Expanding the Use of Precast Concrete in Texas Bridges EXPANDING THE USE OF PRECAST CONCRETE IN TEXAS BRIDGES Graham Bettis, P.E. TxDOT Bridge Division – Construction & Maintenance
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Expanding the Use of Precast Concrete in Texas Bridges
EXPANDING THE USE OF PRECAST CONCRETE IN TEXAS BRIDGES
Graham Bettis, P.E.
TxDOT Bridge Division – Construction & Maintenance
Expanding the Use of Precast Concrete in Texas Bridges
Just the Facts
Total Number of On-System Bridges (Excluding Culverts):
– 21,686
Total Number with Prestressed Concrete Superstructures:
– 11,037 (that’s 51%)
About 90% of New Bridges Built with Prestressed Concrete Superstructures
– 92% in FY 2013
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Expanding the Use of Precast Concrete in Texas Bridges
Standard I-Beam Construction
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Expanding the Use of Precast Concrete in Texas Bridges
Standard U-Beam and Deck Panel Construction
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Concrete - How Do We Love Thee?
Owner’s Perspective
– Inexpensive
– Fast
– Durable
– Redundant
Contractor’s Perspective
– Fast
– $$$*
* Sometimes difficult for Primes to let go of cast-in-place.
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Expanding the Use of Precast Concrete in Texas Bridges
Concrete Production in Texas
Cement
– Lots of Limestone
– 10 Cement Producers
– Coarse Aggregate
• River Rock
• Limestone
Fine Aggregate
– River Beds (Sand)
– Manufactured Sand (Limestone)
Fly Ash
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Coal Plants in Texas
Expanding the Use of Precast Concrete in Texas Bridges
Precast Concrete Fabricators – Major Prestressed
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Concrete Fabricators – Minor Prestressed
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Concrete Fabricators – Nonstressed
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Expanding the Use of Precast Concrete in Texas Bridges
Average Bridge Costs – FY 2013
Structural Steel*
– Plate Girders: $126/SF
– Trapezoidal Tubs: $153/SF
Prestressed Concrete
– Tx Girders (Bulb Tees): $65/SF
– U54 Beams: $52/SF
* Must take into account that almost all steel spans are long and
continuous, raising the construction cost significantly. But still…
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Expanding the Use of Precast Concrete in Texas Bridges
Durability
Extremely Low Permeability
– Fly Ash
– Steel Form Finish
Produced in Controlled Environment
– Self-Consolidating Concrete
– Low Water-to-Cement Ratio
– Moist Curing
– QC/QA
– Repair and Rejection – Plant vs. Job Site
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Expanding the Use of Precast Concrete in Texas Bridges
Curing
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Expanding the Use of Precast Concrete in Texas Bridges
Permeability
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Expanding the Use of Precast Concrete in Texas Bridges
Not All Concrete Cracks
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Expanding the Use of Precast Concrete in Texas Bridges
Conventional Concrete Deterioration
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Expanding the Use of Precast Concrete in Texas Bridges
Conventional Concrete Deterioration
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Expanding the Use of Precast Concrete in Texas Bridges
Conventional Concrete Deterioration
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Expanding the Use of Precast Concrete in Texas Bridges
Conventional Concrete Deterioration
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Expanding the Use of Precast Concrete in Texas Bridges
Conventional Concrete Deterioration
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Expanding the Use of Precast Concrete in Texas Bridges
Structural Steel Deterioration
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Expanding the Use of Precast Concrete in Texas Bridges
Structural Steel Deterioration
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Expanding the Use of Precast Concrete in Texas Bridges
Structural Steel Deterioration
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Expanding the Use of Precast Concrete in Texas Bridges
High Performance Concrete
Item 421: Hydraulic Cement Concrete
8 Mix Design Options
HPC = Design Options 1 through 5
In Reality, HPC = Design Option 1
– Replace 25% of Cement with Class F Fly Ash
– Applies to All Precast Concrete
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Concrete
Current, Widespread Usage
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Expanding the Use of Precast Concrete in Texas Bridges
Standard Precast Items
Prestressed Piling
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Railing Traffic Barrier
Bent Cap for Steel Piling
Box Beams
Slab Beams
Tx Girders (Bulb Tees)
U-Beams
I-Beams
Bent Cap for Round Columns
Spread Boxes – X-Beams
Sheet Piling
Prestressed Deck Panels
End Treatments
Culverts
Reinforced Concrete Pipes
Manholes & Inlets
Decked Slab Beams
Expanding the Use of Precast Concrete in Texas Bridges
Prestressed Piling
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Expanding the Use of Precast Concrete in Texas Bridges
Prestressed Piling
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Expanding the Use of Precast Concrete in Texas Bridges
Standard I-Girder Shapes
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Expanding the Use of Precast Concrete in Texas Bridges
I-Girders
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What We’re Doing Now – Tx Girders
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Expanding the Use of Precast Concrete in Texas Bridges
