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Total Precast Bridge

Accelerated Construction of Ashcom Cove Creek BridgeBedford Co SR 1004-001

Thursday November 21, 2013

Fall 2013 PennDOT-APC Workshop

Ashcom Cove Creek BridgeBedford County SR 1004-001

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Project Location


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Far Approach (Looking East to West) -- 2007


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Far Approach (Looking East to West)


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Upstream Elevation Existing Bridge


8PLAN VIEW FROM AS-BID DRAWINGS

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ELEVATION VIEW FROM AS-BID DRAWINGS


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TYPICAL SECTION FROM AS-BID DRAWINGS


• As-Bid Structure– Let date February 23, 2013

– NES&L low bid $1,651,824 ($450 per sf deck area)

– Conventional construction

• Start 4/25/13, End 11/26/13 – 7 months

– Phased, single-lane traffic control

• New Enterprise Stone & Lime VE Proposal– Detour traffic 8 week maximum duration

– All pre-cast construction

– $125,000 cost saving to Department

– Design of as-bid structure essentially replicated.

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• VE CONSTRAINTS– Conduct public involvement for detour

– Fall wild trout restriction – October 1 thru December 31

– Spring stocked trout restriction – March 1 thru June 15

– Lutzville Bridge on detour route (SR 2019) under construction in 2014

• Decision made to construct prior to October 1 wild trout stream restriction.

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• VE APPROVAL TIMELINE5/15/13 - Conceptual VE proposal submitted

5/28/13 - Conceptual VE approved by District

6/17/13 - Final VE Proposal submitted to District

7/1/13 - Final VE Proposal resubmitted

7/3/13 - VE Proposal sent to Central Office

7/25/13 - Final VE proposal approved

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• VE DESIGN TIMELINEDesign submissions broken into two parts:

Part A – Deck Panels & Revisions to P/S Beams

Submitted 6/25/13Approved 7/25/13

Part B – Footings, Wall Panels & Approach Slabs

Submitted 7/12/13Approved 8/8/13

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• Precast Components of VE Bridge– Footings (same size as as-bid)

– Abutment breast wall and wing wall stems

– Abutment-to-wing wall transition corners

– Deck panels

– Approach slabs

• Cast-in-Place Components– Intermediate diaphragms

– End diaphragms

– Sleeper slabs for approach slabs

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Ashcom Cove Creek Bridge PrecastVE Total Precast Bridge

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Ashcom Cove Creek Bridge Precast Production Schedule

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Dates (in 2013) Components

7/25 – 8/8 Deck Panels (20 panels, 2 panels per day)

8/13 – 8/16 Abutment-to-Wing Corners (4 pieces, 1 piece per day)

8/19, 8/20 Abutment 1 Breast Walls (2 pieces, 1 piece per day)

8/20 – 8/22 Abutment 1 Footings (3 pieces, 1 piece per day)

8/22, 8/23 Abutment 2 Breast Walls (2 pieces, 1 piece per day)

8/24, 8/26, 8/27 Abutment 2 Footings (3 pieces, 1 piece per day)

8/26, 8/27 Abutment 1 Wing Walls (2 pieces, 1 piece per day)

8/28, 8/29 Abutment 2 Wing Walls (2 pieces, 1 piece per day)

8/28, 8/30, 9/3 Approach slabs (6 pieces, 2 pieces per day)

Ashcom Cove Creek Bridge Precast Abutments

• Match-cast, post-tensioned, precast concrete footing and wall panel components

• NMB splice connections for footing-to-stem vertical reinforcement bar continuity.

• SS Mortar by BASF splice sleeve grout. 11 ksi @ 28 days strength

• 5 ksi non-shrink grout to fill 1” gap between top of footing & bottom of wall pieces.

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Ashcom Cove Creek Bridge Precast Abutment Footings

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3 Segments per Abut Footing

Max Segment Weight = 31.5 tons

Transverse Post-Tensioning Duct

19.4 T

17.6 T

26.8 T

18.5 T

7’-9” wide

9’-5” wide


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EXCERPT FROM SHOP DRAWING

OF FOOTING


21Footing Pieces Cast Upside Down

Ashcom Cove Creek Bridge Precast Abut Walls & Corner Transitions

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Transverse Post-Tensioning Duct

