Connection Details Manual ABC Project that Save Money

11

Connection Details ManualConnection Details ManualABC Project that Save MoneyABC Project that Save Money

Connection Details ManualConnection Details ManualABC Project that Save MoneyABC Project that Save Money

Iowa DOT Accelerated Bridge Construction Iowa DOT Accelerated Bridge Construction WorkshopWorkshop

August 11, 2008August 11, 2008

Michael P. Culmo, P.E.Michael P. Culmo, P.E.CME Associates, East Hartford, CTCME Associates, East Hartford, CT

22

Roadblocks to Accelerated ConstructionRoadblocks to Accelerated Construction

The primary concerns that owner agencies The primary concerns that owner agencies have with respect to adopting accelerated have with respect to adopting accelerated construction techniques are:construction techniques are: Need for Quality DetailsNeed for Quality Details DurabilityDurability Design Methodologies and TrainingDesign Methodologies and Training Construction MethodologiesConstruction Methodologies

33

““Connections for Prefabricated Bridge Connections for Prefabricated Bridge Elements and Systems”Elements and Systems”

FHWA has initiated a project to develop FHWA has initiated a project to develop this manual this manual

This publication is intended to provide This publication is intended to provide information that will go a long way to information that will go a long way to answering all four of the previous answering all four of the previous concerns. concerns.

Focus on details that have been used in Focus on details that have been used in the past. the past.

44

Project GoalsProject Goals Gather details of Gather details of ConnectionsConnections that have that have

been used on accelerated bridge been used on accelerated bridge construction projectsconstruction projects

Investigate transfer of technology from Investigate transfer of technology from other markets into the bridge marketother markets into the bridge market Parking GaragesParking Garages StadiumsStadiums BuildingsBuildings

Connection Details for Prefabricated Bridge Connection Details for Prefabricated Bridge Elements and SystemsElements and Systems

55

All details needs to pass a critical test All details needs to pass a critical test before being published in the document:before being published in the document: Does the connection result in a rapid Does the connection result in a rapid

construction process?construction process? Does the connection transmit the forces Does the connection transmit the forces

between elements effectively?between elements effectively? Is the connection durable?Is the connection durable? Has it performed well under traffic and in an Has it performed well under traffic and in an

exposed environment?exposed environment? Is it cost effective and easy to construct?Is it cost effective and easy to construct? If a process or connection is proprietary, can it If a process or connection is proprietary, can it

be incorporated into numerous projects be incorporated into numerous projects without producing contracting issues? without producing contracting issues?

66

Source of DataSource of Data

State DOT’sState DOT’s Questionnaires sent via e-mailQuestionnaires sent via e-mail

Federal AgenciesFederal Agencies International OrganizationsInternational Organizations Researchers (previous and current)Researchers (previous and current) ProducersProducers

Questionnaires sent via e-mailQuestionnaires sent via e-mail

ForwardTable of Contents

Section 1General Topics

Section 2Superstructure Connections

Section 3Substructure Connections

Section 4Foundation Connections

Appendices

1.1Introduction

1.2Accel. Construction

Overview

1.3Applicability to Typical

Bridges

1.4Typical Connection Types

1.5Seismic Considerations

1.6Materials

1.7Tolerances

1.8Fabrication and

Construction

2.1Deck Systems

2.2Adjacent Butted Beam

Systems

2.3Decked Stringer Systems

2.4Modular Superstructures

2.5Connections to Substructures

3.1Pier Systems

3.2Abutment Systems

3.3Wingwalls and Retaining

Walls

Appendix ANotations

Appendix BConnection Design

Examples

Appendix CStandard Products

Appendix DSample Const. Specifications

Appendix ECase Studies

Appendix FGlossary

Manual Manual OrganizationOrganization

88

Connection Data SheetsConnection Data Sheets

99

Some Information that is Some Information that is available todayavailable today

PCI Northeast Bridge PCI Northeast Bridge Technical CommitteeTechnical Committee Guidelines for Accelerated Guidelines for Accelerated

Bridge ConstructionBridge Construction Available at Available at www.pcine.orgwww.pcine.org

FHWAFHWA Framework for Prefabricated Framework for Prefabricated

Bridge Elements and Systems Bridge Elements and Systems (PBES) Decision-Making (PBES) Decision-Making

