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ABC Using Full-Depth Precast Concrete Deck Panel Systems
October 28, 2015
Raj Navalurkar, PhD, PEVice President, NYC Metro Area – Surface Transportation GroupAECOMClifton, NJ
James Hamilton, PEProject Engineer, Ohio – Surface Transportation GroupAECOMColumbus, OH
• Cost
• Duration
• Quality
• Most of the time – we settle for 2 of the 3
Challenges / Goals
COST DURATION
QUALITY
Brooklyn Bridge Rehabilitation• Geometry – Fabrication Tolerances
• Quality Control & Quality Assurance
• Innovation – Traffic Monitoring
• Handling Field Conditions – Contingency Plan
Executing on ‘Accelerated Bridge Construction’
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• Minimizing Disruptions to Traffic/Community
• Applying innovative strategies in planning, construction and design
• Sufficient durability to provide required service life
• Employing prefabricated bridge element systems
• Concrete maturity method to expedite bridge reconstruction
• Grout Systems
• Sufficient Seismic Performance
Accelerated/Rapid Bridge Replacement
• The Brooklyn Bridge is a Designated Historic Landmark
• Opened to Traffic in 1883,
• Construction is Scheduled 2009-2014
– Overnight Construction
– Limited Weekend Construction Rehabilitation of Approach Ramps and Seismic Retrofit
• Accelerated Construction ~ 250,000 SF Re-decking
• Widening of Ramps (Ramp A/C, Ramp A/G Merge)
• Overnight and Limited Weekends
• 4,000,000 SF of Repainting
• Structural Repairs to Main Bridge
• Complex MPT and Innovative Staging
– Maintain Traffic at all Times
• Over $500 Million Construction Cost
NYCDOT Brooklyn Bridge
• Rehabilitation of the Approach (Roadway Pavement)
• Rehabilitation of the Manhattan Side Ramp Structures
• Painting of the Ramp Structures and Main Span
• Rehabilitation of Approach Steel Structures
– Select Options – Enhance Life Expectancy
– Selected Options that Minimizes Traffic Impacts
– Reduce Costs and Overall Project Duration
• Improve Safety
• Improve Aesthetics
Brooklyn Bridge Project Overview
• Replace Waterproofing Membrane under the Approach Roadway Pavement
• Replace Reinforced Concrete Decks (Bridges)
• Correct Deterioration of Steel Framing (Bridges)
• Improve Earthquake Resistance
• Maintain Traffic – No 24/7 Closures
• Increase Capacity
– SB FDR Exit Ramp (Widen Ramp A)
– Meter Traffic Flow of NB FDR Exit Ramp
– Improve Traffic Flow at Merge with Main Approach
– Widen Road F (Brooklyn Side)
Project Challenges
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Brooklyn Bridge
• Restrictive Roadway Width
Executing on ‘ABC Requirements’
Pavement Rehabilitation Deck Replacement
Ramp Rehabilitation (Deck Replacement)
Manhattan Approach
Arch Block C (South View)
Arch Block A (South View) Arch Block B (North View) Franklin Square (South View)
Arch Block E (North View) Arch Block D (North View)
Manhattan Approach
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Full Superstructure Replacement (Inadequate Under Clearance & Deficient Structural Rating)
Pavement Rehabilitation
Deck Replacement
Brooklyn Approach
Arch Block I (South View)
Arch Block II (South View)
Arch Block III (North View)
Brooklyn Approach
York Street (South View) Main Street (South View) Washington Street (South View)
Arch Block I (South View) Sands Street (South View)Prospect Street (South View)
Brooklyn Approach
• Provide 2 Lanes – Free Flow
Ramp A Improvements
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FDR Exit 2 Lanes
Ramp Widening(2 Lanes)
Ramp A Improvements
• Provide 2 Lanes – Free Flow
Ramp A Improvements
Road F/FS Improvements
• Provide 2 Lanes – Free FlowAging Roadway
Promenade
Aging Roadway
Brick Arch
Typical Section Through Arch
Fill
Crown of ArchDeteriorated
Closure Walls (Typ)
Failed Membrane System
Approach Roadway Rehabilitation
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Current Conditions
Heaving of Floors
Current Conditions
Deterioration of the Masonry Arches In-fill Walls
Bricks – Arch Block B
“On-site RILEM tests indicate that the initial absorption rates of the bricks are
high, suggesting that continued deterioration as a result of movement of water
and soluble salts through the brick material is likely, which will result in
increased amount of water infiltration into the structure!..”
“X-ray fluorescence and x-ray diffraction analyses confirmed the presence of
soluble salts primarily in the form of Halite, a common roadway de-icing salt
and Gypsum, a byproduct of acidic water and mortar materials. Mortar
Analyses are pending laboratory analyses results!.”