1 Wall Panel per Wing Wall Corner

Transition

2 Wall Panels per Abut Breast Wall15’ High

NMB Splice Sleeves for Vert ReinfContinuity

30.4 T

24.8

T

34.9 T

36.0 T18

.9 T

21.9

T

18.5

T

17.9

T

Ashcom Cove Creek Bridge Precast Abutment Walls

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EXCERPT FROM SHOP DRAWING OF WALL PANEL

NMB Splice Sleeve

Ashcom Cove Creek Bridge Precast Abutment Walls

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Ashcom Cove Creek Bridge Precast Abut-Wing Corner Transitions

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EXCERPT FROM SHOP DRAWING OF WALL PANEL

NMB Splice Sleeve

Post-Tensioning Duct

Ashcom Cove Creek Bridge Precast Abut-Wing Corner Transitions

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Ashcom Cove Creek Bridge Abutments - Dry Fit in Fabrication Yard

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Ashcom Cove Creek Bridge Precast Deck Slab Panels

• Shear pockets to receive horizontal shear steel from beams.

• Deck panels one-half width of bridge -- 12’ +/- in length.

• Lafarge Ductal Ultra High Performance Concrete (UHPC) used in transverse and longitudinal closure pours.

• Following completion of transverse closure pours, panels post-tensioned in longitudinal direction to achieve 250 psi compression.

• Leveling bolts used for grade adjustment and load distribution.

• Dayton Superior J55 epoxy grout used to fill beam haunches and shear pockets.

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Ashcom Cove Creek Bridge Precast Deck Panels

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Shear Pockets

UHPC Longitudinal Closure Pour

DECK PANELSWidth = ½ of bridgeLength = 12’-2 ½”

12.2 Tons Typ Weight

UHPC Transverse Closure Pours

P/S Bulb-T’s TEKLA-3D GENERATED DRAWING


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Shear Pockets

Typical Deck Panel 12’-2” +/- Long

EXCERPT FROM SHOP DRAWING OF DECK PANELSPLAN VIEW


Transverse Closure Pour

(Typ.)


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Shear Pockets (Typ over Bms)

EXCERPT FROM SHOP DRAWING OF DECK PANELSBRIDGE CROSS SECTION


Barriers Integral w/ Deck Panel

Left Deck Panel Right Deck Panel


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Shear Pockets (Typ over Bms)

EXCERPT FROM SHOP DRAWING OF DECK PANELSPLAN VIEW - TYPICAL PANEL

Barriers Integral w/ Deck Panel


33TRANSVERSE JOINT

LONGITUDINAL JOINT over BEAM 3

P/S Beam Top Flange

Deck Panel (Typ.)

UHPC Closure Pour

Match-cast joint considered but rejected.

Ashcom Cove Creek Bridge Precast Deck Panels – Post Tensioning

34LONGITUDINAL POST-TENSIONING

Flared Anchoring Head

18 Total 0.6” dia. strands

P/T Wedge Chucks

Ashcom Cove Creek Bridge Precast Approach Slabs

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TEKLA-3D GENERATED DRAWING

Barrier Integral w/ Approach Slab

Transverse Post-Tensioning

UHPC Closure Pours

Ashcom Cove Creek Bridge Precast Approach Slabs

36EXCERPT FROM SHOP DRAWINGS - PLAN

Ashcom Cove Creek Bridge Construction Timeline

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Days Activities

1 - 3 Set-up detour; install causeway; demo existing super & Abut 1

3 – 5 Excavate for new Abut 1; install shoring @ Abut 29 Install new Abut 1; demo existing Abut 2; excavate new Abut 2

10 Backfill new Abutment 111 Install new Abutment 212 – 16 Backfill new Abut 2; place scour protection; prep for setting beams17 Set prestressed concrete beams18 – 20 Set deck panels; form & reinforce intermediate & end diaphragms22 – 23 Pour diaphragms; form deck panel transverse shear keys 24 Form beam haunches25 – 26 Place UHPC in transverse deck joints29 Post-tension deck panels30 – 31 Construct approach slab sleeper slab; grout PT ducts

Ashcom Cove Creek Bridge Construction Timeline (continued)

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Days Activities

32 – 33 Set approach slabs

36 Re-prep haunches; begin work on roadway approaches

37 – 38 Place epoxy grout in beam haunches & shear pockets39 Place UHPC in deck longitudinal closure joint.

