Experimental Evaluation of Prefabricated Deck Panel Connections

Prefabricated bridge elements and systems (PBES) are integral to the execution and success of many accelerated bridge construction projects. Prefabricated deck panels are one of many PBES types that have gained popularity. Laboratory research and field studies have indicated the primary challenge for deck systems is the design and construction of the connections, which are typically made using interlaced connector elements and field-cast grout. Poor detailing and design considerations have been shown to pose problems with deck durability, serviceability and ultimate capacity. A series of precast deck panel connection tests were carried out at the Federal Highway Administration (FHWA) Turner-Fairbank Highway Research Center to advance the understanding of deck-level connections under realistic performance demands. A number of parameters frequently considered during the design of these connections, including shear key shape, reinforcement type, joint material type, and precast surface preparation, were investigated. Seventy two large-scale deck-level connection assemblies were tested in four-point bending and subjected to cyclic crack loading, fatigue loading, and monotonic loading until failure. The three loading protocols enabled assessment of the connection parameters as they relate to durability, serviceability and ultimate strength. Results indicate the performance of these connections is heavily influenced by the grout and the precast component interface surface preparation.