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Final Report Structure Design and Rehabilitation, Inc. FINAL REPORT PREFABRICATED STEEL BRIDGE SYSTEMS FHWA SOLICITATION NO. DTFH61-03-R-00113 Prepared for: Federal Highway Administration Office of Acquisition Management 400 Seventh Street, S.W., Room 4410 Washington, DC 20590 September 2005 TABLE OF CONTENTS PROJECT SUMMARY.............................................................................................................1 1. INTRODUCTION .............................................................................................................3 1.1 State of the Problem and Background ...................................................................... 3 1.2 Objectives of the Study............................................................................................. 5 1.3 Organization of the Report........................................................................................ 7 2. HISTORICAL BACKGROUND OF STEEL BRIDGES .................................................9 2.1 Superstructures........................................................................................................ 10 2.1.1 Temporary Bridges / Emergency Bridges....................................................... 10 2.1.2 Permanent Bridges.......................................................................................... 25 2.2 Substructures........................................................................................................... 48 2.2.1 Prefabricated Steel Piers ................................................................................. 48 2.3 Bibliography ........................................................................................................... 49 3. ACCELERATED CONSTRUCTION – MINIMUM SYSTEM REQUIREMENTS.....50 3.1 Conventional Construction and Erection Techniques............................................. 53 3.1.1 Configurations of Modular Systems ............................................................... 53 3.1.2 Cost Effectiveness / Standardization .............................................................. 53 3.1.3 Conventional Fabrication Methods................................................................. 54 3.1.4 Construction Issues Associated With Modular Bridge Systems..................... 54 3.1.5 Transportation and Erection Issues................................................................. 58 3.1.6 Design Loads and 75-Year Service Life......................................................... 60 3.1.7 Future Maintenance........................................................................................ 61 4. NEW CONCEPTS FOR ACCELERATED BRIDGE CONSTRUCTION.....................62 4.1 Evaluation of Existing Systems .............................................................................. 62 4.2 New Systems Development .................................................................................... 69 4.2.1 Modular Cast-in-Place System ....................................................................... 69 4.2.2 Modular Precast System ................................................................................. 76 5. Optimization ....................................................................................................................79 5.1 Review of Global Optimization Methods............................................................... 79 5.1.1 Review of methods and strategies................................................................... 79 5.1.2 Review of Work Related to Steel Section Optimization ................................ 82 5.2 Problem Formulation .............................................................................................. 83 5.2.1 Design Parameters .......................................................................................... 83 5.2.2 Design Objectives........................................................................................... 84 5.2.3 Assumptions.................................................................................................... 84 i 5.2.4 Design Constraints.......................................................................................... 85 5.2.5 Optimization Flow Chart ................................................................................ 94 5.3 Optimization Strategies and Methodology Used .................................................... 96 5.3.1 Overview......................................................................................................... 96 5.3.2 Genetic Algorithms (GA) ............................................................................... 97 5.3.3 Surrogate Based Optimization (SBO)............................................................. 99 5.4 References............................................................................................................. 101 6. OPTIMIZATION RESULTS AND DISCUSSIONS ....................................................103 6.1 Studied Parameters and Limits Considerations .................................................... 103 6.2 Presentation and Discussion of Results ................................................................ 105 6.2.1 Effect of Slab Thickness ............................................................................... 111 6.2.2 Effect of Concrete Strength .......................................................................... 113 6.2.3 Effect of Type of Concrete ........................................................................... 116 7. CONCLUSIONS AND RECOMMENDATIONS ........................................................118 7.1 Conclusions........................................................................................................... 118 7.2 Recommendations................................................................................................. 119 8. Appendix A – GA Optimization....................................................................................120 9. Appendix B – SBO Optimization ..................................................................................190 ii PROJECT SUMMARY The main objective of the present study was to identify and assess the use of new and innovative prefabricated steel bridge systems/elements and methods in bridge construction, rehabilitation and replacement. To this end, the study was divided into three phases: (i) the background and knowledge building phase, (ii) the concept development phase, and (iii) the optimization phase. In the first phase, a literature review was first performed on the history of steel bridges. The current practice and applications of prefabricated systems were then discussed, including innovations that are currently being implemented, as well as several designs schemes that are still in the experimental phase of development. Review and synthesis of such an endeavor led to identification of problems hindering the wide spread use of these systems for accelerated bridge construction and developing possible enhancements by establishing the minimum system requirements (criteria) for rapid construction. It was found that in order to become competitive with “in-place construction” of steel and/or concrete bridges, prefabricated systems must aesthetics acceptable and provide benefits such as: • Cost Effectiveness / Standardization • Faster Installation • Design Flexibility • Easy Handling and Transportation of Components • Reduced Superstructure Depth • Greater Durability • Reduced Maintenance In the second phase of the study, two steel bridge concepts are developed and detailed, using innovative prefabrication and construction techniques. Both concepts are based on modular units made of steel girders and concrete deck. The first concept is made of all- prefabricated system including the deck slab, whereas the second is made of prefabricated steel girder system and cast-in-place concrete deck. These two concepts, in 1 addition to adhering to the rapid construction philosophy, address the current needs, including system adaptability, connection details between components, use of innovative materials, standardization of components, design and construction specifications, transportation weight and size limits, and limits to standard erection cranes and equipment. In the third (optimization) phase, the two concepts were optimized using Genetic Algorithms (GA) and Surrogate Based Optimization (SBO) techniques taking into account objective constraints such as weight limitation due to transportation, and LRFD code requirements. In particular, the optimization was implemented to study the effects of the following parameters: span length, slab thickness, concrete strength, and concrete type (light weight versus normal weight). Performance and Cost analyses were also carried out to compare between systems and assess the influence of the different parameters on cost. Finally, the main findings of the study are presented, followed by recommendations for future research work.. 2 1. INTRODUCTION This chapter introduces the problem statement and the background related to the research study. It also presents the objectives of the study and outlines the organization of the report. 1.1 State of the Problem and Background The nation's infrastructure of highway bridges is plagued with two major problems: premature deterioration and structural deficiency, both of which were underscored as strategic research issues in a recent NSF study (“Civil” 1998). At the national level, over 28% of all bridges are classified as structurally deficient or
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