Segmental Bridge Construction

Plans Review Group p SegmentalBridgeConstruction g g
Structures Design
SegmentalBridges Itsa Segmental Bridges Its a ConstructionTechnique withDesignImplications

2010 FDOT/FTBA Construction Conference February 23-24 Orlando, Florida
Structures Design
Plans Review Group p PresentationSpeakers Presentation Speakers BrianBlanchard,P.E. Brian Blanchard P E

FloridaDepartmentofTransportation
EnriqueEspino,P.E. Enrique Espino P E

Condotte America,Inc.
JimSchneiderman,P.E.
PCLCivilConstructors,Inc.
R.CraigFinley,Jr.,P.E.
FinleyEngineeringGroup,Inc. y g g p,
Structures Design
g Plans Agenda Review Group p

FloridaDepartmentofTransportations Perspective,BrianBlanchard,P.E., Perspective, Brian Blanchard, P.E., FloridaDepartmentofTransportation ContractorsPerspective EnriqueEspino,P.E.,Condotte America,Inc. d JimSchneiderman,P.E.,PCLCivilConstructors Design and Construction Engineers DesignandConstructionEngineers Perspective R.CraigFinley,Jr.,P.E., R. Craig Finley, Jr., P.E., FinleyEngineeringGroup,Inc. FuturePerspective, EnriqueEspino,P.E.,Condotte America,Inc. RoundTableQ&A
February 23, 2010 FDOT/FTBA Construction Conference
FDOT Structures Perspective Design
Segmental Bridge Construction g g Plans Review Group p
Roosevelt Bridge
SegmentalBridges Itsa ConstructionTechniquewith Construction Technique with DesignImplications

Brian Blanchard P.E. Chief Engineer Florida Department of p Transportation
FromtheFloridaDepartmentof TransportationsPerspective
Skyway Bridge
FromtheFloridaDepartmentof From the Florida Department of TransportationsPerspective

HistoryofSegmentalBridgesin Florida FDOTPoliciesandProcedures FDOT Policies and Procedures ExperienceandFutureTreads

Royal Park Bridge
HistoryofSegmentalBridgesin Florida
1981
Span-by-span Balanced Cantilever
1982
1983
hannel Niles Ch
History of Segmental Bridges in Florida The Early Years

Seven Mile M Channe 5 el Long Key K Bridge
1984
Ram I mp Over I-75
All dates given are completion dates
History of Segmental Bridges in Florida The Early Years
Long Key Bridge id Niles Channel Channel 5
Seven Mile

Sk kyway Ap pproach hes
- The Early Years (cont.)

Span-by-span Balanced Cantilever
All dates given are completion dates g ve a e co p et o
1985
1986
I-75/SR 826 8 ( (5 Bridg ges) I-595/I-75 (5 ( Bridg ges)
1987
Ft. Lauderda ale Airpo ort (4 Bridge 4 es)
1988
I-5 595/US 441 4 ( (2 Bridg ges) I-595/I-75 (6 ( Bridg ges)
Segmental Bridge Construction g g Plans Review Group p Long Key Bridge g y g

First application of Precast Span-byspan Bridge Construction in the U.S.
1981
Seven-Mile Bridge
First Application of an Overhead Gantry in Florida y
1982
Ramp I Bridge
First application of Precast Balanced Cantilever Construction in Florida
1984
- Other Firsts
First Demolition of Existing Segmental Bridge in the North America. Fort Lauderdale-Hollywood International Airport expansion required the removal of three precast q p segmental concrete bridges. How did we demolish segmental concrete bridges built by the balancedcantilever method? By reversing the way the segments were i h installed. ll d
2002
- Other Firsts
I-75/ SR 826 Ramp A -First Segmental Bridge p g g Widening in U.S. Mainland
2004

12

FDOT Segmental Bridges Constructed by Year g g y
10
0 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006
Current Number of Segmental Bridges 68

(3 have been removed at Ft. Lauderdale Airport)
Acosta Bridge
FDOT Policies and Procedures

Segmental Bridge Construction g g Plans Review Group p FDOT Policies In Response to PT Corrosion Issues

