Transcript Accelerating Bridge Construction with Prefabricated Bridge

ACCELERATING BRIDGE CONSTRUCTION (ABC)
WITH
PREFABRICATED BRIDGE ELEMENTS & SYSTEMS (PBES)
PBES Technology
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Overview of ABC and PBES/definitions
Why use PBES?
PBES performance goals for the U.S.
Specific Systems and Elements
Structural placement methods
When to consider PBES
Cost Effectiveness of PBES
Resources for ABC/PBES
Accelerated Bridge Construction Components
Foundation &
Wall Elements
Continuous
Flight Auger
Piles
Geosynthetic
Reinforced Soil
(GRS)
Integrated
Bridge System
Rapid
Embankment
Construction
EPS Geofoam
Prefabricated
Bridge
Elements &
Systems
Structural Placement
Methods
Self-Propelled Modular
Transporters (SPMTs)
Prefabricated
Elements
- Superstructure
- Substructure
Prefabricated
Systems
- Superstructure
- Substructure
- Total Bridge
Longitudinal
launching
Horizontal sliding or
skidding
Other heavy
lifting equipment &
methods
Conventional lifting
equipment & methods
Fast
Track
Contracting
Innovative
Contracting
- Best value
- CMGC method
- Design Build
- A+B
- A+B+C
- Warranties
Definition of PBES
Structural elements & systems that are
built off the bridge alignment to
accelerate onsite construction time
relative to conventional practice.
Why Use PBES Technologies?
It offers Major Advantages:
• Faster (offsite, off critical path, less impact)
• Safer (public, construction, & inspection)
• Better Quality (controlled environment)
• Can be Cost Effective: positive Benefit-Cost
ratios when user costs are considered.
Why Use PBES Technologies?
• INDOT’s Lane Closure Policy
•Interstate projects
•Other projects where user costs are
considered
• Result of public involvement
• Design Build – let contractor/designer
decide best method to reduce impact
• Accelerated construction (e.g. A+B)
FHWA PBES Deployment Goals for U.S.
• By December 2012:
• 100 cumulative bridges have been designed
and/or constructed rapidly using PBES.
• 25 percent of replacement bridges authorized
using Federal-aid have at least one major
prefabricated bridge element that shortens
onsite construction time relative to
conventional construction.
Goal of PBES?
Moving more cast-in-place construction
to off-site location
Goal of PBES?
Building the
bridge or
elements first
before you
close lanes,
then quickly
move it into
place – like in
hours or a
weekend!
What are Prefabricated
ELEMENTS AND SYSTEMS?
• Systems
• Elements
– Deck Panels: Partial & Full-Depth
– Superstructure
– Beams: More Efficient Shapes,
– Substructures
– Pier Caps, Columns, & Footings
– Total Bridge
– Abutment Walls, Wing Walls, &
Footings
PBES Element Definitions
Full-depth Deck Panels:
Panels that are prefabricated
the full thickness and do not
require CIP concrete to
complete the deck thickness;
Precast Decks on PS Beams
•Deck panels most common
type of PBES
•Concrete most common
type of deck panel
Precast Decks on Steel Framing
PBES Element Definitions
Pier Caps, Columns, and Footings:
A combination of precast & CIP
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
Precast Columns and Pier Caps
Precast pier cap
PBES System Definitions
Superstructure:
1. Total superstructures
moved in with SPMTs,
skidded, or launched
2. Truss spans and arch
spans constructed off the
bridge alignment
3. Precast segmental box
segments
4. Composite units w/o CIP
deck, w/ or w/o overlay
5. Deck bulb tee beams w/o
CIP deck, w/ or w/o overlay
Superstructure Span on SPMT
How to move PBES into place?
Structural Placement Methods
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Self-Propelled Modular Transporters (SPMTs)
Longitudinal launching
Horizontal/transverse sliding or skidding
Other heavy lifting equipment & methods
Conventional lifting equipment & methods
What Success Looks Like:
FDOT Graves Ave. over I-4 Bridge Replacement - 2006
143-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
Badhoevedorp, Netherlands
Superstructure Roll-In:
390-ft Length, 3300 M Tons
2 Hours to Move - 1 Weekend Road Closure
April 2004
Prefabricated
Bridges
International
Scan
George P. Coleman Bridge, VA - 1995
CONTINUOUS LAUNCHING
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TRANSVERSE LAUNCHING
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Baldorioty Castro Ave. –
San Juan, Puerto Rico 1992
Two 700-ft and two 900-ft bridges,
each installed in 21-36 hrs
Virginia DOT I-95 Bridge
over James River, 2002
102 superstructure spans replaced
in 137 nights …
… with no lane closures during
rush-hour traffic
Benefits of Using ABC/PBES
It offers Major Advantages:
• Faster (offsite & off critical path)
• Safer (public, construction, & inspection)
• Better Quality (controlled environment)
• Can be Cost Effective: positive Benefit-Cost
ratios when user costs are considered.
FASTER: Reduces OnSite Construction Time
• Less time spent on-site
• Traditional tasks can be
done off-site
• Minimal impact from
weather conditions
SAFER: Minimizes Traffic Impacts
• Minimizes traffic delay
and community
disruption
I-59 and I-65 Interchange, AL
US 59 under Dunlavy, TX
• Reduces detours, lane
closures, and narrow lanes
SAFER: Improves
Work Zone Safety
• Minimizes work
near traffic and
power lines,
at high elevations,
or over water.
Meylan Pedestrian Bridge, France
QUALITY: Improves
Constructability
• Prefabricated
elements & Systems
– Minimal impact from
environmental
constraints
– Relieves
constructability
pressure.
