Totally Precast Concrete Bridges

Totally Precast Totally Precast Concrete Concrete BridgesBridges

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Is it possible to Is it possible to design an “Instant design an “Instant Bridge?” Almost! Bridge?” Almost! There are many There are many ways to put a ways to put a bridge together bridge together quickly with quickly with precast concrete precast concrete products. products.

TOTALLY PRECAST BRIDGES -- CASE STUDIES

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The speed and The speed and variety of precast variety of precast prestressed prestressed products and products and methods give methods give designers many designers many options. Consider options. Consider these advantages these advantages of an of an all-precast bridge…all-precast bridge…


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Fast constructionFast construction benefits benefits owner agenciesowner agencies by reducing by reducing the duration of the work zone. the duration of the work zone. Fast construction reduces Fast construction reduces traffic handling costs and traffic handling costs and accident exposure risks. accident exposure risks. There’s less inconvenience to There’s less inconvenience to the traveling public, fewer the traveling public, fewer delays, and fewer motorist delays, and fewer motorist complaints. According to a complaints. According to a report by the Texas report by the Texas Transportation Institute, costs Transportation Institute, costs incurred by drivers passing incurred by drivers passing through a work zone (along through a work zone (along with engineering costs) can be with engineering costs) can be $10,000 to $20,000 per day. A $10,000 to $20,000 per day. A recent Federal report indicates recent Federal report indicates user costs of $50,000 per day user costs of $50,000 per day for work zones in urban areas. for work zones in urban areas.

Benefits to Owner Agencies:Benefits to Owner Agencies:

Reduction in the duration ofReduction in the duration ofwork zoneswork zones

Reduced traffic handling costsReduced traffic handling costsReduced accident exposure risksReduced accident exposure risksLess inconvenience to theLess inconvenience to the

traveling publictraveling publicFewer motorist complaintsFewer motorist complaints


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Contractors benefitContractors benefit from reduced exposure from reduced exposure to traffic hazards. to traffic hazards. More work can be More work can be accomplished in less accomplished in less time, with fewer time, with fewer weather delays. weather delays. Costs are lower for Costs are lower for forms, skilled field forms, skilled field labor, scaffolding and labor, scaffolding and shoring, and cranes.shoring, and cranes.

Benefits to Contractors:Benefits to Contractors:

Reduced exposure to hazardsReduced exposure to hazards

More work -- less timeMore work -- less time

Fewer weather delaysFewer weather delays

Lower costsLower costs

Less skilled laborLess skilled labor


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After foundations have After foundations have been completed, been completed, scheduling can be scheduling can be controlledcontrolled by a single by a single contractor working contractor working with a familiar with a familiar material. material.

Scheduling Control


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Precast concrete Precast concrete structural elements structural elements should always be plant should always be plant produced under produced under carefully controlled carefully controlled conditions…by plants conditions…by plants that are Certified by that are Certified by PCI.PCI.

Plant-produced Elements


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… … so all structural so all structural elements benefit from elements benefit from the excellent the excellent quality quality and corrosion and corrosion resistanceresistance of of prestressed concrete. prestressed concrete.

Quality and Corrosion Resistance


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Fully-cured precast Fully-cured precast concrete structural concrete structural elements can be elements can be stockpiled in stockpiled in advance of needadvance of need… …

Stockpiled in Advance


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……and can be and can be scheduled for “just-in-scheduled for “just-in-time”time” delivery and delivery and erectionerection… …

Immediate Delivery and Erection


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There’s There’s no curing no curing time time required at the required at the jobsite, as with cast-in-jobsite, as with cast-in-place concrete. Bridge place concrete. Bridge piers can be erected in piers can be erected in a day, and beams can a day, and beams can follow immediately. follow immediately.

No Curing Time


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The following photos The following photos illustrate the many illustrate the many products and products and construction methods construction methods that enable very rapid that enable very rapid project completion. In project completion. In addition to the often-addition to the often-used superstructure used superstructure elements of girders and elements of girders and deck slabs, deck slabs, substructure substructure components such as components such as these piers can also be these piers can also be precast. precast.


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Precast concrete piles Precast concrete piles are quite popular in are quite popular in much of the country. much of the country. They come in different They come in different sizes and shapes, sizes and shapes, ranging from 10-inch ranging from 10-inch square piles to 66-inch square piles to 66-inch diameter hollow diameter hollow cylinder piles. cylinder piles.


