Constructability Improvement of Bridges Using Stepping Formwork

Many construction systems have been used to build several highway bridges and elevated roads in Egypt. Recently, the stepping shuttering system has been used in Egypt for cast-in-place concrete bridge. This system is most appropriate for concrete bridges of moderate spans ranging from 40 to 70 m. The stepping shuttering system provides appropriate means to satisfy local needs for concrete bridge construction in an urban environment, practically without infringing on traffic or property below. This paper presents an innovative method of construction that has been used in Egypt for the first time to build the 6th October Bridge extension. Issues regarding the constructability and innovation are highlighted, and the significant aspects during the bridge construction are documented. Also, the difficulties encountered and the lessons learned are thoroughly investigated. In addition, evaluation of the system is discussed in terms of construction cost, schedule, and flexibility. Finally, this paper presents an innovative method that offers substantial opportunity for enhancing constructability of concrete bridges using the stepping shuttering system.     

Constructability Rankings of Construction Systems Based on the Analytical Hierarchy Process

This paper uses the quantitative decision-making technique, the analytical hierarchy process, to derive prioritized scales for (1) the constructability factors; and (2) the relative contribution of common construction systems in a building superstructure comprising structural frames, slabs, envelopes, roof, and internal walls toward constructability. The identified constructability factors show that to enhance constructability design requirements should be easily visualized and coordinated by site staff, while designs should allow economic use of contractors’ resources and enable contractors to develop and adopt alternative construction details. The precast method is rated as the most constructible construction method, indicating its better performance in facilitating efficient and safe construction in the busy urban environment in Hong Kong. However, the methodology adopted in this study should be of international interest, especially for those desirous of improving constructability of designs with different contextual backgrounds.     

Interactive 3D CAD for Effective Derrick Crane Operation in a Cable-Stayed Bridge Construction

The high expectation of esthetic and functional quality in modern civil infrastructure has resulted in the increased demand for long span bridges. In advanced or developing countries, long span bridges such as cable-stayed and suspension bridges are considered even as landmarks that symbolize the prosperity or culture of the region. These long span bridges require higher level of design and construction technologies than other types of bridges. In particular, the construction of cable-stayed bridges involves precise and sophisticated operation of construction equipment such as derrick cranes. However, it is not easy to plan the operations of a derrick crane before the actual construction process takes place. Unexpected spatial constraints in the construction site may hinder the smooth operation of a derrick crane, which leads to lower than expected productivity and safety. This study applies interactive three-dimensional (3D) computer aided design (CAD) to the derrick crane operation for the purpose of identifying potential problems. Construction managers can have the two way process with the 3D CAD system to interactively test their construction plans and scenarios. The case study shows that the interactive 3D CAD system significantly improves the constructability of the cable-stayed bridge construction.     

Modeling of Functional Construction Requirements for Constructability Analysis

Evaluating construction requirements should be an indispensable part of improving the constructability of a facility project. However, a number of existing function analysis approaches focus mainly on the final functions with respect to the finished facility. The construction industry still lacks methodologies to represent and evaluate the functional construction requirements for constructability analysis. This paper develops the concept of intermediate functions for representing the construction requirements from three perspectives, namely, function user, function provider, and the temporal and spatial relationships between the user and the provider. This is followed by the development of an in-progress product model to abstract the construction lifecycle of a facility product utilizing the concept of component state. Furthermore, the reference relationships among such perspectives as in-progress product, intermediate function, resource, and process are addressed. Based on these reference relationships, the bottleneck states for providing the intermediate functions can be detected. A case study of constructing the deck of a bridge using the balanced cantilever approach is presented to illustrate the utilization of this concept and representation.     

Engineering the Tower and Main Span Construction of Stonecutters Bridge

Stonecutters Bridge is the second longest cable-stayed bridge in the world and the first major bridge with a twin-box girder superstructure. It has a number of innovative structural features which made the construction of the bridge a significant challenge. This paper describes the fabrication and erection procedures for the bridge towers and the main span superstructure. These were developed in close interaction between the contractor and his construction engineering consultant to ensure a safe and effective construction. A stage-by-stage analysis was set up to model every step of the main span erection. The results were first used in the verification analyses to establish the adequacy of the permanent works throughout construction. In parallel, extensive wind tunnel testing as well as numerical analyses were performed to ascertain the effects of typhoon wind loads on the structure. The structural deformations predicted by the erection analysis were incorporated into a comprehensive geometric control procedure. This paper describes the construction methodologies developed and the related engineering input. It outlines studies undertaken to achieve an effective construction, ensure structural adequacy of all erection stages, ascertain an acceptable aerodynamic performance of the bridge, and exercise full control over the bridge geometry throughout erection.     

