1 Connection Details Connection Details Manual Manual ABC Project that Save ABC Project that Save Money Money Iowa DOT Accelerated Bridge Iowa DOT Accelerated Bridge Construction Workshop Construction Workshop August 11, 2008 August 11, 2008 Michael P. Culmo, P.E. Michael P. Culmo, P.E. CME Associates, East Hartford, CT CME Associates, East Hartford, CT
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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
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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
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““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.
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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
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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
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
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”
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
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
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
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
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
• 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