national concrete consortium san antonio, tx april 1, · pdf filesuper-structure condition ......

Precast/Prestressed Concrete Institute (PCI)

National Concrete Consortium San Antonio, Tx

April 1, 2009

Precast/Prestressed Concrete Institute (PCI)

National Concrete Consortium San Antonio, Tx

April 1, 2009 William Nickas, P.E.

Director, Transportation Systems

Precast/Prestressed Concrete Institute Chicago, IL

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RapidApproaches

MinimalDisruption

SuccessfulRenewal

Long-LivedFacilities

To develop a consistent, systematic approach to performing highway renewal that

• is rapid • causes minimum

disruption• produces long-

lived facilities

Goal

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TechnologyTechnology Project DeliveryProject Delivery

SuccessfulRenewal

Integrated approach

Concrete Bridges and the NBI dataConcrete Bridges and the NBI data

Post Tensioned Durability StrategiesPost Tensioned Durability Strategies

PCI Quality Systems & Plant CertificationPCI Quality Systems & Plant Certification

FHWA Long Term Bridge Program (LTBP)FHWA Long Term Bridge Program (LTBP)

Cooperative Agreement for PPCP with FHWACooperative Agreement for PPCP with FHWA

AgendaAgenda

A Report Card on Concrete and Bridge Longevity

Data Reduced and Charted by:Heinrich O. BonstedtExecutive DirectorPrestressed Concrete Association of Pennsylvania

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Data Source

The National Bridge Inventory December 2008

Prepared according to a Standard Recording and Coding Guide that covers over 115 items

“By having a complete and thorough inventory, an accurate report can be made to Congress” and it provides the data necessary to “produce Defense Bridge and Federal Emergency Management Agency (FEMA) reports.”

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Evaluation Objectives

Determine deficiency rates for bridgesEvaluate deficiency trendsCompare bridge material alternativesEstablish a basis for projections of service life expectancy

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Sources of Deficiencies

Super-structure conditionSub-structure conditionDeck conditionAppraisal Rating

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Concrete Observations

Deficiency rates for concrete bridges are decliningMarket share of concrete bridge material alternatives is increasingMore work is needed to refine projections of service life expectancy with current methods.

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Florida DOT efforts toward improving Post Tension Durability at UT, Austin ASBI Training April 2006 by William Nickas

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Pile Deterioration

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Pier Deterioration

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Leakage at Segment Joints

pci 30Failure of Tendon Anchorage Pour back

pci 31Boot Removed showing Corrosion

pci 33Wedge Assembly

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Borescope Inspection - Moderate

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Borescope Inspection - Bad

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Partial Grout

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85% of strength

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Cracked Ducts

PO

ST-T

EN

SIO

NIN

G S

TA

ND

AR

D D

ET

AIL

S

•Standardized Details with PCI

Proper Material is CriticalProper Material is Critical

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Pier 133 NB

SE Tendon

NE Tendon

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Field Book Notes

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New Grout Material Specification• Chloride Ion Limited .08% by weight (ASTM C1152)• Volume Change 0.0% @ 24 Hrs. (ASTM C1090)

<=0.3% @ 28 days• Compressive Strength >7,000 PSI (ASTM C942)• Initial Set Time Min. 3 hours (ASTM C953)

Max. 12 hours• Fluidity Test Immediately after mixing (ASTM C939)

30 minutes after mixing• Bleed @4 Hours 0% (ASTM C940)• Permeability @ 28 days Max 2500 Coulombs (ASTM 1202)

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New Type Low Bleed Grout 10 hours old…..No bleed void

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Example Post-Tensioning Tendon Classifications

Essential

87

109

654321

Critical

Very High

High

Moderate

P/C SBS External– EJ SpansP/C SBS External– Typical Spans

Drop in PT Girders; ¼ Point HingeP/C BC – Continuity at EJ

P/C BC – Anchor on FaceP/C BC – Anchor in BlisterP/C BC – Bottom ContinuityCIP Cantilever & ContinuityFlat Slab - TransverseP/C BC – Top Continuity

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FDOT Post-Tensioning Strategy

Anchor Protection

Fully Grouted TendonsMultiple Tendons Paths

Enhanced PT Systems

Watertight Bridges

FDOT PTStrategy

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Requirements

• 4 Levels of Protection• Semi Standard Details• Anchorages Sealed at all Times

Requirements

• Anchorage Accessibility• Low Point Injection• Semi-Standard Drawings• Certified Grouters and Inspectors• Controlled Rates of Grouting• Flow Rate Testing of Ejected Material• Inspect Voids and Secondary Grout

Requirements

• Pre-Approved PT Systems• Pre-Bagged Grout• Three-Level Continuous Protection• Plastic Ducts with Improved Cell Class• Positively Sealed Ducts• Permanent Plastic Anchor Caps• Pressure Testing

Requirements

• No Dry Joints• Pre-formed Tapered Holes• Drip Notches at Anchorages• Bottom Slab Drains• Sealed Surfaces of Secondary Pours• Wearing Surfaces for Ride not Protection• No Permanent Tensile Stresses

