ABC/PBES specifications, contract drawings and details

1. ABC/PBES specifications, contract drawings and details by Mary Lou Ralls, P.E., Principal Ralls Newman, LLC (formerly Texas State Bridge Engineer)

2. Learning Outcomes • Identify resources for examples of various ABC/PBES • Acquire specifications, contract drawings, and details for various ABC/PBES projects • Describe issues concerning regional and national details and standards • Describe seismic considerations and research

3. Resources for ABC/PBES Specifications, Contract Drawings, and Details • FHWA prefabricated bridges website • HfL projects website • ABCT website • ACTT website • ABC Center • PBES Connection Details Manual • PBES Cost Study • State DOT bridge websites • FHWA SPMT Manual • UDOT ABC SPMT manual & guide • NCHRP domestic scan report • NCHRP & other research • ABC Manual • SHRP2 R04 Final Report

4. http://www.fhwa.dot.gov/bridge/prefab/projects.cfm

5. FHWA Prefabricated Bridges Website 50+ Projects View Projects • All projects • By Specific Elements or Systems: ◦ Partial-Depth Deck Panels ◦ Full-Depth Deck ◦ Panels Beams: More Efficient Shapes ◦ Pier Cap, Column, and/or Footing ◦ Abutment Wall, Wingwall, and/or Footing ◦ Superstructure ◦ Substructure ◦ Total Bridge http://www.fhwa.dot.gov/bridge/prefab/projects.cfm

6. FHWA Prefabricated Bridges Website 50+ Projects • Location • State • Completion Date • Contact Person • Description • Project Photo • ABC/PBES Type • Advantages • Related Documents http://www.fhwa.dot.gov/bridge/prefab/projects.cfm

7. FHWA Prefabricated Bridges Website Related Documents • Contract Drawings • Detail Sketches • Construction Photos • Construction Process Description http://www.fhwa.dot.gov/bridge/prefab/projects.cfm

8. FHWA Prefabricated Bridges WebsiteContract Drawings

9. FHWA Prefabricated Bridges WebsiteContract Drawings

10. FHWA Prefabricated Bridges WebsiteContract Drawings Precast Bent Cap Construction Notes – Examples: • Identify which construction specification items to build in accordance with; • Describe how caps are to be handled; • Specify concrete mix design and grouting requirements; • Specify construction process, with note that says what contractor must do if deviating from those requirements

11. FHWA Prefabricated Bridges WebsiteDetail Sketches NHDOT Epping Bridge

12. FHWA Prefabricated Bridges WebsiteOngoing Updates • Contact information updated • Recent projects added • More project details included, e.g.: • Specifications • Contract Drawings • Contracting Strategies • Costs http://www.fhwa.dot.gov/bridge/prefab/projects.cfm

13. http://www.fhwa.dot.gov/hfl/projects.cfm

14. HfLProjectSummaries http://www.fhwa.dot.gov/hfl/summary/projects_summary.cfm

15. http://www.fhwa.dot.gov/bridge/accelerated/index.cfm

16. http://www.fhwa.dot.gov/construction/accelerated/

17. Center for Accelerated Bridge Construction at Florida International University http://www.abc.fiu.edu/

18. General Topics • Superstructure Connections • Substructure Connections • Foundation Connections • Connection Design Examples • Proprietary Products • Sample Construction Specifications • Case Studies http://www.fhwa.dot.gov/bridge/prefab/if09010/

19. Cost-competitive projects • Reduced onsite construction time • Construction cost less than engineer’s estimate • Project details • Project owner contacts • Other contacts, e.g.: • Contractor • Design Engineer • Prefabricator http://www.fhwa.dot.gov/bridge/prefab/successstories/091104/

20. FHWA PBES Cost Study • Case studies of nine projects • Project description • Project size / dimensions • ABC/PBES types • Fabrication/construction details • Construction photos • Contract requirements • Cost – engineer’s estimate vs. bid • Contact information http://www.fhwa.dot.gov/bridge/prefab/successstories/091104/

21. State DOT Websites – UDOT http://www.udot.utah.gov/main/f?p=100:pg:0:::1:T,V:1991,

22. State DOT Websites – UDOT • Full-Depth Precast Concrete Deck Panels Manual • Precast Approach Slab Manual • Precast Box Culvert Manual • Precast Bulb Tee Girder Manual • Precast Substructure Elements Manual • SPMT Process Manual and Design Guide • Master Process for Bridge Moves Using SPMTs http://www.udot.utah.gov/main/f?p=100:pg:0:::1:T,V:2090,

23. State DOT Websites – TxDOT http://www.dot.state.tx.us/insdtdot/orgchart/cmd/cserve/standard/bridge-e.htm

24. Example Standard included in • Guide to Bridge Standard Drawings: • Decked Slab Beam (ABC) • 20-in. & 23-in. depth • 6.5-ft, 7-ft, & 8-ft width • 30-ft to 60-ft span lengths To access TxDOT bridge standards & guide: http://www.dot.state.tx.us/insdtdot/orgchart/cmd/cserve/standard/bridge-e.htm, or Google “TxDOT Bridge Standards”

25. TxDOT Guide to Bridge Standard Drawings • Description of Component • Standard Drawing Location • Standard Drawing Features • Standard Drawings Needed for Bridge Details • Additional Drawings Needed to Complete Bridge Details • Restrictions on Use of Standard Drawings • Special Considerations • Specific Bridge Layout Requirements To access TxDOT bridge standards & guide: http://www.dot.state.tx.us/insdtdot/orgchart/cmd/cserve/standard/bridge-e.htm, or Google “TxDOT Bridge Standards”

