A NEW SYSTEM

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A NEW SYSTEM FOR RAPID PRECAST DECK
CONSTRUCTION
FHWA International Technology Exchange Program
Prefabricated Bridge Elements and Systems in
Japan and Europe Accelerated Construction
GET IN, GET OUT, AND STAY OUT

• Total Precast Concrete Systems
• Piles Pile Caps
• Columns Bent Caps
• Girders
• Deck

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Total Precast

• Every major component of the bridge is precast
  piles, pile caps, columns, pier caps, girders and
  deck (or segmental box).
• Currently, use of precast is common for
  everything but deck construction.
• However, about 50 of the cost of bridge
  construction is tied up in the deck, regardless
  of superstructure type.

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Piles

• Standard Precast Piles
• Square Precast Piles 12 to 36
• Cylinder Piles
• 36 to 66 Outside Diameter
• 6 Wall Thickness
• 16 Spun Cast Sections Post-Tensioned Together

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Pile To Cap Connections
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St George Island Bridge, Franklin County, Florida
Pile to Pier Cap Connection (Low Level)
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Substructure

• Precast Forms
• Precast Forms for Pile Caps
• Precast Tubs for Pile Caps
• Precast Pile Caps
• Precast Piers and Columns
• Design Considerations
• Connections
• High Strength Threadbar
• Grout Sleeve Splices
• Rebar Cages
• Pipe, I-Girder, or Other Structural Steel Section
• Post Tensioning Tendons

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Pile Cap Forms
St. George Island Bridge, Florida
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BAY ST. LOUIS PRECAST FORM SLAB
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Sanibel Causeway Bridges Precast Tub
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Sanibel Causeway Bridges Precast Tub
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Columns
I-287 Cross Westchester Expressway, NY
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Columns
Linn Cove Viaduct, NC
Sunshine Skyway, Tampa, FL
Baldorioty de Castro Ave., Puerto Rico
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Columns
Louetta Road, TX
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Precast Solution
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Stem Element
Footing/Stem Joint
Splice Sleeve
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Pile Caps are 36-0 by 21-0 by 6-0 weigh
in excess of 300 tons
Voids are formed for piles, which extend four
feet into the cap for fixity.
Mass Concrete is monitored using Intellirock
temperature/maturity loggers, insulated using
thermal blankets
Precast Caps are formed on Barges, lifted from
one barge to another for transport
Sanibel Causeway, Lee County, Florida
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Precast Piers are cast on their side, then moved
to barges for storage and transport. NMB Grout
Sleeve Splices are used to Connect piers to pile
caps. Pad-eyes are cast into the caps for
handling, they are later buried in CIP pedestals
. Piers are considered Mass Concrete pours,
monitored and insulated.
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Superstructure

• Girder Systems
• AASHTO Girders
• Bulb Tees
• Deck Bulb Tees
• Boxes, Slabs,
• Spliced Girders
• Simple Span
• Continuous
• Curved

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Deck Bulb Tees

• Bulb tee girders cast integrally with deck
• Longitudinal joints between units
• Typically no field-cast deck concrete
• May have a wearing surface

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Grouting Keyways
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BPA Bridge
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BPA Bridge
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Day 5 6
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Day 7 - Wednesday, August 25th
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Day 8 Membrane Pavement
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CONSTANT BULB HAUNCH
SECTION A-A
HAUNCH VARIATION DETAILS
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CONSTANT WEB DEPTH
SECTION A-A
HAUNCH VARIATION DETAILS
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Decking Systems

• Conventional Forms
• Precast SIP Forms
• Deck Panels

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SIP Deck Form Panels
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Full-Depth Deck Panels

• Previous Woodrow Wilson Bridge
• Deck replaced in 1983 with full depth panels

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Full-Depth Deck Panels
U.S. Highway 6, Near Golden Colorado
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Full-Depth Deck Panels
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Full-Depth Deck Panels
Bid as Cost Time 30 Days Max Two, 12-Hour
Shifts Finished in 12 Days with 2 days weather
delay
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Skyline Bridge NU Deck
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Skyline Bridge NU Deck
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Skyline Bridge NU Deck
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Why Precast Deck Construction?

