2012 CISC Alberta Steel Workshop

Proven Practices for Incremental Launching of Steel Girder Bridges

By: Robert Gale, PEng

1
2012 CISC Alberta Steel Workshop

Presentation Outline
1) Overview of Launching and how can it be used for construction of steel structures bridges or other 2) Site Constraints for Launching - Reviewing the suitability of the site. Two projects Park Bridge & Coast Meridian 3) Bridge Design for Launching - Adequacy of permanent bridge superstructure for temporary launching demands 4) Fabrication and Assembly for Launching - unique aspects 5) Launch Equipment - Function of systems typically used 6) "Jack Down" after Launching - Transfer of bridge superstructure from temporary supports to permanent bearings 7) Summary and Conclusion
2
2012 CISC Alberta Steel Workshop

1) Overview of Launching
Conventional Delivery or Design Build Architect/ Design Engineer Simple Org Chart

General Contractor Construction Engineer or Erector Launching?

Many items need to "fall into place"

Fabricator

Construction Method

3
2012 CISC Alberta Steel Workshop

1) Overview of Launching
Launching can be used for many types of structures, but alignment should be straight or constant curve. Launching is a viable option for regions of: Steep or inaccessible terrain of obstacles below, or heavy vehicle traffic below. Design girders for permanent loads and temporary launch loads. Check elements of superstructure for launching (splices, bottom flange, plan bracing, jacking stiffeners). May need re-design. Require an assembly bed that is wide enough for crane access and long enough to assemble girders to safely cantilever out. Launching may not be cost effective if traditional construction methods are available (Need to manage all girders throughout work).

4
2012 CISC Alberta Steel Workshop

1) Overview of Launching

Examples of Some Recent Launching Projects

5
2012 CISC Alberta Steel Workshop

1) Overview of Launching
Deh Cho Bridge, NWT

6
2012 CISC Alberta Steel Workshop

1) Overview of Launching

Athabasca Bridge, Fort McMurray, AB

7
2012 CISC Alberta Steel Workshop

1) Overview of Launching
South Layton Overpass, UT

8
2012 CISC Alberta Steel Workshop

1) Overview of Launching
Capilano River Bridges, N Vancouver, BC

9
2012 CISC Alberta Steel Workshop

1) Overview of Launching
Peace Bridge, Calgary, AB

10
2012 CISC Alberta Steel Workshop

Presentation Outline
1) Overview of Launching and how can it be used for construction of steel structures bridges or other. 2) Site Constraints for Launching - Reviewing the suitability of the site. Two projects Park Bridge & Coast Meridian. 3) Bridge Design for Launching - Adequacy of permanent bridge superstructure for temporary launching demands 4) Fabrication and Assembly for Launching - Unique aspects 5) Launch Equipment - Function of systems typically used 6) "Jack Down" after Launching - Transfer of bridge superstructure from temporary supports to permanent bearings 7) Summary and Conclusion
11
2012 CISC Alberta Steel Workshop

2) Site Constraints
Old Park Bridge One of the highest rock fall hazard areas in BC. Accident rate double the provincial average.

12
2012 CISC Alberta Steel Workshop

2) Site Constraints

Site Layout for New Park Bridge

13
2012 CISC Alberta Steel Workshop

2) Site Constraints

Assembly Bed at West Abutment

14
2012 CISC Alberta Steel Workshop

2) Site Constraints Launch Video

Courtesy of BC MoT and Focus Corp.

15
WBES 2011 Phoenix, AZ

2) Site Constraints

Assembly Bed

Fabrication Shop

Coast Meridian Overpass (CMO) Site

16
2012 CISC Alberta Steel Workshop

2) Site Constraints

17
2012 CISC Alberta Steel Workshop

2) Site Constraints

CMO first launch

18
2012 CISC Alberta Steel Workshop

2) Site Constraints

CMO in final position after last launch

19
2012 CISC Alberta Steel Workshop

Presentation Outline
1) Overview of Launching and how can it be used for construction of steel structures bridges or other. 2) Site Constraints for Launching - Reviewing the suitability of the site. Two projects Park Bridge & Coast Meridian 3) Bridge Design for Launching - Adequacy of permanent bridge superstructure for temporary launching demands 4) Fabrication and Assembly for Launching - Unique aspects 5) Launch Equipment - Function of systems typically used 6) "Jack Down" after Launching - Transfer of bridge superstructure from temporary supports to permanent bearings 7) Summary and Conclusion
20
2012 CISC Alberta Steel Workshop

3) Bridge Design for Launching

Bridge designed to S-6 with separate launch criteria for load cases for the temporary launching demands. Mostly have to deal with dead load, wind load, and other effects such as training (guiding) forces and temperature. Superstructure designed for permanent load cases and checked and modified as necessary for launch load cases. Most efficient if these are completed concurrently, as with a design-build project. 2-D beam models (typical cases) and 3-D FE models (governing longitudinal cases including transverse loads) used to check structure for launching. Careful of camber effects on the moving structure as can lift off close supports.