26. http://www.fhwa.dot.gov/bridge/pubs/07022/

27. FHWA Manual on Use of SPMTs to Remove & Replace BridgesAppendices • App. A: Example User Cost Model Spreadsheet • App. B: Example Plan Sheet Details for Cast-in-Place Deck Closure Pour Option to Facilitate Span Fit-Up • App. C: Example Calculations for Comparing Total Bridge Weight and Estimated Cost Premium for Normal-Weight Concrete and Lightweight Concrete Bridge • App. D: Example Specification for SPMT Equipment • App. E: Example Plan Sheet for Contractor Alternatives • App. F: Example Specification for Lightweight Aggregate • App. G: Example Specification for Incentive/Disincentive and Bonus Used in Conjunction with App. E

28. FHWA Manual on Use of SPMTs to Remove & Replace Bridges Appendices, cont’d. • App. H: Example Specifications for Incentive/Disincentive • App. I: Example Specifications for Bonus • App. J: Example Specifications for Lane Rental • App. K: Example Specification for Value Engineering • App. L: Examples of Partnering Provisions • App. M: Example Plan Sheets for Traffic Control Plans • App. N: Example Specification for Settlement Report for Temporary Shoring on Shallow Foundations • App. O: Example Diagrams for Path and Motion http://www.fhwa.dot.gov/bridge/pubs/07022/

29. FHWA Manual on Use of SPMTs to Remove & Replace BridgesFDOT I-4/Graves Avenue Case Study • Project Description • Bridge Removal with SPMTs • Bridge Construction and Erection with SPMTs • Time Savings • Initial Construction Costs • Delay-related User Cost Savings • Net Cost Savings from Use of New Technology • Participants • Post-Installation Interviews – Contractor & Subcontractor • Lessons Learned

30. http://www.udot.utah.gov/main/f?p=100:pg:0:::1:T,V:2090,

31. Preconstruction Process http://www.udot.utah.gov/main/f?p=100:pg:0:::1:T,V:2090,/

32. Example of UDOT Responsibilities

33. Example ofEngineer ofRecordResponsibilities

34. Construction & Transport Process http://www.udot.utah.gov/main/f?p=100:pg:0:::1:T,V:2090,

35. Example ofContractor Responsibilities

36. NCHRPDomestic ScanProgram Domestic Scan on Best Practices in Accelerated Construction Techniques March 2009 http://onlinepubs.trb.org/onlinepubs/nchrp/docs/NCHRP20-68A_07-02.pdf

37. National Cooperative Highway Research ProgramProjects Related to ABC

38. Panels designed • per NCHRP 12-65 • – no post-tensioning • or overlay Full-Depth Deck Panelsper NCHRP 12-65 TxDOT Live Oak Creek Bridge – 2008 86 full-depth, full-width deck panels, totaling 22,400 sq ft View shows blockouts for shear studs & transverse connection rebar Erection of deck panels over shear studs on beams

39. NCHRP 12-74 Project Objectives Develop design methodologies, connection details, and design and construction specifications for precast bent cap systems in all seismic regions • Systems and methodologies for entire U.S. • Practical, cost-effective connection details • Design examples • Design and construction specifications with commentary in AASHTO LRFD format Source: Eric Matsumoto, California State University, Sacramento http://onlinepubs.trb.org/onlinepubs/nchrp/nchrp_rpt_681.pdf

40. Grouted Duct and Cap Pocket Details Grouted Duct Section Isometric View of Joint Elevation Cap Pocket Plan Cap Pocket, Full Ductility (CPFD) Elevation Cap Pocket, Limited Ductility (CPLD)Elevation Ref.: NCHRP 12-74

41. NCHRP 12-74 Lateral Load-Displacement for All Specimens Source: Eric Matsumoto, California State University, Sacramento

42. NCHRP 12-74Hysteretic Response Cast-in-place Grouted Duct Cap Pocket, Full Ductility

43. NCHRP 10-71 – PrecastComposite Slab Span System (PCSSS)based on French Poutre Dalle System from 2004 FHWA International Scanning Tour • Span to Depth: 1/28 - 1/30 • Span lengths 20 to 60 ft • (45 ft span – 20 in depth) • Minimum CIP depth 6 in • Place ~12 beams in 4 hours Reference: NCHRP 10-71, C. French, C. K. Shield, Univ of Minnesota; & Z. J. Ma, Univ of Tenn - Knoxville http://onlinepubs.trb.org/onlinepubs/nchrp/nchrp_w173.pdf

44. NCHRP 10-71PCSSS Initial Implementation Horizontal and Vertical Shear Reinforcement Inverted T Precast Sections Roughened Surfaces 8 to 22” Chamfered Corners Constant 6” CIP thickness Variable w/ span length Constant 3” Constant Prestressing Tendons 90oTransverse Hook to facilitate “drop-in” cage

45. NCHRP 10-71 Construction Center City Bridge (3 span: 22-27-22 ft)

46. Longitudinal and Transverse Joints in DBTs and Precast Deck Panels Reference: NCHRP 10-71, C. French, C. K. Shield, Univ of Minnesota; & Z. J. Ma, Univ of Tenn - Knoxville http://onlinepubs.trb.org/onlinepubs/nchrp/nchrp_w173.pdf

47. chloride penetrability 7-day and Overnight Cure Closure Pour Materials shrinkage bond freeze-thaw durability Ref.: NCHRP 10-71

48. National Cooperative Highway Research ProgramProjects that Facilitate the Use of ABC

49. National Cooperative Highway Research Program2011 Project Related to ABC * Funded as a synthesis project to review related past & ongoing research, define what is missing, & make recommendations for future research as a “Program of Work.”