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Schematic Design of an Accelerated Bridge Construction Project

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  1. Schematic Design of an Accelerated Bridge Construction Project Michael P. Culmo, P.E. Vice President of Transportation and Structures CME Associates, Inc., East Hartford, CT

  2. Reference Manual Use the Connections Details Manual Type study concept Select details from various states

  3. 4 lane bridge over an expressway Existing bridge has deteriorated beyond repair Heavy traffic on both roadways There is a short but undesirable detour Case Scenario

  4. Public hearing held Businesses do not want a long construction process with stage construction Businesses are not keen about a detour They will accept a short term closure with the detour As opposed to a long term staged project Public Involvement

  5. Build a temporary bridge to speed up construction of the new bridge $$$$ Not that fast Use multi-stage construction Very long construction Will require long term lane closures Establish the detour and accelerate the bridge construction to less than 30 days Design Approach Options

  6. Existing Bridge

  7. Deck Joints Low Clearance Existing bridge issues

  8. After a formal type study, the owner opted with the following structure criteria Use NEXT Beams to accelerate construction Design as simple span for Dead Load and continuous spans for Live Load Increase clearance by raising approach grades (3’) Use integral abutments (no deck joints) Composite concrete deck Membrane waterproofing and Bituminous wearing surface Use Precast Rail System (Vermont/NH system) Proposed Bridge Type

  9. Push abutments back to top of slope Minimize wingwall requirements Use integral abutments with flying wings Eliminate spray attack on abutments Place abutments in a different footprint than the existing facilitates construction Use open frame pier bent on spread footings Substructures

  10. Proposed Bridge Move abutment away from roadway No Deck joints Increase vertical clearance

  11. Bridge Section

  12. Preliminary Beam Sizing Use PCI NEXT Beam Standards Beam Design

  13. LLDF Beam Design

  14. AASHTO LL Distribution Factor – Type K Beam Design Moment Shear

  15. AASHTO LLDF Type H Beam Design Shear Moment

  16. Beam Design

  17. FHWA manual “Connection details for prefabricated bridge elements and systems” Review Chapter 1 Investigate connection types, materials, tolerances 2. Search applicable sections of other chapters for details How to select details

  18. After reviewing chapter 1, the owner chose the following connection types Grouted reinforcing splice couplers Quick, proven system Can develop full bar strength Simplifies the design process (similar to CIP) Grouted Voids Easy for simple connections Concrete Closure pours between precast elements Use for a limited number of connections (slower) Section 1.4 Typical Connection Types

  19. Emulates a reinforcing steel lap splice Multiple companies – non-proprietary Used in precast parking garages and stadiums and bridges Grouted Reinforcing Splice Connectors

  20. Emulates a reinforcing steel lap splice Multiple companies – non-proprietary Used in precast parking garages and stadiums and bridges Time Lapse Video on YoutubeTM Search “Georgia Pier Construction” Grouted Reinforcing Splice Connectors • Installation Video on YoutubeTM • Search “Georgia Pier Construction” • Installation video

  21. Footing to Sub-grade Connection

  22. Footing Details

  23. Footing to Column Connection

  24. Footing to Column Connection

  25. Column to Cap Connection

  26. Column to Cap Connection

  27. Completed Pier Column to cap connection Column to footing connection Footing to subgrade connection

  28. Integral Abutment to precast piles Section 3.2.3.1 Precast Integral Abutment to Piles Detail developed by Maine DOT Used on three different bridges Abutment Details

  29. Abutment to Pile Connection

  30. Abutment to Pile Connection

  31. Abutment To Wingwall Connection

  32. Abutment To Wingwall Connection

  33. Approach Slab Connection

  34. Completed Abutment Approach slab connection Flying Wingwall connection Abutment cap connection Pile to cap connection

  35. Design as a conventional cast in place deck Use max stem spacing for design (5.0 feet) Design overhang from outside stem (2.53 feet) Deck Design with Next Beam

  36. Parapet Connection

  37. Parapet Connection

  38. Superstructure to Integral Abutment Connection Use a similar detail at the pier

  39. Completed Bridge Composite Deck Membrane waterproofing with bit. Wearing surface Precast Parapet Precast Pier Precast Integral Abutment

  40. Final Bridge

  41. Estimated Construction Schedule

  42. Typical New Bridge (Cost=$200/sf) = $1,920,000 Premium for ABC (assume 20%) = $384,000 Temporary Bridge (Cost=$60/sf) = ($576,000) Net Savings = $192,000 Note: These prices will vary by region Costs

  43. Ways to reduce bid prices with ABC Standardization Programmatic (not one of a kind) Reduced project site costs (trailers, etc.) Reduced Maintenance of Traffic Costs Inflation Other Non- Bid Savings with ABC Fewer Police Details Reduced Resident Engineering time User Costs Plus: $$ Can be significant Minus: $$ Not in the budget Other Cost Savings

  44. Florida has had very good success with precast piers in very harsh environments Precast concrete beams require no maintenance Integral abutments eliminate deck joints Quality

  45. Rapid Construction High Quality Low Cost Old Adage You can only have any two By elimination of temporary bridges or costly stage construction schemes, you CAN have all three

  46. It is possible to build a complete bridge in 30 days (or less) The FHWA manual provides a starting point for a complete bridge prefabrication project You do not need to sacrifice quality to get rapid construction You can save money on an accelerated bridge project by: Reducing construction time Eliminate temporary bridges or staging Conclusions

  47. culmo@cmeengineering.com Questions