JULY 2021 | EDITION I ACCELERATED BRIDGE CONSTRUCTION MANUAL Issued By ABC Manual • July 2021 PREFACE The purpose of this manual is to provide planners and engineers with a basic understanding of the different ABC methods available, help guide -projectspecific selection of ABC methods, and encourage the use of ABC methods. This manual is a guideline document. All provisions contained herein are subject to review and adjustment by the Structure Design Project Engineer (PE) with approval by the owner. In many provisions, the terms “must” and “shall,” are used. These provisions are intended to be used in the development of contract specifications. Other provisions use the terms “should,” “may,” and “recommended.” The term “should” indicates a strong preference for a given criterion. The term “may” indicates a criterion that is usable but other suitably documented, verified and authorized criterion may also be applied. The term “recommended” is used to give guidance based on past experiences. Structure Technical Policies (STPs) and Bridge Design Memos (BDMs) are referenced throughout this manual to supplement design specifications by addressing areas not covered; expanding requirements based on successful past practices; and implementing more recent innovations. These documents include and supersede policies and guidance from previous Memos to Designers (MTDs) and Bridge Design Aids (BDAs). Since STPs and BDMs are under development during the writing of this manual, they may not be available, in which case, the reader should refer to the corresponding MTD or BDA and coordinate with the appropriate technical specialist, if necessary. Lists of STPs and BDMs with corresponding MTDs and BDAs are maintained by the Office of State Bridge Engineer Support. Preface 1 ABC Manual • July 2021 ACKNOWLEDGEMENTS The 2021 first edition of the Accelerated Bridge Construction (ABC) Manual was developed by Caltrans with assistance from T.Y. Lin International under Contract No. 59A1037. The authors were Dorie Mellon and Manode Kodsuntie of Caltrans and Jay Holombo, Kumar Ghosh, and George Rowe of T.Y. Lin International. The Contract Managers were Sam Akkad of Caltrans and Bob Fish of T.Y. Lin International. This manual was developed in the spirit of innovation, collaboration, and continual improvement by a dedicated group of engineers and administrators committed to the advancement of ABC in California. The following is a list of organizations and individuals that contributed valuable input. CALTRANS Division of Engineering SP&I continued Materials Engineering and Services Greg Kaderabek Testing Services Tom Ostrom Kevin Keady Don Adams Structure Design Todd Lambert Robert Ferris Jason Chou Saygunn Low Joe Harline Mike Downs Jim Ma Patrick Lo Amir Gilani Aiman Malak Hamed Sadati Habib Hotaki Kimberly Mori Divyesh Vora Jason Lynch Don Nguyen-Tan Structure Maintenance and Amir Malek Andrew Nicoletti Investigation Sirisha Nelapatla Tom Ruckman Dave Ward Richard Porter Talal Sadek Mark Woods Rene Raynes Shane Salvador HQ Office of Biological Grant Schuster Christian Unanwa Science and Innovation Kuruswamy Selventhiran Toorak Zokaie Melinda Molnar Gudmund Setberg Structure Construction Innovative Design and Sujan Talukder Jarred Burrows Delivery Structure Policy Dave Galarza Amy Fong and Innovation (SP&I) Brandon Miller Ray Tritt Nina Choy Jim Nicholls District 2 Asset & Program Lian Duan Geotechnical Services Project Management Paul Fayer Roberto Lacalle Derek Willis Dena Joseph David T Liao Brett Ditzler Hector Valencia FEDERAL HIGHWAY ADMINISTRATION Jamal Elkaissi Romeo Garcia Acknowledgements 1 ABC Manual • July 2021 INDUSTRY PARTNERS American Council of T.Y. Lin International Con-Fab California Engineering Companies Bala Sivakumar Brent Koch Gary Antonucci CHA Consulting HDR Jack Abcarius Michael P Culmo Mike LaViolette Michelle D’souza from T.Y. Lin International prepared graphics and Jim Collins from JCWrite provided editorial reviews and formatting. Many thanks are extended to the managers, contributors, and industry partners who participated in this project. Go ABC! Gudmund Setberg, P.E. Kevin Keady, P.E. Michael Francis, P.E. Deputy Division Chief Deputy Division Chief Deputy Division Chief Structure Design (Acting) (Acting) Division of Engineering Structure Policy and Structure Construction Services Innovation Division of Engineering Division of Engineering Services Services 2 Acknowledgements ABC Manual • July 2021 Table of Contents Preface Acknowledgements Table of Contents Definitions and Abbreviations Chapter 1 Introduction Chapter 2 Workflow Chapter 3 Planning Chapter 4 Design Chapter 5 Construction Chapter 6 Resources Appendix A Prefabricated Bridge Element Checklists Appendix B Lateral Slide Checklists Appendix C