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Segmental Bridge Construction - Florida Transportation Builders
Structures Design Plans Segmental Bridge Construction g g Review Groupp Segmental Bridges – Segmental Bridges It’s a It’s a Construction Technique with Design Implications 2010 FDOT/FTBA Construction Conference February 23-24 Orlando, Florida Structures Design Plans Review Speakers Group p Presentation Speakers Presentation Brian Blanchard P E Brian Blanchard, P.E. Florida Department of Transportation Enrique Espino P E Enrique Espino, P.E. Condotte America, Inc. Jim Schneiderman, P.E. PCL Civil Constructors, Inc. R. Craig Finley, Jr., P.E. Finley Engineering Group, Inc. y g g p, Structures Design February 23, 2010 FDOT/FTBA Construction Conference g Plans Agenda Review Group p • Florida Department of Transportation’s Perspective, Brian Blanchard, P.E., Perspective, Brian Blanchard, P.E., Florida Department of Transportation • Contractor’s Perspective Enrique Espino, P.E., Condotte d America, Inc. Jim Schneiderman, P.E., PCL Civil Constructors • Design and Construction Engineers Design and Construction Engineers’ Perspective R. Craig Finley, Jr., P.E., R. Craig Finley, Jr., P.E., Finley Engineering Group, Inc. • Future Perspective, Enrique Espino, P.E., Condotte America, Inc. • Round Table Q & A FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p Roosevelt Bridge Segmental Bridges – It’s a Construction Technique with Construction Technique with Design Implications February 23, 2010 FDOT/FTBA Construction Conference Brian Blanchard P.E. Chief Engineer Florida Department p of Transportation From the Florida Department of Transportation’s Perspective ’ FDOT Structures Perspective Design Skyway Bridge February 23, 2010 FDOT/FTBA Construction Conference Brian Blanchard P.E. Chief Engineer Florida Department p of Transportation Segmental g Bridge g Construction Plans Review Group p From the Florida Department of From the Florida Department of Transportation’s Perspective History of Segmental Bridges in Florida FDOT Policies and Procedures FDOT Policies and Procedures Experience and Future Treads FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p Royal Park Bridge History of Segmental Bridges in Florida February 23, 2010 FDOT/FTBA Construction Conference Brian Blanchard P.E. Chief Engineer Florida Department p of Transportation FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p 1982 Span-by-span Balanced Cantilever All dates given are completion dates hannel Niles Ch 1983 1984 Ram mp I Over I-75 1981 Seven M Mile Channeel 5 Long K Key Bridge History of Segmental Bridges in Florida – The Early Years FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p History of Segmental Bridges in Florida – The Early Years Long Key Bridge id Channel 5 Niles Channel Seven Mile All dates given g ve are a e completion co p et o dates I-595/I--75 ((5 Bridgges) 1986 I--75/SR 8826 ((5 Bridgges) 1985 1987 1988 I-5595/US 4441 ((2 Bridgges) Span-by-span Balanced Cantilever I-595/I--75 ((6 Bridgges) - The Early Years (cont.) Sk kyway Ap pproach hes Segmental g Bridge g Construction Plans Review Group p Ft. Lauderdaale Airpoort (44 Bridgees) FDOT Structures Perspective Design FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p Longg Key y Bridge g First application of Precast Span-byspan Bridge Construction in the U.S. 1981 FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p Seven-Mile Bridge First Application of an Overhead Gantryy in Florida 1982 FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p Ramp I Bridge First application of Precast Balanced Cantilever Construction in Florida 1984 FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p - Other Firsts First Demolition of Existing Segmental Bridge in the North America. Fort Lauderdale-Hollywood International Airport expansion required q the removal of three pprecast segmental concrete bridges. How did we demolish segmental concrete bridges built by the balancedcantilever method? By reversing the way the h segments were installed. i ll d 2002 FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p - Other Firsts I-75/ SR 826 Ramp p A -First Segmental g Bridge g Widening in U.S. Mainland 2004 FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p 