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Prefabricated Bridge Elements and Systems Publications

Prefabricated Bridge Elements and Systems Cost Study: Accelerated Bridge Construction Success Stories

Title: Prefabricated Bridge Elements and Systems Cost Study: Accelerated Bridge Construction Success Stories 
Publisher: Federal Highway Administration, Washington DC
Topics: Prefabricated Bridge Elements and Systems, Accelerated Bridge Construction
Abstract: The prefabricated bridge elements and systems (PBES) cost study documents the details related to savings in time and money on nine PBES projects in states across the country. All nine projects are replacement projects, and as such reducing the impact of onsite construction to motorists was a priority. Each project is an example of how various combinations of prefabrication and effective contracting strategies were used to achieve the accelerated onsite construction timeline.
Full Text URL: http://www.fhwa.dot.gov/bridge/prefab/successstories/091104/index.cfm
Publication Type: Print Document; Web Document

Connection Details for Prefabricated Bridge Elements and Systems

Title: Connection Details for Prefabricated Bridge Elements and Systems
Publisher: Federal Highway Administration, Washington DC
Topics: Prefabricated bridges, connection details
Abstract: Prefabricated components of a bridge produced off-site can be assembled quickly, and can reduce design time and cost, minimizing forming, minimize lane closure time and/or possibly eliminate the need for a temporary bridge. This document has been developed to promote the use of prefabricated elements and systems in bridges and focuses on "Connection Details" as part of accelerated construction projects. Accelerated Bridge Construction is one of the prime focus areas of the Office of Infrastructure of Federal Highway Administration. It 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 connections between prefabricated elements in accelerated bridge construction projects. Most of the details were obtained from State Departments of Transportation, industry organizations, and private consultants. This information contained herein should be used to develop designs and determine which details would be appropriate for accelerating bridge construction projects.
Full Text URL: http://www.fhwa.dot.gov/bridge/prefab/if09010/
Publication Type: Print Document; Web Document

The Bridges That Good Planning and Execution Rebuilt

Title: The Bridges That Good Planning and Execution Rebuilt
Author: Gary Jakovich; Jorge Alvarez
Source: Public Roads, Vol. 66, No. 2, September/October 2002, pp. 6-9
Publisher: Federal Highway Administration, Washington DC
Topics: Prefabricated bridge decks for deck replacement
Abstract: The redecking of three bridges, plus minor deck repair on a fourth, along the George Washington Memorial Parkway in Langley, VA, is an informative case study of how meticulous planning, use of modern engineering techniques, and well coordinated execution ensure that a complex construction project can be carried out without major disruptions in traffic flow.
Full Text URL: /publications/publicroads/02sep/02.cfm
Publication Type: Print Document; Web Document

Construction Procedures for Rapid Replacement of Bridge Decks

Title: Construction Procedures for Rapid Replacement of Bridge Decks
Author: Mohsen A. Issa; Alfred A. Yousif; Mahmoud A. Issa
Source: Concrete International, February 1995, pp. 49-52
Publisher: American Concrete Institute, Farmington Hills MI
Topics: Prefabricated Bridge Elements and Systems
Abstract: This short article provides an overview of procedures for replacing deteriorated bridge decks using full-depth precast or precast prestressed deck panel, supported on steel rolled beams or plate girders as well as precast prestressed or reinforced concrete girders.
Publication Type: Print Document
Notes: For ordering information, see http://www.concreteinternational.com/.

Development of a Precast Bent Cap System

Title: Development of a Precast Bent Cap System
Author: E. E. Matsumoto; M. C. Waggoner; G. Sumen; M. E. Kreger; S. L. Wood; J. E. Breen
Publisher: Center for Transportation Research at the University of Texas at Austin; U.S. Department of Transportation, Washington DC; Texas Department of Transportation, Austin TX
Publication Date: 2001
Number of Pages: 372
Report No.: 1748-2
Topics: Precast bent cap systems
Abstract: This research report advances the development of precast bridge substructures by describing development of a precast bent cap system for non-seismic regions. It includes a design methodology, construction guidelines, and example details for connecting a precast bent cap to cast-in-place columns or precast trestle piles. It addresses three categories of connection details: grout pockets, grouted vertical ducts, and bolted connections.
Full Text URL: http://www.fhwa.dot.gov/exit.cfm?link=ftp://ftp.dot.state.tx.us/pub/txdot-info/rti/psr/1748_s.pdf (PDF, 8 mb)
Publication Type: Web Document

