Prefabricated Bridge

Elements and Systems

in Europe and Japan

2004 FHWA/AASHTO
International Technology Scan
Harry Capers, P.E.,
New Jersey Department of
Transportation
September 16, 2005

Overview
Need for Prefabricated Bridges
Mission and Scope of 2004 Scan
Implementation Recommendations

Bridge Movement Systems

Superstructure Systems
Deck Systems
Substructure Systems

Current and Future Scan Activities

Initial DOT Implementation Efforts

National Bridge Inventory

Over 150,000 bridges
structurally deficient
or functionally obsolete
3,000 added annually
Increasing traffic
volumes, weights
Aging infrastructure

Over 130,000 bridges

recommended for
replacement, ~$70B+

What is Driving the Change

from Conventional
Construction?
The infrastructure is aging needed
now are innovative solutions that can
be built quicker and that last longer
Goal: A minimum 75-yr service life
Currently:
Average bridge life is 42 yrs
Average bridge deck life is 20-25 yrs

Challenge of Bridge
Repair and Replacement
Bridges must be
rehabilitated or replaced
while maintaining traffic
flowFixing a car with
the engine running
Work-zone Concerns:
congestion, traffic speed,
time delays, accidents

Get in, Get out, Stay out!

Public prefers short-term
shutdowns with long-term results
Accelerated Construction
Reduces Construction Time &
Traffic Control Costs
Minimizes Traffic Congestion
Reduces Highway Worker
& Motorist Exposure
Enhances Safety
Minimizes Impacts
Promotes Construction Quality

Scan Mission
To investigate and document applications
and experience of prefabricated bridges
in Japan and select European countries,
with emphasis on:
Routine bridges with 20 ft140 ft spans
Innovative systems
Replacement as well as new highway
and railroad bridges
Seismic considerations and
emergency work

Scan Team
FHWA

State DOTs

Benjamin Tang, Co-Chair

Claude Napier, Jr., VA
Barry Brecto, WA

Industry
Shri Bhide, PCA, National
Concrete Bridge Council
Henry G. Russell,
Facilitator
Market Development
Alliance, FRP (Invited)
National Steel Bridge
Alliance (Invited)

Mary Lou Ralls, Co-Chair, TX

Harry Capers, NJ
William Nickas, FL
Dan Dorgan, MN

National Association of
County Engineers
Eugene Calvert

Academia
Eric Matsumoto, California
State University, Sacramento

Scan Organizer
John ONeill, ATI

Focus Areas
Minimized traffic disruption
Improved work zone safety
Minimized environmental impacts
Improved constructibility
Improved product quality
Lower life-cycle costs

Scope
Project Decision Processes
Design and Construction Methods
Innovative and Conventional Materials
Cost Considerations
Maintenance and Inspection

Scan Process
Interview owners, designers,
fabricators, and contractors
on project experiences
Examine and evaluate
prefabricated bridges via
field visits
Evaluate documentation
Report findings & develop
National Implementation Plan

Scan Countries
2. Netherlands

3. Belgium

1. Japan

5. France

4. Germany

Hosts
JAPAN
Japan Highway Public Corporation
East Japan Railway Company
Mitsubishi Heavy Industries
Sumitomo Mitsui Construction Company
Mitsui Engineering and Shipbuilding
Company
Kajima Corporation
NETHERLANDS/BELGIUM
Mammoet Corporation
Sarens

Hosts
GERMANY
Bavarian Construction Ministry, Munich
A3 Anschlusstelle, Frankfurt
German Federal Highway
Research Institute (BASt), Cologne

Hosts
FRANCE
SNCF (French National Railway Authority)
SETRA (Tech. Dept. for Public Works & Transp.)
LCPC (Central Laboratory for Public Works)
CERIB (Techical Ctr of Concrete Industry)
CETE (Technical Studies Ctr for Public Works)
CPCBTP (Producer)
Lafarge Cement

Implementation
Recommendations
Bridge Movement Systems
Superstructure Systems
Deck Systems
Substructure Systems

Bridge Movement
Systems
Self-Propelled Modular Transporters
(SPMTs)
Other Bridge Installation Systems
Horizontal Skidding
Incremental Launching
Floating Methods
Pivoting
Vertical Lifting

