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Successes in Accelerated BridgeSuccesses in Accelerated Bridge Construction

Mary Lou Ralls, P.E. Principal

Ralls Newman, LLC

(formerly Texas State Bridge Engineer)

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Accelerated Bridge Construction (ABC) – Definition

Structural & geotechnical engineering g g gtechnologies that help agencies & the traveling public save time & money when bridge rehabilitation or reconstruction projects are implemented

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Foundation & Wall Elements

Rapid Embankment Construction

Prefabricated Bridge Elements & Systems

Accelerated Bridge Construction Components

Structural Placement Methods

Fast Track Contracting

Reference: Federal Highway Administration (FHWA)

Continuous Flight Auger Piles

Geosynthetic Reinforced Soil (GRS) Integrated Bridge System

EPS GeofoamSystems

Prefabricated Elements- Superstructure- Substructure

Prefabricated Systems- Superstructure- Substructure- Total Bridge

Self-Propelled Modular Transporters (SPMTs)

Longitudinal launching

Horizontal sliding or skidding

Other heavy lifting equipment & methods

Innovative Contracting- Best value- CMGC

method- Design Build- A+B- A+B+C- Warranties

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Prefabricated Bridge Elements & Systems (PBES) – Definition

Bridge structural components that g pare built off the bridge alignment to accelerate onsite construction time relative to conventional practice

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Moving more of the cast‐in‐place construction to an off‐site location 5

How does PBES accelerate bridge construction?

Building the bridge first before youbefore you

set cones,

then quickly move it into place – like

in hours or a weekend!

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Why Use PBES Technologies?

• Faster (offsite & off the critical path)• Safer (public construction &Safer (public, construction, &

inspection)

• Better Quality (controlled environment)

• Positive Cost-Benefit Ratios (with program of work)

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FHWA Every Day Counts (EDC) PBES Deployment Goals

• By December 2012, 100 more PBES bridges

• By December 2012, 25% of replacement bridges have at least one major prefabricated component that shortens onsite construction time relative to conventional construction9

PBES Decision-Making

Framework

incorporated into written policy to use during project development

process

[major outcome of EDC PBES initiative]

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• Elements• Systems

S t t

Prefabricated Bridges

– Deck Panels: Partial & Full-Depth– Beams: More Efficient Shapes

– Pier Caps, Columns, & Footings– Abutment Walls, Wing Walls, &

Footings

– Superstructure

– Substructure

– Total Bridge 11

PBES Element Definitions

Partial-depth Deck Panels:1) Provide a precast

portion of the deck pthickness,

2) Serve as stay-in-place forms, &

3) Require a composite cast-in-place (CIP) concrete topping to complete the deck thickness 12

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Partial-Depth Deck Panels

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PBES Element Definitions

Full-depth Deck Panels:

• Prefabricated the full thickness & do not require CIP concrete to complete the deck thickness

• May include concrete, steel, fiber-reinforced polymers, & aluminum

• Overlays may be included

Precast Decks on Steel Framing

Precast Decks on PS Beams

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George Washington Memorial Parkway, VA – 2002

Replaced deck while

keeping bridge open

to traffic on weekdays 15

Live Oak Creek Bridge, TX – 2008

Erection of deck panels over shear studs on beams

Panels after erection on

Panels designed per NCHRP 12-65,“Full-Depth, Precast-Concrete Deck Panel Systems” – no post-tensioning or overlay

700-ft long, 32-ft wide bridge

86 full-depth, full-width

deck panels, totaling

22,400 sq ft 16

chloride penetrability7-day and Overnight Cure Closure Pour Materials

bond

shrinkage

freeze-thaw durability

Materials

Ref.: NCHRP 10-7117

Fiber-Reinforced Polymer (FRP) Decks

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Rt. 24 Bridge over Deer Creek, MD – 2001

122.5-ft long, 33-ft wide historic through-truss bridge

FRP deck replacement19

PBES Element DefinitionsBeams/More Efficient Shapes: Beams with innovative shapes

eliminating a construction

activity i e :activity, i.e.:

• Spread precast spliced tub girders

• Adjacent precast beams w/CIP deck

• Adjacent inverted tee beams with

full or partial CIP deck

• Adjacent decked bulb tees with

partial CIP decks

NEXT Beams

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NCHRP 10-71 – PrecastComposite Slab Span System (PCSSS)based on French Poutre Dalle System from 2004 FHWA International