Manual on Use of Self-Propelled Modular Transporters to Move Bridges

1010

Precast AbutmentsPrecast Abutments

1111

Precast AbutmentsPrecast Abutments

1212

Precast PiersPrecast Piers

1313

Precast PiersPrecast Piers

1414

Precast Decks on PS BeamsPrecast Decks on PS Beams

1515

Precast Decks on Steel FramingPrecast Decks on Steel Framing

1616

Precast DecksPrecast Decks

1717

FRP DecksFRP Decks

1818

Grid DecksGrid Decks

1919

Partial Depth Deck FormsPartial Depth Deck Forms

2020

Total Bridge PrefabricationTotal Bridge Prefabrication

2121

Total Bridge PrefabricationTotal Bridge Prefabrication

2222

Examples: Epping NHExamples: Epping NH

construction of 1-07.avi

2323

Project ScheduleProject Schedule

Gather informationGather information Fall 2006 through Spring 2007Fall 2006 through Spring 2007

Visit states that are leaders in Visit states that are leaders in accelerated bridge constructionaccelerated bridge construction Winter 2007Winter 2007

Develop manualDevelop manual Summer/Fall 2007Summer/Fall 2007

Complete ManualComplete Manual Fall 2008Fall 2008

2424

Project DeliveryProject Delivery

The document will be available for all The document will be available for all owners and designers for use in future owners and designers for use in future accelerated bridge projectsaccelerated bridge projects Website will be established on the FHWA Website will be established on the FHWA

Highways for Life WebsiteHighways for Life Website

www.fhwa.dot.gov/hfl/www.fhwa.dot.gov/hfl/

2525

Schematic Design of an Schematic Design of an Accelerated Bridge Accelerated Bridge

Schematic Design of an Schematic Design of an Accelerated Bridge Accelerated Bridge

2626

Case ScenarioCase Scenario

4 lane bridge over an expressway4 lane bridge over an expressway Existing bridge has deteriorated beyond Existing bridge has deteriorated beyond

repairrepair Heavy traffic on both roadwaysHeavy traffic on both roadways There is a short but undesirable detourThere is a short but undesirable detour

2727

Public InvolvementPublic Involvement

Public hearing heldPublic hearing held Businesses do not want a long construction Businesses do not want a long construction

process with stage constructionprocess with stage construction Businesses are not keen about a detourBusinesses are not keen about a detour They will accept a short term closure with They will accept a short term closure with

the detourthe detour As opposed to a long term staged projectAs opposed to a long term staged project

2828

Design OptionsDesign Options Build a temporary bridge to speed up construction Build a temporary bridge to speed up construction

of the new bridgeof the new bridge $$$$$$$$ Not that fastNot that fast

Build bridge along side and slide into place with Build bridge along side and slide into place with SPMT’sSPMT’s Definitely possibleDefinitely possible Does not easily solve problem with foundationsDoes not easily solve problem with foundations

Establish the detour and accelerate the bridge Establish the detour and accelerate the bridge construction to less than 30 daysconstruction to less than 30 days

2929

Existing BridgeExisting Bridge

3030

Existing BridgeExisting Bridge

Deck Joints

Low Clearance

3131

Issues with the Existing BridgeIssues with the Existing Bridge

Minimal UnderclearanceMinimal Underclearance 14’-5”14’-5”

Piers and abutments are close Piers and abutments are close to roadwayto roadway Spray from vehicles damaged Spray from vehicles damaged

the piersthe piers Leakage through deck jointsLeakage through deck joints

Led to severe beam end Led to severe beam end deteriorationdeterioration

3232

Proposed BridgeProposed Bridge After a formal type study, the owner opted After a formal type study, the owner opted

with the following structure criteriawith the following structure criteria Continuous steel girders (weathering steel)Continuous steel girders (weathering steel) Reduce to a two span bridgeReduce to a two span bridge Increase clearance by raising approach Increase clearance by raising approach

grades (3’)grades (3’) Use integral abutments (no deck joints)Use integral abutments (no deck joints) Composite concrete deckComposite concrete deck Membrane waterproofing and Bituminous Membrane waterproofing and Bituminous

wearing surfacewearing surface Open steel railings (galvanized)Open steel railings (galvanized)

3333

Existing BridgeExisting Bridge

3434Proposed BridgeProposed Bridge

3535

Proposed BridgeProposed Bridge

3636

Features of New BridgeFeatures of New Bridge Move pier far from roadwayMove pier far from roadway

Possible future widening optionsPossible future widening options Push abutments back to top of slopePush abutments back to top of slope

Minimize wingwall requirementsMinimize wingwall requirements Use integral abutments with flying wingsUse integral abutments with flying wings

Both abutments and the pier are in a different Both abutments and the pier are in a different footprint than the existingfootprint than the existing facilitates constructionfacilitates construction

