VDOT S BRIDGE PRESERVATION PROGRAM Virginia Concrete Conference, 2012 RICHMOND, VA March 9, 2012 Adam Matteo, PE Assistant State Structure and Bridge Engineer for Bridge Maintenance VDOT Structure and Bridge Division
2 The Structure and Bridge Division has the same organizational structure in the Central Office and the Districts Central Office State Structure and Bridge Engineer Ken Walus Preliminary Engineering David Nuckols Inspection & Load Rating Claude Napier Maintenance Adam Matteo Engineering Services Julius Völgyi 9 District Offices District Bridge Engineer Preliminary Engineering Inspection & Load Rating Maintenance
3 The Challenge There isn t enough money to meet all the needs of Virginia s aging Bridges and Culverts $1.7 Billion total maintenance need statewide Replacement value of the inventory is $52.4 Billion Approximately 60% of Virginia s inventory is 40 years old or older Structures built prior to 2007 were designed for 50 year life Replacement value of all structures 40 years or older is $18.7 Billion Structures designed for 50 years may need to be to kept functional for 100 years or more, perhaps even as long as 150 years 4719 structures with a minimum General Condition Rating of 5 (almost ¼ of the entire inventory) Approximately 21,000 structures in the inventory, 19,390 of which are VDOT-maintained (by comparison, Florida has 6,644 structures) 1,537 structures with a min. General Condition Rating of 4 or less Maintenance budgets are about 2/3 needs
4 4,500 4,252 4,000 3,842 3,500 3,458 3,000 No. of Structures 2,500 2,000 1,562 2,332 2,115 1,715 1,500 1,000 853 500 0 114 2010's 2000's 1990's 1980's 1970's 1960's 1950's 1940's 1930's 1920's 1910's 1900's Decade * County Bridges added to the VDOT Inventory during this period with unknown construction dates (Assumed year built equaled year added to system) Structures Built by Decade 513 100 31 21
5 60.0 55.0 50.0 Average Age 45.0 40.0 35.0 30.0 25.0 20.0 Interstate Primary Secondary Urban Total Bristol Salem Lynchburg Richmond Hampton Roads Fredericksburg Culpeper Staunton NOVA Statewide Average Age of Structures by Highway System
6 General Condition Ratings DEFINITIONS 9 EXCELLENT CONDITION 8 VERY GOOD CONDITION 7 GOOD CONDITION 6 SATISFACTORY CONDITION 5 FAIR CONDITION 4 POOR CONDITION 3 SERIOUS CONDITION 2 CRITICAL CONDITION 1 "IMMINENT" FAILURE CONDITION 0 FAILED CONDITION GENERAL CONDITION RATINGS ARE PROVIDED AT EACH INSPECTION FOR: DECK SUPERSTRUCTURE SUBSTRUCTURE CULVERT The General Condition Rating is an imperfect index, but it can provide good broad-based information about an inventory.
7 Number of Structures by Minmum GCR 8,000 7,000 6,000 Total No. of Structures = 20,860 6,944 6,086 Number of Structures 5,000 4,000 3,000 4,719 23% 33% 29% 2,000 1,000 1,473 7% 1,409 7% 0 64 165 3 4 5 6 7 8 9 Minmum GCR Approximately 200 structures per year go from 5 to 4 and become Structurally Deficient
8 The Solution Whine until we get more money?
9 Attacking the Problem Spend Resources as wisely as possible to extend the life of the inventory Replace joints in a timely manner Spend money on the most cost-effective actions Make data-driven decisions when selecting interventions Constantly evaluate new materials and methods Don t pursue a worst first approach Emphasize preventive maintenance Balance spending Perform high quality work Utilize state bridge crews Address highway systems with largest impact to commerce and the public
10 Bridge Maintenance Requires Bridge Management Inspection Inventory Work needs Structure Condition Bridge Management Work Prioritization Project Scoping Project Development Design Permitting Advertisement & Award Construction VDOT uses Pontis for structure inventory and modeling of needs
11 Bridge Longevity New Construction Existing Structures Jointless Bridges Concrete Culverts Preventive Maintenance Restorative Maintenance Corrosion Resistant Reinforcement High Performance Concrete Painting Rehabilitation Replacement
12 Maintenance Activities Examples of Preventive Maintenance Bridge Cleaning (washing and/or sweeping) Deck Sealing Sealing Joints Thin Deck Overlays Removing Large Debris in Channels Cleaning Culverts Spot and Zone Painting VDOT has a system preservation agreement with FHWA to fund these activities Preventive maintenance has been shown to be the most cost-effective of all bridge maintenance activities for sustaining the lives of structures
