SynTerra / US Bridge Presentation (10 24 11)

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Co-presented this to ACEC-SC/SCDOT. Describes the benefits of using steel truss bridges over CSX RR on two projects in Spartanburg, SC saving the County over $500,000.

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SynTerra / US Bridge Presentation (10 24 11)

  1. 1. Innovation in Design Using Pre-fabricated Truss Bridges Presented By: Petrina Butler, P.E. SynTerra Corporation Dennis Gonano, P.E. U.S. Bridge
  2. 2. Ezell Road Before • Low structural rating • Single lane• Blind curves on approach roadway
  3. 3. Ezell Road Alignment2009 and 2011 aerials provided by USDA NCRS
  4. 4. Overhead Bridge Road Before
  5. 5. Overhead Bridge Road Alignment2009 and 2011 aerials provided by USDA NCRS
  6. 6. Design Criteria• Increase Safety• Increase Capacity• Minimize Railroad Interference• Economic Solution
  7. 7. Bridge Replacement Options• Prestressed Concrete Girder Bridge• Steel Plate Girder Bridge• Pre-fabricated Truss Bridge
  8. 8. Advantages of Pre-fabricated Bridge• Shallowest structure depth• Reduced construction activity within railroad right-of-way• Significant cost savings
  9. 9. Shallowest Structure Depth Prestressed Steel Plate Pre-fabricated Girder Girder Truss Deck = 8¼” Deck = 8¼” Deck = 8¼”Cross Slope = 2¾” Cross Slope = 2¾” Cross Slope = 3½” Haunch = 1½” Haunch = 1½” Bottom Chord = 31” Beam = 54” Beam = 42” TOTAL = 42¾” TOTAL = 66½” TOTAL = 54½” DEPTH IS UP TO 2 FEET LESS
  10. 10. Cross Section atBridge Approach
  11. 11. Integral Abutments
  12. 12. Reduced Construction Activity Within Railroad Right of Way• Accelerate construction schedule• Smaller footprint for staging area• Increase Safety• Reduce road closure duration
  13. 13. Significant Cost Savings $1,690,000 Total Cost of Plate Girder Option - $400,000 Savings for Superstructure - $110,000 Savings for Roadway Items - $40,000 Savings for Railroad Flagman $1,140,000 Total Cost of US Bridge Option TOTAL COST SAVINGS = $550,000 OVER 30% COST REDUCTIONCost basis - bid unit cost from actual construction
  14. 14. Advantages of Pre-fabricated Bridge• Shallowest structure depth • Less fill for approaches • Smaller footprint • Same loading capacity• Reduced construction activity within railroad right-of-way • Accelerate construction schedule • Smaller footprint for staging area • Increase safety • Reduce delay
  15. 15. Advantages of Pre-fabricated BridgeSignificant cost savings • Savings of $550,000 for both projects • 30% cost reduction
  16. 16. “... the bridges are great. They provided an economical andaesthetically pleasing solution to obtaining adequate clearanceover CSXT.” Todd Carroll, CTC Engineering Supervisor Spartanburg County Public Works
  17. 17. U.S. Bridge • Founded as American Culvert in 1936 by brothers Herman & Ted Rogovin
  18. 18. History• Designing & Building Truss Bridges for over 60 years
  19. 19. Location • Cambridge, Ohio • Juncture of I-70 & I-77 • 21 shops covering 250,000 sq ft. in 11 buildings
  20. 20. How We Work With You• Feasibility Assessments• Programming Costs• Specifications• Schematic Details• Preliminary Engineering• Supplemental Contract Documents• Modeling & Rendering• Hard Bid Quotes & Information• Engineering Design & Plan Submittals
  21. 21. How We Work With You …• Construction Submittals• Installation Assistance• Engineering Department • 4 Professional Engineers • 2 EIT’s • 4 Detailers
  22. 22. Coordination• Preliminary Engineering • Loads & Substructure Reactions • Structure Depths & Low Steel Clearance• Final Engineering • Abutment Seat Elevations • Plan Submittals & Reviews Adam Stout, EIT Estimating Engineer