FHWA/AASHTO/TxDOT Precast Concrete Bent Cap Demonstration Workshop

Title: FHWA/AASHTO/TxDOT Precast Concrete Bent Cap Demonstration Workshop
Author: Benjamin Tang, P.E.; Federal Highway Administration; Lloyd M. Wolf, P.E.; Texas Department of Transportation; Michael D. Hyzak, Texas Department of Transportation; Tracey Friggle, P.E.; Texas Department of Transportation; William G. Duguay, P.E.; Traylor Brothers, Inc.
Publisher: Texas Department of Transportation, Austin TX
Publication Date: 2002
Number of Pages: Approximately 73 KB
Topics: Precast bent caps
Abstract: This set of presentations was part of a workshop on the use of precast bent caps in bridge construction, and it includes slides on the following topics: National perspective on rapid bridge construction. Prefabricated bridges in Texas. Structural design of Texas' SH 66 over Lake Ray Hubbard bridge. Construction of Texas' SH 66 over Lake Ray Hubbard bridge.
Publication Type: PowerPoint Presentation; CD-ROM
Notes: To order contact Ronald D. Medlock, P.E., Director of Technical Services, Bridge Division, Texas Department of Transportation by email at rmedloc@dot.state.tx.us.

Field Performance of Full Depth Precast Concrete Panels in Bridge Deck Reconstruction

Title: Field Performance of Full Depth Precast Concrete Panels in Bridge Deck Reconstruction
Author: Mohsen A. Issa; Mahmoud A. Issa; Salah Y. Khayyat; Alfred A. Yousif; Iraj I. Kaspar
Source: PCI Journal, May-June 1995, pp. 82-108
Publisher: Precast/Prestressed Concrete Institute, Chicago IL
Topics: Prefabricated Bridge Elements and Systems
Abstract: There have been many applications of full depth precast and precast prestressed concrete deck panels for bridge rehabilitation in North America. This paper presents the findings of an investigation conducted in the US to evaluate the field performance of bridge deck panels. This paper is part of an investigation carried out for an Illinois Department of Transportation rehabilitation program.
Publication Type: Print Document
Notes: For ordering information, see http://www.pci.org/publications/journal/.

Framework for Prefabricated Bridge Elements and Systems (PBES) Decision-Making

Title: Framework for Prefabricated Bridge Elements and Systems (PBES) Decision-Making
Author: Mary Lou Ralls
Publisher: FHWA
Publication Type: Print Document (Spring 2006)
Full Text URL: http://www.fhwa.dot.gov/bridge/prefab/framework.cfm

Full Depth Precast and Precast, Prestressed Concrete Bridge Deck Panels

Title: Full Depth Precast and Precast, Prestressed Concrete Bridge Deck Panels
Author: Mohsen A. Issa; Ahmad-Talal Idriss; Iraj I. Kaspar; Salah Y. Khayyat
Source: PCI Journal, January-February 1995, pp. 59-80
Publisher: Precast/Prestressed Concrete Institute, Chicago IL
Topics: Prefabricated Bridge Elements and Systems
Abstract: Since 1970 there has been a dramatic increase in the use of full-depth precast and precast, prestressed concrete deck panels for the rehabilitation and new construction of bridges. In order to document the various applications of bridge deck panels in North America, a questionnaire survey was sent to the departments of transportation of individual states and one province. Requested information included type of construction, deck dimensions, deck supporting system, panel dimensions and reinforcement, type of connecting system between panels and supporting system, type of joint between adjacent panels, type of bonding material used to fill the joints, problems associated with the joints, reasons for adverse results, and type of protection system. This paper summarizes the significant results of the survey.
Publication Type: Print Document
Notes: For ordering information, see http://www.pci.org/publications/journal/.

