SEISMIC PERFORMNACE AND STRUCTURAL DETAILS OF PRECAST

SEGMENTAL CONCRETE BRIDGE COLUMNS

Jun-ichi Hoshikuma1, Shigeki Unjoh2, Junichi Sakai3

Abstract

The precast segmental concrete bridge column would be one of the options for
the accelerated bridge constructions because the construction period at site can be
shorten due to no need of formwork, placement and curing of concrete. Thus, those
columns are expected to be applied for the bridges for overpass crossings in urban
areas to minimize the effect on existing traffic. Additionally, high quality of the
concrete members would be ensured because the concrete segments are fabricated at
factories. This paper briefly introduces the state-of-practice of the segmental concrete
bridge columns in Japan. Furthermore, recent research activities in PWRI for the
precast segmental concrete bridge columns are summarized.

Introduction

With a background of the generalization of the performance-based design

concept into practices, the applications of new materials, new designs, and new
structures have initiated to be actively employed with necessary performance
verifications. The precast segmental bridge columns are one of such new applications,
and effectively use the combination of high strength materials including steels and
concrete. The precast segments are fabricated at factory, so that the precast segmental
bridge columns can be easily achieved to have better-quality. Therefore, the precast
segmental bridge columns are expected to improve the constructionability at sites and
shorten the construction period.

Public Works Research Institute conducted 2-years joint research program for
the development of the new precast segmental concrete bridge columns with three
private construction companies. In the research program, three types of structural
details of precast segmental concrete bridge columns were proposed and the failure
mechanism of the proposed columns was investigated through a series of shake table
test. Based on the experimental studies, the limit states for the required seismic
performance are discussed in this paper. Structural details for those columns were also
introduced.

1
Chief Researcher, Center for Advanced Engineering Structural Assessment and
Research, Public Works Research Institute (PWRI)
2
Research Coordinator for Earthquake Disaster Prevention, Research Center for
Disaster Risk Management, National Institute for Land and Infrastructure
Management (NILIM)
3
Senior Researcher, Center for Advanced Engineering Structural Assessment and
Research, Public Works Research Institute (PWRI)
Structural Concept of Precast Segmental Bridge Columns

Figure 1 shows the outline of the precast segmental bridge columns which have
been designed and constructed in the past in Japan. The precast segments are produced
at factory and transported to the construction site. These segments are piled up at the
site and connected each other through the steel bars, to be a column. It would be an
important advantage to shorten the construction period at the site because of no need
of formwork, placement and curing of concrete. Therefore, the precast segmental
bridge system would be expected to be applied for overpass crossings in the urban
areas in order to decrease the traffic jamming and then to minimize the effect on
existing traffic.

Structural details of the conventional precast segmental bridge columns are

shown in Figure 2. There are two types of the precast segmental columns. The precast
PC columns are built with the segments connected through the high strength steel bars
columns, as illustrated on the left side section in Figure 2. Each segment is
post-tensioned by all high strength steel bars, to integrate with column structure. After
post-tensioning, the following segment is piled up on the lower segment and the high
strength steel bars are installed into the section through the ducts. These bars are
coupled with the lower high strength steel bars and the grout is injected to the duct to
be bonded. Details of the segment connection are shown in Figure 3. These processes
are repeated up to the column height.

On the other hand, the precast RC

columns are built with the segments
connected basically through the nominal
strength steel bar, as illustrated on the right
side section in Figure 2. A few high-strength
steel bars are installed and minimum
post-tension required for setup of the segment
is applied to these bars. The steel bars are
coupled and grouted with the same procedure
as the precast PC column.

Construction samples of the precast

segmental concrete columns or piles are
shown in Photos 1 and 2. Photo 1 shows
connection of the precast segmental PC piles
with the cast-in-place footing. Photos 2
shows the precast RC oval column
constructed very close to existing bridge
column.

Figure 1 Illustration of Precast Segmental

Concrete Columns
Figure 2 Concepts of Connection Details in Conventional
Precast Segmental Concrete Columns

Figure 3 Connection Details of Steel Bars in Segment

 Photo 1 Connection of Precast Segmental PC Piles with Cast-in-place Footing

Photo 2 Precast RC Oval Column Constructed Very Close to Existing Column

Recent Research Activities for Precast Segmental Bridge Columns in PWRI

PWRI conducted the joint research program on the new precast segmental
concrete columns with 3 private companies including Kajima Co., Sumitomo Mitsui
Construction Co., Ltd., and P.S. Mitsubishi Construction Co., Ltd. Three types of the
precast segmental concrete column details were proposed. Research issues were to
obtain the data on the failure mechanism, the strength and ductility performance, and
the dynamic behavior of proposed precast segmental bridge columns, and to develop
the design method including the limit states to achieve necessary seismic performance,
detailed design methods for segments, joints, PC cables, bending–shear resistance
evaluation, and construction methods. In the joint research program, a series of cyclic
loading tests, shaking table tests, and analytical studies were made to develop the
seismic design guidelines for the proposed precast segmental concrete columns.

