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S2-R04-RR-2 Innovative Bridge Designs for Rapid Renewal ABC Toolkit WWW.TRB.ORG/SHRP2 Innovative B ridge D esigns for R apid R enew al: A B C Toolkit S H R P 2 TR B Non-profit Org. U.S. Postage PAID Washington, DC Permit No. 8970 TRANSPORTATION RESEARCH BOARD 500 Fifth Street, NW Washington, DC 20001 ADDRESS SERVICE REQUESTED

TRB OVERSIGHT COMMITTEE FOR SHRP 2* Chair: Kirk T. Steudle, Director, Michigan Department of Transportation MEMBERS H. Norman Abramson, Executive Vice President (retired), Southwest Research Institute Alan C. Clark, MPO Director, Houston–Galveston Area Council Frank L. Danchetz, Vice President, ARCADIS-US, Inc. Stanley Gee, Executive Deputy Commissioner, New York State Department of Transportation Michael P. Lewis, Director, Rhode Island Department of Transportation Susan Martinovich, Director, Nevada Department of Transportation John R. Njord, Executive Director, Utah Department of Transportation Charles F. Potts, Chief Executive Officer, Heritage Construction and Materials Ananth K. Prasad, Secretary, Florida Department of Transportation Gerald M. Ross, Chief Engineer, Georgia Department of Transportation George E. Schoener, Executive Director, I-95 Corridor Coalition Kumares C. Sinha, Olson Distinguished Professor of Civil Engineering, Purdue University Paul Trombino III, Director, Iowa Department of Transportation EX OFFICIO MEMBERS John C. Horsley, Executive Director, American Association of State Highway and Transportation Officials Victor M. Mendez, Administrator, Federal Highway Administration David L. Strickland, Administrator, National Highway Transportation Safety Administration LIAISONS Ken Jacoby, Communications and Outreach Team Director, Office of Corporate Research, Technology, and Innovation Management, Federal Highway Administration Tony Kane, Director, Engineering and Technical Services, American Association of State Highway and Transportation Officials Jeffrey F. Paniati, Executive Director, Federal Highway Administration John Pearson, Program Director, Council of Deputy Ministers Responsible for Transportation and Highway Safety, Canada Michael F. Trentacoste, Associate Administrator, Research, Development, and Technology, Federal Highway Administration RELIABILITY TECHNICAL COORDINATING COMMITTEE* Chair: Cathy Nelson, Technical Services Manager/Chief Engineer, Oregon Department of Transportation MEMBERS Rachel Arulraj, Director of Virtual Design & Construction, Parsons Brinckerhoff Michael E. Ayers, Consultant, Technology Services, American Concrete Pavement Association Thomas E. Baker, State Materials Engineer, Washington State Department of Transportation John E. Breen, Al-Rashid Chair in Civil Engineering Emeritus, University of Texas at Austin Daniel D’Angelo, Recovery Acting Manager, Director and Deputy Chief Engineer, Office of Design, New York State Department of Transportation Steven D. DeWitt, Chief Engineer, North Carolina Turnpike Authority Tom W. Donovan, Senior Right of Way Agent (retired), California Department of Transportation Alan D. Fisher, Manager, Construction Structures Group, Cianbro Corporation Michael Hemmingsen, Davison Transportation Service Center Manager (retired), Michigan Department of Transportation Bruce Johnson, State Bridge Engineer, Oregon Department of Transportation, Bridge Engineering Section Leonnie Kavanagh, PhD Candidate, Seasonal Lecturer, Civil Engineering Department, University of Manitoba John J. Robinson, Jr., Assistant Chief Counsel, Pennsylvania Department of Transportation, Governor’s Office of General Counsel Michael Ryan, Vice President, Michael Baker Jr., Inc. Ted M. Scott II, Director, Engineering, American Trucking Associations, Inc. Gary D. Taylor, Professional Engineer Gary C. Whited, Program Manager, Construction and Materials Support Center, University of Wisconsin–Madison AASHTO LIAISON James T. McDonnell, Program Director for Engineering, American Association of State Highway and Transportation Officials FHWA LIAISONS Steve Gaj, Leader, System Management and Monitoring Team, Office of Asset Management, Federal Highway Administration Cheryl Allen Richter, Assistant Director, Pavement Research and Development, Office of Infrastructure Research and Development, Federal Highway Administration J. B. “Butch” Wlaschin, Director, Office of Asset Management, Federal Highway Administration CANADA LIAISON Lance Vigfusson, Assistant Deputy Minister of Engineering & Operations, Manitoba Infrastructure and Transportation * Membership as of August 2012. TRANSPORTATION RESEARCH BOARD 2013 EXECUTIVE COMMITTEE* OFFICERS Chair: Deborah H. Butler, Executive Vice President, Planning, and CIO, Norfolk Southern Corporation, Norfolk, Virginia