segmental bridge construction

Structures Design Plans Review GroupSegmental Bridge ConstructionDesign p

Segmental Bridges It’s a

g g

Segmental Bridges – It’s a Construction Technique with Design Implications

2010 FDOT/FTBA Construction Conference

February 23-24Orlando, Florida

Structures Design Plans Review GroupPresentation SpeakersDesign pPresentation Speakers

Brian Blanchard PEBrian Blanchard, P.E.Florida Department of Transportation

Enrique Espino PEEnrique Espino, P.E.Condotte America, Inc.

Jim Schneiderman, P.E.PCL Civil Constructors, Inc.

R. Craig Finley, Jr., P.E.Finley Engineering Group, Inc.y g g p,

Structures Design Plans Review GroupAgendaDesign pg

• Florida Department of Transportation’s Perspective, Brian Blanchard, P.E.,Perspective, Brian Blanchard, P.E., Florida Department of Transportation

• Contractor’s PerspectivedEnrique Espino, P.E., Condotte America, Inc.

Jim Schneiderman, P.E., PCL Civil Constructors• Design and Construction Engineers’• Design and Construction Engineers

Perspective

R. Craig Finley, Jr., P.E.,R. Craig Finley, Jr., P.E., Finley Engineering Group, Inc.

• Future Perspective, February 23, 2010FDOT/FTBA

Enrique Espino, P.E., Condotte America, Inc.

• Round Table Q & A

FDOT/FTBA Construction Conference

Structures Design Plans Review GroupFDOT

Perspective Segmental Bridge ConstructionDesign pPerspective g g

Roosevelt Bridge

Segmental Bridges – It’s a Construction Technique with

Roosevelt Bridge

Construction Technique with Design Implications

February 23, 2010FDOT/FTBA

ConstructionFrom the Florida Department of

’Construction

Conference

Brian Blanchard P.E.Chief Engineer

Florida Department of

Transportation’s Perspective

pTransportation



From the Florida Department ofFrom the Florida Department of Transportation’s PerspectiveSkyway Bridge

History of Segmental Bridges in


Construction

FloridaFDOT Policies and ProceduresConstruction

Conference



FDOT Policies and ProceduresExperience and Future Treads

pTransportation



History of Segmental Bridges in Royal Park Bridge

Florida


ConstructionConstruction Conference


Florida Department of pTransportation



History of Segmental Bridges in FloridaThe Early Years

Key

hann

el

el 5

Mile

– The Early YearsL

ong

KB

ridg

e

Nile

s Ch

Cha

nne

Seve

n M

1981 1982 1983 1984

mp

I I-

75Span-by-span

Ram

Ove

r Balanced CantileverAll dates given are completion dates



History of Segmental Bridges in FloridaThe Early Years– The Early Years

idLong Key Bridge

Niles ChannelChannel 5

Seven Mile



hes- The Early Years (cont.)

kyw

aypp

roac

h

Span-by-spanBalanced Cantilever

All dates given are completion dates

1985 1986 1987 1988

Sk Apdates g ve a e co p et o dates

1985 1986 1987 1988

826

ges) -75

ges)

ale

ort

es)

441

ges)

-75

ges)

-75/

SR 8

(5 B

ridg

I-59

5/I-

(5 B

ridg

aude

rda

Air

po4

Bri

dge

595/

US

4(2

Bri

dg

I-59

5/I-

(6 B

ridg

I- ( (

Ft. L

(4 I-5 ((



Long Key Bridgeg y gFirst application of Precast Span-by-span Bridge Construction in the U.S.

1981



Seven-Mile BridgeSeven-Mile BridgeFirst Application of an Overhead Gantry in Floriday

1982



Ramp I BridgeRamp I BridgeFirst application of Precast Balanced Cantilever Construction in Florida

19841984



- Other FirstsFirst Demolition of Existing Segmental Bridge in the North America.

Fort Lauderdale-Hollywood International Airport expansion required the removal of three precast q psegmental concrete bridges.

How did we demolish segmentalHow did we demolish segmental concrete bridges built by the balanced-cantilever method? By reversing the

h i ll d2002

way the segments were installed.



