NEXT Beam Bridge & Innovative Materials. Darren Conboy, PE & David Massenzio, PE

Transcription

1 NEXT Beam Bridge & Innovative Materials Darren Conboy, PE & David Massenzio, PE

2 Presentation topics Overview of existing & new bridges MATERIAL / DESIGN ELEMENT HUDSON BRIDGE PROJECT USE 10,000 psi Mix Design Seven (7) NEXT 40D Beams Ultra-High Performance Concrete (UHPC) Closure pours between NEXT 40D beam flanges Micropiles with New Casing Steel Support of bridge abutment pile caps 2018 Innovation & Mobility Exchange 2

3 Existing bridge Bridge carried Washington Street over the Assabet River in Hudson, MA. Three-span masonry arch bridge 2018 Innovation & Mobility Exchange 3

4 Existing bridge Significant deterioration Dislodged stones Gunite coating cracks Undermining at abutments Concrete sidewalk deficiencies 2018 Innovation & Mobility Exchange 4

5 Existing bridge 2018 Innovation & Mobility Exchange 5

6 Project constraints/issues Properties located at each corner of bridge Several utilities Limited staging areas at approaches Bridge full closure 105-day duration 2018 Innovation & Mobility Exchange 6

7 New bridge design 2018 Innovation & Mobility Exchange 7

8 New bridge design 2018 Innovation & Mobility Exchange 8

9 Why use NEXT beams? Expedite bridge construction, minimize bridge closure No cast-in-place concrete deck construction Allow pre-piping of utilities Long-term durability with low maintenance 2018 Innovation & Mobility Exchange 9

10 Why use NEXT beams? 2018 Innovation & Mobility Exchange 10

11 NEXT Beams Other Applications 2018 Innovation & Mobility Exchange 11

12 NEXT Beams - Other Applications 2018 Innovation & Mobility Exchange 12

13 Development of project specifications Working group sessions between MassDOT RMS, Gill Engineering & Jacobs Focus of working group sessions: Micropile specification changes 10,000 PSI mix design Ultra-High Performance Concrete (UHPC) Other MassDOT specification updates 2018 Innovation & Mobility Exchange 13

14 Micropile specification changes Micropile specification changes Buy America requirements [23 CFR ] New casing material prime steel versus mill secondary Bid prices with new casing steel Bid prices ranged from $223 to $430 per linear foot of drilled micropiles 2018 Innovation & Mobility Exchange 14

15 Why was a 10,000 PSI concrete mix used? Bridge geometry limitations 85 beam spans Limited beam flange widths High initial concrete compressive strength (8,000 psi) required 2018 Innovation & Mobility Exchange 15

16 10,000 PSI Mix Composition Portland Cement Lafarge, Type HE-1 (720 lb/cy) Fly Ash Class F (25% of total cementitious material weight) Aggregate (3/4 coarse and sand) W:C ratio Chemical Admixtures Air-Entraining Agent Hydration Stabilizer High-Range Water Reducer Shrinkage Reducer Corrosion Inhibitor 2018 Innovation & Mobility Exchange 16

17 Future Use of 10,000 PSI Mix in MA Potentially an available option for precast bridge components with approval of State Bridge Engineer Currently requires mix testing which is expensive NYSDOT experience 2018 Innovation & Mobility Exchange 17

18 Why use UHPC for the Hudson Bridge Project? Rapid-setting material required to expedite opening bridge to traffic Limited closure pour width 14,500 psi compressive strength required Durable closure pour material 2018 Innovation & Mobility Exchange 18

19 What is UHPC? Cementitious composite material W:C ratio < 0.25 Compressive strength > 21.7 ksi Superplasticizer Steel Fibers Pre- and post-cracking tensile strength > 0.72 ksi 2018 Innovation & Mobility Exchange 19

20 UHPC Matrix Conventional Concrete 4,000 psi High Performance Concrete 10,000 psi Ultra High Performance Concrete 21,000 psi Graphics Courtesy of Lafarge 2018 Innovation & Mobility Exchange 20

