Connection Details for Prefabricated Bridge Elements and Systems

Table of Contents

PDF Version (8.5 mb)

• Foreword
• Introduction
• Chapter 1 – General Topics
  • 1.1 Benefits of Prefabrication
  • 1.2 Accelerated Construction Overview
    • 1.2.1 When to Use Accelerated Construction
    • 1.2.2 Rehabilitation Projects
    • 1.2.3 Typical Accelerated Construction Approaches
      • 1.2.3.1 Short-term Full Closure Projects
      • 1.2.3.2 Weekend Closures
      • 1.2.3.3 Overnight Closures
    • 1.2.4 Examples of Prefabricated Elements
    • 1.2.5 Opportunities for Architectural Treatments
  • 1.3 Applicability to Typical Bridges
    • 1.3.1 New Bridges
    • 1.3.2 Replacement of Existing Bridges
    • 1.3.3 Rehabilitation of Existing Bridges
    • 1.3.4 Issues with Curved, Skewed and Flared Bridges
    • 1.3.5 Truss Bridges and Girder Floorbeam Bridges
  • 1.4 Typical Accelerated Construction Connection Types
    • 1.4.1 Steel Elements
      • 1.4.1.1 Bolted
      • 1.4.1.2 Welded
      • 1.4.1.3 Cast-in-place Concrete closure pours with shear studs
    • 1.4.2 Concrete Elements
      • 1.4.2.1 Principles of Emulation Design
        • Grouted Reinforcing Splice Couplers
        • Grouted Post Tensioning (PT) Ducts
        • Grouted Voids
        • Traditional Post-Tensioning (PT)
        • Welded Connections
        • Bolted Connections
        • Cast-in-place Concrete Closure Pours
  • 1.5 Seismic Considerations
    • 1.5.1 General Criteria
    • 1.5.2 Connection of Superstructure to Substructure
      • Pinned Connections
      • Moment Connections
    • 1.5.3 Superstructure Connections
    • 1.5.4 Columns and Column Connections
      • Confinement Reinforcement
    • 1.5.5 Footings
    • 1.5.6 Deep Foundations
    • 1.5.7 Research
  • 1.6 Materials
    • 1.6.1 Concrete
    • 1.6.2 Structural Steel
    • 1.6.3 Timber
    • 1.6.4 Fiber Reinforced Polymers
    • 1.6.5 Grouts
      • 1.6.5.1 Grout types
        • Gas Generating
        • Ettringite
        • Air Release
      • 1.6.5.2 Environmental Conditions
        • Temperature
        • Moisture
        • Surface Preparation
      • 1.6.5.3 Placement Methods
        • Dry Pack
        • Pouring
        • Pumping
        • Post-tensioning Duct Grouting
      • 1.6.5.4 Curing
        • Wet Curing
        • Curing Temperature
        • Curing Compounds
      • 1.6.5.5 Specifications
      • 1.6.5.6 Quality control
        • Test Pours, Trial Batching, and Mock-Ups
        • Grouting of Post-tensioning Ducts
  • 1.7 Tolerances
    • 1.7.1 Element tolerances
    • 1.7.2 Dimensional growth
    • 1.7.3 Hardware tolerances
      • 1.7.3.1 Post-tensioning systems
      • 1.7.3.2 Grouted reinforcing splice couplers
      • 1.7.3.3 Embedded attachments
    • 1.7.4 Layout and Joint widths
    • 1.7.5 Closure Pours
    • 1.7.6 Camber Issues
    • 1.7.7 Specification requirements
  • 1.8 Fabrication and Construction Issues
    • 1.8.1 Quality Assurance and Quality Control (QA/QC)
      • 1.8.1.1 Fabricator Certification
      • 1.8.1.2 Near Site Fabrication
      • 1.8.1.3 Inspection
    • 1.8.2 Handling and Shipping
      • 1.8.2.1 Element Weight and Shipping
        • Over the Road Shipping Limits
        • Barge and Rail Access
        • Near Site Shipping
        • Crane Capacities
        • Lifting Hardware
        • Use of Self-propelled Modular Transporters (SPMT's)