Advanced Corrosion of Strands within Niles Channel Anchorage
FDOTBridgesw/Grout Problems
Niles Channel Bridge
6BridgesatI75&I595 (VoidsinTendons) 1996Inspection

NilesChannel (FailedTendon) (Failed Tendon)
1999Inspection
Skyway Bridge
FDOTBridgesw/Grout Problems(cont.)
Midbay(Spans28and57 ( 2 FailedTendons)
2000Inspection

SkywayApproach(Failed TendonPier133N) Tendon Pier 133 N)

2000Inspection

New Directions for Florida Post-Tensioned Bridges
Corven Engineering, Inc. g g, February 15, 2002


2Policy Revisions y
Specify Minimum Layers of Protection Develop Anchorage Protection Standard Details and QPL Pour-back Materials Develop P.T. Redundancy Requirements Refine Grouting P R fi G ti Procedures d
Seabreeze Bridge

Pre-approved P.T. Systems Qualified Grouting Personnel/ Inspectors Specify Low-Point-Up Grouting Specify Non-bleed QPL Bagged Grouts Specify Inspection Access Points
Dodge Island Bridge
Experience and Future Trends


Experience and Future Trends Segmental top-down construction techniques are cost effective on large waterway projects where insurance and labor rates are governed by time working from barges. Larger projects generally make segmental construction more cost effective due to the casting yard setup cost being spread over more segmental units and when the amount g of work is sufficient to overcome learningcurve inefficiencies.
Hathaway Bridge


Experience and Future Trends (cont.) Segmental alternatives have been competitive against steel box options where p g p the number of segmental units is sufficient (g (greater than 600-700 units). ) Segmental options have not been competitive on small projects when bid against simple span prestressed beam options.
Royal Park Bridge


Future Trends Customized Overhead Gantries Allowing C il All i Cantilever Construction on Curved C i C d Ramps Greatly Reducing Traffic Disruptions y g p
Example: Palmetto Section 5
Roosevelt Bridge

Brian Blanchard P.E. Chief Engineer Florida Department of p Transportation Transverse Deck Beam
Future Trends Greater Use of Combined Steel and Concrete to Reduce Weight?
Core Segment
External Strut + Rib Precast Panel Example: Yamakiri Viaduct (Japan)
Future Trends National Post-Tensioning Specification p PTI is currently developing a nationwide p y p g posttensioning specification based largely on FDOT specifications, research and past experiences.

S.E. 17th Street Bridge
Contractors Structures Perspective Design
Plans Review Group SegmentalBridgeConstruction g SegmentalBridgeConstruction g g g p
Enrique I. Espino, P.E. President Condotte America, Inc.
Jim Schneiderman, P.E. Construction Manager PCL Civil Constructors, Inc. February 23, 2010 FDOT/FTBA Construction Conference
SegmentalBridges ItsaConstruction TechniquewithDesign Technique with Design Implications

TheContractorsPerspective

Types of Segmental Bridges and TypesofSegmentalBridgesand Characteristics
P Precasting S ti Segments t
Superstructures&Substructures
ErectingPrecastSegments
Superstructures&Substructures
CastinPlacewithFormTravelers
TypesofSegmental Bridges andCharacteristics and Characteristics

JimSchneiderman,P.E. Jim Schneiderman P E PCLCivilConstructors,Inc.
Structures Design
Types of Segmental Bridge Structures TypesofSegmentalBridgeStructures

PrecastSpanbySpan Precast Balanced Cantilever PrecastBalancedCantilever PrecastProgressivePlacement C t i Pl CastinPlaceBalancedCantilever B l d C til CastinPlaceIncrementalLaunching C CastinPlace&PrecastCableStayed i Pl &P C bl S d
Structures Design
Precast Span by Span PrecastSpanbySpan
ErnestF.LyonsBridge Stuart,FL
(PhotocourtesyofPCLCivilConstructors,Inc.)
Structures Design
Precast Balanced Cantilever PrecastBalancedCantilever
JohnRinglingCauseway S J h Ri li C Sarasota,FL t FL
Structures Design
Precast Progressive Placement PrecastProgressivePlacement
Temp.Support
LinnCoveViaduct BlueRidgeParkway,NC
(PhotocourtesyofFigg EngineeringGroup)
Structures Design
Precast Progressive Placement (cont ) PrecastProgressivePlacement(cont.)
Temp.Support
Structures Design
CastinPlace Balanced Cantilever Cast in PlaceBalancedCantilever
FormTraveler
FoothillsParkwayBridges SmokeyMountains,Tennessee
(PhotoCourtesyofPCLCivilConstructors,Inc.)
Structures Design
CastinPlaceBalancedCantilever(Cont.) Cast in Place Balanced Cantilever (Cont )
Structures Design
Cast in PlaceIncrementalLaunching CastinPlace Incremental Launching

