Presentation on Segmental Construction Techniques

1. Segmental Bridge Technology –
Established and Evolving
W. Jay Rohleder, Jr, P.E., S.E.
Senior Vice President / Project Development
FIGG
1

2. Segmental Bridge Topics Addressed
• Definition of concrete segmental bridge construction
methods and related design considerations.
• The evolution of concrete segmental bridge
technology over the past 30 years in the U.S.
• Design principles and practices that provide the
economic and durability value for this structure type.
• Continuing evolution of the segmental bridge
construction technology and related design
concepts.
2

3. Definition of Segmental Bridges
Bridges, that are typically concrete box
structure types, constructed using
repetitive elements that are
progressively connected together to
form a completed structure.
Construction Load Cases are
particularly critical considerations in
developing the design and building
methods for segmental bridges.
3

4. CABLE STAYED BRIDGES
CABLE STAYED BRIDGES
LONG SPAN BRIDGES
LONG SPAN BRIDGES ENVIRONMENTALLY SENSITIVE
ENVIRONMENTALLY SENSITIVE
LONG BRIDGES OVER WATER
LONG BRIDGES OVER WATER ARCHES
ARCHES
URBAN BRIDGES
URBAN BRIDGES
SEGMENTAL BRIDGE APPLICATIONS
RAIL BRIDGES
RAIL BRIDGES
4

5. Segmental Bridge Methods,
Components and Evolution
of the Technique
5

6. Segmental Construction Methods
• SPAN-by-SPAN (Precast)
• CANTILEVER (Precast or Cast-in-Place)
> Balanced
> Uni-Directional
• INCREMENTAL LAUNCH
(Typically an Inefficient use of materials,
so Not commonly used –
need tangent or constant curvature)
6

7. Segmental Construction Methods
• Span by Span
JFK AirTrain, NY City
7

8. • Balanced Cantilever
Sagadahoc Bridge, ME
Segmental Construction Methods
8

9. • Uni-Directional Cantilever (shown)
• Mixed Methods
Garcon Point Bridge, FL
Segmental Construction Methods
9

10. Precast
Joints
• Keys (i.e. no reinforcing across joints)
• Epoxy
– Temporary Clamping
– Temperature
10

11. • Reinforcing Bars
• Joint Preparation
• Bulkheads
Cast-in-Place Joints
11

12. Post-Tensioning (PT) Arrangements
Layout Orientation
• Longitudinal
– Span by Span
– Cantilever
• Transverse
• Vertical
Placement Type
• Internal Tendons
• External Tendons
12

13. • Internal Tendons
– Transverse
– Longitudinal
(Cantilever)
Post-Tensioning (PT) Arrangements
13

14. Post-Tensioning
Pre-Tensioning
Internal Transverse Pre-Stressing
14

15. • External Tendons, Longitudinal
Single Point Deviators
Post-Tensioning (PT) Arrangements
15

16. • External Tendons, Longitudinal
Multi-Point Deviators
Post-Tensioning (PT) Arrangements
16

17. Post-Tensioning (PT) Arrangements
• Vertical Tendons
(in Precast Piers)
17

18. Construction Engineering
• Camber
• Geometry Control
• Prestressing Parameters
• Erection Loads
• Erection Equipment
• Casting and Erection Manuals
• Integrated Shop Drawings
18

19. Precasting Yard Operations
• Pre-Tied Reinforcing Cage Jigs
• Casting Beds
> Long Line
> Short Line
• Storage & Delivery
19

20. • Long Line Segment Casting
20

21. • Short Line Segment Casting
21

22. TYPICAL CASTING YARD LAYOUT
Batch Plant
Segment Storage
Rebar Jigs
Casting Beds
Segments in Storage
Possible Double Stack
22