12 FDOT Segmental g Bridges g Constructed by y Year 10 8 6 4 2 Current Number of Segmental Bridges – 68 (3 have been removed at Ft. Lauderdale Airport) 2006 2002 2003 2004 2005 1998 1999 2000 2001 1994 1995 1996 1997 1990 1991 1992 1993 1985 1986 1987 1988 1989 1981 1982 1983 1984 0 FDOT Structures Perspective Design Acosta Bridge February 23, 2010 FDOT/FTBA Construction Conference Brian Blanchard P.E. Chief Engineer Florida Department p of Transportation Segmental g Bridge g Construction Plans Review Group p FDOT Policies and Procedures FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p FDOT Policies In Response to PT Corrosion Issues February 23, 2010 FDOT/FTBA Construction Conference Brian Blanchard P.E. Chief Engineer Florida Department p of Transportation Advanced Corrosion of Strands within Niles Channel Anchorage FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p FDOT Bridges w/ Grout Problems Niles Channel Bridge 6 Bridges at I‐75 & I‐595 (Voids in Tendons) 1996 Inspection February 23, 2010 FDOT/FTBA Construction Conference Brian Blanchard P.E. Chief Engineer Florida Department p of Transportation Niles Channel (Failed Tendon) (Failed Tendon) 1999 Inspection FDOT Structures Perspective Design Skyway Bridge Segmental g Bridge g Construction Plans Review Group p FDOT Bridges w/ Grout Problems (cont.) Mid‐bay (Spans 28 and 57 ( 2‐ Failed Tendons) 2000 Inspection February 23, 2010 FDOT/FTBA Construction Conference Skyway Approach (Failed Tendon Pier 133 N) Tendon Pier 133 N) 2000 Inspection Brian Blanchard P.E. Chief Engineer Florida Department p of Transportation FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p New Directions for Florida Post-Tensioned Bridges Corven Engineering, g g, Inc. February 15, 2002 February 23, 2010 FDOT/FTBA Construction Conference Brian Blanchard P.E. Chief Engineer Florida Department p of Transportation FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p 2Policyy Revisions Specify Minimum Layers of Protection Seabreeze Bridge Develop Anchorage Protection Standard Details and QPL Pour-back Materials Develop P.T. Redundancy Requirements Refine R fi G Grouting ti Procedures P d February 23, 2010 FDOT/FTBA Construction Conference Brian Blanchard P.E. Chief Engineer Florida Department p of Transportation • Pre-approved P.T. Systems • Qualified Grouting Personnel/ Inspectors • Specify Low-Point-Up Grouting • Specify Non-bleed QPL Bagged Grouts • Specify Inspection Access Points FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p Dodge Island Bridge Experience and Future Trends February 23, 2010 FDOT/FTBA Construction Conference Brian Blanchard P.E. Chief Engineer Florida Department p of Transportation FDOT Structures Perspective Design Hathaway Bridge February 23, 2010 FDOT/FTBA Construction Conference Brian Blanchard P.E. Chief Engineer Florida Department p of Transportation Segmental g Bridge g Construction Plans Review Group p Experience and Future Trends – Segmental top-down construction techniques are cost effective on large waterway projects where insurance and labor rates are governed by time working from barges. Larger projects generally make segmental construction more cost effective due to the casting yard setup cost being spread over more segmental units and when the amount g of work is sufficient to overcome learningcurve inefficiencies. FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p Experience and Future Trends (cont.) – Segmental alternatives have been Royal Park Bridge competitive p against g steel box options p where the number of segmental units is sufficient (greater than 600-700 units). (g ) February 23, 2010 FDOT/FTBA Construction Conference Brian Blanchard P.E. Chief Engineer Florida Department p of Transportation Segmental options have not been competitive on small projects when bid against simple span prestressed beam options. FDOT Structures Perspective Design Roosevelt Bridge Segmental g Bridge g Construction Plans Review Group p Future Trends – Customized Overhead Gantries Allowing All i Cantilever C il Construction C i on Curved C d Ramps Greatlyy Reducingg Traffic Disruptions p Example: Palmetto Section 5 February 23, 2010 FDOT/FTBA Construction Conference Brian Blanchard P.E. Chief Engineer Florida