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Designing Bridgesfor
Constructability
Kevin H. Miller, PEBergmann Associates
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What is Constructability ?Construction Industry
Institute
“the optimum use of construction knowledge and experience in planning, design, procurement and field operations to achieve the overall project objectives”
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Using construction knowledge to design bridges that can be constructed efficiently with
minimal change orders
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What are the advantages of constructability ?
•More competitive bids•Fewer change orders•Reduced construction costs•Reduced time of construction•Save lives ??
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How can constructable designs be achieved ?
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• Early and continuous involvement of construction personnel
• Tap the knowledgeContractorsInspectorsFabricatorsOwners
• Build a data base of change orders & RFIs
• Use lessons learned checklist• Establish a constructability program
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Why don’t we do it ?• Adds time to design schedule • Initial cost• Availability of qualified staff• Reluctance to reach out to
contractors
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• Right-of-Way• Utilities• Data Collection• Mobilization• Clearing & Grubbing• Demolition• Excavation• Cofferdams• Deep Foundations
• Substructures• Bank Protection• Bearings• Steel Fabrication, Erection
and Framing• Precast Concrete
Fabrication and Installation• Decks & Approach Slabs• Bridge Rail• Highway Approach
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Do you have sufficient Right-of-Way?
• Staging area• Limits of excavation layback• Access for demolition, construction
and maintenance• On-site detour
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• Right-of-Way• Utilities• Data Collection• Mobilization• Clearing & Grubbing• Demolition• Excavation• Cofferdams• Deep Foundations
• Substructures• Bank Protection• Bearings• Steel Fabrication, Erection
and Framing• Precast Concrete
Fabrication and Installation• Decks & Approach Slabs• Bridge Rail• Highway Approach
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Consider more soil borings
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• Right-of-Way• Utilities• Data Collection• Mobilization• Clearing & Grubbing• Demolition• Excavation• Cofferdams• Deep Foundations
• Substructures• Bank Protection• Bearings• Steel Fabrication, Erection
and Framing• Precast Concrete
Fabrication and Installation• Decks & Approach Slabs• Bridge Rail• Highway Approach
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• Right-of-Way• Utilities• Data Collection• Mobilization• Clearing & Grubbing• Demolition• Excavation• Cofferdams• Deep Foundations
• Substructures• Bank Protection• Bearings• Steel Fabrication, Erection
and Framing• Precast Concrete
Fabrication and Installation• Decks & Approach Slabs• Bridge Rail• Highway Approach
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Is it necessary to remove the entire substructure?
• Temporary cofferdams• Scour protection
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• Right-of-Way• Utilities• Data Collection• Mobilization• Clearing & Grubbing• Demolition• Excavation• Cofferdams• Deep Foundations
• Substructures• Bank Protection• Bearings• Steel Fabrication, Erection
and Framing• Precast Concrete
Fabrication and Installation• Decks & Approach Slabs• Bridge Rail• Highway Approach
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Cofferdams
• Can cofferdam be built without interfering with battered piles?
• To tremie seal or not to tremie seal?• Consider in-the-wet construction
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“In-the-wet" drilled shaft installation using the existing
bridge as falsework
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• Right-of-Way• Utilities• Data Collection• Mobilization• Clearing & Grubbing• Demolition• Excavation• Cofferdams• Deep Foundations
• Substructures• Bank Protection• Bearings• Steel Fabrication, Erection
and Framing• Precast Concrete
Fabrication and Installation• Decks & Approach Slabs• Bridge Rail• Highway Approach
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Drilled Shafts
• Minimize footprint of foundation
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• Right-of-Way• Utilities• Data Collection• Mobilization• Clearing & Grubbing• Demolition• Excavation• Cofferdams• Deep Foundations
• Substructures• Bank Protection• Bearings• Steel Fabrication, Erection
and Framing• Precast Concrete
Fabrication and Installation• Decks & Approach Slabs• Bridge Rail• Highway Approach
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Reinforcing
– Bundle bars– Larger bars at greater spacing
• Avoid threading bars through hoops• Simplify, line up front and back mats
• Avoid rebar congestion
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• Consolidate several small repair areas• Provide sufficient depth for repair• Over estimate repair area
Substructure Concrete Repairs
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• Right-of-Way• Utilities• Data Collection• Mobilization• Clearing & Grubbing• Demolition• Excavation• Cofferdams• Deep Foundations
• Substructures• Bank Protection• Bearings• Steel Fabrication, Erection
and Framing• Precast Concrete
Fabrication and Installation• Decks & Approach Slabs• Bridge Rail• Highway Approach
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• Right-of-Way• Utilities• Data Collection• Mobilization• Clearing & Grubbing• Demolition• Excavation• Cofferdams• Deep Foundations
• Substructures• Bank Protection• Bearings• Steel Fabrication,
Erection and Framing• Precast Concrete
Fabrication and Installation• Decks & Approach Slabs• Bridge Rail• Highway Approach
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Steel Fabrication• Girder economy• Avoid flange width transitions• Avoid sizing in increments of 1/8”
thickness• Use a minimum web thickness of ½”• Consider how steel delivered to site• Consider lead time on steel• Consider how erect steel – any DEC
permits needed?
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• Right-of-Way• Utilities• Data Collection• Mobilization• Clearing & Grubbing• Demolition• Excavation• Cofferdams• Deep Foundations
• Substructures• Bank Protection• Bearings• Steel Fabrication, Erection
and Framing• Precast Concrete
Fabrication and Installation
• Decks & Approach Slabs• Bridge Rail• Highway Approach
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Can you use precast?
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Tolerances with Precast
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6”
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• Right-of-Way• Utilities• Data Collection• Mobilization• Clearing & Grubbing• Demolition• Excavation• Cofferdams• Deep Foundations
• Substructures• Bank Protection• Bearings• Steel Fabrication, Erection
and Framing• Precast Concrete
Fabrication and Installation• Decks &
Approach Slabs• Bridge Rail• Highway Approach
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Avoid Complex Geometry
• Heavy skews• Horizontal curves• Spirals• Superelevation transitions• Can it be built with SIP forms?
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Horizontal Curves on Bridges
• Avoid curved girders if possible• Straight girders with curved deck• Varying width shoulders with straight
deck and girders
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A Few General Tips
• Leave the methods and means to the builders
• Think about allowable tolerances• Repetition is a good thing• Avoid skews, at least heavy skews• “Keep it simple”• “If in doubt, rip it out”
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As Designed As Built
Constructability and Safety
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Questions?