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PRECAST SEGMENTAL BRIDGEPRECAST SEGMENTAL BRIDGE
December 6, 2005December 6, 2005
SPEAKERSPEAKER
Name: KimioKimio SAITOSAITO
Affiliation: Kajima CorporationKajima Corporation
Academic Background: Master of Engineering from Master of Engineering from Waseda Waseda Univ.Univ.
SPEAKERSPEAKERApril 1989 – August 1992:
Design EngineerDesign Div. of Kajima Corp.Designed Concrete CableDesigned Concrete Cable--stayed Bridgestayed Bridge
September 1992 – August 1994:Construction EngineerOsaka Branch of Kajima Corp.Constructed Concrete CableConstructed Concrete Cable--stayed stayed BridgeBridge
September 1994 – September 1996:Design EngineerDesign Div. of Kajima Corp.Designed Concrete Box Girder Bridge Designed Concrete Box Girder Bridge Utilizing Entire External Tendon SystemUtilizing Entire External Tendon System
SPEAKERSPEAKEROctober 1996 – September 1998:
Engineering TraineeEngineering TraineeLoBuonoLoBuono Armstrong and Associates, FloridaArmstrong and Associates, FloridaDesigned Precast Segmental Box Girder Designed Precast Segmental Box Girder BridgeBridge
SPEAKERSPEAKEROctober 1998 – March 2002:
Senior Design EngineerDesign Div. of Kajima Corp.Designed Railway Bridge with Light Designed Railway Bridge with Light Weight ConcreteWeight ConcreteDesigned Designed ““UchimakiUchimaki ViaductViaduct””
April 2002 – Present:Senior Construction EngineerYokohama Branch of Kajima Corp.Constructed Constructed ““UchimakiUchimaki ViaductViaduct””
SCHEDULESCHEDULE
1. 1. General Information (10min.)General Information (10min.)
2. 2. History and Applications in U.S. (15min.)History and Applications in U.S. (15min.)
3. 3. Recent Applications in Japan (10min.)Recent Applications in Japan (10min.)
4. 4. Case Study about Case Study about Uchimaki Uchimaki Viaduct (15min.)Viaduct (15min.)
5. 5. Movie of Movie of UchimakiUchimaki Viaduct Project (15min.)Viaduct Project (15min.)
6. 6. Discussions (15min.)Discussions (15min.)
2
PRECAST SEGMENTAL BRIDGEPRECAST SEGMENTAL BRIDGE
DefinitionsDefinitions
Bridge girders are fabricated as a number of Bridge girders are fabricated as a number of precast segments at a casting yard.precast segments at a casting yard.
The precast segments are transported from the The precast segments are transported from the casting yard to an erection site.casting yard to an erection site.
The precast segments are erected and unified The precast segments are erected and unified into a girder by applying longitudinal prestress. into a girder by applying longitudinal prestress.
