11/15/2010. Construction. Accelerated Bridge Construction (ABC) Definition. Systems (PBES) Definition

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1 Successes in Accelerated Bridge Construction Mary Lou Ralls, P.E. Principal Ralls Newman, LLC (formerly Texas State Bridge Engineer) 1 Accelerated Bridge Construction (ABC) Definition Structural & geotechnical engineering g technologies that help agencies & the traveling public save time & money when bridge rehabilitation or reconstruction projects are implemented 2 Reference: Federal Highway Administration (FHWA) Foundation & Wall Elements Continuous Flight Auger Piles Geosynthetic Reinforced Soil (GRS) Integrated Bridge System Accelerated Bridge Construction Components Rapid Embankment Construction EPS Geofoam Prefabricated Bridge Elements & Systems Prefabricated Elements - Superstructure - Substructure Prefabricated Systems - Superstructure - Substructure - Total Bridge Structural Placement Methods Self-Propelled Modular Transporters (SPMTs) Longitudinal launching Horizontal sliding or skidding Fast Track Contracting Innovative Contracting - Best value - CMGC method - Design Build - A+B - A+B+C - Warranties Prefabricated Bridge Elements & Systems (PBES) Definition Bridge structural components that are built off the bridge alignment to accelerate onsite construction time relative to conventional practice Other heavy lifting equipment & methods 3 4 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 you before you set cones, then quickly move it into place like in hours or a weekend! 1

2 Why Use PBES Technologies? Faster (offsite & off the critical path) Safer (public, construction, & inspection) Better Quality (controlled environment) Positive Cost-Benefit Ratios (with program of work) 7 8 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 construction 9 PBES Decision- Making Framework incorporated into written policy to use during project development process [major outcome of EDC PBES initiative] 10 Systems Prefabricated Bridges Superstructure t Substructure Elements Deck Panels: Partial & Full-Depth Beams: More Efficient Shapes Pier Caps, Columns, & Footings Abutment Walls, Wing Walls, & Footings Total Bridge 11 PBES Element Definitions Partial-depth Deck Panels: 1) Provide a precast portion of the deck thickness, 2) Serve as stay-inplace forms, & 3) Require a composite cast-inplace (CIP) concrete topping to complete the deck thickness 12 2

3 Partial-Depth Deck Panels 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 PS Beams Precast Decks on Steel Framing George Washington Memorial Parkway, VA 2002 Live Oak Creek Bridge, TX 2008 Erection of deck panels over shear studs on beams Panels designed per NCHRP 12-65, Full-Depth, Precast-Concrete Deck Panel Systems no post-tensioning or overlay Panels after erection on 700-ft long, 32-ft wide bridge Replaced deck while keeping bridge open to traffic on weekdays full-depth, full-width deck panels, totaling 22,400 sq ft 16 7-day and Overnight Cure Closure Pour Materials chloride penetrability Fiber-Reinforced Polymer (FRP) Decks shrinkage bond Ref.: NCHRP freeze-thaw durability

4 Rt. 24 Bridge over Deer Creek, MD 2001 FRP deck replacement ft long, 33-ft wide historic throughtruss bridge 19 PBES Element Definitions Beams/More Efficient Shapes: Beams with innovative shapes eliminating a construction 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 20 NCHRP Precast Composite 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 (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 21 Chamfered Corners NCHRP PCSSS Initial Implementation Horizontal and Vertical Shear Reinforcement Constant 3 90 o Transverse Hook to facilitate drop-in cage Inverted T Precast Sections Constant 6 CIP thickness Prestressing Tendons Constant Roughened Surfaces 8 to 22 Variable w/ span length 22 NCHRP Construction Center City Bridge (3 span: ft) 23 PBES Element Definitions Pier Cap, Column, and/or Footing: A combination of precast & CIP concrete 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 cap 24 4

