2012 Section Engineer Meeting Wednesday October 3, 2012
Presented by Steve Applegate Project Consultant Tom Nein - Plate
Production & Plant Manager
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ABC Concepts ALSP & ALBC Shapes Manufacturing Location KYTC
Local Projects & History Kentucky Support Team Questions
Agenda
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Accelerated Bridge Program
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Accelerated Bridge Construction (ABC): ABC is bridge
construction that uses innovative planning, design, materials, and
construction methods in a safe and cost-effective manner to reduce
the onsite construction time that occurs when building new bridges
or replacing and rehabilitating existing bridges Prefabricated
Bridge Elements and Systems PBES are structural components of a
bridge that are built offsite, or near- site of a bridge and
include features that reduce the onsite construction time and the
mobility impact time that occurs when building new bridges or
rehabilitating or replacing existing bridges relative to
conventional construction methods. Accelerated Bridge Program
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+ = ABC Many of our bridge products can be combined with
Express Foundations to help you meet the goal of Accelerated Bridge
Construction.
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Structural Plate Shapes 6
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Aluminum Structural Plate - Design & Loading Aluminum
Structural Plate in AASHTO Material AASHTO M219 Design AASHTO
Section 12 Installation AASHTO Section 26 Loading HS-25 and LRFD
Highway Loading
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Aluminum Structural Plate - Shapes Several Shapes allowed in
AASHTO Section 12; Round Pipe Arch True Arch on Footings Ellipse
Box Shape
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Structural Plate Pipe Arch
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Aluminum Structural Plate Aluminum Structural Plate Advantages
Easy to Design Quick to Install Cost Savings over Concrete
Structures Industry Competition Durability History % Recycled
Material Made in Kentucky Twin Aluminum Plate installed 1968 No
corrosion
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Aluminum Box Culvert Slip Line of Failing Concrete Box road
traffic maintained during construction
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17 Span Aluminum Arch on Footings with Slope Collar
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10 Span ALBC on Precast Footings
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Benefits to You: Provides ease and speed of installation
Alleviates hazardous working conditions Trapezoidal foundation
reduces wing wall concrete quantities Minimal reinforcement to be
placed on site Pick weights and sizes customized to your equipment
Use with Aluminum Plate or CON/SPAN Structures Blends the speed of
precast with the economy of cast-in-place EXPRESS Concrete Footings
Speed and Ease
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Construction Process: Excavate and prepare foundation subgrade
Unload and set precast channels Place minimal reinforcing at joints
to provide foundation continuity Set precast bridge units,
headwalls and wing walls Pour cast-in-place concrete Seal joints,
grout wing walls and backfill. Helping Accelerate Bridge
Construction
Slide 16
+ = ABC Many of our bridge products can be combined with
Express Foundations to help you meet the goal of Accelerated Bridge
Construction.
Slide 17
Accelerated Bridge Construction (ABC): ABC is bridge
construction that uses innovative planning, design, materials, and
construction methods in a safe and cost-effective manner to reduce
the onsite construction time that occurs when building new bridges
or replacing and rehabilitating existing bridges Prefabricated
Bridge Elements and Systems PBES are structural components of a
bridge that are built offsite, or near- site of a bridge and
include features that reduce the onsite construction time and the
mobility impact time that occurs when building new bridges or
rehabilitating or replacing existing bridges relative to
conventional construction methods. Accelerated Bridge Program
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Winchester Plant 18
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Manufactured in Winchester KY Established 1985 Acres 19 180,000
SF Mfg Operation Plant Capabilities Galvanizing Tank On-site water
treatment facility 2 roll forming lines 19 overhead cranes 12
presses 4 press brakes Various sheers, band saws and curving rolls
Machine shop Capacity Running at 35% potential capacity
Little Bennett Regional Park, Clarksburg, MD 10-6 ft. span x
5-7 40.5 lf ALBC Loading: HS25 Engineer: Tim Sharp Dist 3
Installed: Nov 2010 Location: Richardsville Kentucky 263 4 Day Road
Closure Accelerated Construction 4 Day Road Closure
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Little Bennett Regional Park, Clarksburg, MD 253 ft. span x
10-2 66 lf ALBC Loading: HS25 Engineer: Paul Sanders Dist 4
Installed: June 2010 Location: Caneyville Kentucky 2766 Emergency
Replacement
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Little Bennett Regional Park, Clarksburg, MD 254 ft. span x 8-7
24 lf ALBC Loading: HS25 Owner: Webster County Road Rob Mooney
Installed: Oct 2011 Location: Clay KY Williams Clay Road Webster
County County Road Department ALBC
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Bid as an alternate (221span X 66 rise Aluminum Box Culvert) to
Concrete Bridge on piles in 1995 Saved $310,000 versus concrete
bridge Improved Road close time from 3 months to 1 week Increased
road width to allow for wider entrance for Pikeville Elementary
School Chloe Creek US 223 and Hwy 1460 KYTC DIST 12 22 Span ALBC
Before and After
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KYTC DIST 12 Chloe Creek Remove Old Bridge
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KYTC DIST 12 Prepare 4,000 PSF foundation
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KYTC DIST 12 Assemble Box in Parking Lot while old bridge is
taken out and foundation prepared
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KYTC DIST 12 ALBC ready for backfill
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After 17 years of HS-25 Coal Haul Traffic
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Kentucky Support Team 35
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Questions? 36
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Kentucky Support Team
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Summary & Overview Bridge Portfolio Innovative Bridge
Developments Engineering Support & Design Tools CONTECHs
Consultative Approach Building Blocks to a successful Project
Planning & Solution Development Project Design Worksheet
Structure Selection Site & Layout DYOB Engineer Estimate Site
Simulation Proposal Preparation Design Build Support Design Support
Specifications Contract Drawings Permitting Structural/Fabrication
Drawings Approval Assistance Custom Shape Development
Horizontal/Vertical Alignment Hydraulics & Scour Support
Foundations Installation Support Preconstruction Meeting On-Site
Installation Assistance Logistics Coordination Contech. Your
project partner.
