CSCE ABC Workshop October 23, 2013

Program Outline

Developing Precast Guidelines for

• Background on PCI Northeast Bridge
Accelerated Bridge Construction Technical Committee
• Development of Precast Substructure
Guidelines
• Development of the NEXT Beam
• UHPC
• Deck Panels

Rita Seraderian, PE, FPCI

Executive Director
Precast/Prestressed Concrete Institute Northeast
Belmont, MA

PCINE Bridge Technical Committee PCINE Bridge Technical Committee

State DOT
! Rabih Barakat– CTDOT
! Brian Reid - CTDOT
• PCINE Technical Committee was established in ! Robert Bulger - Maine DOT
1990 ! Brian Reeves – Maine DOT
• Members included State Department of ! Alex Bardow - MassDOT
Precasters
• Rita Seraderian - PCI Northeast
• Joe Carrara - J. P. Carrara & Sons
• Ernie Brod - J. P. Carrara & Sons
• Chris Fowler - Oldcastle Precast
• Eric Schaffrick - Dailey Precast

Transportations Engineers from New England and ! Maura Sullivan – MassDOT • Scott Harrigan – Fort Miller
! Edmund Newton - MassDOT
New York, Consultants and Precastors • Chris Moore – United Precast
! Duane Carpenter – NYSDOT • Bill Augustus – Oldcastle Precast
• Focus is on Updating and Developing Regional ! Michael Twiss – NYSDOT
Consultants
Standards for ABC Bridge Construction since 2004 ! Jason Tremblay –NHDOT
• Michael P. Culmo - CME Associates, Inc.
! David Scott - NHDOT
• Eric Calderwood - Calderwood Eng.
! Mike Savella - Rhode Island DOT
• Vartan Sahakian -Commonwealth Eng.
! Rob Young – Vermont AOT
• Darren Conboy - Jacobs Eng.
• Ed Barwicki - Lin Associates

Reports Developed by the Technical Committee In 1995 - First Prestressed Girder Developed - NEBT
•NEBT Preliminary Design Charts Section was adopted by
New England and New York
•NEBT Post-Tensioned Design Guidelines
Also Adopted by
•High Performance Concrete Specification New Brunswick and Quebec
•Prestressed Concrete Girder Continuity Connection
•Precast Deck Panel Guidelines
•Full Depth Precast Concrete Deck Slabs Guidelines
•Bridge Member Repair Guidelines
•Accelerated Bridge Construction Guidelines
•NEXT Beam Details and Design Charts

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CSCE ABC Workshop October 23, 2013

Reports are available at www.pcine.org Cross Street Bridge; Middlebury VT

• Harry H Edwards for Industry Advancement Award
• For Bridges150 ft and Longer Award
•Longest Single Span Splice Girder Bridge in the US
•240 Main Span

Longest Single Piece Bulb Tee Shipped – 157’ I-91 Bridges in Windsor , VT

WorkBridge Technical Committee Focused it’s work on Accelerated

PCINE Accelerated Bridge Guidelines Posted 2006
Bridge Construction starting in 2004.
In 2004 the PCINE Committee began developing ABC Guidelines
Timeline:
• 2004 – Developed an Accelerated Bridge Guidelines Report
Completed 2006
“Guidelines for Accelerated Bridge Construction using
Precast/Prestressed
• 2006 – Begin Development of the NEXT “F” Beam Concrete Components”
Completed 2008 – First Bridge Built in 2010
• 2008 – Begin Development of NEXT “D” Beam • Section 1: Application Overview
Complete 2010 – First Bridge Built in 2011 • Section 2: General Requirements
• 2011 – 2nd Ed. Full Thickness Deck Panel Report Updated • Section 3: Precast Components
• 2012 – Developed Prefabricated Bridge Elements & Systems • Section 4: Joints
Guide Details – Completed and Posted June -2012 • Section 5: Grouting
• 2012 - Develop Guidelines for Precast Approach Slabs – • Section 6: Seismic
Completed and Posted November- 2012
• Section 7: Fabrication & Construction
Current Work
• 2012 Update the Accelerated Bridge Guideline Report
• Develop Standard Details for Deck Bulb Tees
• Development of NEXT E

