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TRANSCRIPT
TTI Short Course 2014 - TxDOT Houston District Bridge
Michael E. Carlson, P.E. TxDOT Houston District Bridge Design
US 290 DOING MORE WITH LESS
TTI Short Course 2014 - TxDOT Houston District Bridge
THE US 290 CORRIDOR
TTI Short Course 2014 - TxDOT Houston District Bridge
US 290 – DOING MORE WITH LESS
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Table Revised: 11/6/2013 Added C-2 Details: 9/26/2014
July 2014
Williams Brothers
Construction Co.
$49 million*
TTI Short Course 2014 - TxDOT Houston District Bridge
US 290 – DOING MORE WITH LESS
13 Total Segments (Approx. 38 Miles) Our Design Began Late 2009 Foresaw Compressed Letting Schedule HNTB is the Project Management Coordinator. Provided Bridge Layouts By a Variety of Consultants Layouts Were Created In-House In Later Segments
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ABOUT TxDOT HOUSTON DISTRICT BRIDGE
US 290 INTRODUCTION & SCOPE
Currently 23 Total Employees – 14 P.Es (10 P.Es designing) – 4 Cad Operators – BRINSAP Personnel & Administrative
33 Employees Back in August 2006 (When J.C. Liu Retired) 2/3 the Staff, Staff is Less Experienced, & Every Job is Now a Rush Job. 14 People Involved When US 290 Design Began
TTI Short Course 2014 - TxDOT Houston District Bridge
US 290 – DOING MORE WITH LESS
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Segment CSJ Type * # of Bridges Let Date Winning Bid (Millions) * Total Bridge Sheets
Seg K (2) 0271-14-217 Recon 20 May-11 $151.6 1423
Seg G (6) 0050-09-071 Recon 9 Sep-12 $110.4 326
Seg J1 (1) 0271-14-228 Recon 10 Oct-12 $107.0 966
Seg F (7) 0050-08-086 Widen 12 Mar-13 $58.0 341
Seg E (8) 0050-08-087 Recon 6 Apr-13 $135.4 427
Seg H (5) 0050-09-070 Recon 16 Apr-13 $153.3 457
Seg I (4) 0050-09-069 Recon 11 May-13 $142.8 333
Seg J2 (3) 0271-14-213 Recon 6 Nov-13 $151.6 380
Seg D (9) 0050-06-081 Widen 12 Nov-13 $85.2 268
Seg C (10) 0050-06-080 Widen 5 (C1 & C2) Jul-14 (C1) $45.6 (C1) 137 (C1 & C2)
Seg B (11) 0050-06-079 Widen 6
Seg A (12) 0114-12-007 Widen 14
* Includes Only Bridges Designed By & Signed & Sealed Sheets Provided By TxDOT Houston District Bridge Foundation Layout Redlines Provided By By TxDOT Houston District Bridge, However Signed & Sealed By Consultants
Total of 5058 Bridge Sheets
Total of $1.1 Billion
TTI Short Course 2014 - TxDOT Houston District Bridge
US 290 Corridor – Compressed Schedule By Segment
US 290 – DOING MORE WITH LESS
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0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
2010 2011 2012 2013 2014
% D
esig
n Ti
me
Design Year (Fiscal Year)
Seg K
Seg 6
Seg J1
Seg 7
Seg 8
Seg 5
Seg 4
Seg J2
Seg 9
Seg 10
Seg 11
Seg 12
TTI Short Course 2014 - TxDOT Houston District Bridge
HOW DID WE DO IT? Changing the Responsibilities & Division of Work Amongst Personnel.
TTI Short Course 2014 - TxDOT Houston District Bridge
The Traditional Way We Design Bridges
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District Bridge Engineer
Assigns New Bridge to Team
Team Leader A Project Manager
Team Leader C Project Manager
Coordinates with other designers outside of bridge & distributes work amongst designers within bridge. Supports team personnel.
Design Engineer
Does majority of design, works with EITs and CAD Operators.
Cad Operator
Does drafting for majority of the bridge details.
Design Engineer or EIT
Team Leader B Project Manager
TTI Short Course 2014 - TxDOT Houston District Bridge
The Mass Production Design of Bridges
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District Bridge Engineer
Design Engineer BGS
Cad Operator Substructure
Design Engineer Concrete
Superstructure
Team Leader Project Manager
Design Engineer Substructure
Design Engineer Foundations
Design Engineer Steel Superstructure
Design Engineer / EIT Quantities
Cad Operator Superstucture
Cad Operator Steel
Design Engineer Support / Other
BGS is created as soon as Bridge layouts are confirmed
Coordination begins to create superstructure design sheets.
Steel superstructures require the most design and detailing time.
