Spliced Precast Concrete Girder Developments. TxDOT Transportation Short Course October 17, 2012
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1 Spliced Precast Concrete Girder Developments TxDOT Transportation Short Course October 17, 2012
2 Agenda Need for Spliced Girder Technology Previous History in Texas Recent Texas and National Developments Texas Implementation
3 Long Span Bridges On and Off System 748 Bridges in Texas over 150 ft Span
4 Long Span Bridges On and Off System
5
6 Plate Girders
7 Direct Connector
8 Curved Plate Girders
9 Steel Trap Girders
10 Segmental: Precast Span-by-Span
11 Segmental: Precast Balanced Cantilever
12 Segmental: CIP Balanced Cantilever 250 ft H 73 ft V
13
14 Average = $54.86 per SF
15 120 Span Length vs. Weight Curved Plate Girder 100 Weight (psf) Span Length (ft)
16 $200 Span Length vs. Cost Curved Plate Girder Average = $ per SF Cost of Steel per SF $150 $100 $50 $ Span Length (ft)
17 120 Span Length vs. Weight Trapezoidal Girder 100 Weight (psf) Span Length (ft)
18 $200 Span Length vs. Cost Trapezoidal Girder Average = $ per SF Cost of Steel per SF $150 $100 $50 $ Span Length (ft)
19 Standard TxGirders
20 Tx28 Tx34 Tx40 Tx46 Tx54 Tx62 Tx70
21 TxGirders: Simple Span Capabilties Girder Span Length at Min Girder Spa Span Length at Max Girder Spa Tx Tx Tx Tx Tx Tx Tx
22 Previous TxDOT Methods for Increasing Span Length: Loy Lake Road Bridge at US 75
23 Previous TxDOT Methods: Drop-In DOUBLE END CANTILEVER BEAMS
24 Drop-In: 190 ft Span Cypresswood over RR (HOU)
25 Drop-In Heavily Reinforced Corbels Non-Continuous, Less Redundancy Multiple Harping Locations in Strands
26 Spliced Girder Bridges Popular in SE & NW US Main Span Up to 250 to 325 ft 2 Texas (non-txdot) projects DART & City of Fort Worth 1 st TxDOT Project let in Dallas July 2011
27 Spliced TxGirders Spliced precast bulb tees have main span lengths of up to 325 ft Competitive with steel plate girders and segmental concrete Two TxDOT research projects underway Project 6651 at TTI/TAMU: Continuous PS Conc Bridges Project 6652 at CTR/UT: TxGirder Splices Three construction projects underway
28 DART Orange Line at Trinity River First Modern Application in Texas Modified Tx82 Sections Variable Depth Pier Section
29 DART Spliced Girder Bridge Variable Depth Section: Max Depth = 10-10
30 DART Spliced Girders
31 DART Spliced Girder
32 Clearfork Main Street Bridge, Fort Worth TX Type VI Mod Girders From: Hamilton Forms, Form and Function, Winter 2010 Parabolic Haunch (10-0 max depth)
33 Clearfork Main Street Bridge, Fort Worth TX From: Hamilton Forms, Form and Function, Winter 2010
34 Dallas Trinity River (Sylvan Ave) Two 3-span continuous PT units (constant depth) (variable depth) Tx82 Mod 10 thick web Max depth Bidders $99 to $112 per SF overall cost $40 per SF for beams and post-tensioning
35 Projects on the Horizon
36 FM 1495 Over Old Brazos River Freeport, TX
37 FM 1495 Freeport min over Old Brazos River 192 min over Dow Chemical RR Yard
38 Bijou Street Bridge, Colorado Erection of Span over Rail Yard
39 FM 457 over ICWW Sargent Beach, TX
40 Sargent
41 Matagorda Segmental Matagorda FM 2013 over GIWW 180 ft 320 ft 180 ft $212 per SF Most aesthetic
42 SH 105 at Brazos River Proposed Span Arrangement
43 Spliced Concrete U-Girders
44 Prestressed U-Beams 54 and 40 Beam Depths Wider Beam Spacing Sloped Sides Aesthetic Solution for Grade Seps