Thrust and Guide Devices for Launched Bridges

Incremental launching is a competitive construction method for medium-span (40–65 m) prestressed concrete bridges. It does not constrain the length and width of the superstructure, and bridges longer than 1 km and wider than 20 m have been successfully launched. This method is hardly constrained by the bridge layout, as varying plan curvatures can be solved by shifting launch supports and varying vertical curvatures by shimming the bottom edges of the superstructure. The launch of a prestressed concrete bridge involves enormous forces and requires the guide and control of big volumes. The devices used for this purpose are described along with their design criteria and optimum fields of utilization, and several suggestions derived from many years of launching practice are given.     

50-Year-Old Prestressed Segmental Concrete Bridges

The first prestressed segmental concrete bridge in the United States opened to traffic was a small bridge in Madison County, Tennessee. The bridge was constructed using prestressed concrete segments and was opened to traffic in October 1950. Prestressed concrete beams were placed side by side to form the superstructure of the bridge. The construction of this bridge and several other similar prestressed concrete bridges are described herein. The existing condition of eleven prestressed concrete bridges remaining in Tennessee is given. Only minor spalling, leaching, and horizontal cracking are present in the superstructure after fifty years of service. Many of the design features introduced in this design can be found in today’s modern precast segmental concrete bridges.     

Constructability Concepts in West Port Highway in Malaysia

This paper presents a case study of the applications and nonapplications of constructability concepts to illustrate, in a practical way, the impact that these concepts can have on a project’s success. This case study, which conveys an important message with regard to the application of constructability concepts, was purposely chosen from among prestigious projects in peninsular Malaysia. The basic message, as viewed by the interviewees, is that applying these constructability concepts will enhance a project’s constructability, consequently optimizing the schedule, cost, and quality of the project for the benefit of all the parties involved. The interviewees for the case study agreed that the applied constructability concepts were derived from their own experience and not based on any existing formal program. The absence of a systematic technique for transferring construction experience and knowledge to all the participants in all phases of a construction project is the reason behind the lack of constructability in our construction industry today.     

Constructability State of Practice Report

This report reviews guidance on constructability programs from a variety of sources and presents the current practice of constructability. The advice of several organizations and researchers is summarized to describe expectations for ideal constructability. Actual current constructability practice, based on results and analysis of a Constructability State of Practice survey, is described. Approximately 100 owners, architects, engineers, consultants, contractors, and construction managers answered the survey’s ten questions and provided written comments. The results provide a picture of current constructability practices in the architecture, engineering, and construction (AEC) industry and progress in recent years. Major conclusions include: (1) constructability has gained acceptance throughout the industry; (2) constructability efforts are clearly beginning in early project phases; (3) a wide variety of constructability techniques and new technologies are being implemented; and (4) obstacles to improving constructability remain, but may be changing. Finally, recommendations are provided based on areas where constructability practice can still be improved. This report is relevant to both industry practitioners and researchers.     

Verification of Incremental Launching Construction Safety for the Ilsun Bridge, the World’s Longest and Widest Prestressed Concrete Box Girder with Corrugated Steel Web Section

The Ilsun Bridge is the world’s longest (801?m in total length) and widest (30.9?m in maximum width) prestressed concrete box girder bridge incorporating a corrugated steel web. This bridge has fourteen spans, twelve of which were erected using an incremental launching method, a method that is rarely applied in this type of bridge. To verify the construction safety of the Ilsun Bridge, this investigation focuses on the span-to-depth ratio, buckling shear stress of the corrugated steel webs, optimization of the length of the steel launching nose, detailed construction stage analysis, and the stress level endured by the corrugated steel webs during the launching process. The span-to-depth ratio of the Ilsun Bridge was found to be well-designed, using a conservative corrugated steel web design. Further, our investigation revealed that the conventional nose-deck interaction equation was not suitable for corrugated steel web bridges. As a result, a detailed construction stage analysis and measurements of this bridge was performed to examine stress levels and ensure safety during the erection process. The results revealed that there are essential design issues that should be considered when designing prestressed concrete box girder bridges with corrugated steel webs and that, when constructing them, the incremental launching method should be used.     

