Enhancing Resiliency and Delivery of Bridge Elements using Ultra-High Performance Concrete as Formwork

A feasibility study of the use of ultra-high performance concrete (UHPC) shell as a formwork is presented. The core concept of the research, developed by the first author, is prefabrication of UHPC shell which acts as a stay-in-place formwork. In the proposed approach, after transporting the UHPC shell to site, the construction of structural elements is completed by placing reinforcing cage inside the UHPC shell and post-pouring with normal concrete. The superior properties of UHPC provide excellent means to enhance the service life of bridge elements, while eliminating the need for assembling or stripping of formwork. As a proof of concept, a combination of experimental and numerical studies was conducted, results of which are reported here. Before conducting experimental work, numerical study in the form of finite element analysis was carried out to investigate performance of shell during placement of the normal concrete. To provide a baseline comparison between UHPC shell formwork and conventional methods, two test specimens were constructed and tested under three-point load setup. The shell test specimen demonstrated flexural strength, 14% greater than an equivalent normal strength concrete specimen. The UHPC shell test specimen failure occurred by debonding of shell at the interface and development of a large crack in the shell. The shell test specimen exhibited improved levels of ductility before failure. The preliminary analysis demonstrated that the idea is feasible and useful for accelerated bridge construction applications.