Research, Development,and Technology

Turner-FaIrbank HighwayResearch Center6300 Georgetown PikeMcLean, Virginia 22101

A Report No.

FHWA/RD-85/045

~Final Report

August 1985

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'P

u.s. Departmentof Transportation

Federal HighwayAdministration

111

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TABLE OF CONTENTS (continued)

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MATERIAL ECONOMICS OF LIGHTWEIGHT CONCRETE

Single-Cell Box Girders

Steel Plate Girders

AASHTO I-Girders

Segmental Box Girders

Cable-Stayed BridgesReduction in Steel by Using Lightweight Concrete

101101102102

103

104

105

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

107107109

FINDINGS AND RECOMMENDATIONS

FindingsRecommendations

110

113

APPENDIXES1. Rotary-Kiln Lightweight-Aggregate Plants

2. Structural Lightweight-Concrete BridgeGuide Specifications

3. Structural Lightweight-Concrete BridgeField Control Procedures 122

138REFERENCES

142BIBLIOGRAPHY

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The first extensive use of structural lightweight concrete was in

the building of ships during World War I. Its use soon spread to

buildings, and then to bridges. On a volume basis, lightweight

aggregates are at present mostly used in the production of concrete

masonry blocks for buildings. Other uses in the building industry

include lightweight structural members, both cast-in-place and

precast. The lighter concrete weight is especially advantageous

for 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 of

bridges has been slower than in buildings. So far, it has mainly

been used in roadway decks over steel girders. Onlyoccasionally

is 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 the

problems have to do with the specifications of the concrete, its

placement 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 that

the material does have sufficient record of successful applications

to make it a suitable construction material for buildings and ships,

as well as for bridges.

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