SHRP2 Project R04 Bridge Designs for ABC Bala Sivakumar HNTB Corp. FHWA P2P Exchange Aug. 2012...
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Transcript of SHRP2 Project R04 Bridge Designs for ABC Bala Sivakumar HNTB Corp. FHWA P2P Exchange Aug. 2012...
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SHRP2 Project R04
Bridge Designs for ABC
Bala SivakumarHNTB Corp.
FHWA P2P ExchangeAug. 2012 Boston
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SHRP2 Project R04PROJECT GOAL
To develop standardized approaches to designing, constructing, and reusing
complete bridge systems that address rapid renewal needs Phase I – Define ABC Challenges
Phase II – Identify & Refine the Best ABC Technologies
Phases III & IV – Standardize & Deploy ABC
Phase V – Beta testing of ABC Toolkit by VAOT
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SHRP2 Project R04
INNOVATIVE BRIDGE DESIGNS FOR RAPID RENEWAL
2008 -- 2013
HNTB (Prime)Iowa State University
Structural Engineering Assoc. Genesis Structures
Dr Monica Starnes, Senior Program Officer SHRP2
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Accelerated Bridge Construction (ABC)
Prefabricated Elements
Prefabricated Modular Systems
Structure Placement Methods
Accelerated Geo-tech Work
ABC ELEMENTS & METHODS
SHRP2 R04 -- Phases I, II, III (2008 – 2011)
Phase IV (2011-2013)
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SHRP2 R04 ABC Toolkit
Expected Outcome: The designer, guided by the standard design concepts, details and the set of ABC design calculations will be better prepared to complete an ABC design for a routine bridge replacement project.
1 ABC STANDARD DESIGN CONCEPTS
2
3
4
ABC SAMPLE DESIGN CALCULATIONS
ABC ERECTION CONCEPTS
5 ABC CONSTRUCTION SPECIFICATIONS
ABC DESIGN SPECIFICATIONS (LRFD)
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ABC Standard Design Concepts
• Focus on conventional bridges• Complete bridges using prefabricated elements• Contractor could self-perform a lot of the work• Fabricate on site or in a plant and erect using
conventional cranes• Fast assembly in the field in 1 to 2 weeks (Tier 3
or less) • Durable connections / durable bridges
GOALS:
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Span Ranges for Superstructures• Simple / continuous spans from 40 ft to 130 ft. • Simple for DL ; Continuous for LL ; No Open Joints• Plans are grouped in the following span ranges:
– 40 ft to 70 ft – 70 ft to 100 ft – 100 ft to 130 ft.
• Spans to 130 ft can usually be transported and erected in one piece at many sites.
• Weight < 200 Kips for erection using conventional cranes commonly used by contractors
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Prefabricated Decked Beam Elements
Deck Bulb Tees
Double Tees
Modular Decked Beams
2 Lane bridge with shoulders shown – customize width for site
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Modular Decked Beams
• Barrier can be precast • Barrier load on exterior module
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Prestressed Decked Girders
Based on the PCI NEXT beamSpans to 90 ftLow depth alternative
Decked Bulb Tee Span lengths from 40 ft to 130 ftUT, WA, ID among states with DBT standards
Adjacent Double Tee
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Prefabricated Substructure Elements
ABUTMENTS & WINGWALLS– Semi Integral Abutments– Integral Abutments– Inline or U type Wingwalls– Supported on Piles and Spread Footings
PIERS– Precast Conventional Pier– Precast Straddle Bent– Drilled Shaft and Spread Footing Options
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Integral and Semi-Integral Bridges for Rapid Renewal
• Well suited for ABC
• They allow the joints to be moved beyond the bridge
• Close tolerances required when utilizing expansion bearings and joints are eliminated
• The backwall is precast with the deck.
• Fast erection in 1 to 2 days, economical
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Semi-Integral AbutmentSuspended Backwall
• H piles or spread footings• Fill pile pockets with SCC• Easy fit-up in the field
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Precast Piers
Conventional Pier
Straddle Bent
• Deep foundation may be outside existing footprint
• Non-prestressed so contractor can self-perform precasting
• Fast erection using grouted splice couplers
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ABC Connections• Connections affect field assembly time.