Eliminate spray attack on piers and abutmentsEliminate spray attack on piers and abutments No deck jointsNo deck joints

3737

How to select detailsHow to select details

FHWA manual “Connection details for FHWA manual “Connection details for prefabricated bridge elements and prefabricated bridge elements and systems”systems”

1.1. Review Chapter 1Review Chapter 1 Investigate connection types, materials, Investigate connection types, materials,

tolerancestolerances

2. Search applicable sections of other chapters 2. Search applicable sections of other chapters for detailsfor details

3838

Section 1.4 Typical Connection TypesSection 1.4 Typical Connection Types

After reviewing chapter 1, the owner chose the After reviewing chapter 1, the owner chose the following connection typesfollowing connection types Grouted reinforcing splice couplersGrouted reinforcing splice couplers

Quick, proven systemQuick, proven system Can develop full bar strengthCan develop full bar strength Simplifies the design process (similar to CIP)Simplifies the design process (similar to CIP)

Grouted VoidsGrouted Voids Easy for simple connectionsEasy for simple connections

Concrete Closure pours between precast elementsConcrete Closure pours between precast elements Use for a limited number of connections (slower)Use for a limited number of connections (slower)

3939Grouted Reinforcing Splice Grouted Reinforcing Splice ConnectorsConnectors Emulates a reinforcing Emulates a reinforcing

steel lap splicesteel lap splice Multiple companies – non-Multiple companies – non-

proprietaryproprietary Used in precast parking Used in precast parking

garages and stadiums and garages and stadiums and bridgesbridges

4040

Schematic Pier DesignSchematic Pier Design

Footing to subgrade connectionFooting to subgrade connection Section 4.1.1 Precast footing to subgrade Section 4.1.1 Precast footing to subgrade

connectionconnection

Detail developed by New Hampshire DOTDetail developed by New Hampshire DOT

4141

Data SheetData Sheet

4242

Footing DetailsFooting Details

4343

Schematic Pier DesignSchematic Pier Design

Footing to column connectionFooting to column connection Section 3.1.4.2 Precast column to Precast Section 3.1.4.2 Precast column to Precast

Footing connectionFooting connection

Detail developed by the Northeast PCI Detail developed by the Northeast PCI Bridge Technical Committee based on Bridge Technical Committee based on work done in Floridawork done in Florida

Used extensively in vertical constructionUsed extensively in vertical construction Parking garages, stadiums and hotelsParking garages, stadiums and hotels

4444

Data SheetData Sheet

4545

Footing/Column DetailsFooting/Column Details

4646

Schematic Pier DesignSchematic Pier Design

Column to Cap Beam connectionColumn to Cap Beam connection Section 3.1.1.2 Precast cap beam to precast Section 3.1.1.2 Precast cap beam to precast

column connectioncolumn connection

Detail used by the Florida DOTDetail used by the Florida DOT Edison BridgeEdison Bridge

4747

Data SheetData Sheet

4848

Column/Cap Beam DetailsColumn/Cap Beam Details

4949

Completed PierCompleted Pier

Footing to subgrade

connection

Column to footing

connection

Column to cap

connection

5050

Schematic Abutment DesignSchematic Abutment Design

Integral Abutment to precast pilesIntegral Abutment to precast piles Section 3.2.3.1 Precast Integral Abutment to Section 3.2.3.1 Precast Integral Abutment to

PilesPiles

Detail developed by Maine DOTDetail developed by Maine DOT Used on three different bridgesUsed on three different bridges

5151

Data SheetData Sheet

5252

Schematic Abutment DesignSchematic Abutment Design

Integral Abutment wall splices and Integral Abutment wall splices and wingwall connectionwingwall connection Section 3.2.3.3 and 3.2.4.1 Precast Integral Section 3.2.3.3 and 3.2.4.1 Precast Integral

Abutment ConnectionsAbutment Connections

Detail developed by the Maine DOTDetail developed by the Maine DOT Used on three different bridgesUsed on three different bridges

5353

Data SheetData Sheet

5454

Abutment Cap SplicesAbutment Cap Splices

5555

Schematic Abutment DesignSchematic Abutment Design

Approach Slab to Abutment wall Approach Slab to Abutment wall connectionconnection Section 3.2.4.2 Precast Approach Slab to Section 3.2.4.2 Precast Approach Slab to

Abutment ConnectionsAbutment Connections

Detail developed by the New Hampshire Detail developed by the New Hampshire DOTDOT

Based on a design used by the Maine Based on a design used by the Maine DOTDOT

5656

Data SheetData Sheet

5757

Completed Completed AbutmentAbutment

Pile to cap connection

Approach slab connection

Flying Wingwall

connection

Abutment cap connection

5858

Schematic Deck DesignSchematic Deck Design

Precast Full Depth deck on steel stringersPrecast Full Depth deck on steel stringers Section 2.1.1.2 Precast full depth deck to Section 2.1.1.2 Precast full depth deck to

steel stringersteel stringer

Detail used by many statesDetail used by many states CT, NY, NH, ID, etc.CT, NY, NH, ID, etc.

