ACCELERATED CONSTRUCTION AND EMERGENCY ......• 40 –Precast 36’ span x 11’ rise CON/SPAN arch...

Knowledge. Solutions. Service.

ACCELERATED CONSTRUCTION AND EMERGENCY REPLACEMENT OPTIONS FOR PRE-

ENGINEERED STRUCTURES

Michigan Bridge ConferenceMarch 24, 2010

David E. Keaffaber, P.E.

Steve Matheny, P.E.

Bridge, Drainage, Erosion Control, Retaining Walls, Sanitary, Soil Stabilization, Stormwater

CONTECH Engineered Site Solutions

Plate:

Precast:

Truss:

Plate:•MULTI-PLATE®/Aluminum Structural Plate

•Aluminum Box Culvert

•SUPER-SPAN™/SUPER-PLATE®

Precast:•CON/SPAN®

•BEBO®

Truss:•Steadfast Bridges®

•Continental® Bridge

Span (ft) 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

Plate 5-52 ft

Precast 12-102 ft

Vehicular Steel Truss Bridges 10-150 ft

Pedestrian Steel Truss Bridges 10–250 ft and more

Bridge Span Ranges

Truss Bridge Styles

Archway® Capstone® Keystone®

Connector® Link® Steel Stringer

*Cable Stayed*Expressway® *Gateway®

*Pedestrian Only

Structural Plate Shapes

(SQUARE FEET)

SPAN (FT.)

12(FT.)

SHORT SPAN SERIES

WATERWAY AREA

(SQUARE FEET)

WATERWAY AREA

(FT.)SPAN

INTERMEDIATE SPAN SERIES

WATERWAY AREA(SQUARE FEET)

RISE (FT.)SPAN

LONG SPAN SERIES

CON/SPAN® WATERWAY CHARTS

BEBO® WATERWAY CHARTS

Waterway Area (ft²)

Rise (ft) Arch Series

E12 E16 E20 E24 E30 E36 E42 E48 E54T E60T E66T E72T E78T E84T

4 34 42 * * * * * * * * * * * *

5 46 57 67 * * * * * * * * * * *

6 58 73 85 * * * * * * * * * * *

7 * 89 105 120 * * * * * * * * * *

8 * * 125 143 * * * * * * * * * *

9 * * 145 167 197 229 * * * * * * * *

10 * * * 191 226 264 300 * * * * * * *

11 * * * 215 256 300 341 * * * * * * *

12 * * * * 286 335 382 427 * * * * * *

13 * * * * 316 371 424 475 * * * * * *

14 * * * * * * * * 588 * * * * *

15 * * * * * * * * 641 * * * * *

16 * * * * * * * * 695 * * * * *

17 * * * * * * * * 749 807 * * * *

18 * * * * * * * * 803 867 * * * *

19 * * * * * * * * 857 927 992 * * *

20 * * * * * * * * 911 987 1058 1131 * *

21 * * * * * * * * * 1047 1124 1203 * *

22 * * * * * * * * * 1107 1190 1275 1349 *

23 * * * * * * * * * * 1256 1347 1427 1502

24 * * * * * * * * * * 1322 1419 1505 1586

25 * * * * * * * * * * * 1491 1583 1670

26 * * * * * * * * * * * * 1661 1754

27 * * * * * * * * * * * * 1739 1838

28 * * * * * * * * * * * * * 1922

29 * * * * * * * * * * * * * 2006

BEBOSINGLE LEAF

E-SERIES

BEBOTWIN LEAF

E-SERIES

Waterway Area (ft²)

