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CAST-IN-PLACE SUBSTRUCTURE
By S. L. Billington1 and J. E. Breen2
ABSTRACT: This paper focuses on improving the efficiency and aesthetics of standard highway bridges with
attention to cast-in-place substructure design. Standard short- and moderate-span bridges are predominantly
functional and nondescript. Recent developments in superstructure design have led to improved efficiency of
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construction and material use, with a resulting slender, attractive appearance. However, typical substructure
design remains a component where creativity can be played out for considerable improvements to the overall
bridge appearance. A review of current cast-in-place substructure systems is presented including individual, wall,
hammerhead, and multicolumn bents. Design recommendations for improving overall bridge appearance and the
efficiency of the substructure are presented. Attention is given to integrating aesthetics with material and con-
struction efficiency and with economic considerations. Recommendations include addressing structural expres-
sion, visibility through the bridge, shaping of the substructure, integration of substructure and superstructure,
and enhancing substructure form with nonstructural details. Issues of coherence for large-scale projects and
suggestions for standardization also are discussed. Economic implications of the design recommendations are
presented.
FIG. 1. For Standard Overpass, Contrast between: (a) Simple Tapered Single Support; (b) Series of Multicolumn Bents
FIG. 2. For River Crossing, Comparison of: (a) Wall Piers; (b) Multicolumn Bents
FIG. 3. Subtle Taper in (a) Tall Rectangular Column Contrasted with Abrupt Changes in Cross Section for (b) Tall Circular Pier
FIG. 10. Careful Examination of (a) Original Skewed Layout Shows (b) Alternate Solution Resulting in Cleaner Design
FIG. 11. Awkward Appearance of Blunt Bent Cap End FIG. 14. Coherence Achieved with Similar Shaping of Differ-
ently Sized Supports
FIG. 15. (a) Small Chamfers Have Little Effect on Short Columns, whereas (b) Larger Chamfers Accentuate Slenderness
FIG. 16. (a) Vertically Oriented Relief Accentuates Pier’s Height and Slenderness, whereas (b) Horizontal Relief Gives More Massive,
Heavy Appearance [Fig. 16(a) from Seim and Lin (1990)]
typically peels within a few years of application, therefore re- shape varies from I, T, U, and box, standard substructure
quiring the additional maintenance of repainting, whereas con- shapes can vary as well to improve and bring diversity to
crete colored through staining does not. substructure design. Wide standardization has proven to be
In choosing among the numerous surface treatments avail- very economical for substructure design in California, result-
able, designers should incorporate finishes according to the ing in over 20 different standard cast-in-place column shapes
design concept of their projects. Similar textures and colors for selection [California Department of Transportation (CAL-
should be used throughout large projects for coherence, and TRANS) 1990]. Elsewhere, over time, more new shapes
colors should be matched for patching and repair work. Sur- should be adopted and standardized in consultation with con-
face treatments that are part of the design concept can be ef- tractors to give designers more flexibility to tailor their designs
fectively used in locations where construction irregularities to particular sites economically with standardized elements.
such as waviness or uneven color may be expected. Two simple details that can add variety and visual interest
In all substructure design, to protect the finish or surface to standard forms are column chamfers and column flares.
treatments, sufficient attention must be given to drainage de- Chamfering rectangular sections to remove the sharp corners
tailing to avoid heavy staining. Details include internal drain- can improve the relative proportions between the columns and
pipes to guide deck runoff water and drip beads to shed water different elements of the bridge as discussed previously. Large
from the underside of the superstructure. wall-like piers could be chamfered to reduce their massive
Surface treatments are often relegated to being last-minute appearance. Chamfers can easily be incorporated into standard
additions to doctor an unattractive bridge. This use of surface designs with attractive and economical results.
treatments in an attempt to disguise a dull form is rarely suc- Column flares can be incorporated into standards quite sim-
cessful and will typically lead to increased costs. Surface treat- ply. Unlike a tapered column where the cross section varies
ment details instead must be incorporated into design decisions along the entire height, a column flare would make up just a
from the beginning of a project, where they are a part of the portion of the section and could thus be standardized along
design concept and therefore a part of the project budget. with the various constant cross-section sizes and shapes.
Clearly new standard shapes can continue to be developed
STANDARDIZATION to broaden the range of standard substructure options.
There often appears to be a conflict between standardization ECONOMIC CONSIDERATIONS
and flexibility in design. To display the efficiency of a design
or to express the flow of forces in a structure often requires The substructure naturally makes up only a portion of the
solutions tailored specifically for each site. For short- and total bridge cost. In Texas, for example, the substructure is
moderate-span bridges, such tailoring can be economical for typically 30% of the total bridge cost. A 30% increase in sub-
repetitive bridge structures—ones in similar sites. However, structure cost would therefore result in only a 9% increase in
standardization should not stop at one or two shapes per ele- bridge cost. A 50% increase in substructure cost would result
ment. Just as in superstructure design where cross-sectional in a 15% increase in bridge cost. Where a bridge is part of an
350 / JOURNAL OF BRIDGE ENGINEERING / NOVEMBER 2000
larly if standard pier sections and, hence, standard forms are an attractive structure with negligible project cost increases, if
developed. any.
Avoiding skewed bents may result in fewer substructure Short- and moderate-span highway bridges are a vital and
units and lead to economic savings. Although providing ade- often highly visible component of our infrastructure. Recog-
quate clearance under straddling (nonskew) bents [Fig. 10(b)] nizing the impact of substructure design on a bridge’s appear-
may increase costs relative to skew bents, the savings on sim- ance, alternative substructure designs must be pursued crea-
plicity in design and fewer bents typically results in a negli- tively to ensure that our bridges will be elegant additions to
gible cost difference. In the case presented in Fig. 10, savings their sites.
resulted.
Splitting a wide bridge into two narrower bridges (Fig. 7) ACKNOWLEDGMENTS
would require a minimal increase in cost for additional railing. The writers gratefully acknowledge the contributions of coresearchers
Savings or additional costs for the superstructure and substruc- Robert Barnes, Carl Holliday, Dan Leary, Scot Listavich, Stephen
Ratchye, and D. Andrew Vernooy. The writers also wish to thank Stewart
ture of a split bridge will be project dependent. Such options Watson, Norman Friedman, and Dean vanLanduyt for their contributions
must be judged based on the total project cost and not simply and participation in the project.
as a percentage of individual element costs. The Texas Department of Transportation, Austin, Tex., and the Federal
Individual columns supporting individual precast beams ef- Highway Administration, Washington, D.C., sponsored this project. The
fectively remove the need for a bent cap. Using individual opinions in this paper are those of the writers and not necessarily those
of the sponsors.
columns to support individual precast beams will be most cost
effective with trapezoidal box and U-beam superstructures, APPENDIX. REFERENCES
where the number of individual columns may be the same as
Billington, S. L. (1997). ‘‘Improving standard bridges through aesthetic
the number of columns required for a multicolumn bent. Foun- guidelines and attractive efficient concrete substructures.’’ PhD disser-
dation costs will typically remain the same. Each of the indi- tation, University of Texas at Austin, Austin, Tex.
vidual columns used to support individual beams will gener- Billington, S. L., Barnes, R. W., and Breen, J. E. (1999a). ‘‘A precast
ally need to be much stronger than each of the columns in a substructure design for standard bridge systems.’’ Res. Rep. 1410-2,
Center for Transportation Research, Austin, Tex.
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