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

2. 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

3. INNOVATIVE BRIDGE DESIGNS FOR RAPID RENEWAL
SHRP2 Project R04
INNOVATIVE BRIDGE DESIGNS FOR RAPID RENEWAL
HNTB (Prime)
Iowa State University
Structural Engineering Assoc.
Genesis Structures
Dr Monica Starnes, Senior Program Officer SHRP2

4. 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 ( )

5. 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.

6. 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

7. 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

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

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

10. 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

11. 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

12. 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

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

14. 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

15. 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

16. 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

17. Grouted Splice Coupler

18. 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)

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

20. 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

21. 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

22. 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

23. 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

24. Gantry Frames
Transverse Gantry Frame
Longitudinal Gantry Frame

25. 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.

26. 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

27. 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.

28. 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

29. 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

30. 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

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

32. 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