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Many highway bridges become functionally obsolete due to inad- CHAPTER 2DEFINITIONS, p. 2
equate width before they become structurally deficient. Widening 2.1Definitions, p. 2
is generally more economical than complete replacement. Thus,
there is a mandate to share the results of research and experi- CHAPTER 3GENERAL DESIGN
ence pertaining to bridge widening. This guide discusses technical
CONSIDERATIONS, p. 2
issues related to the widening of concrete bridges and bridges with
3.1General, p. 2
concrete decks. The primary focus of this document is on bridge
decks, even though substructure issues are raised and discussed. 3.2Appearance and function, p. 3
The effects of differential movements between the existing and new 3.3Differential movement, p. 4
portions are discussed, including movements due to traffic on the
existing structure during construction. General recommendations CHAPTER 4DESIGN AND CONSTRUCTION
are made pertaining to the choice of structure type, design details, DETAILS, p. 7
and construction methods and materials. 4.1General, p. 7
The materials, processes, quality-control measures, and inspec- 4.2Demolition, p. 7
tions described in this document should be tested, monitored, or 4.3Avoidance of damage due to dead load deflections,
performed as applicable only by individuals holding the appro- p. 8
priate ACI certifications or equivalent.
4.4Closure placement details, p. 11
Keywords: bridge decks; bridge widening; bridges (structures); concrete 4.5Substructure details, p. 13
construction; deflection; formwork (construction); reinforced concrete;
reinforcing steel; substructure; superstructure; traffic vibration. CHAPTER 5SUMMARY OF RECOMMENDATIONS,
p. 13
Contents
CHAPTER 6REFERENCES, p. 13
CHAPTER 1INTRODUCTION AND SCOPE, p. 1
1.1Introduction, p. 1 CHAPTER 1INTRODUCTION AND SCOPE
1.2Scope, p. 2
1.1Introduction
Design and construction engineers should investigate
ACI Committee Reports, Guides, and Commentaries are
intended for guidance in planning, designing, executing, and
several potential issues if a bridge is to be considered for
inspecting construction. This document is intended for the use widening. These include retention of bridge elements, traffic
of individuals who are competent to evaluate the significance control, structural constraints, economy and feasibility,
and limitations of its content and recommendations and who expected increase in traffic volume, life span, and construc-
will accept responsibility for the application of the material it
contains. The American Concrete Institute disclaims any and
all responsibility for the stated principles. The Institute shall
not be liable for any loss or damage arising therefrom. ACI 345.2R-13 supersedes ACI 345.2R-98(05) and was adopted and published July
2013.
Reference to this document shall not be made in contract
Copyright 2013, American Concrete Institute.
documents. If items found in this document are desired by All rights reserved including rights of reproduction and use in any form or by any
the Architect/Engineer to be a part of the contract documents, means, including the making of copies by any photo process, or by electronic or
they shall be restated in mandatory language for incorporation mechanical device, printed, written, or oral, or recording for sound or visual reproduc-
by the Architect/Engineer. tion or for use in any knowledge or retrieval system or device, unless permission in
writing is obtained from the copyright proprietors.
1
2 GUIDE FOR WIDENING HIGHWAY BRIDGES (ACI 345.2R-13)
tion limitations. Certain elementary procedures should be It is imperative to perform in-depth nondestructive testing
followed to study the feasibility of widening. These include: (NDT) and invasive testing to quantify the level of existing
a) Review the drawings and specifications of the original concrete deterioration and section losses in existing sections,
structure. and design protection methods to prevent future deteriora-
b) Review any revisions of engineering documents (for tion prior to investing in widening a structure.
example, plans, specifications, and design calculations) that Many problems unique to bridge widening are not encoun-
might have been approved during the original construction. tered in new bridge work. Failures or serious maintenance
c) Thoroughly inspect the structure and note changes problems can be created by misunderstanding these prob-
to in-place conditions, such as deterioration of structural lems. Each bridge widening is unique.
