Module 1 What are Prefabricated Bridge Elements & Systems for Accelerated Bridge Construction (ABC/PBES)?

1. Module 1What are Prefabricated Bridge Elements & Systems for Accelerated Bridge Construction (ABC/PBES)? Benjamin Beerman, P.E. Structural Engineer FHWA Resource Center Structures Technical Service Team

2. Introduction - Learning Outcomes • EDC Program: vision and mission for PBES • The reasons for using ABC/PBES • Definitions of PBES • Case studies of PBES • Benefits of PBES • The status of EDC deployment goals for PBES

3. Focus of Every Day Counts Going Greener Shortening Project Delivery Accelerating Deployment Technology and Innovation

4. Shortening Project Delivery • Design-build • Construction Manager/General Contractor • Planning and Environmental Linkages • Legal Sufficiency Enhancements • Expanding Programmatic Agreements • In Lieu Fees and Mitigation Banking • Clarifying the Scope of Preliminary Design • Flexibilities in Right of Way • Flexibilities in Utilities • Enhanced Technical Assistance on EIS Accelerate the Deployment of Technology and Innovation • Safety Edge • Warm Mix Asphalt • Adaptive Single Control • Prefabricated Bridge Elements and Systems • Geosynthetic Reinforced Soil Integrated Bridge

5. How does EDC impact PBES?

6. Reasons for Using ABC/PBES

7. Present & Future Challenges • Aging Infrastructure • Increased traffic volumes • Freight tonnage • Urban capacity • Rising construction costs • $176B to maintain bridges (2005-2024) • $8.8B annually

8. Work Zone Impacts • 6,400 work zones (2003) • 6,157 lane miles closed • 20% capacity reduction

9. More Challenges Ahead • Globalization of manufacturing increases demands on our transportation Intermodal networks • 1 M more truck traffic by 2016 (ATA) • More drivers on highways • Urban Sprawl Continues

10. Congestion Impact • Congestion robs our nation of productivity and quality of life • 4 billion hours/year time delay • 2.9 billion gallons of wasted gas/year • $78.2 billion in 437 urban areas

11. What are Prefabricated Bridge Elements & Systems and how do they Accelerated Bridge Construction projects?

12. Conventional Bridge Construction (CBC) CBC (v): does not seek out methods to significantly reduce onsite construction times.

13. Accelerate Bridge Construction (ABC) ABC (v): The use of innovativeplanning, design, materials, and construction methods to reduce onsite construction and mobility impact times

14. Definition of ABC cont… Onsite construction time: The period of time from when a contractor alters the project site location until all construction-related activity is removed. This includes, but is not limited to, the removal of Maintenance of Traffic, materials, equipment, and personnel. Mobility impact time: Any period of time the traffic flow of the transportation network is reduced due to onsite construction activities. Tier 1: Traffic Impacts within 1 to 24 hours Tier 2: Traffic Impacts within 3 days Tier 3: Traffic Impacts within 2 weeks Tier 4: Traffic Impacts within 3 months Tier 5: Overall project schedule is significantly reduced by months to years

15. Definition of PBES PBES are structural components of a bridge that are built offsite, or adjacent to the alignment, and includes features that reduce the onsite construction time and mobility impact timethat occurs from conventional construction methods.

16. Element vs. System? • Systems • Elements

17. What are PBES? • Elements: single structural component of a bridge • Deck Element • Beam Elements • “Deck” Beam Elements • “Full-Width” Beam Elements • Pier Elements • Abutment & Wall Elements • Miscellaneous Elements

18. Prefabricated DeckElements • Partial depth precast deck panels • Full depth precast deck panels • FRP deck panels • Steel grid decks • Orthotropic decks

19. Prefabricated BeamElements • Deck Beam Elements • Modular beams and deck • Adjacent steel beam with deck • Adj. hybrid composite beams • Adj. deck bulb tee beams • Adj. double tee beams

20. Prefabricated Beam Elements • Full-Width Beam Elements • Truss span without deck • Arch span without deck • Precast segmental const. • Other prefabricated • full-width beams • without deck

21. Prefabricated PierElements • Prefabricated caisson or pile caps • Prefabricated columns • - Concrete • - Steel

22. Prefabricated Abutment & WallElements • Prefabricated versions footings, wingwalls, or backwalls • Partial or full height wall panels

