rbrp presentation for fiu abc - curt b v3 · 2017. 4. 20. · microsoft powerpoint - rbrp...

Existing Structure• SR 4013 Over Strodes Run

• ADT = 836 Vehicles / Day

• Existing Span Length = 30’

• Existing Curb to Curb Width = 27’

• Structurally Deficient

• Deficient Approach Geometry

• Deficient Guiderail Conditions

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Bridge JV-078 - Mifflin County, PA

Traffic Detour• Limited to 35 Days

• 14.80 Miles

• Rural Area With Farm Equipment Regularly Utilizing the Bridge

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Folded Steel Plate Girder Fabrication• Fabrication Starts in Cleveland Ohio at American Tank & Fabricating Company

• ½” Plates Folded Into Shape• Shear Studs, Stiffeners, Lifting Eyes Attached

• Galvanized at AZZ Inc. – Canton, Ohio

• Then Shipped to Precast Facility

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Photo courtesy of ABC‐UTC (2009 Maico‐Kansas fabrication of a test specimen)

Folded Steel Plate Girder Fabrication

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Photo courtesy of ABC‐UTC (2009 Maico‐Kansas fabrication of a test specimen)

Folded Steel Plate Girder Fabrication• Precast Work Done at AC Miller Concrete Products, Blairsville, PA

• Deck Placement First then Subsequent Placement of Parapet

• Match Casting NOT Required• Minimal Camber Formed Into Deck

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Aesthetic Panels on Exterior Parapet Face Incorporated in Precast Process

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Delivery of FSPG• Shipping Weight of Interior Pieces =

41,000 lb

• Shipping Weight of Exterior Pieces (With Parapets) = 61,000 lb

• Common Flatbed Trailers Used

• Wood Cribbing Used to Stabilize Pieces During Transport

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Bridge ConstructionPre‐Detour Work to Reduce Detour Days

• Sandbag Stream Diversion Installation

• Predrilled Into Limestone Bedrock at Abutment 1, to Attain 15’ Minimum Pile Length for the 7 Piles

• Daytime Flagging Operation Utilized to Maintain Traffic Across the Bridge

• Holes Backfilled and Topped With Cold Patch to Reopen to Traffic at End of Shift

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Bridge ConstructionDemolition

• Deck Sawcut into Sections and Lifted Out With an Excavator

• Beams Lifted Out with an Excavator

• Abutments Demolished Using Traditional Methods with a Hydraulic Impact Hammer Mounted on an Excavator

• Entire Demolition Operation Took 2 Days

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Bridge ConstructionSubstructure Construction

• 7 End Bearing Piles Driven at Each Abutment

• Piles Were Driven Using Traditional Diesel Impact Hammer in Leads Suspended from a Crane

• Cast In Place Integral Abutments

• Both Abutments Placed on the Same Day Utilizing a Pump Truck

• 4000 PSI Concrete Used for Substructure. Minimum Required Strength to Set Substructure is 2500 PSI, Achieved 5 Days After Placement

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Bridge ConstructionBearings

• Standard Neoprene Bearing Pad Design

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Bridge ConstructionFolded Steel Plate Girder Installation

• Pieces Set With a Grove 240 Ton Hydraulic Truck Crane

• Folded Steel Plate Girders Offer Advantage of Reduced Weight vs. Similar Beam/Precast Deck Options

• The 4 Pieces Were Erected in a Half Shift

• Alignment, Bearing, Cross Slope, and Match Up All Checked by Surveyors and Inspectors Prior To Crane Leaving the Site

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Bridge ConstructionFolded Steel Plate Girder Installation

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Bridge ConstructionBird Screen

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Bridge ConstructionLongitudinal Closure Forming

• Inserts Provided in the Precast on Each Side of the Longitudinal Closure Joints

• Inserts Facilitated All‐Thread Coil Rods Supported By the Deck

• All‐Thread Coil Rods Supported Common Wood Soffit Forms

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Bridge ConstructionEnd Diaphragm Forming

