Presented at the 37th Annual Concrete Paving Workshop Nebraska Concrete Paving Association Presenter: Tom Farber; Dr. George Morcous; Jesse Ridder

1. KEARNEY PRECAST CONCRETE DECK PANEL
BRIDGE PROJECT
Presented By
T. Farber, G. Marcous, J. Ridder
37th Annual Concrete Paving Workshop
January 19-20, 2016

2. Acknowledgements
• Nebraska Department of Roads
• University of Nebraska-Lincoln (UNL)
• Hawkins Construction Company
• CoreSlab Structures Inc.

3. • Federal Highway Administration
• Werner Construction, Inc.
3

4. 4
NU Deck
Panel Bridge
Phase 1
(completed)
Phase 2

5. 5

6. 6
Project Specifics
Prime Contractor: Werner Construction, Inc.
Contract Amount: $26.5 million
Calendar Days to complete project: 776 days
Construction Started: July 2014
Construction Costs for the Bridges
Group 6 ( NU Deck Panel ): $2.6 million
Group 6A ( Cast-in-Place ): $1.6 million

7. Table of Contents
• Background
• Project Description
• Construction Sequence
1. Girder Production
2. Panel Production
3. Girder Placement
4. Panel Placement
5. Transverse Joints Grouting
6. Deck Post-tensioning
7. Haunch & Pockets Grouting
8. Deck Grinding

8. Background
• Why precast concrete deck systems are not commonly
used?
– Too many pieces to handle
– Too many joints to grout
– Open channels or pockets need an overlay
– Not fully pre-stressed in both directions
8

9. Background
• The newly developed precast concrete deck system (2nd
Generation NUDECK) has the following features:
1. Full-depth, full-width, 12-ft long panels to minimize CIP transverse joints
2. Covered pockets to eliminate deck overlay
3. 4 ft. spacing between shear connectors to simplify fabrication
4. Prestressed in both directions to enhance durability
9

10. Project Description
10
NU Deck Panel Bridge

11. BB-EB CL: 332 ft
Span: 166 ft 166 ft
Precast: 166.17 ft 166.17 ft
1.33 f t 39 f t 1.33 f t
41.67 f t
7.5in
3.83 f t 8.5 f t 8.5 f t 8.5 f t 8.5 f t 3.83 f t
1 2 3 4 5
11
NU Deck Panel Description
5 ea. NU1800
Girders
13,850 sq.ft.
Bridge Deck

12. NU Deck Panel Description
12
26 Typical Panels
+ 2 End Panels

13. Construction Sequence
1. Girder Production
2. Panel Production
3. Girder Placement
4. Panel Placement
5. Transverse Joints Grouting
6. Deck Post-tensioning
7. Haunch & Pockets Grouting
8. Deck Grinding
13

14. 1- Girder Production
14

15. 1- Girder Production
15

16. 1- Girder Production
16

17. 2- Panel Production
17

18. 2- Panel Production

19. 2- Panel Production

20. 2- Panel Production
20

21. 2- Panel Production
21

22. 3- Girder Placement
22

23. 3- Galvanized Shelf Angles
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24. 3- Post-tensioning Cable Strands
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25. 3- Post-tensioning Cable Strands
25

26. 3- Pier Diaphragm Steel
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27. 4- Deck Panel Placement

28. 4- Panel Placement

29. 4- Panel Placement

30. 4- Panel Placement

31. 4- Panel Placement

32. 4- Panel Placement Progress
• Wednesday 07/08 afternoon only 3 panels
• Thursday 07/09 morning only 2 panels
• Monday 07/13 6 panels
• Tuesday 07/14 6 panels
• Wednesday 07/15 6 panels
• Thursday 07/16 5 panels
TOTAL 28 panels

33. 5- Transverse Joints Grouting

34. 5- Transverse Joint Grouting

35. 5- Transverse Joint Grouting

36. 5- Transverse Joint Grouting
Concrete
Truck
Start Time End Time Quantity No. of Joints Temperature
Deg. F
Relative
Humidity %
#1 6:30 am 7:30 am 3 cy 13.5 63 83
#2 8:00 am 8:30 am 2 cy 7.5 65 80
#3 8:45 am 9:15 am 2 cy 6 66 78
Transverse joint concrete mixture had 6 in. initial slump and was vibrated

37. 6- Deck Post-tensioning

38. 6- Deck Post-tensioning

39. 6- Deck Post-tensioning
Jacking End Movement = 5/16 in. Dead End Movement = ¼ in.
Predicted deck elastic shortening = ½ in.

40. 7- Haunch & End Pocket SCC Grouting
40
20 batches of about 6 cu.yd.
each for a total of 6 hours

41. 7- Haunch & End Pocket SCC Grouting
41
Average SCC slump flow = 29 in.

42. 7- Haunch & End Pocket SCC Grouting
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43. 7- Haunch & End Pocket SCC Grouting
43
H-3 H-3A G-2 J-4 K-5 F-1
4 8,120 7,240 7,480 6,790 7,380 7,860 7,402
7 8,360 7,250 7,690 7,170 7,510 7,870 7,596
28 9,200 9,050 9,170 8,430 8,420 9,030 8,854
Air Content (%) 2.6 3 4.2 4.6 4.6 4.6 3.8
Girder Batch ID
Age (day) Average

44. 8- Deck Grinding
NU Deck Panel
Cast in Place

45. 8- NU Deck Grinding & Texturing
Transverse Joint Grouting Holes

46. 46
Completed Structure
Outside
Setting next to CIP Bridge

47. Video
Questions??
Thankyou