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
2
Project Location
Ashcom Cove Creek BridgeBedford County SR 1004-001
3
Ashcom Cove Creek BridgeBedford County SR 1004-001
4
Ashcom Cove Creek BridgeBedford County SR 1004-001
5
Far Approach (Looking East to West) -- 2007
Ashcom Cove Creek BridgeBedford County SR 1004-001
6
Far Approach (Looking East to West)
Ashcom Cove Creek BridgeBedford County SR 1004-001
7
Upstream Elevation Existing Bridge
Ashcom Cove Creek BridgeBedford County SR 1004-001
8PLAN VIEW FROM AS-BID DRAWINGS
9
Ashcom Cove Creek BridgeBedford County SR 1004-001
ELEVATION VIEW FROM AS-BID DRAWINGS
Ashcom Cove Creek BridgeBedford County SR 1004-001
10
TYPICAL SECTION FROM AS-BID DRAWINGS
Ashcom Cove Creek BridgeBedford County SR 1004-001
• 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.
11
Ashcom Cove Creek BridgeBedford County SR 1004-001
• 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.
12
Ashcom Cove Creek BridgeBedford County SR 1004-001
• 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
13
Ashcom Cove Creek BridgeBedford County SR 1004-001
• 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
14
Ashcom Cove Creek BridgeBedford County SR 1004-001
• 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
15
Ashcom Cove Creek Bridge PrecastVE Total Precast Bridge
16
Ashcom Cove Creek Bridge Precast Production Schedule
17
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.
18
Ashcom Cove Creek Bridge Precast Abutment Footings
19
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
Ashcom Cove Creek Bridge Precast Abutment Footings
20
EXCERPT FROM SHOP DRAWING
OF FOOTING
Ashcom Cove Creek Bridge Precast Abutment Footings
21Footing Pieces Cast Upside Down
Ashcom Cove Creek Bridge Precast Abut Walls & Corner Transitions
22
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
23
EXCERPT FROM SHOP DRAWING OF WALL PANEL
NMB Splice Sleeve
Ashcom Cove Creek Bridge Precast Abutment Walls
24
Ashcom Cove Creek Bridge Precast Abut-Wing Corner Transitions
25
EXCERPT FROM SHOP DRAWING OF WALL PANEL
NMB Splice Sleeve
Post-Tensioning Duct
Ashcom Cove Creek Bridge Precast Abut-Wing Corner Transitions
26
Ashcom Cove Creek Bridge Abutments - Dry Fit in Fabrication Yard
27
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.
28
Ashcom Cove Creek Bridge Precast Deck Panels
29
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
Ashcom Cove Creek Bridge Precast Deck Panels
30
Shear Pockets
Typical Deck Panel 12’-2” +/- Long
EXCERPT FROM SHOP DRAWING OF DECK PANELSPLAN VIEW
UHPC Longitudinal Closure Pour
Transverse Closure Pour
(Typ.)
Ashcom Cove Creek Bridge Precast Deck Panels
31
Shear Pockets (Typ over Bms)
EXCERPT FROM SHOP DRAWING OF DECK PANELSBRIDGE CROSS SECTION
UHPC Longitudinal Closure Pour
Barriers Integral w/ Deck Panel
Left Deck Panel Right Deck Panel
Ashcom Cove Creek Bridge Precast Deck Panels
32
Shear Pockets (Typ over Bms)
EXCERPT FROM SHOP DRAWING OF DECK PANELSPLAN VIEW - TYPICAL PANEL
Barriers Integral w/ Deck Panel
Ashcom Cove Creek Bridge Precast Deck Panels
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
35
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
37
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)
38
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
Ashcom Cove Creek Bridge Construction - Substructure
40ABUTMENT – FOOTING INSTALLATION
Ashcom Cove Creek Bridge Construction - Substructure
41ABUTMENT – FOOTING INSTALLATION
Ashcom Cove Creek Bridge Construction - Substructure
42ABUTMENT – FOOTING INSTALLATION
Ashcom Cove Creek Bridge Construction - Substructure
43ABUTMENT – FOOTING INSTALLATION
Ashcom Cove Creek Bridge Construction - Substructure
44
ABUTMENT – WING WALL SETTING
Ashcom Cove Creek Bridge Construction - Substructure
45ABUTMENT – CORNER TRANSITIONS
Ashcom Cove Creek Bridge Construction - Substructure
46ABUTMENT – BREAST WALL INSTALLATION
Ashcom Cove Creek Bridge Construction - Substructure
47ABUTMENT – COMPLETED PRECAST ASSEMBLY
Ashcom Cove Creek Bridge Construction - Substructure
48ABUTMENT – COMPLETED PRECAST ASSEMBLY
Ashcom Cove Creek Bridge Construction - Substructure
49ABUTMENT – SPLICE SLEEVE GROUTING
Ashcom Cove Creek Bridge Construction - Superstructure
50PRECAST DECK PANELS
Ashcom Cove Creek Bridge Construction - Superstructure
51PRECAST DECK PANELS
Ashcom Cove Creek Bridge Construction - Superstructure
52PRECAST DECK PANELS
Ashcom Cove Creek Bridge Construction - Superstructure
53
PRECAST DECK PANELS
ADJUSTING LEVELING BOLTSAdjusting Leveling Bolt
with Impact Wrench
View of Leveling Bolts from Underside of Deck Panel
Ashcom Cove Creek Bridge Construction - Superstructure
54
PRECAST DECK PANELSUHPC Closure Pours Haunch Formwork
Steel FibersPre-Blended Cementitious
Transverse Closure Pour
Transverse Joint Profile
Ashcom Cove Creek Bridge Construction - Superstructure
55PRECAST DECK PANELS - UHPC Closure Pours
Ashcom Cove Creek Bridge Construction - Superstructure
56
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
Ashcom Cove Creek Bridge Construction - Superstructure
57
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
Ashcom Cove Creek Bridge Construction - Superstructure
59
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:
Ashcom Cove Creek Bridge Construction - Superstructure
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.
61
Ashcom Cove Creek BridgeBedford County SR 1004-001
62
Completed Project54 Calendar Days
Ashcom Cove Creek BridgeBedford County SR 1004-001
63
Ashcom Cove Creek BridgeBedford County SR 1004-001
64
QUESTIONS?