        • Member stresses during lifting
      • 1.8.2.2 Recommended Design Approaches for Element Weight
      • 1.8.2.3 Imperfections, Damage and Repair
    • 1.8.3 Constructability
      • 1.8.3.1 Cranes
      • 1.8.3.2 Self Propelled Modular Transporters
      • 1.8.3.3 Temporary Support of Elements
      • 1.8.3.4 Time Constraints
      • 1.8.3.5 Assembly Plans
• Chapter 2 – Superstructure Connections
  • 2.1 Deck Systems
    • 2.1.1 Full Depth Precast Concrete Deck Slabs
      • 2.1.1.1 Connections Between Slab Elements
        • Strength Direction
        • Distribution Direction
        • Connection Design Considerations
      • 2.1.1.2 Connections to Steel Beam Framing
      • 2.1.1.3 Connections to Concrete Beam Framing
      • 2.1.1.4 Connections of Parapets, Curbs, and Railings
        • Concrete Parapets and Curbs
        • Steel and Aluminum Railings
    • 2.1.2 Open Grid Decks
      • 2.1.2.1 Connections Between Grids
      • 2.1.2.2 Connections to Steel Framing
      • 2.1.2.3 Connections of Parapets, Curbs, and Railings
    • 2.1.3 Concrete/Steel Hybrid Decks
      • • Partially Filled Grid Decks
        • Exodermic Decks
      • 2.1.3.1 Connections Between Panels
      • 2.1.3.2 Connections to Steel Framing
      • 2.1.3.3 Connections of Parapets, Curbs, and Railings
    • 2.1.4 Fiber Reinforced Polymer Decks
      • 2.1.4.1 Connections Between Panels
      • 2.1.4.2 Connections to Steel Framing
      • 2.1.4.3 Connections of Parapets, Curbs, and Railings
    • 2.1.5 Partial Depth Precast Concrete Deck Panels
      • 2.1.5.1 Connection to Steel Beam Framing
      • 2.1.5.2 Connections to Concrete Beam Framing
      • 2.1.5.3 Joints Between Panels
    • 2.1.6 Timber Deck Panels
      • 2.1.6.1 Connection Between Panels
      • 2.1.6.2 Connections to Framing
      • 2.1.6.3 Connections of Parapets, Curbs, and Railings
    • 2.1.7 Grouting Techniques for Deck Systems
      • 2.1.7.1 Joint Grouting
      • 2.1.7.2 Shear Connector Pocket Grouting
      • 2.1.7.3 Post-Tensioning Duct Grouting
      • 2.1.7.4 Bedding under deck panels
    • 2.1.8 Grade Control and Tolerances
    • 2.1.9 Evaluation of Performance and Long Term Durability of Prefabricated Deck Systems
      • 2.1.9.1 Reflective Cracking and Leakage
        • Poor Joint Configurations
        • Lack of Post-Tensioning
        • Reflective Cracking in Concrete Topping over Partial Depth Deck Panels
      • 2.1.9.2 Riding Surface Issues
    • 2.1.10 Estimated Construction Time for Connections
    • 2.1.11 Recommendations for Improvements to Current Practices
      • • Elimination of Post-Tensioning
    • 2.1.12 Connection Detail Data Sheets for Deck Systems
  • 2.2 Adjacent Butted Beam Systems
    • 2.2.1 Precast Prestressed Concrete Deck Bulb Tee Systems
      • 2.2.1.1 Connections Between Beams
      • 2.2.1.2 Welding and Grouting Issues
      • 2.2.1.3 Camber Issues
    • 2.2.2 Precast Prestressed Concrete Tee Systems
      • 2.2.2.1 Connections Between Beams
      • 2.2.2.2 Span to Span Connections
      • 2.2.2.3 Welding and Grouting Issues
      • 2.2.2.4 Camber Issues
    • 2.2.3 Precast Prestressed Adjacent Slab and Adjacent Box Beam Systems
      • 2.2.3.1 Connections Between Slabs and Between Adjacent Box Beams
        • Traditional Post-Tensioning and Bolted Systems
        • Reinforced Closure Pours
