2007-12 U Girder Colorado Dylgo

8/10/2019 2007-12 U Girder Colorado Dylgo

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Design and Construction of CurvedDesign and Construction of Curved

Precast Girder Bridge Projects in ColoradoPrecast Girder Bridge Projects in Colorado


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Current Colorado ProjectsCurrent Colorado Projectsusing Curved Precast Girdersusing Curved Precast Girders

1.1. IH25 / SH270 Ramp K, DenverIH25 / SH270 Ramp K, Denver

2.2. SH270 / IH76 Ramp Y, DenverSH270 / IH76 Ramp Y, Denver

3.3. E470 / IH70, Ramp H, DenverE470 / IH70, Ramp H, Denver4.4. SH58 / IH70, Ramp A, GoldenSH58 / IH70, Ramp A, Golden

5.5. Austin Bluffs Overpass, ColoradoAustin Bluffs Overpass, Colorado

SpringsSprings

6.6. IH25 Viaduct, TrinidadIH25 Viaduct, Trinidad


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Curved Girder Bridge QuantitiesCurved Girder Bridge Quantities

Project Bridge S.F.L.F. Curved

Precast

IH25 / SH270 Ramp K 66,740 s.f. 2,840 l.f.

IH76 / SH270 Ramp Y 77,248 s.f. 4,544 l.f.

IH70 / SH58 Ramp A 79,995 s.f. 4,095 l.f.

Austin Bluffs 57,715 s.f. 2,380 l.f.

IH25 Trinidad 65,728 s.f. 4,141 l.f.

IH70 / E470 Ramp H 75,952 s.f. 3,232 l.f.

Total 414,378 s.f. 21,232 l.f.


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270 Ramp K270 Ramp K

The first of manyThe first of manyContractor Alternate Design to Steel Base BidContractor Alternate Design to Steel Base Bid

Plant Manufactured Precast Girders and Panels.Plant Manufactured Precast Girders and Panels.Limited Time Line for final Design / ApprovalLimited Time Line for final Design / Approval(4 months)(4 months)

Involved Close Cooperation Between DOT,Involved Close Cooperation Between DOT,Engineer, Sub Contractors and ContractorEngineer, Sub Contractors and ContractorDesigned by Summit Engineering, Littleton, CODesigned by Summit Engineering, Littleton, CO

and PBS&J, Denverand PBS&J, DenverBuilt byBuilt by SemaSema ConstructionConstruction


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E470 Ramp HE470 Ramp HContractor Design/Build Project.Contractor Design/Build Project.

Currently Under Construction.Currently Under Construction.Connector Ramp from E470 Toll Road toConnector Ramp from E470 Toll Road toInterstate 70.Interstate 70.

Combination of Simple Span and shoredCombination of Simple Span and shoredconstruction. Spans from 100 to 200 construction. Spans from 100 to 200 3434 U84 Girders, 11 SpansU84 Girders, 11 Spans

1200 Horizontal Curvature1200 Horizontal CurvatureDesigned by DMJM Harris, DenverDesigned by DMJM Harris, DenverBuilt by Lawrence Construction Co, Littleton, COBuilt by Lawrence Construction Co, Littleton, CO


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270 Ramp Y270 Ramp YUnder Construction.Under Construction.

Flyover Connector from EB SH270 to EBFlyover Connector from EB SH270 to EBInterstate 76.Interstate 76.40 Precast Girders, 12 Spans.40 Precast Girders, 12 Spans.

Span Lengths from 100 to 230.Span Lengths from 100 to 230.Numerous traffic crossings and creek crossing.Numerous traffic crossings and creek crossing.760 Radius horizontal curve.760 Radius horizontal curve.

Colorado DOT Design.Colorado DOT Design.Value Engineering by Summit EngineeringValue Engineering by Summit EngineeringEdward Kraemer & Sons, Castle Rock COEdward Kraemer & Sons, Castle Rock CO


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Ramp Y, Unit 2 Erected over IH76 & SH76Ramp Y, Unit 2 Erected over IH76 & SH76


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Falsework Bents Adjacent to IH76 TrafficFalsework Bents Adjacent to IH76 Traffic


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SH 58 Ramp ASH 58 Ramp AUnder VE Design and Construction.Under VE Design and Construction.

Flyover Connector from EB Interstate 70 to WBFlyover Connector from EB Interstate 70 to WBSH 58 into Golden.SH 58 into Golden.3838 -- U86 Precast Girders, 11 Spans.U86 Precast Girders, 11 Spans.