23. JFK AirTrain, NY, NY
9 Miles of Elevated Precast Segmental Bridge
23

24. • 5,500 Segments
• 14 Casting Cells
Precasting Facility - JFK AirTrain
24

25. Precasting Facility - JFK AirTrain
25

26. Segment Delivery
Precasting Facility - JFK AirTrain
26

27. I-93 Viaducts & Ramps, Boston, MA
27

28. Precast plant 85 miles away by truck
Precasting Facility – I-93 Viaducts, Boston
85
Miles
28

29. • 15 Acres
• 1250 Segments
• Casting Cells
4 Typ., 1 Combined
Precast plant in Sanford, ME
Precasting Facility – I-93 Viaducts, Boston
29

30. Central concrete delivery - casting 3 beds / day
Precasting Facility – I-93 Viaducts, Boston
30

31. • 1040 – Total Segments
(958 Typical, 82 Specialty)
• 3 - Typical Casting Cells
• 1 - Specialty Casting Cell
Precasting Facility – Susquahanna River, PA.
31

32. Susquehanna River Bridge, PA
• Assembly Line – Reinforcing Cage Jig
32

33. • Assembly Line – Casting Bed Set-Up
Susquehanna River Bridge, PA
33

34. Match Cast
Segment
Wet Cast
Segment
34

35. • Assembly Line – Segment Pour
35

36. • Assembly Line – Steam Cured Segments
Susquehanna River Bridge, PA
36

37. • Segment Storage Handling,
Lifting with Strap under Wing
Susquehanna River Bridge, PA
37

38. • Segment Handling
Lifting with Bars through Lifting Holes
38

39. 1
2
3
• Segment Storage
Three Point Supports
39

40. • Segment Storage
Double Stacking
40

41. PRECAST SUPERSTRUCTURE
Comparison Table
Project: Susq. I-93 JFK Victory Sagadahoc
(Pa.) (Ma.) (NY) (NJ) (Maine)
No. Segments - 1040 1250 5409 927 202
Max. Wt. (Tons) - 105 80 38 82 100
No. Typical Beds - 3 4 11 8 1
Casting Yard Size - 20 A 15 A N/A N/A 12 A
Cast 1 Segment / Day / Bed
41

42. Precast Segmental
Span-by-Span Construction
42

43. SECTION A-A
A
A
Typical Span-by-Span Erection
43

44. •Advance Truss to Next Span
Typical Span-by-Span Erection
44

45. •Deliver Segments
•Set Segments
Typical Span-by-Span Erection
45

46. •Deliver Segments
•Set Segments
Typical Span-by-Span Erection
46

47. •Epoxy Joints
•Join Segments
•Deliver Segments
•Set Segments
Typical Span-by-Span Erection
47

48. •Epoxy Joints
•Align Pier Segm.
•Deliver Segments
•Set Segments
Typical Span-by-Span Erection
48

49. •Align Pier Segm.
•Thread Tendons
•Cast Closure
•Deliver Segments
•Set Segments
•Epoxy Joints
Typical Span-by-Span Erection
49

50. •Stress Tendons
•Lower Truss and
Repeat Process
SECTION A-A
A
A
Typical Span-by-Span Erection
50

51. - Underslung Trusses
- Overhead Gantry
- Falsework Supports
Precast Span-by-Span
Segments Erected using:
51

52. ERECTION TRUSSES – Under Bottom Soffit
52

53. Deck Designed for Support Condition
ERECTION TRUSSES – Under Wings
53

54. ERECTION with OVERHEAD GANTRY
54

55. • Tower on Foundation
ERECTION TRUSS SUPPORTS
55

56. • Pier Bracket
ERECTION TRUSS SUPPORTS
56

57. Delivery of Segments from Above
Specialized Erection Equipment
WMATA, VA
57

58. SPAN-BY-SPAN CONSTRUCTION EXAMPLE
May 2007
Susquehanna River Bridge, PA
58

59. Casting
Yard
Pennsylvania
Turnpike
Commission
Bridge –
East Approach
Susquehanna River Bridge, PA
59

60. West End
Calver
Island
East End
Casting Yard
New WB
New EB
Existing
Bridge
Twin Bridges with each:
• 5,910’ Long by 57’ Wide
• 40 Spans – 35 @ 150’, 5 @ 132’
• 21 River Piers
• 18 Land Piers
Susquehanna River Bridge, PA
60

