A CCELERATING B RIDGE C ONSTRUCTION (ABC) WITH P REFABRICATED B RIDGE E LEMENTS & S YSTEMS (PBES)

PBES Technology Overview of ABC and PBES/definitions Why use PBES? PBES performance goals for the U.S. Specific Systems and Elements Structural placement methods When to consider PBES Cost Effectiveness of PBES Resources for ABC/PBES

Foundation & Wall Elements Continuous Flight Auger Piles Geosynthetic Reinforced Soil (GRS) Integrated Bridge System Rapid Embankment Construction EPS Geofoam Prefabricated Bridge Elements & Systems Prefabricated Elements - Superstructure -Substructure Prefabricated Systems - Superstructure -Substructure -Total Bridge Accelerated Bridge Construction Components Structural Placement Methods Self-Propelled Modular Transporters (SPMTs) Longitudinal launching Horizontal sliding or skidding Other heavy lifting equipment & methods Conventional lifting equipment & methods Fast Track Contracting Innovative Contracting - Best value - CMGC method - Design Build - A+B - A+B+C - Warranties

Definition of PBES Structural elements & systems that are built off the bridge alignment to accelerate onsite construction time relative to conventional practice.

Why Use PBES Technologies? It offers Major Advantages: Faster (offsite, off critical path, less impact) Safer (public, construction, & inspection) Better Quality (controlled environment) Can be Cost Effective: positive Benefit-Cost ratios when user costs are considered.

Why Use PBES Technologies? INDOT’s Lane Closure Policy Interstate projects Other projects where user costs are considered Result of public involvement Design Build – let contractor/designer decide best method to reduce impact Accelerated construction (e.g. A+B)

FHWA PBES Deployment Goals for U.S. By December 2012: 100 cumulative bridges have been designed and/or constructed rapidly using PBES. 25 percent of replacement bridges authorized using Federal-aid have at least one major prefabricated bridge element that shortens onsite construction time relative to conventional construction.

Goal of PBES? Moving more cast-in-place construction to off-site location

Goal of PBES? Building the bridge or elements first before you close lanes, then quickly move it into place – like in hours or a weekend!

Elements –Deck Panels: Partial & Full-Depth –Beams: More Efficient Shapes, –Pier Caps, Columns, & Footings –Abutment Walls, Wing Walls, & Footings Systems –Superstructure –Substructures –Total Bridge What are Prefabricated ELEMENTS AND SYSTEMS?

PBES Element Definitions Full-depth Deck Panels: Panels that are prefabricated the full thickness and do not require CIP concrete to complete the deck thickness; Deck panels most common type of PBES Concrete most common type of deck panel Precast Decks on Steel Framing Precast Decks on PS Beams

PBES Element Definitions Pier Caps, Columns, and Footings: A combination of precast & CIP 1) Precast pier cap with CIP column(s) 2) Precast pier cap & precast column(s) with CIP pile cap footing, or 3) Precast spread footing with CIP column(s) Precast piers Precast pier cap

Precast Columns and Pier Caps Precast pier cap

PBES System Definitions Superstructure: 1.Total superstructures moved in with SPMTs, skidded, or launched 2.Truss spans and arch spans constructed off the bridge alignment 3.Precast segmental box segments 4.Composite units w/o CIP deck, w/ or w/o overlay 5.Deck bulb tee beams w/o CIP deck, w/ or w/o overlay Superstructure Span on SPMT

How to move PBES into place? Structural Placement Methods Self-Propelled Modular Transporters (SPMTs) Longitudinal launching Horizontal/transverse sliding or skidding Other heavy lifting equipment & methods Conventional lifting equipment & methods

Half-hour rolling roadblocks on I-4 to remove 71-ft long, 30-ft wide, 250-ton spans 143-ft long, 59-ft wide 1,300-ton replacement spans built in adjacent staging area What Success Looks Like: FDOT Graves Ave. over I-4 Bridge Replacement

Superstructure Roll-In: 390-ft Length, 3300 M Tons 2 Hours to Move - 1 Weekend Road Closure April 2004 Prefabricated Bridges International Scan Badhoevedorp, Netherlands

George P. Coleman Bridge, VA

19 CONTINUOUS LAUNCHING

20 TRANSVERSE LAUNCHING

Baldorioty Castro Ave. – San Juan, Puerto Rico 1992 Two 700-ft and two 900-ft bridges, each installed in hrs

102 superstructure spans replaced in 137 nights … … with no lane closures during rush-hour traffic Virginia DOT I-95 Bridge over James River, 2002

Benefits of Using ABC/PBES It offers Major Advantages: Faster (offsite & off critical path) Safer (public, construction, & inspection) Better Quality (controlled environment) Can be Cost Effective: positive Benefit-Cost ratios when user costs are considered.

