Connection details for prefabricated bridge elements and systems
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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. “Connections Details for Prefabricated Bridge Elements and Systems” Project Goals:.

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Connection details for prefabricated bridge elements and systems

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


Connections details for prefabricated bridge elements and systems project goals

“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


Available technologies

Available Technologies

  • Corrugated Void Pockets

    • Developed in Iowa

    • Very good punching shear capacity

      • Footings

      • Integral abutments

      • Pier caps

    • Easy to form

    • Reduces shipping weight


Available technologies1

Available Technologies

  • Corrugated Void Pockets – Integral abutments


Available technologies2

Available Technologies

  • Corrugated Void Pockets – Integral abutments


Available technologies3

Available Technologies

  • Corrugated Void Pockets

    • Cantilever Abutments

    • Cantilever Walls


Available connection technologies

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 connectors

Grouted Reinforcing Splice Connectors

  • Installation Video on YoutubeTM

    • Search “Georgia Pier Construction”


Testing data

Testing data

Grouted Splice coupler @ end of column


Testing data1

Testing data

Control Column w/o Grouted Splice Coupler


Connection details for prefabricated bridge elements and systems

Pile Supported Footings

Pile supported footings

  • Use corrugated pipe forms

  • Used for integral abutment stems also


Connection details for prefabricated bridge elements and systems

Pile Supported Footings

Pile supported footings

  • Use precast stem with CIP Footing

  • Good for footings with closely spaced piles


Available technologies4

Available Technologies

  • Grouted PT Ducts

    • Similar to grouted couplers

    • Good for development into mass concrete

    • Lap splices?

    • Check conflicts with transverse bars


Nchrp report 681 detail

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


Other sources for details

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)

  • MassDOT

    • Working on new ABC manual

  • NCHRP Report 681

    • Development of a Precast Bent Cap System for Seismic Regions

    • Web search “NCHRP Report 681”


Manual distribution

Manual Distribution

  • Availability

    • Published June 2009

    • Is available through FHWA Highways for LIFE website

      www.fhwa.dot.gov/hfl/


Connection details for prefabricated bridge elements and systems

NEW FHWA ABC Manual

Accelerated Bridge Construction

Experience in Design, Fabrication and Erection of Prefabricated Bridge Elements and Systems


Previously published fhwa manuals

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


Goal of new manual

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”


Manual outline

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


Chapter 1

Chapter 1

Introduction

  • Purpose of the Manual

  • Why use ABC?

  • Public perception of ABC

Public Perception

Utah experience with ABC:

Polling results


Chapter 2

Chapter 2

  • ABC Technologies

  • 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


Chapter 21

Chapter 2

  • Fast Track Contracting

  • Design/Build Flowchart


Chapter 22

Chapter 2

  • Fast Track Contracting

  • CMGC Flowchart


Chapter 3

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


Chapter 31

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


Chapter 32

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


Chapter 33

Chapter 3

Determination of appropriate ABC methods


Chapter 34

Chapter 3

Determination of appropriate ABC methods


Chapter 35

Chapter 3

Determination of appropriate ABC methods


Chapter 36

Chapter 3

Determination of appropriate ABC methods


Chapter 37

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


Chapter 4

Chapter 4

Utah Model

Implementing ABC in a Transportation Agency


Chapter 5

Chapter 5

Typical Prefabricated

Elements


Chapter 6

Chapter 6

  • Miscellaneous Bridge Elements:

    • Bearings

    • Railing/Barriers

    • Joints


Chapter 7

Chapter 7

  • Chapter 7: Construction

    • Fabrication

    • Erection

    • Grouting

    • Shoring

    • Paperless submissions

    • Accelerated testing needs


Chapter 8

Chapter 8

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)


Chapter 9

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


Appendices

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


Manual distribution1

Manual Distribution

Availability

Published in November 2011

Available On-Line

Free Download

www.fhwa.dot.gov/bridge/abc


Questions

Questions


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