SIBLEY POND DESIGN-BUILD BRIDGE REPLACEMENT ROUTE 2 - PowerPoint PPT Presentation

SIBLEY POND DESIGN-BUILD BRIDGE REPLACEMENT ROUTE 2 CANAAN/PITTSFIELD, MAINE Keith Donington, P.E. October 2012 1

Sibley Pond - Bridge Elevation 2

Bridge Open to Traffic November 2011 3

Bridge Highlights General:  – Design-Build Project – Bridge designed and constructed in 15 months – Opened to traffic in November 2011 more than 10 months ahead of the owner set completion date of October 2012 – First design of PCI’s NEXT D (Northeast Extreme Double Tee Beam) with full depth integral deck – NEXT D and NEXT F were new beam sections developed by PCI New England in response to FHWA’s nationwide initiative for Accelerated Bridge Construction (ABC) – NEXT D - 8 inch full depth integral deck slab – NEXT F - 4 inch form deck w/CIP topping – NEXT D selected as faster to erect, less costly, improved durability, and perceived higher technical score for D/B 4

Bridge Facts Type of Bridge:  – Highway Bridge – Stream/Pond Crossing Structure & Geometry:  – No. of Spans 10 spans arranged in two 5-span continuous units and a single expansion joint located in the center – Continuity Spans continuous for LL and SDL – Span Length 79’ - 0” – Overall Length 790’ - 0” C.L. to C.L. of end abutments – Overall Width 36’ - 0” curb to curb – No. of Traffic Lanes 2 – Alignment /Skew Tangent /0 skew – Longitudinal Grade ± 1.0% with crown at center of bridge 5

Bridge Highlights Design & Construction:  – Designed to AASHTO LRFD Bridge Design Specifications for HL-93 loading for all limit states except for Strength I – LL for Strength I Limit State is MaineDOT Modified Live Load consisting of the standard HL-93 Live Load with 25% increase in the design truck – Bridge designed to 100- year design life per owner’s project requirements 6

Sibley Pond - Site Plan 7

Design Parameters Substructure:  Organic Silt Silty Sand / Silty Clay Silty/Gravely Sand Fine Sand Bedrock Subsurface Profile 8

Pile Driving Steel pipe piles for piers near the  north abutment were driven from the old road during the first winter Remainder of the piles were  driven by leapfrogging the pile driving crane from pier to pier, supported by temporary decking and temporary intermediate steel pile bents Pile Driving Operations 9

Intermediate Pier Bents Elevation of several pier bents Fixed pier bent 10

Design Parameters Superstructure:  11

Design Parameters Superstructure:  12

Design Parameters Longitudinal Joint detail:  13

PCI NEXT D Beam NEXT D Beam in casting bed NEXT D Beam with steel studs 14

PCI NEXT D Beam NEXT D Beam lifted Completed NEXT D Beams from casting bed 15

Beam Erection 4 – 79’ beams/ span erected using  a custom gantry crane PB designed the gantry transverse  support beam system Gantry lifted the beams from the  transporter vehicle parked on the old bridge deck Transporter removed, steel rail  beams inserted Gantry rolled sideways across the  new piers on Hillman Rollers. Beams lowered onto the bearings  Less costly and quicker than 2  crane pick 4 beams erected in an eight-hour  shift turnaround time of 2 days per  span Beam Erection Operations 16

Existing Bridge Conditions 17

Deck View 18

PCI NEXT D Beam Innovations:  Ends of beams - no rebar or - strand projections allowed to clear legs of gantry crane For live load negative moment - continuity over the piers, mechanical couplers were detailed to field splice the splice bars between adjacent beams This layout required the - precaster to align the deck rebars from adjacent beams to tight tolerances Couplers for (-) Moment continuity at intermediate diaphragms 19

PCI NEXT D Beam Innovations:  For positive moment continuity, - a special detail was developed for the bottom reinforcement using a steel end plate with ASTM A706 weldable rebar In shop, steel plate and rebar - assemblies were cast into ends of NEXT D forms In field, following removal of - the gantry rail support system, hooked rebars were field welded to the steel plates Couplers for (+) Moment continuity at intermediate diaphragms 20

Durability – 100yr Life Superstructure:  NEXT D beams were selected by D/B team for best technical score as well as cost – considerations NEXT D has integral deck which is both precast and prestressed – Beams used a HP performance/self-consolidating concrete mix with 5.5 gals/CY calcium – nitrite corrosion inhibitor (DCI) 8,000 psi was specified by design but 10,000 psi concrete was consistently achieved by the – precaster CIP concrete construction was limited to only the curbs, longitudinal closure joints, and pier – continuity diaphragms HPC was also specified for all field-placed concrete along with 5.5 gals/CY of DCI – MMFX rebar specified in exposed bridge curbs and rail transition barriers – Deck protection: HP machine hot applied deck waterproofing with 3 inch minimum asphalt – overlay Only one expansion joint in 790 ft, located at high point, with semi-integral abutments at – ends Substructure:  Concrete filled steel pipe piles are protected with a shop applied fusion bonded epoxy – coating system, extending from the top of the pile to 10 feet (3 meters) below the mud line 21

Acknowledgments  Owner: – Maine Department of Transportation, Augusta, ME  Contractor: – The Lane Construction Corp., Bangor, ME  Engineer/Designer: – Parsons Brinckerhoff, Inc., Manchester, NH/Boston MA  Precaster: J.P. Carrara & Sons, Inc., Middlebury, VT   PCINE 22

Questions? 23