Vice Chair: Kirk T. Steudle, Director, Michigan Department of Transportation, Lansing Executive Director: Robert E. Skinner, Jr., Transportation Research Board MEMBERS Victoria A. Arroyo, Executive Director, Georgetown Climate Center, and Visiting Professor, Georgetown University Law Center, Washington, D.C. Scott E. Bennett, Director, Arkansas State Highway and Transportation Department, Little Rock William A. V. Clark, Professor of Geography (emeritus) and Professor of Statistics (emeritus), Department of Geography, University of California, Los Angeles James M. Crites, Executive Vice President of Operations, Dallas–Fort Worth International Airport, Texas Paula J. C. Hammond, Secretary, Washington State Department of Transportation, Olympia John S. Halikowski, Director, Arizona Department of Transportation, Phoenix Michael W. Hancock, Secretary, Kentucky Transportation Cabinet, Frankfort Susan Hanson, Distinguished University Professor Emerita, School of Geography, Clark University, Worcester, Massachusetts Steve Heminger, Executive Director, Metropolitan Transportation Commission, Oakland Chris T. Hendrickson, Duquesne Light Professor of Engineering, Carnegie Mellon University, Pittsburgh, Pennsylvania Jeffrey D. Holt, Managing Director, Bank of Montreal Capital Markets, and Chairman, Utah Transportation Commission, Huntsville, Utah Kevin L. Keith, Missouri Department of Transportation, Jefferson City Gary P. LaGrange, President and CEO, Port of New Orleans, Louisiana Michael P. Lewis, Director, Rhode Island Department of Transportation, Providence Joan McDonald, Commissioner, New York State Department of Transportation, Albany Donald A. Osterberg, Senior Vice President, Safety and Security, Schneider National, Inc., Green Bay, Wisconsin Steve Palmer, Vice President of Transportation, Lowe’s Companies, Inc., Mooresville, North Carolina Sandra Rosenbloom, Director, Innovation in Infrastructure, The Urban Institute, Washington, D.C. (Past Chair, 2012) Henry G. (Gerry) Schwartz, Jr., Chairman (retired), Jacobs/Sverdrup Civil, Inc., St. Louis, Missouri Kumares C. Sinha, Olson Distinguished Professor of Civil Engineering, Purdue University, West Lafayette, Indiana Daniel Sperling, Professor of Civil Engineering and Environmental Science and Policy; Director, Institute of Transportation Studies; University of California, Davis Gary C. Thomas, President and Executive Director, Dallas Area Rapid Transit, Dallas, Texas Phillip A. Washington, General Manager, Regional Transportation District, Denver, Colorado EX OFFICIO MEMBERS Rebecca M. Brewster, President and COO, American Transportation Research Institute, Smyrna, Georgia Anne S. Ferro, Administrator, Federal Motor Carrier Safety Administration, U.S. Department of Transportation LeRoy Gishi, Chief, Division of Transportation, Bureau of Indian Affairs, U.S. Department of the Interior, Washington, D.C. John T. Gray II, Senior Vice President, Policy and Economics, Association of American Railroads, Washington, D.C. Michael P. Huerta, Administrator, Federal Aviation Administration, U.S. Department of Transportation Joung Ho Lee, Associate Director for Finance and Business Development, American Association of State Highway and Transportation Officials, Washington, D.C. David T. Matsuda, Administrator, Maritime Administration, U.S. Department of Transportation Michael P. Melaniphy, President and CEO, American Public Transportation Association, Washington, D.C. Victor M. Mendez, Administrator, Federal Highway Administration, U.S. Department of Transportation Robert J. Papp (Adm., U.S. Coast Guard), Commandant, U.S. Coast Guard, U.S. Department of Homeland Security Cynthia L. Quarterman, Administrator, Pipeline and Hazardous Materials Safety Administration, U.S. Department of Transportation Peter M. Rogoff, Administrator, Federal Transit Administration, U.S. Department of Transportation David L. Strickland, Administrator, National Highway Traffic Safety Administration, U.S. Department of Transportation Joseph C. Szabo, Administrator, Federal Railroad Administration, U.S. Department of Transportation Polly Trottenberg, Under Secretary for Policy, U.S. Department of Transportation Robert L. Van Antwerp (Lt. General, U.S. Army), Chief of Engineers and Commanding General, U.S. Army Corps of Engineers, Washington, D.C. Barry R. Wallerstein, Executive Officer, South Coast Air Quality Management District, Diamond Bar, California Gregory D. Winfree, Acting Administrator, Research and Innovative Technology Administration, U.S. Department of Transportation Frederick G. (Bud) Wright, Executive Director, American Association of State Highway and Transportation Officials, Washington, D.C. * Membership as of February 2013.

