SHRP 2 - R04 Innovative Bridge Designs for Rapid Renewal

SHRP 2 - R04 Innovative Bridge Designs for Rapid Renewal

FEHRL Long Life BridgesSQUARE (Brussels)

Thursday June 10, 2010

Objective…

RAPID RENEWAL – Bridge Systems

WHAT IS THE BIG IDEA?

Manufactured Bridges

Off Site

RAPID RENEWAL – Bridge Systems

COROLLARY?

Maximize Off-SiteMinimize On-Site

Off Site

RAPID RENEWAL – Bridge Systems

THINKING LIKE A CONTRACTOR

Off Site

MAXIMIZE Off-Site

WHY?

On Site

MINIMIZE ON-SITE

WHY?

Time – User costs Time – Self Performance Time – Fewer components

Phase 1Define

COMPLETE SYSTEMS Concrete Superstructures Composite Superstructures Eliminate Piles and Caps

Project Overview

Three Phases

Phase 1 – Define Phase 2 – Develop Phase 3 – Demonstrate

Phase 1

PHASE 1 – Define

What has been done? What are the challenges? Feasible concepts (incremental)

Phase 1Define

RAPID RENEWAL – Bridge Systems

As Light as Possible As Simple as Possible As Easy to Erect as Possible

Define

Phase 1 – Lighter

As Light as Possible …

Lighter foundations Lighter equipment

Develop

Phase 1 – Simpler

As Simple as Possible …

Fewer structure elements Fewer field splices Fewer bracing systems

Develop

Phase 1 – Easier

As Easy to Erect as Possible …

Less labor Less CIP Less equipment

ConceptsCategories

Phase 1 - Define Concepts

1. Precast Substructure Systems

2. Complete Superstructure Systems

3. Construction Technologies

Micro-Piles

1a – Foundation Systems

SPER

1b – Precast Shell Systems

On SiteAssembly

1c – Substructure Systems

Offsite Manufacture

2 – Superstructure Systems

2a - Modular beam systems Deck Bulb Tees and Double T’s Decked Girder Stringer systems Decked Box girder systems

2b - Segmental systems Segmental slabs Segmental voided slabs

Modular Systems

2a - Modular Beam Systems

Deck Bulb Tees

FOLDED PLATE - Modular Beam Systems

2b – Segmental Systems Solid Slabs and Voided Slabs

2b - Solid Slabs and Voided Slabs

Solid Slabs and VoidedbsComplete Superstructure Systems

RecommendedConstruction

Concepts

3 – ABC Construction Systems

Methods Launching, Sliding and Lateral shifting

Equipment Wheeled carriers / SPMT Straddle carriers Erection girders

RecommendedConstruction

Concepts

Methods Launching,

Segmental and Slab Systems

Incrementally Launched Slab

RecommendedConstruction

Concepts

Methods Launching, Sliding and Lateral shifting

Lateral Slide

Phase 1Define

3 – Construction Systems

Tier 1 Weekend closures

Tier 2 Completed in a few weeks

Tier 3 Save weeks and/or months on the overall schedule

RecommendedConstruction

Concepts

3 – ABC Construction Systems

Equipment

Wheeled carriers / SPMT Straddle carriers Erection girders

GantrySystems

UNIVERSAL ERECTION GANTRY Piles Substructure units Superstructure units Overlay

Courtesy Flatiron Construction

Washington Bypass

Courtesy Flatiron Construction

Pile driving, precast cap erection, precast beam erection, all from the rear.

Averaging 1 complete span per week

GantrySystems

Gantry Systems

Step 1 – Deliver Gantry and Set-UpStep 2 – Remove Existing Step 3 – Erect New

Carrier delivers erection gantry Secondary vehicles deliver beams / units

ADC’s

ABOVE DECK CARRIER SYSTEMS - (ADC’s)

ADC’s

ADC Removal

Stages

ADCErection

Stages

Phase 3

PHASE 3 – WORK PLAN

Part 1 – ABC Tool Kit of Design Standards

Part 2 – Construct Demonstration Project

Part 3 – Specifications for ABC

Part 4 – ABC Training Materials

Iowa ABC Demonstration ProjectTier 2 - Two week closure

US 6Bridge over Keg Creek

Council BluffsIowa

Outside Existing

Footprint

Substructures ConstructionOutside existing footprint

Stage 1 Work (prior to closure) Construct drilled shafts to ground level Construct wingwalls on piles

Stage 2 work (during 14-day “ABC” period) Close bridge/enact detour Demolish existing bridge Assemble precast columns/capbeams Assemble semi-integral abutments

Precast Columns and Cap

Stage 2 work (cont’d) Straddle existing substructures and

Modular Deck

Modular SuperstructureOff site

Demo Bridge

Sequence

Stage 3 work (during 14-day “ABC” period) Assemble modular superstructure Cast UHPC closure joints Re-open bridge to traffic

Connection Details

Deck Joint

Connection Details

Abutment Joint

Phase 3

PHASE 3 – WORK PLAN

Part 1 – ABC Tool Kit of Design Standards

Part 2 – Construct Demonstration Project

Part 3 – Specifications for ABC

Part 4 – ABC Training Materials

Phase 3

TOOL BOX of ABC STANDARD SOLUTIONSPre-Engineered Solutions

Bridge Concepts

Staging Concepts

Equipment Concepts

CONCLUSIONS

What Have we Learned So Far?

Project Schedule

Conclusions

LESSONS LEARNED?

Lesson 1 - About Innovation?

Lesson 2 - About Changes and Challenges?

Lesson 3 - About Implementation?

Conclusions

What have we learned so far?

Lesson 1…About Innovation

Incremental is essential Out of the box is good Recognize the Lag

Conclusions

What have we learned so far?

Lesson 2 … About Challenges?

Least initial cost vs best value (Owners) Self-performance (Contractors) Reluctance to change (Designers)

Conclusions

What have we learned so far?

Lesson 3 … About Implementation?

Collaboration (ATC – DB) Construction – Value

The EndLa FIN

Avez-Vous des Questions?