SHRP2 Project R04 Bridge Designs for ABC FHWA P2P Exchange Aug. 2012 Boston SHRP2 Project R04  Bridge Designs for ABC  Bala Sivakumar HNTB Corp.

SHRP2 Project R04 PROJECT 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

INNOVATIVE BRIDGE DESIGNS FOR RAPID RENEWAL 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

ABC ELEMENTS & METHODS 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)

SHRP2 R04 ABC Toolkit 1 2 3 4 5 ABC STANDARD DESIGN CONCEPTS ABC ERECTION CONCEPTS 3 ABC SAMPLE DESIGN CALCULATIONS 4 ABC DESIGN SPECIFICATIONS (LRFD) 5 ABC CONSTRUCTION SPECIFICATIONS 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.

ABC Standard Design Concepts GOALS: 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

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

Prefabricated Decked Beam Elements 2 Lane bridge with shoulders shown – customize width for site Deck Bulb Tees Double Tees Modular Decked Beams

Modular Decked Beams Barrier can be precast Barrier load on exterior module

Prestressed Decked Girders Decked Bulb Tee Span lengths from 40 ft to 130 ft UT, WA, ID among states with DBT standards Based on the PCI NEXT beam Spans to 90 ft Low depth alternative Adjacent Double Tee

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

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

Semi-Integral Abutment Suspended Backwall H piles or spread footings Fill pile pockets with SCC Easy fit-up in the field

Precast Piers Non-prestressed so contractor can self- perform precasting Fast erection using grouted splice couplers Conventional Pier Deep foundation may be outside existing footprint Straddle Bent

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

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

Grouted Splice Coupler

UHPC Joints in Bridge Deck 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 (Longitudinal Joint. Longitudinal steel not shown)

Erection Concepts for Prefabricated Elements Erection Concept Drawings Erection using conventional cranes. Erection using ABC construction technologies adapted from long span construction

Erection Concepts for Bridge Replacement Using Cranes Short Single Span over Stream Cranes selected for 90 Kip pick Longer Span over Roadway Weight up to 200 kips

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

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

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

Gantry Frames Transverse Gantry Frame Longitudinal Gantry Frame

ABC Design Specifications for LRFD 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 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

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.

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

ABC Construction Specifications Recommended Special Requirements for ABC Focus heavily on means and methods requirements for rapid construction. Proposed Section in LRFD Construction Specifications XX.1 GENERAL XX.2 RESPONSIBILITIES XX.3 MATERIALS XX.4 FABRICATION XX.5 SUBMITTALS XX.6 QUALITY ASSURANCE XX.7 Handling, Storing, and Transportation XX.8 Geometry Control XX.9 Connections XX.10 ERECTION METHODS XX.11 ERECTION PROCEDURES

First Demonstration Project Demonstrate Use of ABC Concepts Developed in SHRP2 R04 Keg 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

SHRP2 R04 ABC Demonstration Project #2 Lateral Slide (NYSDOT) 2012/ 2013 Construction Overnight replacement I-84 EB & WB Bridges over Dingle Ridge Road

Closing The time for ABC is now 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