2011 09 12 - u buffalo.ppt - mceer: earthquake...
TRANSCRIPT
Recent Advances in Steel Bridge Fabrication
CIE‐580: Emerging Technologies in Bridge EngineeringUniversity at Buffalo (UB)North Campus, 140 Ketter Hall
Ronald D. Medlock, PEVP – Technical ServicesHigh Steel Structures, Inc.Lancaster PA
High Steel StructuresHigh Steel Structures• Steel bridge
f b i t dfabricator and erector
• Four facilities• 50,000+ ton
capacity• ISO 9001 Certified• AISC certified
– Bridges– BuildingBuilding– Erection
Engineer’s InterestEngineer s Interest
• How to get the bestHow to get the best– CostD li– Delivery
– Quality
Project CostProject Cost
• MaterialMaterial– Market price– Usually 30% – 40% of the FOB costU ua y % % o e O o– Can be up to 70% of the FOB cost
• Hours (labor and overhead)Hours (labor and overhead)– Engineering – Fabrication– Shipping
• Margina gi
CRU Plate Price History2007 through 2011 by Month 20112007 through 2011 by Month
$1,400
$1,600
Sept 2008
2011
$1,000
$1,200
t Ton
$600
$800
US$
per S
hort
$200
$400
$0
$ 760$ 760 $ 760$ 795$ 795$ 810 $ 790$ 790 $ 790 $ 790 $ 790 $ 790 $ 860 $ 890 $ 980 $ 980 $ 1,3 $ 1,4 $ 1,4 $ 1,4 $ 1,4 $ 1,3 $ 1,1 $ 850 $ 810 $ 755 $ 665 $ 610 $ 550 $ 540 $ 560 $ 600 $ 640 $ 630 $ 580 $ 580 $ 630 $ 685 $ 730 $ 830 $ 825 $ 815 $ 760 $ 742 $ 765 $ 740 $ 710 $ 760 $ 870 $ 970 $ 990 $ 1,0 $ 1,0 $ 1,0 $ 1,0 $ 994
J'07 F'07M '0
7A '07
M '0
7J'07 J'07 A '07 S'07 O'07 N'07 D'07 J'08 F'08
M '0
8A '08
M '0
8J'08 J'08 A '08 S'08 O'08 N'08 D'08 J'09 F'09
M '0
9A '09
M '0
9J '09 J '09 A '09 S'09 O'09 N'09 D'09 J '10 F'10
M '1
0A '10
M '1
0J '10 J '10 A '10 S'10 O'10 N'10 D'10 J '11 F'11
M '1
1A '11
M '1
1J '11 J '11 A '11
Definition:Price fob mill for ASTM A36 commercial quality plate in thickness between 3/8 of an inch and 2 inches widthPrice, fob mill, for ASTM A36 commercial quality plate, in thickness between 3/8 of an inch and 2 inches, width between 72 and 120 inches and length between approximately 240 and 720 inches. Any further extras for gauge,
width and length are excluded. For medium sized buyers, with standard packaging. Delivery charges and taxes are excluded. Raw materials surcharges (where applicable) are included. Price refers to current price for forward delivery.
Material Optimization – contact industry
Best Economy:-Uniform thickness, orAdditional splices?-Additional splices?
