Determining More Effective Approaches for Grouting Shear Keys of Adjacent Box Beams

The objective of this project was to evaluate improved design and construction practices that have the potential to reduce shear key grout failure (cracking) in PennDOT precast box beam bridges. This objective was met by conducting a state-of-the-practice literature review, numerical parametric studies, and experimental verification tests. The literature review presented four possible parameters that have the potential to reduce cracking: (1) shear key configuration, (2) grouting material, (3) transverse post-tensioning, and (4) bearing pad details. Experimental tests of shear key connections were conducted. Results from these tests were used to validate finite element models of the shear key region. A grillage analysis of a selected bridge configuration was conducted to determine the maximum live-load effects experienced by the shear key. A parametric study using finite element analysis showed that a full-depth, epoxy-grouted shear key could significantly reduce the likelihood of cracking. Moreover, the amount of post-tensioning and the effect of bearing pad at supports also play an important role in reducing the maximum tensile stress and thus cracking.

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