Accelerated Bridge Construction Design...2019 Transportation Short Course October 15, 2019 Accelerated Bridge Construction Design Robert D. Owens, P.E. – TxDOT Bridge Division 2019

2019 Transportation Short Course October 15, 2019

Accelerated Bridge Construction DesignRobert D. Owens, P.E. – TxDOT Bridge Division

October 15, 20192019 Transportation Short Course


Table of contents

2

Accelerated Bridge Construction (ABC)

Project Overview

Superstructure Concept

Substructure Concept

Construction Schedule

Plan Details

Questions

1

2

3

4

5

6

7


ABC

ABC reduces the impact to traveling public

Prefabricated elements have been a part of TxDOT’s ABC approach– Less Formwork/Reduce Risk– Faster Construction– Tighter Inspection (Quality due to

controlled environment)– Typically Safer– Repeatable Construction

3


ABC

Prefabricated Elements– Steel Piling– Concrete Piling

4


ABC

Prefabricated Elements– Steel Girders

5


ABC

Prefabricated Elements– Concrete Girders

6


ABC

Prefabricated Elements– Deck Slab Beams

7


ABC

8

Precast Bent Cap

Steel Piling

Decked Slab Beams

Precast Abutment


ABC

Prefabricated Elements– Precast Deck Panels

9


ABC

10


ABC

Prefabricated Elements– Precast Abutments

11


ABC

Prefabricated Elements– Precast Bent Cap

12


ABC

13


ABC

Prefabricated Elements– Full Depth Panels

14


ABC

SPMT – Fort Worth West 7th

15


ABC

Modular Units

16


ABC

17

Loop Concrete Joint– Wider closure pour– Rapid setting concrete

with steel fibers

UHPC Joint– Narrow longitudinal

closure pour– Utilize Ultra-high

Performance Concrete


ABC

18

Lateral Slide


ABC

19


ABC

Prefabricated Elements Bridge Misc. Standards for Substructure Elements– PBC-P Precast Conc. Bent Cap

Opt. for Conc. & Steel Piles

http://www.dot.state.tx.us/insdtdot/orgchart/cmd/cserve/standard/bridge-e.htm

20



ABC

Prefabricated Elements Bridge Misc. Standards for Substructure Elements– PBC-RC Precast Conc. Bent Cap

Opt. for Round Columns


21



ABC

Prefabricated Elements Bridge Misc. Standards for Substructure Elements– PPBC-RC Prestressed, Precast

Bent Cap Option for Round Columns


22



ABC

Prefabricated Elements Bridge Prestressed Concrete I-Girder Standards– PCP(O)Precast Conc. Panels for

Overhangs


23



ABC

Prefabricated Elements Bridge Prestressed Concrete I-Girder Standards– PCP(O)FAB Precast Conc. Panels

for Overhangs Fab Details


24



ABC

Contract Consideration of Time– Calendar Day– Work Week Definition– A+B Bidding– Incentives/Disincentives– No excuse bonus– Lane Rental

25


ABC

General Guidelines TxDOT Accelerated Construction Guidelines– Road User Costs $18.00 per

user-hour– TxDOT Administrative Costs of

$450 to $2000 a day– Max Incentive 8% of Project

Cost– Tighten Schedule (but not

overly so)

26


Project Overview

5 Bridge Replacements Rural highways with long detours (SH15

and US83) 10 calendar day closure time per bridge West Fork Horse Creek Bridges need to