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FHWA Every Day Counts Initiative & Highways for Life
www.fhwa.dot.gov/everydaycounts
What are Prefabricated Bridge Elements & Systems
Bridge Elements & Systems?
PBES
• Superstructures
— Deck Panels: Partial & Full-Depth
— Prefabricated Beams: Optimized for ABC, Optimized
Shape, or Best Selected Section
— Total Superstructure Systems:
— Composite Units, Truss Spans
• Substructures
— Pier Caps, Columns, & Footings
— Abutment Walls, Wing Walls, & Footings
— Total Substructure Systems
• Totally Prefabricated Bridges

PBES Concrete Elements 15 Latest FHWA ABC Manual

Superstructure: Accelerated Bridge

• Adjacent Slab and Box Beams without Construction
CIP Deck Experience in Design, Fabrication and
Erection of Prefabricated Bridge
— With or Without Overlay; Elements and Systems
• Deck Bulb Tee Beams Without CIP
Published in November 2011
Deck Available On-Line
– With or Without Overlay; Free Download

• NEXT Beams http://www.fhwa.dot.gov/bridge/

abc/docs/abcmanual.pdf
• Precast Segmental Box Segments
• Precast Arch Spans

Chapter 5 Appendices

Design Examples and Guidance

• Full depth precast deck panels
Typical Prefabricated • Precast Concrete Piers & Abutments
Elements • Erection and Lifting calculations for deck
panels
Sample Construction Specifications
• UDOT – Precast Substructure Elements
• UDOT – Precast Concrete Deck Panels

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CSCE ABC Workshop October 23, 2013

PCI Northeast Guide Details posted 2012 Precast Piers

– Based on experience in Utah and the NE region

Typical Connections Integral Abutments

Integral Abutments Cantilever Abutments

• Corrugated Void Pockets

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CSCE ABC Workshop
Cantilever Abutments
Tolerance Details
Splice couplers
SHRP2 Research Project
Transportation Research Board Project
SHRP 2 - Innovative Bridge Designs
for Rapid Renewal
ABC Toolkit
www.trb.org/main/blurbs/168046.aspx
Objective
• Develop standardized approaches
to designing, constructing, and
reusing (including future widening)
complete bridge systems.
• It address rapid renewal needs and
efficiently integrate modern
construction equipment.
\
October 23, 2013
Pile Supported Footings
Pile supported footings
• Use corrugated pipe
forms
• Used for integral abutment
stems also
Tolerance Details
Columns
ABC Toolkit
• Standard Plans for ABC Modular Systems
– General Notes (Designer Notes)
– Abutments (including Approach Slabs)
– Piers
– Steel Girder Superstructure
– Concrete Girder Superstructure
• Erection Concepts for Modular Construction
• LRFD Designs (Mathcad)
• Contracting Language
• ABC Sample Design Calculations
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CSCE ABC Workshop October 23, 2013

Development of the NEXT Beam Development of the NEXT beam

• Started in 2006 – Completed in 2008
Benefits
• Accommodation of Utilities
• Reduce Fabrication and Installation Cost
• Works very well for Accelerated Construction.

Development of the NEXT beam

Depth 24” – 36” in 4” increments

Typical Span Range 50 – 85’
Width will vary 8’-0” – 12’-0” NEXT Beam
Preliminary Design Charts
6000 psi
8000 psi
10000 psi

Beam Depth
24 – 36”
Beam Width 8’-0” – 12’-0”

NEXT Beam Combinations

Bridge Section

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CSCE ABC Workshop October 23, 2013

Preliminary Beam Design Charts Additional Guidance on website www.pcine.org

Beam Design
•FAQ
•Design Assumptions

Load Charts available on PCI National Website - www.pci.org The NEXT Beam

NEXT Beam Production NEXT Beam Time Lapse Production

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CSCE ABC Workshop October 23, 2013

York Maine Project York Maine Route 103 Project

Route 103 over York River York, ME
7 Span Structure - 510 Ft Long
Completed Ahead of Schedule November 2010
4” Additional Navigational Clearance

