Precast bridges

Design principles

Course overview
Introduction to the course
Overview on precast systems
In-situ vs precast bridge (example)
Design principles
Detailing of girder bridge deck
Girder bridge design (example)
Summary and conclusions

Presentation overview
Introduction
Calculation flow chart
Structural system
Design graph
Loadfor bridges
Load distribution
Cross section analyses
Design calculation
Detailing
Summary

Introduction design principles

Bridge deck

Bridge beam and in-situ deck

Bridge beam

Eurocodes
EC0 Basis of design
EN 1990 Eurocode: Basis of design

EC1 General actions

EN 1991-1-1, EC 1: Part 1-1: Densities, self weight
EN 1991-1-4, EC 1: Part 1-4: Wind actions
EN 1991-1-5, EC 1: Part 1-5: Thermal actions
EN 1991-1-6, EC 1: Part 1-6: Actions during execution
EN 1991-1-7, EC 1: Part 1-7: Accidental actions from impact
and explosions
EN 1991-2, EC 1: Part 2: Traffic loads on bridges

EC2 Design of concrete structures

EN 1992-1-1, EC 2: General rules and rules for buildings
EN 1992-2, EC 2: Reinforced and prestressed concrete
bridges

Calculation flow chart

Bridge design

Preliminary design
Structural
system
Design
graphs

Structural system
Loads for bridges
Load distribution

EC1
FEM or GuyonMassonet

element design
Bridge and
deck
Final preliminary
design

Cross sectional
analysis
Design
calculations
Detailing

Pre-tensioning

EC2

Co-operation in design
Preliminary general design:
General design office start with project - roads and bridges
are drafted.

Detailed prefab design:

Concrete-factory design-office does beam calculations, crosssection drawings, check support nodes etc.

Final general design:

General design company finalizes whole bridge and deck

Succesfull bid of the project:

Update of drawings
Finalizing factory drawings of elements

Structural system
Preliminary design of bridge
Spans
support locations
preliminary beam height and cross-section
support solutions
dilatation joints location
etc

Inverted T-beam ZIP

ZIP design graph

Variable load [kN/m2]

ZIP600
30
ZIP1000
ZIP1400

20

10

0
15

20

25

30

35

Span [m]

40

45

50

Variable load [kN/m2]

ZIP design graph

Span [m]

Design graphs
The design graph is based on:
Simply supported beams
Centre to centre distance 1.2 m
Dead weight wear layer is 1.5 kN/m2, edge line load of 3.2
kN/m1
Dutch code NEN 6720 (Structural concrete)
Dutch code bridges NEN 6723 (Loads for bridges)
ZIP and deck: 65 MPa and 35 MPa
No intermediate cross girders
Environmental class 3 NEN 5950 (environment with thawsalts)

Centre to centre distance

For larger spans and heights the centre to centre distance
of the ZIP beams can be increased
moment [kNm]
c. t

c.t

.c

.c

1.8

c.t
2.

.c

3.
0

ZIP1700

5000

ZIP1500
4000

ZIP1300

3000
2000
45

40

35

30

25
span [m]

25

30

35

40

45

Rules of thumb for ZIP bridges

Road bridges
beams 1.20 m distance-to-distance: deck 210 mm
beams 1.80 m distance-to-distance or more: deck
240 mm
Railway bridges
beams 1.20 m distance-to-distance: deck 260 mm
Other applications
beams 1.20 m distance-to-distance: deck
minimum of 180 mm

Overview of loads
Loads

Dead load
Traffic load
Fatigue load
Accidental load
Thermal load

Windload
Load combinations
For bridges, the simultaneity of actions and the particular
required verifications should be specified

Traffic load - lanes

Divide bridge deck into lanes
Lanes have width of 3 m
1 lane if w < 5.4 m
w
2 lanes if 5.4 m < w < 9 m
3 or more lanes if w > 9 m
Lane 1 gives most unfavourable effect

Remaining area
lane 3
lane 2
lane 1

Traffic load load model

Load model 1 of interest
Concentrated and uniformly distributed load,
normal traffic, for general and local verification
1.2 m
2.0 m
lane 3

2.5 kN/m2

lane 2
lane 1

1.0 m
2.0 m
1.0 m

9.0 kN/m

2.0 m

Load Model 1
Two double axle concentrated loads
located at a lane with a weight of QQik
consisting of 2 wheels with each 0.5 QQik weight

Uniformly distributed load

aqqik on lanes
aqqrk on remaining area

Remark: defined as National Parameter

Location

Total load
2 * Qik [kN]

qik (qrk)
[kN/m2]

Lane no 1

2 * Q1 * 300

q1 * 9,0

Lane no 2

2 * Q2 * 200

q2 * 2,5

Lane no 3

2 * Q3 * 100

q3 * 2,5

Other lanes

qi * 2,5

Remaining
area

qr * 2,5

Collision forces
1 axle LM1 on footways and cycle tracks

Collision with kerbs

Impact load underside deck (headroom < 5 m)

