Selection Criteria For Short-Span Bridges Construction Methods Building on Our Growth Opportunities May 27 – 30, 2015 Miser sur nos opportunités de croissance REGINA, SK Selection Criteria For Short-Span Bridges Construction Methods Mohamed Darwish, PhD, PEng Nour Akroush,BSc Mohamed Kasbar, BSc Laila Amin, BSc Tariq Almahallawi, BSc Noorhan Helmy, BSc Presented by: Mohamed Kasbar

Presentation Outline 1. Categorize short-span bridges 2. Segmental bridges Sub-categorization Methodology Governing factors 3. Arched bridges 4. Case study- Ravensbosch Viaduct, Netherlands Construction flowchart Method evaluation 5. Case study- King Fahd Causeway Introduction Segmental Bridges Arched Bridges Case Study 1 Case Study 2 Mohamed Kasbar

Introduction Segmental Bridges Arched Bridges Short-span bridges Concrete steel Arched Bridges Steel Introduction Segmental Bridges Arched Bridges Case Study 1 Case Study 2 Mohamed Kasbar

Pont de Gard Bridge (France- 12 BC) Segmental Concrete Bridges Segmental concrete bridges are made of repetitive structural concrete elements that are progressively joined together to form the complete bridge structure. Introduction Segmental Bridges Arched Bridges Case Study 1 Case Study 2 Pont de Gard Bridge (France- 12 BC) (http://www.asbiassoc.org/cfcs/cmsIT/baseComponents/fileManagerProxy.cfc?method=GetFile&fileID=E0525DDC-B702-7FC0-6675EAE0177DD17E) http://www.bbrnetwork.com/technologies/construction-methods.html Mohamed Kasbar

Segmental Concrete Bridges Method of Construction Casting Method Cast-in-Place Precast Erection Method Cantilever Balanced Unidirectional /Progressive Placement Span-by-span Incremental Launch Introduction Segmental Bridges Casting Methods Erection Methods Span-by-span Cantilever Incremental Launch Arched Bridges Case Study 1 Case Study 2 Mohamed Kasbar

Casting Methods Precast prefabricated , transported to site and installed Cast-in-place Segments cast in their place in the superstructure of the bridge Introduction Segmental Bridges Casting Methods Erection Methods (http://mceer.buffalo.edu/education/bridge_speaker_series/20102011/presentations/Rohleder_presentation.pdf) Span-by-span Cantilever Incremental Launch Table forms Arched Bridges Case Study 1 Case Study 2 http://www.asbiassoc.org/cfcs/cmsIT/baseComponents/fileManagerProxy.cfc?method=GetFile&fileID=9297B6A2-F1F6-B13E-82A97DF4A576B3BC) Mohamed Kasbar

Casting Methods Segmental Bridges Introduction Precast Advantages Disadvantages Precast More economic in short spans since forms of precast elements can be re-used Finishing done on the ground Better quality control. Major reduction in schedule (simultaneous work in do substructure while pre-casting  Not suitable for large, heavy segments High cost of pre-casting plant, the transportation, storage and installation  Cast-in-place Most suitable for large heavy segments, where precast cannot be used since the segments are too large and heavy to be transported High cost of travelling forms Segmental Bridges Casting Methods Erection Methods Span-by-span Cantilever Incremental Launch Arched Bridges Case Study 1 Case Study 2 Mohamed Kasbar

Span-by-span Method Construct piers Introduction Segmental Bridges Place first segments (using mobile cranes) Rapid assembly However high level of mechanization suitable for large number of spans Casting Methods Assemble gantry crane (truss system) Erection Methods Lift segments into position Span-by-span Cantilever Align segments and apply epoxy-grout in connections Incremental Launch Repeat for a few more segments Arched Bridges Post-tension (if necessary) Case Study 1 Case Study 2 Move gantry crane to the next span and continue watch?v=wqcj1GAayYY Mohamed Kasbar

Balanced Cantilever Erection Method Casting Method: pre-cast segments Casting Method: cast-in-situ Introduction Segmental Bridges Casting Methods Erection Methods Span-by-span Cantilever Incremental Launch Arched Bridges Case Study 1 (http://www.concreteconstruction.net/images/Segmental%20Bridges_%20the%20Best%20in%20the%20Business_tcm45-348100.pdf) Case Study 2 (http://scholar.lib.vt.edu/theses/available/etd-120199-224950/unrestricted/11lucko_chapter4.pdf) Mohamed Kasbar

Unidirectional Cantilever Erection Method Introduction Casting Method: pre-cast segments Casting Method: cast-in-situ Segmental Bridges Casting Methods Erection Methods Span-by-span Cantilever Incremental Launch (http://scholar.lib.vt.edu/theses/available/etd-120199-224950/unrestricted/11lucko_chapter4.pdf) http://civildigital.com/wp-content/uploads/2014/03/Segmental-Construction-Method-Progressive-placement.jpg Arched Bridges Case Study 1 Case Study 2 Mohamed Kasbar

