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STATE ROUTE 30 OVER
BESSEMER AVE.
SUPERSTRUCTURE REPLACEMENT IN 57 HOURS
Louis J. Ruzzi P.E., PennDOT District 11-0 Bridge Engineer John Myler, PennDOT Assistant Construction Engineer, District 11- 0 Bala Sivakumar, P.E HNTB, Vice President
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Talking
Points
Quick Facts – Lou Ruzzi,PE, District Bridge Engineer, PennDOT District 11-0 (Pittsburgh area)
Project Goals – Lou Ruzzi,PE
Design Highlights – Bala Sivikumar, PE (HNTB)
Construction Highlights and Lessons Learned – John Myler, Assistant Construction Engineer, PennDOT District 11-0 (Pittsburgh area)
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Existing
Bridge
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Existing
Bridge
Location
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STATE ROUTE 30 over BESSEMER AVE
Allegheny County, Pennsylvania
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Existing
Bridge
Aerial
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Quick
Facts
Project was let on 11/5/2015 with 3 bidders
Brayman Construction was the successful low bidder for $2,333,212.
Second bidder bid the job for $3,130,000
Third bidder was at $3,209,308
Pre Bid meeting attended by 4 contractors
HNTB was the designer
Pre-Cast Abutment Caps, steel beam modules with concrete deck/barrier, Ultra High Performance Concrete (UHPC) joints between the modules with a latex placed over the deck, pre- cast approach slabs
SR 30 ADT is 21,798 (2015) with 4% trucks 6
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Detour
Route
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Project
Goals
Replace the superstructure over a weekend
Utilize as many precast/pre-fab elements as possible, UHPC and cover the deck with an appropriate overlay(latex) that would last a long time(20 years)
Minimize impact to the adjacent property owner
Applied many lessons learned from a previous project that was built in 7 days
Considered innovative bidding
Under-clearance from 13’-9” to 17’-2”
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Design
Highlights
Use of Pro Team Meeting plus subsequent constructability meetings to limit the number of alternatives
Design the bridge as quickly as possible due to the condition of the existing T Beam bridge (falling debris from superstructure and a hole in the deck)
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Built 1930
Carries State Route 30 over Bessemer Ave. in East Pittsburgh, PA; high traffic volume
Concrete T-Beam Superstructure
Span = 52’ - 2” -- curved alignment
Concrete abutments on spread footing. Concrete strengths from 2.5 to 3.6 ksi
Under-clearance from 13’-9” 17’-2”
Project required a superstructure replacement with substructure rehab in a single weekend
Existing
Bridge
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Accuracy of As-Built Information to confirm fit
Choice of ABC method that fits site constraints and 57 hour closure period
Urban area; limited ROW; overhead wires
Skew, curvature, super-elevation considerations for ABC design
Removal and replacement of deteriorated portions of abutment walls
Approach slab replacement
ABC connections
ABC
Design
Decisions
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LIDAR SURVEY : AS-BUILT BRIDGE MODEL
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As-Built Bridge Model
Shows Bridge Elements to be Removed
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ABC Construction Sequence
Pre-Weekend Closure
Precut and brace abutment walls along frontface
Sawcut roadway pavement at ends
Repair abutment spalls and cracks
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ABC Construction Sequence
Weekend Closure (57 Hours) continued
Demolish superstructure, remove approach slabs and excavate backfill
Sawcut abutment along backface and remove sections
Connect abutments caps with dowels
Erect the six superstructure modules with cranes
Erect precast sleeper slabs and approach slabs
Place accelerated cure UHPC closure pours
Reopen to traffic — Monday 6 AM
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ABC Construction Sequence
Post-Weekend Closure
Backfill abutments with flowable fill (approach slabs are designed to support traffic loads)
Place and cure rapid set Latex Modified Concrete (LMC) overlay to 1 ¼” depth and sawcut grooves
Apply epoxy resin protective coating to abutment surfaces
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Engineer’s ABC Schedule
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Activity Duration (hrs)
Superstructure & approach roadway removals, backfill excavation
8
Substructure saw-cutting and removal 6
Install precast abutment caps 8
Install superstructure modules 8
Install approach slabs 4
Place UHPC closure pours 5
Cure time for UHPC 12
Total Duration (ABC) 51 Hrs
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ABC Replacement Using Prefabricated
Bridge Elements
54’-0” Single Span
Composite Steel Modular Superstructure (shop painted)
Straight Steel Beams with Variable Overhangs to Accommodate Curvature
Accelerated Cure UHPC Closure Pours
New Precast Abutment Caps to Address Deterioration and Super-elevation
New Precast Approach Slabs
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New Superstructure Cross Section
Design Live Load:
AASHTO LRFD / PHL-93 OR P-82 (204 Kip PERMIT LOAD)
Lightweight Concrete (5 ksi) to minimize lifting weights
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Crane sizes limited by overhead high voltage electrical lines (De-energized during ABC weekend).