Grouted Connection Tests in Development of Precast Bent Cap System

Title: Grouted Connection Tests in Development of Precast Bent Cap System
Author: Eric E. Matsumoto; Michael E. Kreger; Mark C. Waggoner; Guclu Sumen
Source: Transportation Research Record 1814, pp. 55-64
Publisher: Transportation Research Board, Washington DC
Abstract: Tests were conducted as part of the first two phases of a research project that developed a design methodology, construction guidelines, and design details for connecting precast concrete bent caps to cast-in-place columns or precast concrete trestle piles in nonseismic regions. Three types of precast connections were addressed: grout pockets, grouted ducts, and bolted connections. The first phase of testing included 32 pullout tests of epoxy-coated straight and headed bars embedded in a grout pocket or grouted duct. The yield strength of the bars was developed in grouted connections at an embedment depth of 13 bar diameters or less. Pullout capacity of single- and multiple-headed bars in grout pockets was predicted closely by the concrete capacity design method equations modified by a cracking factor of 0.75 to account for grout-pocket cracking. A development length equation based on a uniform bond stress model was derived for anchorage of straight bars in grouted ducts. The second phase of testing included a full-scale bent cap-to-column connection test for each connection type. Specimens in these proof tests exhibited minor levels of cracking and connector strain in the connection region at factored levels. Failure tests demonstrated adequate connector anchorage, large connector ductility, and negligible influence of shims and the grout bedding layer on response. Results from Phase I and Phase II tests were used to develop anchorage design provisions that are incorporated in the complete design methodology.
Publication Type: Print Document
Notes: This paper appears in Transportation Research Record No. 1814, Design of Structures 2002.

Innovative Prefabrication in Texas Bridges

Title: Innovative Prefabrication in Texas Bridges
Author: Ronald D. Medlock; Michael Hyzak; Lloyd Wolf
Source: Proceedings of the Texas Section, American Society of Civil Engineers, Spring Meeting, March 2002
Publisher: American Society of Civil Engineers - Texas Section, Austin TX
Number of Pages: 6
Topics: Prefabrication in Texas bridges
Abstract: This article describes the evolution of the use of prefabricated bridge elements in bridge design and construction in Texas, focussing on TxDOT innovations in response to public demand for minimized traffic disruption.
Publication Type: Print Document

Keep It Moving

Title: Keep It Moving
Author: Allen Zeyher
Source: Roads & Bridges, Vol. 40, No. 8, August 2002, pp.20-23
Publisher: Scranton Gillette Communications, Inc., Des Plaines IL
Topics: Vancouver replaces a suspension bridge without stopping daytime traffic.
Abstract: Lions' Gate Suspension Bridge links Vancouver and the North Shore of Burrard Inlet, carrying 70,000 vehicle per day. Therefore, it was kept open for daytime traffic during rehabilitation, which included replacement of the bridge deck and trusses.
Full Text URL: http://www.roadsbridges.com/rb/index.cfm?fuseaction=showArticle&articleID=3298
Publication Type: Print Document; Web Document

Laying the Groundwork for Fast Bridge Construction

Title: Laying the Groundwork for Fast Bridge Construction
Author: Mary Lou Ralls; Benjamin M. Tang
Source: Public Roads, November/December 2003, Vol. 67, No. 3
Publisher: Federal Highway Administration, Washington DC
Abstract: Prefabricated elements and systems accelerate construction of bridges to hours or days instead of months or years.
Full Text URL: /publications/publicroads/03nov/02.cfm
Publication Type: Print Document; Web Document

Main Attractions: Prefabricated Bridges

Title: Main Attractions: Prefabricated Bridges
Author: Jessica Johnson
Source: Bridge Builder; Vol. 5, No. 2; March/April 2002; pp. 10-14
Publisher: Mercor Media, Inc., Chicago IL
Topics: Prefabricated bridges
Abstract: Prefabricated bridges meet growing market demands for fast and efficient structures.
Publication Type: Print Document

Manual on Use of Self-Propelled Modular Transporters to Remove and Replace Bridges