Balanced and Unidirectional Cantilever Methods Introduction Balanced Cantilever Unidirectional cantilever Speed Faster Slower Complexity More complex Less complex Need for temporary support No Yes Accessibility Less accessibility More accessibility Segmental Bridges Casting Methods Erection Methods Span-by-span Cantilever Incremental Launch Arched Bridges Case Study 1 Case Study 2 Mohamed Kasbar

Incremental Launch Erection Method Construct Piers Place temporary supports (if segments are long) Cast first segment Launching Nose pulls segment into position (using hydraulic jacks ) Cast segment 2, and cycle is repeated Introduction Segmental Bridges First segment Casting Methods Erection Methods Span-by-span Cantilever Incremental Launch Arched Bridges Case Study 1 Case Study 2 http://scholar.lib.vt.edu/theses/available/etd- 120199224950/unrestricted/11lucko_chapter4.pdf Mohamed Kasbar

Steel Bridges Advantages of using steel: High yielding strength (with a lower dead load) Isotropic material sustainable Introduction Segmental Bridges Casting Methods Erection Methods Span-by-span Cantilever Incremental Launch Arched Bridges Case Study 1 http://www.newsline.dot.state.mn.us/images/08/jan/16-hwy99bridge.jpg Case Study 2 Mohamed Kasbar

Segmental Bridges - Governing Factors   Span-by-Span Balanced Cantilever Unidirectional Cantilever Incremental Launching Need for mid-span temporary supports Not needed Sometimes needed for moderate-long spans Needed Needed for moderate-long spans Material Precast concrete or steel Concrete or steel Level of mechanization High Moderate Need for special design consideration Should account for additional number of load cases Additional load cases and limited for decks of constant sections and slopes Construction Speed Fast Fastest Cost Cost saving for large number of spans Cost saving for short-medium spans Cost saving for shorter spans Cost saving for short-moderate spans Risk Low Highest Mohamed Kasbar

Arched Bridges Aesthetical appearance Structural Behavior Live Loads + Dead Loads  abutments Inflatable forms can be used 50-100 times One inflatable form can be used to built different sizes of bridges Introduction Segmental Bridges Arched Bridges Case Study 1 Case Study 2 Cast-in-situ Pre-cast (http://www.concreteconstruction.net/images/Short- Span%20Arch%20Bridges_tcm45-341968.pdf) (http://www.concreteconstruction.net/images/Short- Span%20Arch%20Bridges_tcm45-341968.pdf) Mohamed Kasbar

Methodology Foundation Formworks: inflated forms or false work Cast-in-situ Pre-cast Foundation Formworks: inflated forms or false work Control shape by steel strapping Set reinforcement rebar Shot Crete (6 to 11 inches/ layer) Disassemble forms Introduction footings Place sections. Takes 1 day or less. Place earth fills on footings Segmental Bridges Arched Bridges Case Study 1 Case Study 2 Mohamed Kasbar

Governing Factors Bridge Construction Type Range of Heights and Spans Cast in situ (single form) span: up to 17 ft Height: up to 8.5 ft Cast-in-situ (multiple forms) span: up to 48 ft Height: up to 8 ft Precast arch Span: 30 ft Height: 14 ft or span: 40 ft Height: 10 ft Introduction Segmental Bridges Arched Bridges Case Study 1 Case Study 2 Mohamed Kasbar

Case Study – Ravensbosch Viaduct Ravensbosch Viaduct, Netherlands Location Maastricht – Heerlen, Netherlands Type Concrete Segmental Erection Method Incremental Launching Casting Method Precast? Duration 26 months (short) Price 7.5 M Dutch Florins Introduction Segmental Bridges Arched Bridges Case Study 1 Case Study 2 Mohamed Kasbar

Construction flowchart Decide on design (42 spans of 6 x 56 x 42) Build construction yard (75m x 25m) Place temporary mid-span supports Assemble launching nose (15m) Assemble jacks (6 hours to move a 19m segment) Place plates between launched box girder and concrete bearings on piers Introduction Segmental Bridges Arched Bridges Case Study 1 Case Study 2 Mohamed Kasbar

Method Evaluation 1. Conventional method :false work for 25 m height 2. Precast segment: Cost of transportation + large cranes + large trucks 3. Left with segmental A. span-by-span requires precast members B. Cantilever methods: cannot C. time is of essence. Incremental Launching Method is the only left alternative and it is the fastest segmental erection method. Introduction Segmental Bridges Arched Bridges Case Study 1 Case Study 2 Mohamed Kasbar