THE SECOND STRATEGIC HIGHWAY RESEARCH PROGRAM HNTB Corporation Genesis Structures, Inc. Structural Engineering Associates Iowa State University TRANSPORTATION RESEARCH BOARD Washington, D.C. 2013 www.TRB.org Innovative Bridge Designs for Rapid Renewal: ABC Toolkit SHRP 2 Report S2-R04-RR-2

SUBSCRIBER CATEGORIES Bridges and Other Structures Construction Design Highways

THE SECOND STRATEGIC HIGHWAY RESEARCH PROGRAM America’s highway system is critical to meeting the mobility and economic needs of local communities, regions, and the nation. Developments in research and technology—such as advanced materials, communications technology, new data collection technologies, and human factors science—offer a new opportunity to improve the safety and reliability of this important national resource. Breakthrough resolution of significant transportation problems, however, requires concentrated resources over a short time frame. Reflecting this need, the second Strategic Highway Research Program (SHRP 2) has an intense, large-scale focus, integrates mul- tiple fields of research and technology, and is fundamentally different from the broad, mission-oriented, discipline-based research programs that have been the mainstay of the high- way research industry for half a century. The need for SHRP 2 was identified in TRB Special Report 260: Strategic Highway Research: Saving Lives, Reducing Congestion, Improving Quality of Life, pub- lished in 2001 and based on a study sponsored by Congress through the Transportation Equity Act for the 21st Cen- tury (TEA-21). SHRP 2, modeled after the first Strategic Highway Research Program, is a focused, time-constrained, management-driven program designed to complement existing highway research programs. SHRP 2 focuses on applied research in four areas: Safety, to prevent or reduce the severity of highway crashes by understanding driver behavior; Renewal, to address the aging infrastruc- ture through rapid design and construction methods that cause minimal disruptions and produce lasting facilities; Reliability, to reduce congestion through incident reduc- tion, management, response, and mitigation; and Capacity, to integrate mobility, economic, environmental, and com- munity needs in the planning and designing of new trans- portation capacity. SHRP 2 was authorized in August 2005 as part of the Safe, Accountable, Flexible, Efficient Transportation Equity Act: A Legacy for Users (SAFETEA-LU). The pro- gram is managed by the Transportation Research Board (TRB) on behalf of the National Research Council (NRC). SHRP 2 is conducted under a memorandum of understand- ing among the American Association of State Highway and Transportation Officials (AASHTO), the Federal Highway Administration (FHWA), and the National Academy of Sci- ences, parent organization of TRB and NRC. The program provides for competitive, merit-based selection of research contractors; independent research project oversight; and dissemination of research results. SHRP 2 Report S2-R04-RR-2 ISBN: 978-0-309-12952-7 Library of Congress Control Number: 2013931860 © 2013 National Academy of Sciences. All rights reserved. COPYRIGHT INFORMATION Authors herein are responsible for the authenticity of their materials and for obtaining written permissions from pub- lishers or persons who own the copyright to any previously published or copyrighted material used herein. The second Strategic Highway Research Program grants permission to reproduce material in this publication for classroom and not-for-profit purposes. Permission is given with the understanding that none of the material will be used to imply TRB, AASHTO, or FHWA endorsement of a particular product, method, or practice. It is expected that those reproducing material in this document for educa- tional and not-for-profit purposes will give appropriate ac- knowledgment of the source of any reprinted or reproduced material. For other uses of the material, request permission from SHRP 2. Note: SHRP 2 report numbers convey the program, focus area, project number, and publication format. Report num- bers ending in “w” are published as web documents only. NOTICE The project that is the subject of this report was a part of the second Strategic Highway Research Program, conducted by the Transportation Research Board with the approval of the Governing Board of the National Research Council. The members of the technical committee selected to moni- tor this project and to review this report were chosen for their special competencies and with regard for appropriate balance. The report was reviewed by the technical commit- tee and accepted for publication according to procedures established and overseen by the Transportation Research Board and approved by the Governing Board of the National Research Council. The opinions and conclusions expressed or implied in this report are those of the researchers who performed the re- search and are not necessarily those of the Transportation Research Board, the National Research Council, or the pro- gram sponsors. The Transportation Research Board of the National Acad- emies, the National Research Council, and the sponsors of the second Strategic Highway Research Program do not en- dorse products or manufacturers. Trade or manufac turers’ names appear herein solely because they are considered essen tial to the object of the report. SHRP 2 REPORTS Available by subscription and through the TRB online bookstore: www.TRB.org/bookstore Contact the TRB Business Office: 202.334.3213 More information about SHRP 2: www.TRB.org/SHRP2

