1. Connection Details for Prefabricated Bridge Elements and Systems
Michael P. Culmo, P.E.
Vice President of Transportation and Structures
CME Associates, Inc., East Hartford, CT

2. “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
The details were gathered from transportation agencies and other industries, which turned out to be a key component of the work. Accelerated construction is also used in vertical construction. Many of the details used in this industry are transferable to bridge construction.

3. Available Technologies
Corrugated Void Pockets
Developed in Iowa
Very good punching shear capacity
Footings
Integral abutments
Pier caps
Easy to form
Reduces shipping weight
Grouted reinforcing splice couplers are an example of a connection that migrated from the vertical construction industry.

4. Available Technologies
Corrugated Void Pockets – Integral abutments
Grouted reinforcing splice couplers are an example of a connection that migrated from the vertical construction industry.

5. Available Technologies
Corrugated Void Pockets – Integral abutments
Grouted reinforcing splice couplers are an example of a connection that migrated from the vertical construction industry.

6. Available Technologies
Corrugated Void Pockets
Cantilever Abutments
Cantilever Walls
Grouted reinforcing splice couplers are an example of a connection that migrated from the vertical construction industry.

7. Available Connection Technologies
Grouted Couplers
Emulates a reinforcing steel lap splice
No special design required
Multiple companies – non-proprietary
Used in vertical construction for
many years
parking garages
Stadiums
Bridges
Favored by Northeast States
Seismic
Used in buildings (ACI)
Previously tested in Japan
New testing underway at Univ. of Nevada
Grouted reinforcing splice couplers are an example of a connection that migrated from the vertical construction industry.

8. Grouted Reinforcing Splice Connectors
The couplers can be used where ever a construction joint would normally be placed in a conventional bridge. This facilitates the design of the bridge because it can be designed as a cast-in-place structure. The couplers replace the normal lap splices. The only design change is the depth of the reinforcing cage in order to get proper cover over the couplers.
Installation Video on YoutubeTM
Search “Georgia Pier Construction”

9. Grouted Splice coupler @ end of column
Testing data
Grouted Splice end of column

10. Control Column w/o Grouted Splice Coupler
Testing data
Control Column w/o Grouted Splice Coupler

11. Pile Supported Footings
Use corrugated pipe forms
Used for integral abutment stems also

12. Pile Supported Footings
Use precast stem with CIP Footing
Good for footings with closely spaced piles

13. Available Technologies
Grouted PT Ducts
Similar to grouted couplers
Good for development into mass concrete
Lap splices?
Check conflicts with transverse bars
Grouted reinforcing splice couplers are an example of a connection that migrated from the vertical construction industry.

14. 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
The NCHRP study was for high seismic regions, however the connections are good for all locations.

15. 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”
There are other sources of details for ABC connections.

16. Manual Distribution Availability Published June 2009
Is available through FHWA Highways for LIFE website
The manual is complete and available for use. A web-site is under development that will include the details in the manual. Other details will be added to the website as they become available.

17. NEW FHWA ABC Manual Accelerated Bridge Construction
Experience in Design, Fabrication and Erection of Prefabricated Bridge Elements and Systems

18. Previously Published FHWA Manuals
2006: Decision-Making Framework for Prefabricated Bridge Elements and Systems
2007: Manual on the Use of Self-Propelled Modular Transporters to Remove and Replace Bridges
2009: Connection Details for Prefabricated Bridge Elements and Systems

19. Goal of New Manual Overview of all aspects of ABC
Fill in areas that are not covered in the other manuals
Dovetail with Every Day Counts Initiative
Compliment SHRP2 R04 Work
“Innovative Bridge Designs for Rapid Renewal”

20. Manual Outline ABC Definitions Chapters Introduction: Why use ABC?
Accelerated Bridge Construction Techniques
Planning and Scoping Projects with ABC and PBES
Implementing ABC in a Transportation Agency
Prefabricated Bridge Elements
Miscellaneous Bridge Elements
Construction
Long-term performance of Prefabricated Elements
Design and Analysis