Case Study – King Fahd Causeway Location Saudi Arabia - Bahrain Type Concrete Segmental Erection Method Span-by-span Casting Method Precast Duration 5 years (time of essence) Price USD 800 m Length 25 km Height Significant variations width 23 m Introduction Segmental Bridges Arched Bridges Case Study 1 Case Study 2 http://kfca.com.sa/en/#/home/ Mohamed Kasbar

Method Statement Phases The causeway was composed of seven embankments (12,570m) and five bridges (12,430m) totaling approximately 12 km in length. Introduction Segmental Bridges |---------------segment 1--------------------------|--------segment 2-----------|----segment 3-------| Arched Bridges Case Study 1 Case Study 2 Mohamed Kasbar

Construction flowchart Cast concrete box sections Connect 2 box sections side by side into a segment Lift by cranes onto barges Transport each segment into its location Lift segments into position using cranes Post-tension continuity cables Pour common slab above each segment Repeat for other segments Introduction Box section 1 span segment Segmental Bridges Arched Bridges Case Study 1 Case Study 2 Mohamed Kasbar

Method Evaluation 1. Conventional (cast-in-place): difficult – in the middle of the Arabian Gulf (6 km) 2. Incremental launching method: impossible – vertical curvature 3. Cantilever methods: time consuming (cast-in-place & precast) 4. Span-by-span with shorter spans: [smaller spans = smaller barges + smaller cranes] BUT would be need more time Introduction Segmental Bridges Arched Bridges Case Study 1 Case Study 2 Mohamed Kasbar

References Alberta Transportation. (2013). Standard Specifications for Bridge Construction. Alberta Transportation, Bridge Engineering Section. Edmonton: Alberta Transportation. Barker, J. M. (1981). Segmental bridges: the best in the business. Retrieved January 29, 2015, from Concrete Construction: Resources for contractors and specifiers including construction methods, materials and equipment.: http://www.concreteconstruction.net/images/Segmental%20Bridges_%20the%20Best%20in%20the%20Business_tcm45- 348100.pdf BBR. (2014). BBR | Construction Methods. Retrieved February 7, 2015, from BBR Network: http://www.bbrnetwork.com/technologies/construction-methods.html Blank, S. A., Blank, M. M., & Luberas, L. R. (2003). Concrete Bridge Construction. In W.-F. Chen, & L. Duan, Bridge Engineering Construction and Maintenance (pp. 2.1-2.17). Boca Raton, FL, USA: CRC Press. CISC. (2008). Handbook of Steel construction (9th ed.). Toronto, ON, Canada: Canadian Institute of Steel Construction. Dunn, L. E. (1996). Bridge Falsework. In R. T. Ratay, Handbook of Temporary Structures in Construction (2nd ed., pp. 20.1-20.43). New York, NY, USA: McGraw-Hill. Durkee, J. (2003). Steel Bridge Construction. In W.-F. Chen, & L. Duan, Bridge Engineering Construction and Maintenance (pp. 1.1-1.63). Boca Raton, FL, USA: CRC Press. FHWA. (2003). Standard Specifications for Construction of Roads and Bridges on Federal Highway Projects. Washington DC: US Department of Transportation. Katz, J. G. (2011, March 13). File:SF-Oakland Bay Bridge Replacement.jpg. Retrieved January 31, 2015, from Wikipidia: http://commons.wikimedia.org/wiki/File:SF- Oakland_Bay_Bridge_Replacement.jpg KFCA. (2013). Causway Technical Information. Retrieved February 7, 2015, from King Fahd Causeway Authority: http://kfca.com.sa/en/#/kfcatec/ Khan, M. A. (2015). Accelerated Bridge Construction Best Practices and Techniques. Oxford, UK: Butterworth-Heinemann. Leonard, G. (2007, October 13). File:Pierre Pflimlin Bridge UC Adjusted.jpg. Retrieved January 31, 2015, from Wikipidea: http://commons.wikimedia.org/wiki/File:Pierre_Pflimlin_Bridge_UC_Adjusted.jpg Ruhl, V. R. (1997). Computer-Aided Design and Manufacturing of Complex Shaped Concrete Formwork. Retrieved February 3, 2015, from Research Gate: http://www.researchgate.net/publication/30874475_Computer-Aided_Design_and_Manufacturing_of_Complex_Shaped_Concrete_Formwork Storfix. (2005, July 24). File:Itztalbruecke 2005-07-24.jpg. Retrieved January 31, 2015, from Wikipidia: http://commons.wikimedia.org/wiki/File:Itztalbruecke_2005-07-24.jpg VSL Inc. (1977). The Incremental Launching Method in Pre-stressed Concrete Bridge Construction. Berne: VSL INTERNATIONAL LTD. VSL Inc. (2013). Bridge Construction Partner. Labege, France: VSL Inc. Mohamed Kasbar