- Other FirstsI-75/ SR 826 Ramp A -First Segmental Bridge p g gWidening in U.S. Mainland

2004



FDOT Segmental Bridges Constructed by Year12

g g y

8

10

6

2

4

0

1981

1982

1983

1984

1985

1986

1987

1988

1989

1990

1991

1992

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006

Current Number of Segmental Bridges – 68 (3 have been removed at Ft. Lauderdale Airport)



FDOT Policies and ProceduresAcosta Bridge







FDOT PoliciesIn Response to PT Corrosion Issues





Advanced Corrosion of Strands within Niles Channel Anchorage

pTransportation



FDOT Bridges w/ Grout Problems

Niles Channel Bridge

6 Bridges at I‐75 & I‐595(Voids in Tendons) 1996 Inspection

Niles Channel(Failed Tendon)


Construction (Failed Tendon)Construction Conference



1999 Inspection

pTransportation



FDOT Bridges w/ Grout Problems (cont.)

(

Skyway Bridge

Mid‐bay (Spans 28 and 57 2‐ Failed Tendons)

2000 Inspection

Skyway Approach (FailedTendon Pier 133 N)


Construction Tendon Pier 133 N)Construction Conference



2000 Inspection

pTransportation



New Directions for Florida Post-Tensioned BridgesCorven Engineering, Inc. g g,February 15, 2002







2Policy RevisionsySpecify Minimum Layers of Protection

Develop Anchorage Protection Standard Details Seabreeze Bridge

and QPL Pour-back Materials

Develop P.T. Redundancy Requirements

R fi G ti P dRefine Grouting Procedures

• Pre-approved P.T. Systems

• Qualified Grouting Personnel/ Inspectors


Construction Qualified Grouting Personnel/ Inspectors

• Specify Low-Point-Up Grouting

• Specify Non-bleed QPL Bagged Grouts

Construction Conference



• Specify Inspection Access Pointsp

Transportation



Dodge Island Bridge

Experience and Future Trends







Experience and Future Trends –Segmental top-down construction techniques are cost effective on large waterway projects Hathaway Bridge

where insurance and labor rates are governed by time working from barges. Larger projects generally make segmental


Construction

Larger projects generally make segmental construction more cost effective due to the casting yard setup cost being spread overConstruction

Conference



casting yard setup cost being spread over more segmental units and when the amount of work is sufficient to overcome learning-p

Transportationg

curve inefficiencies.



Experience and Future Trends (cont.) –

Segmental alternatives have been

competitive against steel box options where Royal Park Bridge p g p

the number of segmental units is sufficient

(greater than 600-700 units).


Construction

(g )

Segmental options have not been competitive

on small projects when bid against simpleConstruction Conference



on small projects when bid against simple

span prestressed beam options.p

Transportation



Future Trends – Customized Overhead GantriesAll i C il C i C dAllowing Cantilever Construction on Curved RampsGreatly Reducing Traffic DisruptionsRoosevelt Bridge y g p

Example: Palmetto Section 5





Transverse Deck Beam



Future Trends – Greater Use of Combined Steel and Concrete to Reduce Weight?Concrete to Reduce Weight?• Core Segment• External Strut + Rib• Precast Panel

Example: Yamakiri Viaduct (Japan)



Future Trends – National Post-Tensioning Specificationp

PTI is currently developing a nationwide post-y p g ptensioning specification based largely on FDOT specifications, research and pastFDOT specifications, research and past experiences.






Florida Department of pTransportation S.E. 17th Street Bridge

Structures Design Plans Review GroupSegmental Bridge ConstructionStructures Design Plans Review GroupContractor’s Perspective Segmental Bridge ConstructionDesign pg gDesign pPerspective g g

Segmental Bridges –Enrique I. Espino, P.E.President

It’s a Construction Technique with Design

Condotte America, Inc.

Technique with Design ImplicationsJim Schneiderman, P.E.

The Contractor’s PerspectiveConstruction Manager

PCL Civil Constructors, Inc.

