Application of Accelerated Bridge Construction for Local Agencies

APWA Public Works ConferenceNovember 9, 2017

Dorie Mellon – Senior Bridge Engineer, CaltransMatt Randall – Senior Engineer, County of Placer

• Accelerated deployment of innovation that meets customers needs and increase efficiency of project delivery

• Accelerated Bridge Construction Workgroup: Gary Antonucci - Moffatt & Nichol/ACECDorie Mellon - Caltrans - Structure Policy & InnovationRyan Moore - City of SacramentoLinda Newton - Caltrans - Local AssistanceMatt Randall - Placer County

www.fhwa.dot.gov/innovation/stic/

ABC uses the most efficient combination of innovative planning, design, materials and construction to

significantly reduce construction related impacts

by reducing the number of onsite construction days and/or minimizing traffic disruption.

Accelerated Bridge Construction (ABC)

Minimize Construction Impacts

Project Goals & Constraints

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FHWA Every Day Counts (EDC)

FHWA set of initiatives to deploy innovation aimed at:

• Shorten the project delivery process • Enhanced roadway safety• Reduced congestion• Improve environmental sustainability

Elements of a Bridgefrom Foundation to Superstructure

Abutment

5

Bent 4Bent 3Bent 2

Abutment

1

PILINGFOOTING

BENT CAP

ABUTMENT

SUPERSTRUCTURE

COLUMN

A bridge is a structure that spans an opening greater than 20 feet.

Conventional Construction

Falsework

TYP FW SYSTEM

Conventional Construction

Reinforcing Steel (Rebar)

Conventional Construction

Cast-in-Place Concrete

ABC Methods

Prefabricated

Slide-In

Large Bridge Move

Launch

ABCPrefabricated Bridge Elements & Systems

Bridge elements are manufactured at an off site facility and assembled at the project location

Ultra-high Performance Concrete(UHPC) connections

for prefabricated bridge elements

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PROPERTIES• Strong• Flexible• Durable• Excellent Bonding• Self Consolidating

ADVANTAGES• Robust connections• Simplified construction• Better long term

performance

Slide-In Bridge ConstructionThe new bridge is constructed next to the old bridge and then slid into place overnight or during off peak hours

Nevada I-15 Bridge

Hartford I-91 Bridge Replacement, Vermont

Large Bridge MoveSelf Propelled Modular Transporters

I-215 Highgrove UnderpassSan Bernardino County

Space Shuttle SPMT move through downtown LA

4500 South Bridge, Utah 2007

Bridges or large portions of bridges are built off site and moved in to place with self propelled modular transporters (SPMT’s)

ABCIncremental Launching

Bridge superstructure is assembled at one end of the bridge and launched across to the other end of the bridge.

Pfeiffer Canyon Bridge Launch

ABC Advantage - Time

Saving time while minimizing headaches for motorists.

Minimize construction impacts by reducing the amount of construction time.

Traffic impacts reduced from years to months and from months to days.

ABC Advantage - Safety

ABC technologies help improve motorist and worker safety by shortening lane restrictions and by performing construction away from traffic.

Each year approximately 600 fatal crashes occur in USA work zones.

On average 1000 CT vehicles are struck each year.

(Fewer Construction Days = Increased Safety)

ABC Advantage - Mobility

Minimize

• Lane closures• Duration of onsite

construction activities• Need for detours

Conventional construction typically leads to heavy congestion and long travel delays

Realizes savings in user costs to the public

• Local businesses• Transportation of

goods• Air quality• Noise

ABC dramatically reduces mobility impacts

ABC Advantage - Constructability

• Less sensitive to weather conditions

• More likely to deliver single season construction

• Effectively addresses unique and challenging site conditions

ABC Advantage - EnvironmentReduced Environmental Impact

Reduced construction time allows scheduling around crucial times for

plant growth and animal life. Eliminating falsework keeps construction

activities out of the stream.

Conduct construction activities offsite Reduce wetland mitigation

Cost ConsiderationsABC can be the most cost effective means of construction when

considering total project cost.

Maintenance of traffic

Environmental Mitigation

Project Administration

Lowered vertical profile

Environmental Compliance

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Case Study: MassDot Fast14

• Replaced 14 bridges in 10 weekend closures along Interstate 93 through the city of Medford

• Project was completed on budget and ahead of schedule

“The I-93 Fast 14 project proves that America is ready, willing, and able to

dream big and build big.” US Secretary of Transportation Ray LaHood

Case Study: Nevada I-15 Bridge

COST MORE, SAVE MOREAs stated by the contractor who proposed the use of ABC:

"We knew that ABC would cost more, but we could make up the difference saving on lane rentals, building the

crossovers, limiting excavation and reducing time and overhead."

ABC saved $10M and 6 months

San Mateo Bridge Replacement Project 2016Caltrain track parallel to Route 82

• Replace four 100 year old structures over 4 weekends• Bridges assembled near the site and moved into place by

SPMT during 16 hour track closure

Poplar Avenue

Original Structure 1903

Replacement Structure 2016

Improve vertical clearance and road width below bridge

Construction Sequencing

Stage I Activities

1. Track is raised to final elevation prior to

change over (by PCJPB).

2. All utilities relocated.

3. Complete pile installation.

Stage II Activities

1. Install temporary restraining system where

excavation is taking place.

2. Complete footing construction.

Stage III Activities

1. Remove temporary restraining system.

2. Construct abutment walls.

Stage IV Activities

1. Build roll-out and roll-in supporting system

(prior to change over).