Span Lengths from 150 to 235.Span Lengths from 150 to 235.820 Horizontal Curvature.820 Horizontal Curvature.Numerous traffic crossings and creek crossing.Numerous traffic crossings and creek crossing.

CH2M Hill Design.CH2M Hill Design.Value Engineering by Summit EngineeringValue Engineering by Summit EngineeringAmes Construction Co, Denver, COAmes Construction Co, Denver, CO


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SH 58 Ramp ASH 58 Ramp A

Erection to begin November 2007Erection to begin November 2007


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Austin Bluffs Overpass Austin Bluffs OverpassUnder Construction.Under Construction.2424 -- U85 Precast Girders, Dual Bridges, 4 Spans.U85 Precast Girders, Dual Bridges, 4 Spans.Span Lengths from 110 to 210.Span Lengths from 110 to 210.950 Radius Curve in two spans.950 Radius Curve in two spans.Major Urban traffic crossing and creek crossing.Major Urban traffic crossing and creek crossing.CH2M Hill Design.CH2M Hill Design.Value Engineering by Summit EngineeringValue Engineering by Summit Engineering

Lawrence Construction Co, Littleton, COLawrence Construction Co, Littleton, CO


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Austin Bluffs Austin Bluffs


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IH25 Viaduct, TrinidadIH25 Viaduct, TrinidadContractor Alternate Design and Construction.Contractor Alternate Design and Construction.Early stages of construction.Early stages of construction.

Elevated Viaduct through downtown Trinidad. 24Elevated Viaduct through downtown Trinidad. 24-- U85 Precast Girders, Dual Bridges, 4 Spans.U85 Precast Girders, Dual Bridges, 4 Spans.Span Lengths from 100 to 265.Span Lengths from 100 to 265.

Major Urban project with numerous traffic, riverMajor Urban project with numerous traffic, riverand railroad crossings.and railroad crossings.Base design, precast segmental.Base design, precast segmental.

Value Engineering by TSH Engineers and SummitValue Engineering by TSH Engineers and SummitEngineeringEngineeringLawrence Construction Co, Littleton, COLawrence Construction Co, Littleton, CO

se recast oncrete or t esese recas oncre e or ese


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y use recast oncrete or t esey use recas oncre e or eseTypes of Bridges?Types of Bridges?

Colorado Preference for Concrete Structures.Colorado Preference for Concrete Structures.Setup Costs were nominal.Setup Costs were nominal.Concrete Alternate less expensive.Concrete Alternate less expensive.Speed of Fabrication.Speed of Fabrication.Design Impact not significant.Design Impact not significant.Composite construction, splicing and postComposite construction, splicing and posttensioning girders extends the span rangetensioning girders extends the span rangeShoring not required over traffic.Shoring not required over traffic.Design used established techniques on newDesign used established techniques on newapplication.application.Attractive appearance.Attractive appearance.


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Why use U Girders?Why use U Girders?

Very Robust Cross Section.Very Robust Cross Section.

Less Girders for a given deck width.Less Girders for a given deck width.Flexible shape to modify.Flexible shape to modify.

Attractive Aesthetics.Attractive Aesthetics.Easier to route post tensioningEasier to route post tensioning ..


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Why use U Girders?Why use U Girders?

Girder Set and in Service.Girder Set and in Service.Minimal Repairs toMinimal Repairs to SpalledSpalled Flange.Flange.Manitowoc 888 wasManitowoc 888 was totalledtotalled ..


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Whats the Catch?Whats the Catch?

Extensive Shoring Necessary.Extensive Shoring Necessary.

Girders are very heavy.Girders are very heavy.Stability must be designed for and maintainedStability must be designed for and maintaineduntil superstructure is self supporting.until superstructure is self supporting.

More field and erection Engineering required.More field and erection Engineering required.Blending of Precast and Post Tensioned industriesBlending of Precast and Post Tensioned industriesand technologies.and technologies.

Slower construction cycle during Erection.Slower construction cycle during Erection.More complex multiple phase constructionMore complex multiple phase construction ..


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270 Ramp Y Cost Comparisons270 Ramp Y Cost Comparisons

Item Steel Design Curved Precast

Girder Cost $5,125,000 $3,086,240

Erection Costs $1,025,000 $890,000

Falsework $50,000 $250,000

Post Tensioning $0 $506,000

Total $6,200,000 $4,732,240

Cost / Ft. $1393 / lf $1063


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270 Ramp Roadway Layout270 Ramp Roadway Layout


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270 Ramp Cross Section270 Ramp Cross Section


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Bridge ConfigurationBridge Configuration8 Spans, 6 and 2 span continuous8 Spans, 6 and 2 span continuousunits.units.

