Field implementations of a novel UHPC beam end repair on steel girder bridges in Connecticut, USA

Abstract

Corrosion at beam ends is one of the most pressing challenges in the maintenance of aging steel bridges. To tackle this challenge, the Connecticut Department of Transportation (CTDOT) worked with the University of Connecticut to develop a repair for corroded beam ends using ultra-high performance concrete (UHPC). The repair involves welding shear studs to the intact portions of the web and encasing the beam end in UHPC. This provides an alternate load path for bearing forces that bypasses the corroded regions of the beam. The structural viability of the repair has been extensively proven through small- and full-scale experiments and comprehensive finite element simulations. The Connecticut Department of Transportation conducted its first field implementation in 2019. The project’s success led to a second implementation in 2021 on a weathering steel bridge. Four beam ends in each project were fully instrumented to collect data on the performance of the repaired locations prior to casting, during curing, and under service loads following repair. This paper provides an overview of the repair implementations and presents the lessons learned during construction. Preliminary data showing the effectiveness of the repair in reducing strains on the web plate as a measure of demand is included. It is expected that this information will provide engineers with a better understanding of the repair implementation process and will provide an additional repair option to enhance the safety of aging steel bridges.