delta girder construction - ohio department of transportation...delta girder construction • pier...
TRANSCRIPT
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Delta Girder Construction
• PIER CAP CONCRETE o Break pier cap into two separate pours
to allow more control over PT bar alignment
• POST TENSION BAR INSTALLATIONo Alignment critical
• DELTA KNUCKLE ERECTION AND POST TENSIONING o Alignment critical
• DELTA GIRDER ERECTION
• DECK GIRDER ERECTION
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Pier Cap Concrete • DELTA PIER CAPS
o 12 Feet Thicko 16 Feet Tallo 87 – 113 Feet Long o 560 – 705 CY Concrete
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Pier Cap Concrete
• PT bars cast 5 feet into pier cap • No adjustment once cap is poured • Elected to pour cap in two lifts to limit movement of formwork
during pour
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Pier Cap Concrete
Pier Cap Concrete Placement in Two Lifts
PRIOR TO FIRST LIFT PRIOR TO SECOND LIFT
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Post Tension Bars
• Piers 8, 9, and 10o 1‐3/4” diameter threaded bars o ASTM A772 Grade 150 ksio 20 bars per delta frameo Design tension = 288 kips
• Piers 3‐7 and 11‐12o 2‐1/2” diameter threaded bars o ASTM A772 Grade 150 ksio 20‐28 bars per delta frameo Design tension = 557 kips
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PT BAR ASSEMBLY UPPER DETAIL LOWER DETAIL
Post Tension Bars
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PT Bar Alignment Frames • Preassemble all bars for each delta leg group• Erect as a unit
Post Tension Bars
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PT Bar Alignment Plates • Holes drilled in
alignment plate to same dimensions and spacing as knuckle base plate
• Alignment plates installed on top and bottom of PT bars
ASSEMBLY
Post Tension Bars
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PT Bar Assembly Erection
Post Tension Bars
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Upper Pier Cap Lift Rebar Installation
Post Tension Bars
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Pier Cap Second Lift Concrete Placement
Post Tension Bars
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Pedestal Placement
Post Tension Bars
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Knuckle Erection and Post Tensioning
Delta Knuckle• Lower bearing point of
delta frame • Post Tensioned and
fixed to pier cap prior to erecting the rest of the delta members
• 32 feet long x 9 feet tall• 2 inch thick x 42 in wide
flanges • 1 inch thick x 48 inch
deep web• 49,000 lbs
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Knuckle Erection and Post Tensioning
• Level and Align Knuckle • Install Diaphragms
Knuckle Erection
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Knuckle Erection and Post Tensioning
Knuckle Grout• Knuckle base plate 6’‐0” x 7’‐5” • Grout pad thickness 3” average• Grout pad approx. 12 cubic feet• 5,000 psi min compressive
strength • BASF 928 Non‐shrink grout
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Knuckle Erection and Post Tensioning What do these have in common?
Manitowoc 2250 Crawler Crane Bolttech Mannings CST‐1053
Hydraulic Tensioner
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Knuckle Erection and Post Tensioning Knuckle Post Tensioning• Elected to use hydraulic center hole tensioners
• Standard post tensioning jacks too heavy and cumbersome to use in tight spaces between knuckle stiffeners
• Center hole tensioners can be linked together to simultaneously operate more than one tensioner at a time
• Compact and lightweight • Short bar length and small elongations
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Knuckle Erection and Post Tensioning
Tensioning Equipment
1‐3/4” Tensioner ‐ CST‐052• Max Load: 510,038 lbs• Max Pressure: 21,750 psi• Max Stroke: ½ Inch• Weight: 65 lbs
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Knuckle Erection and Post Tensioning
Tensioning Equipment
2‐1/2” Tensioner – CST‐1053• Max Load: 819,758 lbs• Max Pressure: 21,750 psi• Max Stroke: ½ Inch• Weight: 110 lbs
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Knuckle Erection and Post Tensioning
Tensioning Equipment
Pump – TP30K• Max Input Pressure: 136 psi• Ratio: 220:1• Max Output Pressure: 30,000
psi
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Knuckle Erection and Post Tensioning
How the Tensioners Work
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Knuckle Erection and Post Tensioning
TGR’s Approach – Utilize 4 Tensioners at a Time
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Knuckle Erection and Post Tensioning
• Tensioning Bars – 980 Each o Tension 4 bars at a time –
reduced tensioning time by 75% compared to tensioning 1 bar at a time
o Jacking force – 17% ‐ 30% higher than design load to account for creep, shrinkage, and steel relaxation
o Specified jacking sequence working from center of knuckle outward
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Knuckle Erection and Post Tensioning
• Lift Off Test o Perform lift off test at
specified locations to design load to verify bars are properly tensioned
• Grout o Annulus between duct and
bar was grouted for corrosion protection
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Knuckle Erection and Post Tensioning
• Monitor jacking force by pump output pressureo Required pressure = Target Load ÷ Ram Area
• Tensioners were calibrated to verify accuracy
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Knuckle Erection and Post Tensioning
•Grout annulus between duct and bar for corrosion protection•Used BASF 1205 PT Grout
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Delta Frame Erection
• Erect remainder of delta frame once knuckle is post tensioned
• Delta frame consists of:o Knuckleo 2 EA – Delta Legs
Tension Tieo 45 total delta
frames
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• Delta Legs ‒ 68 Feet Long ‒ 2” thick x 42” wide
flanges ‒ 1” thick x 48” deep
web‒ 56,000 lbs
• Erect and release delta legs
Delta Frame Erection
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• Tension Tie‒ 107 Ft Long‒ 2” thick x 42”wide
top flange‒ 2” thick x 24”deep
legs‒ 68,000 lbs
Delta Frame Erection