be built at the same time Utilize Accelerated Bridge Construction

(ABC) concepts to reduce traffic impact Sought contractor input on foundation

options, superstructure concept, and access/timeframe issues

Milestone incentives

27

Dallam Sherman Hansford Ochiltree Lipscomb

Hartley Moore Roberts Hemphill

Oldham Potter Carson Gray Wheeler

Deaf Smith Randall Armstrong DonleyCollings-

worth

Parmer Castro Swisher Briscoe Hall

Bailey Lamb Hale Floyd Motley

Dickens King KnoxHockleyLubbock

Crosby

GarzaLynnTerryYoakum

Gaines Dawson Borden Scurry Fisher Jones

Kent StonewallHaskell Throck-morton

Baylor

WilbargerWichita

WICHITAFALLS

Clay

Archer

Young Jack

Howard Mitchell NolanTaylor

CallahanEastland

GlasscockSterling Coke Runnels

ReaganIrion

Cooke Grayson Fannin

Lamar

Delta

Red RiverPARIS

Bowie

Wise Denton Collin Hunt Hopkins

Rains Wood UpshurMarion

CassTitus

Mor

ris

CampATLANTA

HarrisonSmith

VanZandt

Henderson TYLERRusk Panola

AndersonCherokee

Freestone

DallasDALLAS

RockwallPalo Pinto

Parker Tarrant

Shelby

SabineHouston LUFKIN

Angelina

TylerPolk

Trinity

Jasp

er

New

ton

SanJacinto

Walker

Leon

Navarro

Ellis

Hardin

FORTWORTH

Erath

Hood Johnson

HillBosque

McLennanHamilton

Coryell

Bell

FallsWACO

RobertsonMadison

MilamBrazos

Grim

es

Burleson

BRYAN

WashingtonLee

AustinFayette

Harris

Montgomery LibertyBEAUMONT

Orange

Jefferson

ChambersHOUSTON

FortBend

Brazoria

Matagorda

Wharton

Colorado

LavacaGonzales

Dewitt

YOAKUM

JacksonVictoria

CalhounGoliad

Bee Refugio

Karnes

LiveOak

JimWells

SanPatricio

NuecesCORPUSCHRISTIKleberg

Kenedy

WillacyHidalgo

BrooksJimHogg

Zapata

Starr

PHARR

DuvalWebb

LAREDO

La SalleDimmit

Zavala Frio Atascosa

McMullen

Guadalupe

Wilson

Bexar

MedinaUvalde

Real Bandera

KerrKendall

Gillespie Blanco

KinneySAN

ANTONIO

Edwards

Sutton Kimble

Mason LlanoBurnet

Williamson

TravisAUSTIN

BastropHays

CaldwellComal

BrownComanche

BROWNWOOD

Coleman

MillsMc

Culloch San Saba LampasasConcho

Menard

SANANGELO

Schleicher

TomGreen

Andrews Martin

Midland

Pecos

Ector

CraneWard

WinklerLoving

Crockett

Val Verde

Upton

Terrell

ReevesCulberson

Jeff Davis

BrewsterPresidio

Hudspeth

El PasoEL PASO

ODESSA

LUBBOCK

AMARILLO

ABILENE

Cottle Foard

CHILDRESS

Fran

klin

Cameron


Project Overview

28

Dallam Sherman Hansford Ochiltree Lipscomb

Hartley Moore Roberts Hemphill

Oldham Potter Carson Gray Wheeler

Deaf Smith Randall Armstrong DonleyCollings-

worth

Parmer Castro Swisher Briscoe Hall

Bailey Lamb Hale Floyd Motley

Dickens King KnoxHockleyLubbock

Crosby

GarzaLynnTerryYoakum

Gaines Dawson Borden Scurry Fisher Jones

Kent StonewallHaskell Throck-morton

Baylor

WilbargerWichita

WICHITAFALLS

Clay

Archer

Young Jack

Howard Mitchell NolanTaylor

CallahanEastland

GlasscockSterling Coke Runnels

ReaganIrion

Cooke Grayson Fannin

Lamar

Delta

Red RiverPARIS

Bowie

Wise Denton Collin Hunt Hopkins

Rains Wood UpshurMarion

CassTitus

Mor

ris

CampATLANTA

HarrisonSmith

VanZandt

Henderson TYLERRusk Panola

AndersonCherokee

Freestone

DallasDALLAS

RockwallPalo Pinto

Parker Tarrant

Shelby

SabineHouston LUFKIN

Angelina

TylerPolk

Trinity

Jasp

er

New

ton

SanJacinto

Walker

Leon

Navarro

Ellis

Hardin

FORTWORTH

Erath

Hood Johnson

HillBosque

McLennanHamilton

Coryell

Bell

FallsWACO

RobertsonMadison

MilamBrazos

Grim

es

Burleson

BRYAN

WashingtonLee

AustinFayette

Harris

Montgomery LibertyBEAUMONT

Orange

Jefferson

ChambersHOUSTON

FortBend

Brazoria

Matagorda

Wharton

Colorado

LavacaGonzales

Dewitt

YOAKUM

JacksonVictoria

CalhounGoliad

Bee Refugio

Karnes

LiveOak

JimWells

SanPatricio

NuecesCORPUSCHRISTIKleberg

Kenedy

WillacyHidalgo

BrooksJimHogg

Zapata

Starr

PHARR

DuvalWebb

LAREDO

La SalleDimmit

Zavala Frio Atascosa

McMullen

Guadalupe

Wilson

Bexar

MedinaUvalde

Real Bandera

KerrKendall

Gillespie Blanco

KinneySAN

ANTONIO

Edwards

Sutton Kimble

Mason LlanoBurnet

Williamson

TravisAUSTIN

BastropHays

CaldwellComal

BrownComanche

BROWNWOOD

Coleman

MillsMc

Culloch San Saba LampasasConcho

Menard

SANANGELO

Schleicher

TomGreen

Andrews Martin

Midland

Pecos

Ector

CraneWard

WinklerLoving

Crockett

Val Verde

Upton

Terrell

ReevesCulberson

Jeff Davis

BrewsterPresidio

Hudspeth

El PasoEL PASO

ODESSA

LUBBOCK

AMARILLO

ABILENE

Cottle Foard

CHILDRESS

Fran

klin

Cameron


Project Overview

29

West Fork Horse Creek Bridges will have a built detour All SH 15 bridges will have built haul road only Temporary construction license to build detour(s) Approach roadway work 150’ ~ 200’