members due to environmental factors (for example, deicing This guide emphasizes construction practices, but because
salts, weathering, and collision of heavy trucks). construction sequence, structure type, framing details, and
d) Obtain additional subsurface information to accommo- other decisions critical to the success of the work are deter-
date increased superstructure loads, including soil borings. mined during the design phase, some discussion of design
e) Review previous changes or upgrades to the structure. concepts must be included. Structural analysis and design
f) Perform structural analysis with allowance for existing for widening bridges are not addressed. Much of the discus-
deterioration to confirm that the existing elements are sion that follows also applies to new bridges constructed in
adequate for increased loads (due to widening and compli- stages, part width at a time.
ance with current design standards). If the existing elements
are part of the replacement, all possible geometric properties CHAPTER 2DEFINITIONS
need to be considered.
One of the first considerations for widening a bridge is 2.1Definitions
to determine whether to retain structurally adequate parts of ACI provides a comprehensive list of definitions through
the bridge deck. Entire bridge deck replacement should be an online resource, ACI Concrete Terminology, http://
considered if the bridge deck is severely deteriorated, the terminology.concrete.org.
existing bridge deck will become less than a half of the new
bridge deck width, or both (Seible et al. 1991; Operation CHAPTER 3GENERAL DESIGN
Bridgeguard 1992). If the bridge deck, or a portion of it, is CONSIDERATIONS
to be retained and connected to a new deck, the design should
provide for bending moment and shear transfer through the 3.1General
longitudinal joint between the new and old portions of the Certain aspects of structural type selection, framing consid-
bridge deck. The steel passing through the construction joint erations, and design details are unique to bridge widening.
should be protected from possible increases in corrosion AASHTO (2010) and others (Silano et al. 1992) provide
potential between the old and new concrete. specific design guidelines. Questions a design professional
Another important matter is the consideration of whether should consider before commencing design include:
substructures, such as footings, pier caps, and abutments, a) By widening the superstructure, does the substructure
should be widened to accommodate widening a superstruc- also require widening?
ture. Potential interaction between the new substructure and b) Was widening the substructure foreseen in the design of
the existing substructure should be considered. The design the existing bridge?
professional should be aware of possible problems that c) Should one or both sides be widened?
could occur when a bridge is widened on both sides. In most d) Is a parallel structure justified as an alternative to
cases, the existing portion is trapped between new sections, widening?
making it difficult to replace the middle section. e) Does widening the structure provide adequate vertical
clearance?
1.2Scope f) Have geotechnical/ground conditions been evaluated?
This document provides design professionals and g) Does widening provide an acceptable life for the
constructors with general guidelines for bridge widening. existing section?
The widening of highway bridges is commonly conducted In general, current bridge codes and design loads appli-
to improve the functionality of existing structural systems. cable to the route on which the structure is located should
Several factors contribute to this demand: be used for bridge widening. Constructing a widening to
a) Increased traffic volumes requiring additional lanes current standards creates the opportunity of later replacing
b) Safety hazards of narrow bridges requiring wider or strengthening all or portions of the original bridge so that
shoulders the entire structure can be upgraded.
c) Provision for bikeways and pedestrian walkways Bridges to be constructed for special purposes (for example,
Government-funded programs are enabling public agen- military bridges) may require higher design loads than stan-
cies to widen many functionally obsolete bridges as needed dard truck loads shown in AASHTO (2013) due to heavier
to improve safety. If a bridge was designed for current traffic loads, a lack of load limits, or a lack of enforcement of
live loads and has not deteriorated appreciably, widening load limits. Specific structural considerations may be neces-
is likely more cost-effective than complete replacement. sary for widening a bridge in seismic regions; for example,
The U.S. Department of Transportation (2009) details bridge deck riding surface as well as increasing member
the minimum traffic control standards for construction stiffness. Vehicle speed and weight restrictions may not be a
and maintenance operations on streets and highways. This critical issue for the magnitude of traffic-induced vibrations
manual sets forth principles and standards that apply to both (Kim et al. 2009).