PRECAST SEGMENTAL BRIDGEPRECAST SEGMENTAL BRIDGE
Advantage and DisadvantageAdvantage and Disadvantage
Shorten erection period Shorten erection period
Provide high quality members Provide high quality members
Reduce the number of laborsReduce the number of labors
PRECAST SEGMENTAL BRIDGEPRECAST SEGMENTAL BRIDGE
Advantage and DisadvantageAdvantage and Disadvantage
Require large space for fabrication and storage Require large space for fabrication and storage
Require effective transportation systemRequire effective transportation system
Require special fabrication & erection machines Require special fabrication & erection machines
Require enough scale of project (contract)Require enough scale of project (contract)
PRECAST SEGMENTAL BRIDGEPRECAST SEGMENTAL BRIDGE
Technical AspectsTechnical Aspects
Additional prestressAdditional prestress
Special care for geometry controlSpecial care for geometry control
Special care for joints and keys Special care for joints and keys
FABRICATION & ERECTIONFABRICATION & ERECTION
Fabrication MethodFabrication Method
Erection MethodErection Method
ShortShort--line or Longline or Long--line Match Castline Match Cast
Balanced Cantilever (for long span) Balanced Cantilever (for long span)
SpanSpan--byby--span (for short and medium span) span (for short and medium span)
N+1 N
1.Start
Bulkhead Wet cast Match cast
N+1 N
2. Hanging Soffit Form
N+ N
3. Shifting Segments(n & n+1)
N+1 N
4. Hanging Soffit Form
N+1 N
5. Setting Soffit Form & Adjusting Segment(n+1)
N+1 N
6. Hanging Re-bar Cage
N+1
N
7. Setting Re-bar Cage & Taking Segment(n) out
N+1
8. Setting Side Form & Core Form
N+2
N+1
9.Concrete Pouring
N+2
CONCRETE
N
10. Completion of Segment(n+2)
N
CompleteComplete
SHORTSHORT--LINE MATCH CASTLINE MATCH CAST
3
SHORTSHORT--LINE MATCH CASTLINE MATCH CAST
Fixed Bulkhead & Movable Fixed Bulkhead & Movable SoffitSoffit FormForm
Require small space for casting machineRequire small space for casting machine
Suitable for girder with constant depthSuitable for girder with constant depth
Correspond to alignmentCorrespond to alignment
Require careful geometry control Require careful geometry control
LONGLONG--LINE MATCH CASTLINE MATCH CAST
LONGLONG--LINE MATCH CASTLINE MATCH CAST
Movable Bulkhead & Fixed Movable Bulkhead & Fixed SoffitSoffit FormForm
Require large space for casting machineRequire large space for casting machine
Suitable for girder with variable depthSuitable for girder with variable depth
Suitable for straight bridgeSuitable for straight bridge
BALANCED CANTILEVERBALANCED CANTILEVER
SPANSPAN--BYBY--SPANSPAN
1
PRECAST SEGMENTAL BRIDGEPRECAST SEGMENTAL BRIDGE
December 6, 2005December 6, 2005
History & Applications in U.S.History & Applications in U.S.
Griffith Road CrossingGriffith Road Crossing
•• Single 15m Span ISingle 15m Span I--girdergirder•• New YorkNew York•• 1950 and 1951 1950 and 1951
Photo: Provided by ASBI
Griffith Road CrossingGriffith Road Crossing
•• Single 15m Span ISingle 15m Span I--girdergirder•• New YorkNew York•• 1950 and 1951 1950 and 1951
Photo: Provided by ASBI
JFK Memorial CausewayJFK Memorial Causeway
•• 6060m Center Spanm Center Span•• TexasTexas•• 1972 1972
Photo: Provided by ASBI
JFK Memorial CausewayJFK Memorial Causeway
•• 6060m Center Spanm Center Span•• TexasTexas•• 1972 1972
Photo: Provided by ASBI
KishwaukeeKishwaukee River BridgesRiver Bridges