Structural concepts of the proposed precast segmental concrete columns are

shown in Figures 4 to 6. The structural details and properties are described in the
followings. Figure 4 shows the outline of the precast PC column proposed by Kajima
Co. The segments are piled up at the site, and each segment has the outer and inner steel
pipes. Outer steel piles are embedded in the segment when it is produced at factory, and
inner steel pipe are installed at the site between the segments. The inner steel pipe is to
resist against the shear force acted the joints of segments as a shear key. After the piling
up of all segments for columns, the vertical tensioning force is applied for segments by
post-tensioning bars through the inner pipes, in which the those bars work as
longitudinal steel.

Sumitomo Mitsui Construction Co., Ltd proposed the precast segmental PC

hybrid columns as shown in Figure 5. The segments are piled up at the site. Each
segment is made of combination of inside steel shell and outside concrete. Inside steel
shells of the segments are connected by steel bolts. After the piling up of all segments
for column, vertical tensioning is applied for segments by external post-tensioning bars.
At the joints between segments, shear keys are provided at the edge of steel shell and
concrete mortar is placed between the segments outside concrete. Therefore, vertical
axial force by dead load and live load is carried by inside steel shell but the earthquake
force is carried by steel shells, bolts, and outside concrete. Shear force acted at the
joints is carried by the shear keys of steel shell. Steel shells and bolts, and PC cables
works as longitudinal steel. The bolts are designed to be firstly yielded when the
deformation is exceeding the elastic limit and then the steel shells are not expected to
be damaged. It is an important concept for this column that the yielded bolts can be
replaceable after the earthquake and then the columns can be easily recovered to the
original performance.

Figure 6 illustrates the precast RC column proposed by P.S. Mitsubishi

Construction Co., Ltd. The concrete segments are piled up at the site with a few
temporally post-tensioning bars. Those bars are provided not for tensioning as
longitudinal steel but for just construction to assure the quality of the joint connection
between segments by resin. After piling up of all segments, mild longitudinal steel bars
are inserted into the ducts, which are pre-grouted with the mortar from the top to the
bottom of the column. The columns are made of segments but the design concept is the
same as nominal reinforced concrete column. Since the longitudinal steel bars are
placed inside the sheathe of segments, so the confinement effect to prevent the
buckling of longitudinal bars is much higher than the nominal reinforced concrete
columns which is confined by the cover concrete and lateral steel bars.
 Figure 4 Precast Segmental Prestressed Columns Proposed by Kajima Co., Ltd.

Figure 5 Precast Segmental Hybrid Columns Proposed by Sumitomo Mitsui Co., Ltd.

Figure 6 Precast Segmental RC Columns Proposed by P.S. Mitsubishi Co., Ltd.

Limit States of Precast Segmental Bridge Columns

General Concepts of Limit States

It should be essential to determine the limit state for each seismic performance
level, to develop the seismic design method. In Design Specifications for Highway
Bridges issued by Japan Road Association, three seismic performance levels are
specified for intensities of design ground motions and importance of the bridges. The
limit states are determined based on the required seismic performance, which are
described in terms of the safety, serviceability and repairability. The schematic image
of the limit state for the conventional reinforced concrete bridge column is shown in
Figure 7.

For the seismic performance level 1, it is required to ensure the normal

functions of bridges after an earthquake, which means the mechanical properties of the
structural members should behave within the elastic ranges. For each structural
member, the stress induced by an earthquake shall not exceed its allowable stress. For
the seismic performance level 2, it is required to ensure the serviceability and
repairability after an earthquake. As the limit state, the structural members in which the
nonlinear behavior is allowed deform beyond elastic range but within a range of easy
functional recovery. For the seismic performance level 3, it is required to ensure the
structural safety during an earthquake. Since neither serviceability nor repairability is
required, structural members in which the nonlinear behavior is allowed deform within
the ultimate ductility capacity.

Limit States for Proposed Precast Segmental Concrete Bridge Columns

The limit states for the precast segmental concrete bridge columns shown in
Figures 4, 5 and 6 are determined considering the structural properties and nonlinear
behavior of each structure. For the seismic performance level 1, the limit states of the
precast segmental structures are determined to be same to a conventional reinforced
concrete column. For each structural member, the stress induced by an earthquake shall
not exceed its allowable stress.
The limit states for the seismic performance levels 2 and 3 are determined based on the
nonlinear behavior of each structure, which are introduced in details below.

x
Lateral force

: Before Yielding of Rebar

: Minor Spalling of Cover Co.
x : Before Rebar Buckling
Lateral
displacement

Figure 7 Limit states for Conventional Reinforced Concrete Columns

Limit States for Precast Prestressed Concrete Bridge Column
Because no mild longitudinal reinforcement is provided in the precast
prestressed concrete bridge column, the yielding of the post-tensioning steel bar is the
important limit state. Once the yielding of the post-tensioning steel bar occur, it is
difficult to recover the required functions. Based on these properties of the structure,
the limit states shall be determined as shown in Figure 8.

