BEHLOUL, Ductal traIIic bridge, 1/10

DUCTAL PRESTRESSED GIRDERS FOR A TRAFFIC

BRIDGE IN MAYENNE, FRANCE

Mouloud BEHLOUL
LaIarge, France
Olivier BAYARD

LaIarge Ciments, France
Jacques RESPLENDINO
CETE de Lyon, France










Abstract
Ductal, is a new material technology developed over the last decade that oIIers a
combination oI superior technical characteristics including strength, ductility and
durability, while oIIering a variety oI shapes and excellent surIace aspect. Compressive
strengths reach up to 200 MPa and Ilexural strengths reach up to 40 MPa.
Ductal technology covers a range oI Iormulations that can be adapted to meet speciIic
request oI diIIerent customer segments, enhancing the usage value and contributing to
the overall construction perIormance. By utilizing the material`s unique combination oI
superior properties, designs can eliminate passive reinIorcing steel and experience
reduced global construction costs, Iormworks, labour and maintenance. Number oI
reIerences using Ductal have been already established in diIIerent countries, both in
structural and architectural applications. In this paper, the Iirst use oI the Ductal
technology Ior a bridge in France is presented.
As part oI the project Ior a bypass around the Saint-Pierre-la-Cour conurbation
commissioned by the Mayenne General Council, a 20-meter bridge was built over a
railway line. The ten 20-meters length prestressed girders without rebars and 83 precast
slabs they support are all made oI Ductal. Although not exceeding 25 mm thick, the
precast slabs support a conventional 20-cm concrete apron. All the girders and precast
slabs were laid in two days, thanks to the speed this technique aIIords.
A comparison with a traditional solutions indicates a reduction oI the weight oI the
bridge deck by a Iactor 2.2.

1. Introduction

Ductal

, the outcome oI the research over the last 10 years in the area oI concrete, is a

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new construction material technology belonging to UHPFRC Iamily, with very high
durability, compressive strength, Ilexural resistance with ductility and aesthetics (1).
Through the development period, several prototypes have been produced, prior to make
an extensive use in civil works, structural and architectural various applications (2).

A material with such high mechanical and durability properties oIIers interesting
opportunities in the Iield oI bridges and Iootbridges and prestressed applications. As
might be expected, the high Ilexural tension capacity also gives rise to extremely high
shear capacity. This allows Ductal to carry the shear load in the structure, without
providing auxiliary shear reinIorcement. The elimination oI passive reinIorcement
makes it possible to use thinner sections and a wider variety oI innovative and
acceptable cross-sectional shapes.

Several Ductal Iootbridges were constructed round the world : Sherbrooke in Canada
Seonyu in Korea (3) Sermaises in France- Sakata Mirai and Akakura in Japan and
Papatoetoe et in New Zealand. All these projects proved the interest oI the Ductal
technology Ior such applications.
Also several short span bridges were constructed : Bridge oI the Future`, Washington,
US (4) Wappello, Iowa, US- East Kyushu Expressway in Japan- Shepherd in
Australia (5) and Saint Pierre La Cour in France which will be presented in details in
this paper.
For these projects, diIIerent designs were investigated (Iigure 1) :
Double T solution : in that case all the bridge superstructure is made oI Ductal;
this solution was used Ior the Bridge oI the Iuture` in Washington
Composite solution Ductal beam ordinary concrete deck : this solution was
selected Ior the Wappello, Kyushu, Shepherd and Saint Pierre La Cour bridges
Composite solution steel girders Ductal deck : this solution is still under
investigation in the R&D French national project MIKTI (6)

The Iirst two solutions suit the short span bridges. The third one can be used Ior mid
and long span bridges.