• Construction in Remote Areas, over Water,
  Wetlands or Otherwise Inaccessible Sites.
• Minimal Field Labor, Rapid Erection, Resulting
  Schedule Compression.
• Adverse or Uncooperative Climate/Weather.
• High Degree of Quality Control in both the
  Casting Yard and at the Site.
• Total Precast System Piles, Bent Caps, Girders
  and Deck.

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Why Precast Deck Construction?

• Construction in Remote Areas, over Water,
  Wetlands or Otherwise Inaccessible Sites.
• Minimal Field Labor, Rapid Erection, Resulting
  Schedule Compression.
• High Degree of Quality Control in both the
  Casting Yard and at the Site.
• Total Precast System Piles, Bent Caps, Girders
  and Deck.

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Why Precast Deck Construction?

• Construction in Remote Areas, over Water,
  Wetlands or Otherwise Inaccessible Sites.
• Rapid Erection with Minimal Field Labor.
• High Degree of Quality Control in both the
  Casting Yard and at the Site.
• Piles, Pile Caps, Bent Caps, Girders and Precast
  Deck Panels.

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Rapid Precast Construction Systems

• A Patented Forming System and a New Approach to
  Deck Construction
• Low-Profile Bogies Designed to run on Bottom
  Flanges of AASHTO B-T Girders.
• A Leveling System Comprised of Leveling Bolts or
  Automated Screw Jacks
• Full or Partial Depth Precast Panels.

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RPCS

• A Patented Forming System and a New Approach to
  Deck Construction
• Low Profile Bogies Designed to Run on Bottom
  Flanges of AASHTO B-T Girders
• A Leveling System comprised of Leveling Bolts or
  Automated Screw Jacks.
• Full or Partial Depth Precast Panels.

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RPCS

• A Patented Forming System and a New Approach to
  Precast Construction
• Low Profile Bogies Designed to run on the Bottom
  Flanges of AASHTO or B-T Girders
• A Leveling System consisting of Leveling Bolts or
  Automated Screw Jacks.
• Full or Partial Depth Precast Deck Panels.

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How it Works.

• Bogies are Adjustable Variables include Girder
  Type, Spacing, Camber Superelevation
• Deck Panel Width, Jacking Frame Height, Screw
  Jack Stroke, etc.
• Girders are Placed and Braced.
• Panels are Wheeled into Place on Bogies, and Deck
  Elevations Shot over each Jack.
• Panels are lifted/lowered into Alignment, O-Rings
  Installed, and Panel Joints Buttered.
• Panels are Post-Tensioned together while
  Suspended on Bogies.

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How it Works.

• Bogies are Adjustable Variables include Girder
  Type, Spacing, Camber Superelevation
• Deck Panel Width, Jacking Frame Height, Screw
  Jack Stroke, etc.
• Girders are Placed and Braced.
• Panels are Wheeled into Place on Bogies, and Deck
  Elevations Shot over each Jack.
• Panels are lifted/lowered into Alignment, O-Rings
  Installed, and Panel Joints Buttered.
• Panels are Post-Tensioned together while
  Suspended on Bogies.

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How it Works.

• Bogies are Adjustable Variables include Girder
  Type, Spacing, Camber Superelevation
• Deck Panel Width, Jacking Frame Height, Screw
  Jack Stroke, etc.
• Girders are Placed and Braced.
• Panels are Wheeled into Place on Bogies, and Deck
  Elevations Shot over each Jack.
• Panels are lifted/lowered into Alignment and
  Panel Joints Buttered.
• Panels are Post-Tensioned together while
  Suspended on Bogies.

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How it Works (Continued)

• Shear Studs are Shot onto Girders to Provide
  Horizontal Shear Strength
• Before Panel Placement if Full Depth Panels are
  used.
• Rigid Foam Form Stops are placed to Channel
  Grout for Build-Up..
• Grout is Injected through Ports in the Deck
  Panels to Provide Build-Up and
• Composite Bond.
• End Diaphragms and Closure Pours are CIP over the
  Pier/Bent Caps.
• Bogies Proceed, One by One, from One Span to the
  Next.
• Intermediate Diaphragms, if required, can be
  precast, and set after the deck
• is in place delivered on Bogies.

