STATE ROUTE 30 OVER BESSEMER AVE. SUPERSTRUCTURE REPLACEMENT IN 57 HOURS

Transcription

1 STATE ROUTE 30 OVER BESSEMER AVE. SUPERSTRUCTURE REPLACEMENT IN 57 HOURS Louis J. Ruzzi P.E., PennDOT District 11-0 Bridge Engineer John Myler, PennDOT Assistant Construction Engineer, District 11-0 Bala Sivakumar, P.E HNTB, Vice President 1

2 Talking Points Quick Facts Lou Ruzzi,PE, District Bridge Engineer, PennDOT District 11-0 (Pittsburgh area) Project Goals Lou Ruzzi,PE Design Highlights Bala Sivikumar, PE (HNTB) Construction Highlights and Lessons Learned John Myler, Assistant Construction Engineer, PennDOT District 11-0 (Pittsburgh area) 2

3 Existing Bridge 3

4 Existing Bridge Location STATE ROUTE 30 over BESSEMER AVE Allegheny County, Pennsylvania 1 4

5 Existing Bridge Aerial 5

6 Project was let on 11/5/2015 with 3 bidders Quick Facts Brayman Construction was the successful low bidder for $2,333,212. Second bidder bid the job for $3,130,000 Third bidder was at $3,209,308 Pre Bid meeting attended by 4 contractors HNTB was the designer Pre-Cast Abutment Caps, steel beam modules with concrete deck/barrier, Ultra High Performance Concrete (UHPC) joints between the modules with a latex placed over the deck, pre- cast approach slabs SR 30 ADT is 21,798 (2015) with 4% trucks 6

7 Detour Route 7

8 Replace the superstructure over a weekend Project Goals Utilize as many precast/pre-fab elements as possible, UHPC and cover the deck with an appropriate overlay(latex) that would last a long time(20 years) Minimize impact to the adjacent property owner Applied many lessons learned from a previous project that was built in 7 days Considered innovative bidding Under-clearance from 13-9 to

9 Design Highlights Use of Pro Team Meeting plus subsequent constructability meetings to limit the number of alternatives Design the bridge as quickly as possible due to the condition of the existing T Beam bridge (falling debris from superstructure and a hole in the deck) 9

10 Existing Bridge Built 1930 Carries State Route 30 over Bessemer Ave. in East Pittsburgh, PA; high traffic volume Concrete T-Beam Superstructure Span = curved alignment Concrete abutments on spread footing. Concrete strengths from 2.5 to 3.6 ksi Under-clearance from Project required a superstructure replacement with substructure rehab in a single weekend 10

11 ABC Design Decisions Accuracy of As-Built Information to confirm fit Choice of ABC method that fits site constraints and 57 hour closure period Urban area; limited ROW; overhead wires Skew, curvature, super-elevation considerations for ABC design Removal and replacement of deteriorated portions of abutment walls Approach slab replacement ABC connections 11

12 LIDAR SURVEY : AS-BUILT BRIDGE MODEL 12

13 As-Built Bridge Model Shows Bridge Elements to be Removed 13

14 ABC Construction Sequence Pre-Weekend Closure Precut and brace abutment walls along frontface Sawcut roadway pavement at ends Repair abutment spalls and cracks 14

15 ABC Construction Sequence Weekend Closure (57 Hours) continued Demolish superstructure, remove approach slabs and excavate backfill Sawcut abutment along backface and remove sections Connect abutments caps with dowels Erect the six superstructure modules with cranes Erect precast sleeper slabs and approach slabs Place accelerated cure UHPC closure pours Reopen to traffic Monday 6 AM 15

16 ABC Construction Sequence Post-Weekend Closure Backfill abutments with flowable fill (approach slabs are designed to support traffic loads) Place and cure rapid set Latex Modified Concrete (LMC) overlay to 1 ¼ depth and sawcut grooves Apply epoxy resin protective coating to abutment surfaces 16