Department p of Transportation Transverse Deck Beam FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p Future Trends – Greater Use of Combined Steel and Concrete to Reduce Weight? • Core Segment • External Strut + Rib • Precast Panel Example: Yamakiri Viaduct (Japan) FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p Future Trends – National Post-Tensioning Specification p PTI is currently y developing p g a nationwide p posttensioning specification based largely on FDOT specifications, research and past experiences. FDOT Structures Perspective Design Segmental g Bridge g Construction Plans Review Group p February 23, 2010 FDOT/FTBA Construction Conference Brian Blanchard P.E. Chief Engineer Florida Department p of Transportation S.E. 17th Street Bridge Contractor’s Structures Perspective Design Plans Segmental Bridge Construction g Segmental Bridge Construction g Review g Group g p Enrique I. Espino, P.E. President Condotte America, Inc. Jim Schneiderman, P.E. Construction Manager PCL Civil Constructors, Inc. February 23, 2010 FDOT/FTBA Construction Conference Segmental Bridges – It’s a Construction Technique with Design Technique with Design Implications The Contractor’s Perspective Contractor’s Structures Perspective Design Plans Segmental Bridge Construction g Segmental Bridge Construction g Review g Group g p • Types Types of Segmental Bridges and of Segmental Bridges and Characteristics Enrique I. Espino, P.E. President Condotte America, Inc. • Precasting P ti Segments ‐ S t Superstructures & Substructures • Erecting Precast Segments ‐ Jim Schneiderman, P.E. Construction Manager PCL Civil Constructors, Inc. February 23, 2010 FDOT/FTBA Construction Conference Superstructures & Substructures • Cast‐in‐Place with Form Travelers Contractor’s Structures Perspective Design Plans Segmental Bridge Construction g Segmental Bridge Construction g Review g Group g p Types of Segmental Bridges and Characteristics and Characteristics Jim Schneiderman, P.E. Construction Manager PCL Civil Constructors, Inc. February 23, 2010 FDOT/FTBA Construction Conference Jim Schneiderman, P.E. Jim Schneiderman P E PCL Civil Constructors, Inc. Structures Design Plans Review p Segmental Bridge Construction g g Group • Types of Segmental Bridge Structures Types of Segmental Bridge Structures – Precast Span by Span – Precast Balanced Cantilever Precast Balanced Cantilever – Precast Progressive Placement – Cast‐in‐Place Balanced Cantilever C t i Pl B l d C til – Cast‐in‐Place Incremental Launching – Cast‐in‐Place & Precast Cable Stayed C i Pl &P C bl S d Structures Design Plans Review p Segmental Bridge Construction g g Group • Precast Span by Span Precast Span by Span Ernest F. Lyons Bridge – Stuart, FL (Photo courtesy of PCL Civil Constructors, Inc.) Structures Design Plans Review p Segmental Bridge Construction g g Group • Precast Balanced Cantilever Precast Balanced Cantilever J h Ri li C John Ringling Causeway – S Sarasota, FL t FL (Photo courtesy of PCL Civil Constructors, Inc.) Structures Design Plans Review p Segmental Bridge Construction g g Group • Precast Progressive Placement Precast Progressive Placement Temp. Support Linn Cove Viaduct – Blue Ridge Parkway, NC (Photo courtesy of Figg Engineering Group) Structures Design Plans Review p Segmental Bridge Construction g g Group • Precast Progressive Placement (cont.) Precast Progressive Placement (cont ) Temp. Support Structures Design Plans Review p Segmental Bridge Construction g g Group • Cast Cast‐in‐Place in Place Balanced Cantilever Balanced Cantilever Form Traveler Foothills Parkway Bridges – Smokey Mountains, Tennessee (Photo Courtesy of PCL Civil Constructors, Inc.) Structures Design Plans Review p Segmental Bridge Construction g g Group Cast in Place Balanced Cantilever (Cont ) Cast‐in‐Place Balanced Cantilever (Cont.) Structures Design Plans Review p Segmental Bridge Construction g g Group Cast‐in‐Place Cast in Place Incremental Launching Incremental Launching Launching Direction Casting Bed Launching Nose Structures Design Plans Review p Segmental Bridge Construction g g Group • Precast & CIP Segmental Cable Stayed Precast & CIP Segmental Cable Stayed Sunshine Skyway Bridge – Tampa, FL (Photo courtesy of Figg Engineering Group) Structures Design Plans