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Michael P. Culmo, P.E. Vice President of Transportation and Structures CME Associates, Inc., East Hartford, CT CONNECTION DETAILS FOR PREFABRICATED BRIDGE.

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Presentation on theme: "Michael P. Culmo, P.E. Vice President of Transportation and Structures CME Associates, Inc., East Hartford, CT CONNECTION DETAILS FOR PREFABRICATED BRIDGE."— Presentation transcript:

1 Michael P. Culmo, P.E. Vice President of Transportation and Structures CME Associates, Inc., East Hartford, CT CONNECTION DETAILS FOR PREFABRICATED BRIDGE ELEMENTS AND SYSTEMS

2 Learning Outcomes After completing this Module, you will be able to: identify roadblocks to accelerated bridge construction identify the resources for locating Connection Details for PBES describe features of PBES that improve the quality of the finished product recognize a typical construction schedule for a bridge built with PBES recall ways to save money by using ABC and PBES

3 Roadblocks to Accelerated Construction The primary concerns that owner agencies have with respect to adopting accelerated construction techniques are: Need for Quality Details Durability Design Methodologies and Training Construction Methodologies

4 Connections Details for Prefabricated Bridge Elements and Systems FHWA has developed this manual This publication is intended to provide information that will go a long way to answering all four of the previous concerns. Focus on details that have been used in the past.

5 Connections Details for Prefabricated Bridge Elements and Systems Project Goals: Gather details of Connections that have been used on accelerated bridge construction projects Investigate transfer of technology from other markets into the bridge market Parking Garages Stadiums Buildings

6 Connections Details for Prefabricated Bridge Elements and Systems All details need to pass a critical test before being published in the document: Does the connection result in a rapid construction process? Does the connection transmit the forces between elements effectively? Is the connection durable? Is it cost effective and easy to construct? If a process or connection is proprietary, is there more than one supplier?

7 State DOTs – Questionnaires sent via Federal Agencies Researchers (previous and current) Producers/Fabricators Sources of Data

8 Forward Table of Contents Section 1 General Topics 1.1 Introduction 1.2 Accel. Construction Overview 1.3 Applicability to Typical Bridges 1.4 Typical Connection Types 1.5 Seismic Considerations 1.6 Materials 1.7 Tolerances 1.8 Fabrication and Construction Section 2 Superstructure Connections 2.1 Deck Systems 2.2 Adjacent Butted Beam Systems 2.3 Decked Stringer Systems 2.4 Modular Superstructures 2.5 Connections to Substructures Section 3 Substructure Connections 3.1 Pier Systems 3.2 Abutment Systems 3.3 Wingwalls and Retaining Walls Section 4 Foundation Connections Appendices Appendix A Notations Appendix B Connection Design Examples Appendix C Standard Products Appendix D Sample Const. Specifications Appendix E Case Studies Appendix F Glossary Manual Organization

9 Connection Data Sheets

10 Precast Cantilever Abutments

11 Precast Integral Abutments

12 Precast Piers

13

14 Precast Decks on PS Beams

15 Precast Decks on Steel Framing

16 Precast Decks

17 FRP Decks

18 Everything shown can be prefabricated Total Bridge Element Prefabrication

19 Complete Bridge Element Prefabrication New Hampshire Project How fast can we build a bridge? Experimental project All components prefabricated 115 foot span Precast cantilever abutments Clock started after old bridge was removed Roadway open to traffic in 8 days Time Lapse Video on YoutubeTM Search Epping Bridge Construction

20 Manual Distribution Availability – Published June 2009 – Is available through FHWA Highways for LIFE website

21 Other Sources for Details Utah DOT ABC Website – (search ABC) – Piers, abutments, walls, decks PCI Northeast – (Bridge resources) MassDOT – Working on new ABC manual NCHRP Report 681 – Development of a Precast Bent Cap System for Seismic Regions – Web search NCHRP Report 681

22 Schematic Design of a Prefabricated Bridge

23 Case Scenario 4 lane bridge over an expressway Existing bridge has deteriorated beyond repair Heavy traffic on both roadways A temporary bridge or staged construction is an option The local business will accept a short term closure with the detour As opposed to a long term staged project Establish the detour and accelerate the bridge construction to less than 30 days

24 Existing Bridge

25 Leaking Deck Joints Low Clearance Salt spray attack from vehicles Existing bridge issues

26 Proposed Bridge Type After a formal study, the owner opted for the following structure criteria: Continuous steel girders (weathering steel) Reduce to a two span bridge Increase clearance by raising approach grades (3) Use integral abutments (no deck joints) Composite concrete deck Membrane waterproofing and Bituminous wearing surface Open steel railings (galvanized)