FASTER: Reduces On- Site Construction Time Less time spent on-site Traditional tasks can be done off-site Minimal impact from weather conditions

SAFER: Minimizes Traffic Impacts Minimizes traffic delay and community disruption Reduces detours, lane closures, and narrow lanes US 59 under Dunlavy, TX I-59 and I-65 Interchange, AL

SAFER: Improves Work Zone Safety Minimizes work near traffic and power lines, at high elevations, or over water. Meylan Pedestrian Bridge, France

QUALITY: Improves Constructability Prefabricated elements & Systems – Minimal impact from environmental constraints – Relieves constructability pressure. San Mateo-Hayward Bridge, CA

BETTER QUALITY Prefabricated in a controlled environment Increases quality control Optimum concrete curing George P. Coleman Bridge, VA

PBES can be COST-EFFECTIVE It depends on type of structure and elements or systems used. Over time, many systems can cost less than conventional construction First implementation of new elements may cost more. Need a program of projects--economy of scale. Life cycle cost analysis is favorable to PBES and provides a positive Benefit-Cost Ratio when user costs are considered.

COST EFFECTIVE: Declining Cost of Deploying Innovative Technology First time costs more < Potential for new methods to cost less < Promise of time savings < Positive cost-benefit ratios < Promise of programmatic cost savings

COST EFFECTIVE: Costs of PBES

COST EFFFECTIVE: Costs of PBES

State-of-the-Practice ? FHWA Senior management is committed to Every Day Counts technology deployments 40+ States: 1 or more projects 7 States: 20+ projects 11 States actively pursuing as standard practice Opportunity for much greater PBES deployment

Complete Bridge Element Prefabrication New Hampshire Project How fast can we build a bridge? 115-foot span All components prefabricated Precast cantilever abutments Roadway open in 8 days Time Lapse Video on YoutubeTM Search “Epping Bridge Construction”

WHEN TO USE PBES: Framework for Decision-Making – Format Introduction Flowchart – Decision-Making at a Glance Matrix – Decision-Making Questions Decision-Making Considerations – Questions with Discussion and References

ATAGLANCEATAGLANCE DECISION MAKING Flowchart

Decision-Making Matrix Example Questions QuestionYesMaybeNo High traffic volume…? Emergency replacement…? Worker safety concerns…? High daily traffic control costs…?

Decision-Making Matrix One or two factors may warrant use of PBES User may assign weights to factors In any case, a majority of “Yes” responses indicates PBES offers advantages

Framework Available Online

Utah DOT Decision Chart

Resources: For ABC/PBES Manuals, Specifications, Contract Drawings, & Details Websites: – FHWA EDC site – FHWA PBES site – HfL projects site – ABCT site – ACTT site – State DOT bridge sites PBES Cost Study PBES Decision-Making Framework Manuals: – ABC Manual – FHWA SPMT Manual – PBES Connection Details Manual – UDOT ABC SPMT Manual & Guide NCHRP domestic scan report NCHRP & other research SHRP2 R04 Final Report

General Topics Superstructure Connections Substructure Connections Foundation Connections Connection Design Examples Proprietary Products Sample Construction Specifications Case Studies Connections Details Manual

Cost-competitive projects Reduced onsite construction time Construction cost less than engineer’s estimate Project details Project owner contacts Other contacts, e.g.: – Contractor – Design Engineer – Prefabricator Cost Manual

FHWA SPMT Manual

Bridge moving with SPMT

SPMT Resource Providers Barnhart Crane & Rigging Bigge Crane and Rigging Co. Fagioli, Inc. Mammoet USA NDF (New Dafang Group) Sarens Group

Other Sources for Details Utah DOT ABC Website – (search ABC) – Piers, abutments, walls, decks PCI Northeast – (Bridge resources) Short Span Steel Bridge Alliance – Modular steel bridge details coming MassDOT – Working on new ABC manual

Domestic Scan on Best Practices in Accelerated Construction Techniques March 2009 NCHRP Domestic Scan Program

Overview of ABC techniques & practices currently in use App. A: Design Examples App. B: Standard Products App. C: Sample Construction Specifications App. D: Erection and Transportation Equipment Coming Soon! ABC Manual

National Cooperative Highway Research Program Projects Related to ABC No.TitleStatus Full-Depth, Precast-Concrete Bridge Deck Panel Systems Report Design and Construction Guidelines for Long-Span Decked Precast, Prestressed Concrete Girder Bridges Research in progress Development of a Precast Bent Cap System for Seismic Regions Research in progress Evaluation of CIP Reinforced Joints for Full-Depth Precast Concrete Bridge Decks Research in progress

$ State use of program funding for PBES projects $ Highways for LIFE grants $ Innovative Bridge R&D funds Technical Support (FHWA RC, HQ, & Division) Resources previously listed How can FHWA help you deploy PBES ?

Resource Recap Information on innovative projects (50+) by elements and systems on FHWA website ABC/PBES decision-making framework PBES Cost Study based on nine projects FHWA SPMT Manual PBES Connection Details Manual Manual on ABC-Experience in Design, Fabrication, & Erection of PBES (2011) How can FHWA help you deploy PBES ?

PBES and INDOT Milton Madison Bridge over the Ohio River – Showcase project IBRD funded trial project submitted to FHWA – Awaiting approval; plan to let in 2012 Future projects???

Questions/Comments??? Keith Hoernschemeyer FHWA IN Division Bridge Engineer