61. ONE
THREE
TWO
ERECTION PHASES
Susquehanna River Bridge, PA
61

62. Casting Yard
Casting Yard
Segment
Segment
Erection
Erection
Access Road
Access Road
Susquehanna River Bridge, PA
62

63. Susquehanna River Bridge, PA
Segments Delivered from Storage
63

64. Segments Delivered from Above
Susquehanna River Bridge, PA
64

65. Susquehanna River Bridge, PA
65

66. Susquehanna River Bridge, PA
66

67. Susquehanna River Bridge, PA
67

68. Susquehanna River Bridge, PA
Segment Alignment
68

69. Susquehanna River Bridge, PA
69

70. Susquehanna River Bridge, PA
70

71. Susquehanna River Bridge, PA
ELEVATION
SECTION VIEWS
71

72. Susquehanna River Bridge, PA
72

73. Susquehanna River Bridge, PA
Activities Off the Critical Path
73

74. Achieved Typical
Span x Span
Erection Rate of 2
Spans per Week
Susquehanna River Bridge, PA
74

75. VERTICAL
CLEARANCES
RAILROAD LINES
LOCAL AIRPORT
Susquehanna River Bridge, PA
75

76. November 2004 - NTP
May 2007 - New Bridge Complete
Susquehanna River Bridge, PA
76

77. • Quick, Simple Erection (2 - 3 Spans / Week)
• Easy Geometry Control
• Savings from less MOT
• Minimum User Delays
• Cost Effective
• Simple Design
• Durable Structures
ADVANTAGES OF SPAN-BY-SPAN
Beautiful Bridges
77

78. Precast Segmental
Balanced Cantilever Construction
78

79. Balanced Cantilever Erection
ERECTION SEQUENCE I
79

80. Balanced Cantilever Erection
ERECTION SEQUENCE II
80

81. ERECTION SEQUENCE IV
ERECTION SEQUENCE III
Balanced Cantilever Erection
81

82. - Barge-mounted cranes
- Ground based cranes
- Beam and Winch
- Overhead Gantry
Precast Balanced Cantilever
Segments Erected using:
82

83. BALANCED CANTILEVER EXAMPLE
September 2007
Victory Bridge, NJ
• Twin 3,971’ Long Bridges
• Main Span Unit 330’, 440’, 330’
• 100’ Tall Precast Piers
• SxS Appr., B.C. Main Span Unit
83

84. Victory Bridge, NJ
84

85. Victory Bridge, NJ
85

86. Victory Bridge, NJ
86

87. Victory Bridge, NJ
87

88. Victory Bridge, NJ
88

89. Victory Bridge, NJ
89

90. Victory Bridge, NJ
90

91. Average production:
4 to 6 segments/day (45 ft)
Balanced Cantilever Erection
Victory Bridge, NJ
91

92. Victory Bridge, NJ
1st Bridge Open to Traffic in 15 mo.
2nd Bridge Completed in 9 mo.
92

93. Cast-in-Place Segmental
Balanced Cantilever Construction
93

94. Wabasha Street Bridge, MN
1,248’ Long Twin Bridges
with 398’ Main Spans
94

95. Wabasha Street Bridge, MN
95

96. Wabasha Street Bridge, MN
Continue through the Winter
96

97. Blending shapes, texture and color
Wabasha Street Bridge, MN
97

98. Segmental Bridges
Mixing Construction Erection
Methods
98

99. Sagadahoc Bridge, ME
3,000’ Bridge with
420’ Main Span
over Kennebec River
99

100. 68’ Roadway with
2 Cell Box Girder
Cast-in-Place Approach
Units, with Precast
Main Span Unit
Sagadahoc Bridge, ME
100

101. 520,000 sf of Structures - Completed Nov. 2002
I-93 Ramps & Viaducts, Boston MA
101