• End Diaphragms Formed Similar to Normal Integral Abutment Application

• Hand Formed Bulkheads Inside the FSPG Steel For Diaphragms

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Bridge ConstructionAccelerated Concrete

• Special Class AAA Accelerated Concrete Designed for 2500 PSI in 6 Hours, 3500 PSI in 24 Hours. Supplied by Centre Concrete of State College, PA

• The Mix Design Was Developed by Centre Concrete in Close Coordination with PennDOT Materials Engineers

• Due to Rapid Set Nature of the Concrete, Concrete was Made Onsite Using Mobile Mixer Trucks

• Test Batches Using the Mobile Mixers Were Run Well in Advance to Ensure the Mobile Mixing Operation Could Produce Material Within Specifications

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Bridge ConstructionAccelerated Concrete Specification Highlights

• Limited to end diaphragms and deck/barrier closure pours of bridges containing precast decks

• 28 day minimum compressive strength of 5000 psi for acceptance

• Accelerating admixtures that do not contain chlorides allowable

• Maximum cement factor 690 lb/cy

• Point of placement temperature range 65 F – 90 F

• Target Slump 10”

• Target Air = 6.0%

• No backfilling diaphragms until 3500 psi achieved

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Bridge ConstructionLongitudinal Closure and Diaphragm Pour

• Mobile Mixers Placed Concrete into a Telebelt to Move Concrete Quickly to Point of Placement

• Longitudinal Closures Placed First (4 CY)

• End Diaphragms (30 CY) Placed Immediately After Longitudinal Closure Pours Utilizing Same Setup of Mobile Mixers and Telebelt

• The AAA accelerated lost workability quickly and required several cement finishers to keep up with finishing

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Bridge ConstructionWing Parapets, Backfill, and Roadwork

• Waterproofing and Abutment Backfilling Took Place Upon Reaching Strength on Abutments and Diaphragms

• Wing Parapets Formed and Poured the Day After

• Wing Parapets Utilized Normal 4000 PSI Concrete

• Wing Parapets Cured and Attained Bridge Opening Strength While the Roadwork Was Completed

• Roadwork Was All Standard for a PennDOT Bridge Project

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Bridge ConstructionPPC Overlay

• Polyester Polymer Concrete (PPC) Was Approved By PennDOT as a Bridge Overlay Application for Use on The PA Rapid Bridge Replacement

• Due to the Bridge Finishing in Late October and Temperature Restrictions on the PPC Overlay, the Bridge Was Opened with a Temp. Wedge to Maintain Traffic Through the Winter

• PPC to Be Placed in May 2017 to Finalize the Bridge

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Completed PPC Overlay at Another Bridge

Schedule

• The detour was utilized for 33 days, finishing 2 days ahead of schedule

• 12 hour shifts, 7 days a week were utilized during the 33 day detour.

• No night shifts were needed, but were part of our schedule contingency plan

• A similar bridge in our program utilizing all cast in place elements and less overtime takes 70‐75 days

• A similar bridge in our program utilizing all cast in place elements with staged construction to maintain a lane of traffic takes approximately 150 days

Accelerated Construction Time Savings• Stream diversion installation and predrilling prior to the detour saved 4 detour days

• Working overtime for the duration of the detour saved 2 weeks of detour time

• Utilizing the Folded Steel Plate Girder with precast deck system saved 3 weeks of detour time

• Utilizing precast abutments at a significant cost increase could have saved another 3‐5 additional days of detour time

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Economics vs. Other Design OptionsWalsh/Granite Construction Cost – Ranked Lowest to Highest

1. Detour traffic with spread box beam and cast in place deck superstructure

2. Detour traffic with Folded Steel Plate Girder superstructure system

3. Detour traffic with spread box beams and precast deck panel superstructure

4. Staged traffic with spread box beams and cast in place deck superstructure

5. Temporary road “runaround” traffic with spread box beams and cast in place superstructure

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Finished Structure (Rainy Day Photo)

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rbrp presentation for fiu abc - curt b v3 · 2017. 4. 20. · microsoft powerpoint - rbrp...

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