13 Maintenance Activities Examples of Restorative Maintenance Painting (Overcoating or Re-Coating) Rigid Deck Overlays Reconstructing/Closing Joints Superstructure Repairs (Type B patching, etc.) Substructure Repairs (including shotcrete, bearings, other elements) Joint removal Fatigue Retrofitting Scour Repairs Cathodic Protection Electrochemical Chloride Extraction Replace timber decks Much of this work is reactive in nature but needs to be performed to sustain our inventory
14 Maintenance Activities Rehabilitation Generally work of a major nature Deck replacement Superstructure replacement Culvert lining Replacement Part of the maintenance cycle Includes replacement of foundations Often coincides with a need for widening or geometric improvement Many projects are funded through the Dedicated Bridge Fund
15 Codifying Best Practices Chapter 32 has recently been adopted available online Acts as a primer for those not familiar with bridge maintenance Provides strict rules where appropriate Provides guidelines where appropriate Explains and provides guidance on funding Provides guidance on decision processes Provides a schedule for preventive maintenance activities Is based on both practical experience and studies Future revisions will include additional elements such as: Standard details Contract templates for maintenance work Standard Special Provisions Design Aids Additional culvert and timber bridge guidance
16 What Constitutes Best Practices Fundamental Principals Keep the roof dry and clean Replace or eliminate joints Timely installation of overlays Timely spot or zone painting Maintain drains in a functional condition Sweep and wash bridges Perform repairs in a timely manner Evaluate new technologies and implement the good ones Sponsor studies Utilize research performed by others Try new materials and methods Utilize appropriate materials Avoid asphalt overlays Use approved patching materials
17 Fundamental Principals, continued: Utilize proven technologies Perform quality work Treat maintenance work the same as new construction Test and monitor material installation, particularly for concrete Provide adequate inspection Utilize controls where possible Distribute resources appropriately. Chapter 32 suggests: Preventive Maintenance 15% (Program 604) Painting 10% (Program 604) Restorative Maintenance 25% (Program 604) Rehabilitation/Small Structure Replacement 50% (Program 604) Maximize available resources Utilize available funding (state and federal) Plan and perform work for best efficiency (multiple structure contracts)
18 The Importance of Preventive Maintenance - Joints
19 The Importance of Preventive Maintenance - Joints
20 The Importance of Preventive Maintenance - Decks
21 Preventive Maintenance Highest cost benefit ratio of the maintenance categories Most of the problems with bridge deterioration can be significantly reduced or avoided altogether with planned preventive maintenance FHWA agreement allows these activities to be billed as system preservation
22 Preventive Maintenance Proposed Activity Cycle Activity Preferred Cycle (years) Federally Eligible? 1 Bridge Deck Washing 1 Yes 2 Bridge Deck Sweeping 1 Yes 3 Seats & Beam End Washing 2 Yes 4 Cutting & Removing Vegetation 2 No 5 Routine Maintenance of Timber Structures 2 No 6 Scheduled Replacement of Compression Seal Joints 10 Yes 7 Scheduled Replacement of Pourable Joints 6 Yes 8 Cleaning & Lubricating Bearing Devices 4 No 9 Scheduled Installation of Thin Epoxy Overlay 15 Yes 10 Beam Ends Painting 10 Yes 11 Removing Debris from Culverts 5 Yes
23 Number of Structures by Minmum GCR 8,000 7,000 Replacement Candidates Restorative Maintenance Candidates 6,944 System Preservation Candidates 6,086 6,000 Number of Structures 5,000 4,000 3,000 Total Number of Structures = 20,860 4,719 23% 33% 29% 2,000 1,000 1,473 7% 1,409 7% 0 64 165 3 4 5 6 7 8 9 Minmum GCR Approximately 200 structures per year go from 5 to 4 and become Structurally Deficient
24 Using Data to Make Better Decisions There are Several Active Studies with the Research Council Coating Study Process review of how we recoat structures Review enclosure/encapsulation requirements New technologies for removing Other coating systems and application methods available in the market Meeting with the transportation industry and surveying other industries Waterproofing membrane (monitoring effort) Low permeability asphalt such as Rosphalt Asphalt Plug Joints Deterioration rates of structures (data mining) Looks at past performance of structures and the longevity of interventions Developing cost/benefit ratios Will help guide decision-making for maintenance activities VDOT also participates in other studies such as the Long Term Bridge Performance Study being sponsored by FHWA
