ABC By 2010

UTAH
ABC by 2010
Department of Transportation
ACCELERATED
• UDOT goals
BRIDGE CONSTRUCTION BY 2010 – Accelerated Bridge Construction
• Standard practice by 2010
How have we done? • What was needed?
Fred Doehring
– Methods of construction
UDOT Structures
– Standard details
– Commitment to a program

Vision for “Family” of ABC Methods ABC Phase 1

• Early implementation of ABC
Accelerated – Scanning Tours
Bridge
Construction • Looked at what other states were doing
– Workshops held
• Brought all stakeholders together
Precast Modular Structure Accelerated Fast Track
Concrete
Elements
Construction
Large Prefab.
Placement
Methods
Geotech
Work
Contracting
CMGC
• Identified what was needed
Components Design/Build
Prefabricated
Components
SPMT
Sliding
Geofoam
• Prioritized needs
• Looked at several specific pilot projects

ABC Phase 1 ABC Methods Used

• Results of Phase 1 work
– Several key standards were • Precast Deck Panels
developed • Voided Slabs
• Precast Full Depth Deck Panels
• Precast Substructures
• Manual on Self Propelled Modular
Transporters (SPMT’s) – Abutments and Bent Caps
• Development of specifications • Precast Superstructures
and manuals for each
– Crane, Sliding, and SPMT
• Several pilot projects initiated and
built

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 ABC By 2010

Precast Deck Panels - Full Depth Precast Deck Panels - Full Depth

Precast Deck Panels - Full Depth Precast Deck Panels - Full Depth

Precast Deck Panels - Full Depth Precast Deck Panels - Full Depth

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 ABC By 2010

Precast Deck Panels - Full Depth Precast Deck Panels - Full Depth

Voided Slabs Voided Slabs

Precast Substructure Precast Substructure

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 ABC By 2010

Precast Substructure Precast Substructure

Precast Superstructure - Crane Precast Superstructure - Crane

Precast Superstructure - Sliding Precast Superstructure - Sliding

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 ABC By 2010

Precast Superstructure - SPMT Precast Superstructure - SPMT

Precast Superstructure - SPMT Precast Superstructure - SPMT

Precast Superstructure - SPMT Precast Superstructure - SPMT

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 ABC By 2010

Precast Superstructure - SPMT Precast Superstructure - SPMT

UTAH
ABC Phase 2
Department of Transportation
• Standardized the remainder of prefabricated
ACCELERATED element types
BRIDGE CONSTRUCTION BY 2010
• Developed details for:
– Precast substructures
• Piers, Abutments, walls, culverts
Where are we going? – Precast Approach slabs
– Precast Girders
• Pre-tensioned Bulb Tees
Michael Culmo
• Post-Tensioned Bulb Tees
CME Associates, Inc.
• Deck Bulb Tees
• Developed Specifications and Manuals
• Workshops were held for industry input

Connections with Grouted Splice Couplers

ABC Phase 2
• Emulates a reinforcing steel lap splice
• Other work completed in Phase 2 • Used in precast parking garages and
– Reviewed computer monitoring data from first stadiums and bridges
round of SPMT bridge moves • New seismic research coming
– Refined Phase 1 work based on lessons
learned in construction
• Deck Panel standards and specifications
• SPMT Manuals

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 ABC By 2010

Connections with Grouted Splice Couplers

Typical Connection Details
Installation video on Youtube
Search “Georgia Bridge Pier” Column or wall panel
to footing connection

Typical Connection Details Current Typical Details

• Single column hammerhead
Column to cap
connection • Two column bent
• Three column bent

Current Typical Details Current Typical Details

Columns Footings
• Rectangular are possible, • Full Precast
but not preferred
• Round columns are difficult – For smaller footings
to precast
– Must be cast vertically
• Use Hexagonal or
octagonal shape
– Can be cast on side
(one side open)
Shim and grout under footing
through ports in footing

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 ABC By 2010

Current Typical Details Current Typical Details

Footings Pile supported
• Partial Precast footings
– For larger footings • Use corrugated
– Precast designed to support
DL of bridge
pipe forms
– CIP extensions designed for • Used for integral
other loads abutment stems
Precast Portion
also
CIP Extension

Shim and grout under footing

through ports in footing

Pretensioned Bulb Tee Girders Pretensioned Deck Bulb Tee Girders

Post-tensioned Bulb Tee Girders Integral Abutment Details

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 ABC By 2010

Cantilever Abutments and Walls Stage 1

• Use corrugated pipes in stems to reduce weight
– To be filled with concrete in the field
– Reduces the number of pieces

1. Drive Piles

Stage 2 Stage 3

1. Install pier wall panels. (day 4)

2. Connect to footing via grouted
1. Place footings over pile and set
splice couplers (day 4)
to grade and alignment (day 1)
3. Fill voids with concrete to within
2. Cast concrete in voids around
3 feet of top (day 5)
piles (day 1)
4. Install rebar cage in top of voids
3. Cast concrete between footings
extending 2 feet above (day 5)
if required (day 2)
5. Joints between may be grouted
or left dry

