First Application of UHPC Bridge Deck Overlay in North America

Deterioration of existing bridge decks, which usually originates with the deck cracking on the top surface, is a common problem in North America. It causes frequent repair of the decks to limit further damage resulting from water/chloride ingress. Superior engineering and durability properties facilitate the use of ultra-high performance concrete (UHPC) as an attractive alternative for a deck overlay, minimizing both deck deterioration and maintenance costs. Recently developed UHPC thixotropic mix designs, which are different from commonly used self-leveling UHPC, enable UHPC overlay to be used on decks with slopes and meet specific crowning requirements. The use of a UHPC thixotropic mix design with 3.25% of steel fibers was successfully evaluated under laboratory conditions by applying it on sloping deck surfaces with appropriate roughness between the normal concrete (NC) and UHPC. The feasibility of applying this technology in the field was then investigated on a small bridge for the first time in North America in May 2016. This paper presents the details about the laboratory evaluation, field implementation of UHPC overlay, and lessons learned from this first UHPC overlay project in North America.