ABC By 2010

UTAH Department of Transportation

ACCELERATED BRIDGE CONSTRUCTION BY 2010

ABC by 2010
UDOT goals
Accelerated Bridge Construction
Standard practice by 2010

How have we done?

Fred Doehring
UDOT Structures

What was needed?

Methods of construction Standard details Commitment to a program

Vision for Family of ABC Methods

Scanning Tours

ABC Phase 1
Early implementation of ABC

Accelerated Bridge Construction

Looked at what other states were doing

Workshops held
Precast Concrete Elements
Prefabricated Components

Modular Construction
Large Prefab. Components

Structure Placement Methods

SPMT Sliding

Accelerated Geotech Work

Geofoam

Fast Track Contracting

CMGC Design/Build

Brought all stakeholders together Identified what was needed Prioritized needs Looked at several specific pilot projects

ABC Phase 1
Results of Phase 1 work
Several key standards were developed
Precast Full Depth Deck Panels Manual on Self Propelled Modular Transporters (SPMTs) Development of specifications and manuals for each Several pilot projects initiated and built

ABC Methods Used

Precast Deck Panels Voided Slabs Precast Substructures
Abutments and Bent Caps

Precast Superstructures
Crane, Sliding, and SPMT

ABC By 2010

Precast Deck Panels - Full Depth

Precast Deck Panels - Full Depth

Precast Deck Panels - Full Depth

Precast Deck Panels - Full Depth

Precast Deck Panels - Full Depth

Precast Deck Panels - Full Depth

ABC By 2010

Precast Deck Panels - Full Depth

Precast Deck Panels - Full Depth

Voided Slabs

Voided Slabs

Precast Substructure

Precast Substructure

ABC By 2010

Precast Substructure

Precast Substructure

Precast Superstructure - Crane

Precast Superstructure - Crane

Precast Superstructure - Sliding

Precast Superstructure - Sliding

ABC By 2010

Precast Superstructure - SPMT

Precast Superstructure - SPMT

Precast Superstructure - SPMT

Precast Superstructure - SPMT

Precast Superstructure - SPMT

Precast Superstructure - SPMT

ABC By 2010

Precast Superstructure - SPMT

Precast Superstructure - SPMT

UTAH Department of Transportation

ACCELERATED BRIDGE CONSTRUCTION BY 2010

ABC Phase 2
Standardized the remainder of prefabricated element types Developed details for:
Precast substructures
Piers, Abutments, walls, culverts

Where are we going?

Michael Culmo
CME Associates, Inc.

Precast Approach slabs Precast Girders

Pre-tensioned Bulb Tees Post-Tensioned Bulb Tees Deck Bulb Tees

Developed Specifications and Manuals Workshops were held for industry input

ABC Phase 2
Other work completed in Phase 2
Reviewed computer monitoring data from first round of SPMT bridge moves Refined Phase 1 work based on lessons learned in construction
Deck Panel standards and specifications SPMT Manuals

Connections with Grouted Splice Couplers Emulates a reinforcing steel lap splice Used in precast parking garages and stadiums and bridges New seismic research coming

ABC By 2010

Connections with Grouted Splice Couplers Installation video on Youtube Search Georgia Bridge Pier

Typical Connection Details

Column or wall panel to footing connection

Typical Connection Details

Column to cap connection

Current Typical Details

Single column hammerhead Two column bent Three column bent

Current Typical Details

Columns
Rectangular are possible, but not preferred Round columns are difficult to precast
Must be cast vertically

Current Typical Details

Footings
Full Precast
For smaller footings

Use Hexagonal or octagonal shape

Can be cast on side (one side open)
Shim and grout under footing through ports in footing

ABC By 2010

Current Typical Details

Footings
Partial Precast
For larger footings Precast designed to support DL of bridge CIP extensions designed for other loads
Precast Portion CIP Extension Shim and grout under footing through ports in footing

Current Typical Details

Pile supported footings Use corrugated pipe forms Used for integral abutment stems also

Pretensioned Bulb Tee Girders

Pretensioned Deck Bulb Tee Girders

Post-tensioned Bulb Tee Girders

Integral Abutment Details

ABC By 2010

Cantilever Abutments and Walls

Use corrugated pipes in stems to reduce weight
To be filled with concrete in the field Reduces the number of pieces

Stage 1

1.

Drive Piles

Stage 2

Stage 3

1. 2. 3.

Place footings over pile and set to grade and alignment (day 1) Cast concrete in voids around piles (day 1) Cast concrete between footings if required (day 2)

1. 2. 3. 4. 5.