Stage 4 Final Construction

1. Install pier cap, set to grade

(day 6)
2. Pour concrete through ports
to fill voids and make
connection (day 7)
3. Install precast beam seats
(day 7)

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 ABC By 2010

Box Culverts Tolerances

• Precast boxes, aprons, and walls
• Tolerance details developed for all critical
elements
• Based on PCI Tolerance manual
– MNL-135-00

Tolerance Details Tolerance Details

Splice couplers Columns

Precast Full Depth Deck Panels
• First Generation Standards completed in
Phase 1 UDOT ABC Program
• More than 15 project built to date
Precast Full Depth Deck Panels
• Phase 2 Modifications
– Use Longitudinal Post-Tensioning to Connect Panels
• AASHTO Code Recommendation
• Better performance over time (no leakage through joints)

• Costs are coming down – Use multi-strand PT systems

• Developed for slabs
• Welded plate details are not desirable • More Flexible
– Time – Allow blind pockets for shear stud connection
• Based on recent research
– Leakage issues at joints
– Allow skewed deck panels (up to 15 degrees)
• There is new technology in the market

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 ABC By 2010

Precast Full Depth Deck Panels Blind Pocket Project – Texas DOT

• Recommended Post-tensioning System

– Multi-strand deck PT systems
– Developed specifically for decks (thin anchorage)
– Used by other states
– Recommend the use of less than maximum amount
of PT allowed in the ducts (4-0.5” strand)

UDOT Blind Pocket Details

Schematic Construction Details

2 Span Bridge using UDOT Standards

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 ABC By 2010

Excavate and Install Piles Install Abutment Stem and Footings

Typical 2 Span Bridge Typical 2 Span Bridge

Install Pier Columns Install Pier Cap and Wingwalls

Fill Voids in Abutment Stems Cast Footing Closure Pour

Typical 2 Span Bridge Typical 2 Span Bridge

Erect Girders Install Backwalls and Sleeper Slabs

Typical 2 Span Bridge Typical 2 Span Bridge

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 ABC By 2010

Install Deck Panels and Approach Slabs Cast Deck and Approach Slab Closure Pours

Typical 2 Span Bridge Typical 2 Span Bridge

Construction Roadway Approaches Bridge Monitoring (TAC)

• Volunteer group of key stakeholders

– UDOT
– Design Consultants
– Contractors
– Industry Representatives
• Charged with review of data and
recommendations for future SPMT bridge
moves
• Used computer monitoring data from 2008
Typical 2 Span Bridge

Bridge Monitoring (TAC) Bridge Monitoring (TAC)

• Data retrieved Temperature Strain

– Mostly strain data (deck, girders)

– Layouts were similar on each bridge
Dynamic Strain
– Used to study the stresses within the bridge during:
• Lifting
• Moving
Lifting Strain
• Placement
• Utah State University (USU)
– Brought in to analyze and disseminate the data
– With input from the TAC Typical Data

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 ABC By 2010

Bridge Monitoring (TAC) SPMT Manual Revisions

• Final Findings and Recommendations • Build on knowledge gained in 2008
– Lifting stresses are very significant
• Supporting the deck at the lift points eliminated most deck cracking • No major changes
• Lift bridge closer to ends (0.2L or less)
• Lightweight concrete in the deck helps to reduce deck cracking, and
• Define roles of project participants
overall lift weight
• Written to fit in with the UDOT Design
– Dynamic effects can be approximated by increasing dead load
by 15% Network
• Starting and stopping of SPMT’s
• Traversing bumps during the move
– 3d Analysis is needed to estimate lifting stresses if a flexible
carrying beam is used
– Recommended future gaging locations

SPMT Lifting Methods Lessons Learned

• Neg. DL moment on girder
• May be a problem with
prestressed girders
• Light weight concrete could
help
• Little or no deck cracking
• Deck is pre-compressed in
final condition
• Study of Performance of ABC Bridges
• Bridge Types Studied
– Full Depth Deck Panels with welded tie connections
(6)
– Full Depth Deck Panels with Post-Tensioning (2)
– Precast Parapets integral with deck (5)
– SPMT Bridge Moves (9)
• Neg. DL moment on – Precast Abutments (2)
composite section
• Significant deck cracking is – Precast Piers (2)
possible
• Light weight concrete could
• Inspections took place in May, 2009
help

Lessons Learned Lessons Learned

Project locations • Purpose of the study
Milepost 200 on Route 6
not shown – Investigate the performance of each
component type
– What is performing well and what is not
– Not intended to critique past designs
• Most of these bridges were designed prior to
development of standards
• Many were designed as short term fixes prior to full
replacement in the near future (10-25 years)
– Goal: Continuous Improvement of Quality