Rise (ft) Arch Series

C30T C36T C42T C54T

11 250 * * *

12 280 * * *

13 310 * * *

14 339 383 * *

15 369 419 * *

16 399 454 * *

17 429 490 549 *

18 459 526 590 *

19 * 562 632 *

20 * 598 674 791

21 * 634 716 844

22 * 670 758 897

23 * 706 800 950

24 * * 842 1004

25 * * 884 1058

26 * * 926 1112

BEBOTWIN LEAF

C-SERIES

E-Series C-Series

I-88 Emergency Bridge Replacement NYSDOT: Sidney, NY

Project Details

• Temporary Bridge originally considered

• 60 – Precast 42’ span x 12’ rise CON/SPAN arch units

• Cast-in-place pedestal wall foundations on piles

• 21’ of fill on top of arch units, 9’ of which were lightweight

• 3 precast units cast each day to meet schedule

I-88 Emergency Bridge Replacement

• Culvert washed out on June 27th

• A week later the precaster started fabrication

• Last of arch units installed August 19th

• NYSDOT got buy-in from all stakeholders on schedule

• Use of a pre-approved Precast Modular System allowed

for rapid construction

Summary & Conclusions

INDOT SEYMOUR DISTRICT: Morgan County, INSR 144 Emergency Culvert Replacement

Project Details

• Culvert washed out on June 7th, 2008 during 100 year

plus rainfall event

• 100’ – 20’-7” span x 13’-2” rise MULTI-PLATE Pipe

• Culvert produced and delivered with 15 days of July 29th

• Two days to assemble and install structure

• Road opened on September 6th

SR 144 Emergency Culvert Replacement

• Replacement structure provided larger hydraulic opening

and improved alignment

• DOT sense of urgency and available technical support

helped reduce construction time

• Use of “off the shelf” multi-plate structure allowed for

speedy replacement

CALTRANS: Lucerne Valley, CASR 18 Emergency Culvert Replacement

Project Details

w/ precast headwalls and wingwalls

• Precast units diverted from another project

• Cast-in-place slab foundation

• CALTRANS director committed to reopening highway in

2 weeks

Typical Cross Section

• Replacement structure provided larger hydraulic opening

and improved alignment

• Emergency nature of the project helped clear obstacles

that would have increased project time

• Use of “off the shelf” precast structure allowed for 2

week replacement

SEPTA Accelerated Bridge Replacement

Project Details

• SEPTA could not afford extended down time to replace the structure

• 35 – Precast 32’ span x 13’ rise CON/SPAN arch units including

wingwalls, foundations and headwalls

• The South Eastern Pennsylvania Transportation Authority, or

SEPTA, provides commuter rail service throughout Philadelphia and

its four suburban counties

• Replacement of the existing structure to accommodate both the

private road for the college and the shared use path for the township

• Construction transpired over Labor Day Weekend (August 29th –September 1st)

• CONSPAN chosen as a result of extensive rail experience, aesthetics and speed of installation

• Demolition commenced at 4AM Friday morning

• The precast installation was completed in 14 hours

• The trains were back in service for the first run at 5AM Tuesday morning

• The project required close coordination between 4 public agencies, a college, and the contractor

NYSDOT: Albany, NYI-90 Over Anderson Drive

Project Details

• Minimal impact to I-90 was the main selection criteria

including 10 pie-shaped pieces and headwalls

• Unique construction process of building a bridge under

existing structure limited impact to both interstate and

local road

I-90 Over Anderson Drive

Plan view

3-D Model

• Staged Construction process took 5 weeks to complete

• Closure time and inconvenience to the public was greatly

reduced

• Prefabricated bridge greatly reduced overall construction

period – pieces were installed in 5 working days

Springfield Road

Project Details

• Reduce the amount of closure time and traffic

disturbance to hours per day

including precast wingwalls and headwalls

• In a single day operation, the arch units were slid into

position leaving the existing bridge beams and

abutments in place.

• Structure was backfill with grouted through holes cored

in shoulder of existing roadway

Dayton-Springfield Road

Springfield Road

• Project specification stipulated 14 day road closure time

and inconvenience to the public was greatly reduced

• Actual closure time was 12 partial days, the road was

reopened for traffic through most of the day

• Successfully replaced existing structure in a cost-

effective manner while minimizing the closure time on

the road

Dayton-Springfield Road

• All 6 projects demonstrated that the use prefabricated bridge elements decrease construction duration

• Pre-approved systems can cut months out of schedules

• Sense of urgency from DOT combined with road opening commitments to public plays a factor

• The use of on-site manufacturing facilities creates opportunities to save significant time on construction schedules

Conclusions

PREFABRICATED BRIDGES ALLOW DOT’S TO REPLACE BRIDGES AT RECORD SPEEDS

Plate:

Precast:

Truss:

ACCELERATED CONSTRUCTION AND EMERGENCY ......• 40 –Precast 36’ span x 11’ rise CON/SPAN arch...

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