2. Remove existing track.

3. Excavate behind the walls.

4. Disengage existing bridge.

Stage V Activities

1. Lift and roll out central span.

2. Crane lift existing end spans.

3. Place precast abutment seat units and secure in

place.

4. Backfill behind the abutments with soil-cement

mix.

Stage VI Activities

1. Roll in new bridge.

2. Finish backfilling behind the abutmens with soil-

cement mix.

3. Complete trackwork.

4. Test run.

5. Open to traffic.

Complete Structure

1. Install crash beams (not shown)

2. Remove existing bents and supporting system.

3. Complete roadworks including side walks.

4. Open to road traffic for optimum use.

Beyond the

bridge (typ)

ExistingAbutment

Bridge Construction

Substructure Strengthening Prior to Track Shutdown Bridge Demolition 5 AM

Installation of Abutments 11 AM SPMT bridge move 2 PM

16 Hour Construction Window

ABC in California

Programmatic ApproachABC Evaluated for Every Bridge Project

ABC Decision Making Guidance (2015)• Construction Time• Environmental• User Costs and Delays

• Site Conditions• Risk Management• Economy of Scale

The evaluation of ABC is triggered during preliminary project development when adjustments to funding, right of way requirements and the environmental document can

be accomplished with relative ease.

Working Days (ABC vs Conventional)

Construction Completion Time (CCT): Estimate of the number of total onsite construction working days required for the bridge construction work .

Construction Impact Time (CIT): Estimate of the number of working days that a construction activity will affect a specified impact such as traffic or environmental constraints.

Choosing the right ABC solution• Early consideration of ABC

• Identify project goals, constraints, and resources

• Communicate with stakeholders

• Do the benefits balance the costs?

Improving delivery through Innovation

ABC Single Span Programmed Projects

ABC methods delivered:• One season construction• Significantly reduced environmental impact• Minimal traffic disruption• Well suited to streambed restoration

Hardscrabble CreekSlide-In

Craig CreekPrefabricated

North Fork Mill CreekPrefabricated

Fort Goff Creek BridgeSiskiyou County Route 96

Streambed Restoration ProjectGOALS:Restore Fish PassageSingle Season ConstructionReduce Environmental ImpactsQuality Concrete in Remote Location

SOLUTION:Prefabricated Design

Fort Goff Construction: Prefabricated Bridge

02-SIS-096-56.0Bridge No. 02-0200

Hardscrabble CreekLateral Slide 2008

1-DN-199

GOAL:• Reduce Construction to a

Single Season• Reduce Traffic Disruption

from months to hours

SOLUTION:• Lateral Slide

WHAT SUPPORTED THE SOLUTION?:• Room Adjacent to Route for

Construction• Additional $ for Bridge

Construction

Caltrans Multi-Span Precast Pilot Projects

– 2 projects under construction

– D4 Laurel Street OC

– D6 Route 46/99 Sep

– Focus on connections & constructability

– Gather lessons learned Improve efficiency & reduce risk

– Educate project development staff, construction staff and contractors

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Laurel Street Overcrossing Pilot ProjectVallejo CA, Route 780

Precast columns and cap were set in 3 hours under full night closure of 780

Laurel Street Overcrossing Pilot ProjectVallejo CA, Route 780

Rapid strength concrete deck. Concrete cures in 4 hours

Precast Wide Flange Girders set in 2 nights

UHPC connection mock up

ABC Impact on Cost

• Maintenance of traffic

• Wetland mitigation

• Storm water

• Contract administration

• Construction inspection

• Temporary right of way

• Traffic delays• Access to essential services• Impact to local business• Air quality• Noise• Transportation of goods

CAPITAL & SUPPORT COSTS USER COSTS

User Cost ConsiderationCONVENTIONAL METHODS ABC METHODS

Lengthy detours and traffic delays Reduced detours and delays

Long term frontage business impacts

Reduced time of business impact

Negative public perception of lengthy construction duration

Positive perception of “speedy” construction

Environmental impacts over multiple seasons of construction

Reduced environmental impacts due to single season construction (plants, animals, air quality, water quality, noise)

Full Road Closure for Work Zone Operations

• Accelerate construction

• Cost savings (MOT, more efficient work area)

• Improve quality (full access to roadway results in higher standards in efficiency and quality)

• Enhance safety (separate construction activities from through traffic)

• Increase favorable public sentiment

Public Outreach for ABC

BENEFITS

• Traffic avoidance

• Increased awareness

• Decreasing impatient behavior

• Building trust

• Project buy-in

METHODS• Signage• Project specific

websites• Local newspaper &

radio• Social media*• Mobile apps*• Town hall meetings*

Keys to ABC success

• Embrace Innovation

• Define project goals

• Early consideration

• Total Project Cost

• Identify user cost benefits

• Include in initial HBP application when appropriate

• Communicate with stakeholders

ABC Resources

• FHWA Center for Accelerating Innovation: https://www.fhwa.dot.gov/innovation/– Every Day Counts– STIC Network– AID Demonstration– Resources

• FHWA ABC: https://www.fhwa.dot.gov/innovation/everydaycounts/edc-2/abc.cfm

• ABC University Transportation Center: https://abc-utc.fiu.edu/ • STIC ABC:

http://www.dot.ca.gov/hq/LocalPrograms/hbrr99/hbrr99a.htm • Coming Soon: AASHTO Guide Specification for ABC