27 Move substructures away from roadway No Deck joints Build new piers and abutments in new locations Increase vertical clearance Proposed Bridge

28 Sources of details - FHWA Connections manual: Connection Details for Prefabricated Bridge Elements and Systems 1.Review Chapter 1 Investigate connection types, materials, tolerances 2.Search applicable sections of other chapters for details - NCHRP Report 681 Development of a Precast Bent Cap System for Seismic Regions - Utah DOT ABC Standards

29 Connection Types Chosen The owner chose the following connection types – Grouted reinforcing splice couplers Quick, proven system Can develop full bar strength Simplifies the design process (same as CIP) – Grouted PT Ducts Provides significant adjustability at cap connection – Grouted Voids Corrugated metal pipe voids for integral abutments Small blockouts for pinned connections (approach slabs) – Concrete Closure pours between precast elements Use for a limited number of connections (slower)

30 Grouted Reinforcing Splice Couplers Emulates a reinforcing steel lap splice Multiple companies – non-proprietary Used in precast parking garages, stadiums and bridges Installation video on youtube Installation video – Search Georgia Pier Construction

31 Grouted Reinforcing Splice Connectors

32 NCHRP Report 681 Detail Grouted PT Duct Similar to grouted sleeves Used in several states Tested for high seismic regions Significant adjustability Details, specifications and design information available

33 Footing to Sub-grade Connection

34 Footing to Footing Connection Use CIP Closure Pour Cast closure pour during structure erection Design precast for structure DL Design continuous footing for total loads

35 Footing to Column Connection

36 Column to Cap Connection Use details from NCHRP Report 681

37 Completed Pier Footing to subgrade connection Column to footing connection Column to cap connection Footing to footing connection

38 Abutment Details Integral Abutment to piles – Section Precast Integral Abutment to Piles Corrugated metal pipe voids – Place over pile and fill with concrete Detail developed by Iowa DOT – Used in other states also Reduces element weight Has large capacity to transfer pile loads – Shear transfer via shear friction

39 Abutment to Pile Connection

40 Abutment Cap to Cap Connection Use Utah DOT Details –Concreted key –Use integral diaphragm to link caps together

41 Approach Slab Connection

42 Completed Abutment Pile to cap connection Approach slab connection Cap to cap connection

43 Beam to Deck Connection

44 Deck to Deck Connections

45

46

47 PC Deck Connection Details

48 Superstructure to Abutment Connection Use CIP Closure Pour Utah DOT Detail Allows for significant adjustability Provides connection between abutment stem elements

49 Integral Abutment ConnectionLongitudinal PT Longitudinal crown connection Transverse slab connection Connection to beam CIP Curb Completed Superstructure

50 Complete Bridge Precast Integral Abutment Membrane waterproofing with bit. Wearing surface Precast Pier Precast full depth composite deck

51 Estimated Construction Schedule

52 Costs Typical New Bridge (Cost=$175/sf) = $2,200,000 Premium for ABC (assume 20%)= $440,000 Temporary Bridge (Cost=$50/sf) = ($620,000) Net Savings = $180,000 Note: These prices will vary greatly by region

53 Other Cost Savings Ways to reduce bid prices with ABC – Standardization – Programmatic (not one of a kind) – Reduced project site costs (trailers, etc.) – Reduced maintenance of traffic costs – Inflation Other Non- Bid Savings with ABC – Fewer police details – Reduced agency costs during construction (staff time) User Costs – Plus: $$ can be significant – Minus: $$ not in the budget

54 Quality FL has had very good success with precast piers in very harsh environments CT has had Precast full depth decks in place for over 20 years – Crack Free Deck – Excellent condition Integral abutments eliminate deck joints

55 By elimination of temporary bridges or costly stage construction schemes, and accounting for reduced agency costs you CAN have all three Rapid Construction High Quality Low Cost You can only have any two Old Adage

56 Conclusions It is possible to build a complete bridge in 30 days (or less) The FHWA manual provides a starting point for a complete bridge prefabrication project New details are coming on line all the time – NCHRP Report 681, Utah DOT, PCI Northeast (www.pcine.org) You do not need to sacrifice quality to get rapid construction You can save money on an accelerated bridge project by: – Reducing construction time – Eliminate temporary bridges or staging

57 Module Conclusions You should now be able to: identify roadblocks to accelerated bridge construction identify the resources for locating Connection Details for PBES describe features of PBES that improve the quality of the finished product recognize a typical construction schedule for a bridge built with PBES recall ways to save money by using PBES

58 Questions


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