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Edward Power, P.E.
High PerformanceSteel CostComparison StudyACEC / NCDOTBridge CommitteeHPS Bridge WorkshopOctober 22, 2007
Acknowledgements:
High Performance Steel Cost Comparison Study
Joint Study between HDR Engineeringand University of Nebraska at Lincoln
Sponsored by FHWA
Richard Horton, P.E.Gary Krupicka, P.E.Atorod Azizinamini, Ph.D., P.E.
Coauthors:
HPS has been used successfully now on many projects in several states.
Tennessee – One of the first applicationsState Route 53 Bridge over Martin Creek,Jackson CountyWeight Savings 24%
HPS Cost Comparison Study
HPS 70W provides significant advantages over conventional Grade 50W Steel.
Material
Strength
Weldability
Toughness
Weathering
Per
form
ance
50W
HPS 70W
HPS Cost Comparison Study
HPS 70W material cost is greater thanconventional Grade 50W Steel.
Material
HPS Cost Comparison Study
$$$M
ater
ial C
ost HPS 70W
50W
When does greater strength and performance outweigh material unit cost to achieve overall economy?
MaterialOve
rall
Econ
omy
Study showed the economy of hybrid girders.
HPS Cost Comparison Study
50W
HPS 70W
COST COMPARISON STUDY GOALSCompare girder weight and fabricationcost associated with designs usingGrade 50W and HPS 70W steel
Develop relative trendsConsidering Variable:
Span lengthGirder spacingMaterial combinations + HybridsGirder depth
HPS Cost Comparison Study
COST COMPARISON STUDY GOALSDevelop fabrication cost comparisonswith Fabricator input
Determine deflection effects (L/800)
Determine fatigue effects
Determine trends for box girders
HPS Cost Comparison Study
HPS Cost Comparison Study
Two-Span bridge arrangement considered for study
• Positive and negative moment regions
• Simple design approach
• Popular grade separation structure
4 SPA. @ 9'- 0"
5 Girders @ 9’ Spacing
HPS Cost Comparison Study
Design forInterior Girder
HPS Cost Comparison Study
3 SPA. @ 12'- 0"
4 Girders @ 12’ Spacing
Design forInterior Girder
Design Flowchart
HPS COSTCOMPARISON
SPAN LENGTHS
150’-150’ 200’-200’ 250’-250’100’-100’
Design Flowchart
HPS COSTCOMPARISON
SPAN LENGTHS
150’-150’ 200’-200’
9’ SPA 12’ SPA
250’-250’
GIRDERSPACING
100’-100’
12’ SPA
Design Flowchart
HPS COSTCOMPARISON
SPAN LENGTHS
150’-150’ 200’-200’
9’ SPA 12’ SPA
250’-250’
50 W HPS 70 W HYBRIDS1-5
GIRDERSPACING
YIELD STRESS
100’-100’
12’ SPA
Design Flowchart
HPS COSTCOMPARISON
SPAN LENGTHS
150’-150’ 200’-200’
9’ SPA 12’ SPA
250’-250’
50 W HPS 70 W HYBRIDS1-5
L/35L/30L/25
GIRDERSPACING
YIELD STRESS
WEB DEPTHOPTIMIZATION
100’-100’
12’ SPA
50 ksi70 ksi50 ksi
HYBRID 1
50 ksi
50 ksi
50 ksi
70 ksi
50 ksi
50 ksi
HPS Cost Comparison Study
Consider Hybrid 1 for shorter spans where Fatiguecan control at positive moment bottom flanges.
