A feasibility study of the use of ultra-high performance concrete (UHPC) shell as a formwork is presented. The core concept of the research, developed by the first author, is prefabrication of UHPC shell which acts as a stay-in-place formwork. In the proposed approach, after transporting the UHPC shell to site, the construction of structural elements is completed by placing reinforcing cage inside the UHPC shell and post-pouring with normal concrete. The superior properties of UHPC provide excellent means to enhance the service life of bridge elements, while eliminating the need for assembling or stripping of formwork. As a proof of concept, a combination of experimental and numerical studies was conducted, results of which are reported here. Before conducting experimental work, numerical study in the form of finite element analysis was carried out to investigate performance of shell during placement of the normal concrete. To provide a baseline comparison between UHPC shell formwork and conventional methods, two test specimens were constructed and tested under three-point load setup. The shell test specimen demonstrated flexural strength, 14% greater than an equivalent normal strength concrete specimen. The UHPC shell test specimen failure occurred by debonding of shell at the interface and development of a large crack in the shell. The shell test specimen exhibited improved levels of ductility before failure. The preliminary analysis demonstrated that the idea is feasible and useful for accelerated bridge construction applications.

Ultra high-performance concrete (UHPC) application, to enhance the mechanical strength of axially loaded reinforced concrete bridge substructure elements, was proposed and investigated in an earlier study. The results recommended that depending on the UHPC shell thickness, this method may cause shifting of the critical section to undesired locations, due to over-strengthening of the repaired section, and this should be a design consideration. This paper proposes a new simplified analytical approach to calculate the bending moment capacity of the repaired circular section. This method relies on hand calculations and only requires basic material properties (compressive and tensile strengths). The results from the simplified approach are validated with a well-established numerical sectional analysis method. The proposed approach may be considered simple and more straightforward for professional engineers.