Publication No. FHWA-HIF-17-019 Publication Date: June 2013 i Engineering Design, Fabrication and Erection of Prefabricated Bridge Elements and Systems Foreword This manual has been developed for the purposes of enhancing the use of Prefabricated Bridge Elements and Systems (PBES) as part of accelerated construction projects. FHWA continues to focus on a need to create awareness, inform, educate, train, assist and entice State DOT’s and their staff in the use of rapid construction techniques. This manual is a follow-up of a previously completed manual on Accelerated Bridge Construction (ABC). The purpose of this manual is to provide more in-depth information on the design, fabrication and erection of PBES. Significant portions of the previous ABC manual will be reproduced in this manual in order to provide a stand-alone document with minimal cross references. Users of this manual will be able to perform the following tasks: • Understand the different materials used in the construction of prefabricated bridge elements and systems. • Understand the design requirements for the most common PBES technologies in use today. • Understand how to design for durability using PBES. • Understand how to specify PBES and design them for shipping and erection. Joseph L. Hartmann, PhD, P.E. Director, Office of Bridges and Structures i Engineering Design, Fabrication and Erection of Prefabricated Bridge Elements and Systems Notice This document is disseminated under the sponsorship of the U.S. Department of Transportation in the interest of information exchange. The U.S. Government assumes no liability for the use of the information contained in this document. The U.S. Government does not endorse products or manufacturers. Trademarks or manufacturers' names appear in this report only because they are considered essential to the objective of the document. Quality Assurance Statement The Federal Highway Administration (FHWA) provides high-quality information to serve Government, industry, and the public in a manner that promotes public understanding. Standards and policies are used to ensure and maximize the quality, objectivity, utility, and integrity of its information. FHWA periodically reviews quality issues and adjusts its programs and processes to ensure continuous quality improvement. ii Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. Recipient's Catalog No. FHWA-HIF-17-019 4. Title and Subtitle 5. Report Date Engineering Design, Fabrication and Erection of June 2013 Prefabricated Bridge Elements and Systems 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. Michael Culmo, Hugh Boyle, Scott Nettleton, Vijay Chandra, Maher Tadros, Jagannath Mallela 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) ARA, Inc. 100 Trade Centre Drive, Suite 200 11. Contract or Grant No. Champaign, IL 61820 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered Federal Highway Administration Highways for LIFE Program – HIHL-1 14. Sponsoring Agency Code 1200 New Jersey Avenue, SE Washington, D.C. 20590 15. Supplementary Notes 16. Abstract Through the Every Day Counts (EDC) program, the Federal Highway Administration (FHWA) has been taking initiatives to bring Accelerated Bridge Construction (ABC) technologies into the market that can help highway agencies build bridges faster and reduce adverse work zone impacts. The manual focuses on the design aspects of ABC using Prefabricated Bridge Elements and Systems (PBES). The purpose of the PBES/ABC design manual is to provide an overview of design, materials, and construction aspects of PBES; explore typical design, planning, and construction processes; identify how they relate to ABC; and offer guidance on where to obtain more information on each subject. The manual reviews the 4th Edition American Association of State Highway and Transportation Officials (AASHTO) Load and Resistance Factor Design (LRFD) Bridge Design Specifications for their applicability to the design of PBES elements. The manual covers the design aspects of prefabricated bridge superstructure, substructure and foundation elements. While the general design concepts are the same for both cast-in-place and prefabricated elements, this manual discusses subtle differences in the design approach and provide recommendation that are not are not well covered in the AASHTO LRFD Bridge Design Specifications. The design recommendations provided herein are based on research data, engineering judgment, and the concept of emulative design. The manual provides a discussion on the design of jointless decks and critical connections for durability, other precast elements including culverts, arches and frames and other miscellaneous elements. The manual covers the tolerance and quality control requirements for various elements. The manual also explores the effect of shipping, handling, and assembly on the design process. ABC projects often require the use of a wide variety of materials including conventional materials (e.g. steel, aluminum), new materials (e.g. polymers), or higher performance versions of conventional materials (e.g. ultra-high performance concrete). The manual explores the changes that can be made to materials that are commonly used in PBES/ABC projects. In addition, the manual also addresses the materials and construction related specification requirements, including sample specification language, for these materials. 