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Dacio Marin III, P.E. Bridge Division Texas DOT - PowerPoint PPT Presentation

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A ccelerated B ridge C onstruction. Recent TxDOT ABC Projects. Iowa DOT ABC Workshop August 2008. Dacio Marin III, P.E. Bridge Division Texas DOT. Overview ABC on Off-system bridges ABC on On-system bridges What’s next?. Our Bridges …. 50,000 bridges in the state of Texas

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Accelerated Bridge Construction

Recent TxDOT ABC Projects

Iowa DOT ABC Workshop

August 2008

Dacio Marin III, P.E.

Bridge Division

Texas DOT

  • ABC on Off-system bridges
  • ABC on On-system bridges
  • What’s next?
our bridges
Our Bridges …
  • 50,000 bridges in the state of Texas
  • 8% of the total number of bridges in the nation, and
  • About total number of bridges of the four states that border Texas
  • TxDOT builds 600~800 bridges each year
  • 250 bridges each year by others
typical off system bridge replacement environment
Typical Off-System BridgeReplacement Environment
  • Virtually All Stream Crossings
  • Short Overall Length with 1 – 3 Short Spans
    • 40 to 80 ft Each Typically
  • 24 – 30 ft Roadway Width
  • ADT Usually Low
  • Greater Probability of Overtopping
  • Remote and Difficult Site Access
  • Usually Involve Road Closure
  • ROW Limits, Existing Structure Make

Phasing and Temp. Detours Difficult

rapid construction considerations
Rapid Construction Considerations
  • Coordinate with local officials
  • Ensure utilities are clear ahead of letting
  • Determine working day charges
  • Consider LDs & road-user costs
  • Allow adequate time for staging of materials
  • Traffic, detour route, material delivery
simplified geometry
Simplified Geometry
  • Constant or no skew
  • No horizontal curves
  • No flares (width transitions)
  • No superelevation transitions
  • Complicated geometry can better be handled on the roadway than the bridge
design challenges
Design Challenges

Shallow depth

Longer span

Long detour route

Phased replacement not feasible

site challenges
  • Limited ROW
  • Retaining wall
  • Existing utilities
minimum on site construction
Minimum On-Site Construction
  • Before road closure 
    • Beam, cap, and abutment fabrication
  • After road closure 
    • Retaining wall construction
    • Demolition of existing structure
    • Bridge and approach construction

New Bridge Construction

  • Total bridge length 100 ft (50’-50’)
  • Overall width 42 ft
  • Decked slab beams, precast abutments & bent caps, flowable backfill, steel H-piles, stone riprap
  • Contract amount $380,700 (bridge only)
  • $90.60/SF

Steel Anchor Plate

and Shear Studs

flowable backfill
Flowable Backfill
  • Fluid mixture of sand, fly ash,


  • 40% air-entrainment without compaction
  • Self-leveling
construction highlights
Construction Highlights
  • Total 33 days of road closure
  • 6 days total for bridge construction
  • Overall cost $90/SF ($43 Superstructure + $47 Substructure)
advantages of decked slab beam
Advantages ofDecked Slab Beam
  • Field welding vs. transverse post-tensioning
  • No cast in place concrete slab
  • Minimum disruption of traffic
  • Fewer beams and fewer joints
  • Low depth/span ratio (up to 1/30)
  • Reduced SF costs with increased usage

Reduced ramp closure from

several weeks to just 6 hours.

pierce elevated
Pierce Elevated

Faster Rehabilitation: 113 spans in 95 days, vs. 1.5 yrs

sponsored research development of a precast bent cap system
Sponsored Research:“Development of a Precast Bent Cap System”
  • Development of Connection Types
    • Grout Pockets
    • Grouted Vertical Ducts
    • Bolted Connections
  • Testing Program (Behavior and Constructability)
    • Phase I - Pullout Tests
    • Phase II - Full-Scale Connection Tests
    • Phase III - Full-Scale Bent Tests
  • Implementation
    • Sample Details
    • Design Methodology
    • Construction Issues and Specifications
grout pockets
Grout Pockets
  • Technique
    • precast voids/pockets in cap to contain column connectors
  • Advantages
    • flexibility in size and shape
    • large construction tolerances
    • simple grouting operation
  • Disadvantages
    • cracking potential at large top surface
    • congestion of reinforcement
    • larger volume of grout
grouted vertical ducts
Grouted Vertical Ducts
  • Technique
    • steel corrugated ducts embedded in cap to house column connectors
  • Advantages
    • inexpensive stay-in-place ducts
    • minimal reinforcement congestion
    • limited exposed top surface
    • minimal volume of grout
  • Disadvantages
    • more difficult grout placement
bolted connection
Bolted Connection
  • Technique
    • ducts embedded in cap house threaded rods tensioned at the top surface
  • Advantages
    • cap setting via leveling plates/nuts
    • post-tensioning option
    • resistance to larger moments
  • Disadvantages
    • more difficult grouting operations
    • protecting/recessing top anchorage
results of connection tests
Results of Connection Tests
  • Phase I anchorage results validated
  • excellent anchorage and ductility
  • small crack widths, even at factored loads
  • no slip between grout, duct, and concrete
  • shims did not affect performance
  • yield within 10% of prediction
lake ray hubbard plan view of project
Lake Ray HubbardPlan View of Project


Exist Embankment

Exist EB Bridge


lake ray hubbard plan view of project44
Lake Ray HubbardPlan View of Project


New WB Bridge


precast bent cap option
Precast Bent Cap Option



  • Transport of complete caps versus limited volumes of fresh concrete
  • Bent cap cure time removed from critical path
  • Controlled environment of casting yard instead of over lake
final design
Final Design
  • 6 ~ #11 Dowels
  • 4” Dia. Corrugated Galvanized Steel Ducts
  • #3 Spiral for Confinement

Lake Belton Precast Hammer Head Caps

Bell County, SH 36

Existing Bridge

plan view of project
Plan View of Project



new structure
New Structure
  • Construction Began Sept. 2002
  • Phase I: $20.0M ($47/SF)
  • 3840 ft Total Length
  • Twin 40 ft Roadways
  • Phased Construction
  • 32 ~ 120 ft Prestressed Concrete U54 Beam Spans
  • 8” Composite Slab: 4” CIP Topping & PCP SIP Forms
  • Twin Independent Substructures
live oak bridge
Live Oak Bridge
  • Limited access to batch plants (75 mi. nearest)
  • Total bridge length 700ft × Overall width 32 ft
  • AASHTO Type IV Beams
  • 86 full depth prefabricated deck panels, total area 22,400 SF
  • Let in 12-2006, Bridge Cost $2,708,244
  • $121/SF
project overview
Project Overview
  • Conc. U-Beams for LP 340 Bridges
  • Awarded to Archer Western Contractors
    • $40.5 M, 520 days (A+B Bidding)
  • Construction began January, 2005
unique aspects
Unique Aspects

Four new LP 340 bridges were proposed to be constructed over IH 35 using:

  • Pre-Cast Column Shells
  • Pre-Topped U-Beams
pre cast column shells
Pre-Cast Column Shells

Typical Elevation View

pre cast column shells71
Pre-Cast Column Shells
  • Cast Column Shell offsite
  • At Project Site, Place Rebar Cage on top of Footing Constructed on Conventional Drilled Shaft
  • Transport Column Shell to Project Site, Place over Rebar Cage
  • Pour Infill Concrete
standard deck construction at ends

Open Joint


Thickened Slab *



Standard Deck Construction at Ends

* Normally formed

with PMDF or Timber

bottom line
Bottom Line
  • Personnel
  • Equipment
  • Incentive…$