5 Precast Concrete Piers Grouted Duct and Cap Pocket Details - Seismic Precast pier cap Grouted Duct Section Isometric View of Joint Elevation Cap Pocket SH 66 over Lake Belton Bridge, Texas 25 Ref.: NCHRP Plan Cap Pocket, Full Ductility (CPFD) Elevation Cap Pocket, Limited Ductility (CPLD) Elevation 26 NCHRP Lateral Load-Displacement for All Specimens NCHRP Hysteretic Response Cast-in-place Grouted Duct Source: Eric Matsumoto, California State University, Sacramento 27 Cap Pocket, Full Ductility 28 PBES Element Definitions Abutment Wall, Wingwall, and/or Footing: 1) A combination of precast & CIP concrete abutment elements, i.e., a) Precast abutment wall with CIP wingwalls, b) Precast abutment wall & precast wingwalls with CIP footing, c) Precast footing with CIP abutment wall; or 2) Geosynthetic reinforced soil (GRS) abutment Precast Cantilever Abutments 29 Mill Street Bridge over Lamprey River, NH 2004 Placing spread footing segments Prefabricated HPC Substructure: 10 footing segments 11 abutment and wingwall segments Precast reinforced concrete substructure after erection, prior to placing backfill 30 5

6 PBES System Definitions Superstructure: 1) Adjacent slab & box beams w/o CIP deck with or w/o overlay, 2) Deck bulb tee beams w/o CIP deck with or w/o overlay, 3) Composite units with or w/o overlay, Superstructure Span on SPMT 4) Precast segmental box segments, 5) Truss spans and arch spans constructed off the bridge alignment, or 6) Total superstructures moved in with SPMTs, skidded, or launched 31 Graves Avenue Bridge over I-4, FL ft long, 59-ft wide 1,300-ton replacement spans built in adjacent staging area Half-hour rolling roadblocks on I-4 to remove 71-ft long, 30-ft wide, 250-ton spans 32 Graves Avenue Bridge over I-4, FL 2006 I-4 closed two partial nights for installations Each new span installed in few hours overnight 33 Graves Avenue Bid Bridge, FL South Bridge over I-215E, UT Prefabricated Superstructure driven into position with SPMTs I-215 closed over a weekend 4500 South closed only 10 days I-80 State Street to 1300 East Multiple Structures, UT I-80W over Highland Drive I-80W over 500 East Street I-80W over 900 East Street I-80W over 300 East Street I-80W over 700 East Street I-80W 600 East Ramp Bridge I-80W over 600 East Street

7 I-80 State Street to 1300 East Bridge Farm US 15/29 Bridge over Broad Run, VA 2008 Superstructure Replacement & Roadway Widening Existing Bridge Elevation Typical Sections [Median] 2-6 ½ ½ [Exterior Edge] Revised Construction of Span A Span A Span B Span C Existing Bridge Widen ½ ½ Detour SB Traffic During Weekend Roadway Lane 12 Lane Proposed Modular Bridge 8-0 Shoulder 4-0 Shoulder [Median] Remove/Replace Superstructure 40 Steel Beams: Galvanization & Shipping Prefabricating Modular Deck Units Steel beams after galvanizing & shipment to Coastal Precast Systems, Inc

8 11/15/2010 Revised Construction Sequence Revised Maintenance-of-Traffic Plan for Weekend Closures Placing Asphalt at Abutment & Sealing Deck Joints Newark Airport Monorail, NJ PBES System Definitions Substructure: Bridges with: 1) Non-prefab deck or superstructure, superstructure 2) Prefab interior supports that are connected to precast or CIP foundations if multiple span, & 3) Precast or CIP abutments Completed Structure with Asphalt Overlay Steel Substructure Precast Integral Abutments

9 I-287 Cross Westchester Viaduct, NY 1999 Precast Concrete Substructure 49 PBES System Definitions Total 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, & 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 Prefabrication 50 SH 86 over Mitchell Gulch Bridge, CO ft long, 43-ft wide single-span bridge replaced over a weekend Belt Pkwy. over Ocean Pkwy. Bridge, NY span, 149-ft long, 78-ft wide bridge to 3-span, 221-ft long, 134-ft wide bridge No impact to peak-hour traffic 51 No lane closures during peak-hour traffic 52 FHWA Geosynthetic Reinforced Soil (GRS) Integrated Bridge System (IBS) GRS IBS Construction Overview Reinforced Soil Foundation Wall Construction 4 years later 2009 Nova Award for Construction Innovation Beam Placement 9