The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished schol- ars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare. On the authority of the charter granted to it by the Congress in 1863, the Academy has a mandate that requires it to advise the federal government on scientific and techni- cal matters. Dr. Ralph J. Cicerone is president of the National Academy of Sciences. The National Academy of Engineering was established in 1964, under the charter of the National Academy of Sciences, as a parallel organization of outstanding engineers. It is autonomous in its administration and in the selection of its members, sharing with the National Academy of Sciences the responsibility for advis- ing the federal government. The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achieve- ments of engineers. Dr. Charles M. Vest is president of the National Academy of Engineering. The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the services of eminent members of appropriate professions in the examination of policy matters pertaining to the health of the public. The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an adviser to the federal government and, upon its own initia- tive, to identify issues of medical care, research, and education. Dr. Harvey V. Fineberg is president of the Institute of Medicine. The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy’s purposes of furthering knowledge and advising the federal government. Functioning in accordance with general policies determined by the Academy, the Council has become the principal operating agency of both the National Academy of Sci- ences and the National Academy of Engineering in providing services to the government, the public, and the scientific and engineering communities. The Council is administered jointly by both Academies and the Institute of Medicine. Dr. Ralph J. Cicerone and Dr. Charles M. Vest are chair and vice chair, respectively, of the National Research Council. The Transportation Research Board is one of six major divisions of the National Research Council. The mission of the Transportation Research Board is to provide leadership in transportation innovation and progress through research and information exchange, conducted within a setting that is objective, interdis- ciplinary, and multimodal. The Board’s varied activities annually engage about 7,000 engineers, scientists, and other transportation researchers and practitioners from the public and private sectors and academia, all of whom contribute their expertise in the public interest. The program is supported by state transpor- tation departments, federal agencies, including the component administrations of the U.S. Department of Transportation, and other organizations and individuals interested in the development of transportation. www.TRB.org www.national-academies.org

SHRP 2 STAFF Ann M. Brach, Director Stephen J. Andrle, Deputy Director Neil J. Pedersen, Deputy Director, Implementation and Communications James Bryant, Senior Program Officer, Renewal Kenneth Campbell, Chief Program Officer, Safety JoAnn Coleman, Senior Program Assistant, Capacity and Reliability Eduardo Cusicanqui, Financial Officer Walter Diewald, Senior Program Officer, Safety Jerry DiMaggio, Implementation Coordinator Shantia Douglas, Senior Financial Assistant Charles Fay, Senior Program Officer, Safety Carol Ford, Senior Program Assistant, Renewal and Safety Elizabeth Forney, Assistant Editor Jo Allen Gause, Senior Program Officer, Capacity Rosalind Gomes, Accounting/Financial Assistant Abdelmename Hedhli, Visiting Professional James Hedlund, Special Consultant, Safety Coordination Alyssa Hernandez, Reports Coordinator Ralph Hessian, Special Consultant, Capacity and Reliability Andy Horosko, Special Consultant, Safety Field Data Collection William Hyman, Senior Program Officer, Reliability Michael Marazzi, Senior Editorial Assistant Linda Mason, Communications Officer Reena Mathews, Senior Program Officer, Capacity and Reliability Matthew Miller, Program Officer, Capacity and Reliability Michael Miller, Senior Program Assistant, Capacity and Reliability David Plazak, Senior Program Officer, Capacity Monica Starnes, Senior Program Officer, Renewal Onno Tool, Visiting Professional Dean Trackman, Managing Editor Connie Woldu, Administrative Coordinator Patrick Zelinski, Communications/Media Associate

vii This work was sponsored by the Federal Highway Administration in cooperation with the American Association of State Highway and Transportation Offi cials. It was con- ducted in the second Strategic Highway Research Program, which is administered by the Transportation Research Board of the National Academies. The project was man- aged by Monica A. Starnes, Ph.D., Senior Program Offi cer for SHRP 2 Renewal. The research reported on herein was performed by HNTB Corp. with Kenneth Price, P.E., as principal investigator and Bala Sivakumar, P.E., as co-principal inves- tigator. Also providing support were Genesis Structures (Kansas City), Structural Engineering Associates (San Antonio), and Iowa State University (Ames). The authors gratefully acknowledge those individuals from state departments of transportation, industry organizations, contractors, and academia who participated in the project sur- vey and focus group meetings and provided important information and documenta- tion for this project. ACKNOWLEDGMENTS

