Presenter: Contributing Authors: Guy C. Nelson PE, SE TEG Engineering, LLC Structural Engineer
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1 Presenter: Guy C. Nelson PE, SE TEG Engineering, LLC Structural Engineer Contributing Authors: Bill Hazelton St. Clair County Road Commission Director of Engineering Dewayne Rogers St. Clair County Road Commission Project Manager
2 St. Clair County, Michigan 226 Bridges County Wide 38 Load Limit Posted 2 Closed To Traffic Structure Condition Summary Good/Fair (5 or Greater) 185 Poor (4) 21 Serious/Critical (3 or Less) 20
3 History of TEG Engineering Founded in 2007, Licensed Engineering Firm in 41 states. Prequalified for Design Services with both TxDOT and MDOT Headquartered in Grand Rapids, Michigan, other office in Houston Over 22 Employees Civil Structural Engineering Firm Specializing in Precast Concrete for Heavy Civil Construction. Member of AISC, ACI, PCI, NSBA and SSSBA
4 2 Posted Bridges on Marine City Hwy Marine City Highway over Unnamed Canal (4-08) Marine City Highway over Meldrum Drain (4-09) 3000 ft
5 2 Superstructure Replacements on a heavily trafficked local highway Marine City Highway is a 2 lane road with more than 16,000 ADT. Marine City Intersection at County Line Road
6 Goals of Superstructure Replacement Utilize the existing abutments Match the existing superstructure depth Maintain constructability by county maintenance crew Structure design per MDOT HL- 93(MOD) loading Additional 60 year service life Existing Marine City Hwy over Meldrum Drain (4-09)
7 Why Tub Girders Were Chosen Steel Bridge $75,000 + HMA Overlay + Guardrail + Labor + Equipment Pre-Cast Box Culvert $63,000 + Headwalls + Wing Walls + Crane Rental + Earthwork/Heavy Demo + HMA + Labor + Equipment
8 Tub Girder with Pre-Cast Deck $57,000 + HMA Approaches + Epoxy Overlay + Guardrail + Labor + Equipment ***Based on Engineer s Estimate, the Tub Girder system was approximately 10% cheaper in this particular application.
9 History of the Con-Struct System Con-Struct was Developed in 2003 Con-Struct is a Press-Brake-Formed Steel Tub Girder Bridge System with a Network of Manufacturers throughout the United States. First Project was in Saginaw, MI 2004 Approved for use in 5 States and Saskatchewan, Canada. Over 25 bridges installed with Spans ranging from 20 to 80 Bridge Locations in Missouri, Michigan, Texas, Minnesota and Colfax, SK Bridge over Brainerd Raceway Installed in 2007.
10 Con-Struct Bridge System Components Integral Backwall FHWA GRS-IBS Project
11 Con-Struct Prefabricated Bridge Solution Why now? Con-Struct Standardized and Simplified Fabrication and Details Industry can Produce Press Brake Formed Steel Tub Girders in 58 Continuous Lengths Precast Concrete Industry Involved in Manufacturing Process New high-strength, non-shrink grouts provide durable solutions for deck joints FHWA involvement in innovative projects and funding (ABC, UHPC and GRS)
12 Con-Struct Prefabricated Bridge Solution Why now? Independently researched and tested by MDOT through Michigan State University (MDOT installed their own bridge in 2011) Installed and ready for traffic in a single day Tested Capacity Exceeds AASHTO M u = 106 kip-ft Simple and durable deck joint connection 75 year service life Max. Applied Moment (kip-ft) M n = 80 kip-ft (AASHTO) M y = 65 kip-ft Delivered and installed at less cost than that of conventionally Curvature (rad/10 6 in.) constructed concrete beam bridges
13 Press-Brake-Formed Steel Tub Girders 2016 Research Funded by SSSBA IBC Evaluation of Modular Press- Brake-Formed Steel Tub Girders Joint effort from West Virginia University, Marshall University and University of Wyoming Assess Feasibility and Details Test Fatigue and Distribution Factors Determine Applicable Design Methods AASHTO LRFD Press-Brake-Formed Steel Tub Girder
14 Press-Brake-Formed Steel Tub Girder 60 Long Press Brake ASTM A572 or A588 Steel 5t Bend Radius Press-Brake-Formed Steel Tub Girders - No Flange to Web Welds, Reduced Fabrication Costs Per AISC Bend Radius > 5t - No Brittle Fracture, AASHTO Category B Fatigue