21 UHPC Closure Joints 2018 Innovation & Mobility Exchange 21

22 Bridge closure pour placement 2018 Innovation & Mobility Exchange 22

23 What are some of the challenges with using UHPC? Currently high material and construction costs compared with conventional concrete Bid prices ranged from $90 to $580 per CF ($2,400 to $15,700 per CY) No local suppliers Limited local familiarity with UHPC material and placement No generic specification Limited design guidelines 2018 Innovation & Mobility Exchange 23

24 How can UHPC be used in the future? Field-Cast UHPC Connections Closure Pours between Precast Beams Closure Pours between Precast Deck Panels Eliminating Post- Tensioning Shear Keys between Butted Box Beams Eliminating Lateral Post- Tensioned Ties 2018 Innovation & Mobility Exchange 24

25 How can UHPC be used in the future? Rehabilitation UHPC Overlays of Deteriorated Concrete Bridge Decks Link Slabs Encasement of Deteriorated Steel Beam Ends Encasement of Deteriorated Concrete Substructures Strengthening of Concrete Substructures 2018 Innovation & Mobility Exchange 25

26 How can UHPC be used in the future? New Members Precast Beams Piles for Brackish Water Applications Approx. 200 Bridges Built in Malaysia with all UHPC Components 2018 Innovation & Mobility Exchange 26

27 Existing and new bridges NEI & MassDOT opened bridge to traffic in 85 days (milestone for full incentive) 2018 Innovation & Mobility Exchange 27

28 Questions? 2018 Innovation & Mobility Exchange 28

29 UHPC Deck Overlays Mar 2018 Report 2018 Innovation & Mobility Exchange 29

30 FHWA UHPC Usage In US & Canada Graphic Courtesy of FHWA 2018 Innovation & Mobility Exchange 30

31 UHPC Premix/Constituents Premix Blend of cement, silica sand, quartz flour and silica fume Large aggregate less than 1 mm Superplasticizer Water W:C ratio less than 0.25 Fibers Steel (structural) Organic (architectural) Slide Content and Graphics Courtesy of Lafarge 2018 Innovation & Mobility Exchange 31

32 UHPC Properties Compressive Strength 20,000 to 33,000 psi Flexural Strength 3,000 to 7,000 psi Ductility Greater capacity to deform and support flexural and tensile loads even after initial cracking Abrasion Resistance similar to natural rock Impermeability Almost no carbonation and penetration of chlorides Slide Content and Graphic Courtesy of Lafarge 2018 Innovation & Mobility Exchange 32

33 Box Girder UHPC Field Connections Graphics Courtesy of Lafarge and Ministry of Transportation of Ohio 2018 Innovation & Mobility Exchange 33

34 UHPC Pier Jacket Hodder Avenue Underpass, ON Graphic Courtesy of Lafarge 2018 Innovation & Mobility Exchange 34

35 UHPC Pier Jacket Hodder Avenue Underpass, ON Graphics Courtesy of Lafarge 2018 Innovation & Mobility Exchange 35

36 UHPC Pier Retrofit Mission Bridge, BC Graphics Courtesy of Lafarge 2018 Innovation & Mobility Exchange 36

37 UHPC Pier Retrofit Mission Bridge, BC Graphic Courtesy of Lafarge 2018 Innovation & Mobility Exchange 37

38 Runway 33L Safety Area 460 ft. Long (11 Spans) 303 ft. Wide (30 NEXT Beams) 139,380 sf. Deck Area 600 ft. x 160 ft. EMAS 2018 Innovation & Mobility Exchange 38

39 MBTA Littleton Station 2018 Innovation & Mobility Exchange 39

40 MBTA Littleton Station 2018 Innovation & Mobility Exchange 40

41 MBTA Littleton Station 2018 Innovation & Mobility Exchange 41