Inclineerde force at 10
F
Horizontal component: 1100 kN dxmax
Vertical component: 190 kN

Fdymax

Load combinations
Serviceability limit state
Characteristic value combination:
j1 Gk,j + P + Qk,1 + i>1 0,i * Qk,i
Gk + P + Qlastst + 0,4 * qgvb

Ultimate limit state

Fundamental combination

j1 G,j * Gk,j + p * P + Q,1 * Qk,1 + i>1 Q,i * 0,i * Qki

1,35 * Gk + 1,0 * P + 1,35 * Qlastst + 1,35 * qgvb

Load distribution

Load action and reaction

Load model in centre of deck

Load action and reaction

Load model in centre of deck

Load model at one side of deck

Load distribution
Load is carried by more than one beam
Loading leads to:
Deflections and
Rotations

Load distribution is influenced by:

Bending stiffness
Torsional stiffness
In both span direction and transversal direction

Methods to determine transversal load distribution

(moment in beams and deck)
Numerical finite element model method
Analytical Guyon-Massonet method

Numerical method
Finite element modelling of beams and deck

Numerical displacements
Displacements due to edge load

Numerically calculated moment

Bending moment due to edge load

Analytical method
Guyon-Massonet
Transversal dirstribution coefficient K
K = Ko + (K1 - K0)

at a certain

Ko = transversal load distribution for a cross section

without torsional stiffness ( = 0)
K1 = transversal load distribution for a cross section
with full torsional stiffness ( = 1)
K = transversal load distribution for a cross section
with torsional stiffness (0<<1)

Design curves
Design curves for the effects of concentrated loads
on concrete bridge decks
K = Ko + (K1 - K0)

at a certain
K1 values for beam b

Ko values for beam b

K1

Ko

Influence lines
Influence of load on beam position
Beam 0

Location of load

Beam b

Location of load

Example load distribution 1/5

Deck width 10.8 m, 30 m span
9 beams 1.2 m width
600 kN
Load 600 kN

30 m

Effective width = 9/8*10.8 = 12.15 m

Example load distribution 2/5

Full distribution

K
1.0

-b 3/4b 1/2b 1/4b 0 1/4b

1/2b

3/4b

Maximum moment:
M = Fl = *600*30 = 4500 kNm for bridge deck
Hence, average 4500/9 = 500 kNm per beam

Example load distribution 3/5

Real distribution (case = 1 and = 0)
P=8

-0.7

-1

0.19
1.02

1.91
2.34

Maximum moment:

-b 3/4b 1/2b 1/4b 0 1/4b

1/2b

M = Fl = *600*30 = 4500 kNm for bridge deck

Hence, average of 4500/9 = 500 kNm per beam
Beam position 0: 2.34*500= 1170 kNm
Beam position b: -0.7*500 = -350 kNm

3/4b

Example load distribution 4/5

Real distribution (case = 1 and = 0)
-1

-0.34

P=8

-0.16
0.02

0.39
1.00

1.27
1.80

1.89
2.40

Maximum moment:

-b 3/4b 1/2b 1/4b 0 1/4b

1/2b

M = Fl = *600*30 = 4500 kNm for bridge deck

Hence, average of 4500/9 = 500 kNm per beam
Beam position 1/2b: 2.40*500= 1200 kNm
Beam position b: -0.34*500 = -170 kNm

3/4b

Example load distribution 5/5

Variable load moment of all beams due to load
distribution:
Sagging moment of 1200 kNm
Hogging moment of 350 kNm
Composite element: prefab beam with in-situ
topping

30 m

Distribution of shear load

Spread of tan 2/3 is taken into account

200 kN
400 kN
tan2/3 (EC: > 45)

600 kN

Moment in deck
Sagging moment

Hogging moment

Cross section analysis

Cross sectional properties

z = centroid [mm]
ep = excentricity of pre-tensioning
A = area [mm2]
W = section modulus [mm3]
I = moment of inertia [mm4]
k = kern [mm]

Analysis of cross section

ZIP1000
A = 0.490 m2
z = 0.35 m
Wb = 0.126 m3 kt = 0.257 mm

ZIP1000 with 210 mm deck

A = 0.724 m2
z = 0.60 m
Wb = 0.230 m3 kt = 0.318 mm

Wt = 0.067 m3 kb = 0.137 mm

Wt = 0.335 m3 kb = 0.461 mm

e p kb

ep - kb

MG
P

kt kb

MQ
P

kt + kb

Limit criteria in SLS

Stresses and cracking in cross section, influenced
by long term loading:

Change of stresses
Tensile stresses (flexural tensile cracking)
Compressive stresses
Local stresses
Excessive crack width

Deflection:
Excessive deflection

Stresses in cross section

Linear behaviour

Pm e zt
M z
x t
I
I

Vx M x

Pm
A

Np

Pm
P ez
M z
m b x b
A
I
I

A and I are transformed cross sectional properties

Mx is bending moment (G and Q) at section x
Pm is prestressing force (ex/including losses of prestress)
zt and zb are z-coordinate of top and bottom fibres