rural and urban areas and is intended to direct the safe and In situations where the vibrations are carried into freshly
expeditious movement of traffic through construction and placed concrete through reinforcing steel extending from the
maintenance zones and provide for the safety of the work existing bridge, damage to new concrete may occur (Silfw-
force. In addition to the requirements of this manual, supple- erbrand 1992). Adequate construction methods can preclude
mentary protection may be requested by the owner. such damage, for example, by attaching the forms to the
The following should be indicated in the contract docu- existing bridge, with proper traffic control, or both.
ments: the sequence of construction operations, permis- When a reinforcing bar moves relative to the concrete, the
sible lane closure periods, minimum temporary roadway displaced concrete will flow readily back and forth with the
widths, temporary traffic striping requirements, signing bar because it is still in its plastic state. As initial set begins,
layouts, locations and details of temporary barrier railings, only weak, water-diluted grout flows back to surround the bar.
and minimum construction openings for roadways or rail- Also, cracks may develop in the plastic concrete and fill with
ways under the bridge. Contractors should be encouraged to weak material along a horizontal plane with adjacent bars or
propose alternative schemes. along sloping planes running from the bar to the surface of the
When high volumes of traffic need to be carried on a bridge bridge deck. This condition can result in a severe reduction
in which both sides are to be widened, it may be necessary in bond to reinforcement and premature bridge deck spalling.
to complete one side before the other is started to minimize Similar damage can occur in new bridge decks if live loads
disruption of traffic. from workers or equipment are allowed directly on poorly
When heavy volumes of commuter traffic prevent closing supported reinforcing steel on the outside of a construction
the existing bridge lanes except during brief off-peak joint bulkhead. For this reason, during placing and finishing
periods each day, special measures may be needed (Precast/ operations, workers and equipment near the perimeter of a
Prestressed Concrete Institute 1980; Sprinkel 1985). For reinforced concrete bridge deck should be restricted to planks
example, precast bridge deck slabs and concrete-filled steel or runways supported from the forms, rather than bearing
grating can be placed during nighttime or weekend closures. directly on any reinforcing steel that extends through bulk-
heads and into the concrete being placed.
3.3Differential movement Although it would seem that any movement of reinforcing
Deflection characteristics and differential expansion steel extending from a structure carrying traffic into freshly
behavior should be considered when a new deck is added or placed concrete would result in the defects described, certain
connected to existing decks. practices will generally eliminate such damage. These prac-
3.3.1 Vibrations from trafficTraffic-induced vibration tices should be employed on all bridge deck closure place-
has been blamed for distress occasionally observed in new ments or in other situations where concrete is placed against
construction that connects to structures carrying live loads. an existing structural element carrying traffic, and include
Once concrete is placed, consolidated, and finished, it gener- the following.
ally should not be disturbed until it has gained sufficient 3.3.1.1 Use of moderate-slump concrete (2 to 3 in. [50 to
initial strength. For example, over 65 percent of a speci- 75 mm])Surveys found frequent delamination in bridge
fied compressive strength may be achieved after 7 days of decks built or widened in the 1950s and 1960s (Transporta-
casting when a concrete is mixed with ordinary portland tion Research Board 1981). This damage was noted in bridge
cement (Gonnerman and Lerch 1951). This requirement decks connecting to existing structures carrying traffic. Such
leads to concerns about permitting traffic on bridge decks damage was attributed to the use of high-slump concrete
during concrete-placing operations. Experience and research (more than 4 in. [100 mm]) that probably contained excess
have shown, however, that damage due to traffic-induced water. Laboratory research also showed that high-slump
vibrations is very rare when the forms and reinforcing steel concrete mixtures are especially sensitive to segregation
are supported by the same structural members (Whiffen and in the plane of the reinforcing steel (Arnold 1980). Similar
Leonard 1971; Arnold 1980; Furr and Fouad 1981; Trans- damage was not noticed when the slump was reduced.