70 ksi70 ksi70 ksi
HYBRID 2
50 ksi
70 ksi
50 ksi
70 ksi
50 ksi
70 ksi
HPS Cost Comparison Study
70 ksi70 ksi70 ksi
HYBRID 3
50 ksi
70 ksi
70 ksi
70 ksi
50 ksi
70 ksi
HPS Cost Comparison Study
70 ksi70 ksi70 ksi
HYBRID 4
50 ksi
50 ksi
50 ksi
70 ksi
50 ksi
50 ksi
HPS Cost Comparison Study
Hybrid 4 was typically the most cost effective
70 ksi70 ksi70 ksi
HYBRID 5
50 ksi
50 ksi
70 ksi
70 ksi
50 ksi
50 ksi
HPS Cost Comparison Study
AASHTO LRFD 2nd Edition with 2000 Interim
Design parameters:
•Interior girder
•25 ft. max cross frame spacing
•12” x 3/4” minimum flange
Design Criteria
HPS Cost Comparison Study
Girder Optimization
Plate width transitionat field splices
One thicknesstransition - 800# minweight savings
No thickness transitions
Partially stiffened web designStiffener cost 4x web plate cost
HPS Cost Comparison Study
HPS 70W mill lengths
50’Quenching and Tempering(Q&T)
> 2”
120’Thermo Mechanical ControlledProcessing (TMCP)
<= 2”
Process LengthThickness
HPS Cost Comparison Study
GirderWeight
Web Depth
Grade 50W
Grade HPS 70W
Performance Characteristics
Optimal Depth
Optimal Depth
HPS Cost Comparison Study
GirderWeight
Web Depth
Grade 50W
Grade HPS 70W
Performance Characteristics
Deflection L/800
HPS Cost Comparison Study
GirderWeight
Web Depth
Grade 50W
Grade HPS 70W
Performance Characteristics
Phases 1 & 2
49 design combinations
170 girder designs
Fatigue
Deflection L/800
HPS Cost Comparison Study
Optimal Depth and Deflection
2030405060708090
100
100 150 200 250
Span Length (ft.)
Web
Dep
th (
in.)
L/D=25
Web Depth Correspondingto L/D=25
Optimal Depth and Deflection
2030405060708090
100
100 150 200 250
Span Length (ft.)
Web
Dep
th (
in.)
L/D=25 50W
Optimal Depth 50W
Optimal Depth and Deflection
2030405060708090
100
100 150 200 250
Span Length (ft.)
Web
Dep
th (
in.)
L/D=25 50W HPS70W
Optimal Depth HPS 70W
Optimal Depth and Deflection
2030405060708090
100
100 150 200 250
Span Length (ft.)
Web
Dep
th (
in.)
L/D=25 50W HPS70W HY4
Optimal Depth HY 4
Optimal Depth and Deflection
2030405060708090
100
100 150 200 250
Span Length (ft.)
Web
Dep
th (
in.)
L/D=25 50W HPS70W HY4 L/800
∆=L/800
Optimal Girder Depths
9590
7876
71
63
42
50W
94 (93)87 (91)12’
76 (70)72 (69)12’
616012’
86 (86)77 (84)9’250’-250’
7270 (68)9’200’-200’
53569’150’-150’
414012’100’-100’
Hybrid - 4GirderSpacing
HPS 70WBridgeSpans
( ) – Depth where deflection equals L/800
HPS Cost Comparison Study
Fatigue
When does Fatigue affect the costeffectiveness of HPS 70W steel?
HPS Cost Comparison Study
Fatigue
When does Fatigue affect the costeffectiveness of HPS 70W steel?Fatigue resistance is a variable basedon:
detail category
average daily truck traffic
HPS Cost Comparison Study
Fatigue
Welded Cross FrameStiffenerCategory C’
Stud Shear ConnectorCategory C
Two Fatigue Detail CategoriesConsidered
HPS Cost Comparison Study
Fatigue
Limiting value of Average Daily TruckTraffic (ADTT) used for study
Results in conservative lower boundfatigue resistance.
Corresponds to Interstate roadway orurban arterial.
Ramps, overpasses, rural roads, etc. withlower ADTT will have higher fatigue resistancelimits.
