rohleder presentation
TRANSCRIPT
Segmental Bridge Technology –Established and Evolving
W. Jay Rohleder, Jr, P.E., S.E. Senior Vice President / Project Development
FIGG
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Segmental Bridge Topics Addressed
• Definition of concrete segmental bridge construction methods and related design considerations.
• The evolution of concrete segmental bridge technology over the past 30 years in the U.S.
• Design principles and practices that provide the economic and durability value for this structure type.
• Continuing evolution of the segmental bridge construction technology and related design concepts.
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Definition of Segmental BridgesBridges, that are typically concrete box structure types, constructed using repetitive elements that are progressively connected together to form a completed structure. Construction Load Cases are particularly critical considerations in developing the design and building methods for segmental bridges.
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CABLE STAYED BRIDGESCABLE STAYED BRIDGES
LONG SPAN BRIDGESLONG SPAN BRIDGES ENVIRONMENTALLY SENSITIVEENVIRONMENTALLY SENSITIVE
LONG BRIDGES OVER WATERLONG BRIDGES OVER WATER ARCHESARCHES
URBAN BRIDGESURBAN BRIDGES
SEGMENTAL BRIDGE APPLICATIONS
RAIL BRIDGESRAIL BRIDGES
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Segmental Bridge Methods, Components and Evolution
of the Technique
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Segmental Construction Methods• SPAN-by-SPAN (Precast)
• CANTILEVER (Precast or Cast-in-Place)> Balanced> Uni-Directional
• INCREMENTAL LAUNCH(Typically an Inefficient use of materials,
so Not commonly used –need tangent or constant curvature)
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Segmental Construction Methods• Span by Span
JFK AirTrain, NY City
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• Balanced Cantilever
Sagadahoc Bridge, ME
Segmental Construction Methods
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• Uni-Directional Cantilever (shown)• Mixed Methods
Garcon Point Bridge, FL
Segmental Construction Methods
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Precast Joints
• Keys (i.e. no reinforcing across joints)• Epoxy
– Temporary Clamping– Temperature
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• Reinforcing Bars• Joint Preparation• Bulkheads
Cast-in-Place Joints
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Post-Tensioning (PT) Arrangements
Layout Orientation• Longitudinal
– Span by Span– Cantilever
• Transverse• Vertical
Placement Type• Internal Tendons• External Tendons
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• Internal Tendons– Transverse– Longitudinal
(Cantilever)
Post-Tensioning (PT) Arrangements
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Post-Tensioning
Pre-Tensioning
Internal Transverse Pre-Stressing
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• External Tendons, LongitudinalSingle Point Deviators
Post-Tensioning (PT) Arrangements
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• External Tendons, LongitudinalMulti-Point Deviators
Post-Tensioning (PT) Arrangements
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Post-Tensioning (PT) Arrangements
• Vertical Tendons(in Precast Piers)
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Construction Engineering• Camber• Geometry Control• Prestressing Parameters• Erection Loads• Erection Equipment• Casting and Erection Manuals• Integrated Shop Drawings
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Precasting Yard Operations
• Pre-Tied Reinforcing Cage Jigs• Casting Beds
> Long Line> Short Line
• Storage & Delivery
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• Long Line Segment Casting
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• Short Line Segment Casting
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TYPICAL CASTING YARD LAYOUT
Batch Plant
Segment Storage
Rebar Jigs
Casting Beds
Segments in Storage
Possible Double Stack
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JFK AirTrain, NY, NY
9 Miles of Elevated Precast Segmental Bridge
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• 5,500 Segments• 14 Casting Cells
Precasting Facility - JFK AirTrain
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Precasting Facility - JFK AirTrain
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Segment DeliveryPrecasting Facility - JFK AirTrain
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I-93 Viaducts & Ramps, Boston, MA
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Precast plant 85 miles away by truckPrecasting Facility – I-93 Viaducts, Boston
85 Mile
s
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• 15 Acres• 1250 Segments• Casting Cells
4 Typ., 1 Combined
Precast plant in Sanford, MEPrecasting Facility – I-93 Viaducts, Boston
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Central concrete delivery - casting 3 beds / dayPrecasting Facility – I-93 Viaducts, Boston
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• 1040 – Total Segments(958 Typical, 82 Specialty)
• 3 - Typical Casting Cells• 1 - Specialty Casting Cell
Precasting Facility – Susquahanna River, PA.