Review p Segmental Bridge Construction g g Group Precast and Cast‐in‐Place Precast and Cast in Place Cable Stayed (cont.) Cable Stayed (cont ) Pylon Stay Cable Deck Contractor’s Structures Perspective Design Plans Segmental Bridge Construction g Review Group g p Precasting Segments Superstructures & Substructures Enrique Espino, P.E. Condotte America, Inc. Enrique I. Espino, P.E. President Condotte America, Inc. February 23, 2010 FDOT/FTBA Construction Conference Contractor’s Structures Perspective Design Plans Segmental Bridge Construction g Segmental Bridge Construction g Review g Group g p Erecting Precast Segments Superstructures & Substructures Jim Schneiderman, P.E. Construction Manager PCL Civil Constructors, Inc. February 23, 2010 FDOT/FTBA Construction Conference Jim Schneiderman, P.E. Jim Schneiderman P E PCL Civil Constructors, Inc. Structures Design Plans Review p Segmental Bridge Construction g g Group ‐ Precast Segmental Bridge Erection Techniques Precast Segmental Bridge Erection Techniques ‐ Span by Span Erection Methods ‐ Balanced Cantilever Erection Methods Balanced Cantilever Erection Methods ‐ Erection of Segmental Substructures Structures Design Plans Review p Segmental Bridge Construction g g Group • Span by Span Erection Methods – ‘Top Down’ erection using under‐slung truss and segment lifter Segment Lifter Underslung Truss Truss Supports Ernest F. Lyons Bridge – Stuart, FL (Photo Courtesy of PCL Civil Constructors, Inc.) Structures Design Plans Review p Segmental Bridge Construction g g Group • Span by Span Erection Methods – Overhead Erection Truss Overhead Erection Truss Seattle Sound Transit Light Rail Project – Seattle, WA (Photo courtesy of PCL Civil Constructors, Inc.) Structures Design Plans Review p Segmental Bridge Construction g g Group ‐Span by Span Erection Methods ‐Overhead Erection Truss Overhead Erection Truss Overhead Erection Truss C&D Canal Bridge – Delaware (Photo courtesy of Figg Engineering Group) Structures Design Plans Review p Segmental Bridge Construction g g Group • Span by Span Erection Methods p y p – Erected on Falsework using conventional cranes Falsework (Photo courtesy of Flatiron Constructors, Inc.) Structures Design Plans Review p Segmental Bridge Construction g g Group • Span by Span Erection Methods – Lifting of Entire Span at once Lifti f E ti S t Jamestown Bridge – Rhode Island (Photo Courtesy of Figg Engineering Group) Structures Design Plans Review p Segmental Bridge Construction g g Group • Typical Balanced Cantilever Erection Methods yp Structures Design Plans Review p Segmental Bridge Construction g g Group • Balanced Cantilever Erection Methods Crane Erection from Ground Crane Erection from Bridge Deck Structures Design Plans Review p Segmental Bridge Construction g g Group ‐ Balanced Cantilever Erection Methods ‐ Erection using a beam and winch Oakland Bay Bridge ‐ Oakland, CA (Photo courtesy of Flatiron Constructors, Inc.) Structures Design Plans Review p Segmental Bridge Construction g g Group ‐ Balanced Cantilever Erection Methods ‐ Erection using overhead Erection Truss Otay River Bridge – San Diego, CA (Photo courtesy of International Bridge Technologies) Structures Design Plans Review p Segmental Bridge Construction g g Group • Segmental Substructures • Sequence of Erection: – Place and Grout Segment to footing Keway – Erect remaining segments to a predetermined elevation (usually based on stability) elevation (usually based on stability). – Perform intermediate P.T. to maintain pier stability – After all segments have been erected, permanent PT is performed (usually loop permanent PT is performed (usually loop tendons through footing) – Tendons are then grouted. • Typical Precast Column Segment Keyway Splash Zone Requirements: – Many states do not allow precast substructure elements to be used within the splash zone. Above the Splash Zone, precast erection can begin. Keyway in Footing to Align / Stress first Segment Structures Design Plans Review p Segmental Bridge Construction g g Group • Segmental Substructures g C&D Canal Bridge Hoover Dam Bypass Structures Design Plans Review p Segmental Bridge Construction g g Group • Segmental Substructures g Stressing Vertical Column Tendon Structures Design Plans Review p Segmental Bridge