15 Press-Brake-Formed Steel Tub Girder - Galvanize Hot-Dip Galvanized Shear Studs Double-Dip Process Hot-Dip Galvanized to Provide 60+ Year Protective Coating Stern Bayou in Ottawa County was Galvanized in 1966 with no current signs of coating deterioration
16 Optional Precast Overlay Precast Installation Utilizing High Strength Grout Example : MDOT Type H-1 QuickCrete Precision Grout Dayton Superior Conspec 100 HPC Grout Fill
17 Precast Concrete Deck Panels Simple Panel Installation Utilizing High Strength Grout Example : MDOT Type H-1 QuickCrete Precision Grout Dayton Superior Conspec 100
18 Precast Concrete Deck Panel Overlay
19 AASHTO/MDOT Design Procedures Standard Designs from 20 to 80 Spans Follows AASHTO LRFD and MDOT Design for HL-93(MOD) Loading Tested AASHTO Live Load Distribution Factors Easy to Follow and Check Mathcad Calculations Compatible with MDOT Load Rating Standard Spreadsheet
20 Con-Struct Prefabricated Bridge Advantages LEED Material Comparison Prestressed Concrete Beam (PCB) vs. Con-Struct Steel Tub 88% of Steel is Recycled ½ the Volume = ½ the Weight Con-Struct Prestressed Concrete I-Beam LEED MATERIAL COMPARISON Prestressed Concrete Beam (PCB) vs. Con-Struct Steel Tub Girder PCB Con-Struct Unit VOLUME STEEL TOTAL ft 3 /ft VOLUME CONCRETE TOTAL ft 3 /ft VOLUME TOTAL ft 3 /ft VOLUME SAVINGS ft 3 /ft
21 Fabrication For New Superstructures Fabrication of the Con-Struct superstructure began 2 months prior to bridge demolition Bridge units were manufactured at ADL Systems in Portland, MI In-plant Quality Assurance Testing Done by Consultant Galvanized Steel Tub Girders Fabrication of Bridge Unit
22 Demolition of Existing Bridges On Monday Oct 9 th, (Nov 6 th ) Marine City Highway was closed to traffic Monday and Tuesday county crew removed existing bridge superstructure Existing Steel Beams Existing Substructure to Remain
23 Repair of Existing Abutments Existing abutments were repaired with Transpo T-17 Polymer Concrete patch material MDOT heavy riprap was used as scour protection of existing spread footing abutment Existing Abutments Riprap for Scour Protection
24 Install New Superstructure On Thursday Oct 12 th (Nov 9 th ) Con-Struct bridge units were delivered Bearing pads and expansion joint material were placed on abutment Con-Struct superstructure units arrived before 8:00a.m. Bearing and Joint Filler Con-Struct Bridge Units
25 Install New Superstructure County excavator was used to install 25 span units for bridge 4-08 (crane was used for ) All 6 Con-Struct superstructure units were all placed before noon Units were cast with integral backwalls Excavator to Install 4-08 Crane to Install 4-09
26 Install New Superstructure Transpo T-17 Polymer Concrete was used for the deck joint between units T-17 was tested for rebar development length and the joint designed specifically for T-17 material Forming Deck Joint Pouring T-17 Polymer Joint Concrete
27 Finishing Touches Over the following 5 days asphalt approaches were paved, Guardrail posts were installed.. Pave 20 Approach Install Guardrail Posts
28 Finishing Touches Slopes were re-graded, Existing wing walls were repaired Re-grade Slopes at Approach Repair Existing Wingwalls
29 Finishing Touches A thin epoxy overlay was placed on the new concrete deck surface for 4-08 bridge The thin epoxy overlay was not done for 4-09 bridge due to weather limitations Place Epoxy Compound Cover with Aggregate and Re-Epoxy
30 Finishing Touches Guardrail was installed Slopes were restored Install Guardrail Slope Restoration
31 Marine City Hwy over Unnamed Canal (4-08) Total Completed Cost = $180, Includes material, labor, overhead, equipment Total Completion Time = 10 Working Days
32 Marine City Hwy over Meldrum Drain (4-09) Total Completed Cost = $222, Includes material, labor, overhead, equipment Total Completion Time = 10 Working Days
33 Installation Video
34 Installation Video
35 Saving Time with Steel Tub Girders in St. Clair County In Conclusion: 80% Less Expensive Than Reconstruction 90% Less Traffic Delays
36 Thank you for your time! Presenter Info: Bill Hazelton St. Clair County Road Commission Director of Engineering Dewayne Rogers St. Clair County Road Commission Project Manager Guy C. Nelson PE, SE TEG Engineering, LLC www. constructbridge.com
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