MAKE EVERY DAY COUNT
ACCELERATING BRIDGE CONSTRUCTION WITH
PREFABRICATED BRIDGE ELEMENTS & SYSTEMS
Every Day Counts Mission
• To identify and deploy readily available
innovation and operational changes that will
make a difference, incorporating a strong
sense of urgency.
• To identify policy or operational changes
required to advance system innovation in the
longer term.
Core Elements
Every Day Counts core elements:
• Shortening Project Delivery
• Accelerating Technology and Innovation
Deployment
• Going Greener
Shortening Project Delivery
• Accelerating Project Delivery Methods
– Design-build
– Construction Manager/General Contractor
• Shortening Project Delivery Toolkit
– Planning & Environmental Linkages
– Legal Sufficiency Enhancements
– Expanding Use of Programmatic Agreements
– Use of In–Lieu Fee and Mitigation Banking
– Clarifying the Scope of Preliminary Design
– Flexibilities in ROW
– Flexibilities in Utility Relocation
– Enhanced Technical Assistance on Stalled EISs
Project Delivery Methods
Owner
Designerof-Record
DesignBid-Build
Constructor/
GC
Owner
Design
Subs
CM/GC
Trade
Subs
Designerof-Record
CM/GC
Design
Subs
Trade
Subs
Owner
DesignBuilder
Designerof-Record
DesignBuild
Trade
Subs
Design
Subs
5
Technology & Innovation
• Adaptive Signal Control
• Geosynthetic Reinforced Soil Integrated Bridge
System
• Prefabricated Bridge Elements & Systems
• Safety Edge
• Warm-Mix Asphalt
Technology & Innovation
Geosynthetic Reinforced Soil
Fast, cost-effective bridge support method using alternating
layers of compacted fill and sheets of geotextile reinforcement
to provide bridge support.
Lots of Benefits:
• Eliminates approach slab or construction
joint at the bridge-to-road interface
• Reduced construction time (complete in10 days)
• 25 - 60 % less cost depending on standard of
construction
• Less dependent on weather conditions
• Flexible design – easily modified for unforeseen
site conditions
• Easier to maintain because of fewer parts
• Built with common equipment and materials
PBES Technology Orientation
•
•
•
•
•
PBES vision, mission, concepts, & components
The reasons for using PBES
The major benefits of PBES
The status of PBES deployment
PBES performance goals for the U.S.
Accelerated Bridge Construction Components
Foundation &
Wall Elements
Continuous
Flight Auger
Piles
Geosynthetic
Reinforced Soil
(GRS)
Integrated
Bridge System
Rapid
Embankment
Construction
EPS Geofoam
Prefabricated
Bridge
Elements &
Systems
Structural Placement
Methods
Self-Propelled Modular
Transporters (SPMTs)
Prefabricated
Elements
- Superstructure
- Substructure
Prefabricated
Systems
- Superstructure
- Substructure
- Total Bridge
Longitudinal
launching
Horizontal sliding or
skidding
Other heavy
lifting equipment &
methods
Conventional lifting
equipment & methods
Fast
Track
Contracting
Innovative
Contracting
- Best value
- CMGC method
- Design Build
- A+B
- A+B+C
- Warranties
Definition of PBES
PBES consists of bridge structural
elements & systems that are built off the
bridge alignment to accelerate onsite
construction time relative to conventional
practice.
What is PBES?
Moving more cast-in-place construction
to off-site location
How does PBES
accelerate bridge construction?
Building the
bridge first
before you
set cones,
then quickly
move it into
place – like
in hours or
a weekend!
What is PBES?
• Systems
• Elements
– Superstructure
– Deck Panels: Partial & Full-Depth
– Beams: More Efficient Shapes
– Substructures
– Pier Caps, Columns, & Footings
– Abutment Walls, Wing Walls, & Footings
– Total Bridge
How do we accomplish this?
Structural Placement Methods
•
•
•
•
•
Self-Propelled Modular Transporters (SPMTs)
Longitudinal launching
Horizontal sliding or skidding
Other heavy lifting equipment & methods
Conventional lifting equipment & methods
CONTINUOUS LAUNCHING
15
Fort Lane/I-15
South Layton Interchange
Longitudinal Launching
Utah
Fort Lane/I-15
South Layton Interchange
TRANSVERSE LAUNCHING
18
I-80 EBL / 2300E
Easy Site
I-80 WBL / 2300E
Difficult Site
Conditions
Transverse Sliding
What Success Looks Like:
FDOT Graves Ave. over I-4 Bridge Replacement - 2006
143-ft long, 59-ft wide
1,300-ton replacement spans
built in adjacent staging area
Half-hour rolling roadblocks
on I-4 to remove
71-ft long, 30-ft wide, 250-ton spans
FDOT Graves Avenue over
I-4 Bridge Replacement - 2006
Each new span
installed in few
hours overnight
I-4 closed two partial nights
for installations
George P. Coleman Bridge, VA - 1995
Virginia DOT I-95 Bridge
over James River, 2002
102 superstructure spans replaced
in 137 nights …
… with no lane closures during
rush-hour traffic
Maryland SHA MD Rt. 24 Bridge
over Deer Creek, 2001
122.5-ft long, 33-ft wide historic
through-truss bridge
3 days
to install
FRP deck!
