Iowa’s Perspective on ABC

Terry Wipf
Iowa State University
(on behalf of Iowa DOT)

FHWA ABC WORKSHOP

2009 International Bridge Conference

Local System Precast Motivation
 Precast Bridge
Demonstration Project
(Local Systems Application)

Black Hawk County

 Demonstration Bridges
Single span precast modified
beam-in-slab bridge
– 40 ft span w/ 45 degree skew
– 39 ft span w/ 0 degree skew
Goals of Monitoring Program
Evolution of superstructure and
substructure elements
Closure pour connection details
Evaluate structural characteristics
 Laboratory Testing
Evolution of superstructure and
substructure elements
Closure pour connection details
Evaluate structural characteristics
Field Testing and Evaluation
Diagnostic Test
– Evaluate in service
performance
 Background
Overview
ABC history in Iowa and evolution
– Aware of National ABC agenda…part of overall Iowa DOT
research agenda process
– FHWA Program Funding IBRC/IBRD/HfL
Key elements for success
– Funding
– Personnel or office structure
– Cooperation with industry (regular basis and good
opportunity to discuss ABC)
– Standardization (regular process)
– National involvement
 Background
Iowa Climate RE ABC
ADT is relatively moderate w.r.t. National
Obstacles
– Local construction industry resistance
Cheaper labor rate
No alternative delivery allowed
– Culture in Iowa
Precast option is rarely used
 Background
Summary
Be open to innovation
Start simple and “evolve”
Consider implementing on “Low Volume” roads
Include lab and field testing components (for
verification of design assumptions and constructability)
Partner with the industry
Constructability review during design
– Hard to get into process…this can be biggest challenge
Involvement nationally: workshops, demo projects,
IBRD, HfL, FHWA, other states
 Precast Bridge
Demonstration Project
(Primary/Local Systems Application)

Mackey Bridge
Boone County
 Overview
Design by Iowa DOT
– First concerted ABC concept
3 span pre-stressed girder
– 47’-5, 56’-6, 47’-5 Spans
– 33’-2 width overall
Precast substructure and superstructure elements
 Challenge
Steep learning curve
– First use in Iowa – no designer, contractor,
fabricator or inspector experience
AASHTO Standard Specification
– limited guidance on full depth post-tensioned deck
panels
Limited literature and national experience with this
style of deck system
The project was let with short lead time for the
contractor and fabricator
Goals of Monitoring Program

Evaluate
– Structural performance of precast concrete
bridge elements in the laboratory
– Constructability of connections
– Handling of components
Monitor and evaluate structural
performance of field bridge during and
after construction
 Substructure

Precast Abutment Footing

 Full Depth Deck Panel
Fabrication
Pretensioned Transversely
Post-tensioned longitudinally
32 Interior deck panels
Each ½ bridge width
4 End panels with PT
anchorage zones
Modified LXA beams
@ spacing 8’-4
Laboratory Tests
Field Testing and Evaluation
Post-tensioning force in panels
Diagnostic load tests
Evaluate in service performance
Strain Profile
LC 1, Girder 2
45
40

35
30
Height, in.

25

20
15
10

0
-40.00 -20.00 0.00 20.00 40.00 60.00 80.00
Microstrain
 Lessons Learned

Critical interaction with industry

More lead time (early letting) for projects
of this type with non-standard details
Try to reduce critical path steps
High early strength concrete mix is a key
for the project – almost always on the
critical path – testing at the manufacturing
plant prior
 Precast Bridge
Demonstration Project
(Primary Systems Application)

Council Bluffs, IA
 Overview
Reconstruct the 24th Street Interchange over I-
80 / I-29
Replace existing structure with a Two-Span
CWPG 354’ x 106’ bridge
Use staged construction to maintain one-lane
traffic in each direction plus a turning lane
Use ABC techniques
24 Street - Highways for Life
th

Application on 24th Street Project –

– Full-Depth Precast Deck Panels
– High Performance Concrete
– High Performance Steel
– Structural Health Monitoring
– Fully Contained flooded backfill
– A+B Bidding
– Intelligent Transportation Systems
 Challenge
A larger bridge with aesthetic details in a high profile
location
Heavy traffic area
New deck panel details, a new contractor and new
fabricator

NOTE: project went smoothly due to lessons learned on

Mackey Bridge
Advantage of trial ABC project in a low pressure area
first
Goals of Monitoring Program

Evaluate
– Constructability of connections
– Handling of components
Monitor and evaluate structural
performance of field bridge during and
after construction
Full-Depth Precast Deck Panels
Deck is made up of two panels
Pre-tensioned and post-tensioned
concrete deck panels
Cast-in-place transverse joint between
panels
Cast-in-place longitudinal joint that will tie
the two phases of construction
PCC overlay over precast deck panels
Precast Deck Panel

Plan View
Deck Panels
Pre-Construction Testing
Investigation of Shear Stud Installation
and Testing
Evaluation of Concrete Consolidation in
Shear Stud Pocket and Beam Haunch
Evaluation of Joint Shear Transfer
 End of Floor
Section