Self-Propelled Modular Transporter (SPMT) Move Checklists Appendix D Caltrans Implementation of Ultra-High Performance Concrete (UHPC) Appendix E Ultra-High Performance Concrete (UHPC) Checklists Table of Contents 1 ABC Manual • July 2021 DEFINITIONS AND ABBREVIATIONS DEFINITIONS The following definitions include terminology used in this manual and in relevant literature on Accelerated Bridge Construction. Refer to the AASHTO LRFD Accelerated Bridge Construction Manual (AASHTO GSABC) Section 1.3 for further definitions. Accelerated Bridge Construction (ABC)—Bridge construction methods that use the most efficient combination of innovative planning, design, materials, and construction techniques to significantly reduce construction related impacts by reducing the number of onsite construction days and/or minimizing traffic disruption. Assembly Plan—A workplan that is a combination of plans, specifications, and calculations developed by the contractor that describes the step-by-step process for the assembly of prefabricated bridge elements and prefabricated bridge element systems. The assembly plan details how a bridge or bridge components are to be lifted, rolled, launched, slid, or otherwise transported into placeThe. assembly plan may include handling and erection plans, move plans, communication plans, geometric control plans, contingency plans, material specifications, details and calculations for temporary supports, and construction scheduling. Bridge Staging Area (BSA)—A temporary location, often near the bridge’s permanent location, where the bridge is constructed before being moved to its permanent position. Bridge System—A bridge superstructure, or superstructure and substructure, constructed in a BSA using conventional construction methods or assembled prefabricated bridge elements, and moved into place. Construction Completion Time (CCT)—An estimate of the total onsite construction days required for bridge construction work, not including roadway or offsite activities such as roadwork, mobilization, procurement, or traffic handling preparations. Construction Impact Time (CIT)—An estimate of the working days or hours that bridge construction will impact a specific item of interest, such as road closures and detours, environmentally sensitive areas, local businesses, and essential services. Contingency Plan—A plan prepared by the contractor that will be implemented if an event occurs that could cause a significant delay, such as a major equipment malfunction or inclement weather. Conventional Bridge Construction—Construction method where prefabrication is typically limited to beams or girdersConventional. Bridge Construction does not Definitions i-i ABC Manual • July 2021 significantly reduce onsite construction time or any impacts through the use of innovative planning, design, materials, and construction techniques. Construction Manager/General Contractor (CMGC)—A project delivery method that allows Caltrans to engage a construction manager to provide input during the design process. Caltrans and the construction manager agree on a price for construction of the project, and the construction manager then becomes the general contractor. Design-Build (DB)—A project delivery method in which the design and construction of a project is awarded to a single entity. DB involves a single contract between Caltrans and a design-builder covering both the final design and the construction of the project. Design-Bid-Build (DBB)—A traditional linear project delivery method in which the design is first completed and then put out to bid for a qualified contractor to build the project. Every-Day Counts (EDC)—A Federal Highway Administration (FHWA) program that identifies and rapidly deploys proven yet underutilized innovations to shorten the project delivery process, enhance roadway safety, reduce traffic congestion, and integrate automation. Erection Work Plan—A work plan that describes procedures, details, and sequences for unloading, lifting, and erecting prefabricated bridge elements and bridge systems and includes temporary support installation. Geometric Control Plan—A work plan that describes how the geometric detail of the bridge assembly will be controlled and monitored. Geosynthetic Reinforced Soil–Integrated Bridge System(GRS -IBS)—An ABC technology that uses alternating layers of compacted granular fill material and fabric sheets of Geotextile reinforcement to provide support for the bridge in place of a traditional abutment. The use of GRS-IBS to support state bridges in California is not allowed at this time. Interim Loading Condition—A loading condition of a bridge element and bridge system that exists prior to completion of construction. Maintenance of Traffic (MOT)—The requirements for maintaining traffic during