion-damaged prestressed beams removed from existing bridges during their demolition. Three beams were Type II AASHTO I-beams extracted from the Lesner Bridge in Virginia Beach, and three were 48 in wide by 27 in deep box beams extracted from the Aden Road Bridge near Quantico, Virginia. Prior to testing, the beams were visually inspected and two types of non-destructive evaluations were performed to identify corrosion activity: resistivity measurements and half-cell potential measurements. The beams were then tested in the lab to determine their flexural strength. Following testing, samples of strand were removed and tested to determine their tensile properties. Cores were taken from the Aden Road beams and from both the beams and decks of the Lesner Bridge beams to determine compressive strength. Powdered concrete samples were removed to perform chloride concentration tests. The tested strengths of the beams were compared to calculated strengths using two methods for damage estimation and two different calculation approaches. The methods for damage estimation relied exclusively on visual inspections; one was the set of methods recommended by Naito et al. (2010), while the second was a modified method developed in this study from the current tests. The two calculation approaches were a strain compatibility method and the AASHTO LRFD method. Overall, the results yielded reasonable estimates of residual strength, except for one of the box beams that was discovered to have considerable water within the hollow cells. The final recommendations are that bridge inspectors develop detailed damage maps of corrosion-damaged beams, and that load raters use the Naito et al. method to get a conservative estimate of damage for both box beams and I-beams. Either method for calculating strength is valid, however the AASHTO LRFD method is simpler.