Lightweight Concrete (117 pcf) to minimize lifting weights
Concrete Stresses During Erection:
Not to Exceed Modulus of Rupture fr = 7.5*Sqrt(f'ci), Divided by a Safety factor of 1.5.
Dead Loads Multiplied by a Factor of 1.25.
Did not control design
Lifting locations shown for each element
Design
Checks
for
Erection
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AutoCad Revit Software
3D model of existing bridge using Lidar
New elements modeled in 3D and superimposed on existing
Virtual assembly of bridge during design
Check fitup at each stage of assembly
Several dimensional adjustments were made to precast elements to ensure fit
3D renderings shared with Contractor
3D
Model
for
Design
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New Superstructure Plan
Straight beams / modules. Bridge curvature accommodated using
overhangs with variable widths 22
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Removal of Deteriorated Sections
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Precast Abutment Caps
Stepped to Match Superelevation
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Precast Cap Elevation
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• Steel shims used to achieve proper seat elevations • Gap around shims filled with rapid set grout -- through
grout ports in cap
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Replace with Precast Abutment Cap
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Superstructure Interior Module
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Superstructure Exterior Module
Includes Sidewalk and Parapet
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Superstructure Modules Assembly
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Approach Slab Section
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Precast Sleeper Slab
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Abutment Spall and Crack Repairs
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CONSTRUCTION HIGHLIGHTS
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Bridge
Demolition
Friday 11:15 PM
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Bridge
Demolition
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Bridge
Demolition
Friday 11:45 PM
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Precast
Abutment
Cap
Saturday 1:00 PM
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Precast
Abutment
Cap
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Precast
Abutment
Cap
Saturday 3:00 PM
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Precast
Deck
Panel
Sunday 12:00 AM M2- 79 Ton with Rigging
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Precast
Deck
Panel
Sunday 7:00 AM
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UHPC
Placement
Sunday 4:00 PM
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UHPC
Placement
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New
Bridge
after 57
Hours
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Approach
Slab Flow
Fill
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Profile
Milling and
LMC Prep.
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Saturday 1:15 AM
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LMC
Placement
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Saturday 6:20 AM
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New
Structure
and
Roadway
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Sunday 12:00 PM
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New
Structure
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Time
Lapse
Video
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https://youtu.be/0VMMq0fNWjg
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Lessons
Learned
1. More time:
a. Weekend closure duration
b. Additional lead time
2. Improve ability to level precast caps
3. Reduce deck panel weights
4. Discuss straight or hoop reinforcement in the UHPC joint.
5. Water tight seal for UHPC
6. Latex overlay is recommended
7. Is structure dry fit necessary?
8. 3D renderings were very helpful.
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Closing
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Questions
Contact info:
Louis J. Ruzzi : [email protected]> John Myler : [email protected] Bala Sivakumar : [email protected]