Details proven by research and real world Details proven by research and real world projectsprojects

5959

Data SheetData Sheet

6060

PC Deck to Stringer DetailsPC Deck to Stringer Details

6161

Schematic Deck DesignSchematic Deck Design

Precast Full Depth deck transverse Precast Full Depth deck transverse connectionconnection

Section 2.1.1.1 Connection between slab Section 2.1.1.1 Connection between slab elementselements

Detail also used by many statesDetail also used by many states Post tensioned according to AASHTOPost tensioned according to AASHTO

250 psi net (concentric)250 psi net (concentric)

6262

Data SheetsData Sheets

6363

Data SheetsData Sheets

6464

PC Deck Connection DetailsPC Deck Connection Details

6565

Schematic Deck DesignSchematic Deck Design

Precast Full Depth deck longitudinal Precast Full Depth deck longitudinal connectionconnection

Section 2.1.1.1 Connection between slab Section 2.1.1.1 Connection between slab elementselements

Detail also used by several states Detail also used by several states CT, NHCT, NH

Simple closure pourSimple closure pour Accommodates crown in deckAccommodates crown in deck

6666

Data SheetData Sheet

6767

PC Deck connection DetailsPC Deck connection Details

6868

Schematic Deck DesignSchematic Deck Design

Precast Full Depth deck to curb Precast Full Depth deck to curb connectionconnection

There is a lack of crash tested precast There is a lack of crash tested precast parapets or curbsparapets or curbs

Use a simple cast-in-place curbUse a simple cast-in-place curb High Early ConcreteHigh Early Concrete Can be done at the same time as the crown Can be done at the same time as the crown

jointjoint Continuous pour with crack control jointsContinuous pour with crack control joints

6969

Schematic DesignSchematic Design

Connection of superstructure to integral Connection of superstructure to integral abutmentabutment

There is a need for significant tolerances at this There is a need for significant tolerances at this connectionconnection

It also has very complex geometryIt also has very complex geometry Use a simple cast-in-place pourUse a simple cast-in-place pour

High early concreteHigh early concrete Forming can be done while deck is being installedForming can be done while deck is being installed Could use a precast backwall as a partial formCould use a precast backwall as a partial form

7070Completed Completed SuperstructureSuperstructure

Integral Abutment ConnectionLongitudinal PT

Longitudinal crown

connection

Transverse slab

connection

Connection to beamCIP Curb

7171Complete Complete BridgeBridge

Precast Integral Abutment

Membrane waterproofing with

bit. Wearing surface

Precast Pier

Precast full depth

composite deck

7272

Estimated Construction ScheduleEstimated Construction ScheduleTask

Demo Existing Bridge

Install Foundations

Erect Beams

Install Deck and PT

Closure Pours

Curb Pour

Railings

Paving

Approach Roadway

Clean-up

5 Days

8 Days

3 Days

3 Days

3 Days

3 Days

3 Days

2 Days

17 Days

2 Days

Week 1 Week 2 Week 3 Week 4

7373

CostsCosts Typical New Bridge (Cost=$175/sf) = Typical New Bridge (Cost=$175/sf) = $2,200,000$2,200,000

Premium for ABC (assume 20%) = Premium for ABC (assume 20%) = $440,000 $440,000

Temporary Bridge (Cost=$50/sf) = Temporary Bridge (Cost=$50/sf) = ($620,000) ($620,000)

Net Savings =Net Savings = $180,000 $180,000

Note: These prices will vary greatly by regionNote: These prices will vary greatly by region

7474

QualityQuality Florida has had very good success with Florida has had very good success with

precast piers in very harsh environmentsprecast piers in very harsh environments CT has had Precast full depth decks in CT has had Precast full depth decks in

place for over 17 yearsplace for over 17 years Crack Free DeckCrack Free Deck Excellent conditionExcellent condition