Span Lengths from 140 to 200 Span Lengths from 140 to 200 Pier Heights from 10 to 45 Pier Heights from 10 to 45

Spliced ConstructionSpliced ConstructionPhased Erection w/ staged postPhased Erection w/ staged post

tensioningtensioning


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Phased ConstructionPhased Construction


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Typical Girder Cross SectionTypical Girder Cross Section Ramp KRamp K


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Typical Girder Cross SectionTypical Girder Cross Section Ramp YRamp Y


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Ramp K CIP Lid SlabRamp K CIP Lid Slab

R A & Y


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Ramps A & YRamps A & Y

Precast Panel Lid SlabPrecast Panel Lid Slab


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PrePre --Casting of GirdersCasting of Girders

Up to 120 long, 265 Kip max weightUp to 120 long, 265 Kip max weight

Curved FormsCurved FormsPost TensionedPost Tensioned

Precast Anchor BlocksPrecast Anchor BlocksBlock Outs for CIP Anchor BlocksBlock Outs for CIP Anchor BlocksSecondary Casting of Diaphragms,Secondary Casting of Diaphragms,Bottom Slab Thickening and Lid SlabBottom Slab Thickening and Lid Slab

Tongue at Expansion Diaphragms Tongue at Expansion Diaphragms


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Curved Girder FormworkCurved Girder FormworkPrecaster: Encon BridgePrecaster: Encon Bridge


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Reinforcing Cage in FormsReinforcing Cage in FormsPrior to CastingPrior to Casting


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Typical Girder Cross SectionTypical Girder Cross Section


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Girders in Storage AreaGirders in Storage Area


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E i C di iE i C di i


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Erection ConditionsErection ConditionsGirders supported on FalseworkGirders supported on FalseworkTorsionalTorsional Bracing.Bracing.P/C Panels or CIP lid slabs to controlP/C Panels or CIP lid slabs to controltorsiontorsionCantilevered constructionCantilevered constructionTemporary post tensioningTemporary post tensioningStrongbackStrongback FalseworkFalseworkHeavy lifts with limited crane radiiHeavy lifts with limited crane radiiComplicated site conditions.Complicated site conditions.Multiple traffic closuresMultiple traffic closuresStaged Post Tensioning.Staged Post Tensioning.


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Girders Supported on FalseworkGirders Supported on Falsework


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Falsework Design at Pier 5Falsework Design at Pier 5


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Girder ErectionGirder Erection


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Precast Girder Weight = 250 KPrecast Girder Weight = 250 K

Maximum Lift = 330 KMaximum Lift = 330 K300 and 240 Ton Hydraulic Cranes300 and 240 Ton Hydraulic Cranes


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Erection PlanErection Plan Girders 10 L&RGirders 10 L&R


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Setting Girder at Pier 2Setting Girder at Pier 2


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Girder suspended over pierGirder suspended over pierGrout Bearing installed prior to castingGrout Bearing installed prior to castingdiaphragmdiaphragm

Eliminates manufactured bearingsEliminates manufactured bearings


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Completed Pier DiaphragmCompleted Pier Diaphragm

ddl


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Straddle Bents over HOV LaneStraddle Bents over HOV Lane

Continuous traffic maintained during constructionContinuous traffic maintained during construction

Erection over HOV during lane closuresErection over HOV during lane closures

Straddle Bent Design at HOV LanesStraddle Bent Design at HOV Lanes


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Straddle Bent Design at HOV LanesStraddle Bent Design at HOV Lanes

Gi d i OGi d E i HOV L


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Girder Erection over HOV LaneGirder Erection over HOV Lane

HOV O T ffiHOV O T ffi


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HOV Open to TrafficHOV Open to Traffic

E i Pi 4E ti t Pi 4


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Erection to Pier 4Erection to Pier 4

F l k Pi 5F l k t Pi 5


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Extensive Site Preparation RequiredExtensive Site Preparation RequiredVarying Site ConditionsVarying Site Conditions

Falsework at Pier 5Falsework at Pier 5

E ti th h S 5E ti th gh S 5


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Erection through Span 5Erection through Span 5