40 – 44 Clean-up deck45 – 53 Epoxy deck patches; strip haunch formwork; addt’l roadway work54 OPEN BRIDGE

Ashcom Cove Creek Bridge Construction - Substructure

39ABUTMENT – FOOTING INSTALLATION

250-ton crane used for Abutment 2125-ton crane used for Abutment 1


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ABUTMENT – WING WALL SETTING


45ABUTMENT – CORNER TRANSITIONS


46ABUTMENT – BREAST WALL INSTALLATION


47ABUTMENT – COMPLETED PRECAST ASSEMBLY


48ABUTMENT – COMPLETED PRECAST ASSEMBLY


49ABUTMENT – SPLICE SLEEVE GROUTING

Ashcom Cove Creek Bridge Construction - Superstructure

50PRECAST DECK PANELS


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PRECAST DECK PANELS

ADJUSTING LEVELING BOLTSAdjusting Leveling Bolt

with Impact Wrench

View of Leveling Bolts from Underside of Deck Panel


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PRECAST DECK PANELSUHPC Closure Pours Haunch Formwork

Steel FibersPre-Blended Cementitious

Transverse Closure Pour

Transverse Joint Profile


55PRECAST DECK PANELS - UHPC Closure Pours


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PRECAST DECK PANELSPost-Tensioning

Prior to Anchoring Head Installation

6 sets of 3 – 0.6” dia. strands

P/T Ducts at Transverse Deck Panel Joint


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PRECAST DECK PANELSEpoxy Grout in Beam Haunches & Shear Pockets

Epoxy Part ’A’Pre-Blended Cementitious Epoxy Part ’B’

Mixing Parts ‘A’ & ‘B’ Epoxies

Shear Pocket

Ashcom Cove Creek Bridge Issues Encountered

• Wall panels hung up on edges of protruding vertical steel reinforcement coming out of footing. Possible solution is to grind a small taper on the ends of the reinforcement bars.

• Since dimensional tolerances are tight, any gap between wall panels during placement made fit-up more difficult.

• Due to viscous nature of grout materials, special attention and detail had to be paid to beam haunch formwork.

• Viscosity of UHPC & epoxy grout materials sensitive to ambient temperatures. – Ice had to be used for mix water for 1st UHPC pour (transverse deck joints) during period of

higher ambient temperature (+80oF.)

– Reduced aggregate content had to be used for epoxy grout mix (3 bags vs. standard 4 bags) during periods of lower ambient temperatures (60oF +/-.)

• Challenging to achieve proper top of deck grade using leveling bolts while simultaneously evenly distributing weight to beams.

• Alignment of barrier was primary control when setting deck panels. This resulted in some unevenness of top of deck near C/L bridge.

• Prefabrication of approach slabs to achieve cross-slope was challenging. • Steel fibers in UHPC mix settled to an unexpected extent during second

placement operation (longitudinal closure pour.)58


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PRECAST DECK PANELSUltra High Performance Concrete (UHPC) – Steel Fiber Dispersion

Atypical Steel Fiber

Separation in Longitudinal Closure Pour

Normal Steel Fiber

Dispersion in Transverse

Closure Pour

3” dia x 6” Cylinders Saw Cut in HalfCompression Test

Cylinder from Transverse

Closure Pour

Cylinder from Longitudinal Closure Pour

Cylinder from Longitudinal Closure Pour

• Three 1 5/8” diameter cores were extracted from longitudinal closure pour.

• Sub-cores were created – one from “upper” zone and one from “lower” zone.

• Compressive strength tests were performed by PADOT structures lab. Below are results:


60Ultra High Performance Concrete (UHPC) – Steel Fiber Dispersion

CORE ZONE STRENGTH(psi)

1 Upper 18,030

Lower 23,000

2 Upper 28,180

Lower 27,910

3 Upper 24,210

Lower 22,550CORE 2 CORE 3

Ashcom Cove Creek Bridge Lessons Learned

• Planning and preparation is key to success (forms, erection, coordination with outside suppliers, etc.)

• UHPC and epoxy grout materials are expensive and do not lend themselves to placement from ready-mix trucks. Different grout options need to be investigated.

• Beam haunch forming is time consuming.• Load distribution of precast deck panels onto beams is different from

conventional cast-in-place construction. This needs to be considered in camber computations and beam designs.

• Coarse aggregate bedding for footings should be graded after pieces are dry fit together.

• The schedule needs to be clearly communicated to the entire team including manufacturer representatives required to be on-site.

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Completed Project54 Calendar Days


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QUESTIONS?

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