Title: Manual on Use of Self-Propelled Modular Transporters to Remove and Replace Bridges
Publisher: Federal Highway Administration, Washington DC
Topics: Prefabricated bridges
Abstract: This manual contains information on the equipment, benefits, costs, project selection criteria, planning, design, contracting issues, and example contract documents for using self-propelled modular transporters to move bridges. It also includes case studies and lessons learned from previous projects. The manual is intended for use by bridge owners, construction contractors, suppliers, and other professionals involved in bridge design and construction.
Full Text URL: http://www.fhwa.dot.gov/bridge/pubs/07022/
Publication Type: Print Document; Web Document

MnDOT/FHWA Precast Slab System Workshop Summary Report

Title: MnDOT/FHWA Precast Slab System Workshop Summary Report
Publisher: Federal Highway Administration, Washington DC
Topics: Prefabricated bridges
Abstract: Increasing traffic volumes, an aging highway bridge infrastructure, and dwindling resources are increasing the need for State DOTs and the Federal Highway Administration (FHWA) to look for innovative ways to more quickly construct longer-lasting bridges while minimizing traffic disruption.
Full Text URL: http://www.fhwa.dot.gov/bridge/prefab/slab.cfm
Also See: Mn/DOT Precast Slab System
Publication Type: Print Document; Web Document

Precast Posttensioned Abutment System and Precast Superstructure for Rapid On-site Construction

Title: Precast Posttensioned Abutment System and Precast Superstructure for Rapid On-site Construction
Author: Andrew Scanlon; Alex Aswad; James Stellar
Source: Transportation Research Record 1814, pp. 65-71
Publisher: Transportation Research Board, Washington DC
Abstract: A prefabricated bridge system was designed to minimize on-site construction time. The system consists of a double-cell adjacent box beam superstructure supported on precast posttensioned abutment units on cast-in-place footings. The design concept was implemented in a demonstration bridge replacement project, a single-span bridge crossing a creek in southwestern Pennsylvania. The construction project demonstrated the feasibility of the design concept as a means to reduce construction time by eliminating cast-in-place concrete for abutment walls.
Publication Type: Print Document
Notes: This paper appears in Transportation Research Record No. 1814, Design of Structures 2002.

A Precast Substructure Design for Standard Bridge Systems

Title: A Precast Substructure Design for Standard Bridge Systems
Author: Billington, Sarah Barnes; Robert Breen, John E.
Publisher: University of Texas at Austin, Center for Transportation Research
Publication Date: 1999
Report No.: CTR 1410-2F
Topics: Bridge precast substructure
Abstract: The proposed substructure system described in this report has been developed to improve the aesthetics and reduce the construction time of the support structures for standard bridges. The form of the proposed substructures is highly attractive, and is a distinct improvement over many traditional short- and medium-span bridge substructures. The substructure system developed is particularly well suited for precasting, although the geometric form could be cast-in-situ. Precasting would result in increased use of high performance concrete in the substructures. The use of such concrete will bring improved durability since the high performance concrete is greatly resistant to ingress of moisture and chlorides. In addition, the greater compressive strength of the high performance concretes is utilized for reducing the handling weight and dead load of the substructure units. The bent cap units are more complex than traditional cast-in-place bent caps but appear feasible for plant production or large-scale, cast-on-site projects. The construction method proposed could shorten construction times on-site in certain applications. Shortened construction time, in turn, leads to important safety and economic advantages when traffic disruption or re-routing is necessary. Cost studies based on input from precasters and contractors indicate that if the proposed system (or one quite similar) is actually standardized and used on several projects, the direct costs will be competitive with costs of current designs for concealed bent cap substructures, while the on-site construction time could be reduced substantially. This reduction can have important economic and safety implications on some projects.
Publication Type: Print Document

Precast Technology and Bridge Design

Title: Precast Technology and Bridge Design
Author: John S. Dick
Source: Structural Engineer: News, Views, and Industry Trends; Vol. 3, No. 4; May 2002; pp. 24-29
Publisher: Mercor Media, Inc., Chicago IL
Topics: Precast technology and bridge design
Abstract: A range of new techniques, including girder designs, strand technologies, and concrete mixes, are making precast prestressed concrete bridges more popular.
Publication Type: Print Document

