CR 30 Roaring Brook Bridge Rehabilitation...CR 30 over Roaring Brook Deck Design • Loads =>...

Concrete Deck Panels with FRP Reinforcement 

CR 30 over Roaring Brook Bridge RehabilitationRehabilitation

CR 30 over Roaring BrookCR 30 over Roaring Brook

I  Introduction

II  Deck design

III ConstructionIII  Construction

IV Food for thoughtIV  Food for thought

CR 30 over Roaring BrookCR 30 over Roaring BrookLocation: Lewis County

CR 30 over Roaring BrookCR 30 over Roaring BrookLocation: Lewis County

Snow Snow 

WindmillsWindmillsWindmills Windmills 

CR 30 over Roaring BrookCR 30 over Roaring Brook

IntroductionIntroduction

Project Background

• C&S => 7 FRP Projects (4 – Lewis)• FHWA IBRD Program• FHWA IBRD Program • Precast panels with FRP Bars• Galvanized steel girders• Galvanized steel girders• County fabricated panels

CR 30 over Roaring BrookCR 30 over Roaring Brook

IntroductionIntroduction

Project Specifics 

• Bridge adjacent to Town facility Town/County cooperation– Town/County cooperation

– Town facility for staging area• Windmill permit loads• Windmill permit loads

CR 30 over Roaring BrookCR 30 over Roaring Brook

Deck DesignDeck Design

Loads > AASHTO LRFD 4th Ed 4 6 2• Loads => AASHTO LRFD 4th Ed. 4.6.2

• Concrete => ACI 440.1R‐06 “Guide for      Design and Const. of Structural  Reinforced Concrete with FRP Bars”

• Details – PCI New England Guidelines

CR 30 over Roaring BrookCR 30 over Roaring Brook

Deck DesignDeck Design

• Non‐composite design • Design deck for strength• Check for serviceability

– Deflection– Crack widthD fl ti d k idth ll• Deflection and crack width usually  control with FRP Bars

CR 30 over Roaring BrookCR 30 over Roaring BrookDeck Details

• Panel width  – Ease of handling– Bridge cross slopeBridge cross slope

• Panel thickness250 mm (10”) thick– 250 mm (10 ) thick 

– 50 mm FRP cover

CR 30 over Roaring BrookCR 30 over Roaring BrookDeck Details

• Transverse FRPTransverse FRP 

– Top => # 8 @ 5” (overhang governs)

B tt # 7 @ 5”– Bottom => # 7 @ 5” 

• Longitudinal FRP– Bottom => # 7 @ 5” 

CR 30 over Roaring BrookCR 30 over Roaring BrookFRP vs. Steel rebar

4 # 8 FRP b 1 # 8 t l (26 7 lb )• 4 # 8 FRP bars = 1 # 8 steel (26.7 lbs)

• FRP cost = 2 ‐ 2.5 times > steel

• FRP tensile strength = 2 times > steel

• FRP EFRP = 20‐25% of ESTEELFRP EFRP  20 25% of ESTEEL

CR 30 over Roaring BrookCR 30 over Roaring Brook

Deck DetailsDeck Details

• Deck continuity• Deck continuity

– Post tensioning 

–Grouted transverse joints

• Deck to girder connection 

– Conventional shear studs 

CR 30 over Roaring BrookCR 30 over Roaring BrookTown Highway FacilityTown Highway Facility

Casting PadCasting Pad

CR 30 over Roaring BrookCR 30 over Roaring Brook

Shear Stud BlockoutShear Stud Blockout PT DuctPT Duct

Bottom FRP BarsBottom FRP Bars

Plastic ChairPlastic ChairPT BlockoutPT Blockout

CR 30 over Roaring BrookCR 30 over Roaring Brook

HP Concrete PlacementHP Concrete Placement

CR 30 over Roaring BrookCR 30 over Roaring Brook

Lifting/LevelingLifting/LevelingLifting/Leveling Lifting/Leveling DeviceDevice

Wet cureWet cure

CR 30 over Roaring BrookCR 30 over Roaring Brook

Steel PreSteel Pre--assemblyassembly

CR 30 over Roaring BrookCR 30 over Roaring Brook

Steel ErectionSteel Erection

CR 30 over Roaring BrookCR 30 over Roaring Brook

Panel SettingPanel Setting

CR 30 over Roaring BrookCR 30 over Roaring BrookLongitudinal Longitudinal JointJoint

Transverse jointsTransverse joints

JointJoint

8 Panels in Place8 Panels in Place

CR 30 over Roaring BrookCR 30 over Roaring Brook

Transverse Joint GroutingTransverse Joint Grouting

CR 30 over Roaring BrookCR 30 over Roaring Brook

Panel PostPanel Post--TensioningTensioning

CR 30 over Roaring BrookCR 30 over Roaring Brook

Shear Stud GroutingShear Stud Grouting

CR 30 over Roaring BrookCR 30 over Roaring Brook

Long. Jt. GroutingLong. Jt. Groutingg gg g

CR 30 over Roaring BrookCR 30 over Roaring Brook

Waterproofing MembraneWaterproofing Membrane

CR 30 over Roaring BrookCR 30 over Roaring Brook

Nov. 14, 2008 50 + degreesNov. 14, 2008 50 + degrees

CR 30 over Roaring BrookCR 30 over Roaring Brook

Lessons LearnedLessons Learned 

• Pick point locationsPick point locations

• Coordinate PT equipment with blockout  sizesize  

• Galv. bars not good for rehab. of  bsubstructures 

CR 30 over Roaring BrookCR 30 over Roaring Brook

Food for thoughtFood for thought

• Design Construction• Design   Construction  

• County built = $ saved 

• Simple & constructible

• Designer was inspector

• Panel Details => Build long lasting

– Life cycle cost savings– Life cycle cost savings 

CR 30 over Roaring BrookCR 30 over Roaring Brook

Special Thanks:Special Thanks:

••Lewis CountyLewis County••NYSDOT NYSDOT –– Reg. 7Reg. 7••FHWAFHWA••FHWAFHWA••Project Mascot Project Mascot ––“Buddy”“Buddy”BuddyBuddy