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 ABC By 2010

Lessons Learned Lessons Learned

• Welded Tie Connections • Welded Tie Connections
– Joint Leakage is widespread
– Shear transfer is still working
– Composite connection is good

Lessons Learned Lessons Learned

• Welded Tie • Welded Tie Connections
Connections

Lessons Learned Lessons Learned

• Post Tensioned Connections • Post Tensioned
– 3 span continuous bridge Connections
– No Joint Leakage
– Even in negative
moment areas

Underside of deck
I-215 at 3900 South

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 ABC By 2010

Other Long Term Performance Information Project Information

• Curved structure (straight beams)
• I-84/Route 8 Interchange –Waterbury, CT • 6 Span bridge with continuous spans
• Single lane
• Prestressed transversely and post tensioned
longitudinally
• Details similar to UDOT
• 42 Day construction
• No construction problems
• Built in 1991

After 18 years of service After 18 years of service

• Excellent condition
• Used membrane waterproofing and Asphalt Wearing
surface
• No leakage through joints

Another long term example project Lessons Learned

Route 8 Viaduct, Seymour, CT • Precast parapets integral with precast
• 2 Curved structures decks
• Over 50 spans (all simple spans) – Most are good
• Prestressed and post tensioned – Problem with panels cast with 2 parapets
• Weekend closures only
• No transverse adjustment during installation
• Old deck removed on Friday night
• New deck erected on Saturday
morning
• Post tensioned on Saturday night
• Grouting on Sunday morning
• Open to traffic Sunday night
• Asphalt wearing surface with
waterproofing membrane
• In service for 15 years
• Excellent condition

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 ABC By 2010

Lessons Learned Lessons Learned

• Precast Abutments
– Few have been built
• Horizontal joints (Lego bridges)
• None built to new standards yet
• There were significant fit-up
problems on one bridge
– Can be resolved with
appropriate casting tolerances
• Performing well

Lessons Learned Lessons Learned

• Precast Piers
– Few have been built
• None built to new standards yet
– One is similar
• Construction went well
• Performing well

Lessons Learned Lessons Learned

• SPMT Bridge Moves
– Deck cracking is common
– Exceptions:
• Bridges cast while supported at lift points
• Lightweight Concrete Deck
– Some leakage through cracks
– Performing well

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 ABC By 2010

Lessons Learned Lessons Learned

Lessons Learned Lessons Learned

• Cast-in-place closure pours
– Some have significant shrinkage
cracks
• Restraint of adjacent panels
• Some leakage through cracks

Lessons Learned Lessons Learned

• Shear Connector Pockets
– Several have minor leakage
around pockets (not all)
• Shrinkage of Grout
• Blind pockets should alleviate this

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 ABC By 2010

Lessons Learned Lessons Learned

• Recommendations
– Full Depth Deck Panels
• Eliminate welded tie detail
• Always use post-tensioning
• Use blind pocket detail for shear connectors
• New Standards address these recommendations

Lessons Learned Lessons Learned

• Recommendations • Recommendations
– Precast integral parapets – Precast Abutments and Piers
• Do not use 2 per panel • Use vertical joints in abutment stems and wall
stems
– Use a longitudinal closure pour in deck to allow for
– Allows for easier fit-up in the field
adjustment in the field
• No problems noted with pier construction
– Cast one or both in the field behind temp. barriers
• New Standards address these recommendations

Lessons Learned Lessons Learned

• SPMT Moves • Other general recommendations
– TAC Committee work verifies issues found in – Overlays
the field • Consider thicker overlay with a quality
• Pick bridges closer to ends waterproofing membrane
• If possible, support girders at lift points during – European and East Coast Systems
deck casting – CME recommendation, not UDOT policy
• Investigate the use of lightweight concrete to – Closure Pours
reduce deck and girder stresses • Use a better high early strength concrete mix
• New SPMT Manual will address these – Shrinkage compensating mixes
recommendations – NY State mix is being investigated

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 ABC By 2010

Where are we going? Where are we going?

• UDOT Themes • Implementation of Phase 2 Standards
– Accelerate Delivery – Training
• Design and Construction • Designers
– Decrease MOT • Construction Inspectors
• Reduce User Costs and impact to society • Bridge Inspectors
– Encourage Innovation • Bridge Maintenance Personnel

– Get a good price – On-call technical support

Where are we going? Where are we going?

• Manuals
– Develop a Bridge Design Manual
– New SPMT design guide to be issued
• Lightweight Concrete
– SPMT Decks (minimize deck cracking)
– Substructure Elements (reduce shipping and
handling costs)
• Continue to monitor progress
– Annual inspection of ABC Bridges
– Address issues as they arise
• Goal:
Continuous Improvement

Questions? Testing data

This presentation will
be posted on the
UDOT website

Grouted Splice coupler @ end of column

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 ABC By 2010

Testing data

Control Column w/o Grouted Splice Coupler

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