        • Welded Connections
      • 2.2.3.2 Concrete Over Pours and Composite Toppings
    • 2.2.4 Glue Laminated Timber Adjacent Deck Slabs
      • 2.2.4.1 Connections Between Slabs
    • 2.2.5 Grade Control and Tolerances
    • 2.2.6 Evaluation of Performance and Long Term Durability of Adjacent Beam Systems
    • 2.2.7 Estimated Construction Time for Connections
    • 2.2.8 Recommendations for Improvements to Current Practices
    • 2.2.9 Connection Detail Data Sheets for Adjacent Butted Beam Systems
  • 2.3 Decked Stringer Systems
    • 2.3.1 Transverse Connections
      • 2.3.1.1 Connections Between Steel Beams
      • 2.3.1.2 Connections Between Prestressed Precast Beams
    • 2.3.2 Longitudinal Connections
      • 2.3.2.1 Steel Beams
      • 2.3.2.2 Prestressed Precast Concrete Beams
    • 2.3.3 Simple Span Beams Made Continuous For Live Load
      • 2.3.3.1 Prestressed Precast Concrete Beams
      • 2.3.3.2 Steel Beams
    • 2.3.4 Tolerances
    • 2.3.5 Evaluation of Performance and Long Term Durability of Stringer Beam Systems
    • 2.3.6 Estimated Construction Time for Connections
    • 2.3.7 Recommendations for Improvements to Current Practices
    • 2.3.8 Connection Detail Data Sheets for Decked Stringer Systems
  • 2.4 Modular Prefabricated Superstructure Systems
    • 2.4.1 Precast Deck/Stringer Systems (inverset)
      • 2.4.1.1 Transverse Connection Between Units
    • 2.4.2 Large Precast Deck/Stringer Superstructure Systems for Bridges with Floorbeams
      • 2.4.2.1 Connection to Steel Floorbeams
    • 2.4.3 Precast Concrete Arch Systems
      • 2.4.3.1 Connection Between Arch Elements
      • 2.4.3.2 Connection Between Arch Segments
      • 2.4.3.3 Connection of Spandrel Walls
    • 2.4.4 Precast Concrete Box Culverts
    • 2.4.5 Grade Control and Tolerances
    • 2.4.6 Evaluation of Performance and Long Term Durability of Modular Prefabricated Superstructure Systems
    • 2.4.7 Estimated Construction Time for Connections
    • 2.4.8 Recommendations for Improvements to Current Practices
    • 2.4.9 Connection Detail Data Sheets for Modular Prefabricated Superstructure Systems
  • 2.5 Connections between Superstructures and Substructures
    • 2.5.1 Integral Pier Caps
    • 2.5.2 Integral Abutments
    • 2.5.3 Semi-Integral Abutments
    • 2.5.4 Structural Bearings
    • 2.5.5 Grade Control and Tolerances
    • 2.5.6 Evaluation of Performance and Long Term Durability of Superstructure to Substructure Connections
    • 2.5.7 Estimated Construction Time for Connections
    • 2.5.8 Recommendations for Improvements to Current Practices
    • 2.5.9 Connection Detail Data Sheets for Superstructure to Substructure Connections
  • 2.6 Miscellaneous Superstructure Connections
    • 2.6.1 Utilities and Drainage Assemblies and other Appurtenances
    • 2.6.2 Barriers, Curbs and Railings
    • 2.6.3 Evaluation of Performance and Long Term Durability of Superstructure Connections
    • 2.6.4 Estimated Construction Time for Connections
    • 2.6.5 Recommendations for Improvements to Current Practices
    • 2.6.6 Connection Detail Data Sheets for Miscellaneous Superstructure Connections
• Chapter 3 – Substructure Connections
  • 3.1 Pier Elements
    • 3.1.1 Precast Concrete Cap Beam Connections
      • 3.1.1.1 Connection to Cast-in-Place Concrete Columns and Piles
      • 3.1.1.2 Connection to Precast Columns