HPS Cost Comparison Study
Fatig
ue P
erfo
rman
ce R
atio
Span Lengths (ft.)
50 ksi70 ksiHybrid-4
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
Load Induced FatigueBottom Category C’ - 12 ft. Girder Spacing
100 150 200 250
GirderWeight
Web Depth
Grade 50W
Grade HPS 70W
Girder Weight Comparisons
Deflection L/800
HPS Cost Comparison Study
Gird
er W
eigh
t (lb
. x10
00)
Web Depth (in)
110
115
120
125
130
135
140
145
150
155
160
70 ksi
Optimal Depth
50 ksi
50 ksi70 ksi
14%
13%
Girder Weight Comparisons100 ft. Spans & 12 ft. Girder Spacing
Optimal Depth
35 37 39 41 43 45 47 49
Gird
er W
eigh
t (lb
. x10
00)
Web Depth (in)
110
115
120
125
130
135
140
145
150
155
160
35 37 39 41 43 45 47 49
70 ksi
50 ksi Fatigue
70 ksi Fatigue
Optimal Depth
50 ksi
50 ksi70 ksi
14%
6% (FAT
)
(FAT
)8%
13%
Girder Weight Comparisons100 ft. Spans & 12 ft. Girder Spacing
Optimal Depth
50 55 60 65 70 75 80L/25L/30L/35
85
200
220
240
260
280
300
320
340
17%
23%
21%
Optimal Depth
Optimal Depth
50 ksi70 ksi
Girder Weight Comparisons150 ft. Spans & 12 ft. Girder SpacingG
irder
Wei
ght (
lb. x
1000
)
Web Depth (in)
50 55 60 65 70 75 80L/25L/30L/35
85
200
220
240
260
280
300
320
340
17%∆=L/800
23%
21%
70 ksi Fatigue
Optimal Depth
Optimal Depth
50 ksi70 ksi
Girder Weight Comparisons150 ft. Spans & 12 ft. Girder SpacingG
irder
Wei
ght (
lb. x
1000
)
Web Depth (in)
400
420
440
460
480
500
520
540
560
580
600
55 60 65 70 75 80 85 90 95 100L/40 L/25L/30
20%
17%
OptimalDepth
Optimal Depth
16%
L/35
Girder Weight Comparisons200 ft. Spans & 12 ft. Girder SpacingG
irder
Wei
ght (
lb. x
1000
)
Web Depth (in)
50 ksi
70 ksi
400
420
440
460
480
500
520
540
560
580
600
55 60 65 70 75 80 85 90 95 100L/40 L/25L/30
20%
17%
OptimalDepth
Optimal Depth
16%
L/35
∆=L/800
Girder Weight Comparisons200 ft. Spans & 12 ft. Girder SpacingG
irder
Wei
ght (
lb. x
1000
)
Web Depth (in)
50 ksi
70 ksi
“L/D” 25
1000
700
750
800
850
900
950
1050
70 75 80 85 90 95L/30L/35L/40100 105
21%
Optimal Depth
Optimal Depth
22%
50 ksi70 ksi
Girder Weight Comparisons250 ft. Spans & 12 ft. Girder Spacing
Web Depth (in)
Gird
er W
eigh
t (lb
. x10
00)
1000
700
750
800
850
900
950
1050
70 75 80 85 90 95L/30L/35L/40100 105
21%
∆=L/800
Optimal Depth
Optimal Depth
22%
“L/D” 25
50 ksi70 ksi
Girder Weight Comparisons250 ft. Spans & 12 ft. Girder Spacing
Web Depth (in)
Gird
er W
eigh
t (lb
. x10
00)
68
10121416182022
100 150 200 250
Span Length (ft.)
% W
eigh
t Sa
ving
s
70W
HY4
Girder Weight ComparisonsWeight Savings from 50W
68
10121416182022
100 150 200 250
Span Length (ft.)
