1. Spliced Precast Girders
Solving Transportation and Handling Problems

2. Project Genesis Problem: Girder Weight and/or Length
Haul weight limitations
Haul size limitations
Permitting costs and scheduling
Terrain and access
Precast limited to spans < 160’

3. Pennsylvania Permit Vehicles
33X95.5 PABT

4. Project Genesis Solution: Spliced Girder Design
Segment girder into 2 or more pieces
Pretension for handling
Haul segments to jobsite
Assemble segments using post-tensioning
Erect girder as “pretensioned” girder

5. Drop-In Span Projects Fuller Warren Bridge, Jacksonville, Florida
Moore Haven Bridge, Florida
Highland View Bridge, Florida
Main Street Viaduct, Pueblo, CO

6. FULLER WARREN BRIDGE, JACKSONVILLE, FL

7. MOORE HAVEN BRIDGE, FLORIDA

8. HIGHLAND VIEW BRIDGE, FL

9. MAIN STREET VIADUCT, PUEBLO, CO

10. MAIN STREET VIADUCT, PUEBLO, CO

11. Simple-Span Projects Harbour Island People Mover, Tampa, FL
Klickitat County, WA
Rock Cut Bridge, WA
I-15 Reconstruction, Salt Lake City, UT

12. Klickitat County, WA Built 1954 90 ft total length 3 – 30 ft segments
Erected on falsework
Spliced because of contractor’s equipment

13. KLICKITAT COUNTY, WA

14. Harbour Island People Mover
Built 1984
Single box beam elevated guideway
140 ft total length
2 – 70 ft segments
Erected on falsework

15. HARBOUR ISLAND PEOPLE MOVER

16. HARBOUR ISLAND PEOPLE MOVER

17. HARBOUR ISLAND PEOPLE MOVER

18. HARBOUR ISLAND PEOPLE MOVER

19. HARBOUR ISLAND PEOPLE MOVER

20. Rock Cut Bridge, WA Built in 1995 190 ft total length 3 segments
Spliced near site, then launched
Access required splicing
Owners wanted concrete bridge
Very tight schedule and budget

21. ROCK CUT BRIDGE, WA

22. ROCK CUT BRIDGE, WA

23. ROCK CUT BRIDGE, WA

24. Project Objectives Extend current span limit
Provide a concrete alternative for the 150’ – 225’ span range
Provide pretensioned girder equivalency
Utilize PennDOT detailing to degree possible
No additional complexity for contractor

25. PA Spliced Girder Standards
Based on PA Bulb Tee
Single-span splicing
2- or 3-piece segmentation
Span Limit: 225 ft

26. Project Scope Phase I: Concept design
Phase II: Standard drawings & details
Phase III: Design examples

27. Standard Drawings

28. Based on PA Bulb Tee

29. Single-Span Spliced Girder

30. End Block

31. End Block

32. Reinforcing

33. Reinforcing

34. Concepts & Design Issues
Detailing issues
Fabrication details
Erection details
Splice details
Post-tensioning and grouting

35. Detailing Issues Girder geometry End blocks and anchorages
Flange
Bulb
End blocks and anchorages
Joints – Girder end treatments
Post-tensioning ducts
Rebar placement
Bearings

36. Fabrication Issues Post-tensioning End blocks and anchorages
Haunched pier segments
More intensive fabrication effort

37. Erection Issues Splicing before erection In-place splicing
Girder stability
Crane pick

38. Erection Scheme

39. Erection Scheme

40. Splice Details
Shear keys
Rebar splicing
Duct splicing
Wet joints

41. Closure Pour

42. Post-Tensioning Issues
Tendon size (7-0.6”, ”, ”)
Duct size and type (plastic or metal)
Anchorage type
Anchorage zone reinforcement
Anchorage protection
Grouting

43. Prestressing Materials
PT Strand
Strength (ksi)
250/270/300

44. Types of Post-Tensioning Tendons

45. Plastic vs. Metal Ducts Metal Plastic More widely used Less costly
Unlimited sizes
Stiffer
Better grout flow
Plastic
More durable
Non-corrosive
Lower coefficient of friction

46. Anchorage Types

47. Multistrand Anchorage Sizes
Anchor head
Trumpet
Bearing plate
Duct and coupler
Permanent grout cap
Inspectability
The VSLAB+TM System was developed for use in slabs. If your project has beams, VSL will combine our ES multistrand grouted system for beams with our VSLAB+TM System for slabs.
0.5” Strand - 12,19,31,43,55
0.6” Strand - 7,12,19,22,31,37,55

48. Anchorage Zone Reinforcement

49. Corrosion Protection of Strand
Corrugated plastic duct
Galvanized corrugated metal duct
Smooth HPDE duct
The VSLAB+TM System was developed for use in slabs. If your project has beams, VSL will combine our CS multistrand grouted system for beams with our VSLAB+TM System for slabs.

50. Protection of Anchorages
Non metallic permanent grout caps
We see here the stress and components, both assembled and disassembled. Looking at the line of disassembled components from left to right we see the recess former, the grout cap, the end anchor head, the bearing plate, the 2 half shells, the wedge clamps and the duct. When assembled, the system is mechanically locked together, providing the strand with reliable encapsulation. .
Galvanized
Bearing plates
Anchorheads
Spiral reinforcement

51. Multistrand Stressing Equipment
Stress 20% then 100%
Elongation measured during stressing

52. PT Grouting
Details
Procedures QC
Specifications
Inspection

53. Practice Recommended by ASBI and PTI Specifications
Grouting Materials
Testing, Q/A, Q/C
Construction
VSL decided few years ago to carry out an extensive R & D program on grout to review the Grout Mix Design, Procedures, Equipment and Personnel on the impact of grout
We will show you selected results of the R&D program

54. Grout Vents

55. Materials - Anchorages
Permanent Cap
Positive Seal
Integral Vent
Positive Duct Connections

56. Materials - Vents & Drains
Positive Shut-Off
Reopen & Close
Grouting Pressure

57. Grouted Duct
VSL decided few years ago to carry out an extensive R & D program on grout to review the Grout Mix Design, Procedures, Equipment and Personnel on the impact of grout
We will show you selected results of the R&D program

58. Completed Girder

59. Summary
Extend practical span range of precast/prestressed girders to 225’
Solve handling problem with segmentation: Spliced Girders
Final girder is erected as ordinary precast/pretensioned girder
No additional complexity for contactor

60. Project Status Phase I: Concept design
Complete
Phase II: Standard drawings & details
Phase III: Design examples
Awaiting release by PennDOT

61. Questions? Developer of Standards and Design Examples
Roy L. Eriksson, P.E. Eriksson Technologies, Inc.
Tampa, FL
LRFD.com