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.

Structurally deficient bridges are commonly retrofitted using conventional methodologies, including reinforced concrete, steel jackets, and fiber-reinforced polymers. Although these retrofit methods aim to improve structural performance, exposure to aggressive environments may undermine the durability performance of the retrofit material. More recently, ultra-high-performance concrete (UHPC) has provided an alternative to conventional construction methods, with its superior material characteristics favoring its use in retrofit applications. In this study, a large-scale reinforced concrete (RC) T-beam is constructed and artificially damaged. The T-beam is then retrofitted with an external envelope of UHPC on all faces. Sandblasting is introduced to the surface, providing partially exposed reinforcement in the T-beam to simulate material deterioration. Additional reinforcement is placed in the web and flange, followed by casting the enveloping layer of UHPC around the specimen. The feasibility of this method is discussed, and the structural performance of the beam is assessed by subjecting the beam to cyclic and ultimate flexural loading. This paper presents the results of cyclic and ultimate testing on the RC-UHPC composite T-beam regarding load–displacement, failure mode, and strain responses. The retrofitted T-beam specimen is subjected to a cyclic loading range of 131 kN for 1.576 million cycles. Despite no visible cracks in the cyclic testing, the specimen experiences a 12.22% degradation in stiffness. During the ultimate flexural testing, the specimen shows no relative slip between the two concretes, and the typical flexural failure mode is observed. By increasing the longitudinal reinforcement ratio in the web, the failure mode can shift from localized cracking, predominantly observed in the UHPC shell, toward a more distributed cracking pattern along the length of the beam, which is similar to conventional reinforced concrete beams.