- Add a field splice at ~ 80’
Allow splice location- Allow splice location flexibility
Standardization
• OwnerOwner standards and preferencespreferences
• Industry standards andstandards and guidelines
AASHTO/NSBA– AASHTO/NSBA Steel Bridge CollaborationCollaboration
Project CostProject Cost
• MaterialMaterial– Market price– Usually 30% – 40% of the FOB costU ua y % % o e O o– Can be up to 70% of the FOB cost
• Hours (labor and overhead)Hours (labor and overhead)– Engineering – Fabrication– Shipping
• Margina gi
Steel Bridge ManufacturingSteel Bridge Manufacturing
Sales SchedulingSales SchedulingSales SchedulingSales SchedulingSales SchedulingSales SchedulingSales SchedulingSales
Estimating
Sales
Engineering
Scheduling
Estimating
Sales Scheduling
Estimating
Sales
Engineering
Scheduling
Estimating
Sales
Engineering
Scheduling
Estimating
Sales
Engineering
Scheduling
Estimating
Sales
Engineering
Scheduling
Estimating
Sales
Engineering
Scheduling
Estimating
Sales
Estimating Engineering
Field
EstimatingEstimating EngineeringEstimating EngineeringEstimating EngineeringEstimating EngineeringEstimating EngineeringEstimating
FieldShop Shipping FieldOperationsMaterial ShopMaterial ShippingShopMaterialField
OperationsShippingShopMaterial
Purchasing ProjectManagement
ProjectManagement
ProjectManagement
ProjectManagementPurchasing ProjectManagement
ContinuousImprovement
QualityControl
ContinuousImprovement
QualityControl
ContinuousImprovement
QualityControl
ContinuousImprovement
Engineer’s InterestEngineer s Interest
• How to get the bestHow to get the best– CostD li– Delivery
– Quality
Critical for StartCritical for Start• Shop Drawingsp g
– Designs• Complete?• Web and Flange Information• Web and Flange Information
– RFI answers– Field information– Utility information– ApprovalM t i l• Materials– Web and flange information– DrawingsDrawings
ModelingModeling
• Past Workflow
ShopDesign Shopdrawings
Hand layout of geometry by tapeand soap stone
Hand punch hole layout and drillAssemble and ream
• Current workflow
Design Shopdrawings Models CAM
• Parametric 3D models created for
CalculationsParametric 3D models created for
cross frames
• One associative part model utilized by all disciplines
Eliminates manual calculationsCAM Model of • Eliminates manual calculationsComponent
CAD Drawings
BOMPart Model
• Parametric 3D models created for
CAD/CAM/CNC InterfaceParametric 3D models created for
girder parts
• One associative part model shared by all disciplines
Reduces redundant efforts• Reduces redundant efforts
CNC Code
CAD Drawings
Part Model
BOM
CAM ToolpathPart Model
• Models created for complex welded
Visualization
pieces or complex geometry
•Accomplishes clearance checks
• Validates fabrication sequence
blDetail of Connection
Assembly
Visualization
ModelingModeling
• Current workflowCurrent workflow
Design Shopd i Models CAM
F t kfl
g drawings
• Future workflow
M d li Improved quality and efficiencyModeling- Design- Models- CAM
₋ Improved quality and efficiency₋ Faster project delivery
ESW Advantages• Productivity
– No bevel ‐ square edge preparationN t ki– No tacking
– No preheat or interpass– Single pass full penetration– Little slag removal and waste– No distortionNo distortion
• Safety / Environmental– no arc– nearly smokefreenearly smokefree– virtually noiseless
• Quality– No multi‐pass associated defectsNo multi pass associated defects– No arc spatter, arc strikes
ESW Limitations• Thicker joints only• Thicker joints only• Vertical up welding• Practical limits to weld length• Not for Q&T or TCMP materials (HPS)Q ( )
CoatingsCoatings• 3 coat most popular– Inorganic zinc– Epoxy primerEpoxy primer– Urethane top coat
• 2 cost systems• 2 cost systems– Organic zinc– Urethane top coat
• Galvanizing• Metalizing• Metalizing
Shipping/Fabrication Piece Limits
• Most competitive:p‐ Length < 125 feet‐ Weight < 35 tons‐ Height < 9 feet tallg
• General truck limit:‐ Length ~ 175 feet
(rules vary)(rules vary)‐ Weight ~ 80 tons
(rules vary)‐ Height < 13.5 feet g
(on side) or 9.5 feet (upright)
Shipping/Fabrication Piece Limits
11” deck~ 12 ½ foot depth allowancep
Maximum weight 85 tons (at 70 feet)(at 70 feet)
NCHRP 12‐79NCHRP 12 79
Recommendations for detailing andRecommendations for detailing and associated analysis
• Straight Straight Skewed Bridges• Straight, Straight‐Skewed Bridges– Total deal load (TDL) fit / detailingC d B d• Curved Bridges– Steel dead load (SDL) fit / detailing
• Complex Bridges, Tub Girders Bridges– No‐load fit (NL) fit / detailing( ) g
SummarySummary• Effective projects
– Use standard details, materials, and practices; consider shipping b lcapability
– Speak with industry to get answers– Provide timely answers
• Materials– Use of grade 50 and 50W (weathering steel) is the norm– Increased used of HPS 70W– Advent of HPS 100W and A1010
• Modeling– More automation less handwork– More automation, less handwork– Improved accuracy– Less assembly
Improved workflow– Improved workflow– Synergy on design / build projects?
SummarySummary• Welding
– Increased use of GMAWIncreased use of GMAW– Increased use of ESW (ESW‐NG)
• Erection– Understand system behavior on skewed bridges– Future guidance from NCHRP 12‐79 (no‐load, steel‐load full dead‐load)load, full dead load)
• Durability– Weathering steel provides excellent performanceg p p– Zinc‐primer systems are excellent– Metalizing is good but expensiveG l i i i t ti f bi b– Galvanizing is not an option for big members