From HCB to ABC - The Knickerbocker Bridge, Boothbay, Maine

Transcription

1 From HCB to ABC - The Knickerbocker Bridge, Boothbay, Maine John Hillman, PE, SE President & CEO HCB, Inc. hillmanjr@hcbridge.com Wayne Frankhauser, Jr., PE Bridge Program Manager Maine DOT Wayne.FrankhauserJr@maine. gov

2 Focus on reducing impacts to travelling public Get In, Get Out and Stay Out! Longevity & durability are critical to reducing overall impacts Wise investment to extend the life of high priority bridges If MOT is difficult now what will it be like in the future. 2

3 MaineDOT ABC Projects Kittery, Overpass Bridge Constructed late summer span NEXT-D beam superstructure prestressed with CFCC Shallow variable bedrock Prefabricated abutments, wingwalls, approach slabs & NEXT Beam Superstructure 28,000 AADT on Route 1B and Route 236 Rt 236 closed for 11 hours for demo and Rt 1B for 29 days 3

4 MaineDOT ABC Projects Naples, Crockett Bridge Constructed fall span NEXT-F beam superstructure CIP superstructure slab with GFRP reinforcing Integral abutments on spun piles ability to drill through obstructions Prefabricated abutments and approach slabs Significant roadway reconstruction to improve vertical alignment Completed in 18 days (26 allowed by contract) 4

5 MaineDOT ABC Projects Naples, Crockett Bridge 5

6 MaineDOT ABC Projects Fairfield, Western Avenue Bridge over I-95 Accelerated deck replacement constructed summer span overpass bridge Full-depth precast deck panels with UHPC connections Phased construction completed in 53 days Lessons learned being used to develop standard details and specifications 6

7 MaineDOT ABC Projects Bath, West Approach Bridge Route 1 33,000 AADT 20 span 1,282 structure Prefabricated piers constructed on existing footings Superstructure options NEXT-D beams or PBUs both with UHPC connections A+B bidding 7 mo. maximum closure of Rt 1 between November & May Additional limitations to impacts under bridge 7

8 Maine DOT Composites Initiative Extending Bridge Service Life Deterioration caused by severe climate Recognition that we need to build long lasting, lowmaintenance bridges 8

9 Systemic Corrosion & Deterioration 9

10 Maine Bridge Innovation and Composite Initiative An Act to Keep Bridge Safe Maine State Legislature, April 2008 Called for a partnership between MaineDOT, UMaine Advanced Structures & Composites Center & industry to incorporate composite technologies into bridge construction Objectives Extend the service life of our bridges Accelerate the application of new composite technologies Grow Maine s composite industry Fostered a culture of innovation & creativity within MaineDOT 10

11 HCB Bridges completed by Maine DOT Westbrook, Bridge Street span structure 80 max span 5 4 beam spacing Construction 2015/16 Bangor, Union Street span structure 92 max span beam spacing Construction 2014/15 11

12 HCB Bridges completed by Maine DOT Thomaston, Wadsworth Street Bridge span structure 70 max span 5 4 beam spacing Construction 2015/16 Boothbay, Knickerbocker Bridge span structure 70 max span 4 0 beam spacing Construction 2010/11 12

13 Westbrook, Bridge Street Bridge Located downstream of a dam and natural falls Ease of construction lightweight beams easily set from shore avoiding a work trestle FRP deck panels used to speed construction 13

14 Thomaston, Wadsworth Street Bridge Severe saltwater exposure Ease of construction precast concrete deck panels used to speed construction GFRP deck reinforcing and FRP drains 14

15 Bangor, Union Street Bridge Interstate overpass salt spray from trucks Lightweight beams easily set at night minimizing traffic impacts on I95 15

16 Boothbay Knickerbocker Bridge Severe saltwater exposure Ease of construction lightweight beams could be set from existing bridge 16

17 What is a Hillman Composite Beam (HCB)? And why would I want to use HCB for ABC? 17

18 HCB Compression Reinforcing Shear Connectors A structural member using several different building materials resulting in a cost effective composite beam designed to be stronger, lighter and more corrosion resistant 18 FRP Shell Tension Reinforcement

19 Fiberglass Box (FRP Shell) Balanced quadknit fabric with fibers that are horizontal (0 0 ), vertical (90 0 ) and (± 45 0 ) infused in an epoxy vinyl ester resin matrix 19

