ABC - Folded Plate Bridge System Uxbridge Massachusetts Maury - - PowerPoint PPT Presentation

ABC - Folded Plate Bridge System Uxbridge Massachusetts

Maury Tayarani Bridge Project Management Massachusetts Department of Transportation Email: morteza.tayarani@state.ma.usa Phone: 857-368-9282

Presentation Outline

1- Introduction to Mass DOT ABC Initiative 2- Introduction to Folded Plate Girder Bridge System for ABC Application 3- Description of the bridge using folded plate by MassDOT in Uxbridge, MA 4- Design Information- Uxbridge 5- Procurement and design process 6- Sequence of fabrication and construction 7- Future MassDOT plans 8- Contact information

Presentation Outline

1- Introduction to Mass DOT ABC Initiative 2- Introduction to Folded Plate Girder Bridge System 3- Description of the bridge using folded plate by MassDOT- Uxbridge 4- Design Information- Uxbridge 5- Procurement and design process 6- Sequence of fabrication and construction 7- Future MassDOT plans 8- Contact information

Mass DOT in 2007 initiated $3 billion Patrick-Murray Accelerated Bridge Program Since 2008, number of deficient bridges has dropped by 19% (as of August 1, 2013)

In eight years program

• ver 200 bridges are planned to be replaced or repaired

138 bridge projects – Completed Fast 14 is just one of the MassDOT - ABC projects 38 bridge projects in construction 22 bridge projects scheduled to start in 2014.

Presentation Outline

1- Introduction to Mass DOT ABC Initiative 2- Introduction to Folded Plate Girder Bridge System for ABC Application 3- Description of the bridge using folded plate by MassDOT- Uxbridge 4- Design Information- Uxbridge 5- Procurement and design process 6- Sequence of fabrication and construction 7- Future MassDOT plans 8- Contact information

Folded Plate Girder System is best suited for ABC application using steel alternate

Utilizing ABC philosophy One folded plate bridge systems constructed and is in service in Uxbridge Massachusetts and has been monitored since construction Second folded plate bridge system using is scheduled for construction in summer of 2014 (Nebraska) Additional bridges are in development

• r design stages

Development of Folded Plate Bridge System for ABC application involved conducting more than seven years

• f research, under direction of Dr. Azizinamini while he

was at University of Nebraska - Lincoln

Part of the research included fatigue test by subjecting the test specimen to more than 7.5 million cycles of loading

Folded Plate Bridge System is a proprietary product However, it is available from more than one source

Folded Plate Girders are made by bending flat plate into a C shape by using press break Plate thicknesses used are 3/8 inches or ½ inches

Maximum length of the folded plate girder is limited to 60 ft., which is the reflection of the maximum press brakes that are available.

Eleven Standard Shapes

Folded Plate comes in 11 standard shapes

Each shape come in 3/8 inch or ½ inch thickness

Stable Shape During Casting Deck

No need for internal cross frames No need for external cross frames No fatigue prone details Lowest fatigue category detail is B

Design is conservatively based on girders being supported at two ends, when casting deck. The actual production is based on girder sitting on flat bed (shored construction) and supported continuously.

Open bottom allows easy Inspection This was very important for MassDOT

Three main options exist for corrosion protection of steel

1- Galvanizing - Used by MassDOT for folded plate

Three options for corrosion protection

• f folded plate girders are

1- Galvanizing – Used by MassDOT 2- Weathering steel – will be used for second Folded Plate Bridge in USA (in Nebraska) 3- Coating, metalizing

Presentation Outline

1- Introduction to Mass DOT ABC Initiative 2- Introduction to Folded Plate Girder Bridge System 3- Description of the bridge using folded plate by MassDOT in Uxbridge, MA 4- Design Information- Uxbridge 5- Procurement and design process 6- Sequence of fabrication and construction 7- Future MassDOT plans 8- Contact information

Uxbridge Project

As one of the leading States in utilizing ABC And willingness to incorporate new technologies into a bridge program In 2009, Mass DOT decided to use Folded plate as a pilot project in town of Uxbridge

(River Rd. / Ironstone Brook, 40 miles SW of Boston)

Existing bridge Uxbridge Massachusetts

Presentation Outline

1- Introduction to Mass DOT ABC Initiative 2- Introduction to Folded Plate Girder Bridge System 3- Description of the bridge using folded plate by MassDOT- Uxbridge 4- Design Information- Uxbridge 5- Procurement and design process 6- Sequence of fabrication and construction 7- Future MassDOT plans 8- Contact information

New Bridge Using Folded Plate

46 ft. Span (C-C Bearing)

New Bridge was designed to be wider

Two 12.0 ft. lanes with two 4.0 ft. shoulders

New Bridge using Folded Plate

(4) Pre-top deck Girders @ 9’-5” C-C Spacing 13” Closure Width

Interior Pre-top Beam- 100 Inch wide

and 2 inch overlay

Exterior Pre-top Beam- 92 inch wide Edge beam cast in the plant for facilitating attachment of the railing

Cross section of one girder All Girders are the same

Design was based on AASHTO LRFD

Bridge Design Specification using HL93 Loads

Strength

• Moment

– Demand 29000 Kip-in – Resistance 35000 Kip-in

• Shear

– Demand 220 Kips – Resistance 580 Kips

Service Limit States

• Deflection

– 2 HS20 Trucks = 0.28 in. – Span/800 = 0.69 in.