Scanning Tour

• Span to Depth: 1/28 - 1/30

• Span lengths: 20 ft to 60 ft• Span lengths: 20 ft to 60 ft

(45-ft span – 20-in depth)

• Minimum CIP depth 6 in

• Place ~12 beams in 4 hrs

Reference: NCHRP 10-71, C. French, C. K. Shield, Univ of Minnesota; & Z. J. Ma, Univ of Tenn - Knoxville

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NCHRP 10-71PCSSS Initial Implementation

Roughened Surfaces

Inverted T Precast Sections

Horizontal and Vertical Shear Reinforcement

8 to 22”

Chamfered Corners

90oTransverse Hook to facilitate “drop-in” cage

Prestressing Tendons

ConstantVariable w/ span length

Constant 6” CIP thickness

Constant 3”

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NCHRP 10-71 Construction

Center City Bridge (3 span: 22-27-22 ft)

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PBES Element DefinitionsPier Cap, Column,

and/or Footing: A combination of precast & CIP

concrete interior support elements i econcrete interior support elements, i.e.,

1) Precast pier cap with CIP column(s)

2) Precast pier cap & precast column(s) with CIP pile cap footing, or

3) Precast spread footing with CIP column(s)

Precast piers

Precast pier cap24

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Precast Concrete Piers

Precast pier cap

SH 66 over Lake Belton Bridge, Texas

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Grouted Duct and Cap Pocket Details - Seismic

Grouted Duct

Cap Pocket, Full Ductility (CPFD)

Elevation

Plan Cap Pocket, Limited Ductility (CPLD)

Elevation

Cap

Pocket

Section ElevationIsometric View of Joint

Ref.: NCHRP 12-7426

NCHRP 12-74 Lateral Load-Displacement for All Specimens

Source: Eric Matsumoto, California State University, Sacramento27

NCHRP 12-74Hysteretic Response

Cast-in-place

Grouted Duct

Cap Pocket,Full Ductility

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Abutment Wall, Wingwall, and/or Footing: 1) A combination of precast & CIP

concrete abutment elements, i.e., a) Precast abutment wall with

PBES Element Definitions

a) Precast abutment wall withCIP wingwalls,

b) Precast abutment wall &precast wingwalls withCIP footing,

c) Precast footing withCIP abutment wall; or

2) Geosynthetic reinforced soil (GRS) abutment

Precast Cantilever Abutments

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Mill Street Bridge over Lamprey River, NH – 2004

Placing spread footing segments

Prefabricated HPCSubstructure:10 footing segments11 abutment and

wingwall segments

Precast reinforced concrete substructureafter erection, prior to placing backfill

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PBES System DefinitionsSuperstructure: 1) Adjacent slab & box beams

w/o CIP deck with or w/o overlay,

2) Deck bulb tee beams w/o2) Deck bulb tee beams w/o CIP deck with or w/o overlay,

3) Composite units with or w/o overlay,

4) Precast segmental box segments,5) Truss spans and arch spans constructed off the

bridge alignment, or6) Total superstructures moved in with SPMTs,

skidded, or launched

Superstructure Span on SPMT

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143-ft long, 59-ft wide1,300-ton replacement spans built in adjacent staging area

Graves Avenue Bridge over I-4, FL – 2006

Half-hour rolling roadblocks on I-4 to remove 71-ft long, 30-ft wide, 250-ton spans 32

Each new span installed in few hours overnight

Graves Avenue Bridge over I-4, FL – 2006

I-4 closed two partial nights for installations

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GravesAvenueB idBridge,

FL –2006

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4500 South Bridge over I-215E, UT - 2007Prefabricated Superstructuredriven into position with SPMTs

• I-215 closed over a weekend• 4500 South closed only 10 days

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I-80 State Street to 1300 EastMultiple Structures, UT - 2008

I-80W over Highland Drive

I-80W over 900 East Street

I-80W over 700 East Street

I-80W over 500 East Street

I-80W over 300 East Street

I-80W 600 East Ramp Bridge

I-80W over 600 East Street

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I-80 State Street to 1300 East – Bridge Farm