Tensile stresses
Flexural tensile strength of concrete

h
f ctm, fl max 1.6
f
,
f
ctm ctm
1000

Cracking patterns of pre-tensioned beams

Tensile stresses
Flexural tensile cracking
Cracking of top fibers
(after release)

M r f ctm, fl

cracking of bottom fibers

(after Mx)

I Pm I

Pm e
zt A zt

f ctm, fl

+
-

M r f ctm, fl

f ctm, fl

I Pm I

Pm e M x
zb A zb

Reduce head tensile stresses

Beam head stresses are too high (3 Mpa)
Debonded strand at beam end

Inclination of strands with pressure point

Compressive stresses
changes under long-term loading

zt

Pm
Pm e zt M x zt

A
I
I

+
Vx

Mx
d
e

zb

Pm

Pm,t Pm0 Pc s r

Mx Mg

for t0 t t1

M x M g M lt

for t t1

Pm Pm e zb
M z

x b
A
I
I

Composite: beam and deck

Composite action between ZIP beam and deck
More complex stress distribution
Dead weigth on ZIP beam
Live load on composite beam

prestress + dead =
weight

Slab and
transverse +
girders

Additional Variable
dead + loads =
weight

Total
stresses

Change of stresses
Change of stresses in strands and concrete due
to time dependent loss of pre-stressp,c+s+r by
shrinkage, creep and relaxation
5% at time after release of prestress
10% at time of erection of elements and
imposed loading
25% at infiniy (50 years), but more
indicative

Design calculation

Main design parameters

Depth of unit
Strand pattern
Degree of prestress

ZIP reinforcement
Longitudinal strands anchored by bond
Prestressed steel wires or strands
Longitudinally placed in bottom and web of unit
7-wire helical strand of 12.5 or 15.7 mm diameter
Ultimate tensile strength is 170 kN and 280 kN, respectively

No longitudinal reinforcement bars

Shear reinforcement
Stirrups
Projecting reinforcement

Head reinforcement

Some characteristic strengths

Concrete:
C40/50 to C60/75 utilized
Characteristic compressive strength is 4060 Mpa
Strands:
Characteristic tensile strength for strands is 1700
1900 Mpa
Pre-stress level is 1350 1450 MPa

Failure modes in ULS

Cracking and failure of concrete
Balanced failure design
Flexural compression failure
Failure of prestress
Yielding (rupture) of the strands
Anchorage failure of strands

Balanced failure design

Good design is balanced failure design:
At increased loading from SLS to ULS
Beam starts cracking followed by
yielding of strands such that extensive cracking occurs and large
deflections
finaly followed by failure of concrete compression zone

At ULS strain and stress distribution are:

cu

pu

Ncu = 0.8bxfcd
Npu

Balanced failure design

FeP1860
p [N/mm2]

p in SLS
pu in ULS

1570
1260

pu = p + p
6.5

Ncu = Npu

20.0

p []

Flexural compression failure

Crushing of concrete compression zone prior to
failure (over-reinforced cross-sections)
p [N/mm2]
1570
1260

FeP1860

pu = p + p
6.5

Npu > Npu

20.0

p []

p in SLS
pu in ULS

Yielding (rupture) of strands

Yielding of strands prior to failure (underreinforced cross-sections)
p [N/mm2]

p in SLS
pu in ULS

1570
1260

FeP1860
pu = p + p
6.5

Npu < Ncu

20.0

p []

Anchorage failure of strands

Anchorage failure capacity (rotational model)
Shear force affects crack due to bending moment so that it
forms an angle x to the strands
x 0
35

90
cracked

uncracked
Vc
Ncu
Np
a

Vx
90 0
V0

a+

M a N p d 0.4 x
Va Vc

Anchorage failure of strands

Anchorage and tensile capacity of strands
Np

Pd
Pi
P

at ULS
at
release

Np (Pi, P)
lpt1 lpt2

lbpd

l pt1 0.8l pt , l pt 2 1.2l pt

l pt

1 2 pm 0
f bpt

lbpd l pt 2

distance
2 ( pd pm )
f bpd

Main design parameters

Standardised strand pattern
ZIP

maximum
number 12.5
mm

500

50

600

53

700

56

800

59

900

62

1000

65

1100

68

1200

71

1300

74

1400

77

1500

80

1600

83

1700

86

Shear force

Shear
stress
area

Interface ZIP beam-deck

Stirrup reinforcement
Standardisation of stirrups

Stirrup reinforcement
Standardisation of stirrups

Projecting stirrups

Stirrups and production

Detailing

Local stresses
Anchorage stresses in the transmission zone
Bursting and spalling, related to distribution of
prestress force over cross-section
Splitting due to bond action
Bond stress
Ribbed bar

e0

spalling
splitting

strand

bursting
spalling

slip

Concrete product
Concrete cover
Tolerances of product

Summary
Bridge deck

Bridge beam and in-situ deck

Bridge beam