• Stress in top flange

– Demand 7 ksi – Resistance 47 ksi

• Stress in Bottom Flange

– Demand 39 ksi – Resistance 47 ksi

Fatigue Detail Design and Categories

• Lowest Fatigue Category

Lowest fatigue category detail is B

which is at the Bottom Flange at the Tie Plate location

• For Uxbridge, Design based on Infinite Life

– Stress Range = 9 KSI – Resistance = 16 KSI (Threshold)

Shear Studs

• 4 Studs per Line

– Based on strength requirements, stud spacing is 11.4 inches – Based on fatigue requirements, stud spacing is 17.5 inches

• Actual stud spacing used is= 11 in.

Presentation Outline

1- Introduction to Mass DOT ABC Initiative 2- Introduction to Folded Plate Girder Bridge System 3- Description of the bridge using folded plate by MassDOT- Uxbridge 4- Design Information- Uxbridge 5- Procurement and design process 6- Sequence of fabrication and construction 7- Future MassDOT plans 8- Contact information

Uxbridge Project

Engineering estimate by MassDOT was $2 million

This included 600’ of roadway work as well as substructure and superstructure

The winning contract was 20% lower than estimate Job was advertised July 2010 Notice To Proceed Dec. 2010 Bridge Opened to traffic on Nov 2011

Folded plate bending – Kansas Galvanizing – Kansas

Girders were then shipped to Vermont Casting deck- Carrara- Vermont

Contractor – John Rocchio

Four Folded plate with pre-top deck was provided and delivered to the contractor, to the job site, at the cost of $192,000

Design of superstructure:

By folded plate provider

Independent Check:

Mass DOT hired consultant to carry out independent design check of folded plate provider and design the substructure

Bridge instrumentation:

University of Mass instrumented and have monitored the bridge Performance since construction.

Presentation Outline

1- Introduction to Mass DOT ABC Initiative 2- Introduction to Folded Plate Girder Bridge System 3- Description of the bridge using folded plate by MassDOT- Uxbridge 4- Design Information- Uxbridge 5- Procurement and design process 6- Sequence of fabrication and construction 7- Future MassDOT plans 8- Contact information

Girders were first fabricated in the shop by bending flat plate

Additional photos of bending the girders

Additional photos of bending the girders

Additional photos of bending the girders

Photo showing one completed girder

Summary of Fabrication Steps

1- Bending girders 2- welding the end Plates 3- bolting four tie plates 4- Welding Shear Studs

1 3 2 4

Fabrication

Shear studs were called to be attached according to the requirements of AWS D1.5 And the girders were then sent to galvanizing

Corrosion protection is provided by galvanizing the girder

Fabrication

Unfortunately there were fabrication errors in attaching the shear studs Problem was not noticed until after the galvanizing the girders We had to replace some of the shear studs with bolts

After galvanizing , all four girders were transferred to the precast plant

For ABC application, the formwork is simple. For Uxbridge the contractor built the formwork

• ver pre-stressing bed and placed the folded

plate in between the formwork

Design was based on girder being supported at two ends while casting the deck, However, during Construction, girders were supported over the entire length (shored construction)

Casting Deck- Note use of headed shear studs for closure pour

Pre-top folded plate units were placed over trailers, following casting and curing deck

The shipping width of completed module were 10’-2”. Including 11” headed rebar All four units were ready for shipping by August 2011 Units shipped to job site on October 2011 All four units were shipped to the job site on a same day

Type of Substructure Used

Next few slides shows type of substructure elements utilized Pre-fabricated sub-structure elements were used to accelerate the construction processes.

Steel piles were placed in pre-drilled holes. The bottom 5 ft. of the pre-drilled holes, were filed with concrete. The rest of the pre-drilled holes were then filled with crushed stone.

This slide shows portion of the steel piles extending outside the pre-drilled holes

Abutment wall consisted of precast units that were placed adjacent to each other & then post tensioned

All pieces of abutment wall being installed

View of completed abutment wall, showing the four concrete pedestals, used as girder seats and anchor rods

Construction Pad (Not for Bearing) Holes at the top of concrete pedestals were used to grout the cavity

Girder Units Placed

Truck delivering a completed pre-top folded plate girder

Placing Girder Unit over abutments

Placing Girder Unit

Girder Ends

Cast-in-place concrete used for closure pour and concrete diaphragm to complete the construction

From Below

Finished Structure

Finished Roadway

Presentation Outline

1- Introduction to Mass DOT ABC Initiative 2- Introduction to Folded Plate Girder Bridge System 3- Description of the bridge using folded plate by MassDOT- Uxbridge 4- Design Information- Uxbridge 5- Procurement and design process 6- Sequence of fabrication and construction 7- Future MassDOT plans 8- Contact information

MassDOT’s Chief Engineer’s office and its directors emphasize the ABC and use of more pre-fabricated bridge elements in future projects. One of MassDOT’s projects is considering using the next generation of the folded plate, consisting of full depth deck with end wall casted in the plan.

For more information Contact Maury Tayarani

Bridge Project Management Massachusetts Department of Transportation Email: morteza.tayarani@state.ma.usa

Phone: 857-368-9282