M-25 over Harbor Beach Creek

M-25 over Harbor Beach Creek

• Bridge to Culvert Replacement• $1.27M Programmed Cost

– $270,000 Innovative Bridge Research and Deployment Program Federal Grant

Existing Harbor Beach Creek Bridge

M-25 over Harbor Beach Creek

• Composite Arch Culvert System

• aka “Bridge in a Backpack”

“Bridge in a Backpack”

Installing arches

Composite decking

Arches inflatedand formed

“Bridge in a Backpack”Filling arches with concrete

FasciaBackfill to road

M-25 over Harbor Beach Creek

• Traffic currently detoured

• Fix Life of >75 years

• Every Day Counts

• Faster + Cheaper + Safer + Smarter = Better

Existing Harbor Beach Creek Bridge

M-25 over Harbor Beach Creek

• Started in Spring 2012

• Original completion date August 25

Sixteen 12” diameter arch tubes arriving at project site

M-25 over Harbor Beach Creek

Arch end section

Inlet holes for concrete

M-25 over Harbor Beach Creek

Large lateral forces from arches required battered piles

First arch rib install

M-25 over Harbor Beach Creek

Reinforcement for arch end anchoring into abutment

Multiple arch tubes installed

M-25 over Harbor Beach Creek

Arch tube installation complete

Finishing concrete around arch tube endings

M-25 over Harbor Beach Creek

Composite decking installation

M-25 over Harbor Beach Creek

Expansive Self Consolidating Concrete (SCC) slump flow test

Measuring slump flow

M-25 over Harbor Beach Creek

Filling arches from top with SCC

Sounding for voids – 8/9

M-25 over Harbor Beach Creek

• Challenges:• Still need a conventional deep foundation• Remote project location, readi-mix supplier 1 hour away• Issues with SCC remaining fluid and workable long enough• Concrete setting too fast in arch ribs causing voids

• Working with AIT to resolve issues:• Revising SCC mix with additional admixtures• Drilling additional holes in arch ribs to fill voids with grout• Identify high stress areas via finite model to avoid drilling in those

locations

M-25 over Harbor Beach Creek

• When arches complete and composite with concrete, a 7” concrete overlay will be cast over the composite decking for lateral stability

• Decorative composite finish will be placed on headwalls and wingwalls

• Placement of roadway fill and pavement section

M-25 over Harbor Beach Creek

• Design specifications recently voted on and approved by AASHTO Subcommittee on Bridges and Structures

MDOT CFRP Implementation: Building bridges for the 21st century

AASHTO Subcommittee on Bridges & Structures

Technical Committee T-6 Austin, TX, July 9, 2012

Matt Chynoweth, Engineer of Bridge Field Services

Existing Structure

Two span simply supported prestressed I-beam structure in poor condition (based on NBIS ratings)

MDOT CFRP Deployment• Pembroke over M-39 Bridge Replacement

Materials stored at Detroit Maintenance Garage through winter and spring of 2011

MDOT CFRP Deployment• Pembroke Bridge CFCC cables

Special provisions for handling instructions were written for installation

MDOT CFRP Deployment• NEFMAC Grid installation

Finished installation

MDOT CFRP Deployment• NEFMAC Grid installation

Measuring deck deflections, deck strains and PT tendon loads

MDOT CFRP Deployment• Monitoring and Data Collection

MDOT CFRP Deployment• Complete Pembroke Structure

Photos taken October 2011

Existing structure

Project let January 2012

MDOT CFRP Deployment• M-50/US-127 BR over NS RR

Cables were double sheathed and fed into 5” conduits

MDOT CFRP Deployment• M-50 Bridge CFCC cables

Cables were double sheathed and fed into 5” conduits

MDOT CFRP Deployment• M-50 Bridge CFCC cables

Fabricator’s stressing chair: cables stressed to 75 kips, then 150 kips once deck is placed & cured

MDOT CFRP Deployment• M-50 Bridge CFCC cables

Load cells placed on dead end measure micro-strain, which is converted to force

MDOT CFRP Deployment• M-50 Bridge CFCC cables

Steel/CFRP stirrups along the span

Steel/CFRP stirrups at diaphragms

Transverse ducts for TPT

Steel/CFRP prestressing strands

Next Steps

Other research:

• MDOT project OR14-24: Evaluating Long Term Capacity and Ductility of Carbon Fiber Reinforced Polymer prestressing and post tensioning strands subject to long term losses, creep, and environmental factors

• To begin in FY 2013

• NCHRP 12-97: Design Guidelines for Field Deployment CFRP prestressed beams in Bridge Construction

• MDOT submitted research idea

Thank you

Questions?