Current Conditions Current Conditions
Floor Beam
Connection Failure
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Approach Roadway Rehabilitation (Precast)
Dowel Bar (Typ)
Precast Concrete Pavement Panel
Precast Option
Sprayed-On
Waterproofing
Membrane
Distribution Channel
Grouting Ports
Existing Concrete Fill Fine Fill (Bedding)
3” Thickness
Approach Roadway Rehabilitation – Unforeseen Conditions
Manhattan Approach – Arch Block Strengthening - Complete Current Conditions
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Ramp and Approach Structures Rehabilitation
Existing Steel Beam
Limits of Deck Removal
Ramp and Approach Structures Rehabilitation
Existing Steel Beam
Limits of Temporary Mabey Bridge Units
Over Filled Steel Grid Deck Deck Replacement – Ramp A
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Ramp A – Precast Decks Maturity Method
Data Loggers Ramp Construction
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York Street Rehabilitation York Street Rehabilitation
York Street Construction York Street Rehabilitation
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• Temporarily Close Brooklyn Bridge West Bound Weekends and Overnight Traffic
• Maintain Brooklyn Bridge East Bound Weekends and Overnight Traffic
• Divert Brooklyn Bridge West Bound Weekend and Overnight Traffic to Manhattan Bridge
• Implement Disincentive and Incentives Clauses (User Cost Based)
Maintenance & Protection of Traffic
• Weekend Closures are Critical, total number 24 (12 EB and 12 WB)
• Weekend Closures, Demolition/Erection Work on the Approach Bridges
– 6 Structures x 2 = 12 (All bridges except Park Row)
• Weekend Closures, Installation of Precast Panels on the Approaches (Concurrent to Bridges)
Requested Closure Hours
Westbound Detours Traffic Studies
Manhattan Side Study Area
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Traffic Studies
Brooklyn Side Study Area NEWARK BAY BRIDGE
REHABILITATION
INTERCHANGE 14
INTERCHANGE 14A
Pier W15
E. Abutment
ZONE 1 – MP N0.00 TO INT. 14A
ZONE 2 – INT. 14A TO INT. 14C
ZONE 3 – INT. 14C TO TERMINUS
Project Location / Zone 1 And Zone 2 Limits
NJTA Casciano Memorial Bridge
• Rehabilitation of 1.5 Miles of Viaduct
– Total Design/Construction Support Services
• Accelerated Construction ~ 500,000 SF of Redecking
• Preliminary Seismic Evaluations
• Tie-Chord Redundancy
• First Time for NJTA to use Precast Panels
• Maintain 4 Lanes of Traffic at all Times
• Over $100 Million Construction Cost
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Scope Of Work
• Major Items
– Deck Reconstruction
– Structural Steel Repairs/Strengthening
– Gusset Plate Retrofitting
– Lighting Improvements
– Drainage Improvements
Girders (General Condition)
Floorbeams (Typical Repair Locations)
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Critical Gusset PlatesGusset Plate Inspection Findings
PANEL POINT
TRUSS LOCATION
PLATE LOCATION ON PLATE
MAXIMUM MISALIGNMENT
[G]
RANGE OF MISALIGNMENT
TYPE OF DEFORMATION
WEST
EDGE 1/2" 12" FREE END
OUTBOARD DIAGONAL
MEMBER 1/2" 48" INTERIOR
EAST
EDGE 1/4" 48" INTERIOR
SW
INBOARD WEST
EDGE 1/4" 48" INTERIOR
EAST
EDGE 1/4" 24" INTERIOR
OUTBOARD WEST
EDGE 1/4" 18" INTERIOR
EAST
EDGE 1/4" 24" INTERIOR
SE
INBOARD WEST
EDGE 1/4" 18" INTERIOR
EAST
EDGE 3/4" 12" FREE END
OUTBOARD VERTICAL
MEMBER 1/4" 24" FREE END
INBOARD EAST
EDGE 1/4" 24" INTERIOR
NE
INBOARD
TOP EDGE
TO
DIAGONAL
1/2" 18" FREE END
OUTBOARD WEST
EDGE 1/2" 24" FREE END
EAST
EDGE 1/4" 24" INTERIOR
L7
NW
INBOARD WEST
EDGE 1/4" 24" INTERIOR
SW INBOARD TOP EDGE 3/8" 8" FREE END
SE OUTBOARD BOTTOM
EDGE 1/4" 24" INTERIOR M7
NE INBOARD TOP EDGE 1/2" 18" FREE END
U2 NW INBOARD WEST
EDGE 1/4" 24" FREE END
U8 NW OUTBOARD BOTTOM
EDGE 3/16" 24" INTERIOR
L11 NE INBOARD TOP EDGE 1/8" 48" INTERIOR
L15 NW INBOARD WEST
EDGE 1/8" 24" INTERIOR
Precast Deck Details Precast Deck Panel Details
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Maximum concrete deck strain at for Scheme C1 Ⅲ for Girder span. (Trucks GVW 55 kips)
