VDOT’S BRIDGE PRESERVATION PROGRAM
Transcript of VDOT’S BRIDGE PRESERVATION PROGRAM
VDOT’S BRIDGE PRESERVATION PROGRAM
Virginia Concrete Conference, 2012
RICHMOND, VA
March 9, 2012
Adam Matteo, PE Assistant State Structure and Bridge Engineer for Bridge Maintenance
VDOT Structure and Bridge Division
2
The Structure and Bridge Division has the same organizational structure in the Central Office and the Districts
State Structure and Bridge Engineer Ken Walus
Preliminary Engineering David Nuckols
Inspection & Load Rating Claude Napier
Maintenance Adam Matteo
Engineering Services Julius Völgyi
District Bridge Engineer
Preliminary Engineering Inspection & Load Rating Maintenance
Central Office
9 District Offices
3
The Challenge There isn’t enough money to meet all the needs of Virginia’s aging
Bridges and Culverts
• $1.7 Billion total maintenance need statewide • Replacement value of the inventory is $52.4 Billion • Approximately 60% of Virginia’s inventory is 40 years old or older • Structures built prior to 2007 were designed for 50 year life • Replacement value of all structures 40 years or older is $18.7 Billion • Structures designed for 50 years may need to be to kept functional for
100 years or more, perhaps even as long as 150 years • 4719 structures with a minimum General Condition Rating of 5 (almost
¼ of the entire inventory) • Approximately 21,000 structures in the inventory, 19,390 of which are
VDOT-maintained (by comparison, Florida has 6,644 structures) • 1,537 structures with a min. General Condition Rating of 4 or less • Maintenance budgets are about 2/3 needs
4
114
1,562
2,332
2,115
3,458
4,252
1,715
853
3,842
513
100 31 21 0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
2010's 2000's 1990's 1980's 1970's 1960's 1950's 1940's 1930's 1920's 1910's 1900's
No. o
f Stru
ctur
es
Decade* County Bridges added to the VDOT Inventory during this period with unknown construction dates (Assumed year built equaled year added to system)
Structures Built – by Decade
5
20.0
25.0
30.0
35.0
40.0
45.0
50.0
55.0
60.0
Interstate Primary Secondary Urban Total
Ave
rag
e A
ge
Bristol Salem Lynchburg Richmond Hampton Roads Fredericksburg Culpeper Staunton NOVA Statewide
Average Age of Structures – by Highway System
6
General Condition Ratings
DEFINITIONS 9 EXCELLENT CONDITION 8 VERY GOOD CONDITION 7 GOOD CONDITION 6 SATISFACTORY CONDITION 5 FAIR CONDITION 4 POOR CONDITION 3 SERIOUS CONDITION 2 CRITICAL CONDITION 1 "IMMINENT" FAILURE CONDITION 0 FAILED CONDITION GENERAL CONDITION RATINGS ARE PROVIDED AT EACH INSPECTION FOR: • DECK • SUPERSTRUCTURE • SUBSTRUCTURE • CULVERT
The General Condition Rating is an imperfect index, but it can provide good broad-based information about an inventory.
7
64
1,473
4,719
6,944
6,086
1,409
165 0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
3 4 5 6 7 8 9
Num
ber o
f Str
uctu
res
Minmum GCR
Number of Structures by Minmum GCR
Total No. of Structures = 20,860
7%
23%
33%
29%
7%
Approximately 200 structures per year go from “5” to “4” and become Structurally Deficient
8
The Solution
Whine until we get more money?
9
Attacking the Problem
Spend Resources as wisely as possible to extend the life of the inventory
• Replace joints in a timely manner • Spend money on the most cost-effective actions
• Make data-driven decisions when selecting interventions • Constantly evaluate new materials and methods
• Don’t pursue a “worst first” approach • Emphasize preventive maintenance • Balance spending
• Perform high quality work • Utilize state bridge crews • Address highway systems with largest impact to commerce and the
public
10
Bridge Maintenance Requires Bridge Management
Inventory • Work needs • Structure Condition
Inspection
Bridge Management • Work Prioritization • Project Scoping
Project Development • Design • Permitting • Advertisement & Award
Construction
VDOT uses Pontis for structure inventory and modeling of needs
11
Bridge Longevity
New Construction Existing Structures
Jointless Bridges
High Performance Concrete
Corrosion Resistant Reinforcement
Concrete Culverts Preventive Maintenance
Rehabilitation
Replacement
Restorative Maintenance
Painting
12 Maintenance Activities
Examples of Preventive Maintenance
• Bridge Cleaning (washing and/or sweeping) • Deck Sealing • Sealing Joints • Thin Deck Overlays • Removing Large Debris in Channels • Cleaning Culverts • Spot and Zone Painting
VDOT has a system preservation agreement with FHWA to fund these activities Preventive maintenance has been shown to be the most cost-effective of all bridge maintenance activities for sustaining the lives of structures
13 Maintenance Activities