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US 15/29 Bridge over Broad Run, VA – 2008 Superstructure Replacement & Roadway Widening

38 Existing Bridge Elevation

Typical Sections

Existing Bridge

[Exterior Edge]

[Median]

2’-6 ½” 28’-0” 2’-6 ½”

2 Lanes @ 12’-0” + 2 Shoulders @ 2’-0”

Widen 5’- 4”

3’-2 ½”3’-2 ½” 8’-10” 9’-0” 8’-10”

Proposed Modular Bridge

36’- 0” Roadway1’- 3” 1’- 3”

7’-10” 8’- 9” 9’-0” 12’-11”

8’-0”Shoulder

12’ Lane 12’ Lane

4’-0”Shoulder

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Revised Construction of Span ASpan A Span B Span C

Detour SB Traffic

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Detour SB TrafficDuring Weekend

[Median]

Remove/ReplaceSuperstructure

Steel Beams: Galvanization & Shipping

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Coastal Precast Systems, Inc.

Prefabricating Modular Deck Units

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Revised Construction SequenceRevised Maintenance-of-Traffic Plan for Weekend Closures

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Placing Asphalt at Abutment & Sealing Deck Joints

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Completed Structure with Asphalt Overlay

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PBES System Definitions

Substructure: Bridges with:

1) Non-prefab deck or superstructuresuperstructure,

2) Prefab interior supports that are connected to precast or CIP foundations if multiple span, &

3) Precast or CIP abutments Precast Integral

Abutments 47

Newark Airport Monorail, NJ

Steel Substructure

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I-287 Cross Westchester Viaduct, NY – 1999

PrecastConcrete

Substructure

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PBES System DefinitionsTotal Bridge:1) Bridges with:

a) Superstructure as defined above or superstructure consisting of spread prefab beams & prefab deck,

b) Prefab interior supports that are connected to precast or CIP foundations if multiple span &precast or CIP foundations if multiple span, &

c) Precast or CIP abutments;

2) Prefabricated culverts that

meet the National Bridge

Inventory (NBI) definition, or

3) Geosynthetic reinforced soil

(GRS) integrated bridge system

Everything shown can be prefabricated

Total Bridge Prefabrication50

SH 86 over Mitchell Gulch Bridge, CO – 2002

40-ft long, 43-ft widesingle-span bridgereplaced over aweekend

No impact topeak-hour traffic

weekend

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Belt Pkwy. over Ocean Pkwy. Bridge, NY- 2004

2-span, 149-ft long,78-ft wide bridge to 3-span, 221-ft long, 134-ft wide bridge

No lane closures during peak-hour traffic

3 de b dge

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FHWA Geosynthetic Reinforced Soil (GRS) Integrated Bridge System (IBS)

2009 Nova Award for Construction Innovation53

GRS IBS Construction OverviewReinforced Soil Foundation

Wall Construction

Beam Placement

4 years later

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How is PBES installed?

• Self-Propelled Modular Transporters (SPMTs)

• Longitudinal launchingLongitudinal launching

• Horizontal sliding or skidding

• Other heavy lifting equipment & methods

• Conventional lifting equipment & methods

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CTA Wells Street Bridge, IL – 2002

111-ft long, 25-ft high, 425-ton truss span installed over a weekend56

I-195 Providence River Bridge, RI – 2006

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Network Arch:• 400-ft long• 165-ft wide• 10º skew

Assembled in staging area & barged tosite on SPMTs 58

Continuous Launching

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Fort Lane/I-15 South Layton Interchange, UT – 2010

Longitudinal Launching

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Fort Lane/I-15 South Layton Interchange

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Transverse Launching

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I-80E Bridge at 2300E, UT – 2009

TransverseSliding

Easy Site Conditions

I-80W Bridge at 2300EDifficult Site Conditions

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Church Street Bridge, CT – 2003Erected in hours over a weekend night to minimize rail disruption

320-ft, 850-ton steeltruss center spanover New HavenRail Yard

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I-95 over James River Bridge, VA – 2002

102 superstructure spans replaced with no lane closures during peak traffic

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Benefits of Using PBES for ABC