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Pile caps also can be Pile caps also can be precast concrete, precast concrete, reducing exposure, reducing exposure, forming and curing informing and curing inthe field. the field.


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Piers can be made of Piers can be made of precast concrete precast concrete pieces quickly pieces quickly assembled inassembled inthe field. the field.


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Abutments can also be Abutments can also be made of precast. made of precast.


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The The Sucker Creek Sucker Creek BridgeBridge in Hague, New in Hague, New York, consists of York, consists of precast concrete box precast concrete box beams supported on beams supported on precast concrete precast concrete abutments assembled abutments assembled into a jointless, rigid into a jointless, rigid frame.frame.

Sucker Creek Bridge in Sucker Creek Bridge in HagueHague


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In San Juan, Puerto In San Juan, Puerto Rico, the totally Rico, the totally precast concrete precast concrete Baldorioty de Castro Baldorioty de Castro AvenueAvenue bridges bridges were were built in record-setting built in record-setting time, attractively, and time, attractively, and economically.economically.

Puerto Rico


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Each of four bridges, Each of four bridges, ranging in length from ranging in length from 700 to 900 feet, was 700 to 900 feet, was erected in about 24 erected in about 24 hours. This was well hours. This was well within the owner’s within the owner’s construction allowance construction allowance of 72 hours per bridge, of 72 hours per bridge, a condition established a condition established to minimize disruption to minimize disruption to one of the city’s to one of the city’s highly traveled highly traveled corridors. corridors.

Puerto Rico -A totallyprecast bridge


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In addition to speed, In addition to speed, the bridges also met the bridges also met the city’s budgetary the city’s budgetary needs. The four box-needs. The four box-beam bridges were beam bridges were constructed for $2 constructed for $2 million less than the million less than the next lowest bid for next lowest bid for another material. another material.

Puerto Rico


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Totally precast bridge Totally precast bridge systems may be the only systems may be the only viable solution in harsh viable solution in harsh field conditions. field conditions. The The Confederation BridgeConfederation Bridge connecting Canada’s connecting Canada’s Prince Edward Island to Prince Edward Island to mainland New Brunswick is mainland New Brunswick is such such an example. an example. The bridge spanned the The bridge spanned the eight-mile-wide eight-mile-wide Northumberland strait, Northumberland strait, which experiences severe which experiences severe winters and is covered winters and is covered with ice floes for five with ice floes for five months of the year.months of the year.

Confederation BridgeNew Brunswick, Canada


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Even in such harsh Even in such harsh conditions, precast conditions, precast concrete was able to concrete was able to meet the owner’s meet the owner’s requirements of a requirements of a 100-year service life, 100-year service life, a 3½-year construction a 3½-year construction period, and period, and attractiveness.attractiveness.

Confederation Bridge


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It just makes economic It just makes economic sense to evaluate sense to evaluate conversion of cast-in-conversion of cast-in-place to precast place to precast concrete. This was concrete. This was done for the done for the Edison Edison BridgeBridge in Florida. in Florida. Precast piers and Precast piers and beams were spliced to beams were spliced to produce tall pier bents.produce tall pier bents.

Edison BridgeFlorida


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The state of Texas has The state of Texas has constructed several constructed several bridges with segmental bridges with segmental precast concrete piers. precast concrete piers. The attractive piers and The attractive piers and pier caps are hollow pier caps are hollow members. Some are members. Some are made of high-made of high-performance concrete. performance concrete. Such segments may be Such segments may be match-cast, similar to match-cast, similar to segmental box girder segmental box girder bridges, or separated by bridges, or separated by a thin mortar bed, much a thin mortar bed, much like giant masonry units.like giant masonry units.

Texas - Precast Piers


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In Houston, the In Houston, the Louetta Louetta Road OverpassRoad Overpass utilized utilized precast concrete precast concrete match-cast piers, as match-cast piers, as well as precast, well as precast, prestressed U-beams prestressed U-beams and stay-in-place deck and stay-in-place deck panels.panels.

Louetta Road BridgeTexas


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Another famous bridge Another famous bridge is the is the Sunshine Skyway Sunshine Skyway BridgeBridge over Tampa Bay over Tampa Bay in Florida. The piles, in Florida. The piles, piers and pier caps piers and pier caps were constructed of were constructed of precast concrete precast concrete elements connected elements connected together with post-together with post-tensioning threadbars.tensioning threadbars.

Sunshine Skyway BridgeFlorida


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