•• 7676m Interior Spansm Interior Spans•• IllinoisIllinois•• 1979 1979
Photo: Provided by ASBI
2
KishwaukeeKishwaukee River BridgesRiver Bridges
•• 7676m Interior Spansm Interior Spans•• IllinoisIllinois•• 1979 1979
Photo: Provided by ASBI
Long Key BridgeLong Key Bridge
•• FloridaFlorida•• 1979 1979
Photo: Provided by ASBI
Long Key BridgeLong Key Bridge
•• FloridaFlorida•• 1979 1979
Photo: Provided by ASBI
Seven Mile BridgeSeven Mile Bridge
•• FloridaFlorida•• 1982 1982
Photo: Provided by ASBI
Seven Mile BridgeSeven Mile Bridge
•• FloridaFlorida•• 1982 1982
Photo: Provided by ASBI
Windward ViaductWindward Viaduct
•• HawaiiHawaii•• 1993 1993
Photo: Provided by ASBI
3
Garcon Point BridgeGarcon Point Bridge
•• FloridaFlorida•• 1998 1998
VARIATIONSVARIATIONS
Photo: Provided by ASBI
Linn Cove ViaductLinn Cove Viaduct
•• North CarolinaNorth Carolina•• 1984 1984
Photo: Provided by ASBI
Sunshine Skyway BridgeSunshine Skyway Bridge
•• FloridaFlorida•• 1987 1987
Photo: Provided by ASBI
Sunshine Skyway BridgeSunshine Skyway Bridge
•• FloridaFlorida•• 1987 1987
Photo: Provided by ASBI
James River BridgeJames River Bridge
•• VirginiaVirginia•• 1990 1990
Photo: Provided by ASBI
4
New Baldwin BridgeNew Baldwin Bridge
•• MassachusettsMassachusetts•• 1993 1993
Photo: Provided by ASBI
New Baldwin BridgeNew Baldwin Bridge
•• MassachusettsMassachusetts•• 1993 1993
Photo: Provided by ASBI
Natchez Trace ParkwayNatchez Trace Parkway
•• TennesseeTennessee•• 1993 1993
Confederation BridgeConfederation Bridge
•• CanadaCanada•• 1996 1996
Confederation BridgeConfederation Bridge
•• CanadaCanada•• 1996 1996
Confederation BridgeConfederation Bridge
•• CanadaCanada•• 1996 1996
5
APPLICATIONS IN URBAN AREAAPPLICATIONS IN URBAN AREA
Photo: Provided by ASBI
San Antonio Y ProjectSan Antonio Y Project
•• TexasTexas•• 1993 1993
Photo: Provided by ASBI
San Antonio Y ProjectSan Antonio Y Project
•• TexasTexas•• 1993 1993
Photo: Provided by ASBI
II--75 / I75 / I--95 Interchange95 Interchange
•• FloridaFlorida•• 1994 1994
Photo: Provided by ASBI
MARTAMARTA
•• GeorgiaGeorgia•• 1985 1985
Photo: Provided by ASBI
Boston ProjectBoston Project
•• MassachusettsMassachusetts•• 200X200X
Photo: Provided by ASBI
6
STANDARD SEGMENTSTANDARD SEGMENT
Develop Standard SegmentDevelop Standard Segment
Supplied by Precast MakersSupplied by Precast Makers
Reduce Equipment CostReduce Equipment Cost
Extend the Application to Smaller ProjectsExtend the Application to Smaller Projects
Spans: 30.5m Spans: 30.5m -- 45.7m 45.7m (Span by span)(Span by span)30.5m 30.5m –– 61.0m 61.0m (Balanced Cantilever)(Balanced Cantilever)
Width: 8.40m Width: 8.40m –– 13.50m13.50mGirder Height: 1.80m Girder Height: 1.80m –– 3.00m3.00m
1
PRECAST SEGMENTAL BRIDGEPRECAST SEGMENTAL BRIDGE
December 6, 2005December 6, 2005
Recent Applications in JapanRecent Applications in Japan
RECENT APPROACHRECENT APPROACH
The weight of segments are reduced by dividing The weight of segments are reduced by dividing the cross section into several parts.the cross section into several parts.
The segments can be transported through The segments can be transported through general highway by reducing the weight.general highway by reducing the weight.
The cost of erection machines can be reduced The cost of erection machines can be reduced by light weight segments. by light weight segments.
The erection period can not be minimized.The erection period can not be minimized.