Ductal segment
Composite solution :
Ductal girders
ordinary concrete deck
Composite solution :
Steel girders
Ductal deck
Solution 1
Solution 2 Solution 3

Figure 1. DiIIerent investigated solutions









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2. Ductal

technology

Ductal is based on the principle that a material with a minimum oI deIects such as
micro-cracks and pore spaces will achieve a greater percentage oI the potential ultimate
load carrying capacity deIined by its component materials, and it will also have greater
durability. By applying this principle as a guideline, a concrete has been proportioned to
provide a very dense mixture that will minimise voids and a very high compressive
strength, but with not enough ductility compared to a conventional mortar. The
inclusion oI adequate Iibres improves drastically tensile strength and provides a
substantial level oI ductility.
The various Ductal Iormulations are all based on an optimized composition
combining homogeneity and adequate granular compactness.

To enhance and to stabilize the perIormances, especially mechanical ones, the option oI
heat treatment can be chosen. For each application according to technical and
economical challenges, adequate adjustments are made within Ductal technology in
order to achieve the most adapted product to the customer requirements.
As described above, Ductal is an Ultra-High PerIormance Concrete reinIorced with
Iibres. These Iibres can be made oI steel (Ductal-FM), made oI organic material
(Ductal-FO) or combination oI both steel and organic material (Ductal AF).
The Iresh mix oI all these ranges oI material have very useIul properties in term oI
Iluidity and selI placing. Most oI the standard industrial batching Iacilities are able to
mix Ductal requiring only minors adjustments.

Ductal-FM, used Ior structural applications, includes small steel Iibres at a dosage oI
2 per volume, and oI 0.20 mm in diameter and 12 mm in length. In a typical load
deIlection graph oI a sample under three-point loading, the material exhibits linear
behaviour up to its Iirst crack stress, a post-Iirst-crack strain hardening phase up to its
ultimate Ilexural load, and a post-ultimate-load strain soItening phase. It has an ultimate
bending stress that is over twice its Iirst crack stress and more than ten times the
ultimate stress oI conventional concrete (Figure 1).
0
I0
Z0
30
40
b0
o0
0 Z00 400 o00 800 I000 IZ00 I400
Displacement in m
B
e
n
d
i
n
g

s
t
r
e
s
s

i
n

M
P
a

Ordinory concrefe

Figure 2. Ductal-FM behaviour in bending









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Table 1. Main properties oI the material with steel Iibres or organic Iibres

Ductal-FM or
Ductal-AF
With Thermal Treatment
Ductal-FO
Without Thermal
Treatment
Density 2500 kg /m3 2350 kg/m3
Mean value 180 200 MPa 130 160 MPa Compressive
Strength Characteristical value 150 180 MPa 100 140 MPa
Mean value 40 45 MPa 18 25 MPa Flexural Strength
(4*4*16 cm) Characteristical value 30-40 MPa 15-20 MPa
Mean value 11 MPa 8 MPa Tensile Strength
Characteristical value 8 MPa 5 MPa
Mean value 10 MPa 4 MPa Residual tensile
strength (0.3mm) Characteristical value 8 MPa 3 MPa
Young Modulus (E) 50 GPa 45 GPa
Poisson Ratio 0.2 0.2
Shrinkage 10 m/m 550 m/m
Creep Iactor 0.3 0.8
Thermal expansion coeIIicient 11.8 m/m/C 11.8 m/m/C

The Ductal microstructure is completely closed, making it resistant to abrasion,
corrosion or chemical attacks. Such superior characteristics give the material ultra-high
perIormance durability properties. The table 2 hereaIter shows some durability
properties oI heat treated Ductal-FM and a comparison with ordinary concrete and
high perIormance concrete properties.

Table 2. Ductal main durability properties

Durability indicator Ordinary
concrete
HPC Ductal-FM
Water porosity () 12-16 9-12 2-6
Oxygen permeability(m) 10
-15
10
-16
10
-17
10
-19

Carbonation depth (mm) aIter
one month oI accelerated tests
10 2 0.1
Abrasion test IV/V
glass
4 2.8 1.3-1.7

3. Description of the bridge

The Saint Pierre La Cour bridge was constructed by Quille, designed by
VSL&Bouygues Travaux Publics, controlled by CETE de Lyon Ior the owner LaIarge
Ciments. This bridge is approximately 22 km west oI Laval city. It comprises two
traIIic lanes plus a Iootway (Iigure 3). The bridge is a single span oI 19m length. It has a
width oI 12.9m and is on a skew oI 45 degrees. The superstructure comprises 10 precast
pretensioned Ductal-FM beams and an in-situ reinIorced concrete deck slab.









