Lateral Slide and UHPC Integral

Abutment Connections on
Iowa’s 2019 Camp Creek
Bridge Replacement
May 21st, 2020

James Nelson, Iowa DOT

Brent M. Phares, Iowa State University
Matt Erickson, Iowa DOT
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Mackey Bridge – Boone Co. IA
IBRC Grant
Prefabricated
Bridge Elements &
Systems

Constructed 2006
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IOWA DOT ABC Policy

• Iowa DOT Bridge Design Manual –

Chapter 8 ABC
– https://iowadot.gov/bridge/policy/08-00-
00AbcLRFD.pdf
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IOWA DOT ABC Past
Projects (2006-2013)
• Prefabricated Bridge Elements and
Systems (PBES) – 10 projects
– Various precast components
– Full-depth deck panels
– UHPC connections
• Lateral Bridge Slide – 1 project
(Massena Bridge Slide)
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IOWA DOT ABC Decision
Making Framework
• Part 1 – ABC Rating Score (0 to 100)
– Average Annual Daily Traffic (AADT)
– Out of distance travel
– Daily road user costs
– Economy of scale

• Score >50 then further ABC

consideration is warranted.
• <50 not considered a good candidate
for ABC.
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IOWA DOT ABC Decision
Making Framework

• Part 2 – Analytical Hierarchy Process

(AHP) - optional
– Direct Costs
– Indirect Costs
– Schedule Constraints
– Site Constraints
– Customer Service
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Iowa DOT Highlighted ABC
Past Projects
• https://iowadot.gov/bridge/Research-and-
Investigations/Accelerated-Bridge-
Construction
• US 6 over Keg Creek – PBES
• IA 92 over Small Stream (Massena) –
lateral bridge slide
• IA 92 over Little Silver Creek Bridge –
PBES
• US 52 over Mississippi River Overflow
(Sabula Bridge) – PBES
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Massena Lateral Bridge Slide
Jacking the bridge to
remove the rollers and
lower the bridge onto the
laminated neoprene
bearings

Lateral bridge
superstructure
slide
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Typical Iowa DOT Integral Abutment
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UHPC Integral Abutment Connection

Sections through abutment footing and

superstructure diaphragm
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Research Project Goal
• Develop Integral Abutment
Connection(s) that meet the design
and construction demands of an
Accelerated Bridge Construction
(ABC) project
– Slide-in Construction Capable
– Durable
– Construction Friendly
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Research
• Funding
– Accelerated Bridge Construction -
University Transportation Center (ABC-
UTC)
– Iowa DOT
• Project Co-PIs: Brent Phares, Travis
Hosteng, and Behrouz Shafei
• Two phases of laboratory testing
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Objective and Scope
• Assess the strength and durability of
three integral abutment connection
details for ABC applications as
compared to conventional details
• Scope
– Conventional integral abutment detail
(control)
– Grouted coupler connection
• Two configurations
– Pile coupler connection
• Two configurations
– UHPC connection
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Laboratory Specimens
Design, Construction, and Testing
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Conventional Integral Abutment
Specimen (control)
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Conventional Integral Abutment
Specimen (control)
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ABC Specimens
• Three ABC specimens evaluated in
Phase II (report(s) available on ABC-
UTC website):
– Grouted Reinforcing Bar Coupler (GRBC)
Connection
• 8 couplers revised from 17 couplers in Phase I
– Pile Coupler (PC) Connection
• 4 couplers revised from 2 couplers in Phase I
– Ultra High Performance Concrete (UHPC)
Connection
• Designed in conjunction with Iowa DOT
• Structural Response & Constructability
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Grouted Reinforcing Bar Coupler
(GRBC) – Plan View
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Pile Coupler (PC) – Plan View
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Pile Coupler (PC) – Section
View
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Pile Coupler (PC)
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UHPC Connection – Plan
View
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UHPC Connection – Section
Views

Note: beam extends into the diaphragm/backwall beyond the bearing but
isn’t shown for clarity
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UHPC Connection –
Bottom Portion
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UHPC Connection – Top
Portion Formwork
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UHPC Connection
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UHPC Connection
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UHPC Connection
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Laboratory Test Setup
• Two independent static loads
applied to the fixed-base specimens
– 100-kip horizontal load
– 400-kip vertical load
• Instrumentation
– Global displacement transducers
– Strain gauges
– Displacement gauges for crack
opening
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Laboratory Test Setup
400 kip Vertical Load