102. I-93 Ramps & Viaducts, Boston MA
Span-by-Span Construction
102

103. I-93 Ramps & Viaducts, Boston MA
Balanced Cantilever Construction
103

104. Mid-Bay Bridge, FL
• Span-by-Span Approaches
• One-Directional Cantilever Main Span
CIP low
level piers
P/C high
level piers
104

105. Precast Segmental Piers
105

106. Precast Piers
Direction
of Erection
Erect 1 Segment an Hour,
Approximately 1 Pier per Day
106

107. Victory Bridge, NJ
107

108. First segment cast
6 weeks after NTP
Precast Piers
Victory Bridge, NJ
108

109. Precast Piers Casting Bed
Victory Bridge, NJ
109

110. Typical Precast Pier Details
110

111. Precast Pier Erection
Victory Bridge, NJ
111

112. Precast Pier Erection
Victory Bridge, NJ
112

113. Precast Pier Erection
Victory Bridge, NJ
113

114. Precast Pier Erection
Victory Bridge, NJ
114

115. Precast Pier Erection
Victory Bridge, NJ
115

116. Precast Pier Erection
Victory Bridge, NJ
116

117. First pier erected
5 months after NTP
Completed Precast Piers
Victory Bridge, NJ
117

118. Cable Stayed
Segmental Superstructure
118

119. U.S. Senator William V. Roth Jr. Bridge over C&D Canal, DE
1st concrete cable-stayed bridge in the Northeast – 1995
119

120. Entirely Precast Segmental Bridge
U.S. Senator William V. Roth Jr. Bridge over C&D Canal, DE
120

121. Segmental Cable-Stay Bridges
I-280 Veterans’ Glass City Skyway, Ohio
1,225’ main span (2 @ 612’-6”)
Penobscot Narrows Bridge
& Observatory, Maine (1,161’ main span)
Open Dec. 2006
Open June 2007
121

122. Veterans’ Glass City Skyway
Precast Superstructure
Completed in 8 Months
New Penobscot Narrows Bridge
Cast-in-Place Superstructure
Completed in 15 Months
122

123. Penobscot Narrows Bridge & Observatory, ME
123

124. CIP Balanced Cantilever Construction
Form
Traveler
Form
Traveler
Penobscot Narrows Bridge & Observatory, ME
124

125. Penobscot Narrows Bridge & Observatory, ME
125

126. Penobscot Narrows Bridge & Observatory, ME
126

127. Carbon Fiber Composite Strand Demonstration Project
Penobscot Narrows Bridge & Observatory, ME
127

128. Veteran’s Glass City Skyway,
Ohio
Veteran’s Glass City Skyway, OH
128

129. Typical Pre-Cast Cross-Sections: Main Span
Veteran’s Glass City Skyway, OH
129

130. Main Span Precast Segmental Construction
• Backspans: Span-by Span
• Mainspan: One-Directional Cantilever
Veteran’s Glass City Skyway, OH
130

131. • 3 pairs of segments
erected in cantilever
– Epoxied segment joints
– Segments post-tensioned
Veteran’s Glass City Skyway, OH
131

132. Segmental Bridge Construction Benefits
• Rapid Construction
• Segments Delivered over Completed Spans
– No Need for Barge Delivery
• Maintained Shipping Lanes at All Times
– Access to Port of Toledo
Veteran’s Glass City Skyway, OH
132

133. Review Questions
• Define a segmental concrete bridge structure type?
• List 3 methods for constructing segmental bridges?
• List benefits during construction that result from
using a segmental bridge construction technique?
• List permanent bridge site layout benefits resulting
from using a segmental box girder bridge type?
• What structural benefits apply to using a closed cell
box girder for a segmental bridge?
• What segmental bridge technological advances offer
the most immediate benefits?
133

134. Open-ended Assignment Questions
Can you identify a viable candidate location
for a segmental bridge given your
understanding of the potential benefits from
using this structure type?
What new innovative applications of the
segmental bridge construction technique
can you envision?
134

135. America
Deserves Beautiful
Bridges
135