Furukawa ViaductFurukawa Viaduct
•• U shape Segment + RibU shape Segment + Rib•• Precast Panel Precast Panel
Reference: Bridge and Foundation Engineering
Furukawa ViaductFurukawa Viaduct
•• U shape Segment + RibU shape Segment + Rib•• Precast Panel Precast Panel
Reference: Bridge and Foundation Engineering
Furukawa ViaductFurukawa Viaduct
•• U shape Segment + RibU shape Segment + Rib•• Precast Panel Precast Panel
Reference: Bridge and Foundation Engineering
Kamikazue Kamikazue ViaductViaduct
•• Dual SegmentDual SegmentReference: Bridge and Foundation Engineering
2
Kamikazue Kamikazue ViaductViaduct
•• Dual SegmentDual SegmentReference: Bridge and Foundation Engineering
Kamikazue Kamikazue ViaductViaduct
•• Dual SegmentDual SegmentReference: Bridge and Foundation Engineering
Uchimaki Uchimaki ViaductViaduct
•• Core SegmentCore Segment•• External StrutExternal Strut•• Cast in Place Wing SlabCast in Place Wing Slab
Uchimaki Uchimaki ViaductViaduct
•• Core SegmentCore Segment•• External StrutExternal Strut•• Cast in Place Wing Slab Cast in Place Wing Slab
Uchimaki Uchimaki ViaductViaduct
•• Core SegmentCore Segment•• External StrutExternal Strut•• Cast in Place Wing Slab Cast in Place Wing Slab
YamakiriYamakiri ViaductViaduct
•• Core SegmentCore Segment•• External Strut + RibExternal Strut + Rib•• Precast Panel Precast Panel
Reference: Bridge and Foundation Engineering
3
YamakiriYamakiri ViaductViaduct
•• Core SegmentCore Segment•• External Strut + RibExternal Strut + Rib•• Precast Panel Precast Panel
Reference: Bridge and Foundation Engineering
YamakiriYamakiri ViaductViaduct
•• Core SegmentCore Segment•• External Strut + RibExternal Strut + Rib•• Precast Panel Precast Panel
Reference: Bridge and Foundation Engineering
1
PRECAST SEGMENTAL BRIDGEPRECAST SEGMENTAL BRIDGECase Study about Case Study about Uchimaki Uchimaki ViaductViaduct
December 6, 2005December 6, 2005
East BoundEast Bound
West BoundWest Bound
UCHIMAKI VIADUCT UCHIMAKI VIADUCT (PLOFILE)(PLOFILE)
TokyoTokyoNagoya
STRUTTED WING SLABSTRUTTED WING SLAB
Concrete Struts
CROSS SECTIONCROSS SECTION
Ac=11.910m2 8.940m2
Phase 1: Cast in Place Pier SegmentsPhase 1: Cast in Place Pier SegmentsPhase 2:Phase 2: Span by Span Erection of Precast SegmentsSpan by Span Erection of Precast SegmentsPhase 3: Assembling Struts + C.I.P. Wing Slabs Phase 3: Assembling Struts + C.I.P. Wing Slabs
ERECTION SEQUENCEERECTION SEQUENCE
ERECTION SEQUENCEERECTION SEQUENCE
2
TYPICAL SEGMENTTYPICAL SEGMENT
770
12.5φ 530
10,74010,740
CASTING YARDCASTING YARD
CASTING YARDCASTING YARD C.I.P. PIER SEGMENTC.I.P. PIER SEGMENT
C.I.P. PIER SEGMENTC.I.P. PIER SEGMENTCasting YardHighway+River
Highway
HighwayHighway
ERECTION SITEERECTION SITE
3
SEGMENT DELIVERYSEGMENT DELIVERY
Erected
Bridge
Dec
k
Casting Yard
SEGMENT DELIVERYSEGMENT DELIVERY
SEGMENT DELIVERYSEGMENT DELIVERY
STEP 1:セグメントの運搬・仮吊り 引寄せ・接着
SPANSPAN--BYBY--SPAN ERECTIONSPAN ERECTION
SPANSPAN--BYBY--SPAN ERECTIONSPAN ERECTION
STEP 2:目地コンクリートの打設
SPANSPAN--BYBY--SPAN ERECTIONSPAN ERECTION
STEP 3:主方向PC鋼材の挿入・緊張
4
SPANSPAN--BYBY--SPAN ERECTIONSPAN ERECTION
STEP 4:次径間への架設桁の移動 106106mm
ERECTION TRUSSERECTION TRUSS
WEIGHT: 7,840kNWEIGHT: 7,840kN