• Goal is rapid field assembly and long-term durability of joints
• Also, flexural continuity between modules to emulate CIP construction
• Connections affect seismic performance
• REFERENCE: FHWA Connections Manual
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Connections for ABC– Ultra High Performance Concrete (UHPC)
longitudinal & transverse joints between superstructure modules
– Grouted splice couplers in piers replace the typical lap splice
– Self Consolidating Concrete (SCC) pile connections and abutment to wingwall connections
……………………………………………………………………………………– Grouted cap pockets / grouted ducts for
substructure connections (seismic)– Other rapid set concrete options may be used
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Grouted Splice Coupler
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• Allows rapid construction. No post tensioning required• UHPC joints are typically 6 in wide. Good durability• Can be reinforced with hairpin bars or straight bars
UHPC Joints in Bridge Deck
(Longitudinal Joint. Longitudinal steel not shown)
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Erection Concept Drawings• Erection using conventional cranes. • Erection using ABC construction technologies adapted
from long span construction
Erection Concepts for Prefabricated Elements
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Erection Concepts for Bridge Replacement Using Cranes
Short Single Span over Stream Cranes selected for 90 Kip pick
Longer Span over RoadwayWeight up to 200 kips
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Erection with ABC Construction Technologies
• Use ABC construction technologies where ground access for cranes below the bridge may be limited.
• Conventional cranes with enough reach
• ABC technologies that allow construction from above:
– Above Deck Driven Carriers – Launched Temporary Bridge– Transverse Gantry Frames– Longitudinal Gantry Frames
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Above Deck Driven Carriers
Allows fast rate of erection
Rides on existing bridge, new bridge (check capacity to support)
Ideal for bridges with many spans. long viaducts
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Launched Temporary Bridge• Sites with limited ground access or long spans• Launched across or lifted over a span to act as a “temporary
bridge” • Used to deliver the heavier modules without inducing large
erection stresses.• Temp bridge can also support transverse gantry frames
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Gantry Frames
Longitudinal Gantry Frame
Transverse Gantry Frame
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• The LRFD Design Specifications do not explicitly deal with the unique aspects of large scale prefabrication
• In some cases, the most extreme load case may occur during shipping and handling.
• The work in SHRP2 R04 entailed the identification of any shortcomings in the current LRFD Bridge Design Specifications
• Recommendations are provided for addressing these limitations.
ABC Design Specifications for LRFD
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ABC Sample Design Calculations• Three ABC design examples for prefabricated systems
in the toolkit:– Modular Decked Beams– Decked Precast Prestressed Girder– Precast Pier
• Design Criteria:• AASHTO LRFD (5th Edition)• Supplemental ABC criteria
The design examples provide guidance on the overall structural design of bridge components for ABC
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LRFD for ABC Design• The design of most ABC elements and systems
follows traditional LRFD design specifications.
• Design the ABC elements and the completed structure using all applicable LRFD Limit States
• Additional requirements apply for ABC connections, lifting and moving of prefabricated elements and modules.
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Decked Steel Girder Design for ABC
• Three Stages for Design Prefabrication Stage (many support options)
– Load Case 1 = Dead load on module steel section only– Load Case 2 = Dead load on module composite section Erection Stage (many lift options)– Load Case 3 = Modules are lifted into place Final Stage– Load Case 4 = Modules are assembled and made continuous
» DL» FWS» LL + IM» Utilities
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• Recommended Special Requirements for ABC • Focus heavily on means and methods requirements for rapid
construction.
Proposed Section in LRFD Construction Specifications
XX.1 GENERALXX.2 RESPONSIBILITIESXX.3 MATERIALSXX.4 FABRICATIONXX.5 SUBMITTALSXX.6 QUALITY ASSURANCEXX.7 HANDLING, STORING, AND TRANSPORTATIONXX.8 GEOMETRY CONTROLXX.9 CONNECTIONSXX.10 ERECTION METHODSXX.11 ERECTION PROCEDURES
ABC Construction Specifications
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First Demonstration Project Demonstrate Use of ABC Concepts Developed
in SHRP2 R04Keg Creek Bridge, Iowa
– Total prefabricated bridge– ABC design concepts & details developed in SHRP2 R04
Project were used with minimal customization for the site
14 day ABC period Opened Nov 1, 2011
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SHRP2 R04 ABC Demonstration Project #2Lateral Slide (NYSDOT)
2012/ 2013 ConstructionOvernight replacement
I-84 EB & WB Bridges over Dingle Ridge Road
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Closing• New generation PBES for ABC are economical to
construct and designed for durability• SHRP2 R04 ABC Toolkit and training materials will be
available to provide guidance to those new to ABC and the use of PBES
• SHRP2 R04 demonstration projects showcase the use of the Toolkit
• SHRP2 R04 ABC Toolkit to be available soon• The time for ABC is now