Construction g g Group • When When does Precast Segmental Substructure does Precast Segmental Substructure make sense? – When you have a large volume production of typical pier shapes y g p yp p p – When high quality concrete and geometry control of the piers is extremely important – When there is a long lead time for foundations that allows fabrication When there is a long lead time for foundations that allows fabrication of pier segments concurrently with foundation work * The The major advantage of precasting major advantage of precasting substructure segments is the substructure segments is the speed of erection, which surpasses any other conventional method of pier construction. Structures Design Plans Review p Segmental Bridge Construction g g Group Scheduled Seminars : Scheduled Seminars : February 17‐18 Denver, Colorado June 22‐23 Orlando, Florida For More Information, Please Go To: http://www asbi assoc org http://www.asbi‐assoc.org Contractor’s Structures Perspective Design Plans Segmental Bridge Construction g Review Group g p Cast‐in‐Place Cast in Place with Form Travelers Enrique Espino, P.E. Condotte America, Inc. America Inc Enrique I. Espino, P.E. P President id Condotte America, Inc. February 23, 2010 FDOT/FTBA Construction Conference Contractor’s Structures Perspective Design Enrique I. Espino, P.E. President Condotte America, Inc. Jim Schneiderman, P.E. Construction Manager PCL Civil Constructors, Inc. February 23, 2010 FDOT/FTBA Construction Conference Plans Segmental Bridge Construction g Review Group g p Segmental Bridges – Segmental Bridges – It’s a Construction Technique with Design Implications ith D i I li ti Structures Design Plans Review Group p Design g and Construction Engineer’s g Perspective R. Craig Finley, Jr., P.E. Managing Principal FINLEY Engineering Group, Inc. February 23, 2010 FDOT/FTBA Construction Conference R. Craig Finley, Jr., P.E. R. Craig Finley, Jr., P.E. Finley Engineering Group, Inc. Structures Design Plans Review Group p Design and Construction Engineer’s Perspective g g p Presentation Outline • • • • • Key Points to Understanding Segmental My Background & Perspective Importance of Project Procurement Engineering Roles & Responsibilities p Special Considerations Structures Design Plans Review Group p Design and Construction Engineer’s Perspective g g p Key Points to Understanding Segmental Segmental bridges are based on a construction technique that has design implications. Know how to build it before starting to design it. g g Structures Design Plans Review Group p Design and Construction Engineer’s Perspective g g p Background • A bridge engineer, a Florida PE and FTBA member b • Involved with segmental bridges continuously since 1979 continuously since 1979 • Working in the USA and internationally • Started in Florida on the Keys and now doing SR 826/836 Interchange Structures Design Plans Review Group p Design and Construction Engineer’s Perspective g g p Perspective • As a designer and construction engineer • Preference for contractor driven and design/build projects • Typically involved with the bid Typically involved with the bid The best approach is not always the same for every one or every project. Structures Design Plans Review Group p Design and Construction Engineer’s Perspective g g p Importance of Project Procurement Three ways to do it: • Design – Bid – Build g Build • Design – • After the fact – Value Engineering or “Construction Modification” Different approaches to ff pp incorporate construction methods Structures Design Plans Review Group p Design and Construction Engineer’s Perspective g g p Design – Bid - Build • Generic design – many assumptions • Code based – not construction methods or schedule • Will be reworked by construction engineer before it can be built • Multiple steps/approvals Procurement Structures Design Plans Review Group p Design and Construction Engineer’s Perspective g g p Design - Build • Specific design – known construction method • Better initial optimization and faster process • More efficient – best results • Responsibility is where it needs to be Procurement Structures Design Plans Review Group p Design and Construction Engineer’s Perspective g g p Value Engineering / “Construction Construction