module 1 what are prefabricated bridge elements & systems for accelerated bridge construction...
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MODULE 1WHAT ARE PREFABRICATED BRIDGE ELEMENTS & SYSTEMS FOR ACCELERATED BRIDGE CONSTRUCTION (ABC/PBES)? Benjamin Beerman, P.E.Structural EngineerFHWA Resource Center Structures Technical Service Team
Introduction - Learning Outcomes
• EDC Program: vision and mission for PBES • The reasons for using ABC/PBES• Definitions of PBES• Case studies of PBES• Benefits of PBES• The status of EDC deployment goals for PBES
Focus of Every Day Counts Going Greener
Shortening
Project
Delivery
Accelerating
Deployment
Technology
and
Innovation
– Design-build – Construction Manager/General Contractor – Planning and Environmental Linkages– Legal Sufficiency Enhancements – Expanding Programmatic Agreements– In Lieu Fees and Mitigation Banking– Clarifying the Scope of Preliminary Design – Flexibilities in Right of Way– Flexibilities in Utilities– Enhanced Technical Assistance on EIS
Shortening ProjectDelivery
Accelerate the Deployment of Technology and
Innovation
– Safety Edge– Warm Mix Asphalt– Adaptive Single Control – Prefabricated Bridge Elements and Systems– Geosynthetic Reinforced Soil Integrated Bridge
ABC
PreliminaryDesign
Utilities
EISProgrammatic Agreements
Geotechnical
SolutionsContracting
Methods
PBES
Right of Way
How does EDC impact PBES?
Reasons for Using ABC/PBES
Present & Future Challenges• Aging Infrastructure• Increased traffic volumes
• Freight tonnage• Urban capacity
• Rising construction costs• $176B to maintain bridges
(2005-2024)• $8.8B annually
• 6,400 work zones (2003)• 6,157 lane miles closed• 20% capacity reduction
Work Zone Impacts
• Globalization of manufacturing increases demands on our transportation Intermodal networks
• 1 M more truck traffic by 2016 (ATA)• More drivers on highways• Urban Sprawl Continues
More Challenges Ahead
• Congestion robs our nation of productivity and quality of life
• 4 billion hours/year time delay• 2.9 billion gallons of wasted gas/year• $78.2 billion in 437 urban areas
Congestion Impact
What are Prefabricated Bridge Elements & Systems and how do
they Accelerated Bridge Construction projects?
Conventional Bridge Construction (CBC)
CBC (v): does not seek out methods to significantly reduce onsite construction times.
Accelerate Bridge Construction (ABC)
ABC (v): The use of innovative planning, design, materials, and construction methods to reduce onsite construction and mobility impact times
Definition of ABC cont…Onsite construction time: The period of time from when a contractor
alters the project site location until all construction-related activity is removed. This includes, but is not limited to, the removal of Maintenance of Traffic, materials, equipment, and personnel.
Mobility impact time: Any period of time the traffic flow of the transportation network is reduced due to onsite construction activities.
Tier 1: Traffic Impacts within 1 to 24 hoursTier 2: Traffic Impacts within 3 daysTier 3: Traffic Impacts within 2 weeksTier 4: Traffic Impacts within 3 monthsTier 5: Overall project schedule is significantly reduced by months to years
Definition of PBES
PBES are structural components of a bridge that are built offsite, or adjacent to the alignment, and includes features that reduce the onsite construction time and mobility impact time that occurs from conventional construction methods.
Element vs. System?
• Elements • Systems
What are PBES?Elements: single structural component of a bridge
• Deck Element
• Beam Elements“Deck” Beam Elements“Full-Width” Beam Elements
• Pier Elements
• Abutment & Wall Elements
• Miscellaneous Elements
Prefabricated Deck Elements
• Partial depth precast deck panels• Full depth precast deck panels• FRP deck panels• Steel grid decks• Orthotropic decks
Prefabricated Beam Elements
Deck Beam Elements• Modular beams and deck• Adjacent steel beam with deck• Adj. hybrid composite beams• Adj. deck bulb tee beams• Adj. double tee beams
Prefabricated Beam Elements
Full-Width Beam Elements• Truss span without deck• Arch span without deck• Precast segmental const.• Other prefabricated full-width beams without deck
Prefabricated Pier Elements
• Prefabricated caisson or pile caps• Prefabricated columns
- Concrete- Steel
Prefabricated Abutment & Wall Elements
• Prefabricated versions footings, wingwalls, or backwalls
• Partial or full height wall panels
Prefabricated Miscellaneous Elements
• Prefabricated parapets• Precast approach slabs
Precast approach slab
What are PBES?