      • 3.1.1.3 Connection to Steel Piles (pile bents)
      • 3.1.1.4 Connection to Precast Concrete Piles (pile bents)
      • 3.1.1.5 Connection of Precast Concrete Cap to Precast Concrete Cap
    • 3.1.2 Precast Concrete Column Connections
      • 3.1.2.1 Connection of Column to Column
    • 3.1.3 Wall Pier Connections
      • 3.1.3.1 Connection of Precast Wall to Precast Footing
    • 3.1.4 Precast Concrete Column to Footing Connections
      • 3.1.4.1 Connection to Cast-in-Place Concrete Footing
      • 3.1.4.2 Connection to Precast Concrete Footing
    • 3.1.5 Grade Control and Tolerances
    • 3.1.6 Evaluation of Performance and Long Term Durability of Prefabricated Pier Systems
    • 3.1.7 Estimated Construction Time for Connections
    • 3.1.8 Recommendations for Improvements to Current Practices
    • 3.1.9 Connection Detail Data Sheets for Pier Systems
  • 3.2 Abutment Systems
    • • Backfilling Options
    • 3.2.1 Cantilever Wall Abutments
      • 3.2.1.1 Precast Abutment Stem to Precast Footing Connection
      • 3.2.1.2 Precast Backwall to Abutment Stem Connection
      • 3.2.1.3 Precast Breastwall (cheekwall) to Abutment Stem Connections
    • 3.2.2 Spill-through Abutments
    • 3.2.3 Precast Concrete Integral Abutments
      • 3.2.3.1 Connection Between Abutment Stem or Cap and Steel Piles
      • 3.2.3.2 Connection Between Abutment Stem or Cap and Concrete Piles
      • 3.2.3.3 Connection Between Adjacent Abutment Stems or Caps
    • 3.2.4 Miscellaneous Abutment Connections
      • 3.2.4.1 Flying Wingwalls
      • 3.2.4.2 Approach Slabs
    • 3.2.5 Grade Control and Tolerances
    • 3.2.6 Evaluation of Performance and Long Term Durability of Prefabricated Abutment Systems
    • 3.2.7 Estimated Construction Time for Connections
    • 3.2.8 Recommendations for Improvements to Current Practices
    • 3.2.9 Connection Detail Data Sheets for Abutment Systems
  • 3.3 Wingwall and Retaining Wall Systems
    • 3.3.1 Cantilever Walls
      • 3.3.1.1 Precast Wall Stem to Precast Footing Connection
      • 3.3.1.2 Precast Wall Stem to Precast Wall Stem Connection
    • 3.3.2 Modular Precast Wall Systems
      • 3.3.2.1 Mechanically Stabilized Earth Systems
      • 3.3.2.2 Modular Block Systems
    • 3.3.3 Tolerances
    • 3.3.4 Evaluation of Performance and Long Term Durability of Prefabricated Wall Systems
    • 3.3.5 Estimated Construction Time for Connections
    • 3.3.6 Recommendations for Improvements to Current Practices
    • 3.3.7 Connection Detail Data Sheets for Wingwall and Retaining Wall Systems
• Chapter 4 – Foundation Connections
  • 4.1 Footing and Pile Systems
    • 4.1.1 Precast Footing to Subgrade Connections
    • 4.1.2 Precast Footing to Precast Footing Connections
    • 4.1.3 Precast Footing to Steel Pile Connections
    • 4.1.4 Precast Footing to Precast Concrete Pile Connections
    • 4.1.5 Precast Footing to Cast-in-place Pile or Drilled Shaft Connections
    • 4.1.6 Precast Pile to Precast Pile Connection
    • 4.1.7 Precast Pier Box Cofferdams
    • 4.1.8 Grade Control and Tolerances
    • 4.1.9 Evaluation of Performance and Long Term Durability of Prefabricated Footing and Pile Systems
    • 4.1.10 Estimated Construction Time for Connections
    • 4.1.11 Recommendations for Improvements to Current Practices
    • 4.1.12 Connection Detail Data Sheets for Footing and Pile Systems

