Contenido Accelerated Bridge Construction: Experience in Design, Fabrication and Erection of Prefabricated Bridge Elements and Systems

This document represents the “State of the Practice” with respect to all aspects of accelerated bridge construction (ABC). The intent of this manual is to fill in the gaps left by publication of the previous manuals. The manual covers ABC techniques, project planning and scoping, implementing ABC in a Transportation Agency, prefabricated elements, long-term performance of prefabricated elements, construction and design. The manual can be used by transportation agencies to establish a successful accelerated bridge construction program.

Table of Contents

Listing of Figures.
Listing of Tables
Listing of Acronyms..
ABC Definitions.
Accelerated Bridge Construction (ABC)
Conventional Bridge Construction
Time Metrics for ABC
Onsite Construction Time
Mobility Impact Time
Prefabricated Bridge Elements and Systems (PBES)
Elements
Deck Elements
Beam Elements
Pier Elements
Abutment and Wall Elements
Miscellaneous Elements
Systems
Superstructure Systems
Superstructure/Substructure Systems
Total Bridge Systems
Glossary of Terms

Chapter 1 Introduction WHY ABC?.

1.1. Purpose and Use of this Manual
   1.1.1. Intended Users
          1.1.1.1. Decision Makers.
          1.1.1.2. Project Managers
          1.1.1.3. Bridge Designers
1.2. Why use Accelerated Bridge Construction?
   1.2.1. Benefits of ABC projects using PBES.
          1.2.1.1. Reduced Road User Impacts.
          1.2.1.2. Improved Worker and Motorist Safety.
          1.2.1.3. Expedited Project Planning Process
          1.2.1.4. Improved Quality
          1.2.1.5. Improved Constructability
          1.2.1.6. Reduced Cost to Society
   1.2.2. Positive Public Perception of ABC
          1.2.2.1. Public Response to ABC Projects.

Chapter 2 Accelerated Bridge Construction Technologies..

2.1. Foundation and Wall Elements
    2.1.1. Continuous Flight Auger Piles (CFA).
    2.1.2. Geosynthetic Reinforced Soil Integrated Bridge System (GRS/IBS)
    2.1.3. Prefabricated Pier Cofferdams
2.2. Rapid Embankment Construction.
   2.2.1. Expanded Polystyrene (EPS) Geofoam
   2.2.2. Accelerated Embankment Preload Techniques.
   2.2.3. Column Supported Embankment Techniques
2.3. Prefabricated Bridge Elements and Systems
   2.3.1. Prefabricated Elements
   2.3.2. Prefabricated Systems
2.4. Structural Placement Methods
   2.4.1. Self Propelled Modular Transporters (SPMTs)
   2.4.2. Longitudinal Launching
   2.4.3. Horizontal Skidding or Sliding..
   2.4.4. Other Heavy Lifting Equipment and Methods
   2.4.5. Conventional Cranes
2.5. Fast Track Contracting.
   2.5.1. Accelerated Project Delivery
          2.5.1.1. Design-Build (DB).
          2.5.1.2. Construction Manager General Contractor (CMGC)
2.5.2. Contracting Provisions
          2.5.2.1. Best Value Selection
          2.5.2.2. A+B and A+B+C Bidding
          2.5.2.3. Continuity of the Construction Process.
          2.5.2.4. Incentive/Disincentive (I/D) Clauses
          2.5.2.5. Warranties.
          2.5.2.6. Lane Rental
2.6. Applicability of ABC Technologies to Different Bridge Projects
    2.6.1. Rehabilitation of Existing Bridges
          2.6.1.1. Deck Replacement
          2.6.1.2. Superstructure Replacement
          2.6.1.3. Substructure Replacement
    2.6.2. Replacement of Existing Bridges and New Bridges.
          2.6.2.1. Staging
          2.6.2.2. Full Closure and New Construction
   2.6.3. Effect of Structure Type on ABC Methods.
          2.6.3.1. Curved, Skewed and Flared Bridges
          Bridges with Transverse Floor Beams.
          2.6.3.2. (trusses and widely spaced girder bridges)
          2.6.3.3. Box Culverts

Chapter 3 PBES for ABC – Planning and Scoping Projects.

3.1. ABC Decision Making Process
3.2. Decision Process for Selection of Appropriate ABC Methods.
    3.2.1. Defining the Problem
           3.2.1.1. Site Constraints
           3.2.1.2. Staging Areas
           3.2.1.3. Traffic Management.
           3.2.1.4. Right of Way Issues.
           3.2.1.5. Utilities.
           3.2.1.6. Local Government Constraints
           3.2.1.7. Structure Type Options
   3.2.2. Flowcharts for Determination of Appropriate ABC Methods
          3.2.2.1. Example Project
   3.2.3. Structure Type Selection Analysis Including Overall Project Costs.
          3.2.3.1. Cost Evaluation
   3.2.4. Public Involvement

Chapter 4 Implementing ABC in a Transportation Agency (A Case Study from the Utah DOT)160

4.1. General Approach: No Magic Bullet
   4.1.1. Strategic Layers of Implementation
   4.1.2. Upper Management and Politics
   4.1.3. Mid-Level and Organization
   4.1.4. Project Level
   4.1.5. Identify ABC Champions at All Levels
4.2. Stakeholder Buy-in
4.3. Scanning Tours
4.4. Demonstration Projects
4.5. The Role of Innovative Contracting.
4.6. PBES Decision Making Framework
4.7. Establish a “Program of Projects”.
4.8. Develop Specifications, Standards, and Standard Details.
4.9. Communication.
4.10. Measure and Share Successes
4.11. Conclusions