A specific engineer and CAD operator is designated to this task.
As soon as the superstructure is laid out, substructure engineers begin coordinating with CAD operators to produce sheets.
Foundation loading is calculated and documented for Geotech engineers.
Foundations are designed and detailed.
Team Leader coordinates with PMC, assigns work loads, and offers design support.
Quantities are calculated and tabulated for the entire bridge and are inserted on design sheets.
TTI Short Course 2014 - TxDOT Houston District Bridge
US 290 – DOING MORE WITH LESS
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Mass Production Pros
Encourages Standardization For Each Design Element – Greatly Increases Speed of Design, Drafting, & Later Calculations – Provides Consistency That Aids Contractor Later During Construction. – Provides Consistency of Architectural Elements.
Reduces Redesign of Similar Elements – Designs Can Be Grouped and Re-Referenced – A Similar Design May Already Exist on Another Bridge.
Pull and Document the Previous Design. – Make a Library.
As the Library Grows Design Becomes Even More Efficient.
TTI Short Course 2014 - TxDOT Houston District Bridge
US 290 – DOING MORE WITH LESS
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Mass Production Challenges
Requires Complete Bridge Layouts Increased Collaboration Between Multiple Engineers / CAD Operators CAD File Ownership Concerns Increased Burnout Amongst Personnel Engineers Become “Rusty” on Designing Elements Outside Their Mass
Production Task
TTI Short Course 2014 - TxDOT Houston District Bridge
STANDARDIZE Architecture, Design, & Detailing.
TTI Short Course 2014 - TxDOT Houston District Bridge
Houston Area Green Ribbon Project
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Developed with the Katy Freeway Reconstruction.
Comprised of 4 Schemes – Vertical Scheme – Horizontal Scheme – Wave Scheme – Interchange Scheme
(Similar to Horizontal Scheme with more robust structural elements)
TTI Short Course 2014 - TxDOT Houston District Bridge
Houston Area Green Ribbon Project
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US 290 comprised of Vertical Scheme & Interchange Scheme Columns Standardizes Use of Inverted-T Caps, U-Beams, and Steel Tub Girders. Architectural Details & Rustication is Defined.
Green Ribbon Requirements
We Went One Step Further…
Encouraged standardization of engineering details through standardization of architectural elements.
Standardized Inverted-T Cap Dimensions Throughout. U54 Beams Used Throughout Reconstructed
Areas Unless Steel Tubs Required. Column Details Were All Standardized
and a Library was Developed. Footing Details Were All Standardized
and a Library was Developed.
TTI Short Course 2014 - TxDOT Houston District Bridge
Standardizing Designs
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Engineer is encouraged to adapt methods of increasing design efficiency when faced with hundreds of elements to design.
Engineer is encouraged to tabularize results or create a library of previous designs.
Engineer is encouraged to pull previous designs for other similar elements.
Design Engineer Pros
CAD Operator Pros
Drafting takes a long time. Encouraged to reuse as much as possible.
Using existing goby's prevents missing callouts and notes.
CAD Operator becomes more familiar with details can catch dimension errors.
TTI Short Course 2014 - TxDOT Houston District Bridge
CHANGE PRIORITIES Changing the Priority and Order of Work.
TTI Short Course 2014 - TxDOT Houston District Bridge
Prioritize Your Work
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Start drawing sheets before design. Some sheet may not need to be drawn to the perfect scale.
As long as dimensions and callouts are correct. Minimize down time.
Manage Employee Work Loads
Be Smart With Your Redlines Breakdown and simplify redlines between CAD Operator and Engineer. Make sure one element is perfect then copy to minimize having to
make the same change later to multiple elements.
What Really Needs to Be Shown on the Plans Eliminate repeated design information on different sheets. Can it be built with what is provided? Minimizes the locations of revisions if something changes.
TTI Short Course 2014 - TxDOT Houston District Bridge
WORK SMARTER Let The Computer Do The Heavy Lifting.
TTI Short Course 2014 - TxDOT Houston District Bridge
Let the Computer Do the Heavy Lifting
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The Biggest Waste of Time For Engineers & CAD Operators…
DATA MANAGEMENT!
TTI Short Course 2014 - TxDOT Houston District Bridge
Let the Computer Do the Heavy Lifting
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Let standardization work for you. Engineer is automatically encouraged to make tools to enhance
productivity while designing hundred of similar elements Design spreadsheets to require as little tampering as possible but also so
they can be easily modified for different situations. One tool is not required to do everything. Simplify each tool. Improve your tools when downtime permits between jobs. When possible, design tools to work together. Design tools that require inputs only once.
