Kearney Precast Concrete Deck Panel Bridge Project

KEARNEY PRECAST CONCRETE DECK PANEL BRIDGE PROJECT

Presented By

T. Farber, G. Marcous, J. Ridder

37th Annual Concrete Paving Workshop

January 19-20, 2016

Acknowledgements

• Nebraska Department of Roads

• University of Nebraska-Lincoln (UNL)

• Hawkins Construction Company

• CoreSlab Structures Inc.

• Federal Highway Administration

• Werner Construction, Inc.

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4

NU Deck Panel Bridge

Phase 1(completed)

Phase 2

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Project Specifics

Prime Contractor: Werner Construction, Inc.

Contract Amount: $26.5 million

Calendar Days to complete project: 776 days

Construction Started: July 2014

Construction Costs for the Bridges

Group 6 ( NU Deck Panel ): $2.6 million

Group 6A ( Cast-in-Place ): $1.6 million

Table of Contents• Background

• Project Description

• Construction Sequence

1. Girder Production

2. Panel Production

3. Girder Placement

4. Panel Placement

5. Transverse Joints Grouting

6. Deck Post-tensioning

7. Haunch & Pockets Grouting

8. Deck Grinding

Background• Why precast concrete deck systems are not commonly

used?– Too many pieces to handle

– Too many joints to grout

– Open channels or pockets need an overlay

– Not fully pre-stressed in both directions

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Background

• The newly developed precast concrete deck system (2nd

Generation NUDECK) has the following features:1. Full-depth, full-width, 12-ft long panels to minimize CIP transverse joints

2. Covered pockets to eliminate deck overlay

3. 4 ft. spacing between shear connectors to simplify fabrication

4. Prestressed in both directions to enhance durability

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Project Description

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NU Deck Panel Bridge

BB-EB CL: 332 ft

Span:

166 ft

166 ft

Precast:

166.17 ft

166.17 ft

1.33 f t

39 f t

1.33 f t

41.67 f t

7.5

in

3.83 f t

8.5 f t

8.5 f t

8.5 f t

8.5 f t

3.83 f t

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2

3

4

5

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NU Deck Panel Description

5 ea. NU1800Girders

13,850 sq.ft.Bridge Deck

NU Deck Panel Description

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26 Typical Panels + 2 End Panels

Construction Sequence1. Girder Production

2. Panel Production

3. Girder Placement

4. Panel Placement

5. Transverse Joints Grouting

6. Deck Post-tensioning

7. Haunch & Pockets Grouting

8. Deck Grinding

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1- Girder Production

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2- Panel Production

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2- Panel Production

2- Panel Production

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2- Panel Production

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3- Girder Placement

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3- Galvanized Shelf Angles

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3- Post-tensioning Cable Strands

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3- Post-tensioning Cable Strands

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3- Pier Diaphragm Steel

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4- Deck Panel Placement

4- Panel Placement

4- Panel Placement Progress• Wednesday 07/08 afternoon only 3 panels

• Thursday 07/09 morning only 2 panels

• Monday 07/13 6 panels

• Tuesday 07/14 6 panels

• Wednesday 07/15 6 panels

• Thursday 07/16 5 panels

TOTAL 28 panels

5- Transverse Joints Grouting

5- Transverse Joint Grouting

5- Transverse Joint GroutingConcrete

TruckStart Time End Time Quantity No. of Joints Temperature

Deg. FRelative

Humidity %

#1 6:30 am 7:30 am 3 cy 13.5 63 83

#2 8:00 am 8:30 am 2 cy 7.5 65 80

#3 8:45 am 9:15 am 2 cy 6 66 78

Transverse joint concrete mixture had 6 in. initial slump and was vibrated

6- Deck Post-tensioning

6- Deck Post-tensioning

Jacking End Movement = 5/16 in. Dead End Movement = ¼ in.

Predicted deck elastic shortening = ½ in.

7- Haunch & End Pocket SCC Grouting

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20 batches of about 6 cu.yd. each for a total of 6 hours


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Average SCC slump flow = 29 in.


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H-3 H-3A G-2 J-4 K-5 F-1

4 8,120 7,240 7,480 6,790 7,380 7,860 7,402

7 8,360 7,250 7,690 7,170 7,510 7,870 7,596

28 9,200 9,050 9,170 8,430 8,420 9,030 8,854

Air Content (%) 2.6 3 4.2 4.6 4.6 4.6 3.8

Girder Batch IDAge (day) Average

8- Deck Grinding

NU Deck Panel

Cast in Place

8- NU Deck Grinding & Texturing

Transverse Joint Grouting Holes

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Completed Structure

Outside

Setting next to CIP Bridge

VideoQuestions??

Thankyou

Kearney Precast Concrete Deck Panel Bridge Project

Presentations & Public Speaking

Transcript of Kearney Precast Concrete Deck Panel Bridge Project