100 kip Horizontal Load

Post-tensioned
Bars

Reaction
Blocks
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Laboratory Test Results – UHPC
Connection

Beam
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Laboratory Test Results – UHPC
Connection

Beam
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Laboratory Test Results

Notes:
• “Blue” specimens tested in Phase I; “Green” specimens tested in Phase II
• GRBC – Grouted Rebar Coupler Connection
• PC – Pile Coupler Connection
• UHPC – Ultra High Performance Concrete Connection
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Recommended UHPC
Connection Improvement –
Section View
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Concluding Remarks
• Grouted Rebar Coupler Connection
– Phase I specimen performed well but
not constructible.
• Pile Coupler Connection
– Phase II specimen performed well and is
ready for implementation consideration.
• UHPC Connection
– Has been shown to perform satisfactorily
and is highly constructible.
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Camp Creek Bridge

Design and Construction

Owner – Iowa DOT

Designer – Iowa DOT
Contractor – Peterson Contractors Inc.
37
General Information
Washington County, IA
Iowa 1 over Camp Creek

120’x44’ Prestressed Pretensioned Concrete Beam Bridge

AADT 3400, 11% trucks

2 Bids for the project

$1.7 million project total
$1.1 million bridge portion

336 hour (14 day) critical closure

Incentive/disincentive for critical closure $300/hr ($7,200/day)
Actual critical closure was 12 days
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Project Location

IA 1 Over
Camp Creek
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Situation Plan
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UHPC Connection Design
• FHWA-HRT-14-084 Technote Design
and Construction of Field-Cast UHPC
Connections.
• Development length ld =8db
• Lap-splice ls = 0.75 ld
• Cover 3db
• Clear spacing to nearest lap-spliced bar
should be less than or equal to ls
• Clear spacing minimum = 1.5 x longest
fiber length.
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UHPC Connection Design
• Interface roughening:
• Roughened to an amplitude of ¼”
• Roughness to comply with International
Concrete Repair Institute (ICRI)
Concrete Surface Profile (CSP) 9
minimum or 10.
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Specifications
• Special Provision for Prefabricated
Bridge Move
– Open to various sliding systems (e.g. rollers
and PTFE sliding pads) and SPMT’s
– Some requirements are dependent on the
methodology
• e.g. - Twist is an issue when using SPMT’s but
may not be an issue when sliding on falsework
onto precast footing.

• Special Provision for UHPC

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Abutment Cross Section

Abut. Cross Section

Typ. Abut. Cross Section through UHPC pour port
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Bridge Approach Detail
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Recommended Improvement

Laboratory Abut. Cross Section

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Pre-Slide Construction
• Site preparation
• Temporary works construction
• Bearing plates and setting beams
• Pouring abutment diaphragms and
deck
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Staging Plan
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Staging Area & Temporary
Works & Beam Bearing Plates
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Beam Setting
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Bridge Deck Placement
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Abutment Diaphragm
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Critical Closure Activities
• Close roadway / bridge demolition (1 day)
• Grading & revet. / driving abut. Piles (2 days)
• Abutment footing curing & wing placement
(4 days)
• Slide preparation (1 day)
• Bridge Slide (1 day)
• Backfill abutment & approach pavement
curing & paving shoulders (5 days)
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Demolition of Existing Bridge
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Bridge Removed / Piles Driven
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Abutment Footing Pour
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Precast Abutment Wing
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Jacking Pocket
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Hydraulic Jack
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Rollers
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Bridge Slide
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Bridge Slide
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Bridge Slide
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UHPC Pour
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Back Face of Abutment Showing
UHPC Connection and Pour Ports
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Construction Time Lapse – Summer 2019
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Finished Bridge – April 2020
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Finished Bridge – April 2020
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Lessons Learned
• Suggest UHPC pour locations on the
back face of abutment only. The pour
locations on the front face conflicted
with the jacking locations.
• Ensure good construction of top of
abutment. Poor construction of
abutment footings led to issues with
beam bearings.
• Temporary works should be surveyed to
ensure the sliding channel lines up with
permanent position
 THANK YOU FOR YOUR TIME AND ATTENTION

CONTACT INFORMATION CONTACT INFORMATION CONTACT INFORMATION

James Nelson
Director, Bridges and
Structures Bureau, Iowa DOT
james.s.nelson@iowadot.us
Brent Phares
Director, Bridge Engineering
Center, ISU
bphares@iastate.edu
Matt Erickson
Engineer Associate, Bridges
and Structures Bureau, Iowa
DOT
matthew.erickson@iowadot.us