21. Utah experience with ABC:
Chapter 1
Introduction
Purpose of the Manual
Why use ABC?
Public perception of ABC
Public Perception
Utah experience with ABC:
Polling results

22. Chapter 2 ABC Technologies FHWA Every Day Counts ABC Toolbox
Foundation and Wall Elements
Rapid Embankment Construction
Prefabricated Bridge Elements and Systems
Structural Placement Methods
Fast Track Contracting
Contracting Provisions
Best Value Selection
A+B and A+B+C Bidding
Incentive and Disincentive Clauses
Warranties
Lane Rental
Applicability of ABC Technologies to Different Bridge Projects
FHWA Every Day Counts
ABC Toolbox

23. Chapter 2
Fast Track Contracting
Design/Build Flowchart

24. Chapter 2
Fast Track Contracting
CMGC Flowchart

25. Chapter 3 Planning and Scoping Projects ABC Decision Making process
Is ABC Appropriate?
Decision Process for Selection of ABC Methods
What type of ABC should I use?
Defining the problem
Flow charts for determination of appropriate ABC methods
Structure type selection analysis including overall project costs
Public Involvement

26. Chapter 3 Planning and Scoping 3 Basic types of ABC in use today
Prefabricated Bridge Elements
(LEGO bridges)
Individual prefabricated elements
Modular Prefabricated Elements
Larger components made up of several prefabricated elements
Large Scale prefabrication
Full structures
SPMT bridge moves
Lateral skidding/sliding
Barge installations

27. Chapter 3 Planning and Scoping: Decision flowcharts
Used to determine the appropriate methods of ABC
Construction with Prefabricated elements (LEGO Bridge) is always an option
Identifies other potential options
Based on the following assumptions
ABC is already on the table
The time and cost are not factors at this point
A time and cost analysis is recommended after determining the appropriate ABC methods for the site

28. Chapter 3
Determination of appropriate ABC methods

29. Chapter 3
Determination of appropriate ABC methods

30. Chapter 3
Determination of appropriate ABC methods

31. Chapter 3
Determination of appropriate ABC methods

32. Chapter 3 Once appropriate methods of ABC are determined
Investigate all viable options
Time for each option
Traffic management for each option
Determine mobility Impacts
Calculate overall project costs
Determine User Costs

33. Chapter 4
Utah Model
Implementing ABC in a Transportation Agency

34. Chapter 5
Typical Prefabricated
Elements

35. Chapter 6 Miscellaneous Bridge Elements: Bearings Railing/Barriers
Joints

36. Chapter 7 Chapter 7: Construction Fabrication Erection Grouting
Shoring
Paperless submissions
Accelerated testing needs

37. Chapter 8 Long-term Performance
Example: UDOT SPMT Bridge after 3 years in service
Long-term Performance
Durability of PBES based on lessons learned
Case Studies
Conventional Construction
SPMT Install
Edison Bridge in Florida
15 years in service
Corrosive environment
Conclusion: Cracking in deck is no worse than conventional construction (better in some cases)

38. Chapter 9 Design and Analysis Design of bridges for SPMT moves
Precast Substructures
Integral Abutments
Cantilever abutment
Piers
Full Depth Deck Panel
Post tensioning
Issues not covered in LRFD
Mechanical Connectors in hinge zones - seismic
Corrugated void shear capacity

39. Appendices Design Examples and Guidance
Full depth precast deck panels
Precast Concrete Piers
Precast Integral Abutments
Erection and Lifting calculations for deck panels
Reference Documents that contain Design Information
Standard and Proprietary Products
Sample Construction Specifications
UDOT – Precast Substructure Elements
UDOT – Precast Concrete Deck Panels
UDOT – Bridge Construction using Self Propelled Modular Transporters
UDOT – Structural Lightweight Concrete
MassDOT – High Early Strength Concrete

40. Manual Distribution Availability Published in November 2011
Available On-Line
Free Download
Some of these technologies are new to the States who submitted an application

41. Questions