23. Prefabricated MiscellaneousElements • Prefabricated parapets • Precast approach slabs Precast approach slab

24. What are PBES? Systems: - entire superstructure, - entire superstructure & substructure, - total bridge

25. What Success Looks Like:FDOT Graves Ave. over I-4 Bridge Replacement - 2006 143-ft long, 59-ft wide 1,300-ton replacement spans built in adjacent staging area Half-hour rolling roadblocks on I-4 to remove 71-ft long, 30-ft wide, 250-ton spans

26. FDOT Graves Avenue over I-4 Bridge Replacement - 2006 Each new span installed in few hours overnight

27. George P. Coleman Bridge, VA - 1995

28. Wells Street Bridge, Chicago – 2002 111-ft long, 25-ft high, 425-ton truss span installed over a weekend

29. Virginia DOT I-95 Bridge over James River, 2002 102 superstructure spans replaced in 137 nights … … with no lane closures during rush-hour traffic

30. Maryland SHA MD Rt. 24 Bridge over Deer Creek, 2001 122.5-ft long, 33-ft wide historic through-truss bridge 3 days to install FRP deck 10 week bridge closure before school started

31. Baldorioty Castro Ave. – San Juan, Puerto Rico 1992 Two 700-ft and two 900-ft bridges, each installed in 21-36 hrs

32. Badhoevedorp, Netherlands April 2004 International Prefabricated Bridge Scan Superstructure Roll-In: 390-ft Length, 3300 M Tons 2 Hours to Move - 1 Weekend Road Closure

33. SPMTs Install Complete Multiple-Span Railroad Bridge RR Bridge 1309, Nohant le Pin, Normandy 2,200 tons moved using SPMTs

34. Benefits of ABC with PBES Benefits of ABC ABC: Work-zone safety for the traveling public Total project delivery time ABC: Mobility Impacts Onsite construction times Weather-related time delays ABC: Work-zone safety for the traveling public Total project delivery time ABC: Mobility Impacts Onsite construction times Weather-related time delays ABC / PBES improves: Work-zone safety for the traveling public and contractor personnel Material quality and product durability Total project delivery time Site constructability issues ABC / PBES reduces: Mobility Impacts Onsite construction times Weather-related time delays ABC / PBES can minimize: Environmental impacts Impacts to existing roadway alignment Utility relocations and right-of-way take

35. Reduces On-Site Construction Time • Less time spent on-site • Traditional tasks can be done off-site • Minimal impact from weather conditions

36. Minimizes Traffic Impacts • Minimizes traffic delay and community disruption • Reduces detours, lane closures, and narrow lanes I-59 and I-65 Interchange, AL US 59 under Dunlavy, TX

37. Minimizes environmental impacts Robin Hood Bridge, WV • Permitting • ROW take • Utility relocation • Temporary Alignment • MOT

38. Improves Work Zone Safety • Minimizes work near traffic and power lines, at high elevations, or over water. Meylan Pedestrian Bridge, France

39. Improves SiteConstructability Remote Locations 150’ + Limited Construction Season • Prefabricated elements & Systems • Minimal impact from environmental constraints • Relieves constructability pressure. San Mateo-Hayward Bridge, CA

40. Increases quality • Prefabricated in a Controlled environment • Increases quality control • Improved life cycle costs

41. Paradigm Shift PBES becomes the standardmethod of bridge construction, and the use conventional construction methods - such as on-site CIP operations, are used in a limited manner.

42. Performance Measures for PBES under the EDC Initiative

43. State-of-the-Practice in the past? • 40 States: 1 or more projects • 3 States: 20+ projects • 11 States actively pursuing as standard practice • Opportunity for much greater PBES deployment

44. State-of-the-Practice in the past?

45. Pursuing PBES for EDC

46. Current Status

47. What is being selected

48. Deployment Goals • By December 2012, 100 cumulative bridges have been designed and/or constructed rapidly using PBES. • By December 2012, 25 percentof single- or multi-span replacement bridges authorized using Federal-aid have at least one major prefabricated bridge element that shortens onsite construction time relative to conventional construction. • By June 2012, 40 States adopt PBES decision making framework in their design process

49. Fully Implemented More than 20 bridges have been designed and/or constructed using PBES in the past 3 years and a decision making framework that considers the use of PBES is incorporated in the design process.

50. Module Conclusions • EDC Program: vision and mission for PBES • The reasons for using ABC/PBES • Definitions of PBES • Case studies of PBES • Benefits of PBES • The status of EDC deployment goals for PBES