  23. 23. Bridge Truss Design• Final Design • Stringer Beams & Connections • Floor Beams & Connections • Truss Members & Connections • Truss Stability • Gusset Plates • Bearings • Deck Slab & SIP Forms • Misc. Scott Flaten, PE Project Engineer
  24. 24. Bridge Design CriteriaSpan: 104’-4” c/c BearingRoadway Width: 29’-0” curb/curb + 6” curbsSidewalk: N/ASkew: 24o-0’-0” RF (right fwd.)Design Live Load: HL-93Expansion: N/A (jointless bridge)Connections: Shop & Field BoltedDesign Loads: SIP Forms & Fill: 15 psf Utility Loading: 100 plf 8 ¼” Concrete Slab: 105 psf Future Wearing Surface: 15 psfTruss Reactions: Dead Load, DC: 120.4k Dead Load, DW: 17.0k Live Load: 125.7k Impact: 27.4k Braking (Horiz.): 20.8k Wind (Horiz.): 15.6k
  25. 25. Member Calculations• Non-Composite Stringers sized for • Connections are sized for Strength I Flexure Strength I and Service Load II Shear (Slip Critical) and• Composite Floor Beams sized by checked against block shear Strength I Flexure • Floor beam-to-truss connection• Top Chords sized using truss is also checked against Service analysis and checked U-Frame Load III (Wind on structure) Stability to confirm axial capacity can be developed • Gusset Plates are designed in accordance with FHWA• Bottom Chords sized using truss Publication FHWA-IF-09-014 analysis and checked against fatigue allowable stress• Truss tension members checked for gross section yielding and net section fracture (shear lag and block shear) and bolt shear
  26. 26. Calculations
  27. 27. Plan Development• Model Creation (Smart Solids) Software• Connection Design(s) AutoCAD Structural• 3D Solid Additions (Dumb Detailing 2012 (ASD) Solids)• Groups & Views• Detailing• Sheet Creation
  28. 28. Plan Development• Design Criteria, General Notes, Sheet Index• Framing & Geometry, Section Views, Field Splices, Bearing Details• SIP Forms, Deck Slab Layout, Railing Installation• Bill of Materials (BOM)• Shop Assemblies• Shop Drawings (Piece Details)
  29. 29. Fabrication• AISC Certifications • Simple Bridge • Major Bridge • Fracture Critical Endorsement • Sophisticated Paint Systems Endorsement
  30. 30. Processing Equipment• CNC 3-Axis Drill Line for Shape Processing• CNC Plasma Arc/Drill for Plate Processing• Shot Blaster
  31. 31. Finish & Corrosion Protection• Hand Grinding• Brush Blasting• Hot-Dip Galvanizing• 2-Coat Paint System (Paint on Galvanizing)• 3-Coat Paint System (DOT Specifications)
  32. 32. Shop Assembly Bolt TighteningShop Layout
  33. 33. Shipping
  34. 34. Construction• Overhead Bridge Road Bridge • Constructed by Taylor & Murphy Construction Company• Ezell Road Bridge • Constructed by Saddlebrook Construction Inc.
  35. 35. Overhead Bridge Road ConstructionStepped Truss & Stringer Abutment Seat with Integral Abutments
  36. 36. Overhead Bridge Road Construction Staging area
  37. 37. Overhead Bridge Road Construction Two field splices complete
  38. 38. Overhead Bridge Road ConstructionLifting first truss and walks to abutment
  39. 39. Overhead Bridge Road Construction First truss is in position
  40. 40. Overhead Bridge Road Construction Stabilized by cables
  41. 41. Overhead Bridge Road Construction Lifting the second truss into place
  42. 42. Overhead Bridge Road Construction Erecting first floor beam
  43. 43. Overhead Bridge Road Construction Floor beams being erected
  44. 44. Overhead Bridge Road Construction SIP forms in place
  45. 45. Overhead Bridge Road Construction Open for traffic
  46. 46. Ezell Road

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