LaunchingDirection CastingBed
LaunchingNose
Structures Design
Precast & CIP Segmental Cable Stayed Precast&CIPSegmentalCableStayed
SunshineSkywayBridge Tampa,FL
(PhotocourtesyofFigg EngineeringGroup)
Structures Design
PrecastandCast in PlaceCableStayed(cont.) Precast and CastinPlace Cable Stayed (cont )

Pylon StayCable Deck
Plans Review Group SegmentalBridgeConstruction g g p
Precasting Segments Superstructures&Substructures EnriqueEspino,P.E. Condotte America,Inc.

Enrique I. Espino, P.E. President Condotte America, Inc. February 23, 2010 FDOT/FTBA Construction Conference
ErectingPrecastSegments Superstructures& Substructures

JimSchneiderman,P.E. Jim Schneiderman P E PCLCivilConstructors,Inc.
Structures Design
Precast Segmental Bridge Erection Techniques PrecastSegmentalBridgeErectionTechniques

SpanbySpanErectionMethods Balanced Cantilever Erection Methods BalancedCantileverErectionMethods ErectionofSegmentalSubstructures
Structures Design
SpanbySpanErectionMethods
TopDownerectionusingunderslungtrussandsegmentlifter
SegmentLifter
Underslung Truss
TrussSupports
ErnestF.LyonsBridge Stuart,FL
(PhotoCourtesyofPCLCivilConstructors,Inc.)
Structures Design
Overhead Erection Truss OverheadErectionTruss
SeattleSoundTransitLightRailProject Seattle,WA
Structures Design
SpanbySpanErectionMethods OverheadErectionTruss Overhead Erection Truss

Overhead ErectionTruss
C&DCanalBridge Delaware(PhotocourtesyofFigg EngineeringGroup)
Structures Design
SpanbySpanErectionMethods p y p
ErectedonFalsework usingconventionalcranes
Falsework
(PhotocourtesyofFlatironConstructors,Inc.)
Structures Design
Lifti LiftingofEntireSpanatonce f E ti S t
JamestownBridge RhodeIsland(PhotoCourtesyofFigg EngineeringGroup)
Structures Design
TypicalBalancedCantileverErectionMethods yp
Structures Design
BalancedCantileverErectionMethods
CraneErectionfromGround
CraneErectionfromBridgeDeck
Structures Design
Erectionusingabeamandwinch
OaklandBayBridge Oakland,CA
(PhotocourtesyofFlatironConstructors,Inc.)
Structures Design
ErectionusingoverheadErectionTruss
Otay RiverBridge SanDiego,CA

(PhotocourtesyofInternationalBridgeTechnologies)
Structures Design
SegmentalSubstructures
SequenceofErection:
PlaceandGroutSegmenttofootingKeway Erectremainingsegmentstoapredetermined elevation(usuallybasedonstability). elevation (usually based on stability) PerformintermediateP.T.tomaintainpier stability Afterallsegmentshavebeenerected, permanentPTisperformed(usuallyloop permanent PT is performed (usually loop tendonsthroughfooting) Tendonsarethengrouted.
TypicalPrecastColumnSegment
Keyway
SplashZoneRequirements:
Manystatesdonotallowprecastsubstructure elementstobeusedwithinthesplashzone.Above theSplashZone,precasterectioncanbegin.
KeywayinFootingtoAlign/StressfirstSegment
Structures Design
SegmentalSubstructures g
C&DCanalBridge
HooverDamBypass
Structures Design
SegmentalSubstructures g
StressingVerticalColumnTendon
Structures Design
When does Precast Segmental Substructure WhendoesPrecastSegmentalSubstructure makesense?