Flor

ida

PT S

trate

gy

Enhanced PT Systems

Fully Grouted Tendons

Watertight Bridges

Anchor Protection

Requirements

• Maximize Use of Smaller Tendons• No Impact Due to Loss of Critical Tendon• Compensation for Loss Due to Corrosion

Multiple Tendon Paths

A non-Florida Project

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Why not always use Plastic Duct ?Why not always use Plastic Duct ?

pci 57Mid-Bay Bridge

www.dot.state.fl.us/structures

Temporary Design Bulletin (Post-Tensioning Issues)

http://www.dot.state.fl.us/structures

About PCIAbout PCI

• PCI is an international trade association and Technical Institute – Promotes technical understanding and use

of high-quality precast and prestressed concrete

– Full staff of technical and marketing specialists

About PCIAbout PCI

• Over 350 Producer Member plants – Architectural, structural, and specialty

precast concrete products and structures– Every U.S. PCI Producer Member plant

must be PCI Certified– PCI Membership is not required to be PCI

Certified– Over 80 Technical Committees

About PCIAbout PCI

• Approximately 200 Supplier Associate Members

• 100 Erector Associate Members – PCI Qualified/Certified Erector Program

• Over 1,300 Professional Members – Academics, design professionals,

and other industry stakeholders – Provide much of the technical

knowledge contained in PCI design guides and other technical publications

About PCIAbout PCI

PCI Publications• Design Manuals and Guidelines• Quality Control Manual• PCI Journal, Ascent, and Aspire

Magazines

About PCIAbout PCI

• Codes and Standards– PCI works very closely with code bodies,

such as ACI, ICC, ASTM, AASHTO, etc.

• Industry Events– PCI works with FHWA in producing the

National Bridge Conference

About PCIAbout PCI

• Research & Development– DSDM Seismic Project– FHWA Precast Pavement

Project

TeTeTe

Side Walls

Load Cell

Floor Diaphragms

Shake Table

ReactionWall

Steel Base withCantilever Outriggers

6 ft – 6 in

These concepts and ideas are early findings sharedby the team during the 2009 TRB Briefing of FHWAand the Researchers.

Program manager is:Dr. Hamid Ghasemi (202-493-3042)[email protected]

He is the official POC for information regarding the program, rather than Rutgers.

In addition for information regarding the LTBP pilot program,they can contact:John Penrod (202-493-3051)[email protected],He is a member of the LTBP project team and will be managing the pilot program activities.

mailto:[email protected]

mailto:[email protected]

Team Organization

Roadmap: First Five Years

Process and Timeline

Defining and Measuring Bridge Performance

What Does Bridge Performance Mean?

•

Is it a measure of cost?

•

Is it a measure of condition?

•

Is it a measure of traffic service?

•

Is it a measure of load capacity/safety?

•

And what purpose will measuring bridge

performance

serve?



Study Goal

Develop Performance Measures that:

•

Define bridge performance in terms of things we

can measure•

Determine cost effective design/maintenance

strategies•

Evaluate serviceability and durability

•

Establish accurate traffic safety evaluation

•

Provide an accurate measure of load capacity


Factors in the Difficulties of Measuring Bridge Performance

•

Bridge Inspection Policy

•

QA/QC

•

Personnel / Inspector Qualifications and

Training•

Programmatic Considerations

•

Bridge Load Rating

•

Documentation

•

New Technologies

•

Bridge Deterioration Database

•

Communications

•

Research Needs


ASCE/SEI White Paper Bridge Inspection and Rating

2007 Structurally Deficient NHS Bridges


Objectives of NDE Performance Monitoring

Ultimate Objectives

Develop and implement plan for high quality quantitative data collection using NDE technologies that will:

»

Enable

condition monitoring that will be objective and linked to bridge performance measures

»

Improve

understanding of deterioration processes and bridge performance

»

Advance

predictive methods and bridge management practices

Bridge Monitoring: NDE

Serviceability: Degradation and Improvement

A-$2 B-$10

C-$50

D-$100

Age

Ser

vice

abili

ty

Cost to improve serviceability:A - Initial ConstructionB - Preventive MaintenanceC - Corrective MaintenanceD - Reconstruction

LTBP Monitoring

Bridge Monitoring: NDE

Precast Concrete PavementsPrecast Concrete Pavementspcipcipcipci

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Precast/Prestressed Concrete InstitutePrecast/Prestressed Concrete Institute(PCI)(PCI)

Federal Highway AdministrationFederal Highway Administration(FHWA)(FHWA)


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PRECASTING PLANTSPRECASTING PLANTS

A A manufacturing operationmanufacturing operation……

……not offnot off--site construction!site construction!


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PCIPCI--FHWA Cooperative Agreement FHWA Cooperative Agreement

““Advancement of Precast Prestressed Advancement of Precast Prestressed Concrete Pavement SystemConcrete Pavement System

throughthrough Technology TransferTechnology Transfer

andand Development of Industry GuidanceDevelopment of Industry Guidance

forfor Design and EngineeringDesign and Engineering””


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•• NonNon--ProprietaryProprietary•• Manufactured in PCIManufactured in PCI--Certified Plants Certified Plants •• ““Precast Prestressed Concrete PavementsPrecast Prestressed Concrete Pavements””

(PPCP)(PPCP)


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What is PPCP?What is PPCP?

