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 over 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 or design stages
Development of Folded Plate Bridge System for ABC application involved conducting more than seven years of 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 of 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 over 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
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