Design Spreadsheet Tools Smartly
TTI Short Course 2014 - TxDOT Houston District Bridge
Let the Computer Do the Heavy Lifting
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Use Axiom importer as much as possible for all data (bar tables, etc) Design your tools around Axiom. However….
– This requires cooperation between Engineers and CAD Operators. – Originally this was a challenge as CAD Operators were concerned of allowing others access to drawings. – Everyone is happier now.
Do Not 10 Key!
TTI Short Course 2014 - TxDOT Houston District Bridge
Let the Computer Do the Heavy Lifting
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BGS output format is very predicable. Spreadsheet Visual Basic macros developed in house. Extract bearing seat elevations, bearing taper reports, slab data, & beam
data from BGS outputs. Tabulation of quantities summarized Working to be even more Axiom friendly Results in major decrease of time and reduction of errors.
Example: BGS Extractors
Factoid:
Is This Really Necessary? – Connector C (Located In Segment J1) Connects 2 Lanes of IH-10 Traffic to US 290
Westbound. – It is 95 Spans Long (11,690ft). – Would you like to copy and paste all that BGS output data to summarize you EQ sheet?
TTI Short Course 2014 - TxDOT Houston District Bridge
Let the Computer Do the Heavy Lifting
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Example: BGS Extractors
TTI Short Course 2014 - TxDOT Houston District Bridge
Let the Computer Do the Heavy Lifting
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This “Excels” with standardization. Setup for direct Axiom from calculations to CAD bar table. Revised, and revised again to be easily adaptable for different bents. Easily adopt to bents with similar rebar details.
Change the length, skew, bar spacing and go on… Does not require re-drawing of bent that changed slightly.
A disadvantage of Bentley Rebar. Resulted in a major decrease of time and reduction of errors.
Example: Rebar Quantity Tables
Factoid: No Errors!
– No substantial quantity errors have been found since letting using these tools. – There have been very limited field change orders resulting from these techniques.
TTI Short Course 2014 - TxDOT Houston District Bridge
Let the Computer Do the Heavy Lifting
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Example: Rebar Quantity Tables
TTI Short Course 2014 - TxDOT Houston District Bridge
Let the Computer Do the Heavy Lifting
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Library of columns & footings developed for Green Ribbon. Every footing and column used along the corridor has a unique name.
Aka: Footing DSF-2, or Column Type A is always the same no matter what segment of US 290 you are on.
Footing dimensions, quantities are looked up from the master library. Column and foundation spreadsheets are setup to require very little
modification and are formatted the same to allow data to be easily migrated between each spreadsheet.
Fully Axiom supported. Resulted in a major decrease of time and reduction of errors.
Example: Column & Foundation Tables
TTI Short Course 2014 - TxDOT Houston District Bridge
Let the Computer Do the Heavy Lifting
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Example: Column Tables
TTI Short Course 2014 - TxDOT Houston District Bridge
Let the Computer Do the Heavy Lifting
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Example: Foundation Tables
TTI Short Course 2014 - TxDOT Houston District Bridge
Let the Computer Do the Heavy Lifting
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Example: Foundation Tables
TTI Short Course 2014 - TxDOT Houston District Bridge
Let the Computer Do the Heavy Lifting
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We had to design many, many, many U-Beams…. How to Design U-Beams (We started this before PGSuper)….
– Run BGS 2 Times. – Compute LLDF using Bridge Division Spreadsheets. – Compute your loadings due to dead loads. – Create a PSTRS14 Input file – Run PSTRS14 – Use a spreadsheet to compute drops and slab section depths with BGS and PSTRS14 output data. – Run BGS one last time.
…..And it better all have satisfied the design requirements, otherwise start from the top again.
How long should it take an engineer to perform the tasks after creating BGS for a 20 span 28’ wide connector?
Superstructure U-Beam Design
TTI Short Course 2014 - TxDOT Houston District Bridge
Let the Computer Do the Heavy Lifting
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We can do it in less than 10 minutes. Remember the biggest waste of time is data management so let the
computer do the heavy lifting. Envisioned by John F. Corbett back in 2001. Revived and improved upon back in 2009, and again in 2014. Automatically integrates BGS, LLDF, PSTRS14, and Bearing Drop data.
– Automatically Imports BGS LS2 Data (# of Beams, Beam Lengths, Spacing's & Skews. – Provides user capable automatic calculation and distribution of dead loads such as
railings, medians, sidewalks, and haunch weights. – Automatically calculates LLDF using Bridge Division spreadsheets for each beam using
exact BGS output data. – Automatically creates and runs PSTRS14 input files – Automatically imports PSTRS14 outputs such as number of strands, f’ci, f’c, deflections
and cambers. – Automatically calculates bearing drops and slab depth sections. – Automatically summarizes BGS drops and slab depth sections.
