The application of Ultra-High-Performance Concrete (UHPC) materials in rehabilitating bridges and constructing primary bridge components is increasing rapidly across the world because of their superior strength and durability characteristics when compared to regular concretes. However, there have been few new bridges constructed using UHPC materials with regular formworks, ready-mix trucks, and construction equipment. This paper presents a comprehensive report encompassing the design, construction, and performance monitoring of a new bridge constructed in Iowa using a unique UHPC technology that includes steel fibers of two different lengths embedded in the concrete. By using optimized lengths of steel fibers, both the tensile strength and the toughness were increased. The UHPC material was produced with local cement and aggregates in the US using typical ready-mix concrete equipment. This paper discusses the experience gained from the design and construction process including mix design, batching, delivery of steel fibers to the ready-mix concrete batch unit, and post-tensioning of precast slabs at the jobsite. For four years after construction, the joints of the bridge decks were monitored using strain sensors mounted on both sides of the deck joints. The strain values were quite similar between the two sides of each joint, indicating a good load transfer between precast bridge girders. A bridge was successfully constructed using a unique UHPC technology incorporating two different lengths of steel fibers and utilizing local cement and aggregates and a ready-mix truck, and has been performing satisfactorily with a good load transfer across post-tensioned precast girder joints.
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