% W
eigh
t Sa
ving
s
70W
70W FAT
HY4
HY4 FAT
Girder Weight ComparisonsWeight Savings from 50W
Weight Savings at Optimal Depth from 50W
20%21% (19%)12’
15%17%12’
16% (14%)17% (15%)12’
13%17%9’250’-250’
16%17%9’200’-200’
11% (9%)17% (13%)9’150’-150’
13% (8%)13% (8%)12’100’-100’
Hybrid - 4Girder Spacing HPS 70WBridge Spans
( ) - Weight savings considering fatigue
( ) - Weight savings considering deflection
HPS Cost Comparison Study
Goal: Determine relative cost effectiveness of HPS70W steel over Grade 50W
Fabricator participation requested for cost comparison• Costs requested for 16 designs• 10 Fabricators selected to represent entire country
Costs included material and labor
Fabricator Cost Estimates
HPS Cost Comparison Study
Fabricator Cost Estimates
Fabricator Average Unit Costs ($/lb.)
HPS Cost Comparison Study
$0.14/lb
$0.92/lb
$0.78/lbBoxI-Girder
$0.17/lb
$0.87/lb
$0.70/lb
Phase III 2004
$0.14/lb$0.14/lbDifference
$0.52/lb$0.61/lb50W
$0.66/lb$0.75/lbHPS 70W
Phase II2002
Phase I2000
Steel Grade
Fabricator Average Cost Estimates ($/lb.)
Bridge Spans Girder 50W HPSSpacing 70W
150’ - 150’ 9’ N.R. N.R. 12’ 0.56 0.71
200’ - 200’ 9’ 0.53 0.67 12’ 0.51 0.63
250’ - 250’ 9’ N.R. N.R. 12’ 0.48 0.61
Average 0.52 0.66
HPS Cost Comparison Study
$320
$330
$340
$350
$360
$370
$380
$390
$400
$410
55 60 65 70 75 80 85 90 95 100
Girder Cost ComparisonsTypical Cost Comparison for All Hybrid Alternatives
Gird
er C
ost (
x100
0)
Web Depth (in)
50 ksi70 ksiHybrid-1Hybrid-2Hybrid-3Hybrid-4Hybrid-5
Girder Cost Comparisons100 ft. Spans & 12 ft. Girder Spacing
$80
$82
$84
$86
$88
$90
$92
$94
$96
$98
$100
34 36 38 40 42 44 46 48 50
2%
Gird
er C
ost (
x100
0)
Web Depth (in)
50 ksi70 ksiHybrid-4
8%
Optimal Depth
Optimal Depths
Girder Cost Comparisons100 ft. Spans & 12 ft. Girder Spacing
$80
$82
$84
$86
$88
$90
$92
$94
$96
$98
$100
34 36 38 40 42 44 46 48 50
70 ksi Fatigue
50 ksi Fatigue
HY-4 Fatigue
HY-4
(FAT
)4%
2%
Gird
er C
ost (
x100
0)
Web Depth (in)
50 ksi70 ksiHybrid-4
Girder Cost Comparisons150 ft. Spans & 12 ft. Girder Spacing
50 55 60 65 70 75 80 85$155
$160
$165
$170
$175
$180
$185
$190
$195
$200
$205
Optimal Depth
Optimal Depth
8%
50 ksi70 ksiHybrid-4
Gird
er C
ost (
x100
0)
Web Depth (in)
L/35 L/25L/30
2%
Girder Cost Comparisons150 ft. Spans & 12 ft. Girder Spacing
50 55 60 65 70 75 80 85$155
$160
$165
$170
$175
$180
$185
$190
$195
$200
$205
70 ksi Fatigue
HY-4 Fatigue
Optimal Depth
Optimal Depth
8%
5% (FAT
)
50 ksi70 ksiHybrid-4
Gird
er C
ost (
x100
0)
Web Depth (in)
L/35 L/25L/30
2%
Girder Cost Comparisons200 ft. Spans & 12 ft. Girder Spacing
$290
$300
$310
$320
$330
$340
$350
$360
$370
$380
55 60 65 70 75 80 85 90 95 100
70 ksi Deflection (L/800)
HY-4 Deflection (L/800)Optimal Depth
Optimal Depth
3%6%
Gird
er C
ost (
x100
0)
Web Depth (in)
50 ksi70 ksiHybrid-4
L/40 L/25L/35 L/30“L/D” 25
Girder Cost Comparisons250 ft. Spans & 12 ft. Girder Spacing
$480
$500
$520
$540
$560
$580
$600
$620
70 75 80 85 90 95 100 105
70 ksi Deflection (L/800)
Optimal Depth
Optimal Depth
HY-4 Deflection (L/800)
9%1%
Gird
er C
ost (
x100
0)
Web Depth (in)
50 ksi70 ksiHybrid-4
Optimal Depth
L/40 L/30L/35“L/D” 25
-16-14-12-10
-8-6-4-202468
10
100 150 200 250
Span Length (ft.)
