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KEARNEY PRECAST CONCRETE DECK PANEL BRIDGE PROJECT
Presented By
T. Farber, G. Marcous, J. Ridder
37th Annual Concrete Paving Workshop
January 19-20, 2016
Acknowledgements
• Nebraska Department of Roads
• University of Nebraska-Lincoln (UNL)
• Hawkins Construction Company
• CoreSlab Structures Inc.
6
Project Specifics
Prime Contractor: Werner Construction, Inc.
Contract Amount: $26.5 million
Calendar Days to complete project: 776 days
Construction Started: July 2014
Construction Costs for the Bridges
Group 6 ( NU Deck Panel ): $2.6 million
Group 6A ( Cast-in-Place ): $1.6 million
Table of Contents• Background
• Project Description
• Construction Sequence
1. Girder Production
2. Panel Production
3. Girder Placement
4. Panel Placement
5. Transverse Joints Grouting
6. Deck Post-tensioning
7. Haunch & Pockets Grouting
8. Deck Grinding
Background• Why precast concrete deck systems are not commonly
used?– Too many pieces to handle
– Too many joints to grout
– Open channels or pockets need an overlay
– Not fully pre-stressed in both directions
8
Background
• The newly developed precast concrete deck system (2nd
Generation NUDECK) has the following features:1. Full-depth, full-width, 12-ft long panels to minimize CIP transverse joints
2. Covered pockets to eliminate deck overlay
3. 4 ft. spacing between shear connectors to simplify fabrication
4. Prestressed in both directions to enhance durability
9
BB-EB CL: 332 ft
Span:
166 ft
166 ft
Precast:
166.17 ft
166.17 ft
1.33 f t
39 f t
1.33 f t
41.67 f t
7.5
in
3.83 f t
8.5 f t
8.5 f t
8.5 f t
8.5 f t
3.83 f t
1
2
3
4
5
11
NU Deck Panel Description
5 ea. NU1800Girders
13,850 sq.ft.Bridge Deck
Construction Sequence1. Girder Production
2. Panel Production
3. Girder Placement
4. Panel Placement
5. Transverse Joints Grouting
6. Deck Post-tensioning
7. Haunch & Pockets Grouting
8. Deck Grinding
13
4- Panel Placement Progress• Wednesday 07/08 afternoon only 3 panels
• Thursday 07/09 morning only 2 panels
• Monday 07/13 6 panels
• Tuesday 07/14 6 panels
• Wednesday 07/15 6 panels
• Thursday 07/16 5 panels
TOTAL 28 panels
5- Transverse Joint GroutingConcrete
TruckStart Time End Time Quantity No. of Joints Temperature
Deg. FRelative
Humidity %
#1 6:30 am 7:30 am 3 cy 13.5 63 83
#2 8:00 am 8:30 am 2 cy 7.5 65 80
#3 8:45 am 9:15 am 2 cy 6 66 78
Transverse joint concrete mixture had 6 in. initial slump and was vibrated
6- Deck Post-tensioning
Jacking End Movement = 5/16 in. Dead End Movement = ¼ in.
Predicted deck elastic shortening = ½ in.
7- Haunch & End Pocket SCC Grouting
43
H-3 H-3A G-2 J-4 K-5 F-1
4 8,120 7,240 7,480 6,790 7,380 7,860 7,402
7 8,360 7,250 7,690 7,170 7,510 7,870 7,596
28 9,200 9,050 9,170 8,430 8,420 9,030 8,854
Air Content (%) 2.6 3 4.2 4.6 4.6 4.6 3.8
Girder Batch IDAge (day) Average