Structural Behavior of Single Key Joints in Precast Concrete Segmental Bridges

A group of five full-depth male–female shear key specimens were match cast and tested to examine the shear capacity of epoxy-jointed single keys. Another group of four specimens were match cast using full-scale dimensions of a segmental construction bridge deck system for testing the fatigue and water tightness at a segment joint. Both cold-weather and hot-weather epoxy types were used to join the specimens. In addition to the experimental testing, finite-element analysis was also used to model the static response of the joint specimens. The observed failure mode of all shear-key specimens was fracture of concrete along the joint with shearing of the key. Good agreement was observed between the experimental test results and the finite-element analysis in terms of the failure mode of unreinforced specimen and the load of crack initiation of the specimens. Fatigue loading had a minor effect on the behavior of the posttensioning bars. The contribution of either the cold-weather or hot-weather epoxies to the joint shear strength was significant knowing that for similar concrete properties, the hot-weather epoxy specimens showed an increase of about 28% in the shear capacity, in comparison to the cold-weather epoxy specimens. The excellent performance of the epoxy-jointed shear keys was verified by field application on a prototype model simulating a portion of the Wacker Drive Bridge system. It was concluded that implementing AASHTO procedures result in conservative estimates of the shear strength of the single keyed joint since it neglects the contribution of the epoxy and underestimates the strength of the key itself.