10 week bridge closure
before school started
Even Good for Railroad/Transit Bridges
Wells Street Bridge, Chicago – 2002
111-ft long, 25-ft high,
425-ton truss span installed over a weekend
Baldorioty Castro Ave. –
San Juan, Puerto Rico 1992
Two 700-ft and two 900-ft bridges,
each installed in 21-36 hrs
Badhoevedorp, Netherlands
Superstructure Roll-In:
390-ft Length, 3300 M Tons
2 Hours to Move - 1 Weekend Road Closure
April 2004
Prefabricated
Bridges
International
Scan
SPMTs Install Complete
Multiple-Span Railroad Bridge
RR Bridge 1309, Nohant le Pin, Normandy
2,200 tons moved using SPMTs!
Benefits of Using ABC/PBES
This process offers significant advantages over on-site
construction, resulting in:
•
•
•
•
•
Reduced onsite construction time
Minimized traffic disruption – months to days
Reduced Environmental impact
Improved work zone & worker safety
Positive Cost-Benefit ratios when user costs are
considered
• Improved product quality – controlled
environment, cure times, easier access, etc.
Reduces On-Site
Construction Time
• Less time spent on-site
• Traditional tasks can be
done off-site
• Minimal impact from
weather conditions
Minimizes Traffic Impacts
• Minimizes traffic delay
and community
disruption
I-59 and I-65 Interchange, AL
US 59 under Dunlavy, TX
• Reduces detours, lane
closures, and narrow lanes
Minimizes
environmental impact
• Keep heavy
equipments out of
sensitive
environment
Linn Cove Viaduct, NC
Improves
Work Zone Safety
• Minimizes work
near traffic and
power lines,
at high elevations,
or over water.
Meylan Pedestrian Bridge, France
Improves
Constructability
• Prefabricated
elements & Systems
– Minimal impact from
environmental
constraints
– Relieves
constructability
pressure.
San Mateo-Hayward Bridge, CA
Increases quality
• Prefabricated in a
Controlled environment
• Increases quality control
George P. Coleman Bridge, VA
PBES: Improves Quality &
Lowers Life-Cycle Costs – to “Stay Out”
• Controlled environment
– Reduced dependence on weather
– Established materials suppliers for consistent
quality of materials
– Standardized plant operations for consistent
quality of production
– Optimum concrete curing
Is PBES more cost-effective?
Yes, in many cases.
• It depends on type of structure and elements or
systems used.
• Many systems can cost less than conventional
construction like adjacent slab or box girders.
• First implementation of new elements may cost more.
• Need a program of projects--economy of scale.
• Life cycle cost analysis is favorable to PBES and
provides a positive Cost-Benefit Ratio when user
costs are considered.
Declining Cost of
Deploying Innovative
Technology
First time costs more
< Potential for new
methods to cost less
< Promise of time savings
< Positive cost-benefit ratios
< Promise of programmatic cost savings
Costs of PBES
Costs of PBES
State-of-the-Practice?
• Senior management is committed to
Every Day Counts technology deployments
• 40+ States: 1 or more projects
• 7 States: 20+ projects
• 11 States actively pursuing as standard
practice
• Opportunity for much greater PBES
deployment
FHWA PBES Deployment Goals for U.S.
• By December 2012, 100 cumulative bridges have
been designed and/or constructed rapidly using
PBES.
• By December 2012, 25 percent of single- or multispan replacement bridges authorized using Federalaid have at least one major prefabricated bridge
element that shortens onsite construction time
relative to conventional construction.
Why Use PBES Technologies?
It offers Major Advantages:
+ Faster (offsite & off critical path)
+ Safer (public, construction & inspection)
+ Better Quality (controlled environment)
+ Positive Cost-Benefit Ratios when user
costs are considered.
Questions?
FHWA Contacts:
PBES Innovation Team
• Claude Napier, Team Lead
claude.napier@dot.gov
• Louis Triandafilou, Team Leader, TFHRC Bridge &
Foundation Engineering Team
lou.triandafilou@dot.gov
• FHWA Resource Center
Structures Technical Service Team
• Website Link
•http://www.fhwa.dot.gov/everydaycounts/index.cfm
MAKE EVERY DAY COUNT
ACCELERATING BRIDGE CONSTRUCTION WITH
PREFABRICATED BRIDGE ELEMENTS & SYSTEMS