portation Research Board 1981; Deaver 1982; Harsh and 3.3.1.2 Reinforcing detailsFurr and Fouad (1981)
Darwin 1983; Silfwerbrand 1992). In these cases, fresh reported that reinforcing dowels extending straight from old
concrete, reinforcement, and forms are in synchronous concrete and lapping with the new bridge deck reinforcing
movement. None of these reports were able to identify any bars in fresh concrete did not cause any defects in the fresh
occurrences of damage for these conditions. Therefore, concrete. Splicing dowel bars to existing reinforcement may
special precautions, such as closing the bridge to traffic in be necessary for cantilever slabs.
such situations, are generally not necessary even though Good practice also requires that when bridge deck
vibrations may cause some minor cracks during the curing closure placements are to be employed, the reinforcing bars
of concrete members (Ng and Kwan 2007). or dowels extending from the existing concrete to the new
Effective ways to reduce the amplitude of traffic-induced concrete should not be connected to the reinforcing bars of the
vibrations are to maintain a smooth structure approach and closure placement during concrete placement. They should
Fig. 3.3.2aTransverse view showing vertical lip at longi- Fig. 3.3.2bLongitudinal view showing proximity of wheel
tudinal joint in traveled lane. path to joint.
out of the traveled lanes whenever possible; however, most
be adequately connected prior to, but as close to, casting the
frequently the joint between new and existing bridge decks
concrete (Fig. 3.3.1.2). Measures should be taken to avoid the
occurs within the traveled way. If bridge decks with longitu-
formation of corrosion macrocells with the new bars being
dinal joints in the traveled lanes are not structurally connected,
cathodic sites and the existing bars being anodic sites.
differential deflections will create offsets in the riding surface
Some damage was observed in California when a single
that could result in potentially hazardous vehicle control prob-
row of dowels was drilled and grouted into the face of the
lems. Figures 3.3.2a and 3.3.2b show two different views of a
existing bridge deck midway between the steel mats used in
joint with differential deflection. Figure 3.3.2c shows attempts
the widening (Shaw and Stewart 1974). This problem was
to minimize differential deflections; however, such situations
solved when two rows of dowels were used, one secured to
may not be recommended because maintenance of joint seals
each plane of steel in the new bridge deck (refer to the left-
between bridge deck slabs can be difficult, hazardous to
side elevation in Fig. 3.3.1.2).
workers, expensive, and delay road users.
3.3.1.3 Forming detailsWhen the closure is placed, its
Whenever a new bridge deck joins the existing bridge deck
supporting form should be secured to both the old and the
within the roadway, the two should be structurally connected
new structure.
(McMahon and Womack 1965; Whiffen and Leonard 1971;
3.3.2 Superstructure deflection characteristicsDifferen-
Shaw and Stewart 1974; Arnold 1980; Furr and Fouad 1981;
tial deflections between new and existing superstructures are
Transportation Research Board 1981; Deaver 1982; Harsh
not a problem if the joint between the two occurs in a median
and Darwin 1983). The amount of reinforcement across the
or untraveled area. Generally in such cases, the superstruc-
joint should be the same amount that is in the decks being
tures are not structurally connected. Joints should be located
connected. Additional analysis may be required when signif-
showed that deflections actually occurred in bridge deck the new structure is in the median or if rigid attachment of
slabs by traffic immediately adjacent to the widening during the widening to the existing structure is not required for
concrete placement. overall stability, the existing and new structures may not
Surveys of bridge deck widenings with temporary vertical be connected and differential settlements are tolerated. It is
displacement control measures in place during concrete usually necessary for the new foundation to be compatible
placement (Shaw and Stewart 1974; Furr and Fouad 1981; with the current condition of the existing one in terms of
Transportation Research Board 1981; Deaver 1982) showed settlement.