Install pier wall panels. (day 4) Connect to footing via grouted splice couplers (day 4) Fill voids with concrete to within 3 feet of top (day 5) Install rebar cage in top of voids extending 2 feet above (day 5) Joints between may be grouted or left dry

Stage 4

Final Construction

1. 2.

3.

Install pier cap, set to grade (day 6) Pour concrete through ports to fill voids and make connection (day 7) Install precast beam seats (day 7)

ABC By 2010

Box Culverts
Precast boxes, aprons, and walls

Tolerances
Tolerance details developed for all critical elements Based on PCI Tolerance manual
MNL-135-00

Tolerance Details
Splice couplers Columns

Tolerance Details

Precast Full Depth Deck Panels

First Generation Standards completed in Phase 1 UDOT ABC Program More than 15 project built to date Costs are coming down Welded plate details are not desirable
Time Leakage issues at joints

Precast Full Depth Deck Panels

Phase 2 Modifications
Use Longitudinal Post-Tensioning to Connect Panels
AASHTO Code Recommendation Better performance over time (no leakage through joints)

Use multi-strand PT systems

Developed for slabs More Flexible

Allow blind pockets for shear stud connection

Based on recent research

There is new technology in the market

Allow skewed deck panels (up to 15 degrees)

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ABC By 2010

Precast Full Depth Deck Panels

Recommended Post-tensioning System
Multi-strand deck PT systems Developed specifically for decks (thin anchorage) Used by other states Recommend the use of less than maximum amount of PT allowed in the ducts (4-0.5 strand)

Blind Pocket Project Texas DOT

UDOT Blind Pocket Details

Schematic Construction Details 2 Span Bridge using UDOT Standards

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ABC By 2010

Excavate and Install Piles

Install Abutment Stem and Footings

Typical 2 Span Bridge

Typical 2 Span Bridge

Install Pier Columns Fill Voids in Abutment Stems

Install Pier Cap and Wingwalls Cast Footing Closure Pour

Typical 2 Span Bridge

Typical 2 Span Bridge

Erect Girders

Install Backwalls and Sleeper Slabs

Typical 2 Span Bridge

Typical 2 Span Bridge

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ABC By 2010

Install Deck Panels and Approach Slabs

Cast Deck and Approach Slab Closure Pours

Typical 2 Span Bridge

Typical 2 Span Bridge

Construction Roadway Approaches

Bridge Monitoring (TAC) Volunteer group of key stakeholders

UDOT Design Consultants Contractors Industry Representatives

Charged with review of data and recommendations for future SPMT bridge moves Used computer monitoring data from 2008 Typical 2 Span Bridge

Bridge Monitoring (TAC)

Data retrieved
Mostly strain data (deck, girders) Layouts were similar on each bridge Used to study the stresses within the bridge during:
Lifting Moving Placement

Bridge Monitoring (TAC)

Temperature Strain

Dynamic Strain

Lifting Strain

Utah State University (USU)

Brought in to analyze and disseminate the data With input from the TAC

Typical Data

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ABC By 2010

Bridge Monitoring (TAC)

Final Findings and Recommendations
Lifting stresses are very significant
Supporting the deck at the lift points eliminated most deck cracking Lift bridge closer to ends (0.2L or less) Lightweight concrete in the deck helps to reduce deck cracking, and overall lift weight

SPMT Manual Revisions

Build on knowledge gained in 2008 No major changes Define roles of project participants Written to fit in with the UDOT Design Network

Dynamic effects can be approximated by increasing dead load by 15%

Starting and stopping of SPMTs Traversing bumps during the move

3d Analysis is needed to estimate lifting stresses if a flexible carrying beam is used Recommended future gaging locations

SPMT Lifting Methods

Lessons Learned
Study of Performance of ABC Bridges Bridge Types Studied
Full Depth Deck Panels with welded tie connections (6) Full Depth Deck Panels with Post-Tensioning (2) Precast Parapets integral with deck (5) SPMT Bridge Moves (9) Precast Abutments (2) Precast Piers (2)

Neg. DL moment on girder May be a problem with prestressed girders Light weight concrete could help Little or no deck cracking Deck is pre-compressed in final condition

Neg. DL moment on composite section Significant deck cracking is possible Light weight concrete could help

Inspections took place in May, 2009

Lessons Learned
Project locations
Milepost 200 on Route 6 not shown

Lessons Learned
Purpose of the study
Investigate the performance of each component type What is performing well and what is not Not intended to critique past designs
Most of these bridges were designed prior to development of standards Many were designed as short term fixes prior to full replacement in the near future (10-25 years)