Development of the NEXT Deck “D” beam Development of the NEXT Deck “D” beam
• Full Thickness Slab. •Preliminary Load Charts for Normal & Light
• Details, section properties and connections. Weight Concrete

Light Weight Concrete

Charts where developed

Development of the NEXT Deck beam Case Study- Sibley Pond Bridge – Canaan-Pittsfield, ME
First NEXT “D”

Design-Build Project
Opened November 21, 2011
10-1/2 months ahead schedule
The bridge was designed and completed in 15 months.
Designed for 100 year Service Life.

Credits – Parsons Brinckerhoff

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CSCE ABC Workshop October 23, 2013

Case Study- Sibley Pond Bridge – Canaan-Pittsfield, ME Design Considerations

" Type of Bridge: Superstructure:
Highway Bridge – Stream/Pond Crossing • Beams - 8000 psi SCC mix with (DCI)
• MMFX rebar specified in exposed bridge curbs & rail barriers
" Structure & Geometry:
• Deck protection: Deck waterproofing with asphalt overlay.
• 10 spans - two 5 span continuous units and a single • One expansion joint at high point, with semi-integral
expansion at center
abutments.
• Spans Designed for continuous for LL and SDL
Substructure:
• Span Length - 79’-0” With Overall Bridge Length - 790’-0”
• Concrete filled steel pipe piles - shop applied fusion bonded
• Overall Width - 36’-0” curb to curb
epoxy coating system, extending from the top of the pile to
• No. of Traffic Lanes - 2
10 feet (3 meters) below the mud line
• Alignment/Skew - Tangent /0 skew
• Longitudinal Grade ± 1.0% with crown at center of bridge

Sibley Pond Bridge – Canaan-Pittsfield, ME Sibley Pond Bridge – Canaan-Pittsfield, ME

Custom Gantry Crane
" Gantry lifted the beams from trailers on the old bridge.
" Rolled sideways across the new piers.
" Less costly and quicker than 2 crane pick.
" 4 Beams Erected in an 8 hour shift
" Turnaround time of 2 days/span

Sibley Pond Bridge – Canaan-Pittsfield, ME Continuity Connection

Live Load negative moment

continuity over the piers.
Mechanical Couplers were
detailed to field splice the
splice bars between
adjacent beams.

Couplers for (-) Moment continuity at

intermediate diaphragms

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CSCE ABC Workshop October 23, 2013

Hurricane Irene Vermont Accelerated Bridge

Hurricane Irene Storm Damage Bridge Pre-cast Integral Abutments
Replacements. There will be additional
projects this year using precast.

Examples of Projects:
Holiday Farm Road – Bridgewater, VT
Water Andric Road; Dansville, VT
Jim Earl Bridge; Bridgewater, VT
Bracket Brook; Carrabassett, ME
North Branch; Carrabassett, ME
Richards Road Bridge, Grafton, VT
Taylor Brook; Grafton, VT
GMRC; Cavendish, VT
Green MT. RR; Clarendon; VT
Titus Rd Bridge; Moriah, NY
East Lake Rd; Ludlow, VT

NEXT Beams Approach Slabs Complete

Elapsed)Time)1hr)16)mins)

Bridge 8 Finished MassPort Logan Airport Runway Extension, Boston, MA

Began in the Fall of 2011 Expected Completion Fall 2012
NEXT Beams: 330 beams.
Pile Caps: 88 pieces
Precast, Prestressed Piles: 330 18-inch square piles.