Modification” Modification • • • • Combination approach Combination approach Used for an advantage Has been very successful Has been very successful More common in tough times Procurement Structures Design Plans Review Group p Design and Construction Engineer’s Perspective g g p Engineering Roles & Responsibilities • Design Engineer Owner Client • Construction Engineer Contractor Client • Value Engineering / Design Build Structures Design Plans Review Group p Design and Construction Engineer’s Perspective g g p Design Engineer • Works for the owner • Typical scope – – – – Design Drawings Specifications Cost estimates Based on an assumed schedule and means & methods d & h d Roles & Responsibilities Structures Design Plans Review Group p Design and Construction Engineer’s Perspective g g p The Design Engineer provides post-design services. services • R Reviews and approves construction i d t ti engineering • Based on actual construction engineering Based on actual construction engineering – Takes time – Inefficient – Personalities involved Roles & Responsibilities Structures Design Plans Review Group p Design and Construction Engineer’s Perspective g g p Construction Engineer • Works for contractor • Typical scope – – – – – Integrated shop drawings Construction analysis and camber Temporary works / special equipment Geometry controll Post‐tensioning support Roles & Responsibilities Structures Design Plans Review Group p Design and Construction Engineer’s Perspective g g p The Construction Engineer does the detailed design. design • Performs Performs time dependent, step by time dependent, step by step analysis • Incorporates schedule and sequence p q • Analyzes means and methods Uses sophisticated software and is • Uses sophisticated software and is very detailed Roles & Responsibilities Structures Design Plans Review Group p Design and Construction Engineer’s Perspective g g p Value Engineering and Design - Build • In VE projects, there is overlap between the design and construction engineers. engineers • With With Design‐Build, the design and D i B ild th d i d construction engineer are the same. Roles & Responsibilities Structures Design Plans Review Group p Design and Construction Engineer’s Perspective g g p Special Considerations The Construction Method Dictates Design • Takes more engineering to Bid & Build q g p g • Requires high level of planning and coordination • Calls for a factory/assembly line mentality • Is optimum in design/build Structures Design Plans Review Group Design and Construction Engineer’s Perspective g g p p Managing Principal Structures Design Plans Review Group p Design g and Construction Engineer’s g Perspective R. Craig Finley, Jr., P.E. Managing Principal FINLEY Engineering Group, Inc. February 23, 2010 FDOT/FTBA Construction Conference R. Craig Finley, Jr., P.E. R. Craig Finley, Jr., P.E. Finley Engineering Group, Inc. Segmental Bridge Construction Plans Review Group p Future Perspective Future Perspective Structures Design February 23, 2010 FDOT/FTBA Construction Conference • More More design design‐build build & experienced & experienced Contractors. • Standardization of precast segments Standardization of precast segments – Supply like pre‐stressed girders. • Higher strength and composite materials. • National specifications for materials and training. g Segmental Bridge Construction Plans Review Group p Future Perspective Future Perspective Structures Design • More More sophisticated erection sophisticated erection equipment. • Rehab market will develop. Rehab market will develop • 100+ year service life – durability. February 23, 2010 FDOT/FTBA Construction Conference Segmental Bridge Construction Plans Review Group p Round Table Q & A Round Table Q & A Structures Design • Florida Florida Department of Transportation Department of Transportation’ss Perspective, Brian Blanchard, P.E., Florida Department of Transportation • Contractor’s Perspective – Enrique Espino, P.E., Condotte q p , , America, Inc. , – Jim Schneiderman, P.E., PCL Civil Constructors, Inc. • Design and Construction Engineers’ Perspective February 23, 23 2010 FDOT/FTBA Construction Conference g y y g g p R. Craig Finley, Jr., P.E., Finley Engineering Group
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