Basic Performance of the Composite Deck System Composed of Orthotropic Steel Deck and Ultrathin RPC Layer

Abstract

Fatigue damage in a conventional orthotropic steel bridge deck system poses a formidable challenge to bridge engineers all over the world because of ever-increasing heavy traffic volumes and higher wheel loads over the past decade. An effective solution may be to enhance the stiffness of the bridge deck to reduce the fatigue stress amplitude of its components. This paper proposes an innovative composite bridge deck system that consists of an orthotropic steel deck stiffened with a 45-mm reactive powder concrete (RPC) layer. Based on the analysis of HuMen Bridge in China (a suspension bridge with a conventional orthotropic steel bridge deck system with span length of 888 m) and two types of full-scale model tests, a comparison investigation is conducted between a conventional orthotropic deck system where the asphalt wearing course has been ignored and the proposed orthotropic deck system that includes an integral concrete wearing course, and the proposed composite bridge deck system proves to be considerably effective in reducing the stress range caused by service vehicle loads when applied to long-span steel suspension bridges. The thin RPC layer can be reliably integrated with the deck plate through stud shear connectors, and no shrinkage cracking occurs on the surface of the RPC layer that is cast on the deck plate. The fact that the tensile stress of the RPC layer is up to 42.7 MPa before cracking occurs demonstrates that cracking will not appear in the RPC layer under service vehicle loads. The analysis, which is investigated on the premise that the dead load weight of the bridge deck of HuMen Bridge is approximately the same for the two different deck systems, demonstrates that the stress of the orthotropic steel deck is significantly reduced with the application of the proposed composite deck system. Analysis with a three-dimensional finite-element model indicates that the transverse tensile stress of the deck plate is reduced by 71%, while that of the connection between the deck plate and the longitudinal troughs is reduced by 72%. This indicates that the risk of causing fatigue cracks in the steel bridge deck system can be considerably reduced during the entire life cycle of the bridge.