17. Key Words 18. Distribution Statement Accelerated bridge construction, ABC, prefabricated No restrictions. This document is available to the public through bridge elements and systems, PBES, Every Day the National Technical Information Service, Springfield, VA Counts, EDC 22161. 19. Security Classification (of this report) 20. Security Classification (of this page) 21. No. of Pages 22. Price Unclassified Unclassified 347 iii SI* (Modern Metric) Conversion Factors APPROXIMATE CONVERSIONS TO SI UNITS SYMBOL WHEN YOU KNOW MULTIPLY BY TO FIND SYMBOL LENGTH in inches 25.4 millimeters mm ft feet 0.305 meters m yd yards 0.914 meters m mi miles 1.61 kilometers km AREA in2 square inches 645.2 square millimeters mm2 ft2 square feet 0.093 square meters m2 yd2 square yard 0.836 square meters m2 ac acres 0.405 hectares ha mi2 square miles 2.59 square kilometers km2 VOLUME fl oz fluid ounces 29.57 milliliters mL gal gallons 3.785 liters L ft3 cubic feet 0.028 cubic meters m3 yd3 cubic yards 0.765 cubic meters m3 NOTE: volumes greater than 1000 L shall be shown in m3 MASS oz ounces 28.35 grams g lb pounds 0.454 kilograms kg T short tons (2,000 lbs) 0.907 megagrams (or Mg (or "t") "metric ton") TEMPERATURE (exact degrees) oF Fahrenheit 5 (F-32)/9 Celsius oC or (F-32)/1.8 ILLUMINATION fc foot-candles 10.76 lux lx fl foot-Lamberts 3.426 candela/m2 cd/m2 FORCE and PRESSURE or STRESS lbf poundforce 4.45 newtons N lbf/in2 poundforce per square inch 6.89 kilopascals kPa iv SI* (Modern Metric) Conversion Factors APPROXIMATE CONVERSIONS FROM SI UNITS SYMBOL WHEN YOU KNOW MULTIPLY BY TO FIND SYMBOL LENGTH mm millimeters 0.039 inches in m meters 3.28 feet ft m meters 1.09 yards yd km kilometers 0.621 miles mi AREA mm2 square millimeters 0.0016 square inches in2 m2 square meters 10.764 square feet ft2 m2 square meters 1.195 square yards yd2 ha hectares 2.47 acres ac km2 square kilometers 0.386 square miles mi2 VOLUME mL milliliters 0.034 fluid ounces fl oz L liters 0.264 gallons gal m3 cubic meters 35.314 cubic feet ft3 m3 cubic meters 1.307 cubic yards yd3 MASS g grams 0.035 ounces oz kg kilograms 2.202 pounds lb Mg (or megagrams (or "metric 1.103 short tons (2,000 lbs) T "t") ton") TEMPERATURE (exact degrees) oC Celsius 1.8C+32 Fahrenheit oF ILLUMINATION lx lux 0.0929 foot-candles fc cd/m2 candela/m2 0.2919 foot-Lamberts fl FORCE and PRESSURE or STRESS N newtons 0.225 poundforce lbf kPa kilopascals 0.145 poundforce per lbf/in2 square inch *SI is the symbol for the International System of Units. Appropriate rounding should be made to comply with Section 4 of ASTM E380. (Revised March 2003). v Table of Contents Chapter 1. PURPOSE AND USE OF THE MANUAL ............................................................. 1 1.1. INTRODUCTION .......................................................................................................... 1 1.2. INTENDED USERS ....................................................................................................... 2 1.2.1. Design Engineers .................................................................................................... 2 1.2.2. Materials Engineers ................................................................................................ 3 1.2.3. Construction Engineering and Inspection Staff ...................................................... 4 Chapter 2. MATERIALS FOR ABC AND PBES ..................................................................... 7 2.1. CEMENTITIOUS MATERIALS ................................................................................... 7 2.1.1. Concrete .................................................................................................................. 7 2.1.2. Lightweight Concrete............................................................................................ 12 2.1.3. Grout for Voids ..................................................................................................... 15 2.1.4. Grout for Post-Tensioning Ducts .......................................................................... 16 2.1.5. Flowable