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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

Project Location

Far Approach (Looking East to West) -- 2007

Far Approach (Looking East to West)

Upstream Elevation Existing Bridge

8PLAN VIEW FROM AS-BID DRAWINGS

ELEVATION VIEW FROM AS-BID DRAWINGS

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.

• 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.

• 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

• 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

• 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

Ashcom Cove Creek Bridge PrecastVE Total Precast Bridge

Ashcom Cove Creek Bridge Precast Production Schedule

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.

Ashcom Cove Creek Bridge Precast Abutment Footings

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

EXCERPT FROM SHOP DRAWING

OF FOOTING

21Footing Pieces Cast Upside Down

Ashcom Cove Creek Bridge Precast Abut Walls & Corner Transitions

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

34.9 T

36.0 T18

Ashcom Cove Creek Bridge Precast Abutment Walls

EXCERPT FROM SHOP DRAWING OF WALL PANEL

NMB Splice Sleeve

Ashcom Cove Creek Bridge Precast Abutment Walls

Ashcom Cove Creek Bridge Precast Abut-Wing Corner Transitions

EXCERPT FROM SHOP DRAWING OF WALL PANEL

NMB Splice Sleeve

Post-Tensioning Duct

Ashcom Cove Creek Bridge Precast Abut-Wing Corner Transitions

Ashcom Cove Creek Bridge Abutments - Dry Fit in Fabrication Yard

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.

Ashcom Cove Creek Bridge Precast Deck Panels

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

Shear Pockets

Typical Deck Panel 12’-2” +/- Long

EXCERPT FROM SHOP DRAWING OF DECK PANELSPLAN VIEW

Transverse Closure Pour

(Typ.)

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

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

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

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)

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

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

PRECAST DECK PANELS

ADJUSTING LEVELING BOLTSAdjusting Leveling Bolt

with Impact Wrench

View of Leveling Bolts from Underside of Deck Panel

PRECAST DECK PANELSUHPC Closure Pours Haunch Formwork

Steel FibersPre-Blended Cementitious

Transverse Closure Pour

Transverse Joint Profile

55PRECAST DECK PANELS - UHPC Closure Pours

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

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

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

• 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.

Completed Project54 Calendar Days

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