Behavior of Existing Box Beams Repaired with High-Strength Mortar Layer and Ultra-High-Performance Concrete (UHPC) Overlay: Experimental, Numerical, and Theoretical Investigations

Box beams constructed earlier were prone to inadequate bending capacity owing to low construction standards, overloading, and environmental degradation. To resolve the challenge, three full-scale box slab beams in service for 15 years were strengthened with a high-strength mortar layer and an ultra-high-performance concrete (UHPC) layer in this paper. The flexural performances of unstrengthened beams (control beam) and strengthened beams (mortar beam, UHPC beam) were investigated by in situ four-point bending tests and numerical simulations. The experimental results showed that the cracking of box beams, strengthened with high-strength mortar and UHPC layers, was effectively mitigated. In comparison to the control beam, the cracking load of the mortar beam and the UHPC beam increased by 20%, and the ultimate load increased by 23.5% and 35.3%, respectively. The high-strength mortar layer had little influence on the elastic-phase stiffness of box beams. In contrast, the stiffness of the elastic phase of the box beam, strengthened by the UHPC layer, increased by 32.9%. In the numerical simulations, the load-deflection curves obtained from finite elements and tests coincided well. The characteristic loads showed relatively good agreement with the test results, with errors below 10%. Combined with the tests and numerical analyses, the proposed equations for predicting the ultimate bearing capacities of the control beam, mortar beam, and UHPC beam were presented with a better prediction accuracy.