ix FOREWORD As the nation’s bridge inventory continues aging and the need for its renewal increases, new approaches on how to design and build bridges are paramount. This need, com- bined with increasing traffi c congestion, will require the implementation of faster and less-disruptive construction methods. Accelerated bridge construction (ABC) tech- niques have proved their ability to fulfi ll these needs in some unique bridge projects and, most importantly, in a limited number of statewide bridge programs such as in Utah. While the key for successful implementation of ABC on a large scale requires a range of technical and programmatic solutions, one mechanism that has proved suc- cessful in implementing past bridge innovations is the idea of standard concepts and, in some cases, standard plans. This SHRP 2 project started its research with an ulti- mate goal of developing a set of such standard concepts. At its inception, the project focused on identifying and evaluating the historical barriers to prevalent use of ABC. Based on the assessment, the research team led by HNTB developed a set of technical solutions to overcome those identifi ed barriers. The solutions were directed toward modular (i.e., prefabricated) bridge substructure and superstructure systems that (1) can be installed with minimal traffi c disruptions and (2) can be easily constructed by local contractors using conventional equipment. With those goals in mind, the research team set itself to develop new structural concepts by incrementally improving proven and accepted bridge systems, components, and details. Structural evaluations, analyses, designs, and laboratory testing provided the tools to achieve the sought improvements. This ABC Toolkit (the Toolkit) was produced with bridge practitioners in mind. It provides a series of design and construction concepts for prefabricated elements and their connections. Based on the scope of work, the Toolkit also provides proposed language for AASHTO design and construction specifi cations. Monica A. Starnes, PhD SHRP 2 Senior Program Offi cer, Renewal

xSince the initiation of this research project, other ABC-related programs either have matured (e.g., Utah DOT’s ABC program) or have been established (e.g., FHWA’s Every Day Counts [EDC]) in parallel. While the Toolkit provides concepts for design- ing and building complete bridges, it is not meant to be a complete manual on ABC or prefabricated bridge elements and systems (PBES), but rather an additional resource that complements the body of knowledge and other publications on the subject. The Toolkit is being published as an interim publication with the understanding that additional work will be completed by SHRP 2 to include lateral sliding concepts for bridges in a future version of the Toolkit. Additional work will be undertaken by others to bring the terminology of the Toolkit into agreement with that used in the FHWA-EDC program.

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TRB’s second Strategic Highway Research Program (SHRP 2) SHRP 2 Report S2-R04-RR-2: Innovative Bridge Designs for Rapid Renewal: ABC Toolkit describes standardized approaches to designing and constructing complete bridge systems for rapid renewals.

The report includes design standards and design examples for complete prefabricated bridge systems, and proposes specification language for accelerated bridge construction systems, which adheres to the American Association of State Highway and Transportation Officials (AASHTO) Load and Resistance Factor Design (LRFD) Bridge Design and Construction Specifications.

ABC Standard Concepts: The Lateral Slide, produced as an addendum to the Innovative Bridge Designs for Rapid Renewal: ABC Toolkit, provides additional detail on the lateral slide construction technique.

An e-book version of this report is available for purchase at Amazon, Google, and iTunes.

The R04 MathCAD files for the SHRP 2 Report S2-R04-RR-2 are available to help illustrate the sample accelerated bridge construction (ABC) design calculations. The sample design calculations serve as training tools for engineers to increase familiarity with ABC design issues and criteria.

A demonstration project on US 6 over the Keg Creek near Council Bluffs, Iowa used the accelerated bridge construction standards developed as part of Renewal Project R04.

The following three videos were produced related to the Keg Creek project:

ABC for Everyday Bridges (18:39) highlights the specific techniques used to deliver a new bridge with only a 10-day closure.

One Design—10,000 Bridges (9:46) describes a tool kit for designing and constructing bridges that brings home the benefits of accelerated bridge construction techniques so local contractors can use typical equipment to build bridges quickly and efficiently.

Time-Lapse Video (1:30) shows ABC techniques being used by a local contractor with standard equipment to replace the Keg Creek three-span bridge.

A second demonstration project on I-84 in New York also used the ABC Toolkit in applying bridge slide technologies, which were used over two weekend nights to save millions of dollars and two years of traffic detours. The "Two Weekend Nights" video documents the successful use of the technology. A case study I-84 bridge project in also available.

The R04 Renewal project also developed a half- and full-day presentations to help facilitate training on of the accelerated bridge process to interested parties.

In June 2013, SHRP 2 produced a Project Brief on the project that developed the ABC Toolkit.

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