Longitudinal
End of Floor Section Closure Pour
Shear Stud Pocket / Haunch Pour Testing
Joint Tests
Post-Construction Testing
Diagnostic load tests
Deck panel joint performance
Long term structural performance
P/T and pretension reinforcement
corrosion
Lessons Learned
Collaboration with the industry prior to design
was very important for the success of this
project
Preconstruction testing program to evaluate
selected items and this was very helpful
Experience gained with many innovations
introduced
Lab testing to validate design assumptions
prior to construction will reduce risk
Precast Bridge Approach
Demonstration Project

O’Brien County
Iowa 60
Why Precast Concrete Panels?
Expedited construction
– Overnight placement
– Reduced user cost
– Almost immediate exposure to traffic
Controlled Fabrication Conditions
– Adequate curing, reduced curling
PPCP Bridge Approaches
– Rapid replacement of bridge approaches
 Challenge
How take skew into account
How to implement a precast approach
– Use for ABC repair (time)
Deteriorated approach slabs
– Post tensioning
– Grouting
– Tie transverse in keyways without match cast
– Gain Industry experience
– How forces from precast tied to integral abutment
would affect bridge
 Demonstration Project
Precast Prestressed Bridge Approach Slabs
– ~77 ft at either end of a skewed bridge
– Tied to integral bridge abutment
2-way Post-Tensioning
Partial-width panels (lane-by-lane construction)
Installed over crushed aggregate base graded
to crown
Panels: 14 ft x 20 ft x 12 in.
Precast Approach Slab Layout
25.0' 3 spa. @ 20.0'

2 spa. @ 14'

6 spa. @ 2.0'
Longitudinal PT (1 - 0.6" dia. strands)
Transverse PT (1 - 0.6" dia. strands)
 The Companion Bridges
Southbound Bridge Schematic
Expansion
Approach Slab Integral Abutment
Joint

Sleeper Slab Integral Precast Girder

Connection LXD90

Single Row of
HP10x57 Piles

Northbound Bridge Schematic

Expansion Precast Panels

Joint

Polyethylene Sheet
Integral
Connection
Goals of Monitoring Program
Verify structural performance of PPCP as
bridge approach pavement
– Joint openings
– Bridge movements
– Girder flexural behavior
– Pile axial/flexural behavior
Provide useful comparison with adjacent
CIP bridge approach pavement
 Instrumentation Plan
NB Bridge

Joint movement crackmeters (10) Displacement transducers (3)

PT strandmeters (7) Tiltmeters (2)
Embedded strain sensors (16) Girder strain sensors (18)
Pile strain sensors (12)
 Field
Long-term monitoring
– Bridge behavior
– Slab behavior
cracking
– Abutment behavior
60

40

20

0
(me)
L oad S train

-20

-40

-60

-80

-100
4/13 5/11 6/8 7/6 8/3 8/31 9/28 10/26 11/23 12/21 1/18 2/15 3/14 4/11
Time
Monitoring Lessons Learned
The two approaches impacted the
bridges in different ways
The integral connection between both
types of approaches appear to be
functioning well
A force exists at the joint between the
approach and the mainline pavement
ABC Lessons Learned
Significant experience (Precast/PT)
The forces developed in the slab and
bridge are large enough that they need to
be considered in the design process
Can take next step for ABC repair under
staged construction
Precast Bridge Approach
Demonstration Project

Bremer County
U.S. 63
 Project Details
Precast system shown to be feasible from
O’Brien Project
ABC schedule
– 12 hr closures (NB daytime; SB night time)
– One traffic lane w/ shoulder for staged
construction
Bremer County Project
 Panel Layout
12 ft Roadway panel width
3’-10 and 7’-10 shoulder panel width
1’-10 Cast-in-place shoulder at gutterline
match w/ existing pavement and wing
Approach length ~ 24 ft from bridge at
roadway centerline
Pavement tied to bridge abutment
EF joint precast in panels and next to
existing pavement for expansion
Individual Panel Description
12 inches thick, 9.5 inches at abut.
Skewed at abutment ~ 2.5 degrees
fc = 5000 psi
Epoxy coated rebar (mild reinforcing)
Mechanical connection with 3” x 12”
grouted pockets (1’-0 spacing)
 Longitudinal Section

Expansion
Precast Panel
Joint

Polyethylene Sheet
Existing Integral
Pavement
Connection
Longitudinal Joint at Centerline
 Project Construction

Pre-construction meeting August 7, 2008

Casting– August 2008
Construction – September 2008
Panel
Roadway/Shldr. Joint Detail
Roadway/Shldr. Joint Fit Up
 Monitoring
Similar to O’Brien
Long term force effects
Project Lessons Learned
12 hour closure was not an issue
Restrictive 20 min lane closure would be
helpful, but…
Existing bridge paving notch ~uneven
– individual pads instead for shim
Applying to high traffic area next