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CSCE ABC Workshop October 23, 2013

NEXT E Beam Cost Considerations

Box Beam Next Beam Conclusion
Fabrication Multi-stage pour Simple Pour Next Beam should
have significantly
Draping Straight Strand
lower fabrication
cost per SF
Shipping One beam per One beam per Next Beam
truck (3’-4’) truck (8’-12’) reduces the
number of trucks
(½ to ¼)
Cranes Lighter picks Heavier picks Probably a wash
Shorter erection
time
Installation Requires Set it an move on Much easier
Transverse PT installation, no
and grouting special grouts, no
post-tensioning

NEXT Research Underway Research Objectives

Title: Field Monitoring of an Integral Prestressed • Determine live load distribution factors (LLDF)
Concrete Bridge in Massachusetts
Sponsored by: – Estimate LLDFs using AASHTO equations (different S)
MASSDOT - PCI - PCI Northeast - NHDOT
Central Atlantic Bridge – Compare Estimates with Finite Element Models

– Evaluate estimated LLDFs with live-load testing of

prototype bridge (Brimfield, MA)

• Monitor long-term performance of integral

abutment NEXT beam bridge (3 years)

Live-load testing (24 May 2012) Update on Project Activities

• Parametric study of LLDFs complete

• Construction completed in Spring 2012

• Load test conducted on 24 May 2012

• Draft Report under review

• Long-term monitoring ongoing (3 years)

– Readings every 2 hours since 24 May 2012

16’-7” 4’-6” 6’-6” 19’-1” 4’-7” 7’-0” 17’-0” 4’-3”

24.6 kip 56.1 kip 20.5 kip 59.7 kip 20.5 kip 56.5 kip

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CSCE ABC Workshop October 23, 2013

TIMELINE NEXT Beam Developed in 2008 I-84 Dingle Road NY NEXT Beam Slide

7 Bridges
First NEXT D Logan Airport
bridges are uses NEXT
First
NEXT Built in Maine beams for
Beam & Vermont Runway
Cast MA and NY Extension
Build first and new
Bridges Airport
Viaduct

2009 2011 2011-12

2010 2012 2013

First Curved Several

First Flange Projects
NEXT F
Project already
Bridges Built
awarded
York ME and
NJ and RI NY will build
Kittery ME
build their First Lateral
first projects Slide

2 Bridges 12 Bridges

NEXT Beam Acceptance South Worthington, MA – Total Precast Built in 60 Days

• States with NEXT Beam Built:
• MassDOT; VermontAOT; MaineDOT, RIDOT,
NJDOT; NYSDOT, DEDOT, NHDOT
• States with NEXT Beam in Design/Construction:
• CTDOT; Pennsylvania DOT
• States considering the use of the NEXT Beam:
• Virginia; North Carolina; South Carolina and Georgia

Parking Industry Capabilities

• NEXT Beam Suppliers
• Blakeslee Prestress; Branford, CT
Precastor –
Dailey • J.P. Carrara & Sons; Middlebury, VT
Precast
• Oldcastle Precast; S. Bethlehem, NY
• Dailey Precast; Shaftsbury, VT
• Jersey Precast; Hamilton Township, NJ
• Coastal Precast; Chesapeake, VA
• High Concrete; Denver PA
•

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CSCE ABC Workshop October 23, 2013

South Maple Street ; Enfield, CT New York’s First Deck Bulb Tee Project

ROUTE 31 OVER CANANDAIGUA OUTLET

• 85’-0” (25.91 m) SPAN

• 42’-9” (13.03 m) WIDE
• 15 DEGREE SKEW
• 3’-5” (1.04 m) DEEP DBT
• 5’-4” (1.63 m) DBT SPACING

NY’s First Deck Bulb Tee Project NY’s First Deck Bulb Tee Project
ROUTE 31 OVER CANANDAIGUA OUTLET

Ultra High Performance Concrete (UHPC) For Joints

COMPRESSIVE STRENGTHS UP TO 29,000 psi

NY’s First Deck Bulb Tee Project NY’s First Deck Bulb Tee Project

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CSCE ABC Workshop October 23, 2013

NY’s First Deck Bulb Tee Project NY’s First Deck Bulb Tee Project

Ultra-High Performance Concrete UHPC Closure Pour – Cyclic Testing

Connections Between Precast Bridge Deck Elements

Testing began in May 2009

Test Plan:
A Joint NYSDOT-FHWA Precast Panel UHPC Precast Panel
Research
Cyclic testing Effort — TPF-5(217)
below static cracking for 2M+
cycles
Cyclic testing above static cracking for 5M+
cycles
Static loading to flexural failure
Surface is ponded with water during dynamic
testing. Wheel Patch Above Here