Whenyouhavealargevolumeproductionoftypicalpiershapes y g p yp p p Whenhighqualityconcreteandgeometrycontrolofthepiersis extremelyimportant When there is a long lead time for foundations that allows fabrication Whenthereisalongleadtimeforfoundationsthatallowsfabrication ofpiersegmentsconcurrentlywithfoundationwork * The major advantage of precasting substructure segments is the Themajoradvantageofprecasting substructuresegmentsisthe speedoferection,whichsurpassesanyotherconventionalmethodof pierconstruction.
Structures Design

ScheduledSeminars: Scheduled Seminars : February1718 Denver,Colorado June2223 Orlando,Florida
ForMoreInformation,PleaseGoTo: http://www.asbiassoc.org http://www asbi assoc org
Cast in Place CastinPlace withFormTravelers EnriqueEspino,P.E. Condotte America Inc America,Inc.

Enrique I. Espino, P.E. President P id Condotte America, Inc. February 23, 2010 FDOT/FTBA Construction Conference
SegmentalBridges Segmental Bridges ItsaConstructionTechnique withDesignImplications ith D i I li ti
Structures Design
Plans Review Group p
Design and Construction Engineers g g Perspective

R. Craig Finley, Jr., P.E. Managing Principal FINLEY Engineering Group, Inc. February 23, 2010 FDOT/FTBA Construction Conference
R.CraigFinley,Jr.,P.E. R. Craig Finley, Jr., P.E. FinleyEngineeringGroup,Inc.
Structures Design
Plans Review Group p DesignandConstructionEngineersPerspective g g p Presentation Outline

KeyPointstoUnderstandingSegmental MyBackground&Perspective ImportanceofProjectProcurement EngineeringRoles&Responsibilities p SpecialConsiderations
Structures Design
Plans Review Group p DesignandConstructionEngineersPerspective g g p Key Points to Understanding Segmental Segmentalbridgesarebasedona constructiontechniquethathas designimplications. Knowhowtobuilditbefore startingtodesignit. g g
Structures Design
Plans Review Group p DesignandConstructionEngineersPerspective g g p Background

Abridgeengineer,aFloridaPEand FTBAmember b Involvedwithsegmentalbridges continuouslysince1979 continuously since 1979 WorkingintheUSAandinternationally StartedinFloridaontheKeysandnow doingSR826/836Interchange
Structures Design
Plans Review Group p DesignandConstructionEngineersPerspective g g p Perspective

Asadesignerandconstructionengineer Preferenceforcontractordrivenand design/buildprojects Typically involved with the bid Typicallyinvolvedwiththebid
Thebestapproachisnotalwaysthesame foreveryoneoreveryproject.
Structures Design
Plans Review Group p DesignandConstructionEngineersPerspective g g p Importance of Project Procurement Threewaystodoit:

Design Bid Build g Design Build Afterthefact ValueEngineeringor ConstructionModification Differentapproachesto ff pp incorporateconstructionmethods
Structures Design
Plans Review Group p DesignandConstructionEngineersPerspective g g p Design Bid - Build

Genericdesign manyassumptions Codebased notconstruction methodsorschedule Willbereworkedbyconstruction engineerbeforeitcanbebuilt Multiplesteps/approvals
Procurement
Structures Design
Plans Review Group p DesignandConstructionEngineersPerspective g g p Design - Build

Specificdesign knownconstruction method Betterinitialoptimizationandfaster process Moreefficient bestresults Responsibilityiswhereitneedstobe
Procurement
Structures Design
Plans Review Group p DesignandConstructionEngineersPerspective g g p Value Engineering / Construction Modification Construction Modification
Combinationapproach Combination approach Usedforanadvantage Hasbeenverysuccessful Has been very successful Morecommonintoughtimes
Procurement
Structures Design
Plans Review Group p DesignandConstructionEngineersPerspective g g p Engineering Roles & Responsibilities DesignEngineer