Integral abutments eliminate deck jointsIntegral abutments eliminate deck joints

7575

Old AdageOld Adage

By elimination of temporary bridges or costly By elimination of temporary bridges or costly stage construction schemes, stage construction schemes,

you you CANCAN have all three have all three

Rapid Rapid ConstructionConstruction

High QualityHigh Quality

Low CostLow Cost

You can only You can only have any twohave any two

7676

Reduced Bid PricesReduced Bid Prices StandardizationStandardization Programmatic (not one of a kind)Programmatic (not one of a kind) Reduced project site costs (trailers, etc.)Reduced project site costs (trailers, etc.) Reduced Maintenance Of Traffic CostsReduced Maintenance Of Traffic Costs InflationInflation

Non- Bid SavingsNon- Bid Savings Fewer Police DetailsFewer Police Details Reduced Inspection timeReduced Inspection time

User CostsUser Costs Plus: $$ Can be significantPlus: $$ Can be significant Minus: $$ Not in the budgetMinus: $$ Not in the budget

Other Cost SavingsOther Cost Savings

7777

FDOT Graves Avenue over I-4 FDOT Graves Avenue over I-4 Bridge Replacement - 2006Bridge Replacement - 2006

Each new spaninstalled in few hours overnight

I-4 closed twopartial nights for installations

7878

FDOT Graves Avenue over I-4 FDOT Graves Avenue over I-4 Bridge Replacement - 2006Bridge Replacement - 2006

• Costs:Costs:• Supplemental Agreement for Change Order to existing Supplemental Agreement for Change Order to existing

contract – $570,000contract – $570,000

• Benefits:Benefits:• Graves Avenue detour from 12 to 8 months, in time for Graves Avenue detour from 12 to 8 months, in time for

start of schoolstart of school

• I-4 lane closures from 32 nights to 4 nightsI-4 lane closures from 32 nights to 4 nights

• Delay-related user cost savings of $2.2MDelay-related user cost savings of $2.2M

7979

UDOT 4500 South over I-215E UDOT 4500 South over I-215E Bridge Replacement - 2007Bridge Replacement - 2007

4-lane, 173-ft long,1,750 ton spaninstalled overweekend

with noImpact torush-hourtraffic

removal

installation

8080

UDOT 4500 South over I-215E UDOT 4500 South over I-215E Bridge Replacement - 2007Bridge Replacement - 2007

• Costs:Costs:• Additional $800,000 for use of SPMTsAdditional $800,000 for use of SPMTs

• Benefits:Benefits:• I-215E closed 53 hours over a weekend (versus 6-I-215E closed 53 hours over a weekend (versus 6-

month conventional construction)month conventional construction)

• 4500 South Bridge closed 10 days4500 South Bridge closed 10 days

• Delay-related user cost savings of $4MDelay-related user cost savings of $4M

8181

NJDOT Rt. 1 over Olden/Mulberry NJDOT Rt. 1 over Olden/Mulberry Span Replacements – 2005Span Replacements – 2005

New Jersey’s1st HyperbuildProject

Replaced 3 spansin 3 weekends

Elevation of new Route 1 Bridgesover Mulberry Street

8282

NJDOT Rt. 1 over Olden/Mulberry NJDOT Rt. 1 over Olden/Mulberry Span Replacements – 2005Span Replacements – 2005• Costs:Costs:

• $3.5M low bid compared to engineer’s estimate of $3.5M low bid compared to engineer’s estimate of $3.8M (8% savings)$3.8M (8% savings)

• Benefits:Benefits:• Each bridge opened in less than 57 hoursEach bridge opened in less than 57 hours

• 3 spans over 3 weekends (6 days vs. 22 mo.)3 spans over 3 weekends (6 days vs. 22 mo.)

• No impact to peak-hour trafficNo impact to peak-hour traffic

• Anticipated 75-100 year life (vs. 50 years)Anticipated 75-100 year life (vs. 50 years)

• $2M design/construction savings incl. user cost$2M design/construction savings incl. user cost

8383

ConclusionsConclusions It is possible to build a complete bridge in 30 It is possible to build a complete bridge in 30

days (or less)days (or less) The FHWA manual provides a starting point for a The FHWA manual provides a starting point for a

complete bridge prefabrication projectcomplete bridge prefabrication project You do not need to sacrifice quality to get rapid You do not need to sacrifice quality to get rapid

constructionconstruction By eliminating a temporary bridge or staging, By eliminating a temporary bridge or staging,

you could save money on an accelerated bridge you could save money on an accelerated bridge projectproject

ABC can lead to a significant reduction in user ABC can lead to a significant reduction in user costscosts

8484

Questions?Questions?culmo@cmeengineering.comculmo@cmeengineering.com

Questions?Questions?culmo@cmeengineering.comculmo@cmeengineering.com