Prefabricated Bridge Elements and Systems: A Winning Idea

Title: Prefabricated Bridge Elements and Systems: A Winning Idea
Source: Focus, May 2002
Publisher: Federal Highway Administration, Washington DC
Topics: Accelerating infrastructure innovations
Abstract: Prefabricated elements can increase construction zone safety, minimize the traffic impacts of bridge construction projects, and improve constructibility.
Full Text URL: /publications/focus/02may/prefab.cfm
Publication Type: Print Document; Web Document

Prefabricated Bridge Elements and Systems Fact Sheet


Title: Prefabricated Bridge Elements and Systems Fact Sheet
Publisher: AASHTO Technology Implementation Group
Publication Date: 2004
Abstract: A fact sheet about the Prefabricated Bridge Elements and Systems technology of the AASHTO Technology Implementation Group (TIG).
Full Text URL: Publication Type: Print Document; Web Document

Prefabricated Bridge Elements and Systems in Japan and Europe Summary Report

Title: Prefabricated Bridge Elements and Systems in Japan and Europe Summary Report
Publisher: Federal Highway Administration
Publication Date: 2004
Abstract: Summary of the scanning tour
Full Text URL: Publication Type: Print Document; Web Document

Prefabricated Bridge Technology: Get In, Get Out, and Stay Out

Title: Prefabricated Bridge Technology: Get In, Get Out, and Stay Out
Source: Focus, April 2003
Publisher: Federal Highway Administration, Washington DC
Topics: Prefabricated bridge elements and systems
Abstract: For a growing number of States, the use of prefabricated bridge elements and systems is helping them to achieve reduced traffic and environmental impacts, enhanced safety, improved bridge constructibility, and accelerated project completion. Prefabricated bridge elements, which range from bent caps to deck panels, and superstructure and substructure systems are manufactured under controlled conditions and brought to the construction site ready to install.
Full Text URL: /publications/focus/03apr/04.cfm
Publication Type: Web Document; Print Document

Prefabricated Bridges

Title: Prefabricated Bridges
Author: AASHTO Technology Implementation Group (TIG)
Publisher: American Association of State Highway and Transportation Officials, Washington DC
Publication Date: 2002
Number of Pages: 16
Topics: Prefabricated bridges
Abstract: This brochure celebrates the emergence and growth of innovative prefabricated bridge technology and its implementation. It provides descriptions of 15 bridge projects that solved site-specific challenges using prefabricated bridge elements and systems.
Full Text URL: Publication Type: Print Document; Web Document

Prefabricated Bridges 2004

Title: Prefabricated Bridges 2004
Author: AASHTO Techology Implementation Group (TIG) and Federal Highway Administration (FHWA)
Publisher: FHWA and American Association of State Highway and Transportation Officials, Washington DC
Publication Date: 2004
Number of Pages: 16
Topics: Prefabricated bridges
Abstract: This brochure highlights best-practice applications of bridge prefabrication across the United States.
Full Text URL: Publication Type: Print Document; Web Document

Prefabrication Minimizes Traffic Disruptions

Title: Prefabrication Minimizes Traffic Disruptions
Author: Kevin R. Pruski; Ronald D. Medlock; Mary Lou Ralls
Source: HPC Bridge Views, No. 21, May/June 2002
Publisher: Federal Highway Administration, Washington DC; National Concrete Bridge Council, Skokie IL
Topics: Prefabrication in Texas bridges
Abstract: Not available.
Full Text URL:
Publication Type: Print Document; Web Document

Prefabricated Steel Bridge Systems: Final Report

Title: Prefabricated Steel Bridge Systems: Final Report
Author: FHWA
Publisher: FHWA
Topics:
Abstract: 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.
Full Text URL: http://www.fhwa.dot.gov/bridge/prefab/psbsreport00.cfm
Publication Type: Web Document

Rapid Bridge Construction: How to Get There

Title: Rapid Bridge Construction: How to Get There
Author: Mary Lou Ralls Newman
Publisher: Federal Highway Administration, Washington DC
Full Text URL: http://www.fhwa.dot.gov/bridge/prefab/pbesreport.cfm