February 23, 2010FDOT/FTBAFDOT/FTBA



• Types of Segmental Bridges andTypes of Segmental Bridges and Characteristics

P ti S tEnrique I. Espino, P.E.

President • Precasting Segments ‐Superstructures & Substructures

Condotte America, Inc.

• Erecting Precast Segments ‐Superstructures & Substructures

Jim Schneiderman, P.E.

• Cast‐in‐Place with Form TravelersFebruary 23, 2010

FDOT/FTBA

Construction ManagerPCL Civil Constructors, Inc.



Types of Segmental Bridges

and Characteristicsand Characteristics

Jim Schneiderman P EJim Schneiderman, P.E.





Structures Design Plans Review GroupSegmental Bridge ConstructionStructures Design Plans Review GroupSegmental Bridge ConstructionDesign pg gDesign pg g

• Types of Segmental Bridge StructuresTypes of Segmental Bridge Structures– Precast Span by Span

Precast Balanced Cantilever– Precast Balanced Cantilever

– Precast Progressive Placement

C t i Pl B l d C til– Cast‐in‐Place Balanced Cantilever

– Cast‐in‐Place Incremental Launching

C i Pl & P C bl S d– Cast‐in‐Place & Precast Cable Stayed


• Precast Span by SpanPrecast Span by Span

Ernest F. Lyons Bridge – Stuart, FL(Photo courtesy of PCL Civil Constructors, Inc.)


• Precast Balanced CantileverPrecast Balanced Cantilever

J h Ri li C S t FLJohn Ringling Causeway – Sarasota, FL(Photo courtesy of PCL Civil Constructors, Inc.)


• Precast Progressive PlacementPrecast Progressive Placement

Temp. Support

Linn Cove Viaduct – Blue Ridge Parkway, NC(Photo courtesy of Figg Engineering Group)


• Precast Progressive Placement (cont )Precast Progressive Placement (cont.)

Temp. Support


• Cast‐in‐Place Balanced CantileverCast in Place Balanced Cantilever

Form Traveler

Foothills Parkway Bridges – Smokey Mountains, Tennessee(Photo Courtesy of PCL Civil Constructors, Inc.)


Cast in Place Balanced Cantilever (Cont )Cast‐in‐Place Balanced Cantilever (Cont.)


Cast‐in‐Place Incremental LaunchingCast in Place Incremental Launching

Launching Direction

Launching NoseCasting Bed


• Precast & CIP Segmental Cable StayedPrecast & CIP Segmental Cable Stayed

Sunshine Skyway Bridge – Tampa, FL(Photo courtesy of Figg Engineering Group)


Precast and Cast‐in‐Place Cable Stayed (cont )Precast and Cast in Place Cable Stayed (cont.)

PylonStay Cable

Deck

Structures Design Plans Review GroupContractor’s Perspective Segmental Bridge ConstructionDesign pPerspective g g

Precasting SegmentsPrecasting SegmentsSuperstructures & Substructures

Enrique Espino, P.E.Condotte America, Inc.

Enrique I. Espino, P.E.


PresidentCondotte America, Inc.



Erecting Precast SegmentsSuperstructures & SubstructuresSubstructures

Jim Schneiderman P EJim Schneiderman, P.E.






‐ Precast Segmental Bridge Erection TechniquesPrecast Segmental Bridge Erection Techniques‐ Span by Span Erection Methods

Balanced Cantilever Erection Methods‐ Balanced Cantilever Erection Methods

‐ Erection of Segmental Substructures


• Span by Span Erection Methods– ‘Top Down’ erection using under‐slung truss and segment lifter

Segment Lifter

Underslung Truss

Truss Supports

Ernest F. Lyons Bridge – Stuart, FL(Photo Courtesy of PCL Civil Constructors, Inc.)


• Span by Span Erection Methods– Overhead Erection TrussOverhead Erection Truss

Seattle Sound Transit Light Rail Project – Seattle, WA(Photo courtesy of PCL Civil Constructors, Inc.)