% C
ost
Savi
ngs
70W
HY4
Cost Savings from 50WGirder Cost Comparisons
-16-14-12-10
-8-6-4-202468
10
100 150 200 250
Span Length (ft.)
% C
ost
Savi
ngs
70W
70W FAT
HY4
HY4 FAT
Cost Savings from 50WGirder Cost Comparisons
9% 1%12’
6%-3%12’
8% (5%)-2% (-6%)12’
6%-3%9’250’-250’
7%-4%9’200’-200’
4% (2%)-4% (-8%)9’150’-150’
2% (-4%)
Hybrid - 4HPS 70W
-8% (-14%)12’100’-100’
GirderSpacing
Spans
( ) – Cost savings considering fatigue
Relative Girder Fabrication Cost Savings w.r.t. Grade 50W
HPS Cost Comparison Study
Summary and Conclusions
The study compared weight, depth and cost of 49girder configurations for a range of span lengths,girder spacing, and steel types.
HPS Cost Comparison Study
Summary and Conclusions
Performance Issues:• Use of homogenous HPS 70W steel resulted in weight savingsof 13% to 20% relative to 50W. Hybrid 4 had 11% to 20%savings.
• Greater weight savings occur at shallower depths.
• Optimal girder depths were shallower by an average of 8% to9% in all spans except 100’.
• Fatigue affected 100’ and 150’ spans. Truck volume is afactor.
• Deflection (L/800) affected 70W design at 250’ spans atoptimal depth. In 200’ spans, depths below optimal wereaffected.
HPS Cost Comparison Study
Summary and Conclusions
• At optimal depths, homogenous Grade 50 designs were typicallymore economical than HPS 70W designs. Advantage reduces withspan length.
• At shallower depths, HPS 70W designs were typically moreeconomical.
Cost Issues:
HPS Cost Comparison Study
• Hybrid designs were the most economical with cost savings of2% to 9% at optimal depths. Savings increase with span length.
• Hybrid 4 was the most economical with:HPS 70W top and bottom flanges in negative moment regionHPS 70W bottom flanges in positive moment regionGrade 50 top flanges in positive moment region and all webs
Additional cost savings can be realized with HPS 70W inshipping and erection, foundations, and reduced approach fillheights.