Examples of Restorative Maintenance • Painting (Overcoating or Re-Coating) • Rigid Deck Overlays • Reconstructing/Closing Joints • Superstructure Repairs (Type B patching, etc.) • Substructure Repairs (including shotcrete, bearings, other elements) • Joint removal • Fatigue Retrofitting • Scour Repairs • Cathodic Protection • Electrochemical Chloride Extraction • Replace timber decks
Much of this work is “reactive” in nature but needs to be performed to sustain our inventory
14 Maintenance Activities
Rehabilitation
• Generally work of a major nature • Deck replacement • Superstructure replacement • Culvert lining
Replacement
• Part of the maintenance cycle • Includes replacement of foundations • Often coincides with a need for widening or geometric improvement • Many projects are funded through the Dedicated Bridge Fund
15 Codifying “Best Practices”
Chapter 32 has recently been adopted – available online
• Acts as a primer for those not familiar with bridge maintenance • Provides strict rules where appropriate • Provides guidelines where appropriate • Explains and provides guidance on funding • Provides guidance on decision processes • Provides a schedule for preventive maintenance activities • Is based on both practical experience and studies • Future revisions will include additional elements such as:
• Standard details • Contract templates for maintenance work • Standard Special Provisions • Design Aids • Additional culvert and timber bridge guidance
16 What Constitutes “Best Practices”
Fundamental Principals
• Keep the roof dry and clean • Replace or eliminate joints • Timely installation of overlays • Timely spot or zone painting • Maintain drains in a functional condition • Sweep and wash bridges
• Perform repairs in a timely manner • Evaluate new technologies and implement the good ones
• Sponsor studies • Utilize research performed by others • Try new materials and methods
• Utilize appropriate materials • Avoid asphalt overlays • Use approved patching materials
17
Fundamental Principals, continued:
• Utilize proven technologies • Perform quality work
• Treat maintenance work the same as new construction • Test and monitor material installation, particularly for concrete • Provide adequate inspection • Utilize controls where possible
• Distribute resources appropriately. Chapter 32 suggests: • Preventive Maintenance – 15% (Program 604) • Painting – 10% (Program 604) • Restorative Maintenance – 25% (Program 604) • Rehabilitation/Small Structure Replacement – 50% (Program 604)
• Maximize available resources • Utilize available funding (state and federal) • Plan and perform work for best efficiency (multiple structure contracts)
18
The Importance of Preventive Maintenance - Joints
19 The Importance of Preventive Maintenance - Joints
20
The Importance of Preventive Maintenance - Decks
21
Preventive Maintenance
• Highest cost benefit ratio of the maintenance categories • Most of the problems with bridge deterioration can be significantly
reduced or avoided altogether with planned preventive maintenance • FHWA agreement allows these activities to be billed as system
preservation
22
Preventive Maintenance Proposed Activity Cycle
Activity Preferred
Cycle (years) Federally Eligible?
1 Bridge Deck Washing 1 Yes
2 Bridge Deck Sweeping 1 Yes
3 Seats & Beam End Washing 2 Yes
4 Cutting & Removing Vegetation 2 No
5 Routine Maintenance of Timber Structures 2 No
6 Scheduled Replacement of Compression Seal Joints 10 Yes
7 Scheduled Replacement of Pourable Joints 6 Yes
8 Cleaning & Lubricating Bearing Devices 4 No
9 Scheduled Installation of Thin Epoxy Overlay 15 Yes
10 Beam Ends Painting 10 Yes
11 Removing Debris from Culverts 5 Yes
23
64
1,473
4,719
6,944
6,086
1,409
165 0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
3 4 5 6 7 8 9
Num
ber o
f Str
uctu
res
Minmum GCR
Number of Structures by Minmum GCR
Total Number of Structures = 20,860
7%
23%
33%
29%
7%
Approximately 200 structures per year go from “5” to “4” and become Structurally Deficient
System Preservation Candidates Restorative MaintenanceCandidates
Replacement Candidates
24
Using Data to Make Better Decisions
There are Several Active Studies with the Research Council • Coating Study
• Process review of how we recoat structures • Review enclosure/encapsulation requirements • New technologies for removing • Other coating systems and application methods available in the market • Meeting with the transportation industry and surveying other industries
• Waterproofing membrane (monitoring effort) • Low permeability asphalt such as Rosphalt • Asphalt Plug Joints • Deterioration rates of structures (data mining)