Erection Approaches 270 Bridge andErection Approaches 270 Bridge and


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pp gpp g

IH25IH25

Casting of Anchor Block and Lid SlabCasting of Anchor Block and Lid Slab


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gg

at Girders 10 and 13at Girders 10 and 13

Anchor Block ReinforcingAnchor Block Reinforcing


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Anchor Block Reinforcing Anchor Block Reinforcing

Setting Girders 10L&R at Pier 6Setting Girders 10L&R at Pier 6


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Setting Girders 10L&R at Pier 6Setting Girders 10L&R at Pier 6

330 Kip Lift weight330 Kip Lift weightCantilevers 54 beyond Pier 6 over 270 BridgeCantilevers 54 beyond Pier 6 over 270 BridgeGirder 10 is restrained to Girder 9 to preventGirder 10 is restrained to Girder 9 to preventtippingtipping

Girder 10 Tie DownGirder 10 Tie Down


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Girders 10 L&R Set at Pier 6Girders 10 L&R Set at Pier 6


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Girders 10 L&R Set at Pier 6Girders 10 L&R Set at Pier 6


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Girders 10 L&R from 270 BridgeGirders 10 L&R from 270 Bridge


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Girder Erection from Abutment 9 over IH25Girder Erection from Abutment 9 over IH25

and On Rampand On Ramp

Girder Strong Back DesignGirder Strong Back Design


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Girder Girder


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StrongStrongBacksBacks

In PlaceIn Place

Girders 11 L&R Set over 270 BridgeGirders 11 L&R Set over 270 Bridge


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Girders 11 L&R Set over 270 BridgeGirders 11 L&R Set over 270 Bridge


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rec on o r ers omp e e


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Erected Girders w/ Lid SlabErected Girders w/ Lid Slab


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Erected Girders w/ Lid SlabErected Girders w/ Lid Slab

Setting Precast PanelsSetting Precast Panels


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Panels installed, overhang forms set andPanels installed, overhang forms set andd k tdeck cast


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deck castdeck cast

Completed StructureCompleted Structure


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Completed Structurep

Design Lessons LearnedDesign Lessons LearnedT i l d fl i d d i


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TorsionalTorsional

deflections and stresses duringdeflections and stresses during

erection were critical.erection were critical.Haul weight limits the girderHaul weight limits the girder precastingprecastingand erection more than any other factor.and erection more than any other factor.Limited eccentricity of web tendons.Limited eccentricity of web tendons.Local tendons were effective in longLocal tendons were effective in longspans.spans.Negative moments at interior piersNegative moments at interior pierscontrolled much of the design.controlled much of the design.StrainStrain compatabilitycompatability analysis necessaryanalysis necessarydue to limited compression block.due to limited compression block.Service stresses in deck steel is important.Service stresses in deck steel is important.Lightweight Concrete can significantlyLightweight Concrete can significantlyimpact future long span designs.impact future long span designs.

Construction SolutionsConstruction Solutionsl l l ll fQ li l i i l ll f


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Quality control is essential at all stages ofQuality control is essential at all stages ofconstruction.construction.Simplify precast formingSimplify precast formingUse CIP anchor zones.Use CIP anchor zones.Design of economical handling reinforcingDesign of economical handling reinforcingTemporary structure design and bracing is criticalTemporary structure design and bracing is criticalto project success.to project success.Establish continuity as soon as possible.Establish continuity as soon as possible.Create a closed box section early after erection.Create a closed box section early after erection.PrecastersPrecasters and postand post tensionerstensioners must understandmust understandeach other.each other.Evaluate site conditions during design.Evaluate site conditions during design.Make significant allowances for heavy cranesMake significant allowances for heavy cranes

during erection to handle heavy loads.during erection to handle heavy loads.


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Gateway Bridge to DowntownGateway Bridge to DowntownColorado Springs from IH25Colorado Springs from IH25


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Colorado Springs from IH25Colorado Springs from IH25

Erection support for all spans usingErection support for all spans using


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StrongbackStrongback FalseworkFalsework

Seven Continuous Girder LinesSeven Continuous Girder LinesSpliced and Splayed to AccommodateSpliced and Splayed to Accommodate

Deck Width from 88 to 168Deck Width from 88 to 168


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Deck Width from 88 to 168Deck Width from 88 to 168


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Drop in Girders @ Span 3Drop in Girders @ Span 3


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over UPRRover UPRR

Demolition began January 2007Demolition began January 2007


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Open to Traffic, Labor Day 2007Open to Traffic, Labor Day 2007


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Documents

2007-12 U Girder Colorado Dylgo