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

1

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)

2

Existing

Bridge

3

Existing

Bridge

Location

4

1

STATE ROUTE 30 over BESSEMER AVE

Allegheny County, Pennsylvania

Existing

Bridge

Aerial

5

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

Detour

Route

7

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”

8

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)

9

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

10

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

11

LIDAR SURVEY : AS-BUILT BRIDGE MODEL

12

As-Built Bridge Model

Shows Bridge Elements to be Removed

13

ABC Construction Sequence

Pre-Weekend Closure

Precut and brace abutment walls along frontface

Sawcut roadway pavement at ends

Repair abutment spalls and cracks

14

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

15

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

16

Engineer’s ABC Schedule

17

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

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

18

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

19

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

20

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

21

New Superstructure Plan

Straight beams / modules. Bridge curvature accommodated using

overhangs with variable widths 22

Removal of Deteriorated Sections

23

Precast Abutment Caps

Stepped to Match Superelevation

24

Precast Cap Elevation

25

• Steel shims used to achieve proper seat elevations • Gap around shims filled with rapid set grout -- through

grout ports in cap

Replace with Precast Abutment Cap

26

27

Superstructure Interior Module

28

Superstructure Exterior Module

Includes Sidewalk and Parapet

29

Superstructure Modules Assembly

30

Approach Slab Section

31

Precast Sleeper Slab

32

Abutment Spall and Crack Repairs

33

CONSTRUCTION HIGHLIGHTS

34

Bridge

Demolition

Friday 11:15 PM

35

Bridge

Demolition

36

Bridge

Demolition

Friday 11:45 PM

37

Precast

Abutment

Cap

Saturday 1:00 PM

38

Precast

Abutment

Cap

39

Precast

Abutment

Cap

Saturday 3:00 PM

40

Precast

Deck

Panel

Sunday 12:00 AM M2- 79 Ton with Rigging

41

Precast

Deck

Panel

Sunday 7:00 AM

42

UHPC

Placement

Sunday 4:00 PM

43

UHPC

Placement

44

New

Bridge

after 57

Hours

45

Approach

Slab Flow

Fill

46

Profile

Milling and

LMC Prep.

47

Saturday 1:15 AM

LMC

Placement

48

Saturday 6:20 AM

New

Structure

and

Roadway

49

Sunday 12:00 PM

New

Structure

50

Time

Lapse

Video

51

https://youtu.be/0VMMq0fNWjg

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.

52

Closing

53

Questions

Contact info:

Louis J. Ruzzi : lruzzi@pa.gov> John Myler : jmyler@pa.gov Bala Sivakumar : bsivakumar@hntb.com