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Susquehanna River Bridge, PA
• Assembly Line – Reinforcing Cage Jig
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• Assembly Line – Casting Bed Set-Up
Susquehanna River Bridge, PA
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Match CastSegment
Wet CastSegment
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• Assembly Line – Segment Pour
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• Assembly Line – Steam Cured Segments
Susquehanna River Bridge, PA
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• Segment Storage Handling,Lifting with Strap under Wing
Susquehanna River Bridge, PA
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• Segment Handling
Lifting with Bars through Lifting Holes
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1
2
3
• Segment Storage
Three Point Supports
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• Segment Storage
Double Stacking
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PRECAST SUPERSTRUCTUREComparison Table
Project: Susq. I-93 JFK Victory Sagadahoc(Pa.) (Ma.) (NY) (NJ) (Maine)
No. Segments - 1040 1250 5409 927 202 Max. Wt. (Tons) - 105 80 38 82 100 No. Typical Beds - 3 4 11 8 1 Casting Yard Size - 20 A 15 A N/A N/A 12 A
Cast 1 Segment / Day / Bed
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Precast SegmentalSpan-by-Span Construction
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SECTION A-AA
A
Typical Span-by-Span Erection
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•Advance Truss to Next Span
Typical Span-by-Span Erection
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•Deliver Segments•Set Segments
Typical Span-by-Span Erection
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•Deliver Segments•Set Segments
Typical Span-by-Span Erection
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•Epoxy Joints•Join Segments
•Deliver Segments•Set Segments
Typical Span-by-Span Erection
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•Epoxy Joints•Align Pier Segm.
•Deliver Segments•Set Segments
Typical Span-by-Span Erection
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•Align Pier Segm.•Thread Tendons•Cast Closure
•Deliver Segments•Set Segments•Epoxy Joints
Typical Span-by-Span Erection
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•Stress Tendons•Lower Truss andRepeat Process
SECTION A-AA
A
Typical Span-by-Span Erection
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- Underslung Trusses- Overhead Gantry- Falsework Supports
Precast Span-by-SpanSegments Erected using:
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ERECTION TRUSSES – Under Bottom Soffit
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Deck Designed for Support ConditionERECTION TRUSSES – Under Wings
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ERECTION with OVERHEAD GANTRY
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• Tower on FoundationERECTION TRUSS SUPPORTS
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• Pier BracketERECTION TRUSS SUPPORTS
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Delivery of Segments from AboveSpecialized Erection Equipment
WMATA, VA
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SPAN-BY-SPAN CONSTRUCTION EXAMPLEMay 2007
Susquehanna River Bridge, PA
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Casting Yard
Pennsylvania Turnpike
Commission
Bridge –East Approach
Susquehanna River Bridge, PA
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West EndCalverIslandEast End
Casting Yard
New WB
New EB
Existing Bridge
Twin Bridges with each:• 5,910’ Long by 57’ Wide• 40 Spans – 35 @ 150’, 5 @ 132’• 21 River Piers• 18 Land Piers
Susquehanna River Bridge, PA
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ONE
THREE
TWO
ERECTION PHASES
Susquehanna River Bridge, PA
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Casting YardCasting Yard
Segment Segment ErectionErection
Access RoadAccess Road
Susquehanna River Bridge, PA
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Susquehanna River Bridge, PA
Segments Delivered from Storage
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Segments Delivered from Above
Susquehanna River Bridge, PA
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Susquehanna River Bridge, PA
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Susquehanna River Bridge, PA
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Susquehanna River Bridge, PA
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Susquehanna River Bridge, PA
Segment Alignment
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Susquehanna River Bridge, PA
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Susquehanna River Bridge, PA
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Susquehanna River Bridge, PA
ELEVATION
SECTION VIEWS
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Susquehanna River Bridge, PA
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Susquehanna River Bridge, PA
Activities Off the Critical Path
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Achieved Typical Span x Span
Erection Rate of 2 Spans per Week
Susquehanna River Bridge, PA
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VERTICAL CLEARANCES
RAILROAD LINESLOCAL AIRPORT
Susquehanna River Bridge, PA
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November 2004 - NTPMay 2007 - New Bridge Complete
Susquehanna River Bridge, PA
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• Quick, Simple Erection (2 - 3 Spans / Week)• Easy Geometry Control• Savings from less MOT• Minimum User Delays• Cost Effective• Simple Design• Durable Structures
ADVANTAGES OF SPAN-BY-SPAN
Beautiful Bridges
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Precast SegmentalBalanced Cantilever Construction
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Balanced Cantilever Erection
ERECTION SEQUENCE I
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Balanced Cantilever Erection
ERECTION SEQUENCE II
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ERECTION SEQUENCE IV
ERECTION SEQUENCE III
Balanced Cantilever Erection
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- Barge-mounted cranes- Ground based cranes- Beam and Winch- Overhead Gantry
Precast Balanced Cantilever Segments Erected using:
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BALANCED CANTILEVER EXAMPLE
September 2007
Victory Bridge, NJ
• Twin 3,971’ Long Bridges• Main Span Unit 330’, 440’, 330’• 100’ Tall Precast Piers• SxS Appr., B.C. Main Span Unit
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Victory Bridge, NJ
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Victory Bridge, NJ
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Victory Bridge, NJ
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Victory Bridge, NJ
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Victory Bridge, NJ
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Victory Bridge, NJ
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Victory Bridge, NJ
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Average production:4 to 6 segments/day (45 ft)
Balanced Cantilever Erection
Victory Bridge, NJ
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Victory Bridge, NJ
1st Bridge Open to Traffic in 15 mo.2nd Bridge Completed in 9 mo.