Goal: Continuous Improvement of Quality

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ABC By 2010

Lessons Learned
Welded Tie Connections
Joint Leakage is widespread Shear transfer is still working Composite connection is good

Lessons Learned
Welded Tie Connections

Lessons Learned
Welded Tie Connections Welded Tie Connections

Lessons Learned

Lessons Learned
Post Tensioned Connections
3 span continuous bridge

Lessons Learned
Post Tensioned Connections
No Joint Leakage Even in negative moment areas

Underside of deck I-215 at 3900 South

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ABC By 2010

Other Long Term Performance Information I-84/Route 8 Interchange Waterbury, CT

Project Information
Curved structure (straight beams) 6 Span bridge with continuous spans Single lane Prestressed transversely and post tensioned longitudinally Details similar to UDOT 42 Day construction
No construction problems

Built in 1991

After 18 years of service

Excellent condition Used membrane waterproofing and Asphalt Wearing surface No leakage through joints

After 18 years of service

Another long term example project

Route 8 Viaduct, Seymour, CT
2 Curved structures Over 50 spans (all simple spans) Prestressed and post tensioned Weekend closures only
Old deck removed on Friday night New deck erected on Saturday morning Post tensioned on Saturday night Grouting on Sunday morning Open to traffic Sunday night

Lessons Learned
Precast parapets integral with precast decks
Most are good Problem with panels cast with 2 parapets
No transverse adjustment during installation

Asphalt wearing surface with waterproofing membrane In service for 15 years Excellent condition

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ABC By 2010

Lessons Learned
Precast Abutments
Few have been built

Lessons Learned
Horizontal joints (Lego bridges) None built to new standards yet There were significant fit-up problems on one bridge
Can be resolved with appropriate casting tolerances

Performing well

Lessons Learned
Precast Piers
Few have been built
One is similar

Lessons Learned
None built to new standards yet Construction went well Performing well

Lessons Learned

Lessons Learned
SPMT Bridge Moves
Deck cracking is common Exceptions:
Bridges cast while supported at lift points Lightweight Concrete Deck

Some leakage through cracks Performing well

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ABC By 2010

Lessons Learned

Lessons Learned

Lessons Learned
Cast-in-place closure pours
Some have significant shrinkage cracks
Restraint of adjacent panels Some leakage through cracks

Lessons Learned

Lessons Learned

Lessons Learned
Shear Connector Pockets
Several have minor leakage around pockets (not all)
Shrinkage of Grout Blind pockets should alleviate this

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ABC By 2010

Lessons Learned
Recommendations

Lessons Learned
Full Depth Deck Panels
Eliminate welded tie detail Always use post-tensioning Use blind pocket detail for shear connectors New Standards address these recommendations

Lessons Learned
Recommendations
Precast integral parapets
Do not use 2 per panel
Use a longitudinal closure pour in deck to allow for adjustment in the field Cast one or both in the field behind temp. barriers

Lessons Learned
Recommendations
Precast Abutments and Piers
Use vertical joints in abutment stems and wall stems
Allows for easier fit-up in the field

No problems noted with pier construction New Standards address these recommendations

Lessons Learned
SPMT Moves
TAC Committee work verifies issues found in the field
Pick bridges closer to ends If possible, support girders at lift points during deck casting Investigate the use of lightweight concrete to reduce deck and girder stresses New SPMT Manual will address these recommendations

Lessons Learned
Other general recommendations
Overlays
Consider thicker overlay with a quality waterproofing membrane
European and East Coast Systems CME recommendation, not UDOT policy

Closure Pours
Use a better high early strength concrete mix
Shrinkage compensating mixes NY State mix is being investigated

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ABC By 2010

Where are we going?

UDOT Themes
Accelerate Delivery
Design and Construction

Where are we going?

Implementation of Phase 2 Standards
Training
Designers Construction Inspectors Bridge Inspectors Bridge Maintenance Personnel

Decrease MOT
Reduce User Costs and impact to society

Encourage Innovation Get a good price

On-call technical support

Where are we going?

Manuals
Develop a Bridge Design Manual New SPMT design guide to be issued

Where are we going?

Continue to monitor progress
Annual inspection of ABC Bridges Address issues as they arise

Lightweight Concrete
SPMT Decks (minimize deck cracking) Substructure Elements (reduce shipping and handling costs)

Goal: Continuous Improvement

Questions?
This presentation will be posted on the UDOT website

Testing data

Grouted Splice coupler @ end of column

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ABC By 2010

Testing data

Control Column w/o Grouted Splice Coupler

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