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The slab is placed onto thin precast Ductal-FM permanent Iormwork slabs that span
between the beams (Iigure 4). The beams are oI I-section, with a depth oI 750mm. They
are spaced at 1.395m. The Iormwork slabs are 1.1m wide, 2.4m long, with a thickness
oI 25mm. The reinIorced concrete slab is 200mm thick.


Figure 3. Transversal section oI the bridge

On this structure a Iorm layer oI 350mm thickness was spread. On the Iorm layer an
asphalt layer oI 90mm thickness was spread. And Iinally a continuous reinIorced
concrete layer was developed on the top (Iigure 3). All these successive layers induce
high loads on the bridge structure. Using Ductal allows the reduction oI the beam
sizes.

350
750
1395 mm
200
Ductal precast slab
e=25 mm
Ductal beam
Ordinary concrete deck

Figure 4. Description oI the composite solution

The Ductal girders are prestressed by 14 0.6strands in the lower Ilange and 4
0.6strands in the upper strands.
Steels bars are embedded in the Ductal girders during the Iabrication (Iigure 5). These
elements are then used to connect the girders to the cast in-situ ordinary concrete deck.










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Figure 5. Girders-deck connexion

4. Design and characterization tests

In France, new recommendations Ior the use oI ultra-high strength concretes reinIorced
with Iibres have been issued in May 2002 (7). These recommendations were established
by a BFUP working group (Beton Fibre Ultra PerIormant) coordinated by SETRA
(Road and traIIic national agency) and with representatives oI construction industries
(contractors, control agencies, suppliers, certiIication authorities).
These recommendations were used to design the Saint Pierre La Cour bridge. There are
two steps : pre-design value determination and suitability tests.
The pre-design value determination is made on 7*7*28 cm samples Iabricated in a
laboratory. Two diIIerent tests are perIormed on the samples :
- Four point bending tests on un-notched specimens : these tests allow to
determine the Iirst cracking strength in bending Irom which the direct tensile
strength deduced using the FIB scale eIIect model. In the case oI this project,
the direct tensile strength equals 9.7 MPa (characteristic value).
- Three point bending tests on notched specimens : these tests allow to
determine the tensile stress versus crack opening using a reverse analysis
method (7). In this project, the tensile strength Ior a crack opening oI 0.3 mm
equals 7.5 MPa.











Figure 6. Prototype Ior suitability tests









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The suitability tests are then perIormed on a prototype Iabricated using the same casting
procedures as Ior the Iull scale elements. The objective is to determine Iiber orientation
Iactors K. These K Iactors are then used Ior the Iinal design. ThereIore the actual Iiber
distribution in the girder is taken into account Ior the design.
In the case oI the present project, a prototype oI the beam oI 3 m in length was
Iabricated using the same casting procedures as Ior the Iull scale girders (Iigure 6). The
prototype was heat treated and then several 7*7*28 cm samples were taken out Irom
this prototype in diIIerent orientations (Iigure 7). Mechanical tests have been then
perIormed on these specimens in order to determine the Iiber orientation Iactors K. The
obtained orientation Iactor was equal to 1.34 Ior the global eIIect (e.g. shear, bending,
.) and 1.81 Ior the local eIIect (e.g. zone oI prestressing introduction, punching
zone.).
Figure 7. Position oI the specimens taken out Irom the prototype


5. Prefabrication of the Ductal elements

The girders and panels were preIabricated at CPC precast plant, next to Brives. The
Ductal was mixed in batchs oI 1.9 m3 in a traditional mixer with a capacity oI 2.5m
3
.
The Iresh Ductal is basically selI-placing, so no vibration was required during casting
oI the elements.