SPMTs

Construct bridge off-line

then move on-line in hours
4-6 axle lines, 33 tons/axle
Computer-controlled by one
operator
Horizontal movement in any
direction, ~8% grades used
Equal loads maintained on
axles on irregular surfaces

The NetherlandsMammoet

BelgiumSarens

SPMTs

Two 154-ton RR
Bridges, Germany

3600-ton, 390-ft Superstructure Moved in

2 hours, Netherlands

SPMTs

390-ft, 900-ton Twin

Steel Arch Bridges
Moved across Canal
1900-ton Bridge
Movement, Germany

SPMTs

Lifting and Rolling of Complete 2200-ton

RR Bridge 1309, Nohant le Pin, Normandy

Horizontal Skidding

Skidding of Complete
3600-ton Bridge Using
Strand Jacks, Normandy

72-hour Skidding
of 10,500-ton
Bridge/Abutments
on Track, UK

Incremental Launching

Arimatsu Viaduct,
Above Route 23,
Nagoya, Japan

Two 6-span, 2150-ft,

13,000-ton bridges
Each span launched
in 12-hour window
56 synchronized
550-ton, 9-in stroke
jacks control
movement
Course correction at
each bent
2-in gap maintained

Floating

Floating 950-ton
Box Culvert Underpass,
22-hour installation,
St. Pierre du Vauvray

Pivoting

Pivoting 2700-ton 262-ft Superstructure

45 Degrees Using Synchronized Jacks
and Guide Pin, Viaduc do Ventabren

Lifting

Hydraulic Jacks Used to Lift

1300-ton Bridge Segment

Implementation
Recommendations
Bridge Movement Systems
Superstructure Systems
Deck Systems
Substructure Systems

Superstructure Systems
Poutre Dalle System
Partial-Depth Concrete Decks
Prefabricated on Steel/Concrete
Beams
U-Shaped Segments
with Transverse Ribs

Poutre Dalle System

Eliminates formwork, provides safe working surface
Precast, pretensioned
inverted-tees side-by-side
Overlapping hooks and CIP
for continuity
L~20-82 ft, L/H~28-30 SS
Width~16 in-80 in (28 ton)
Fast, versatile, simple,
durable, economical, safe

Partial-Depth Precast Decks

on Steel or Concrete Beams

Precast Deck on Steel

Precast Deck on
Beam, Germany
PC/PS Beam, Germany

U-Shaped Segments
with Transverse Ribs
Furukawa
Viaduct
L=4800 ft

Side-by-side PC/PS
Box Girders
41 112-148 ft spans

Restrictions: weight, height, environment

Limited space for casting & stock yard
Segments 33 tons & 52 ft wide, haul
from plants w/in 37 mi

New Tomei Expressway

New Meishin Expressway

Implementation
Recommendations
Bridge Movement Systems
Superstructure Systems
Deck Systems
Substructure Systems

Deck Systems
Full-Depth Prefabricated
Concrete Decks
Deck Joint Closure Details
Hybrid Steel-Concrete
Deck Systems
Multiple Level Corrosion
Protection Systems

Full-Depth Pretensioned
Decks

Reduces construction time, formwork, CIP

Provides quality, work surface, safety
Route 23 Nagoya, full-width pretensioned panels
(6.6 ft x 10.6 in x 49.2 ft) placed on steel girders
Studs welded to girder, pockets grouted, closure

Connection Details
Overlapping loops
Full anchorage
w/o splicing
Minimizes CIP
Rigid for handling
& placement

Deck Joint Closure Details

Transverse & longitudinal
joints for continuity
Epoxy-coated loop bars
Continuous center loop
Bars threaded through
Fiber-reinforced
expansive concrete
Experimental testing
Waterproof membrane &
asphalt wearing surface

Hybrid Steel-Concrete
Deck Systems

Light-weight stay-in-place formwork with

transverse joists for fast erection
Transverse joists support formwork & rebar
Shear studs and CIP pour produce
composite deck system

Multiple-Level Corrosion
Protection Systems

Asphalt wearing surf.

Asphalt protective layer
Bituminous fabric sheet
Epoxy-coating cover
Concrete cover

Implementation
Recommendations
Bridge Movement Systems
Superstructure Systems
Deck Systems
Substructure Systems

SPER System
Sumitomo Precast form for resisting
Earthquakes and for Rapid construction
Segmental Pier System
Factory-manufactured
stay-in-place precast
concrete panels
w/CIP concrete
Panels serve as both
formwork & structural
elements.