Example: Corbett Automatic Superstructure Design
TTI Short Course 2014 - TxDOT Houston District Bridge
Let the Computer Do the Heavy Lifting
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Example: Corbett Automatic Superstructure Design
TTI Short Course 2014 - TxDOT Houston District Bridge
Let the Computer Do the Heavy Lifting
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Example: Corbett Automatic Superstructure Design
TTI Short Course 2014 - TxDOT Houston District Bridge
Let the Computer Do the Heavy Lifting
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Example: Corbett Automatic Superstructure Design
TTI Short Course 2014 - TxDOT Houston District Bridge
SOFTWARE New Software Used.
TTI Short Course 2014 - TxDOT Houston District Bridge
Software
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Uses beam element finite element modeling Allowed for a quick cap design or CAP18 check. Program includes load combinations, no need to spend hours specifying. Program includes wind loading, and breaking forces, along with dead load
and HL-93 automatic calculation. Quick and easy calculation of single column foundation loadings. Basic post-tensioning capabilities. Allowed for quick special designs: irregular footings, straddle bents,
eccentric Bents, & unsymmetrical bents. A model can take 15-30 minutes to develop versus a week to develop a
STAAD model. Very reasonable software cost to TxDOT. http://www.viathor.com
Viathor VBent
TTI Short Course 2014 - TxDOT Houston District Bridge
Software
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Viathor Vbent Example: Single Column Bent
Model Inputs - Deck - Cap - Reinforcing
TTI Short Course 2014 - TxDOT Houston District Bridge
Software
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Viathor Vbent Example: Single Column Bent
Model Inputs - Column - Foundation - Reinforcing - Live Loads
TTI Short Course 2014 - TxDOT Houston District Bridge
Software
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Viathor Vbent Example: Single Column Bent
Reports - Summary - Cap Flexure - Foundation
Loads
TTI Short Course 2014 - TxDOT Houston District Bridge
Software
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Viathor Vbent Example: Single Column Ecc. Post Tensioned
TTI Short Course 2014 - TxDOT Houston District Bridge
Software
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Viathor Vbent Example: Straddle Caps
TTI Short Course 2014 - TxDOT Houston District Bridge
RESULTS Conclusions & Results.
TTI Short Course 2014 - TxDOT Houston District Bridge
US 290 Corridor – Timesheet Billed Engineering Hours / Signed Bridge Sheet
US 290 – DOING MORE WITH LESS
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Average 21Hrs / Sheet
15.7
37.3
17.6 19.2
15.6
20.2
25.5 25.9
11.4
21.6
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
Seg K (2) Seg G (6) Seg J1(1)
Seg F (7) Seg E (8) Seg H (5) Seg I (4) Seg J2 (3) Seg D (9) Seg C(10)
Seg B(11)
Seg A(12)
Bill
ed H
rs (F
unct
ions
164
& 1
70)
Per S
igne
d &
Sea
led
Brid
ge S
heet
US 290 Job Segment - In Order of Lettings (2011-2014)
US 290 Corridor - Timesheet Billed Engineering Hours / Signed Bridge Sheet TxDOT Houston District Bridge Design
Currently in Design
TTI Short Course 2014 - TxDOT Houston District Bridge
US 290 – DOING MORE WITH LESS
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Segment CSJ Type * # of Bridges * Total Hrs * Total Bridge Sheets * Hrs / Sheet
Seg K (2) 0271-14-217 Recon 20 22,330 1,423 15.69
Seg G (6) 0050-09-071 Recon 9 12,168 326 37.33
Seg J1 (1) 0271-14-228 Recon 10 16,983 966 17.58
Seg F (7) 0050-08-086 Widen 12 6,549 341 19.21
Seg E (8) 0050-08-087 Recon 6 6,657 427 15.59
Seg H (5) 0050-09-070 Recon 16 9,239 457 20.22
Seg I (4) 0050-09-069 Recon 11 8,487 333 25.49
Seg J2 (3) 0271-14-213 Recon 6 9,828 380 25.86
Seg D (9) 0050-06-081 Widen 12 3,062 268 11.43
Seg C (10) 0050-06-080 Widen 5 2,953 137 21.55
Seg B (11) 0050-06-079 Widen 6
Seg A (12) 0114-12-007 Widen 14
* Includes Only Bridges Designed By & Signed & Sealed Sheets Provided By TxDOT Houston District Bridge Foundation Layout Redlines Provided By By TxDOT Houston District Bridge, However Signed & Sealed By Consultants
TTI Short Course 2014 - TxDOT Houston District Bridge
THANK YOU US 290 - DOING MORE WITH LESS
Michael E. Carlson, P.E TxDOT Houston District Bridge Design [email protected] 713-802-5366
QUESTIONS?