Project Overview

30

Original bridges built in the 1930’s on timber piles and steel beams

Widened in the 60’s and 70’s with steel piles

Structures need to be replaced

Milestone incentives for each bridge will be available for timely completion of construction


Project Overview

31

US 83 West Fork Horse Creek (North)

Detour Road

Haul Road


Project Overview

32

US 83 West Fork Horse Creek (South)

Detour Road

Haul Road


Project Overview

33

SH 15 Farwell Creek

Haul Road


Project Overview

34

SH 15 Palo Duro Creek

Haul Road



35

SH 15 Ivanhoe Creek

Haul Road



36

Cast Deck with Tx-Girders off site

Pick 1 or 2 girder systems at a time

Cast closure pour with UHPC or Rapid Setting Fiber Reinforced Concrete (RSFRC)



37

Guidance from AGC:– Maximum desirable

transportable load over long distance ~ 100 Tons

– Maximum desirable lift load (assuming two crane lift) ~ 150 Tons

Widths over 10 – 12 ftbecome problem for long distance transportation



38

Single Girder assumes 7’ deck width

Two Girder assumes 8’ deck width



39

UHPC vs RSFRC



40

Lift decked girders into place 2 girder systems to reduce

number of closure pours

Cast closure pours with minimal reinforcement placement

Use full length galvanized reinforcement Original deck 9” to included 0.5” mill to

ensure smooth riding surface



41

Due to geometric complexities: Bridge girders need to be installed in the plumb condition, but the deck

needs to be cast with the roadway cross slope inherent. Because of girder camber, a variable haunch will be needed to achieve the

intended profile grade. Because of the use of “full depth” precast units, the risks of differential

cambers may require the beams to be built on simulated bearing seats and the precast deck cast with all girder lines in place to ensure achieving goal of correct grades.



42



43

Substructure Option #1– Remove 2 exterior girders on

each side and clear substructure as needed

– Drill and pour shafts and columns



44

Substructure Option #1– Close and demo bridge– Lift pre-cast abutment and bents

into place

– Lift decked girders into place and cast closure pours

– Use temporary barriers while casting new traffic rail



45

Substructure Option #2– Piles



46


Construction Schedule

47

10 Calendar Day Road Closure Demo – 2 Days* Earthwork and placing bent/abut caps

– 3 Days* Placing Pre-Decked Beams and Casting

Closure Pours – 3 Days* Closure Pour Curing – 2 Days*(*Estimated)

Cast bridge rail after road is reopened


Plan Details

48

Details for superstructure Re-evaluate the use of the

drop in deck pieces due to fabrication and handling concerns


Plan Details

49


Plan Details

50


Plan Details

51


Plan Details

52


Plan Details

53

Abutment & Bent Details Drilled shafts will be placed

off the critical path


Plan Details

54

Ducts for drilled shaft to cap connection

Precast Concrete Bent Cap Option for Round Columns


Plan Details

55

Backwall at the back of the cap

Wingwall cast-in-place


Plan Details

56


Plan Details

57

2019 Transportation Short Course October 15, 2019 58

Alternate Designs SOP

There is increasing interest in utilizing prefabricated elements in all facets of bridge design and construction.

Precast alternate not always included in plans.

Developed a Standardized Method to allow Contractors to propose alternate to Cast-in-Place (CIP) Construction or to propose alternate to ABC method as detailed in the plans

2019 Transportation Short Course October 15, 2019 59

Alternate Designs SOP

Will be an update to existing Alternate Prestressed Bent/Abutment SOP

New Precast and Accelerated SOP

Communication of the SOP will not be enough, it will need to be in the plans.

http://ftp.dot.state.tx.us/pub/txdot-info/brg/design/alt-prestressed-bent-abutment.pdf

http://ftp.dot.state.tx.us/pub/txdot-info/brg/design/alt-prestressed-bent-abutment.pdf


Conclusion

Precast options offer more Accelerated Bridge Construction (ABC) solutions– Many options– Considerations for site location and shipping– Ask for contractor input– Allow for innovations– Must include non-traditional precast bridge standards in the plan set

Thorough planning Great communication is key to success Must offer milestone incentives to offset the cost and risk to the contractor

60

Documents

Accelerated Bridge Construction Design...2019 Transportation Short Course October 15, 2019 Accelerated Bridge Construction Design Robert D. Owens, P.E. – TxDOT Bridge Division 2019