3D Printed Advanced Materials to Mitigate Prestressed Concrete Girder End Cracks

Details

• Creators:
  Singh, Pranay ; Ranade, Ravi ; Zhou, Chi ; Okumus, Pinar
• Corporate Creators:
  State University of New York at Buffalo
• Corporate Contributors:
  Transportation Infrastructure Precast Innovation Center (TRANS-IPIC) Tier-1 University Transportation Center (UTC) ; United States. Department of Transportation. University Transportation Centers (UTC) Program ; United States. Department of Transportation. Office of the Assistant Secretary for Research and Technology
• Subject/TRT Terms:
  Anchorages Beams Cement Content Composite Materials Crack Control Cracking Durability Finite Element Method Girders Nonlinear Differential Equations Prestressed Concrete Strain Hardening Structural Tests Three Dimensional Printing

  More +
• Publication/ Report Number:
  UB-23-RP-02
• Resource Type:
  Tech Report
• Geographical Coverage:
  United States
• Edition:
  Final Report: September 2023 - December 2025
• Corporate Publisher:
  Transportation Infrastructure Precast Innovation Center (TRANS-IPIC) Tier-1 University Transportation Center (UTC)
• Abstract:
  Pretensioned bridge girders with thin, deep webs often suffer anchorage-zone cracking during prestress release, leading to durability issues such as chloride ingress and strand corrosion. This study proposes a 3D-printed ductile concrete cover at anchorage zones to prevent macro-cracks from occurring at the external surface. A performance-based design approach integrating structural analysis, material development, and fabrication is adopted. Nonlinear finite element analyses defined hardened-state requirements, while experiments established rheological properties for printability. Beam tests confirmed that tensile strain capacity above 0.6%—achievable with strain-hardening cementitious composites—is essential. Interlayer bonding in 3D-printed concrete was improved through optimized printing parameters. Surface imperfections enhanced bonding between 3D-printed and conventional concrete. Durability and structural tests demonstrated improved crack control and performance, offering a practical pathway to integrate 3D-printed ductile concretes into girders while preserving efficiency and economy.
• Format:
  PDF
• Funding:
  69A3552348333
• Collection(s):
  University Transportation Centers
• Main Document Checksum:
  urn:sha-512:38a9b11dc3adb1bbef680edfd7a89aca1572a9b013e2bdd14d90e47ab231afecf487c794008bbad7fc88cd11cc4b1427f7a2249ab3c3909aa49566d30ce80358
• Download URL:
  https://rosap.ntl.bts.gov/view/dot/89206/dot_89206_DS1.pdf
• File Type:
  [PDF - 4.38 MB ]