‐Span by Span Erection MethodsOverhead Erection Truss‐Overhead Erection Truss

Overhead Erection Truss

C&D Canal Bridge – Delaware (Photo courtesy of Figg Engineering Group)


• Span by Span Erection Methodsp y p– Erected on Falsework using conventional cranes

Falsework

(Photo courtesy of Flatiron Constructors, Inc.)


• Span by Span Erection MethodsLifti f E ti S t– Lifting of Entire Span at once

Jamestown Bridge – Rhode Island (Photo Courtesy of Figg Engineering Group)


• Typical Balanced Cantilever Erection Methodsyp


• Balanced Cantilever Erection Methods

Crane Erection from Ground Crane Erection from Bridge Deck


‐ Balanced Cantilever Erection Methods‐ Erection using a beam and winch

Oakland Bay Bridge ‐ Oakland, CA(Photo courtesy of Flatiron Constructors, Inc.)


‐ Balanced Cantilever Erection Methods‐ Erection using overhead Erection Truss

Otay River Bridge – San Diego, CA(Photo courtesy of International Bridge Technologies)


• Segmental Substructures• Sequence of Erection:

– Place and Grout Segment to footing Keway– Erect remaining segments to a predetermined

elevation (usually based on stability)elevation (usually based on stability).– Perform intermediate P.T. to maintain pier

stability– After all segments have been erected,

permanent PT is performed (usually looppermanent PT is performed (usually loop tendons through footing)

– Tendons are then grouted.Typical Precast Column Segment

Keyway

• Splash Zone Requirements:– Many states do not allow precast substructure

elements to be used within the splash zone. Above the Splash Zone, precast erection can begin.

Keyway in Footing to Align / Stress first Segment


• Segmental Substructuresg

C&D Canal Bridge Hoover Dam Bypass


• Segmental Substructuresg

Stressing Vertical Column Tendon


• When does Precast Segmental SubstructureWhen does Precast Segmental Substructure make sense?– When you have a large volume production of typical pier shapesy g p yp p p

– When high quality concrete and geometry control of the piers is extremely important

– When there is a long lead time for foundations that allows fabricationWhen there is a long lead time for foundations that allows fabrication of pier segments concurrently with foundation work

* The major advantage of precasting substructure segments is the* The major advantage of precasting substructure segments is the speed of erection, which surpasses any other conventional method of pier construction.


Scheduled Seminars :Scheduled Seminars :

February 17‐18Denver, Colorado

June 22‐23Orlando, Florida

For More Information, Please Go To:

http://www asbi assoc orghttp://www.asbi‐assoc.org


Cast‐in‐PlaceCast in Place with Form Travelers

Enrique Espino, P.E.Condotte America IncCondotte America, Inc.

Enrique I. Espino, P.E.P id


PresidentCondotte America, Inc.



Segmental Bridges –Segmental Bridges –It’s a Construction Technique

ith D i I li tiEnrique I. Espino, P.E.

Presidentwith Design ImplicationsCondotte America, Inc.

Jim Schneiderman, P.E.Construction Manager

PCL Civil Constructors, Inc.



Structures Design Plans Review GroupDesign p

Design and Construction Engineer’s g gPerspective

R. Craig Finley, Jr., P.E.Managing Principal R. Craig Finley, Jr., P.E.


FINLEY Engineering Group, Inc.

R. Craig Finley, Jr., P.E.Finley Engineering Group, Inc.


Structures Design Plans Review GroupDesign and Construction Engineer’s Perspective Design pg g p

Presentation Outline

• Key Points to Understanding Segmental

Presentation Outline

• My Background & Perspective

• Importance of Project Procurement

• Engineering Roles & Responsibilities

• Special Considerationsp


Key Points to Understanding SegmentalKey Points to Understanding Segmental

Segmental bridges are based on a construction technique that has

design implications.

Know how to build it beforestarting to design it.g g


Background

• A bridge engineer, a Florida PE and b

Background

FTBA member

• Involved with segmental bridges continuously since 1979continuously since 1979

• Working in the USA and internationally

• Started in Florida on the Keys and now doing SR 826/836 Interchange


Perspective

• As a designer and construction engineer

Perspective

• Preference for contractor driven and design/build projects

• Typically involved with the bid• Typically involved with the bid

The best approach is not always the same for every one or every project.