Summary and Conclusions
Cost Issues Continued:
HPS Cost Comparison Study
High Performance SteelBox Girder Study
2 Box Girder Section
12'- 0" 12'- 0" 12'- 0"
14Longitudinal
Stiffener (LS)when used
HPS Box Girder Study
0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.00.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
50 ksi70 ksi
E.Q. 6.11.8.2-2(70)
E.Q. 6.11.8.2-3(70)
E.Q. 6.11.8.2-3 (50)
E.Q. 6.11.8.2-2(50)
Flange b/t Ratio
Com
pres
sion
Fla
nge
Res
ista
nce
(ksi
)HPS Box Girder Study
300 250 200 150Spans50W
50 ksi50 ksi
50 ksi
50 ksi
50 ksi 50 ksi
50 ksi
70 ksi
Top Flange
HPS Box Girder Study
Hybrid B1
150 ft Spans – HY, HY LS
200 ft Spans – HY
250 ft Spans – HY
50 ksi50 ksi
50 ksi
50 ksi
50 ksi 50 ksi
50 ksi
70 ksi
Top Flange
50 ksi50 ksi
70 ksi
HPS Box Girder Study
Hybrid B2
200 ft Spans – HY LS
250 ft Spans – HY LS
Bottom Flange
70 ksi70 ksi
50 ksi
50 ksi
50 ksi 50 ksi
50 ksi
70 ksi
Top Flange
50 ksi50 ksi
Bottom Flange Bottom FlangeBottom Flange70 ksi
HPS Box Girder Study
Hybrid B3
300 ft Spans – HY
70 ksi70 ksi
50 ksi
50 ksi
50 ksi 50 ksi
50 ksi
70 ksi
Top Flange
Bottom Flange Bottom FlangeBottom Flange70 ksi
HPS Box Girder Study
Hybrid B4
300 ft Spans – HY LS
Weight Savings from 50W
02468
101214161820
150 200 250 300Span Length (Feet)
% W
eigh
t Sav
ings
HY LS
50 LS
HY
Box Girder Weight Comparisons
Weight Savings with Longitudinal Stiffener
02468
1012141618
150 200 250 300Span Length (Feet)
% W
eigh
t Sav
ings HY to HY LS
50 to 50 LS
Box Girder Weight Comparisons
Fabricator Cost Estimates
HPS Box Girder Study
Fabricator participation requested for cost comparison• Costs obtained for 16 designs• 4 Fabricators participated
Costs included material and labor
0.920.290.630.780.290.49Average0.740.740.790.84TotalMaterial
0.490.480.490.48
50W HPS 70W
0.890.260.630.26250 - 250
0.88
0.921.00TotalLabor
0.25
0.300.37
0.630.25300 - 300
0.630.36150 - 150
0.620.30200 - 200
MaterialLaborSpan
Fabricator Cost Estimates
Fabricator Average Unit Costs ($/lb.)
HPS Box Girder Study
$0.14/lb
$0.92/lb
$0.78/lbBoxI-Girder
$0.17/lb
$0.87/lb
$0.70/lb
Phase III 2004
$0.14/lb$0.14/lbDifference
$0.52/lb$0.61/lb50W
$0.66/lb$0.75/lbHPS 70W
Phase II2002
Phase I2000
Steel Grade
Fabricator Average Unit Costs ($/lb.)
Fabricator Cost Estimates
HPS Box Girder Study
0
2
4
6
8
10
12
14
150 200 250 300
Span Length (Feet)
% C
ost S
avin
gs
HY LS
50 LS
HY
Cost Savings from 50WBox Girder Cost Comparisons
Cost Savings with Longitudinal Stiffener
0
2
4
6
8
10
12
14
150 200 250 300
Span Length (Feet)
% C
ost S
avin
gs
HY to HY LS50 to 50 LS
Box Girder Cost Comparisons
Summary and Conclusions
• Hybrid design with bottom flange longitudinal stiffening isthe most economical use of HPS 70W in box girders.• Effectiveness of HY increases with increasing span length• Effectiveness of bottom flange negative momentlongitudinal stiffening decreases with increasing span length.• The optimal HY combination varies. All optimal hybrids hadHPS 70W in negative moment top flanges, and 50W for allwebs. Bottom flanges had varying use of HPS 70Waccording to span length and use of bottom flangelongitudinal stiffening.
HPS Box Girder Study
Edward Power, P.E.
High PerformanceSteel CostComparison Study
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