Work Zone Mobility and Safety Program
Peer-to-Peer Program for Work Zones > Accelerated Road Works for Work Zone Safety and Mobility

Virginia Demonstration Project: Rapid Removal and Replacement of U.S. 15/29 Bridge Over Broad Run Near Gainesville, VA

slide 1: Rt. 15/29 (SBL) Bridge Superstructure Replacement and Roadway Widening

March 5, 2009

Nicholas J. Roper
NOVA District Bridge Engineer

Robert F. Price
Resident Administrator of Loudoun/Prince William Construction

Virginia Department of Transportation

slide notes:



slide 2: Prior to Construction

West side view of SBL bridge prior to construction.
West side view of SBL bridge prior
to construction 		East side view of SBL bridge prior to construction.
East side view of SBL bridge prior
to construction

slide notes:

None



slide 3: Existing Bridge Elevation

Diagram shows cutaway view of bridge elevation from the side. Bridge is composed of three spans ranging from 42 to 44 feet, two abutments, and two piers. The bridge is 130 feet long from abutment A to abutment B.

slide notes:

None



slide 4: Project Information

  • Location: The Route 15/29 (SBL) Bridge Superstructure Replacement and Roadway Widening Project over Broad Run is located in Prince William County, 0.55 Mile North of Route 215.
  • Scope: Work includes replace and widen existing bridge superstructures with offsite-fabricated superstructure segments, substructure concrete widening and repairs, re-alignment and approach work.
  • Superstructure: 3-Span, Concrete T beam, Simply Supported
  • Substructure: Wall type piers and abutments
  • Year Built: 1952
  • ADT: 25,000
  • Condition: Structurally deficient and functionally obsolete.

slide notes:

None



slide 5: Traffic Impacts Identification and Mitigation – Design Phase

  • Analysis of Impacts
    • Traffic analysis, to show the impact of closing a lane for 24 hours, was performed by Simulation Modeling . The data used was based on both published VDOT traffic data as well as the site-specific traffic counts obtained during the project.
    • The results of the analysis showed that conventional bridge construction caused a significant daily traffic backup – 1.5 miles – for the duration of the construction (100 days), and resulted in at least $15M in user cost, due to traffic delays only
  • Identification of traffic impact mitigation strategies
    • Implement Accelerated Bridge Construction (ABC) method
    • ABC during low volume traffic periods only – night construction
    • Phase ABC if the construction time exceeds low volume traffic period

slide notes:

None



slide 6: Project Limits

Project limits within the Buckland Historical District and the Mosby Heritage Area

Approach to the work zone area. Cones and other work zone devices are set up in the area upstream and downstream of the bridge.

slide notes:

None



slide 7: Construction Concept

slide notes:

None



slide 8: Typical Sections

Diagram of existing bridge shows two lanes at 12 feet plus two shoulders at 2 feet. The outermost spans between the piers are 8 feet 10 inches and the central span is 9 feet.
Diagram of the proposed modular bridge shows a 36 foot wide roadway with two lanes at 12 feet plus one shoulder 8 feet and one shoulder at 4 feet. The module width arrangement in the transverse Section is 7 feet 10 inches, 8 feet 9 inches, 9 feet 0 inches, and 12 feet 11 inches.

slide notes:

None



slide 9: Proposed Modular Structure

  • Module Configuration:
    • Each Module Consists of a Prefabricated Conc. Deck on Two Steel Beams
    • Module Width Arrangement in Transverse Section: (7'-10") (8'- 9") (9'-0")(12'- 11")
    • Module Length = Span Length (~ 44')
    • Max. Module Weight = ~35 tons (~30 tons w/ Lightweight Concrete)
  • Longitudinal Joints between Modules:
    • Grouted/Waterproofed Keyways
  • Diaphragms between Modules:
    • Field Installed Steel Diaphragms
  • Deck Parapets:
    • Plant Cast Concrete
  • Asphalt Overlay:
    • 3" Thick with Waterproof Membrane

slide notes:

None



slide 10: Proposed Sequence of Construction

Simple constructed diagram of bridge deck. Deck is rectangular and is divided by verticle lines separating the deck into spans A, B, and C. Horizontal lines divide the dec into stages 1 through 4.

slide notes:

Reduced Scope of Work Plan: Replacing Bridge Deck and Use Existing Bridge substructure.



slide 11: Extending Pier with External PT

Diagram of pier with external PT. From base up, diagram comprises the following: a footing toppied with a pier, topped with a cap, topped with the bridge deck. Horizontal lines through teh cap and the top part of the pier are labeled external post-tensioning. Triangular and rectangular structures are attached to the left of the pier. The triangular piece is the corbel (cast in place or prefabricated, match cast) and the cap. The triangular piece is attached to the pier by grouted dowels.

slide notes:

None



slide 12: Extending Abutment A (Typical)

Diagram depicts the plan and elevation for Abutment A. Both show the footing, seat, and backwall and indicate that grouted dowels will be used to attach new structures. Concret removal will be conducted for parts of the footing and backwall.

slide notes:

None



slide 13: Proposed Construction – Stage I at Night: 9 p.m. to 5 a.m.

Diagram depicts a bridge cutaway. The gap between the new structure on the left and the transport lane will be covered by a temporary plate or filled with asphalt. The new structure is 7 feet 10 inches wide, with a three inch gap between it and the transport lane, which is 14 feet 9 inches wide. A 1 foot three inch traffic barrier will separate the transport lane from the 12 foot wide traffic lane.

slide notes:

Reduced Scope of Work Plan: Replacing Bridge Deck and Use Existing Bridge substructure



slide 14: Proposed Construction – Stage I Night

Rectangular diagram represents the bridge deck. Vertical lines divide the bridge into spans A, B, and C. A horizontal traffic barrier separates teh traffic lane from teh transport lane. Three rectangles at the lower edge of the diagram indicate superstructure that is removed/replaced as part of stage 1 construction.

