Project title: Development of precast bridge deck overhang system

Project 0-6100The implementation of full-depth, precast overhang panel systems has the potential to improve constructability,productivity, and make bridges more economical. Initial testing and analyses reported in the 0-6100-2 report resulted ina design that required a large number of shear pockets in the overhang panels. The general design methodology used inthis report was to determine the number of connectors based on the shear capacity of a girder with conventional R-bars(not necessarily based on the required demand). The large number of shear pockets reduced the constructability andeconomy of the precast overhang system. Report 0-6100-1 (produced after 0-6100-2) used the American Association ofState Highway Officials Load and Resistance Factor Design (AASHTO LRFD [2008]) demand requirements to designthe number of shear pockets for a precast overhang panel system and reported that the number of pockets per panel couldbe reduced from the numbers reported in report 0-6100-2. However, this report only included an analysis for one beamtype and one span length. In addition, the demand load used did not include all factors typically used by designers.Additional testing was required to assess different connector systems and further analyses were needed for the new TexasDepartment of Transportation (TxDOT) girders. The testing and analyses documented in this report (0-6100-3) providesa new equation for determining the number of shear pockets required for the various shear connector/coupler systemsevaluated in this research. This equation was used to determine the number of shear pockets required for the newerTxDOT girders. Results from this research indicate that the roughened surface provides strong adhesion between the topgirder surface and a precast panel. Steel reinforcing hoops placed in the shear pocket and shear reinforcing hoops placedin the overhang panel around the opening of the shear pocket provided limited or no improvement in capacity of theshear connector/coupler system. Hollow structural section (HSS) steel tubes placed around the perimeter of the shearpocket during fabrication did result in samples with higher shear capacities and could result in overhang panels withfewer shear pockets. This system could make constructing bridges with precast overhang systems more constructible,economical, and could reduce the construction time