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I-95 Accelerated Bridge Construction Project: PCUs, Method of Delivery, & Lessons Learned

I-95 Accelerated Bridge Construction Project: PCUs, Method of Delivery, & Lessons Learned. FHWA Peer Exchange Norfolk, VA February 28 , 2013. Scott J. Fisher, P.E. Jorge M. Suarez, P.E . Andrew Palahnuk. Project Background. Replace 11 bridges Richmond I-95 Corridor

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I-95 Accelerated Bridge Construction Project: PCUs, Method of Delivery, & Lessons Learned

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  1. I-95 Accelerated Bridge Construction Project: PCUs, Method of Delivery, & Lessons Learned FHWA Peer Exchange Norfolk, VA February 28, 2013 Scott J. Fisher, P.E. Jorge M. Suarez, P.E. Andrew Palahnuk

  2. Project Background • Replace 11 bridges • Richmond I-95 Corridor • Why ABC and not conventional? • 150,000 VPD • 234 PCUs

  3. Maintenance of Traffic (MOT) • Crossovers/Zipper barrier • Local traffic under bridge closures • VSP coordination • 8 pm - 6 am shift

  4. Casting Yard • 25-acre site • Mi-jack gantry cranes • Casting beds • Actual field substructure geometry • PCU storage

  5. Preconstructed Composite Units (PCUs) • LW concrete 9 inch slab • Fabricated plate girders • 2 or 3 girder components • Transverse PT bars • Cast-in-place closure pours • Continuity bars

  6. Existing Bridge Demo / PCU Erection

  7. Construction Challenges • Haul routes for PCUs / load ratings • 10 hour window for night work • Deploy zipper barrier • Sawcut deck • Remove demo pieces • Prepare beam seats • Set PCUs • Temp & final PT • Temp grid deck

  8. Construction Photos

  9. Lessons Learned • Allow for prep work prior to PCU replacement • Carefully review existing bridges for embedded expansion dams • Do not detail temp. grid deck design. Allow contractor to provide design • Avoid unreinforced “knife edges” for skewed bridges • Identify haul routes and bridge ratings • Eliminate anchor bolts (use restraint blocks)

  10. Lessons Learned • Maintenance/Repairs of existing structures during life of project • Consider slotted holes in diaphragm w/ friction connections • NEVER cut PT bars in the field w/o approval • CSX Railroad Constraints • Overhead Power Lines • Staging Areas • Final Grinding of PCUs

  11. Lessons Learned Cones make for great temporary supports!!!

  12. Acknowledgements • Owner: Virginia Department of Transportation (Richmond District) • CEI Consultant: Michael Baker Jr., Inc. • Engineer: URS Corporation • General Contractor: Archer Western Constructors, LLC

  13. I-95 Accelerated Bridge Construction Project: PCUs, Method of Delivery, & Lessons Learned FHWA Peer Exchange Norfolk, VA February 28, 2013 Scott J. Fisher, P.E. Jorge M. Suarez, P.E. Andrew Palahnuk

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