17 Engineer s ABC Schedule Activity Superstructure & approach roadway removals, backfill excavation Duration (hrs) 8 Substructure saw-cutting and removal 6 Install precast abutment caps 8 Install superstructure modules 8 Install approach slabs 4 Place UHPC closure pours 5 Cure time for UHPC 12 Total Duration (ABC) 51 Hrs 17

18 ABC Replacement Using Prefabricated Bridge Elements 54-0 Single Span Composite Steel Modular Superstructure (shop painted) Straight Steel Beams with Variable Overhangs to Accommodate Curvature Accelerated Cure UHPC Closure Pours New Precast Abutment Caps to Address Deterioration and Super-elevation New Precast Approach Slabs 18

19 New Superstructure Cross Section Design Live Load: AASHTO LRFD / PHL-93 OR P-82 (204 Kip PERMIT LOAD) Lightweight Concrete (5 ksi) to minimize lifting weights 19

20 Design Checks for Erection Crane sizes limited by overhead high voltage electrical lines (De-energized during ABC weekend). Lightweight Concrete (117 pcf) to minimize lifting weights Concrete Stresses During Erection: Not to Exceed Modulus of Rupture fr = 7.5*Sqrt(f'ci), Divided by a Safety factor of 1.5. Dead Loads Multiplied by a Factor of Did not control design Lifting locations shown for each element 20

21 3D Model for Design AutoCad Revit Software 3D model of existing bridge using Lidar New elements modeled in 3D and superimposed on existing Virtual assembly of bridge during design Check fitup at each stage of assembly Several dimensional adjustments were made to precast elements to ensure fit 3D renderings shared with Contractor 21

22 New Superstructure Plan Straight beams / modules. Bridge curvature accommodated using overhangs with variable widths 22

23 Removal of Deteriorated Sections 23

24 Precast Abutment Caps Stepped to Match Superelevation 24

25 Precast Cap Elevation Steel shims used to achieve proper seat elevations Gap around shims filled with rapid set grout -- through grout ports in cap 25

26 Replace with Precast Abutment Cap 26

27 27

28 Superstructure Interior Module 28

29 Superstructure Exterior Module Includes Sidewalk and Parapet 29

30 Superstructure Modules Assembly 30

31 Approach Slab Section 31

32 Precast Sleeper Slab 32

33 Abutment Spall and Crack Repairs 33

34 CONSTRUCTION HIGHLIGHTS 34

35 Bridge Demolition Friday 11:15 PM 35

36 Bridge Demolition 36

37 Bridge Demolition Friday 11:45 PM 37

38 Precast Abutment Cap Saturday 1:00 PM 38

39 Precast Abutment Cap 39

40 Precast Abutment Cap Saturday 3:00 PM 40

41 Precast Deck Panel Sunday 12:00 AM M2-79 Ton with Rigging 41

42 Precast Deck Panel Sunday 7:00 AM 42

43 UHPC Placement Sunday 4:00 PM 43

44 UHPC Placement 44

45 New Bridge after 57 Hours 45

46 Approach Slab Flow Fill 46

47 Profile Milling and LMC Prep. Saturday 1:15 AM 47

48 LMC Placement Saturday 6:20 AM 48

49 New Structure and Roadway Sunday 12:00 PM 49

50 New Structure 50

51 Time Lapse Video 51

52 Lessons Learned 1. More time: a. b. Weekend closure duration Additional lead time 2. Improve ability to level precast caps 3. Reduce deck panel weights 4. Discuss straight or hoop reinforcement in the UHPC joint. 5. Water tight seal for UHPC 6. Latex overlay is recommended 7. Is structure dry fit necessary? 8. 3D renderings were very helpful. 52

53 Closing Questions Contact info: Louis J. Ruzzi : lruzzi@pa.gov> John Myler : jmyler@pa.gov Bala Sivakumar : bsivakumar@hntb.com 53