20 Tension Reinforcing Tension reinforcing consisting of 270 ksi galvanized prestressing strand along bottom of beam 20

21 Work Cell - VARTM Fabrication 21

22 Staging Area and Top Flange Cell 22

23 Compression Reinforcing - SCC Compression reinforcing consisting of 6,000 psi Self- Consolidating Concrete (SCC) pumped into internal arch-shaped conduit 23

24 Engineering Theory Behind HCB 24 Use arch analogy of reinforced concrete to eliminate all concrete in tension Resist compression thrust of arch with steel tie Carry shear in arch and FRP webs

25 Internal Load Path 25

26 Load Path for Continuous Structures T Load on the deck is transferred through the shear connectors to the arch Redundant load path with tension tie Whether simple span or continuous, concrete slab acts compositely with HCB C 26

27 Tension Field Action - (TFA) Experimental vs. ABAQUS (no bracing) Images courtesy of Virginia Tech 27

28 C=T C=0.85fc ab ΦMn=ΦC(d-a/2) 28

29 Things you might want to know about an HCB Bridge HCB s can span anywhere from 20ft. To 120ft. When placed empty they are only 1/10 th the weight of a concrete beam with equal capacity They can also be pre-filled and still be only1/3 the weight of a similar concrete beam There is an inspection manual available based on the 0 to 9 NBIS rating criteria They require little or no maintenance, even in extremely aggressive environments 29

30 Reasons to use HCB for ABC They work well with GRS abutments, particularly when your setting the beams on the ground and /or the bridge is constructed with local forces not having access to big cranes. 30

31 Reasons to use HCB for ABC Placing beams side by side or using composite SIP forms eliminates deck forming and stripping. Provides greater corrosion resistance to deck. 31

32 Reasons to use HCB for ABC Bridge can be erected using PBES like HCB double-t units that are much lighter than NEXT beams. Also well suited for bridge slides or SPMT installation. 32

33 Reasons to use HCB for ABC Lighter weight allows use of smaller equipment a longer pick radius and possibly fewer cranes Setting from abutment can mitigate ROW takes, causeways, and environmental permits 33

34 Reasons to use HCB for ABC You can take cool pictures of yourself standing underneath the bridge to send to your friends! 34

35 Sounds great John! Where do I start? 35

36 Knickerbocker Bridge Completed 2011 Owner: Maine Department of Transportation Engineer of Record: Calderwood Engineering Contractor: Wyman & Simpson Testing: University of Maine AEWC Center Beams: HCB, Inc. 36

37 Beam Fabrication 37

38 Don t try this with precast concrete! 38

39 Testing at University of Maine AEWC Center Inventory Rating = 1.34 Operating Rating =

40 Four 70 ft. Beams - One Truck 40

41 HCB Erection 2 Spans/Day Barge and Crane were used to install substructure and superstructure Beams for Second Span parked on existing wooden bridge ready for erection 41

42 Offloading HCB Units 42

43 Setting Beams 43

44 Filling HCB s insitu 44

45 Diaphragm Details Abutment Intermediate Piers 45

46 Miscellaneous Details 46

47 View from Below 47

48 Knickerbocker Bridge Boothbay, Maine 540 ft. Overall Length 8 Span Continuous 2 60 ft., 6 70 ft. 48

49 Additional HCB bridges using ABC Route 23 over Peckman s Brook NJ Bridge B0478 MO Bridge B MO Colonial Beach VA USACE Fort Knox - KY Dry Branch Bridge - WV Potomac Hollow MD Research Pier, Machias - ME CP Railway - Fernie BC BNSF Railway - CO 49

50 Tides Mill - Colonial Beach, VA - Feb ft. span 45 degree Skew 21 in. HCB 50

51 University of Maine Research Pier, Machias, ME 100 ft. 3-span w/18 in. HCB - Sep

52 1st HCB Railroad Revenue Service - Fernie, BC 33 ft. - Canadian Pacific Railway, Oct

53 BNSF Railway Bridge B ft. span - Boise City Subdivision, CO 53

54 What do these 3 objects have in common? Arch Reinforcing Intellectual Properties 54

55 Evolution of Telecommunications (140 years) 55

56 Evolution of Aviation (106 years) 56

57 Evolution of Bridge Technology (110 years) 57

58 The Value of Intellectual Property 58

59 Title 23 CFR Roadblock Ahead! 59

60 Title 23 CFR

61 How to comply with Do a demonstration project Get a Public Interest Finding Have the State DOT self-certify Design Build ( does not apply) Detail-Build (Performance Specification) Tell your Congressmen to change legislation 61

62 Thank You!!! Questions?