25 Average General Condition Ratings of Virginia s Structures 8 Average General Condition Rating 7.5 7 6.5 6 5.5 5 4.5 deck GCR Super GCR Sub GCR Min bridge GCR Culvert GCR 4 2001-2010 1991-2000 1981-1990 1971-1980 1961-1970 1951-1960 1941-1950 1931-1940 1921-1930 1911-1920 pre-1911 Decade Built
26 Using Data to Make Better Decisions Theoretical Deterioration 9 Extending Bridge Life 8 General Condition Rating 7 6 5 4 3 Minimal Maintenance Overlay at years 10, 25 & 40 New Construction 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 Age of Bridge
27 Evaluating Interventions Hunter Mill Road over Difficult Run 1969-2011 Superstructure Condition Rating Average Daily Traffic 10 1969 - VDOT builds new 1993 - VDOT builds new 25,000 9 9 9 9 21,716 8 7 7 7 7 8 8 7 7 7 8 8 17,282 20,000 Condition Rating 6 5 4 3 1984 - Bridge is rated as Critical & classified as 5 6 6 12,512 3 3 3 3 3 3 3 6 6 6 6 5 5 5 5 5 5 5 2008 - Bridge is rated as Poor & classified as Structurally Deficient 2005 - Posted 4 4 4 3 15,000 10,000 Average Daily Traffic 2 1988 - Posted 15 Yrs 15 Yrs 5,000 1 2011 - Bridge rated as Critical; Posted 0 0
28 Evaluating Interventions Epoxy Overlays 6.55 Average Deck General Condition Rating 6.5 6.45 6.4 6.35 6.3 6.25 6.2 6.15 6.1 Concrete decks no overlays Bridges with Epoxy Overlays Type of Deck Surface Conc Bridges with Asphalt Overlays Effect of Overlays on Deck General Condition Rating
29 6 year GCR Trends (2006 through 2011) 6.700 Average GCR of Bridge Decks 6.600 6.500 6.400 6.300 6.200 2006 2007 2008 2009 2010 2011 Interstate 6.387 6.361 6.338 6.310 6.285 6.253 Primary 6.339 6.342 6.340 6.307 6.286 6.291 Secondary 6.614 6.617 6.613 6.603 6.598 6.606 Average 6.516 6.504 6.497 6.481 6.474 6.477 Deck General Condition Rating
30 6 year GCR Trends (2006 through 2011) Average GCR by Superstructures 6.500 6.400 6.300 6.200 6.100 2006 2007 2008 2009 2010 2011 Interstate 6.400 6.415 6.352 6.273 6.210 6.152 Primary 6.375 6.367 6.346 6.313 6.287 6.288 Secondary 6.411 6.394 6.379 6.362 6.366 Average 6.408 6.383 6.357 6.328 6.324 Superstructure General Condition Rating
31 6 year GCR Trends (2006 through 2011) 6.400 6.300 Average GCR of Substructures 6.200 6.100 6.000 5.900 Deck GCR 2006 2007 2008 2009 2010 2011 Interstate 6.147 6.162 6.132 6.091 6.008 5.974 Primary 6.349 6.338 6.317 6.296 6.268 6.258 Secondary 6.386 6.369 6.347 6.326 6.319 Average 6.350 6.330 6.307 6.283 6.271 Superstructure General Condition Rating
32 Evaluating the Performance of Culverts Average Culvert GCR by Decade and Material 9.00 8.00 GCR 7.00 6.00 5.00 2010-2012 2000-2009 1990-1999 1980-1989 1970-1979 1960-1969 1950-1959 1940-1949 1930-1939 Pre 1900-1929 Concrete 8.49 7.53 7.03 6.68 6.40 6.27 6.32 6.11 6.15 5.90 Steel 8.00 7.27 6.39 6.06 5.91 5.66 5.80 5.17 5.75 5.33 Decade Culverts have outperformed bridges and concrete culverts have outperformed steel culverts
33 Evaluating the Performance of Culverts Percentage of Structurally Deficient Culverts by Material Type and Decade 20.00% 29/157 Percentage of Structurally Deficient Culverts 18.00% 16.00% 14.00% 12.00% 10.00% 8.00% 6.00% 4.00% 2.00% 0.00% 1/18 2010-2012 2000-2009 29/332 37/414 1/818 1/460 3/840 1990-1999 1980-1989 83/633 1970-1979 10/ 1,494 46/308 1960-1969 7/525 15/88 2/12 1950-1959 1/211 1940-1949 13/824 Pre 1900-1939 Concrete Steel Decade Culverts have outperformed bridges and concrete culverts have outperformed steel culverts
34 Importance of Quality Control Governmental procurement rules require many steps before any work can be done in the field Inspection Inventory Work needs Structure Condition Bridge Management Work Prioritization Project Scoping Project Development Design Permitting Right of Way Advertisement & Award Construction Preconstruction Conf. Mobilization Traffic Control Joint Preparation Installation
35 Importance of Quality Control Installation All previous efforts are wasted if the final step isn t properly performed
36 Importance of Quality Control
37 Importance of Quality Control
38 Summary Replace joints in a timely manner Spend resources wisely Emphasize preventive maintenance Make data-driven decisions when selecting interventions Constantly evaluate new materials and methods Balance spending Perform high quality work