Construction Techniques for Segmental Concrete Bridges
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••N♦N^j1♦j.•♦j^♦j-.•je♦j-♦•j1♦N♦••♦N•N♦N♦N•N♦NeeeN•N•N•N♦N•N•N♦N•♦ ♦•t Construction Techniques for Segmental Concrete Bridges •2•.i. •i• •e• .i. James M. Barker .i. Associate •Z• H. W. Lochner, Inc. Consulting Engineers Chicago, Illinois ne of the primary advantages of struction or in design in the United O segmental concrete bridge con- States, few have been or will be con- struction is the economics. In a large structed in exactly the same manner. majority of cases, segmental construc- The multitude of choices available to tion has been the winner where alternate contractors allows them to tailor each construction methods have been avail- project to their manpower and equip- able to contractors at the time of bidding. ment in the interest of maximizing effi- There are many reasons for this rela- ciency and optimizing cost. tively new method of bridge construction Segmental bridge construction is also in the United States competing so well in revising the basic thinking of design en- the 10 years since the European transfer gineers. Until recently, designers have technology was started. I believe, how- concerned themselves mainly on how to ever, that the principle reason for the build the project after preparing compu- success of segmental concrete con- tations and plans. Segmental construc- struction is the number of construction tion has revised this thinking. The first techniques available to build these question asked about a project now is bridges. Of approximately 35 to 40 such "What is the best and most economical bridges either completed, under con- way to build this project?" Once this question has been satisfactorily an- swered, the designer can proceed with a NOTE: This article is based on a presentation given design based on the most efficient con- at the Long Span Concrete Bridge Conference in Hartford, Connecticut, March 18-19, 1980. The struction method. conference was sponsored by the Federal Highway In order to make intelligent decisions, Administration, Portland Cement Association, Pre- stressed Concrete Institute, Post-Tensioning Insti- both designers and contractors need to tute, and Concrete Reinforcing Steel Institute. become familiar with the available 66 0FFIT ARRIAGE CCC e ^ ^ ^^1^i1i1^o oo oo o O Fig. 1. Schematic of short line match casting system. The usual rate of production is four segments per week per set of forms. methods of segmental construction. Not methods to be discussed utilize the con- all methods are applicable to all projects cept of match casting. The basic prem- but all should be considered for each ise of match casting is to cast the seg- job. There are several fundamental con- ments so their relative erected position cepts relating to casting and erection of is identical to their relative casting posi- segments which could be considered for tion. This requires a perfect fit between practically every bridge project. By no the ends of the segments and is accom- means should these basic concepts be plished by casting each segment directly the only ones considered. Segmental against the face of the preceding one bridge construction was born out of in- using a debonder to prevent bonding of novation and will continue to grow the concrete. The segments are then through more innovation by both con- erected in the same sequence they were tractors and design engineers. cast. The most common method for match Precasting Techniques casting segments is called the "short line" method. Fig. 1 shows a schematic Short line system—All the casting of a short line match casting system. PCI JOURNAUJuly-August 1980 67 Fig. 2. Casting machines (forms) fold back hydraulically or with screw jacks to permit moving of segments. With this system, the rate of segment When the workers arrive at the pre- production will approach one segment casting yard on Wednesday morning, per line of forms per day. A good aver- the side forms are closed, the inside age to use for a project is four segments form is rolled forward, Tuesdays seg- per line every 5 days. ment is in the new segment position and For the sake of explaining the casting Mondays segment is in the old segment procedure, assume today is Wednes- position. The first operation is to deter- day. The older segment was cast on mine the relative position as the seg- Monday and is now cured and ready for ments actually were cast. This is done the storage yard. The old segment was by shooting elevations and centerline cast yesterday or Tuesday and was with an accurate survey instrument. match cast against Mondays segment. These shots are called "early morning Today a new segment will be cast shots." (Geometry control will