Appendices

• Appendix A: Connection Design Examples
  • Full Depth Precast Concrete Deck Slabs
  • Precast Column Connections
    • Column to Cap Connection using mild reinforcement embedded in grouted post-tensioning duct
  • Precast Column Connections
    • Precast Column Connections using Grouted Reinforcing Splice Couplers
• Appendix B: Proprietary Products
  • Prefabricated Superstructure Systems
    • Inverset
    • Effideck™
    • CON/SPAN® Bridge Systems
    • BEBO® Concrete Arch System
    • HY-SPAN® Bridge System
  • Grouted Reinforcing Splice Couplers
    • NMB Splice Sleeve
    • Dayton Superior DB Grot Sleeve
    • Erico Lenton Interlok Rebar Splicing System
  • Proprietary Retaining Wall Systems
    • Reinforced Earth» and Retained Earth™ Retaining Walls
    • Doublewal Retaining Wall
    • T-WALL® Retaining Wall System
  • Post-tensioning Systems
    • Dydiwag Systems
    • VSL Post-tensioning Systems
    • Williams Threadbar Systems
• Appendix C: Sample Construction Specifications
  • New Hampshire DOT – Prefabricated Substructures
  • New Hampshire DOT - Full Depth Precast Concrete Deck Slabs
  • Maine DOT – Prefabricated Integral abutments, piers and approach slabs
  • Texas DOT Precast Column Connections:
    • Column to Cap Connection using mild reinforcement embedded in grouted post-tensioning duct
• Appendix D: Case Studies
  • New Hampshire DOT
    • Mill Street over the Lamprey River, Epping, New Hampshire
  • Texas DOT
    • State Highway 36 over Lake Belton, Belton, Texas
  • Texas DOT
    • Short Span Local Bridges in Texas
  • Hypothetical Bridge Replacement Project using All Prefabricated Components.
    Details taken from this document
• Appendix E: Glossary
• Appendix F: References

Foreword

This document has been developed for the purposes of promoting the use of prefabricated elements and systems in bridges as part of accelerated construction projects. Accelerated construction and long term durability are integral parts of the Federal Highway Administration (FHWA) Bridge Program. Part of this program focuses 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 document represents the "State of the Practice" at this time with respect to accelerated bridge construction. Most of the details were obtained after an extensive search process that included the following sources:

• State Departments of Transportation
• Industry organizations
• Private consultants
• International organizations

In several cases, details were developed by the authors where details did not surface during the search process. These details have been labeled as "conceptual". The authors developed these details based on experience with similar details and materials. Owners should evaluate the effectiveness of these details for use in specific bridges.

This information contained herein should be used to develop designs that have the purpose of accelerating the construction of bridge projects. This will assist designers in determining which details would be appropriate for accelerated construction techniques. Some of the considerations for accelerated construction are:

• Improved work zone safety.
• Minimizing traffic disruption during bridge construction.
• Maintaining and/or improving construction quality.
• Reducing the life cycle costs and environmental impacts.

Prefabricated components produced off-site can be quickly assembled, and can reduce design time and cost, minimize forming, minimize lane closure time and/or possibly eliminate the need for a temporary bridge.

This document is organized so that designers can pick and choose the details that will eventually make up the final bridge. In most cases, several options are presented for a particular connection. The details are presented on concise one page (2 sided) data sheets that can be pulled and copied. This will allow the designer to quickly build a "detail library" that will be specific to the intended project.

This document only focuses on "details" for connections of prefabricated bridge elements and systems. Some guidance is given for general accelerated construction techniques. The Federal Highway Administration will publish a more encompassing accelerated bridge construction manual in the future, that will likely include or reference this work.

Byron Lord
Program Coordinator
Office of Highways for LIFE

Myint Lwin
Director
Office of Bridge Technology

Notices

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. This report does not constitute a standard, specification, or regulation.

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.

SI* (MODERN METRIC) CONVERSION FACTORS

*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)

Listing of Acronyms