Note: Stages III and IV are similar.

slide notes:

Reduced Scope of Work Plan: Replacing Bridge Deck and Use Existing Bridge substructure.



slide 15: Stage II MOT for Nighttime Construction

Diagram depicts the traffic pattern for nighttime construction, which involves closing the southbound bridge from 9 p.m. to 5 p.m., routing the southbound traffic on the northbound side via a median crossover 300 feet north of teh bridge, routing southbound traffic back onto the southbound lanes via a median crossover 400 feet south of the bridge. Both lanes of traffic are open on the southbound bridge from 5 a.m. to 9 p.m.
  1. Close the SB bridge to traffic from 9 p.m. to 5 a.m.
  2. Route the SB traffic on NB via the crossover 300' north of the bridge.
  3. Route the SB traffic back on SB via the crossover 400' south of the bridge
  4. Maintain both lanes of traffic on SB bridge from 5 a.m. to 9 p.m.

slide notes:

Reduced Scope of Work Plan: Replacing Bridge Deck and Use Existing Bridge substructure



slide 16: Proposed Construction – Stage II at Night: 9 p.m. to 5 a.m.

Diagram depicts horizontal cutaway of proposed construction. The existing structure's transport lane is divided by a three inch gap from the new construction surface. A blowup of the joing between two new segments shows an L-shaped connection.

slide notes:

None



slide 17: Proposed Construction –Stage II at Night

Rectangular diagram shows that the superstructure is being removed/replaced in spans A, B, and C as part of stage II construction.

slide notes:

Reduced Scope of Work Plan: Replacing Bridge Deck and Use Existing Bridge substructure.



slide 18: Completed Structure

Rectangular diagram depicts the completed bridge replacement/expansion, and a cutaway diagram shows the two 12 foot lanes, 4 and 8 foot shoulders, the support spacing for the structure.

slide notes:

Reduced Scope of Work Plan: Replacing Bridge Deck and Use Existing Bridge substructure.



slide 19: Construction Phase

slide notes:

None



slide 20: Traffic Impacts Identification and Mitigation – Construction Phase

  • Final TMP
    • Use ABC during weekends: Begin Friday Mid-night; End Sunday PM.
    • Detour Traffic during ABC
    • Designate separate detour for trucks
    • Repeat ABC/detour 3 weekends to complete construction
    • Provide Complete MOT Plans with traffic signs, VMS, etc.
    • Incident Management Plan during construction

slide notes:

None



slide 21: Revised Construction Sequence –Revised MOT Plan for Weekend Closures

Map of area surrounding construction site showing car and truck detours and road closures.

slide notes:

None



slide 22: Revised Construction of Span A

Rectangular diagram depicts spans A, B, and C, with span A being highlighted showing that the superstructure is removed/replaced. A note indicates the southbound lanes are detoured during the weekend.

slide notes:

Reduced Scope of Work Plan: Replacing Bridge Deck and Use Existing Bridge substructure.



slide 23: Revised Construction of Span B

Rectangular diagram depicts spans A, B, and C, with span A and B highlighted to indicate that the superstructure was removed/replaced. A note indicates the southbound lanes are detoured during the weekend.

slide notes:

Reduced Scope of Work Plan: Replacing Bridge Deck and Use Existing Bridge substructure.



slide 24: Revised Construction of Span C

Rectangular diagram depicts spans A, B, and C, with each span highlighted to indicate that the superstructure was removed/replaced. A note indicates the southbound lanes are detoured during the weekend.

slide notes:

Reduced Scope of Work Plan: Replacing Bridge Deck and Use Existing Bridge substructure.



slide 25: Completed Structure

Rectangular diagram depicts the completed bridge replacement/expansion, and a cutaway diagram shows the two 12 foot lanes, 4 and 8 foot shoulders, the support spacing for the structure.

slide notes:

Reduced Scope of Work Plan: Replacing Bridge Deck and Use Existing Bridge substructure.



slide 26: Lessons Learned – Traffic Management with Accelerated Bridge Construction

  • Achievement of Project Goals
    • Project was completed with minimum disruption of traffic and inconvenience to public, and full satisfaction of the Buckland community.
    • Superstructure construction reduced from 100 days to 6 days
  • Lessons Learned
    • Accelerated Bridge Construction is slightly more expensive than the conventional construction, but it could result in significant savings in User cost and eliminate inconvenience during construction
    • Public communication essential to success of the TMP
  • Future Directions on Traffic Operations Management for High Impact Projects
    • Accelerated Bridge Construction as a valid construction option for projects in congested areas where full traffic capacity during peak hours must be maintained

slide notes:

None



slide 27: Lessons Learned – Conflicts With Beams

  • Encourage full detailed survey/as-built investigation during Preliminary Engineering Phase.
  • Design should use maximum tolerances to allow for field adjustments.
  • Designers need to insure all specified materials are readily available (standard typical beam sizes).
Existing and new bridge diagram cutaways showing that the actual width of the existing beams was greater than the as-built plans indicated.

slide notes:

None



slide 28: Lessons Learned (Continued) – Crane Issues

  • Larger crane required
  • Limited work area

Two photos of cranes placing precast bridge segments.

slide notes:

None



slide 29:

Large trucks transporting precast bridge segments to the work zone.

slide notes:

None



slide 30: Placing Asphalt at the Abutment and Sealing Deck Joints

Workers placing asphalt at the abutment and sealing the deck joints.

slide notes:

None



slide 31: Completed Structure with Asphalt Overlay

Completed bridge structure after asphalt has been overlaid.

slide notes:

None

Return to List of Presentations
Office of Operations