Decked Slab Beams
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Expanding the Use of Precast Concrete in Texas Bridges
Decked Slab Beams
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Expanding the Use of Precast Concrete in Texas Bridges
U-Beams
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Deck Panels
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Deck Panels
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Deck Panels with PMDF
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Deck Panels to Joints
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Overhang Deck Panels with Pockets
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Overhang Deck Panels with Channel
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Overhang Deck Panels with Channel
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Expanding the Use of Precast Concrete in Texas Bridges
Full Depth Panels
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Expanding the Use of Precast Concrete in Texas Bridges
Full Depth Panels
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Expanding the Use of Precast Concrete in Texas Bridges
Full Depth Panels
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Expanding the Use of Precast Concrete in Texas Bridges
MSE Panels
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Expanding the Use of Precast Concrete in Texas Bridges
Existing Concepts
Desire for Expanded Use
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Bent Caps
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Bent Caps
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Bent Caps
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Bent Caps
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Abutments
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Abutments
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Expanding the Use of Precast Concrete in Texas Bridges
Precast Segmental
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Expanding the Use of Precast Concrete in Texas Bridges
New Concepts
Current Implementation
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Expanding the Use of Precast Concrete in Texas Bridges
Long Spans - Existing
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Long Spans – Trending Upwards
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Expanding the Use of Precast Concrete in Texas Bridges
Long Spans – Existing Bridge Construction
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Expanding the Use of Precast Concrete in Texas Bridges
Spliced Precast Girders
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Uniform Cross Section (Non-
Haunched): 225’ – 240’
Haunched: 325’
Curved Tubs: 240’ – 260’
Expanding the Use of Precast Concrete in Texas Bridges
Spliced Precast Girders
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Expanding the Use of Precast Concrete in Texas Bridges
Haunched Section
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Expanding the Use of Precast Concrete in Texas Bridges
Spliced Precast Girders
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Expanding the Use of Precast Concrete in Texas Bridges
Spliced Precast Girders with Haunch
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Expanding the Use of Precast Concrete in Texas Bridges
Spliced Precast Girders with Haunch
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Expanding the Use of Precast Concrete in Texas Bridges
Post-Tension Anchorage Zones
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Expanding the Use of Precast Concrete in Texas Bridges
Post-Tension Anchorage Zones
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Expanding the Use of Precast Concrete in Texas Bridges
Post-Tension Anchorage Zones
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Expanding the Use of Precast Concrete in Texas Bridges
Post-Tension Anchorage Zones
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Expanding the Use of Precast Concrete in Texas Bridges
Cylinder Piling
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Expanding the Use of Precast Concrete in Texas Bridges
Cylinder Piling
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Expanding the Use of Precast Concrete in Texas Bridges
Cylinder Piling
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Expanding the Use of Precast Concrete in Texas Bridges
Innovation and
Unique Applications
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Expanding the Use of Precast Concrete in Texas Bridges
Curved Precast Concrete Tubs
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Expanding the Use of Precast Concrete in Texas Bridges
Curved Precast Concrete Tubs
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Expanding the Use of Precast Concrete in Texas Bridges
Curved Precast Concrete Tubs
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Expanding the Use of Precast Concrete in Texas Bridges
Spliced Concrete Tubs
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Expanding the Use of Precast Concrete in Texas Bridges
Prestressed Concrete Bent Caps
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Expanding the Use of Precast Concrete in Texas Bridges
Unique Precast Applications – West 7th Street Arch
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Expanding the Use of Precast Concrete in Texas Bridges
Unique Precast Applications – West 7th Street Arch
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Expanding the Use of Precast Concrete in Texas Bridges
Graham Bettis, P.E.
TxDOT Bridge Division - Field Operations Section
Construction & Maintenance Group
Office: 512-416-2526
Mobile: 512-658-1231
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