–– 22--way way prestressingprestressing–– Combination of Combination of pretensioningpretensioning/post/post--tensioningtensioning–– OrOr 22--way postway post--tensioningtensioning–– Bonded/grouted PBonded/grouted P--T systemT system


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Typical PPCP PanelTypical PPCP Panel


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Typical PPCP Panel LayoutTypical PPCP Panel Layout


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BenefitsBenefits

WHY PRESTRESSED CONCRETE?WHY PRESTRESSED CONCRETE?–– Reduces/eliminates slab cracking (maintenance)Reduces/eliminates slab cracking (maintenance)–– Reduced number of joints Reduced number of joints

(maintenance/smoothness)(maintenance/smoothness)–– Reduced Slab Thickness (8Reduced Slab Thickness (8”” vs. 12vs. 12””) )

•• Material savingsMaterial savings•• Allows for replacement of pavement inAllows for replacement of pavement in--kindkind

–– Ability to span voids/unsound support layersAbility to span voids/unsound support layers–– Proven LongProven Long--Term Performance Term Performance

•• 66”” CIP postCIP post--tensioned pavement constructed in 1985 tensioned pavement constructed in 1985 (near West, Texas)(near West, Texas)

•• Virtually no maintenance in 23 yearsVirtually no maintenance in 23 years


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Picture of Connection detailsPicture of Connection details


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Getting ready to post tension the PC pavementGetting ready to post tension the PC pavement


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Cooperative Effort to Engage Industry and AgenciesCooperative Effort to Engage Industry and Agencies

Concluding and Departing Thoughts Concluding and Departing Thoughts

• Manufactured Concrete offers further enhancements opportunities when used properly in routine projects and ABC

• Higher Concrete strengths and innovative engineering is extending span ranges for concrete,

• We all as an industry should guard against New Specifications and code changes allowing unintended consequences,

• Loads, Stresses, and Environment all contribute to the total Durability of the Concrete not just the mix design

Dr. Galambos writes DEFINITION: RESEARCH

Dr. Galambos writes DEFINITION: RESEARCH

• THE ACTIVITY THAT CONNECTS THEORY WITH PRACTICE

• COMPUTATION METHODS

• PHYSICAL AND COMPUTATIONAL EXPERIMENTS

• ORGANIZATION OF DATA AND DESIGN ACTIVITIES

• ETC.

Dr. Galambos writes FEATURES OF STRUCTURAL DESIGN

CREATION OF A STRUCTURE THAT WILL

Dr. Galambos writes FEATURES OF STRUCTURAL DESIGN

CREATION OF A STRUCTURE THAT WILL

• PERFORM SATISFACTORILY DURING ITS INTENDED LIFETIME

• NOT COLLAPSE OR EXPERIENCE EXCESSIVE DAMAGE DURING ITS INTENDED LIFETIME

• BE ECONOMICAL TO DESIGN, BUILD AND MAINTAIN

• SERVICEABILITY

• SAFETY

• ECONOMY

Dr. Galambos write EXPECTATIONS FROM STRUCTURAL

DESIGN

Dr. Galambos write EXPECTATIONS FROM STRUCTURAL

DESIGN• GENERAL PUBLIC

• STRUCTURAL ENGINEER

• BUILDING AUTHORITY

• CODE COMMITTEE

• STRUCTURE IS UNCONDITIONALLY SAFE AND RIGID

• SAFETY, SERVICEABILITY, ECONOMY DURING INTENDED LIFETIME WHEN USED FOR PLANNED FUNCTION

• CODE REQUIREMENTS MUST BE MET

• CHANCE OF EXCEEDING A LIMIT STATE DURING

Dr. Galambos writes HOW TO ATTAIN SAFE

STRUCTURAL DESIGNS?

Dr. Galambos writes HOW TO ATTAIN SAFE

STRUCTURAL DESIGNS?• MINIMIZE HUMAN

ERROR

• QUALITY CONTROL

• ENSURE THAT CHANCE OF EXCEEDING LIMIT STATE IS ACCEPTABLY SMALL

• LOAD STANDARDS AND DESIGN CODES

REQUIREMENTS FOR THE DESIGN OF THE INDIVIDUAL STRUCTURE

APPLICABLE LEGAL BUILDING CODES

MODEL BUILDING CODES

MATERIAL CODES, LOAD STANDARDS,DESIGN SPECIFICATIONS

Dr. Galambos writesPYRAMID OF DESIGN REQUIREMENTS

Concluding and Departing Thoughts Concluding and Departing Thoughts

• Structural Engineering Congress in London in 1960’s….

• “Structural Engineering is the art of assembling materials we do not fully understand, to resist loads that we cannot accurately estimate, in a fashion that the general public does not understand the extent of our ignorance”

Concrete BridgesConcrete BridgesAnd other Transportation Delivery

Opportunities

THANK YOU!

And other Transportation Delivery Opportunities

THANK YOU!

William Nickas, P.E.Director, Transportation [email protected]

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