• Looks at past performance of structures and the longevity of interventions • Developing cost/benefit ratios • Will help guide decision-making for maintenance activities
VDOT also participates in other studies such as the Long Term Bridge Performance Study being sponsored by FHWA
25
Average General Condition Ratings of Virginia’s Structures
4
4.5
5
5.5
6
6.5
7
7.5
8
2001-2010 1991-2000 1981-1990 1971-1980 1961-1970 1951-1960 1941-1950 1931-1940 1921-1930 1911-1920 pre-1911
Aver
age
Gen
eral
Con
ditio
n R
atin
g
Decade Built
deck GCR
Super GCR
Sub GCR
Min bridge GCR
Culvert GCR
26
Using Data to Make Better Decisions Theoretical Deterioration
3
4
5
6
7
8
9
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
Gen
eral
Con
ditio
n R
atin
g
Age of Bridge
Extending Bridge Life
Minimal Maintenance
Overlay at years 10, 25 & 40
New Construction
27
Evaluating Interventions
9
7 7 7
8 8
7 7 7
5
6 6
3 3 3 3 3 3 3
9 9
8 8
6 6 6 6
5 5 5 5 5 5 5
4 4 4
3
12,512
17,282
21,716
0
5,000
10,000
15,000
20,000
25,000
0
1
2
3
4
5
6
7
8
9
10
Aver
age
Dai
ly T
raffi
c
Con
ditio
n R
atin
g
Hunter Mill Road over Difficult Run 1969-2011
Superstructure Condition Rating Average Daily Traffic
15 Yrs 15 Yrs
1969 - VDOT builds new 1993 - VDOT builds new
1984 - Bridge is rated as Critical & classified as
2008 - Bridge is rated as Poor & classified as
Structurally Deficient
1988 - Posted
2005 - Posted
2011 - Bridge rated as Critical; Posted
28
Evaluating Interventions – Epoxy Overlays
Effect of Overlays on Deck General Condition Rating
6.1
6.15
6.2
6.25
6.3
6.35
6.4
6.45
6.5
6.55
Concrete decks no overlays
Bridges with Epoxy Overlays
Conc Bridges with Asphalt Overlays
Aver
age
Dec
k G
ener
al C
ondi
tion
R
atin
g
Type of Deck Surface
29
6 year GCR Trends (2006 through 2011)
6.200
6.300
6.400
6.500
6.600
6.700
Ave
rag
e G
CR
of
Bri
dg
e D
ecks
Interstate 6.387 6.361 6.338 6.310 6.285 6.253
Primary 6.339 6.342 6.340 6.307 6.286 6.291
Secondary 6.614 6.617 6.613 6.603 6.598 6.606
Average 6.516 6.504 6.497 6.481 6.474 6.477
2006 2007 2008 2009 2010 2011
Deck General Condition Rating
30
6 year GCR Trends (2006 through 2011)
6.100
6.200
6.300
6.400
6.500
Ave
rage
GC
R b
y S
uper
stru
ctur
es
Interstate 6.400 6.415 6.352 6.273 6.210 6.152
Primary 6.375 6.367 6.346 6.313 6.287 6.288
Secondary 6.411 6.394 6.379 6.362 6.366
Average 6.408 6.383 6.357 6.328 6.324
2006 2007 2008 2009 2010 2011
Superstructure General Condition Rating
31
6 year GCR Trends (2006 through 2011)
Deck GCR
5.900
6.000
6.100
6.200
6.300
6.400
Ave
rage
GC
R o
f Sub
stru
ctur
es
Interstate 6.147 6.162 6.132 6.091 6.008 5.974
Primary 6.349 6.338 6.317 6.296 6.268 6.258
Secondary 6.386 6.369 6.347 6.326 6.319
Average 6.350 6.330 6.307 6.283 6.271
2006 2007 2008 2009 2010 2011
Superstructure General Condition Rating
32
Evaluating the Performance of Culverts
Culverts have outperformed bridges and concrete culverts have outperformed steel culverts
2010 - 2012
2000 - 2009
1990 - 1999
1980 - 1989
1970 - 1979
1960 - 1969
1950 - 1959
1940 - 1949
1930 - 1939
Pre 1900 - 1929
Concrete 8.49 7.53 7.03 6.68 6.40 6.27 6.32 6.11 6.15 5.90 Steel 8.00 7.27 6.39 6.06 5.91 5.66 5.80 5.17 5.75 5.33
5.00
6.00
7.00
8.00
9.00
GC
R
Decade
Average Culvert GCR by Decade and Material
33
Evaluating the Performance of Culverts
Culverts have outperformed bridges and concrete culverts have outperformed steel culverts
0.00%
2.00%
4.00%
6.00%
8.00%
10.00%
12.00%
14.00%
16.00%
18.00%
20.00%
2010 - 2012
2000 - 2009
1990 - 1999
1980 - 1989
1970 - 1979
1960 - 1969
1950 - 1959
1940 - 1949
Pre 1900 - 1939
Perc
enta
ge o
f Str
uctu
rally
Def
icie
nt C
ulve
rts
Decade
Percentage of Structurally Deficient Culverts by Material Type and Decade
Concrete
Steel
1/18
29/332 37/414
83/633
46/308
15/88 2/12
29/157
1/818 1/460 3/840 10/ 1,494
7/525 1/211
13/824
34
Inventory • Work needs • Structure Condition
Inspection Bridge Management • Work Prioritization • Project Scoping
Project Development • Design • Permitting • Right of Way • Advertisement & Award
Construction •Preconstruction Conf. •Mobilization •Traffic Control •Joint Preparation
Importance of Quality Control Governmental procurement rules require many steps before any work can be done in the field
Installation
35
Importance of Quality Control
Installation
All previous efforts are wasted if the final step isn’t properly performed
36
Importance of Quality Control
37
Importance of Quality Control
38
Summary
• Replace joints in a timely manner • Spend resources wisely
• Emphasize preventive maintenance • Make data-driven decisions when selecting interventions • Constantly evaluate new materials and methods • Balance spending
• Perform high quality work