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How it Works (Continued)

• Shear Studs are Shot onto Girders to Provide
  Horizontal Shear Strength
• Rigid Foam Form Stops are Placed to Channel
  Grout for Build-Up.
• Grout is Injected through Ports in the Deck
  Panels to Provide Build-Up and
• Composite Bond.
• End Diaphragms and Closure Pours are CIP over the
  Pier/Bent Caps.
• Bogies Proceed, One by One, from One Span to the
  Next.
• Intermediate Diaphragms, if required, can be
  precast, and set after the deck
• is in place delivered on Bogies.

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How it Works (Continued)

• Rigid Foam Backer Rod is Placed and Panels
  lowered to Finished Grade
• Shear Studs are Shot onto Girders to Provide
  Horizontal Shear Strength
• Grout is Injected through Ports in the Deck
  Panels to Provide Build-Up and
• Composite Bond.
• End Diaphragms and Closure Pours are CIP over the
  Pier/Bent Caps.
• Bogies Proceed, One by One, from One Span to the
  Next.
• Intermediate Diaphragms, if required, can be
  precast, and set after the deck
• is in place delivered on Bogies.

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How it Works (Continued)

• Rigid Foam Backer Rod is Placed and Panels
  lowered to Finished Grade
• Shear Studs are Shot onto Girders to Provide
  Horizontal Shear Strength
• Grout is Injected through Ports in the Deck
  Panels to Provide Build-Up and
• Composite Bond.
• End Diaphragms and Closure Pours are CIP over the
  Pier/Bent Caps.
• Bogies Proceed, One by One, from One Span to the
  Next.
• Intermediate Diaphragms, if required, can be
  precast, and set after the deck
• is in place delivered on Bogies.

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Field Services

• Supply and Maintenance of Bogies and Jacks over
  the life of the Project.
• Supply and Maintenance of Battery Molds for
  Casting Panels.
• Field Measurements of Girder Camber,
  Determination of Dead Load Deflections,
• and Calculation of Required Build-Up.
• Field Crews to Set, Level, Post-Tension and
  Grout the Deck Panels.
• Load Ratings, if Required by the Owner.

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Design and Construction Considerations

• Transverse Prestress By varying strand size, a
  full range of girder spacing
• can be accommodated using the same strand
  pattern.

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Design and Construction Considerations

• Longitudinal Post-Tensioning Finite Element
  Analysis can be used to
• size tendons based on tension across panel
  joints. Residual Compression ensures
• adequate shear transfer across panel joints.

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Design and Construction Considerations

• Composite/Horizontal Shear Transfer The current
  AASHTO Equations
• recognize that cohesion as well as shear
  friction contributes to composite
• shear transfer. On Wide Flange Bulb-Tees,
  cohesive forces are adequate to resist
• virtually all horizontal interface shear
  forces. At girder ends, headed studs
• can be used to supplement cohesive forces. Two
  foot stud spacing can
• be provided, though analysis shows strength is
  adequate at greater stud spacing.

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Design and Construction Considerations

• Bracing Bracing is needed to stabilize girders.
  A simple system for bracing
• the girders over piers has been developed that
  allows bogies to roll freely
• from one span to another. A stiffened plate
  or wheel bridge spans the gap
• between girders.
• Between piers, thrust due to wheel loads is
  resisted by friction between
• polyurethane treads on the concrete, but
  supplemented using a system
• of brackets clamped to the bottom flanges
  (brackets can be placed from above).

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A Flexible Approach Rapid Precast Construction
Systems Can Provide

• Bogies (precast deck panels or traditional form
  stripping) and/or Battery Moulds.
• Full or Partial Depth Precast Slabs.
• Engineering Field Support from Conceptual
  Design thru Project Completion.
• Total Precast Solutions.

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Automated System Operation
Bogies are winched forward incrementally (winches
are located on the lead bogie) Screw jacks are
pre-leveled, and a panel is set. The train is
pulled forward, and the next panel is set. At
the end of each step, screw jacks are adjusted to
maintain uniform panel support. Jacks adjustment
is made from a touch screen panel, either
individually, or uniformly as a group. Once
the entire span is filled, elevations are shot
over each jack, and each jack is adjusted to
level all panels into the same plane. Panels are
then post-tensioned. After post-tensioning, the
deck is lowered uniformly - to final grade,
and the build-up is placed between girders and
deck.
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QUESTIONS?