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Cast-in-Place SegmentalBalanced Cantilever Construction
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Wabasha Street Bridge, MN
1,248’ Long Twin Bridgeswith 398’ Main Spans
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Wabasha Street Bridge, MN
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Wabasha Street Bridge, MN
Continue through the Winter
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Blending shapes, texture and color Wabasha Street Bridge, MN
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Segmental BridgesMixing Construction Erection
Methods
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Sagadahoc Bridge, ME
3,000’ Bridge with420’ Main Span
over Kennebec River
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68’ Roadway with2 Cell Box Girder
Cast-in-Place Approach Units, with Precast
Main Span Unit Sagadahoc Bridge, ME
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520,000 sf of Structures - Completed Nov. 2002
I-93 Ramps & Viaducts, Boston MA
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I-93 Ramps & Viaducts, Boston MA
Span-by-Span Construction
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I-93 Ramps & Viaducts, Boston MA
Balanced Cantilever Construction
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Mid-Bay Bridge, FL
• Span-by-Span Approaches• One-Directional Cantilever Main Span
CIP low level piers
P/C high level piers
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Precast Segmental Piers
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Precast Piers
Directionof Erection
Erect 1 Segment an Hour,Approximately 1 Pier per Day
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Victory Bridge, NJ
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First segment cast6 weeks after NTP
Precast Piers
Victory Bridge, NJ
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Precast Piers Casting Bed
Victory Bridge, NJ
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Typical Precast Pier Details
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Precast Pier Erection
Victory Bridge, NJ
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Precast Pier Erection
Victory Bridge, NJ
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Precast Pier Erection
Victory Bridge, NJ
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Precast Pier Erection
Victory Bridge, NJ
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Precast Pier Erection
Victory Bridge, NJ
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Precast Pier Erection
Victory Bridge, NJ
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First pier erected5 months after NTP
Completed Precast Piers
Victory Bridge, NJ
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Cable StayedSegmental Superstructure
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U.S. Senator William V. Roth Jr. Bridge over C&D Canal, DE
1st concrete cable-stayed bridge in the Northeast – 1995
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Entirely Precast Segmental Bridge
U.S. Senator William V. Roth Jr. Bridge over C&D Canal, DE
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Segmental Cable-Stay BridgesI-280 Veterans’ Glass City Skyway, Ohio
1,225’ main span (2 @ 612’-6”)
Penobscot Narrows Bridge& Observatory, Maine (1,161’ main span)
Open Dec. 2006
Open June 2007
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Veterans’ Glass City SkywayPrecast SuperstructureCompleted in 8 Months
New Penobscot Narrows BridgeCast-in-Place SuperstructureCompleted in 15 Months
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Penobscot Narrows Bridge & Observatory, ME
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CIP Balanced Cantilever Construction
FormTraveler
FormTraveler
Penobscot Narrows Bridge & Observatory, ME
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Penobscot Narrows Bridge & Observatory, ME
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Penobscot Narrows Bridge & Observatory, ME
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Carbon Fiber Composite Strand Demonstration Project
Penobscot Narrows Bridge & Observatory, ME
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Veteran’s Glass City Skyway, Ohio
Veteran’s Glass City Skyway, OH
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Typical Pre-Cast Cross-Sections: Main SpanVeteran’s Glass City Skyway, OH
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Main Span Precast Segmental Construction
• Backspans: Span-by Span• Mainspan: One-Directional Cantilever
Veteran’s Glass City Skyway, OH
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• 3 pairs of segmentserected in cantilever– Epoxied segment joints– Segments post-tensioned
Veteran’s Glass City Skyway, OH
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Segmental Bridge Construction Benefits• Rapid Construction• Segments Delivered over Completed Spans
– No Need for Barge Delivery• Maintained Shipping Lanes at All Times
– Access to Port of Toledo
Veteran’s Glass City Skyway, OH
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Review Questions• Define a segmental concrete bridge structure type?• List 3 methods for constructing segmental bridges? • List benefits during construction that result from
using a segmental bridge construction technique?• List permanent bridge site layout benefits resulting
from using a segmental box girder bridge type?• What structural benefits apply to using a closed cell
box girder for a segmental bridge?• What segmental bridge technological advances offer
the most immediate benefits?
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Open-ended Assignment Questions
Can you identify a viable candidate location for a segmental bridge given your understanding of the potential benefits from using this structure type?
What new innovative applications of the segmental bridge construction technique can you envision?
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America Deserves Beautiful
Bridges
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