Constructability Practices among Construction Contractors in Indonesia

The concept of constructability in the United States or buildability in the United Kingdom emerged in the late 1970s, which evolved from studies into how improvement can be achieved to increase cost efficiency and quality in the construction industry. It is an approach that links the design and construction processes. The studies in the Unites States, United Kingdom, and Australia have demonstrated that improved constructability has lead to significant savings in both cost and time required for completing construction projects. However, in implementing constructability improvement, it is important to consider the uniqueness of the construction industry in a specific country. This paper presents the study performed on the construction contractors in Indonesia with regard to their current constructability practices and its impact on the project performance. The study shows that many contractors in Indonesia have been implementing part of the constructability concept in their projects. The concepts that usually applied during the construction stage as part of the overall construction plan were planning the sequence of field tasks and analyzing layout, access, and temporary facilities     

Design and Evaluation of Experimental Bridges in Tennessee

This paper describes the design and evaluates the adequacy of the moment connection of an experimental two-span highway bridge designed by the Tennessee Department of Transportation. The Massman Drive Bridge is an experimental design that unifies the construction economy of simple span bridges and the structural economy of continuous span bridges. The experimental connection, consisting of cover plates and kicker wedge plates, is used to connect the two adjoining girders over the center pier. As a result, the bridge is designed to function as a continuous bridge during the deck pour and behave compositely with the reinforced concrete deck under the live load. After completing a moment comparison analysis, it is concluded that the Massman Drive Bridge indeed acts as continuous over the pier as it was designed.     

AASHTO-LRFD Live Load Distribution for Beam-and-Slab Bridges: Limitations and Applicability

This paper presents a comparison between the live load distribution factors of simple span slab-on-girders concrete bridges based on the current AASHTO-LRFD and finite-element analysis. In this comparison, the range of applicability limits specified by the current AASHTO-LRFD is fully covered and investigated in terms of span length, slab thickness, girder spacing and longitudinal stiffness. All the AASHTO-PCI concrete girders (Types I–VI) are considered to cover the complete range of longitudinal stiffness specified in the AASHTO-LRFD. Several finite-elements linear elastic models were investigated to obtain the most accurate method to represent the bridge superstructure. The bridge deck was modeled as four-node quadrilateral shell elements, whereas the girders were modeled using two-node space frame elements. The live load used in the analysis is the vehicular load plus the standard lane load as specified by AASHTO-LRFD. The live load is positioned at the longitudinal location that produced the extreme effect, and then it is moved transversely across the bridge width in order to investigate all possibilities of one-lane, two-lane and three-lane design loads. A total of 886 bridge superstructure models were built and analyzed using the computer program SAP2000 to perform this comparison. The results of this study are presented in terms of figures to be practically useful to bridge engineers. This study showed that the AASHTO-LRFD may significantly overestimate the live load distribution factors compared to the finite-element analysis.     

Comparison of Measured and Computed Stresses in a Steel Curved Girder Bridge

Steel curved I-girder bridge systems may be more susceptible to instability during construction than bridges constructed of straight I-girders. The primary goal of this research is to study the behavior of the steel superstructure of a curved steel I-girder bridge system during all phases of construction and to ascertain whether the actual stresses in the bridge are represented well by linear elastic analysis software developed for this project and typical of that used for design. Sixty vibrating wire strain gauges were applied to a two-span, four-girder bridge, and elevation measurements were taken by a surveyor's level. The resulting stresses and deflections were compared to computed results for the full construction sequence of the bridge as well as for live loading from up to nine 50-kip trucks. The analyses correlated well with the field measurements, especially for the primary flexural stresses. Stresses due to lateral bending and restraint of warping induced in the girders and the stresses in the cross frames were more erratic but generally showed reasonable correlation. In addition, it is shown that, for the magnitude of live load applied to the bridge, analyses in which composite behavior is assumed in the negative moment region yield better correlation than analyses in which just the bare steel girders are used (no shear connectors were used on the bridge in the negative moment region). It is concluded that the curved girder analysis software captures the general behavior well for these types of curved girder bridge systems at or below the service load level, and that the stresses in these bridges may be relatively low if their design is controlled largely by stiffness.     