45
46
47 Curved Spliced U-Girders: National Efforts Concept Genesis: Colorado Built 10 projects, 2 under construction Over 800,000 SF deck, 41,000 LF beams in service PCI-SE (Zone 6) Effort Developed standards FDOT Implementation Orlando-Orange County Expressway Authority Interchanges TxDOT Implementation
48 Construction Steps
49 PCI-SE: 72 Deep Sections Max Main Span Lengths 185 to 220 Range Continuous 175 to 180 Range Simple Span Two Different Sections Type 3 = 9 Webs for 3 Plastic Ducts (12 x 0.6 Tendons) Type 4 = 10 Webs for 4 Plastic Ducts (19 x 0.6 Tendons) 2117 and 2271 plf, respectively (U54 = 1167 plf)
50 PCI-SE: 84 Deep Sections Max Main Span Lengths 195 to 265 Range Continuous 190 to 200 Range Simple Span Two Different Sections Type 3 = 9 Webs for 3 Plastic Ducts (12 x 0.6 Tendons) Type 4 = 10 Webs for 4 Plastic Ducts (19 x 0.6 Tendons) 2349 and 2529 plf, respectively (U54 = 1167 plf)
51 PCI-SE: 96 Deep Sections Max Main Span Lengths 205 to 280 Range Continuoous 200 to 220 Simple Span Two Different Sections Type 3 = 9 Webs for 3 Plastic Ducts (12 x 0.6 Tendons) Type 4 = 10 Webs for 4 Plastic Ducts (19 x 0.6 Tendons) 2581 and 2787 plf, respectively (U54 = 1167 plf)
52 PCI-SE: Variable Depth Max Main Span Length of 300 ft Requires 19 x 0.6 Tendons Constant Depth Section = U84-4 Variable Depth Section 11 ft max depth Maintains 4:1 side slope (4-0 wide, thick bottom flange) Weighs 303 kips Requires More Splices
53 PCI-SE Design Considerations Focus 40 ft nominal overall, 37 ft roadway 2 girder system Radius down to 750 ft Weight considerations Lifting and shipping weights Loads over 254 kips require special permits in Texas Typical piece lengths will be limited to around 100 ft Precast panels not considered structural Intermediate lid slabs needed for torsional stiffness on longer spans Slab usually placed after full PT to allow redecking
54 Fab Example: Encon CO
55 Fab Example: Plum Creek CO
56 Reinforcing Cage in Forms Prior to Casting, CO
57 Girders in Storage Area, CO
58 Design Features: Thickened Bottom Flange over Piers Varying Web Thickness Cantilever PT Anchors in Webs Precast Supports for Strong Back Shoring
59 Preferences at Anchorage Regions Precast blockouts for post-tensinoing hardware at plant CIP diaphragm and PT anchorage in the field Minimizes weight and hardware coordination
60 Typical Shoring, CO
61 Girders spliced, Lid Slab in place and diaphragms cast. Girders ready for post tensioning (CO)
62 Precast Deck Panels placed between Girders (CO)
63 Bijou Bijou Street Street Bridge, Bridge CO Erection of Span 3 over Rail yard Erection used Strongbacks exclusively to avoid ground supported falsework
64 Bijou Street Bridge, CO Erection of Span 3 over Rail Yard
65 U-Girders In Service: Colorado
66 TxDOT Implementation Status Construction underway on Sylvan Ave (Tx82 Mod) Three Projects in Early Stage of Design FM 1495 Old Brazos River Freeport (HOU) Spliced U (Tangent) SH 105 Brazos River (BRY) Spliced I (Variable Depth) FM 457 at GIWW (YKM) Spliced I (Variable Depth) Standardization Effort New I Girder Shape Multi-piece Single Span Post Tensioning Continuous Spans Standardize Variable Depth Practice U Girders (with aid of PCI-SE standards) Industry Involvement from PCMA of Texas and AGC of Texas
67 Questions?
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