SPER-LP System
Piers up to ~40 ft
50% less construction time (660 ft total ht):
formwork and curing time savings

SPER-HP System
Piers up to ~164 ft
1/3 less in construction time (328 ft total ht):
formwork & lateral rebar installation
High Strength Ti
Longitudinal
Panel Re
Dowe

Hollow section
Two C sections w/ lateral rebar
Lateral rebar coupled in field
Ties anchored w/ U-bars

Current and Future

Activities

Disseminate Final Report

Scan Technology Implementation Plan
Implementation through Federal
Funding Programs, etc.
Innovative Bridge Research and
Deployment (IBRD)
Highways for LIFE
Federal Bridge

STIP

Identified 10 technologies in four

categories for implementation in U.S.

STIP includes:

Background
Implementation Strategy
Scan Team Leads
Deliverables
Timeframe
Funds Required

$85K Request for Development and

Dissemination

STIP Efforts

Disseminate technology via meetings,

workshops, articles, and website

Solicit Pilot Projects
Obtain further informationdesign basis,
drawings, specifications, photosfrom hosts
Prepare Project Planning Guide and Draft
Specifications for use of SPMTs
Translate documents, conduct lit search
Recommend research
Coordinate with NCHRP and other
organizations

Initial DOT Efforts

MNDOTPoutre Dalle

Poutre Dalle-type deck slab for two bridges

under development based on Scan

Interaction with Precasters to develop feasible

section without overhauling beds

TxDOTSPMTs: Bridge Replacements

along I-35 corridor widening through
central Texas.

FDOTSPMTs: Rapid Repair of I-10 after

Hurricane Ivan Damage

Initial DOT Efforts

MNDOTPoutre Dalle

Poutre Dalle-type deck slab for two bridges

under development based on Scan

Interaction with Precasters to develop feasible

section without overhauling beds

NJDOT Launching in Rt I-295/I-76/NJ 42.

RIDOT Looking at SPMT

FDOTSPMTs: Rapid Repair of I-10 after

Hurricane Ivan Damage

Hurricane Ivan I-10 Damage

East Side

West side

I-10 East Side Repair

Phase 1: 24-day contract

$250K/day incentive/disinc.

Modular Transporters,
supplied by Barnhart Crane &
Rigging Co, Memphis, Tenn.
were instrumental to moving
265-ton spans

Shifted 12 spans from East

bound to open West bound
Contractor finished 7 days
early$1.75M bonus

Future Directions
Widespread use of accelerated

construction (e.g., PBES) for bridges in

urban areas
In each case, engineering the solution
to meet the unique constraints; i.e.,

Reduced traffic disruption

Improved work-zone safety
Reduced environmental impact
Improved constructability
Improved quality
Lower life-cycle costs

Future Directions, contd.

More elements combined off-site
More efficient, innovative prefabricated

bridge systems using the enhanced

properties of high performance materials
More prefabricated substructures
More innovative methods of
construction; e.g., use of self-propelled
modular transporters (SPMTs), other
total bridge movements.

Future Directions, contd.

Increased focus on durability to extend
bridge service life to 75 years
Rehabilitation of the existing
infrastructure, with more public
involvement (CSS solutions)
More owner, industry, consultant,
academia, public partnerships to find
optimum solutions

A Suggested Role for

You

Insist on consideration of innovative

technologies to accelerate construction
9 Be willing to specify the first use
9 Select a large project or multiple projects
with repetitive sections for the first use
9 Use contracting strategies that are
significant to the contractor
9 Include cost trade-offs in project estimate
9 Engage all stakeholders for their input,
from initial planning through construction

Available Resources
For PBES bridges and contact information
http://www.fhwa.dot.gov/bridge/prefab/
For Accelerated Construction Technology Transfer
(ACTT) Workshop information
http://www.fhwa.dot.gov/construction/accelerate
d/

FHWA technical workshops on innovative

techniques

Mark your calendars!

FHWA National Prefabricated Bridge
Elements & Systems Workshop
December 14-16, 2005
San Diego, California
The Conference Website is (http://www.acceleratedbridge.com/)

The future is here!:

Substructures

Superstructures
& Decks

Looking for
a few champions
Thank You

SPMT