EXPANDING THE USE OF PRECAST CONCRETE IN TEXAS BRIDGES
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1 EXPANDING THE USE OF PRECAST CONCRETE IN TEXAS BRIDGES Graham Bettis, P.E. TxDOT Bridge Division Construction & Maintenance
2 Just the Facts Total Number of On-System Bridges (Excluding Culverts): 21,686 Total Number with Prestressed Concrete Superstructures: 11,037 (that s 51%) About 90% of New Bridges Built with Prestressed Concrete Superstructures 92% in FY
3 Standard I-Beam Construction 3
4 Standard U-Beam and Deck Panel Construction 4
5 Precast Concrete - How Do We Love Thee? Owner s Perspective Inexpensive Fast Durable Redundant Contractor s Perspective Fast $$$* * Sometimes difficult for Primes to let go of cast-in-place. 5
6 Concrete Production in Texas Cement Lots of Limestone 10 Cement Producers Coarse Aggregate River Rock Limestone Fine Aggregate River Beds (Sand) Manufactured Sand (Limestone) Fly Ash Coal Plants in Texas 6
7 Precast Concrete Fabricators Major Prestressed 7
8 Precast Concrete Fabricators Minor Prestressed 8
9 Precast Concrete Fabricators Nonstressed 9
10 Average Bridge Costs FY 2013 Structural Steel* Plate Girders: $126/SF Trapezoidal Tubs: $153/SF Prestressed Concrete Tx Girders (Bulb Tees): $65/SF U54 Beams: $52/SF * Must take into account that almost all steel spans are long and continuous, raising the construction cost significantly. But still 10
11 Durability Extremely Low Permeability Fly Ash Steel Form Finish Produced in Controlled Environment Self-Consolidating Concrete Low Water-to-Cement Ratio Moist Curing QC/QA Repair and Rejection Plant vs. Job Site 11
12 Curing 12
13 Permeability 13
14 Not All Concrete Cracks 14
15 Conventional Concrete Deterioration 15
16 Conventional Concrete Deterioration 16
17 Conventional Concrete Deterioration 17
18 Conventional Concrete Deterioration 18
19 Conventional Concrete Deterioration 19
20 Structural Steel Deterioration 20
21 Structural Steel Deterioration 21
22 Structural Steel Deterioration 22
23 High Performance Concrete Item 421: Hydraulic Cement Concrete 8 Mix Design Options HPC = Design Options 1 through 5 In Reality, HPC = Design Option 1 Replace 25% of Cement with Class F Fly Ash Applies to All Precast Concrete 23
24 Precast Concrete Current, Widespread Usage 24
25 Standard Precast Items Railing Traffic Barrier Decked Slab Beams Prestressed Piling Bent Cap for Round Columns Bent Cap for Steel Piling Spread Boxes X-Beams End Treatments Manholes & Inlets Tx Girders (Bulb Tees) U-Beams Slab Beams I-Beams Prestressed Deck Panels Sheet Piling Culverts Reinforced Concrete Pipes Box Beams 25
26 Prestressed Piling 26
27 Prestressed Piling 27
28 Standard I-Girder Shapes 28
29 I-Girders 29
30 What We re Doing Now Tx Girders 30
31 Decked Slab Beams 31
32 Decked Slab Beams 32
33 U-Beams 33
34 Precast Deck Panels 34
35 Precast Deck Panels 35
36 Precast Deck Panels with PMDF 36
37 Precast Deck Panels to Joints 37
38 Precast Overhang Deck Panels with Pockets 38
39 Precast Overhang Deck Panels with Channel 39
40 Precast Overhang Deck Panels with Channel 40
41 Full Depth Panels 41
42 Full Depth Panels 42
43 Full Depth Panels 43
44 MSE Panels 44
45 Existing Concepts Desire for Expanded Use 45
46 Precast Bent Caps 46
47 Precast Bent Caps 47
48 Precast Bent Caps 48
49 Precast Bent Caps 49
50 Precast Abutments 50
51 Precast Abutments 51
52 Precast Segmental 52
53 New Concepts Current Implementation 53
54 Long Spans - Existing 54
55 Long Spans Trending Upwards 55
56 Long Spans Existing Bridge Construction 56
57 Spliced Precast Girders Uniform Cross Section (Non- Haunched): Haunched: 325 Curved Tubs:
58 Spliced Precast Girders 58
59 Haunched Section 59
60 Spliced Precast Girders 60
61 Spliced Precast Girders with Haunch 61
62 Spliced Precast Girders with Haunch 62
63 Post-Tension Anchorage Zones 63
64 Post-Tension Anchorage Zones 64
65 Post-Tension Anchorage Zones 65
66 Post-Tension Anchorage Zones 66
67 Cylinder Piling 67
68 Cylinder Piling 68
69 Cylinder Piling 69
70 Innovation and Unique Applications 70
71 Curved Precast Concrete Tubs 71
72 Curved Precast Concrete Tubs 72
73 Curved Precast Concrete Tubs 73
74 Spliced Concrete Tubs 74
75 Prestressed Concrete Bent Caps 75
76 Unique Precast Applications West 7 th Street Arch 76
77 Unique Precast Applications West 7 th Street Arch 77
78 Graham Bettis, P.E. TxDOT Bridge Division - Field Operations Section Construction & Maintenance Group graham.bettis@txdot.gov Office: Mobile:
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