little evidence of distress due to differential deflection
caused by traffic. This is probably due to the fact that, in CHAPTER 4DESIGN AND CONSTRUCTION
addition to practices recommended previously, one or more DETAILS
of the following measures were taken:
a) Diaphragms between adjacent girders or a rigid tempo- 4.1General
rary blocking system were used to equalize girder deflec- Standards and guides used for new bridge construc-
tion until the bridge deck slab pour strip gained sufficient tion should be used for bridge widening. These include the
strength. Sometimes the forming system itself offers suffi- AASHTO LRFD Bridge Design Specifications (AASHTO
cient rigidity. 2013), AASHTO Guide Specifications for Highway
b) A smooth riding surface was maintained on the bridge Construction (AASHTO 2010), state-specific bridge design
deck and the approach roadway, and a good grade match was manuals, ACI 343R, and ACI 345R. It should be noted that
obtained where they joined. these provisions are not necessarily used for every project
c) Traffic speed, allowable loads, or both, were reduced on because each widening represents a unique situation. Some
the existing bridge during and immediately after placing new construction operations unique to widening are discussed in
bridge deck concrete. While no recommended speeds were this chapter.
given, it is generally understood that the lower the speed,
the less the risk of deck cracking. User service level will be 4.2Demolition
a factor in the speed that is selected. Reduced vehicle traffic Most bridge widening projects require that a portion of
speeds of 20 mph (30 km/h) have been reported in practice. the existing bridge be removed. This is usually the railing
d) The traffic lane adjacent to the connecting joint was or sidewalk and sometimes portions of the bridge deck,
closed for a few days after placing new bridge deck concrete. substructure, or wing-walls. Methods of removal that could
The total load would have approximately been reduced by damage the existing structure to remain should not be
the amount of the AASHTO lane load not present during the permitted.
lane closure. 4.2.1 Shored excavationBridge widening generally
e) Temporary shoring was installed under the existing involves shored excavation immediately adjacent to the
bridge during this period. existing bridge and removal of portions of the existing bridge
Although all of these measures have been used, Items c (Fig. 4.2.1). When groundwater is concerned, the design
and d are generally more economical when compared to professional should minimize the depth of excavation.
others. They require only a short-term restriction of traffic. Shoring of excavations is usually the responsibility of
3.3.3 Differential longitudinal shortening for post- the contractor. Construction engineers should monitor this
tensioned applicationsFor cast-in-place, longitudinally- phase of the work carefully because public safety and safety
post-tensioned concrete widening, it is essential that the new of the existing bridge or adjacent highway facilities can be
work be allowed to shorten initially without restraint from jeopardized by the failure of shoring. Specifications should
the existing bridge. If connected during post-tensioning,
restraints will cause some of the stressing force to be trans-
ferred into the existing bridge, creating undesirable stresses
in it and reducing the prestressing force in the new work.
When the two are to be rigidly connected in their completed
state, a specific construction sequence and the use of delayed
closure placements are strongly recommended.
3.3.4 Differential expansion characteristics for transverse
expansion jointsWhenever the widening is to be connected
to the existing bridge, it is important that transverse bridge
deck joints be located in the superstructure of the widening
in the same longitudinal locations where such joints occur in
the existing bridge.
3.3.5 Differential foundation settlementThe amount
of tolerable differential foundation settlement between old
and new construction depends on the configuration of the Fig. 4.2.1Shoring to protect roadway during abutment
widening. If the joint between the existing structure and widening.
extending from the existing bridge deck that are too short
to give sufficient development length may be extended by
approved mechanical connections or full-strength welds.
Welding can be used when the extension being welded is
free from restraint during the welding process to permit
shortening of the bar as the weld cools.
AWS D1.4/D1.4M contains recommended details for
making welded splices in reinforcing steel and requires
making a chemical analysis of the steel to determine its
weldability. The document provides procedures for welding
splices if chemical composition is unknown.