7’ between
Simple
Supports 7’ Wide
Specimen

Panel G1/G2 – After 5.8 Million Cycles to 21.3 kips

MADOT First Deck Bulb Tee Project MADOT First Deck Bulb Tee Project

Eight – 1220 mm NEBT 5’ wide 95’ long Deck Bulb

Easthampton, MA Tees 8000 psi Concrete – UHPC Joint

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CSCE ABC Workshop October 23, 2013

MADOT First Deck Bulb Tee Project MADOT First Deck Bulb Tee Project

Eight – 1220 mm NEBT 5’ wide 95’ long Deck Bulb Eight – 1220 mm NEBT 5’ wide 95’ long Deck Bulb
Tees 8000 psi Concrete – UHPC Joint Tees 8000 psi Concrete – UHPC Joint

Deck Bulb Tee Standards under development UHPC Projects

UHPC Projects Deck Bulb Tees Deck Panels Box Beam Joint

NYSDOT 2 16

IowaDOT 2

MassDOT 1

Ministry of 10 7
Transportation
Ontario

Full Depth Precast Deck Slabs Guidelines Precast Deck Panels

Typical Framing Plan

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CSCE ABC Workshop October 23, 2013

Precast Deck Panels Precast Deck Panels

Typical Piece Plan Composite Shear

PT Info Connection

Precast Deck Panels FAQ’s at www.pcine.org Full Depth Precast Concrete Projects
Sanbornton, NH Precast Deck Panels

Two Phase Deck Replacement

58 panels per phase
Bridge Length 468 feet
90 Day Construction Time

NE & NY NEXT Deck Substructures Bulb Box Piles Educational Programs

Producers Beams Panels Tees Beams

Blakeslee X X X Precast/Prestressed Concrete

Prestress Bridge Design Seminar
Coreslab X
Structures November 5, 2013 (8:00 am - 4:00pm)
Fort Miller X X X
Location: VTrans Training Center Precast/Prestressed Concrete Bridge Design using the

JP Carrara X X X X X 1716 Route 302

Berlin, VT 05633
Northeast X X X X X
Prestressed Speakers: 1. Introduction to Prestressed Concrete
6.
7.
PCI Northeast Topics
Vertical Shear Design

Products Roy L. Eriksson, PE - Eriksson

• Why prestress?
• Pretensioned vs. post-tensioned concrete
• Flexural regions vs. disturbed regions
•
• Plant-cast precast, prestressed concrete • Longitudinal reinforcement

Oldcastle Precast X X X X X Technologies, Tampa, FL 2. Preliminary Design

• PMember type selection
8.
9.
Interface (Horizontal) Shear Design

• Camber calculations
• PComposite vs. non-composite
• PStatical system: simple-span or continuous • Accommodating beam camber in bridges
3. AASHTO Load and Resistance Factor Design (LRFD) 10. Flange/Deck Design

SD Ireland X X Register at www.pcine.org

• Overview of the design process
• AASHTO limit states
• Loads, load distribution, and load combinations
• Crash load requirements
• Loads and load combinations • Reinforcement design
• Load distribution 11. Miscellaneous (Time Permitting)
4. Flexural Design - Stresses • Bursting steel
Unistress • Theory
• Prestress losses
•
• Girder stability

(Segmental Only) • Stress limits

• Control of end stresses: Draped strands vs. straight strands
with debonding
12. Design Examples
• Single-span, composite NEXT beam
• Single-span, composite bulb-tee design
5. Flexural Design - Strength • Multi-span, continuous composite bulb-tee design

United X X X • Assumptions
• Flexural resistance
• Limits for reinforcement

Dailey Precast X X X X This fee includes seminar notes and lunch. Space is limited so please register early.

You can register online at

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CSCE ABC Workshop October 23, 2013

Resources

Thank-You for your Attention

Questions?
Rita Seraderian, PE, FPCI
Precast/Prestressed Concrete Institute
Northeast
www.pcine.org
Email – rseraderian@pcine.org

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