• Reduced onsite construction time• Minimized traffic disruption – months to

days• Reduced environmental impact• Improved worker & motorist safety • Improved constructability• Increased product quality – controlled

environment, cure times, easier access, …

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Reduces Onsite Construction Time

• Less time spent onsite

• Traditional tasks can beTraditional tasks can be done offsite

• Minimal impact from weather conditions

Minimizes Traffic Impacts

Minimizes traffic delay & community disruption

I-59 and I-65 Interchange, AL

Reduces detours, lane closures, & narrow lanes

US 59 under Dunlavy, TX

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Minimizes environmental impact

• Keeps heavy equipment out q pof sensitive environments

• Shortens construction season

Linn Cove Viaduct, NC

Improves Work Zone Safety• Reduces onsite

construction time

Mi i i k• Minimizes work near traffic and power lines, at high elevations, or over water

Meylan Pedestrian Bridge, France 70

Improves Constructability

• Prefabricated elements & systems– Minimized impact

from environmental constraints

– Less work over water, near power lines, …

San Mateo-Hayward Bridge, CA

Increases quality

• Prefabricated in a controlled environment

• Increases quality control• Increases quality control

George P. Coleman Bridge, VA –1995 72

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PBES: Improves Quality & Lowers Life-Cycle Costs – to “Stay Out”

• Controlled environmentR d d d d th– Reduced dependence on weather

– Established materials suppliers for consistent quality of materials

– Standardized plant operations for consistent quality of production

– Optimum concrete curing73

Is PBES more cost-effective?

• Depends on type of structure & elements or systems used

• Many systems can cost less than y yconventional construction

• First implementation of new components frequently costs more

• Need a program of projects for economy of scale

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Declining Cost of Deploying Innovative Technology

• First use typically costs more

• Potential for new methods to cost less

• Promise of time savings

• Positive cost-benefit ratios

• Promise of programmatic cost savings 75

Full-Depth Precast Deck Costs in Utah

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SPMT Bridge Move Costs in Utah

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Accelerated Bridge Construction Decision Making & Economic Modeling Tool

Transportation Pooled Fund Study TPF-5(221)

P j t St t D t D b 2009Project Start Date: December 2009

Project End Date: June 2011

Participating: Oregon (lead), California, Iowa, Minnesota, Montana, Texas, Utah, Washington, FHWA

PI: Toni Doolen, Oregon State University 78

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Task 3: Develop Models• Develop decision tree & economic

modeling tool for ABC vs conventional construction

• Test & validate model using data from previously-completed ABC projects

• Use MS Visual Basic .NET to create tool incorporating model

• Create user’s guide & training materials79

ABC Decision Making & Economic Modeling Tool

Based on Analytical Hierarchy Process (AHP)

• Evaluates various alternative construction• Evaluates various alternative construction strategies by considering both quantitative & qualitative criteria

• Uses paired comparisons for relative importance

• Considers tangible & intangible factors80

Survey Form

• AHP survey scale is based on previous research & is well-developed, tested, &

lid t d ( S t 1990)validated (e.g., Saaty, 1990)

• AHP survey contains a series of pair-wise comparisons between criteria located at each level of a decision hierarchy

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Decision Hierarchy

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Survey Form – Level 1

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Oregon’s Elk Creek Project

• Project Stage: Completed

• Best Alternative: ABC

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• Critical Factors: Site Constraints & Work Windows

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Accelerated Bridge Construction Decision Making & Economic Modeling Tool

Transportation Pooled Fund Study TPF-5(221)

P j t MProject Manager:

Benjamin Tang, P.E.

Oregon Department of Transportation

Phone: 503-986-3324

Email: Benjamin.M.Tang@odot.state.or.us

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Questions

1. What are the five major components of accelerated bridge construction (ABC)?

2. What is the definition of prefabricated bridge elements or systems (PBES)?

3. What are the different factors to consider when determining whether to use ABC or conventional construction?

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Questions

4. Which parts of a bridge can be prefabricated?

5. What are the benefits of using PBES?

6. What are some of the structural placement methods that can be used to move a bridge or bridge component?

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Open-Ended Questions

1. Evaluate the cost effectiveness of using accelerated bridge construction techniques versus conventional construction.

2. For what types of bridge projects would you consider using self-propelled modular transporters?

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Thank You

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