Figure 8&9. Casting oI the panels

The Ilat panels were demoulded 18 hours aIter casting and were then heat treated at
90C and HR~90 Ior 48 hours.










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Figure 10. Casting oI the beam

Adapted curing conditions were applied Ior the Iabrication oI the girders. The
Iormworks were heated at a temperature oI 40C until the setting time. This curing
conditions allowed to reach a compressive strength oI 80 MPa at 18 hours needed Ior
the prestressing de-tensioning (Iigure 11).

Figure 11. De-tensioning oI the prestressing

AIter complete demoulding, the girders were covered and heat treated with a humidity
saturated atmosphere with a temperature between 70C and 90C.










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6. Erection

Conventional construction method was used Ior the erection oI the bridge. The 20m
length girders have the signiIicant advantage oI being light and with a weigh not
exceeding 9.5 tons. This lightness allows to reduce the size oI the crane.

Figure 12&13 Erection oI the bridge

AIter installation oI the girders and the panels, the ordinary concrete deck was poured
using traditional method. The design allows a quick installation oI the deck and
thereIore reduces the perturbation oI the traIIic under the bridge.



Figure 14. View oI the bridge aIter completion










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7. Conclusion

Ductal is a new technology oI ultra-high strength concretes that constitutes a
breakthrough in concrete technology. This Iamily oI products is characterised by a very
dense microstructure and very high compressive strength achieving and possibly
exceeding 200 MPa.
The current structural precast shapes used Ior prestressed beams in bridges and
buildings have been shaped Ior concretes with much lower strength properties. Their
dimensions and design would not allow to take advantage oI very high perIormances oI
Ductal. In order to make the best use oI the higher mechanical properties, there is
several opportunities to introduce new shapes in prestressed beam design. Through such
re-design approach oI the elements the beam dead load can be reduced by a Iactor
which reaches three. In the case oI the Saint Pierre La Cour bridge, a comparison was
made with a traditional concrete deck solution (Iigure 15). The reduction Iactor equals
2.2.

12.909
Traditional reinIorced concrete solution


Figure 15. Comparison Ductal and traditional solution

8. References
1. Orange, G.; Dugat, J.; Acker, P.; 'A new generation oI UHP concrete : Ductal.
Damage resistance and micromechanical analysis; Proc. oI the 3d Internat. RILEM
Workshop, HPFRCC3-1999, 101-111.
2. Behloul, M.; Durukal, A.; Batoz, J.-F.; Chanvillard, G.; 'Ductal : Ultra High-
PerIormance Concrete Technology with Ductility; International Rilem Symposium
on Fibre ReinIorced Concretes BEFIB`2004, September 22-24 Varenna, 2004.
3. Behloul, M.; Lee, KC.; 'Ductal Seonyu Iootbridge ; Structural Concrete. 4 (4),
(2003) 195-201.
4. Graybeal, B.; Hartamann, J.; Perry, V.; "Ultra-high perIormance concrete Ior
highway bridge"; FIB Symposium, Avignon - 26-28 April 2004.
5. Cavill, B. and Chirgwin, G; 'The worlds Iirst Ductal road bridge Sherpherds gully
creek bridge, NSW ; 21st Biennial ConIerence oI the Concrete Institute oI
Australia, Brisbane, 2003.
6. Toutlemonde F. et al ; 'Innovative design oI ultra-high perIormance Iiber-reinIorced
Concrete ribbed slab : experimental validation and preliminary detailed analyses;
7th International Symposium on Utilization oI High Strength / High PerIormance
Concrete, Washington D.C. (USA), June 20-22, 2005, ACI SP-228.
7. BFUP-AFGC; 'Ultra High PerIormance Fibre-ReinIorced Concretes, Interim
Recommendations ; AFGC publication, France, (2002).