next beam bridge & innovative materials

NEXT Beam Bridge & Innovative Materials

Darren Conboy, PE & David Massenzio, PE

2018 Innovation & Mobility Exchange 2

MATERIAL / DESIGN ELEMENT HUDSON BRIDGE PROJECT USE

10,000 psi Mix Design Seven (7) NEXT 40D Beams

Ultra-High Performance

Concrete (UHPC)

Closure pours between NEXT 40D

beam flanges

Micropiles with New

Casing SteelSupport of bridge abutment pile caps

Presentation topics

• Overview of existing & new bridges


Existing bridge

• Bridge carried Washington Street over the Assabet River

in Hudson, MA.

• Three-span masonry arch bridge

2018 Innovation & Mobility Exchange

Existing bridge

4

• Significant deterioration

— Dislodged stones

—Gunite coating cracks

— Undermining at abutments

— Concrete sidewalk deficiencies

2018 Innovation & Mobility Exchange

Existing bridge

5

Project constraints/issues

• Properties located at

each corner of bridge

• Several utilities

• Limited staging areas

at approaches

• Bridge full closure

105-day duration



New bridge design


Why use NEXT beams?

• Expedite bridge construction, minimize bridge closure

— No cast-in-place concrete deck construction

— Allow pre-piping of utilities

• Long-term durability with low maintenance


Why use NEXT beams?


NEXT Beams – Other Applications


NEXT Beams - Other Applications


Development of

project specifications

• Working group sessions between MassDOT RMS, Gill

Engineering & Jacobs

• Focus of working group sessions:

—Micropile specification changes

— 10,000 PSI mix design

— Ultra-High Performance Concrete (UHPC)

—Other MassDOT specification updates


Micropile specification changes

• Micropile specification changes

— Buy America requirements

[23 CFR 635.410]

— New casing material – ‘prime’ steel versus ‘mill

secondary’

• Bid prices with new casing steel

— Bid prices ranged from $223 to $430 per linear foot

of drilled micropiles


Why was a 10,000 PSI

concrete mix used?

• Bridge geometry limitations

— 85’ beam spans

— Limited beam flange

widths

— High initial concrete

compressive strength

(8,000 psi) required


10,000 PSI Mix Composition• Portland Cement – Lafarge, Type HE-1 (720 lb/cy)

• Fly Ash – Class F (25% of total cementitious material weight)

• Aggregate (3/4” coarse and sand)

• W:C ratio - 0.26

• Chemical Admixtures

• Air-Entraining Agent

• Hydration Stabilizer

• High-Range Water Reducer

• Shrinkage Reducer

• Corrosion Inhibitor


Future Use of 10,000 PSI Mix in MA

• Potentially an available option for precast bridge

components with approval of State Bridge Engineer

• Currently requires mix testing which is expensive

• NYSDOT experience


Why use UHPC for

the Hudson Bridge Project?

• Rapid-setting material

required to expedite

opening bridge to traffic

• Limited closure pour width

— 14,500 psi compressive

strength required

• Durable closure pour

material


What is UHPC?

• Cementitious composite material

• W:C ratio < 0.25

• Compressive strength > 21.7 ksi

• Superplasticizer

• Steel Fibers

• Pre- and post-cracking tensile

strength > 0.72 ksi


UHPC Matrix

Ultra High Performance

Concrete – 21,000 psiHigh Performance

Concrete – 10,000 psiConventional Concrete –

4,000 psi

Graphics Courtesy of Lafarge


UHPC Closure Joints


Bridge closure pour placement


What are some of the

challenges with using UHPC?

• Currently high material and construction costs compared

with conventional concrete

— Bid prices ranged from $90 to $580 per CF

($2,400 to $15,700 per CY)

• No local suppliers

• Limited local familiarity with UHPC material and placement

• No generic specification

• Limited design guidelines


How can UHPC be used in the future?

• Field-Cast UHPC Connections

• Closure Pours between Precast Beams

• Closure Pours between Precast Deck Panels Eliminating Post-

Tensioning

• Shear Keys between Butted Box Beams Eliminating Lateral Post-

Tensioned Ties



• Rehabilitation

• UHPC Overlays of Deteriorated Concrete Bridge Decks

• Link Slabs

• Encasement of Deteriorated Steel

Beam Ends

• Encasement of Deteriorated Concrete

Substructures

• Strengthening of Concrete

Substructures



• New Members

• Precast Beams

• Piles for Brackish Water Applications

• Approx. 200 Bridges Built in Malaysia with all UHPC Components


Existing and new bridges

• NEI & MassDOT

opened bridge to traffic

in 85 days (milestone

for full incentive)


Questions?


UHPC Deck Overlays – Mar 2018 Report


FHWA – UHPC Usage In US & Canada

Graphic Courtesy of FHWA


UHPC Premix/Constituents• Premix

• Blend of cement, silica sand, quartz flour and silica fume

• Large “aggregate” less than 1 mm

• Superplasticizer

• Water

• W:C ratio less than 0.25

• Fibers

• Steel (structural)

• Organic (architectural)

Slide Content and Graphics Courtesy of Lafarge


UHPC Properties• Compressive Strength

• 20,000 to 33,000 psi

• Flexural Strength

• 3,000 to 7,000 psi

• Ductility

• Greater capacity to deform and support

flexural and tensile loads even after

initial cracking

• Abrasion Resistance similar to natural rock

• Impermeability

• Almost no carbonation and penetration of chlorides

Slide Content and Graphic Courtesy of Lafarge


Box Girder UHPC Field Connections

Graphics Courtesy of Lafarge and Ministry of Transportation of Ohio


UHPC Pier Jacket – Hodder Avenue

Underpass, ON

Graphic Courtesy of Lafarge


UHPC Pier Jacket – Hodder Avenue

Underpass, ON



UHPC Pier Retrofit – Mission Bridge, BC



UHPC Pier Retrofit – Mission Bridge, BC

Graphic Courtesy of Lafarge


Runway 33L – Safety Area

• 460 ft. Long (11 Spans)

• 303 ft. Wide (30 NEXT Beams)

• 139,380 sf. Deck Area

• 600 ft. x 160 ft. EMAS


MBTA Littleton Station

next beam bridge & innovative materials

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