Construction of a Horizontally Curved Steel I-Girder Bridge. Part I: Erection Sequence

In the case of horizontally curved steel I-girder bridges, girder and cross-frame members are frequently detailed for erection in the no-load condition as a matter of convention. As a result, it is imperative that the erection sequence used to construct such bridges be comprehensively studied to ensure that the no-load condition can be achieved in the field and that significant superstructure component fit-up problems do not occur. The current research investigates the erection of a recently constructed horizontally curved steel I-girder bridge, in which significant difficulties were encountered during erection. The bridge erection is recreated through an analytical simulation using a detailed nonlinear finite element model. The analytical results demonstrate that a condition that closely resembles the no-load condition can be achieved in the field during construction with the proper implementation of temporary support structures; and that the difficulties encountered during the erection of the subject bridge superstructure could not be attributed to the erection scheme followed.     

Approximate Series Solution for Analysis of FRP Composite Highway Bridges

The design of a deck-and-stringer bridge system is usually reduced to the analysis of a T-beam section, loaded by concentrated loads corresponding to an equivalent fraction of the applied truck load. This equivalent load is defined by wheel load–distribution factors, which approximate the overall behavior of the bridge superstructure. In this paper, a one-term approximation of a macroflexibility series solution including deformations for fiber-reinforced polymer (FRP) deck-and-stringer orthotropic bridge systems, is used to develop explicit expressions for symmetric and asymmetric load distribution factors. It is significant that the equations presented herein include important parameters that represent, as accurately as possible, the response characteristics of the super structure, such as the geometry and material properties of the FRP deck and stringers, bridge aspect ratio, and number and spacing of stringers. As an illustration in actual design applications, the formulation presented in this paper is used to develop an analytical method for FRP deck-and-stringer bridge systems, and the method is verified by predicting the response of an all FRP model bridge in the lab and an FRP deck on steel stringers in the field. The results of the present formulation compare well with experimental lab and field results. The simplified analysis presented in this paper can be used with sufficient accuracy for the design of composite FRP deck on stringers bridges.     

Automated Rebar Constructability Diagnosis

In spite of impressive progress in project modeling and computer-integrated construction, there is little real integration—manual or computerized—between design and construction of building projects. Consequently, constructability problems are experienced during the construction phase. With regard to rebar, constructability problems are discovered either after casting the reinforced concrete element or not at all, resulting in a weaker element. This paper describes a rebar constructability model, which was developed in an object-oriented graphic environment. The model is intended to be used during the design phase to automatically diagnose potential rebar-related constructability problems (the Diagnosis Module), as well as to offer solutions and implement them (the Correction Module). Of these two modules, the Diagnosis Module was implemented in a concept-proving prototype. The proposed model searches for constructability problems through all relevant parts of the building. This search includes the structural design, as well as other building systems (e.g., sanitary, drainage, HVAC). The model also checks for potential collisions between reinforcement bars and temporary inserts (e.g., form ties). Thus, in addition to the resulting increased constructability, the model also has potential as a system coordination tool.     

Constructability Concepts in Kuala Selangor Cable-Stayed Bridge in Malaysia

The writers formulated a case study of the Kuala Selangor Cable Stayed Bridge to examine the application of the constructability concepts particularly during the conceptual planning and the design phases of the project. This paper presents the advantages of implementing the constructability concepts and the barriers that were encountered when applying these concepts during the planning and design phases of the cable stayed bridge project of Kuala Selangor in Malaysia. The writers concluded that barriers to constructability implementation that are related to the owner were the major impediments in the application of constructability concepts during the early conceptual planning phase. The opinion of the engineer was another factor behind nonapplication of some other concepts. At the same time, many others were implemented due to the awareness and opinion of the engineer and his ability to control their application.     

Prestressing Schemes for Incrementally Launched Bridges

Incremental launching is a competitive construction method for medium-span prestressed concrete bridges. Compared with other techniques for in situ casting, in short bridges it is an alternative to the use of falseworks and reduces the cost of labor with the same investment. In longer bridges it is an alternative to movable shuttering systems and reduces both investment and labor cost. Compared with segmental precasting, it may reduce both investment and the cost of prestressing, which may be partial instead of total, with the same advantages in terms of industrial production. Due to its competitiveness and overall quality, this construction method is widely used in Europe. During launch, the superstructure is moved over fixed bearings. The superstructure dead load produces temporary flexural and shear stresses within the cross section that are quite different from those produced by the service loads and, consequently, require special prestressing schemes, thoroughly illustrated in this paper.