Importance of Project Procurement

Three ways to do it:

Importance of Project Procurement

• Design – Bid – Build

• Design – Buildg

• After the fact – Value Engineering or “Construction Modification”

Different approaches to ff ppincorporate construction methods


Design – Bid - Build

• Generic design – many assumptions

Design – Bid - Build

• Code based – not construction methods or schedule

• Will be reworked by construction engineer before it can be built

• Multiple steps/approvals

Procurement


Design - Build

• Specific design – known construction

Design - Build

method

• Better initial optimization and faster process

• More efficient – best results

• Responsibility is where it needs to be

Procurement


Value Engineering / “Construction Modification”

• Combination approach

Value Engineering / Construction Modification

Combination approach

• Used for an advantage

• Has been very successfulHas been very successful

• More common in tough times

Procurement


Engineering Roles & Responsibilities

• Design Engineer

Engineering Roles & Responsibilities

Owner Client

• Construction EngineerContractor Client

• Value Engineering / Design Build


Design Engineer

• Works for the owner

Design Engineer

• Typical scope– Design

– Drawings

– Specifications

– Cost estimates

Based on an assumed schedule d & h dand means & methods

Roles & Responsibilities


The Design Engineer provides post-design services

R i d t ti

The Design Engineer provides post-design services.

• Reviews and approves construction engineering

• Based on actual construction engineering• Based on actual construction engineering– Takes time

– InefficientInefficient

– Personalities involved



Construction Engineer

• Works for contractor

Construction Engineer

• Typical scope– Integrated shop drawings

– Construction analysis and camber

– Temporary works / special equipment

l– Geometry control

– Post‐tensioning support



The Construction Engineer does the detailed design

• Performs time dependent, step by

The Construction Engineer does the detailed design.

Performs time dependent, step by step analysis

• Incorporates schedule and sequencep q

• Analyzes means and methods

• Uses sophisticated software and isUses sophisticated software and is very detailed



Value Engineering and Design - BuildValue Engineering and Design - Build

• In VE projects, there is overlap between the design and construction engineersengineers.

With D i B ild th d i d• With Design‐Build, the design and construction engineer are the same.



Special Considerations

The Construction Method Dictates Design

Special Considerations

• Takes more engineering to Bid & Build

• Requires high level of planning and q g p gcoordination

• Calls for a factory/assembly line mentality

• Is optimum in design/build


Managing Principal

Structures Design Plans Review GroupDesign p

Design and Construction Engineer’s g gPerspective

R. Craig Finley, Jr., P.E.Managing Principal R. Craig Finley, Jr., P.E.


FINLEY Engineering Group, Inc.

R. Craig Finley, Jr., P.E.Finley Engineering Group, Inc.


Structures Design Plans Review Group

Segmental Bridge ConstructionFuture PerspectiveDesign pFuture Perspective

• More design‐build & experiencedMore design build & experienced Contractors.

• Standardization of precast segments• Standardization of precast segments

– Supply like pre‐stressed girders.

• Higher strength and composite materials.

• National specifications for materials and training.February 23, 2010

FDOT/FTBA gFDOT/FTBA Construction Conference


Segmental Bridge ConstructionFuture PerspectiveDesign pFuture Perspective

• More sophisticated erectionMore sophisticated erection equipment.

• Rehab market will develop• Rehab market will develop.

• 100+ year service life – durability.




Segmental Bridge ConstructionRound Table Q & ADesign pRound Table Q & A

• Florida Department of Transportation’sFlorida Department of Transportation s Perspective, Brian Blanchard, P.E., Florida Department of Transportation

• Contractor’s Perspective

– Enrique Espino, P.E., Condotte America, Inc.q p , , ,

– Jim Schneiderman, P.E., PCL Civil Constructors, Inc.

February 23 2010

• Design and Construction Engineers’ Perspective

R. Craig Finley, Jr., P.E., Finley Engineering GroupFebruary 23, 2010


g y y g g p

segmental bridge construction

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