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Connection Details Manual ABC Project that Save Money

Connection Details Manual ABC Project that Save Money

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Connection Details Manual ABC Project that Save Money

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  1. Connection Details ManualABC Project that Save Money Iowa DOT Accelerated Bridge Construction Workshop August 11, 2008 Michael P. Culmo, P.E. CME Associates, East Hartford, CT

  2. Roadblocks to Accelerated Construction • The primary concerns that owner agencies have with respect to adopting accelerated construction techniques are: • Need for Quality Details • Durability • Design Methodologies and Training • Construction Methodologies

  3. “Connections for Prefabricated Bridge Elements and Systems” • FHWA has initiated a project to develop this manual • This publication is intended to provide information that will go a long way to answering all four of the previous concerns. • Focus on details that have been used in the past.

  4. Connection 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

  5. All details needs to pass a critical test before being published in the document: • Does the connection result in a rapid construction process? • Does the connection transmit the forces between elements effectively? • Is the connection durable? • Has it performed well under traffic and in an exposed environment? • Is it cost effective and easy to construct? • If a process or connection is proprietary, can it be incorporated into numerous projects without producing contracting issues?

  6. Source of Data • State DOT’s • Questionnaires sent via e-mail • Federal Agencies • International Organizations • Researchers (previous and current) • Producers • Questionnaires sent via e-mail

  7. Manual Organization

  8. Connection Data Sheets

  9. Some Information that is available today • PCI Northeast Bridge Technical Committee • Guidelines for Accelerated Bridge Construction • Available at www.pcine.org • FHWA • Framework for Prefabricated Bridge Elements and Systems (PBES) Decision-Making • Manual on Use of Self-Propelled Modular Transporters to Move Bridges

  10. Precast Abutments

  11. Precast Abutments

  12. Precast Piers

  13. Precast Piers

  14. Precast Decks on PS Beams

  15. Precast Decks on Steel Framing

  16. Precast Decks

  17. FRP Decks

  18. Grid Decks

  19. Partial Depth Deck Forms

  20. Total Bridge Prefabrication

  21. Total Bridge Prefabrication

  22. Examples: Epping NH construction of 1-07.avi

  23. Project Schedule • Gather information • Fall 2006 through Spring 2007 • Visit states that are leaders in accelerated bridge construction • Winter 2007 • Develop manual • Summer/Fall 2007 • Complete Manual • Fall 2008

  24. Project Delivery • The document will be available for all owners and designers for use in future accelerated bridge projects • Website will be established on the FHWA Highways for Life Website www.fhwa.dot.gov/hfl/

  25. Schematic Design of an Accelerated Bridge

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

  27. Public Involvement • 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

  28. Design Options • Build a temporary bridge to speed up construction of the new bridge • $$$$ • Not that fast • Build bridge along side and slide into place with SPMT’s • Definitely possible • Does not easily solve problem with foundations • Establish the detour and accelerate the bridge construction to less than 30 days

  29. Existing Bridge

  30. Existing Bridge Deck Joints Low Clearance

  31. Issues with the Existing Bridge • Minimal Underclearance • 14’-5” • Piers and abutments are close to roadway • Spray from vehicles damaged the piers • Leakage through deck joints • Led to severe beam end deterioration

  32. Proposed Bridge • After a formal type study, the owner opted with the following structure criteria • Continuous steel girders (weathering steel) • Reduce to a two span bridge • Increase clearance by raising approach grades (3’) • Use integral abutments (no deck joints) • Composite concrete deck • Membrane waterproofing and Bituminous wearing surface • Open steel railings (galvanized)

  33. Existing Bridge

  34. Proposed Bridge

  35. Proposed Bridge

  36. Features of New Bridge • Move pier far from roadway • Possible future widening options • Push abutments back to top of slope • Minimize wingwall requirements • Use integral abutments with flying wings • Both abutments and the pier are in a different footprint than the existing • facilitates construction • Eliminate spray attack on piers and abutments • No deck joints

  37. How to select details 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

  38. Section 1.4 Typical Connection Types • 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)

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

  40. Schematic Pier Design • Footing to subgrade connection • Section 4.1.1 Precast footing to subgrade connection • Detail developed by New Hampshire DOT

  41. Data Sheet

  42. Footing Details

  43. Schematic Pier Design • Footing to column connection • Section 3.1.4.2 Precast column to Precast Footing connection • Detail developed by the Northeast PCI Bridge Technical Committee based on work done in Florida • Used extensively in vertical construction • Parking garages, stadiums and hotels

  44. Data Sheet

  45. Footing/Column Details

  46. Schematic Pier Design • Column to Cap Beam connection • Section 3.1.1.2 Precast cap beam to precast column connection • Detail used by the Florida DOT • Edison Bridge

  47. Data Sheet

  48. Column/Cap Beam Details

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

  50. Schematic Abutment Design • 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