Cast-In-Place Precast
S1
S2
S3
S4
S5
S6
S7
S8
S9
S10
S11
S12
New Concrete
-20
0
20
40
60
80
100
120
140
0 20 40 60 80 100 120 140
Deck StrainDeck Strain + IMCracking Strain
Te
ns
ile
Str
ain
(µεµε µεµ
ε)
Distance ( ft)
-20
0
20
40
60
80
100
120
140
0 20 40 60 80 100 120 140
Deck StrainDeck Strain + IMCracking Strain
Te
ns
ile
Str
ain
(µεµε µεµ
ε)
Distance ( ft)
Deck Cracking Studies Precast Deck Benefits
• Minimize the number of shear stud pockets (fatigue and ultimate strength)
– AASHTO 24” Current
– 1941 – limit 3 to 4 deck thickness
– NCHRP Report 48” – No Negative Effects
• HSS Tube Used to Provide Confinement
• No Exposed Pockets
• Eliminate the need for an overlay and waterproofing system
• Eliminate Post Tensioning
Panel to Panel Joints
• Female-to-female joints filled with non-shrink grout provide superior performance compared with match-cast, male-to-female joints
• Sharp corners of the shear key enhance the shear transfer across the joint
• The design criteria for a successful joint detail - no cracks and no water leakage
• Although longitudinal posttensioning, which puts the joint in compression and secures it against leakage, increases the cost of the deck system
Local Post-tensioning
• Hand Held Torque Wrench
• Hair Pin Reinforcement can
be used in lieu of Spiral
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Grout SystemsGrout Types Set 45 Set 45 HW SS Mortar Masterflow
928
Masterflow
648 CP +
Polymer Grout
Description Magnesium
phosphate patching
and repair mortar. It
sets in 15 minutes.
Hot weather,
magnesium
phosphate patching
and repair mortar
High-precision,
high-strength,
cement-based,
metallic aggregate
mortar.
High-precision,
hydraulic-cement
based, mineral
aggregate grout.
High-precision, Plus
is a solvent-free,
high flow epoxy
resin based grout.
High-precision, Polymer grout.
Features - High early strength
at 1 hour
- Superior bonding
- Very low drying
shrinkage -
Resistant to
freeze/thaw, sulfate
and deicing
chemicals
- Superior bonding
- Very low drying
shrinkage
- Resistant to
freeze/thaw, sulfate
and deicing
chemicals
Nonshrink grout
- High flowability,
suitable for
pumping in tight
spaces
- Can be used over
wide range of
temperature
- Nonshrink grout
- Resistant to
freeze/thaw &
sulfates
- High flowability,
suitable for pumping
in tight spaces
- Designed for the
40º F to
90º F range
- Nonshrink grout
- Resistant to
freeze/thaw &
sulfates
- High flowability,
suitable for
pumping in tight
spaces
- Designed for the
55º F to
90º F range.
- Nonshrink grout
- Resistant to freeze/thaw & sulfates
- High flowability, suitable for pumping
in tight spaces
- Designed for the 14º F to
90º F range
Compressive
Strength
1,200 psi @ 6 hours
(36º F)
1,200 psi @ 6 hours
(36º F)
4,000 psi @ 1 day
(70º F)
No data at lower
temperatures
1,000 psi @ 3 days
(70º F)
No data at lower
temperatures
1,300 psi @ 1 day
(55º F)
No data at lower
temperatures
2,500 psi @ 2 hours (15º F)
Flexural Strength 600 psi 600 psi 1,000 psi 1,000 psi 4,600 psi 5,900 psi
Finish Color Dark Brown Dark Brown Dark Brown Dark Gray Dark Gray Concrete Gray
LAFARGE® Ductal Joint Fill Material (UHPC) and the FORT MILLER (PRO-SPEC)
GEORGE WASHINGTON BRIDGE
REHABILITATION
PANY&NJ George Washington Bridge
• In-Depth Inspection and Design Approval Documents• 178th Street and 179th Street Ramps, Bus Ramps
and Turnabout• New Jersey Anchorage and Hudson Terrace• Upper Level Sidewalks Construction Documents for• Rehabilitation• Redecking Alternative• Seismic Evaluations and Retrofitting• Value Engineering• Complex MPT and Innovative Staging
PANY&NJ George Washington Bridge
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• What are the 3 most important Mobility Requirement needed for ABC ?
• What is important when considering Precast Construction?
• What is Maturity Method?
• Why is the 2,500 year return period earthquake used?
• Why was the WB Traffic Detoured?
Questions
Questions and Answers