Rapid Bridge Deck Replacement: A Field Demonstration and Load Test

Title: Rapid Bridge Deck Replacement: A Field Demonstration and Load Test
Author: R.A. Osegueda; J.S. Noel
Publisher: Texas State Department of Highways and Public Transportation -Transportation Planning Division
Publication Date: 1988
Number of Pages: 73
Report No.: FHWA/TX-88-324-5F
Abstract: This report describes a full-size demonstration of a rapid bridge deck replacement concept. The demonstration used a sand mortar made with rapid-setting epoxy to provide the shear tie between precast concrete deck panels and existing steel stringer beams. The demonstration site was a 50-ft. simple span that serves as part of the SPUR 326 overpass over the AT&SF railroad tracks in downtown Lubbock. Eight precast panels, each 6 ft. 3 in. x 45 ft. x 8 in. were used to form the experimental deck. Subsequent load tests and deflection measurements were compared to results obtained using a 3D computer model.
Publication Type: Print Document
Notes: Full text report can be purchased for $15 on the TTI website at: http://tti.tamu.edu/publications/catalog/record_detail.htm?id=1136.

Short and Sweet

Title: Short and Sweet
Author: Mohsen Issa; Shahid Islam
Source: Bridge Design and Engineering, Issue No. 27, Second Quarter 2002, pp.44
Publisher: Hemming Information Services, London UK
Topics: Prefabricated Bridge Elements and Systems
Abstract: Precast units can dramatically reduce closure times for replacement of short-span bridges.
Publication Type: Print Document
Notes: Ordering information is available at http://www.bridgeweb.com/.

Soaring on the feet of an elephant

Title: Soaring on the feet of an elephant
Author: Allen Zeyher
Source: Roads & Bridges, Vol. 41, No. 8, August 2003
Publisher: Scranton Gillette Communications, Inc., Des Plaines IL
Topics: deck systems, precast concrete deck panels, composite panels, post-tensioned concrete box structures, land spans,
Abstract: It took nearly 10 years, but Bangkok, Thailand, now has a fifth bridge crossing the Chao Phraya River at the center of the city. The bridge is intended to relieve traffic congestion on the nearby Pinklao Bridge and serve as a memorial to King Rama VIII, the late brother of the current Thai king, who ruled for a short time.
Publication Type: Print Document; Web Document
Notes: Download the full-text of the article at http://www.roadsbridges.com/rb/index.cfm?fuseaction=showArticle&articleID=4358

TxDOT/FHWA Workshop on Prefabricated Bridge Systems to Eliminate Traffic Disruptions

Title: TxDOT/FHWA Workshop on Prefabricated Bridge Systems to Eliminate Traffic Disruptions
Author: Jim Cooper, P.E.; Federal Highway Administration; Paul Wells, P.E.; New York State Department of Transportation; Tom Moon, P.E., New York State Department of Transportation; Ken Price, P.E., J. Muller International; Mal Kerley, P.E., Virginia Department of Transportation; William Garbade, P.E.; Virginia Department of Transportation; Daniel Tassin, P.E.; International Bridge Technologies; Mohsen Issa, Ph.D., P.E.; University of Illinois; John P. Vogel, P.E.; Texas Department of Transportation; Gregg Freeby, P.E.; Texas Department of Transportation
Publisher: Texas Department of Transportation, Austin TX
Publication Date: 2001
Number of Pages: Approximately 126 KB
Topics: Prefabricated bridge elements and systems
Abstract: This set of ten presentations was part of a conference on various rapid bridge construction approaches in use throughout the United States. It provides slides addressing the following topics: National perspective on rapid bridge construction. AASHTO TIG for precast substructure elements. Use of precast elements at NYSDOT. Precast experience and concepts. Early prefabricated bridges in Vietnam. Innovative bridge construction techniques for limited site disruption. Illinois precast full-depth concrete deck panels. Techniques to minimize traffic disruption due to bridge construction. Evolution of TxDOT prefabricated bridge construction.
Publication Type: PowerPoint Presentation; CD-ROM
Notes: To order contact Ronald D. Medlock, P.E., Director of Technical Services, Bridge Division, Texas Department of Transportation by email at rmedloc@dot.state.tx.us.

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Updated: 05/23/2012

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