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Repair of Traffic-Impacted Box Beam Bridge

Repair of Traffic-Impacted Box Beam Bridge. Hawkins Road Crossing Interstate 94 in Michigan. January 1983: Impact Breaks 7 Strands. March 1983: Second Impact Breaks 2 More Strands. The Original Shop Drawings. Repair Approach. Use District Maintenance Crew Repair Each Strand Using

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Repair of Traffic-Impacted Box Beam Bridge

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  1. Repair of Traffic-Impacted Box Beam Bridge Hawkins Road Crossing Interstate 94 in Michigan

  2. January 1983:Impact Breaks 7 Strands

  3. March 1983:Second Impact Breaks 2 More Strands

  4. The Original Shop Drawings

  5. Repair Approach • Use District Maintenance Crew • Repair Each Strand Using • Splice Chuck Coupler • Hex Splice Sleeve and • Two ¾ inch Diameter A449 Rods (one right hand thread and left hand thread on the other to allow tensioning)Hardware cost is about $175 per strand but delivery is a long five months

  6. Splice Chucks

  7. Cutting Damaged Strands

  8. Installing Splice Chucks

  9. Installing Splice Chucks

  10. Drilling for Void Form Attachment

  11. Installing Turnbuckles

  12. Tensioning Rods with Stain Gauges

  13. Installing Tensioning Rods

  14. Strain Gauge

  15. Tensioning Computation • Tensioning allowed for losses that had occurred during the 25 year life of the bridge

  16. Tensioning

  17. Tensioning was accomplished in 4 passes from the inside to the outside of the beam

  18. All Strands Repaired

  19. Deflecting Beams • A preload was used so that the repair-concrete would be in compression after the preload removal

  20. A New Bridge Opening Height

  21. Preparation for Form Attachment

  22. Preparation of Form

  23. Form Release Agent Applied

  24. Form Installation

  25. Creating Vibration Access

  26. Final Deflection Verification

  27. Concrete Delivery

  28. Concrete Quality Control

  29. Concrete Quality Control

  30. Placing of Concrete

  31. Vibration of Concrete

  32. Repair Completed!

  33. Four Months After Completion of First Repair: • Bridge was hit for the third time

  34. Most of the splices done earlier were intact, indicating a durable repair

  35. The damage this time was 19 of the 25 strands of the fascia beam, 7 strands of the first interior beam and 4 strands of the second interior beam. • The repair involved replacement of the fascia beam with a solid concrete beam and repair of the interior beam using the successful approach of the earlier repair.

  36. Post Script • Shortly after the second repair was completed the bridge was hit a fourth time. This time it only suffered a nick in the solid fascia beam.

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