Make Every day count Accelerating Bridge Construction with Prefabricated Bridge Elements & Systems

1. Make Every day countAccelerating Bridge Construction with Prefabricated Bridge Elements & Systems

2. Every Day Counts Mission • To identify and deploy readily available innovation and operational changes that will make a difference, incorporating a strong sense of urgency. • To identify policy or operational changes required to advance system innovation in the longer term.

3. Core Elements Every Day Counts core elements: • Shortening Project Delivery • Accelerating Technology and Innovation Deployment • Going Greener

4. Shortening Project Delivery • Accelerating Project Delivery Methods • Design-build • Construction Manager/General Contractor • Shortening Project Delivery Toolkit • Planning & Environmental Linkages • Legal Sufficiency Enhancements • Expanding Use of Programmatic Agreements • Use of In–Lieu Fee and Mitigation Banking • Clarifying the Scope of Preliminary Design • Flexibilities in ROW • Flexibilities in Utility Relocation • Enhanced Technical Assistance on Stalled EISs

5. Project Delivery Methods Design-Bid-Build CM/GC Design-Build

6. Technology & Innovation • Adaptive Signal Control • Geosynthetic Reinforced Soil Integrated Bridge System • Prefabricated Bridge Elements & Systems • Safety Edge • Warm-Mix Asphalt

7. Technology & Innovation GeosyntheticReinforced Soil • Fast, cost-effective bridge support method using alternating layers of compacted fill and sheets of geotextile reinforcement to provide bridge support. • Lots of Benefits: • Eliminates approach slab or construction joint at the bridge-to-road interface • Reduced construction time (complete in10 days) • 25 - 60 % less cost depending on standard of construction • Less dependent on weather conditions • Flexible design – easily modified for unforeseen site conditions • Easier to maintain because of fewer parts • Built with common equipment and materials

8. PBES Technology Orientation • PBES vision, mission, concepts, & components • The reasons for using PBES • The major benefits of PBES • The status of PBES deployment • PBES performance goals for the U.S.

9. Accelerated Bridge Construction Components Foundation & Wall Elements Continuous Flight Auger Piles Geosynthetic Reinforced Soil (GRS) Integrated Bridge System Rapid Embankment Construction EPS Geofoam • Prefabricated Bridge Elements & Systems • Prefabricated Elements •   Superstructure • Substructure • Prefabricated Systems • Superstructure • Substructure • Total Bridge Structural Placement Methods Self-Propelled Modular Transporters (SPMTs) Longitudinal   launching Horizontal sliding or skidding Other heavy lifting equipment & methods Conventional lifting equipment & methods Fast Track Contracting Innovative Contracting - Best value - CMGC method - Design Build - A+B - A+B+C - Warranties

10. Definition of PBES PBES consists of bridge structural elements & systems that are built off the bridge alignment to accelerate onsite construction time relative to conventional practice.

11. What is PBES? Moving more cast-in-place construction to off-site location

12. How does PBES accelerate bridge construction? Building the bridge first before you set cones, then quickly move it into place – like in hours or a weekend!

13. What is PBES? • Elements • Deck Panels: Partial & Full-Depth • Beams: More Efficient Shapes • Pier Caps, Columns, & Footings • Abutment Walls, Wing Walls, & Footings • Systems • Superstructure • Substructures • Total Bridge

14. How do we accomplish this?Structural Placement Methods • Self-Propelled Modular Transporters (SPMTs) • Longitudinal launching • Horizontal sliding or skidding • Other heavy lifting equipment & methods • Conventional lifting equipment & methods

15. CONTINUOUS LAUNCHING

16. Fort Lane/I-15South Layton Interchange Longitudinal Launching Utah

17. Fort Lane/I-15South Layton Interchange

18. TRANSVERSE LAUNCHING

19. I-80 EBL / 2300E Easy Site I-80 WBL / 2300E Difficult Site Conditions Transverse Sliding

20. 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

21. FDOT Graves Avenue over I-4 Bridge Replacement - 2006 Each new span installed in few hours overnight I-4 closed two partial nights for installations

22. George P. Coleman Bridge, VA - 1995

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

25. Maryland SHA MD Rt. 24 Bridgeover 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

26. Wells Street Bridge, Chicago – 2002 Even Good for Railroad/Transit Bridges 111-ft long, 25-ft high, 425-ton truss span installed over a weekend

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

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

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

30. Benefits of Using ABC/PBES This process offers significant advantages over on-site construction, resulting in: • Reduced onsite construction time • Minimized traffic disruption – months to days • Reduced Environmental impact • Improved work zone & worker safety • Positive Cost-Benefit ratios when user costs are considered • Improved product quality – controlled environment, cure times, easier access, etc.

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

32. 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

33. Minimizes environmental impact • Keep heavy equipments out of sensitive environment Linn Cove Viaduct, NC

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

35. Improves Constructability • Prefabricated elements & Systems • Minimal impact from environmental constraints • Relieves constructability pressure. San Mateo-Hayward Bridge, CA

36. Increases quality • Prefabricated in a Controlled environment • Increases quality control George P. Coleman Bridge, VA

37. PBES: Improves Quality & Lowers Life-Cycle Costs – to “Stay Out” • Controlled environment • Reduced dependence on weather • Established materials suppliers for consistent quality of materials • Standardized plant operations for consistent quality of production • Optimum concrete curing

38. IsPBES more cost-effective? Yes, in many cases. • It depends on type of structure and elements or systems used. • Many systems can cost less than conventional construction like adjacent slab or box girders. • First implementation of new elements may cost more. • Need a program of projects--economy of scale. • Life cycle cost analysis is favorable to PBES and provides a positive Cost-Benefit Ratio when user costs are considered.

39. Declining Cost of Deploying Innovative Technology First time costs more < Potential for new methods to cost less < Promise of time savings < Positive cost-benefit ratios < Promise of programmatic cost savings

40. Costs of PBES

41. Costs of PBES

42. State-of-the-Practice? • Senior management is committed to • Every Day Counts technology deployments • 40+ States: 1 or more projects • 7 States: 20+ projects • 11 States actively pursuing as standard practice • Opportunity for much greater PBES deployment

44. FHWA PBES Deployment Goals for U.S. • By December 2012, 100 cumulative bridges have been designed and/or constructed rapidly using PBES. • By December 2012, 25 percent of 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.

45. Why Use PBES Technologies? • It offers Major Advantages: • Faster (offsite & off critical path) • Safer (public, construction & inspection) • Better Quality (controlled environment) • Positive Cost-Benefit Ratios when user costs are considered.

46. Questions? FHWA Contacts: PBES Innovation Team • Claude Napier, Team Leadclaude.napier@dot.gov • Louis Triandafilou, Team Leader, TFHRC Bridge & Foundation Engineering Team lou.triandafilou@dot.gov • FHWA Resource Center Structures Technical Service Team • Website Link • http://www.fhwa.dot.gov/everydaycounts/index.cfm

47. Make Every day countAccelerating Bridge Construction with Prefabricated Bridge Elements & Systems