Chapter 5 Prefabricated Bridge Elements

5.1. Materials
   5.1.1. Structural Steel
   5.1.3. Timber.
   5.1.4. Aluminum.
   5.1.5. Fiber-Reinforced Polymer
   5.1.6. Grouts
          5.1.6.1. Grout Types
   5.1.7. Ultra High Performance Concrete
   5.1.8. Corrosion Resistant Reinforcing Steel
          5.1.8.1. Stainless Steel
          5.1.8.2. Low-carbon, Chromium, Steel Bars
          5.1.8.3. Coated and Galvanized Bars.
          5.1.8.4. Fiber Reinforced Polymer (FRP) Bars
5.2. Superstructure Elements
   5.2.1. Beams and Girders
          5.2.1.1. Steel.
          5.2.1.2. Precast/Prestressed Concrete
   5.2.2. Stay-in-place Deck Forming
          5.2.2.1. Corrugated Steel
          5.2.2.2. Partial-depth Precast Concrete Deck Panels
   5.2.3. Full-Depth Deck Panels
          5.2.3.1. Precast/Prestressed Concrete.
          5.2.3.2. Steel Grid
          5.2.3.3. Fiber Reinforced Polymer
   5.2.4. Modular Superstructure Systems
          5.2.4.1. Modular Steel Systems
          5.2.4.2. Modular Precast Concrete Superstructure Systems
          5.2.4.3. Modular Timber Superstructure Elements and Systems
5.3. Substructure Elements
   5.3.1. Piers.
          5.3.1.1. Open Frame Bents
          5.3.1.2. Wall Piers
          5.3.1.3. Seismic Requirements
   5.3.2. Abutments.
          5.3.2.1. Cantilever
          5.3.2.2. Spill-Through.
          5.3.2.3. Integral and Semi-Integral Abutments
          5.3.2.4. Geosynthetic Reinforced Soil Integrated Bridge System (GRS).
          5.3.2.5. Seismic Requirements.
   5.3.3. Wing Walls and Retaining walls
         5.3.3.1. Precast Concrete Cantilever.
         5.3.3.2. Modular Precast
   5.3.4. Modular Culvert/Arch Systems
         5.3.4.1. Precast Arches and Three Sided Frames
         5.3.4.2. Steel Arches and Pipes
         5.3.4.3. Box Culverts.
5.4. Foundations
    5.4.1. Common Deep Foundations
    5.4.2. Foundation Challenges
         5.4.2.1. Earth Retention
         5.4.2.2. Deep Water
    5.4.3. Prefabricated Foundation Elements
         5.4.3.1. Spread Footings
         5.4.3.2. Pile Cap Footings
         5.4.3.3. Precast Pier Box Cofferdams

Chapter 6 Miscellaneous Bridge Elements

6.1. Deck Overlays I Riding Surface Quality
6.2. Bridge Deck Expansion Joints
6.3. Bridge Bearings
6.4. Drainage Assemblies.
6.5. Barriers and Railings.
   6.5.1. Crash Testing Requirements
   6.5.2. Concrete Barril
   6.5.4. Barriers on MSE and Modular Walls.
6.6. Utilities

Chapter 7 Construction.

7.1. Shoring Systems and Temporary Works
    7.1.1. Shoring for Large-scale Bridge Moves
    7.1.2. Geotechnical Investigations
7.2. Acceleration of Submissions and Reviews.
    7.2.1. Electronic Data Transfer.
           7.2.1.1. Electronic Shop Drawing and Submittals
           7.2.1.2. Digital Stamps and Signatures
    7.2.2. “Intent to build” Drawings
7.3. Materials Testing on ABC Projects.
    7.3.1. Accelerated Testing Protocol
    7.3.2. Concrete Maturity Method
    7.3.3. Load Indicating Washers for Steel Structures
7.4. Fabrication.
    7.4.1. Plant Certification.
    7.4.2. Near-site Casting Certification.
    7.4.3. Tolerances
           7.4.3.1. Element Tolerances
           7.4.3.2. Dimensional Growth
           7.4.3.3. Hardware Tolerances
    7.4.4. Lifting/Moving Elements
    7.4.5. Workmanship
7.5. Erection Issues
    7.5.1. Responsibilities
           7.5.1.1. Designer.
           7.5.1.2. Contractor
           7.5.1.3. Fabricator
    7.5.2. Large-scale Bridge Lifting
    7.5.3. The Effect of Tolerances and Adjustability.
7.6. Field Inspection.
    7.6.1. Accelerated Decision Making
    7.6.2. Staff Training
7.7. Grout Placement and Curing
    7.7.1. Small Void Grouting
    7.7.2. Grouting of Post-tensioning Ducts.
7.8. High Early Strength Concrete
    7.8.1. Mix Design Approach
    7.8.2. Accelerated Curing

Chapter 8 Long Term Performance of Prefabricated Elements

8.1. Inspection Preservation, and Maintenance .
8.2. Durability of Modular Systems
   8.2.1. Case Studies in Durability
          8.2.1.1. Joints in Substructure Elements
          8.2.1.2. Joints in Precast Concrete Deck Panels
          8.2.1.3. Large-scale Bridge Moves

Chapter 9 Design and Analysis .

9.1. LRFD Design
9.1.1. Precast Substructure Elements.
9.1.2. Deck Panel Elements
9.1.3. ABC Issues not Covered in the LRFD Bridge Design Specifications
9.1.4. Design of Bridges with Large-scale Lifting Methods
9.2. LRFR Ratings
9.3. Design and Analysis of Temporary Works
9.4. Evaluation of Existing Structures

References..

Appendices .
Appendix A: Design Examples.
Appendix B: Standard and Proprietary Products
Appendix C: Sample Construction Specifications