10 How is PBES installed? CTA Wells Street Bridge, IL 2002 Self-Propelled Modular Transporters (SPMTs) Longitudinal launching Horizontal sliding or skidding Other heavy lifting equipment & methods Conventional lifting equipment & methods ft long, 25-ft high, 425-ton truss span installed over a weekend 56 I-195 Providence River Bridge, RI 2006 Network Arch: 400-ft long 165-ft wide 10º skew 57 Assembled in staging area & barged to site on SPMTs 58 Continuous Launching Fort Lane/I-15 South Layton Interchange, UT 2010 Longitudinal Launching

11 Fort Lane/I-15 South Layton Interchange Transverse Launching Transverse Sliding I-80E Bridge at 2300E, UT 2009 Easy Site Conditions Church Street Bridge, CT 2003 Erected in hours over a weekend night to minimize rail disruption I-80W Bridge at 2300E Difficult Site Conditions ft, 850-ton steel truss center span over New Haven Rail Yard 64 I-95 over James River Bridge, VA superstructure spans replaced with no lane closures during peak traffic 65 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, 66 11

12 Reduces Onsite Construction Time Less time spent onsite Traditional 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 US 59 under Dunlavy, TX Reduces detours, lane closures, & narrow lanes 68 Minimizes environmental impact Keeps heavy equipment out of sensitive environments Shortens construction season Improves Work Zone Safety Reduces onsite construction time Minimizes i i work near traffic and power lines, at high elevations, or over water Linn Cove Viaduct, NC Meylan Pedestrian Bridge, France 70 San Mateo-Hayward Bridge, CA Improves Constructability Prefabricated elements & systems Minimized impact from environmental constraints Less work over water, near power lines, Increases quality Prefabricated in a controlled environment Increases quality control George P. Coleman Bridge, VA

13 PBES: Improves Quality & Lowers Life-Cycle Costs to Stay Out Controlled environment Reduced d dependence d on weather Established materials suppliers for consistent quality of materials Standardized plant operations for consistent quality of production Optimum concrete curing 73 Is PBES more cost-effective? Depends on type of structure & elements or systems used Many systems can cost less than conventional construction First implementation of new components frequently costs more Need a program of projects for economy of scale 74 Declining Cost of Deploying Innovative Technology Full-Depth Precast Deck Costs in Utah 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 SPMT Bridge Move Costs in Utah Accelerated Bridge Construction Decision Making & Economic Modeling Tool Transportation Pooled Fund Study TPF-5(221) Project Start t Date: December 2009 Project End Date: June 2011 Participating: Oregon (lead), California, Iowa, Minnesota, Montana, Texas, Utah, Washington, FHWA 77 PI: Toni Doolen, Oregon State University 78 13

14 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 materials 79 ABC Decision Making & Economic Modeling Tool Based on Analytical Hierarchy Process (AHP) Evaluates various alternative construction strategies by considering both quantitative & qualitative criteria Uses paired comparisons for relative importance Considers tangible & intangible factors 80 Survey Form Decision Hierarchy AHP survey scale is based on previous research & is well-developed, tested, & validated d (e.g., Saaty, 1990) AHP survey contains a series of pair-wise comparisons between criteria located at each level of a decision hierarchy Survey Form Level 1 Oregon s Elk Creek Project Project Stage: Completed Best Alternative: ABC Critical Factors: Site Constraints & Work Windows

15 Accelerated Bridge Construction Decision Making & Economic Modeling Tool Transportation Pooled Fund Study TPF-5(221) Project Manager: Benjamin Tang, P.E. Oregon Department of Transportation Phone: 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? 86 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? 87 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? 88 Thank You 89 15