Durable Bridge Columns using Stay-In-Place UHPC Shells for Accelerated Bridge Construction

Ultra-high performance concrete (UHPC) is a durable material that allows the construction of innovative structural elements and conforms with accelerated bridge construction (ABC) goals. The main idea of this research is to utilize UHPC to prefabricate a shell that acts as a stay-in-place form for bridge columns. The prefabricated shell eliminates the conventional formwork while reducing the on-site construction time and acting as a durable protective layer for the normal concrete inside the shell against environmental attacks. In addition, the UHPC shell provides additional confinement to the column concrete, which improves the column’s structural performance. During construction and after completing the column reinforcement work onsite, based on the conventional construction methods, the prefabricated UHPC shell is placed around the column reinforcement, followed by casting a portion of UHPC for a column-to-footing connection, which improves the capacity of the connection and shifts the plastic hinge zone above the connection. Once the UHPC portion hardens, normal concrete is placed inside the shell, forming a permanent concrete-filled UHPC shell. The construction process is finalized by placing and connecting a prefabricated cap beam to the column through the same developed connection as that in this research. This technical note presents the development of two test specimens using an UHPC shell in lieu of a conventional formwork with the advantage of improving the column performance and durability.