San Mateo-Hayward Bridge, CA
BETTER QUALITY
• Prefabricated in a
controlled environment
• Increases quality control
• Optimum concrete curing
George P. Coleman Bridge, VA
PBES can be COST-EFFECTIVE
• It depends on type of structure and elements or
systems used.
• Over time, many systems can cost less than
conventional construction
• First implementation of new elements may cost more.
• Need a program of projects--economy of scale.
• Life cycle cost analysis is favorable to PBES and
provides a positive Benefit-Cost Ratio when user
costs are considered.
COST EFFECTIVE:
Declining Cost of
Deploying Innovative
Technology
First time costs more
< Potential for new
methods to cost less
< Promise of time savings
< Positive cost-benefit ratios
< Promise of programmatic cost savings
COST EFFECTIVE: Costs of PBES
COST EFFFECTIVE: Costs of PBES
State-of-the-Practice?
• FHWA Senior management is committed to
Every Day Counts technology deployments
• 40+ States: 1 or more projects
• 7 States: 20+ projects
• 11 States actively pursuing as standard
practice
• Opportunity for much greater PBES
deployment
Complete Bridge Element Prefabrication
New Hampshire Project
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How fast can we build a bridge?
115-foot span
All components prefabricated
Precast cantilever abutments
Roadway open in 8 days
Time Lapse Video on YoutubeTM
Search “Epping Bridge Construction”
WHEN TO USE PBES: Framework for
Decision-Making – Format
• Introduction
• Flowchart
– Decision-Making at a Glance
• Matrix
– Decision-Making Questions
• Decision-Making Considerations
– Questions with Discussion and References
Flowchart
DECISION
MAKING
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Decision-Making Matrix
Example Questions
Question
High traffic volume…?
Emergency replacement…?
Worker safety concerns…?
High daily traffic control
costs…?
Yes
Maybe
No
Decision-Making Matrix
• One or two factors may warrant use of PBES
• User may assign weights to factors
• In any case, a majority of “Yes” responses
indicates PBES offers advantages
Framework Available Online
www.fhwa.dot.gov/bridge/prefab/framework.cfm
Utah DOT Decision Chart
Resources:
For ABC/PBES Manuals, Specifications,
Contract Drawings, & Details
• Websites:
– FHWA EDC site
www.fhwa.dot.everydaycounts
– FHWA PBES site
– HfL projects site
– ABCT site
– ACTT site
– State DOT bridge sites
• PBES Cost Study
• PBES Decision-Making
Framework
• Manuals:
– ABC Manual
– FHWA SPMT Manual
– PBES Connection Details
Manual
– UDOT ABC SPMT Manual &
Guide
• NCHRP domestic scan report
• NCHRP & other research
• SHRP2 R04 Final Report
Connections Details Manual
• General Topics
• Superstructure Connections
• Substructure Connections
• Foundation Connections
• Connection Design Examples
• Proprietary Products
• Sample Construction Specifications
• Case Studies
www.fhwa.dot.gov/bridge/prefab/if09010/
Cost Manual
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Cost-competitive projects
Reduced onsite construction time
Construction cost less than
engineer’s estimate
Project details
Project owner contacts
Other contacts, e.g.:
– Contractor
– Design Engineer
– Prefabricator
www.fhwa.dot.gov/bridge/prefab/if09010/successstories/091104/
FHWA
SPMT Manual
http://www.fhwa.dot.gov/bridge/pubs/07022/
Bridge moving with SPMT
SPMT Resource Providers
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Barnhart Crane & Rigging
Bigge Crane and Rigging Co.
Fagioli, Inc.
Mammoet USA
NDF (New Dafang Group)
Sarens Group
Other Sources for Details
• Utah DOT ABC Website
– www.udot.utah.gov (search ABC)
– Piers, abutments, walls, decks
• PCI Northeast
– www.pcine.org (Bridge resources)
• Short Span Steel Bridge Alliance
– Modular steel bridge details coming
• MassDOT
– Working on new ABC manual
NCHRP
Domestic Scan
Program
Domestic Scan on
Best Practices in
Accelerated
Construction
Techniques
March 2009
http://onlinepubs.trb.org/onlinepubs/nchrp/docs/NCHRP20-68A_07-02.pdf
Coming Soon!
ABC Manual
• Overview of ABC techniques
& practices currently in use
• App. A: Design Examples
• App. B: Standard Products
• App. C: Sample Construction
Specifications
• App. D: Erection and
Transportation Equipment
National Cooperative Highway Research Program
Projects Related to ABC
No.
Title
Status
12-65
Full-Depth, Precast-Concrete Bridge Deck Panel
Systems
Report 584
12-69
Design and Construction Guidelines for Long-Span
Decked Precast, Prestressed Concrete Girder Bridges
Research in
progress
12-74
Development of a Precast Bent Cap System for
Seismic Regions
Research in
progress
10-71
Evaluation of CIP Reinforced Joints for Full-Depth
Precast Concrete Bridge Decks
Research in
progress
How can FHWA help you
deploy PBES ?
$ State use of program funding for PBES projects
$ Highways for LIFE grants
$ Innovative Bridge R&D funds
• Technical Support (FHWA RC, HQ, & Division)
• Resources previously listed
How can FHWA help you
deploy PBES ?
Resource Recap
• Information on innovative projects (50+) by
elements and systems on FHWA website
• ABC/PBES decision-making framework
• PBES Cost Study based on nine projects
• FHWA SPMT Manual
• PBES Connection Details Manual
• Manual on ABC-Experience in Design, Fabrication,
& Erection of PBES (2011)
PBES and INDOT
• Milton Madison Bridge over the Ohio River
– Showcase project
• IBRD funded trial project submitted to FHWA
– Awaiting approval; plan to let in 2012
• Future projects???
Questions/Comments???
Keith Hoernschemeyer
FHWA IN Division Bridge Engineer
[email protected]
317-226-7490