In addition, AASHTO LRFD (AASHTO 2010) includes
additional limits on maximum slip. Several types of mechan-
ical connectors are available that meet the ACI 318 criteria
of development of at least 125 percent of the yield strength
of the bar. AASHTO LRFD (AASHTO 2010) includes limits
on maximum slip not included in ACI 318. Fig. 4.4.7Corrosion of epoxy-coated reinforcement at the
Longitudinal reinforcing bars should be placed in the leaking closure pour construction joint.
closure placement to distribute shrinkage cracks and mini-
The amount of creep deflection in concrete members is a
mize crack width per the distribution reinforcement require-
direct function of the level of applied stresses. The rate of
ments in AASHTO LRFD (AASHTO 2010).
creep decreases with the age of the concrete and the length
4.4.3 FormsForms for the bridge deck closure place-
of time since the formwork has been removed. Any creep
ment should be supported from the superstructure on both
deflection of the girders in the widening that occurs after the
sides of the closure. They then act as an articulated ramp to
bridge deck closure has been placed will produce stresses in
spread the effect of any differential vertical movements over
the closure and adjacent bridge deck. These stresses will, in
the widths of the closure. These forms should not be placed
turn, however, be reduced by creep in the closure concrete.
between old and new structures until all other concrete in
The rate of deflection of the girders must be considered
the widening has been placed and the falsework is released.
to decrease to a level that can be tolerated by the closure
4.4.4 ConcreteSpecific requirements are necessary for
concrete before closure concrete is placed.
encasing reinforcing steel that is subject to vibration from
These combined actions, with younger concrete in the
external forces during the first few days after placement
closure than in the widening, make the required delay period
(Whiffen and Leonard 1971; Arnold 1980; Furr and Fouad
very difficult to calculate and is normally based on experi-
1981). This applies to closure placements and bridge deck
ence. For several years, the California Department of Trans-
widenings when traffic is allowed on the old bridge during
portation (Caltrans) has required that whenever the false-
construction. An appropriate specification for the concrete for
work is removed at the earliest permitted date, the closure
bridge decks will include performance criteria for concrete
concrete should not be placed until at least 60 days after the
mixture design development and quality control as well
falsework is removed (Caltrans 1991). As an alternative, if
as quality assurance that is used to accept concrete during
the falsework is left in place for at least 28 days after casting,
construction. If the quality of existing concrete is consider-
then the closure concrete should not be placed sooner than
ably different from that of new concrete, constructed bridge
14 days after falsework removal.
decks may need a corrosion protection system to preclude
4.4.6. DiaphragmsWhen bridge deck closure placements
the potential of corrosion propagation.
are employed, diaphragms connecting new to old girders are
4.4.5 Time of placementThe timing of the placement
left disconnected until all other work is completed, except
of concrete for closure placements depends on the type of
for the placement of the closure. The diaphragms are then
structure. For steel girders or precast prestressed concrete
connected just before the placement of the closure.
girder bridges, closure placements can be made as soon as
4.4.7 MaintenanceExperience indicates that one or
the majority of new dead load (for example, any overlay,
both of the longitudinal construction joints in a closure
sidewalk, or other) is on the widening. For widenings
pour can leak. The joints may leak because of shrinkage of
consisting of more than one girder, the exterior railing need
the concrete in the closure pour as well as shrinkage of the
not be placed before closure.
concrete in widened portion of the bridge deck. Reinforce-
For cast-in-place concrete construction, a delay after
ment, including epoxy-coated reinforcement, across the
removal of falsework should be provided to allow the rela-
leaking joint can corrode, lose section, and fail as shown in
tively rapid early dead-load deflection to occur before the
Fig. 4.4.7 (Sprinkel et al. 2010). The problem can be reduced
bridge decks are connected. The length of the delay period,
by using concrete materials that do not have high exotherm
along with the width of the closure placement, should be
and drying shrinkage. These infill sections are highly
engineered to accommodate the dead-load deflection that
restrained and small shrinkages will induce large tensile
will occur in the widening after the closure is placed.
stresses leading to cracking upon later shrinkage. Leaking
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Research Laboratory Section, Michigan Department of Scordelis, A. C., and Seible, F., 1983, Time-Depen-
Transportation. dent Behavior of a Skew Reinforced Concrete Box Girder
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Project No. 7604, Georgia Department of Transportation. Steel Structures, Bridge Inspection and Rehabilitation: A
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