be dis- against Tuesdays segment. cussed in greater detail later.) Once the Fig. 2 shows the form arrangement early morning shots are taken, the forms for short line match casting. The French are released and Mondays segment is call these forms casting machines. taken to the storage yard. Tuesdays The appropriateness of this name will segment is then moved from the new soon become apparent for they really segment position to the old segment po- are machines. The length of the side sition. forms is equal to the length of the seg- All of the geometry of the bridge (hori- ment being cast plus 1 or 2 in. (25 or 51 zontal or vertical curves and super- mm) to seal around the match cast elevation or transitions) is cast in by ad- joint. The side forms have the capability justing the old segment. The forms are of being folded back away from the never adjusted for geometry. Therefore, segment to permit removal of the seg- once Tuesdays segment is in the old ment. This is done either with screw segment position, its attitude is adjusted jacks or hydraulic rams. The collapsible by screw jacks between the carriage and inside formwork which forms the void of the soffit to provide the proper bridge the box girder rolls on rails to allow re- geometry. A prefabricated reinforcing moval of the form, enabling the segment bar cage is then set in the new segment to be lifted vertically. position. Once the side forms are closed 68 Fig. 3. Casting machine. Proper geometry is obtained by adjusting the alignment of the cast-against (concrete) segment with screw jacks under the supporting soffit. and the inside form is rolled forward, the screw jacks for adjusting the attitude of casting machine is ready for casting to- the old segment. days (Wednesdays) segment. Fig. 4 is a schematic of the geometry Fig. 3 shows a casting machine for a control layout for a short line casting short line match cast system. Note the method. The survey instrument is PERMANENT PERMANENT TARGET INSTRUMENT ^ I STEEL BULKHEAD I H NEW SEGMENT 7/7,177/77/77/ 77777/77?/ PERMANENT SOFFIT Fig. 4. Geometry control layout for short line system. The instrument support and target should be stationary and permanent. PCI JOURNAUJuly-August 1980 69 nent survey control points. its are located over the ninate any influence of top rents. The center points 9oretical centerline. ally a theodilite capable of measuring Round-headed bolts placed 2 or 3 in. accurately to 1/32 of an inch (nearly 1 (51 or 76 mm) from the edge of segment mm). The permanent target is generally are used for the elevation control points. a concrete pile driven into the ground They are assumed to be at the edge of and insulated to prevent bending due to the segment for computation purposes the sun shining on one side. Elevations and should always be placed over the are shot using a survey rod. A metric rod webs to eliminate any influence of top may be more practical because the slab deflections. Since only relative po- smallest graduations are approximately sitions of segments are of concern, 1/32 of an inch which eliminates some of these bolts do not have to be placed at the guesswork involved when using rods any specific elevation but may be placed marked in feet and inches. The data in the wet concrete so the bottom of the measured are elevation differences so head is approximately at the concrete the metric rod does not result in exten- level. The early morning shots on these sive unit conversion. points establish the basis of relative po- The segment survey control point po- sitions. sitions are shown in Fig. 5. Each seg- The two centerline control points usu- ment has six control points—four over ally consist of U-shaped wires placed in the two webs and two on the centerline. the wet concrete after the top slab has ERECTED CANTILEVER FINAL PROFILE \ a THEORETICAL CASTING CURVE PIER LOCATION A = DEFLECTION DUE TO PRESTRESS Fig. 6. Theoretical casting curve is drawn from data provided by the design engineer. 70 been finished. The theoretical centerline by the erected cantilever curve in Fig. 6. is established by notching these wires Therefore, it is obvious the segments with a hammer and chisel during the must be cast with -a downward deflection early morning shots. of A so when the camber occurs the The designer of the bridge will provide proper alignment will be achieved. A information to develop a theoretical curve depicting this downward deflection casting curve. The theoretical casting is the theoretical casting curve. In reality, curve is a curve along which the seg- when all the deformations are consid- ments should be cast so the final de- ered, the theoretical casting curve usu- sired alignment will be achieved after all ally bends upward rather than down- deformations.