Case Study 1

Castlewood Canyon Bridge

Rehabilitation

All information on this project is provided by

Mr. Mike Mohseni

Lead Bridge Engineer of Colorado DOT

1
Existing Conditions

2
 Scopes of Work

• This structure is in Douglas County 5 miles south of Frank-town and about 35 miles from Denver,
Colorado on State Highway 83 crossing over Cherry Creek.
• The original design of the structure (built between 1946 to 1948) was open spandrel with joints at
the beginning and end of every span. The joints kept leaking through on to the caps and columns
down to the arch ribs corroding the entire structure members.
• The project goal was to preserve the structure, improve safety, upgrade structural capacity and
widening the bridge with consideration for the environmental, aesthetical and historical issues.
The task required new creative, imaginative thinking about the use of the concrete and other
material available. The work had to be done from the top not to disturb the environment below.
The option presented and accepted would preserve the arch ribs and part of the south abutment
as well as north end spread footers for their historical values. All other members including deck
and girders, pier caps and spandrel columns would be removed in a special sequence with
consideration for balanced load design criteria for the arch ribs. The sequence was to remove
from the center and replace with two crews working toward each abutment. Innovative material
and new techniques were to be used to achieve this task such as (Carbon Fiber Wrap and
carbon fiber plastic bar 9 mm lead line for confinement and strength and NMB splice connections
to connect the precast members together, Joggle bars to miss the existing square rebar, end
Terminators to gain development length of the embedded rebar, etc). The sections were almost
all precast and prestressed for ease of use and rapid construction. The aesthetic of the structure
was also very important in particular the Bridge rails doghouse look was to be preserved. Pre-
cast and pre-tensioned members were designed so that they would be assembled at site. The
girders would also function as the new deck. Wet Application of shotcrete was used to restore
the arch ribs. The arch ribs were wrapped with CFRP in 3 phases to accommodate continuation
of construction during all phases. Carbon Fiber Plastic Rebar (CFPR) was also utilized to
strengthen the connection of the arch ribs to the foundation. A walkway path was also designed
under the structure by the south abutment to connect the two sides of the park together.

3
 Existing Condition Prior to Rehab
• Deterioration and spalling of Arch ribs, spandrel columns and caps
due to moisture penetrating through the existing joints.
• Erosion at the north Abutment.
• Safety issues on Rail and lack of any shoulders.

4
 Step 1:
Performed detailed inspection, and determine concrete strength and
steel / concrete section losses

5
 Step 2:
Performed load rating / structural analysis to determine which elements
should be rehabilitated or replaced – life cycle analysis should be used
when comparing costs

6
 Step 3:
Once what to do is determined, we should consider construction
method, maintenance of traffic, rehabilitation materials and techniques,
and construction costs. A decision matrix is usually employed to assist
decision making process.

7
Concrete Coring
for concrete tests

8
Concrete Test Report

9
10
 Arch Repair Step 1
Removed delaminated concrete and coat existing reinforcing steel

11
 Arch Repair Step 2
Patch concrete to match existing surfaces. Seal cracks where necessary

12
Arch Repair Step 3
Apply FRP

13
Apply FRP

14
Apply FRP

15
Arch Repair Step 4
Test FRP bonding with concrete

16
Arch Repair Step 5
Coat FRP with color of choice

17
18
Precast Spandrel Column Installation

19
Pier Cap Replacement

20
Precast Pier Cap Installation

21
Precast Deck Slab Installation

22
Precast Deck Slab Installation

23
Joint Details

24
Waterproofing and Pavement

25
Ceremony and Cake Cutting

26
New Bridge

27
Contract Plan

28