Research, Development,and Technology

Turner-FaIrbank HighwayResearch Center6300 Georgetown PikeMcLean, Virginia 22101

A Report No.FHWA/RD-85/045

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Final ReportAugust 1985

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u.s. Departmentof TransportationFederal HighwayAdministration

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TABLE OF CONTENTS (continued)

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MATERIAL ECONOMICS OF LIGHTWEIGHT CONCRETESingle-Cell Box GirdersSteel Plate GirdersAASHTO I-GirdersSegmental Box GirdersCable-Stayed BridgesReduction in Steel by Using Lightweight Concrete

101101102102

103104105

DISCUSSIONAdvantages of Lightweight ConcreteDisadvantages of Lightweight ConcreteAdequacy of SpecificationsMaterial and Structural Propertiesof Lightweight AggregatesPrestressing of Lightweight ConcreteCost Analysis

107107109

FINDINGS AND RECOMMENDATIONSFindingsRecommendations

110

113

APPENDIXES1. Rotary-Kiln Lightweight-Aggregate Plants2. Structural Lightweight-Concrete Bridge

Guide Specifications3. Structural Lightweight-Concrete Bridge

Field Control Procedures 122

138REFERENCES

142BIBLIOGRAPHY

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The first extensive use of structural lightweight concrete was inthe building of ships during World War I. Its use soon spread tobuildings, and then to bridges. On a volume basis, lightweightaggregates are at present mostly used in the production of concretemasonry blocks for buildings. Other uses in the building industryinclude lightweight structural members, both cast-in-place andprecast. The lighter concrete weight is especially advantageousfor the transportation and erection of precast concrete members.

Lightweight concrete has become established in the building con-struction industry. Building designers and contractors are famil-iar with the material, and have routinely used it where it is

economically or functionally justified.

The acceptance of lightweight concrete in the construction ofbridges has been slower than in buildings. So far, it has mainlybeen used in roadway decks over steel girders. Onlyoccasionallyis it used in the primary structural members of a bridge.

The performance of the lightweight concrete in bridges has gen-erally been satisfactory, but there have been problems. Most of theproblems have to do with the specifications of the concrete, itsplacement in the field, and the familiarity with its behavior.There have also been conflicting opinions regarding the occasional

poor performance of the material.

Although there is no consensus of opinion concerning the suita-bility of lightweight concrete for bridge structures, nor con-cerning experiences with its performance, it should be noted thatthe material does have sufficient record of successful applicationsto make it a suitable construction material for buildings and ships,

as well as for bridges.

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