Systems: - entire superstructure, - entire superstructure & substructure, - total bridge
Half-hour rolling roadblocks on I-4 to remove 71-ft long, 30-ft wide, 250-ton spans
143-ft long, 59-ft wide1,300-ton replacementspans built in adjacent staging area
What Success Looks Like:FDOT Graves Ave. over I-4 Bridge Replacement - 2006
Each new spaninstalled in few hours overnight
FDOT Graves Avenue over I-4 Bridge Replacement - 2006
George P. Coleman Bridge, VA - 1995
111-ft long, 25-ft high, 425-ton truss span installed over a weekend
Wells Street Bridge, Chicago – 2002
102 superstructure spans replaced in 137 nights …
… with no lane closures duringrush-hour traffic
Virginia DOT I-95 Bridge over James River, 2002
Maryland SHA MD Rt. 24 Bridge over Deer Creek, 2001
10 week bridge closurebefore school started
122.5-ft long, 33-ft wide historic through-truss bridge
3 days to install FRP deck
Baldorioty Castro Ave. – San Juan, Puerto Rico 1992
Two 700-ft and two 900-ft bridges, each installed in 21-36 hrs
Superstructure Roll-In: 390-ft Length, 3300 M Tons 2 Hours to Move - 1 Weekend Road Closure
April 2004InternationalPrefabricated
BridgeScan
Badhoevedorp, Netherlands
RR Bridge 1309, Nohant le Pin, Normandy
2,200 tons moved using SPMTs
SPMTs Install CompleteMultiple-Span Railroad Bridge
Benefits of ABC ABC / PBES improves:
Work-zone safety for the traveling public and contractor personnelMaterial quality and product durabilityTotal project delivery timeSite constructability issues
ABC / PBES reduces:Mobility ImpactsOnsite construction timesWeather-related time delays
ABC / PBES can minimize:Environmental impacts Impacts to existing roadway alignmentUtility relocations and right-of-way take
ABC:Work-zone safety for the traveling public
Total project delivery time
ABC:Mobility ImpactsOnsite construction timesWeather-related time delays
ABC:Work-zone safety for the traveling publicTotal project delivery time
ABC:Mobility ImpactsOnsite construction timesWeather-related time delays
Benefits of ABC with PBES
Reduces On-Site Construction Time• Less time spent
on-site• Traditional tasks can be
done off-site• Minimal impact from
weather conditions
Minimizes Traffic Impacts
• Minimizes traffic delay and community disruption
• Reduces detours, lane closures, and narrow lanes
US 59 under Dunlavy, TX
I-59 and I-65 Interchange, AL
Minimizes environmental impacts• Permitting• ROW take• Utility relocation• Temporary
Alignment• MOT
Robin Hood Bridge, WV
Improves Work Zone Safety
• Minimizes work near traffic and power lines, at high elevations, or over water.
Meylan Pedestrian Bridge, France
Improves SiteConstructability• Prefabricated
elements & Systems– Minimal impact from
environmental constraints
– Relieves constructability pressure.
San Mateo-Hayward Bridge, CA
Remote Locations Limited
Construction Season
150’ +
Increases quality• Prefabricated in a
Controlled environment
• Increases quality control
• Improved life cycle costs
Paradigm Shift
PBES becomes the standard method of bridge construction, and the use conventional construction methods - such as on-site CIP operations, are used in a limited manner.
Performance Measures for PBES under the EDC Initiative
State-of-the-Practice in the past?
• 40 States: 1 or more projects • 3 States: 20+ projects • 11 States actively pursuing as standard practice• Opportunity for much greater PBES deployment
State-of-the-Practice in the past?
Pursuing PBES for EDC
Current Status
What is being selected
Deployment Goals
• By December 2012, 100 cumulative bridges have been designed and/or constructed rapidly using PBES.
• By December 2012, 25 percent of single- or multi-span replacement bridges authorized using Federal-aid have at least one major prefabricated bridge element that shortensonsite construction time relative to conventional construction.
• By June 2012, 40 States adopt PBES decision making framework in their design process
More than 20 bridges have been designed and/or constructed using PBES in the past 3 years and a decision making framework that considers the use of PBES is incorporated in the design process.
Fully Implemented
Module Conclusions
• EDC Program: vision and mission for PBES • The reasons for using ABC/PBES• Definitions of PBES• Case studies of PBES• Benefits of PBES• The status of EDC deployment goals for PBES
Why Use PBES Technologies? Advantages:
+ Faster (offsite & off critical path)+ Safer (public and construction) + Better Quality (controlled environment)+ Lower Cost (total project/life cycle costs)+ Easily adaptable to many site constraints
Why Use PBES Technologies?Bottom Line:
The traveling public deserves a new driving experience with
reduced user costs due to reduced
work zones and congestion
Questions?
FHWA Contacts: PBES Innovation Team
Benjamin Beerman, Team Lead [email protected]
Jamal Elkaissi, Structural Engineer [email protected]