For the seismic performance level 2, the yielding of the post-tensioning steel
bar is determined as the limit state to ensure the serviceability and repairability. Figure
9 shows the force-displacement hysteresis and the failure mode obtained from the
shake table tests for the precast prestressed columns during the design level earthquake
ground motion. The post-tensioning steel bars remained in the elastic range and minor
spalling of cover concrete was observed. Although the column model performed well
beyond the yielding of the post-tensioning steel bars in the shake table test, the range
beyond this point is not considered in the seismic design of the precast prestressed
concrete bridge for safety consideration. Thus, the limit state for the seismic
performance levels 3 should be determined beyond the yielding of the post-tensioning
steel bars. Further research may be needed for consideration of the behavior after
yielding of the post-tensioning steel bars.
Lateral force

: Elastic range
x : Before Yielding of
Prestressing Steel

Lateral
displacement

Figure 8 Limit states of precast prestressed concrete columns

Lateral force (kN)

600

400

200

-200

-400

-600
-120 -80 -40 0 40 80 120
Lateral displacement (mm)
慣性力作用位置の変位（mm）

Figure 9 Seismic Response and Failure Mode after Design Ground Motion Level Test
for Precast Prestressed Column
Limit States of Precast Hybrid Bridge Column
The schematic image of the limit states of the precast hybrid bridge column is
shown in Figure 10. Since the key feature of this column is the repairability by
replacement of the connecting bolts, the limit states of the seismic performance level
3 should be determined to be same as those of the seismic performance level 2. The
replaceable limit of the connecting bolts is determined as the limit state for the seismic
performance level 2. The allowable strain of the bolts is estimate to be 2% based on the
low-cycle fatigue tests and the shake table tests. The other structural members should
remain in the elastic range. Figure 11 shows the force-displacement hysteresis and the
failure mode obtained from the shake table tests during the design level earthquake
ground motion. The results from as-built series (case 1) and post-repair series (case 2)
are compared. After the design level tests in the post-repair series, the response
displacement was still smaller than the design displacement while about 2% strain was
induced in the connecting bolts and minor spalling of cover concrete was observed.
Lateral force

: Opening of Joints
: Limit State of
Connecting Bolts

Lateral
displacement

Figure 10 Limit states of precast hybrid concrete columns

Response acceleration (gal)

1200
case1-80%
case2-80%
800

400
加速度（gal）

-400

-800

-1200
-80 -60 -40 -20 0 20 40 60 80
変位（mm）
Lateral displacement (mm)

Figure 11 Seismic Response and Failure Mode after Design Ground Motion Level
Test in Post-repair Series for Precast Hybrid Column
Limit States of Precast Reinforced Concrete Bridge Column
It was confirmed that the nonlinear behavior of the precast reinforced concrete
bridge column was similar or even better than the conventional reinforced concrete
bridge column because the longitudinal reinforcing bars inserted into the mortal-
grouted ducts have better performance on anti-buckling. The limit states of this column
can be determined to be the same as those of the conventional reinforced concrete
columns, which is shown in Figure 7. Figure 12 shows the force-displacement
hysteresis and the failure mode obtained from the shake table tests during the design
level earthquake ground motion. Only flexural cracks were observed, and the stable
hysteresis loop was obtained.

Response acceleration (gal)

1500

1000

500

0
-200 -150 -100 -50 0 50 100 150 200
-500

-1000 150%
-1500
水平変位（mm)
Lateral displacement (mm)

Figure 12 Seismic Response and Failure Mode after Design Ground Motion Level
Test for Precast Reinforced Concrete Column

Conclusions

This paper introduces the state-of-practice of the conventional segmental

concrete bridge columns in Japan. Also, recent research works for the development of
the new precast segmental concrete columns were introduced in this paper. Design
Guidelines for the seismic effect of the precast segmental concrete columns is
scheduled to be published in 2010. The seismic performance and the seismic limit
states of the precast segmental columns will be described in the guidelines based on
discussion of the test results. Furthermore, connection design details of those columns
will be specified.

Acknowledgments

Some illustrations and photos of the structural details of the precast segmental
concrete bridge columns in this paper were provided by PC-WELL Method
Association, Kajima Co., Sumitomo Mitsui Construction Co., Ltd., and P.S. Mitsubishi
Construction Co., Ltd. Author would like to appreciate their contribution for the paper.