OwnerClient
ConstructionEngineer
ContractorClient
ValueEngineering/DesignBuild
Structures Design
Plans Review Group p DesignandConstructionEngineersPerspective g g p Design Engineer

Worksfortheowner Typicalscope
Design Drawings Specifications Costestimates
Basedonanassumedschedule andmeans&methods d & h d

Roles & Responsibilities
Structures Design
Plans Review Group p DesignandConstructionEngineersPerspective g g p The Design Engineer provides post-design services services.
R i Reviewsandapprovesconstruction d t ti engineering Based on actual construction engineering Basedonactualconstructionengineering
Takestime Inefficient Personalitiesinvolved
Structures Design
Plans Review Group p DesignandConstructionEngineersPerspective g g p Construction Engineer

Worksforcontractor Typicalscope
Integratedshopdrawings Constructionanalysisandcamber Temporaryworks/specialequipment Geometrycontrol l Posttensioningsupport
Structures Design
Plans Review Group p DesignandConstructionEngineersPerspective g g p The Construction Engineer does the detailed design design.
Performs time dependent, step by Performstimedependent,stepby stepanalysis Incorporatesscheduleandsequence p q Analyzesmeansandmethods Usessophisticatedsoftwareandis Uses sophisticated software and is verydetailed
Structures Design
Plans Review Group p DesignandConstructionEngineersPerspective g g p Value Engineering and Design - Build

InVEprojects,thereisoverlap betweenthedesignandconstruction engineers. engineers With D i B ild th d i WithDesignBuild,thedesignand d constructionengineerarethesame.
Structures Design
Plans Review Group p DesignandConstructionEngineersPerspective g g p Special Considerations

TheConstructionMethodDictatesDesign
TakesmoreengineeringtoBid&Build q g p g Requireshighlevelofplanningand coordination Callsforafactory/assemblylinementality Isoptimumindesign/build
Structures Design
Plans Review Group DesignandConstructionEngineersPerspective g g p p
Managing Principal
Structures Design
Plans Review Group p
Design and Construction Engineers g g Perspective

R. Craig Finley, Jr., P.E. Managing Principal FINLEY Engineering Group, Inc. February 23, 2010 FDOT/FTBA Construction Conference
R.CraigFinley,Jr.,P.E. R. Craig Finley, Jr., P.E. FinleyEngineeringGroup,Inc.
Structures Design
SegmentalBridgeConstruction Plans Review Group p FuturePerspective Future Perspective

More designbuild & experienced Moredesign build&experienced Contractors. Standardization of precast segments Standardizationofprecastsegments Supplylikeprestressedgirders. Higherstrengthandcomposite materials. Nationalspecificationsformaterials andtraining. g
Structures Design
SegmentalBridgeConstruction Plans Review Group p FuturePerspective Future Perspective

More sophisticated erection Moresophisticatederection equipment. Rehab market will develop Rehabmarketwilldevelop. 100+yearservicelife durability.
Structures Design
SegmentalBridgeConstruction Plans Review Group p RoundTableQ&A Round Table Q & A

Florida Department of Transportations FloridaDepartmentofTransportation s Perspective,BrianBlanchard,P.E.,Florida DepartmentofTransportation ContractorsPerspective EnriqueEspino,P.E.,Condotte America,Inc. q p , , , JimSchneiderman,P.E., PCLCivilConstructors,Inc. DesignandConstructionEngineersPerspective
February 23, 2010 23 FDOT/FTBA Construction Conference
g y y g g p R.CraigFinley,Jr.,P.E.,FinleyEngineeringGroup

Segmental Bridge Construction

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Segmental Bridge Construction

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Plans Review Group p SegmentalBridgeConstruction g g

SegmentalBridges Itsa Segmental Bridges Its a ConstructionTechnique withDesignImplications

Plans Review Group p PresentationSpeakers Presentation Speakers BrianBlanchard,P.E. Brian Blanchard P E

EnriqueEspino,P.E. Enrique Espino P E

g Plans Agenda Review Group p

February 23, 2010 FDOT/FTBA Construction Conference

FDOT Structures Perspective Design