Comparative Study of Precast Super Girder vs.

Cast-in-Place Box
15th Annual Caltrans/PCMAC Bridge Seminar Jay Holombo, PBS&J Maher Tadros, PBS&J & UNL Sami Megally, PBS&J

Acknowledgements
Funded by PCMAC Caltrans Technology Committee Producer and Industry Members University of Nebraska, Lincoln (UNL)

Outline
1. 2. 3. 4. 5. 6. Design Example Layout Super Girder Design Threaded Rod Continuity Bent Details Seismic Continuity Cost and Schedule

Layout

Layout

Flexural pin

Layout

Approach Slab Integral

Layout Summary Span = 175 ft D/S = 0.04 Girder spacing = 12 ft (1.7 D) Integral abutments Seismic continuity at piers

Super Girder
Up to 70 strands WWR Long span capability Can be P/T

220

200

72 in. Super Girder

72 in. Super Girder with Threaded Rod

180 170 ft Span

Span length (ft)

160

72 in. Bulb-Tee 140

120

100 6 7 8 9
Girder spacing (ft)

10

10.7 ft

11

12

10

FDOT Adopts New I-Beam

11

Super Girder

12

Super Girder

13

14

First Bridge: Pacific Street Bridge over I-680, Omaha, NE 10 NU900 girders spaced 10 ft -8 in
30-0.7 in straight strands spaced 2 in horizontally and 2.5 in vertically. Two spans 98 ft each with TR continuity Opened to traffic in August 2008 D/S = 0.038

15

Type Selection

16

Threaded Rod Continuity

17

Threaded Rod Continuity Internal

18

Threaded Rod Continuity - External

19

Threaded Rod Validation Testing

20

Threaded Rod Continuity

21

Deck Weight Only

6000 5000 Moment resistance fs = 54 ksi ld = 5 ft

4000

3000

2000 Moment (k-ft)

1000

0 0 -1000 20 40 60 80 100 120 140 160 180 Distance from CL Bent (ft)

-2000 Deck weight moment demand -3000

22
-4000

Service III Moments

10000

5000

Threaded Rod Non-Continuous

Moment (k-ft)

0 0 -5000 20 40 60 80 100 120 140 160 180

-10000

-15000

10% Difference
23

Bent Cap

24

Bent Cap

25

Bent Cap

26

Bent Cap
Shear friction transfer = 1.0 Vu = 930 kip (Strength II)

P/S strand

Vn = 0.85(1.0)(15.8(120)+12.7(60)+2.6(243)) = 2800 kip

Rods Deck reinf.

27

Seismic Connection
Experimental results: unstressed strands UCSD 1998 (SSRP 98/05) Missouri U. 1974 (Salmons, FHWA 72-2) U. Nebraska 2002 (Tadros et al, PCI Journal, 2002)

28

29

30

UCSD

31

Missouri U.

32

U. Missouri

33

U. Nebraska

34

Cost Analysis

35

CIP Box Alternative

36

Super Girder Unit Prices PRICE ($) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 STRUCTURE EXCAVATION (BRIDGE) STRUCTURE BACKFILL (BRIDGE) FURNISH CONCRETE PILING (ABUTMENT) DRIVE CONCRETE PILING (ABUTMENT) FURNISH CONCRETE PILING (BENT) DRIVE CONCRETE PILING (BENTS) FURNISH PC/PS CONCRETE SG I-GIRDERS ERECT PC/PS CONCRETE GIRDERS STRUCTURAL CONCRETE, BRIDGE STRUCTURAL CONCRETE, BRIDGE (FOOTING) STRUCTURAL CONCRETE, APPROACH SLAB BAR REINFORCING STEEL (BRIDGE) CONCRETE BARRIER JOINT SEAL HS RODS 37 70 150 50 2000 60 2500 58000 10000 600 450 620 1 150 100 10.5 UNIT CY CY LF EA LF EA EA EA CY CY CY LB LF LF LF

CIP Box Girder Unit Prices PRICE ($) 1 2 3 4 5 6 7 8 9 10 11 12 13 STRUCTURE EXCAVATION (BRIDGE) STRUCTURE BACKFILL (BRIDGE) FURNISH CONCRETE PILING (ABUTMENT) INSTALL CONCRETE PILING (ABUTMENT) FURNISH CONCRETE PILING (BENT) DRIVE CONCRETE PILING (BENTS) STRUCTURAL CONCRETE, BRIDGE STRUCTURAL CONCRETE, BRIDGE (FOOTING) STRUCTURAL CONCRETE, APPROACH SLAB BAR REINFORCING STEEL (BRIDGE) PRESTRESSING, CAST-IN-PLACE CONCRETE BARRIER JOINT SEAL 70 150 50 2000 60 2500 700 450 620 1 2 150 100 UNIT CY CY LF EA LF EA CY CY CY LB LB LF LF

38

Cost Comparison by Component

Item Superstructure Substructure Other* Total

Super G $2,034,000 $770,000 $398,000 $3,202,000

CIP Box $2,515,000 $1,055,000 $304,000 $3,874,000

CIP/Super G 1.24 1.37 0.76 1.21

*Includes approach slab, concrete barriers and joint seal

39

40

Summary
Super Girder HPC Wide range of application D/S ratios equivalent to CIP Box Monolithic seismic connections Significant cost and schedule savings

41

Where to next?
Develop cost-effective standards Contract flexibility Workshops with GEC Precast full-depth deck

42

43

44

45

46

 Completed deck Requires grinding Improved durability

47

NU 2800 (9.25 ft) 213 ft Shipped in Calgary

48