21
2012 CISC Alberta Steel Workshop

3) Bridge Design for Launching

Superstructure:
Girder non-composite bending moment Bolted field splices Localized web buckling for cantilever reaction Transverse Loads (wind loads and others) Jack Down loads

Piers & Abutments:

Longitudinal and transverse reactions at Pier Equipment Jack Down loads. Sequence may cause increase loads.

22
2012 CISC Alberta Steel Workshop

3) Bridge Design for Launching

Example 3-span plate girder bridge for launching

23
WBES 2011 Phoenix, AZ

3) Bridge Design for Launching

Typical bridge cross section for permanent bridge

24
2012 CISC Alberta Steel Workshop

3) Bridge Design for Launching

Governing case for launching

25
2012 CISC Alberta Steel Workshop

3) Bridge Design for Launching

Launching cross section

26
2012 CISC Alberta Steel Workshop

3) Bridge Design for Launching

Girders in final position but not on permanent bearings yet

27
2012 CISC Alberta Steel Workshop

3) Bridge Design for Launching

Jack Down at Piers

28
2012 CISC Alberta Steel Workshop

3) Bridge Design for Launching

Image provided by Structural Concepts

Span to depth ratio not greater than range of about 20 to 25

29
2012 CISC Alberta Steel Workshop

3) Bridge Design for Launching

Flush bottom flange to allow girder unobstructed advance on rollers. Constant width of bottom flange easier, but not required, for guiding

30
2012 CISC Alberta Steel Workshop

3) Bridge Design for Launching

Bolted field splices detailed to allow passage of roller No coatings in roller path or use weathering steel
31
2012 CISC Alberta Steel Workshop

Presentation Outline
1) Overview of Launching and how can it be used for construction of steel structures bridges or other. 2) Site Constraints for Launching - Reviewing the suitability of the site. Two projects Park Bridge & Coast Meridian. 3) Bridge Design for Launching - Adequacy of permanent bridge superstructure for temporary launching demands 4) Fabrication and Assembly for Launching - Unique aspects 5) Launch Equipment - Function of systems typically used 6) "Jack Down" after Launching - Transfer of bridge superstructure from temporary supports to permanent bearings 7) Summary and Conclusion
32
2012 CISC Alberta Steel Workshop

4) Fabrication and Assembly

Assemble at "no load" camber so that DL steel deflections are correct after launching
33
2012 CISC Alberta Steel Workshop

4) Fabrication and Assembly

Launched uphill in two section due to 6% slope

34
2012 CISC Alberta Steel Workshop

4) Fabrication and Assembly

Detailed for steel dead load in position with oversize holes

35
2012 CISC Alberta Steel Workshop

4) Fabrication and Assembly

36
2012 CISC Alberta Steel Workshop

4) Fabrication and Assembly

Deliver 1 girder every 3 days

37
2012 CISC Alberta Steel Workshop

4) Fabrication and Assembly

View of Interior framework and two main rib beams for cable-stay loads. More than 180,000 bolts for structure
38
2012 CISC Alberta Steel Workshop

Presentation Outline
1) Overview of Launching and how can it be used for construction of steel structures bridges or other. 2) Site Constraints for Launching - Reviewing the suitability of the site. Two projects Park Bridge & Coast Meridian. 3) Bridge Design for Launching - Adequacy of permanent bridge superstructure for temporary launching demands 4) Fabrication and Assembly for Launching - Unique aspects 5) Launch Equipment - Function of systems typically used 6) "Jack Down" after Launching - Transfer of bridge superstructure from temporary supports to permanent bearings 7) Summary and Conclusion
39
2012 CISC Alberta Steel Workshop

5) Launch Equipment Nose

Temporary lighter girders attached to leading end of permanent girders. Sloped up for cantilever deflection Reduce cantilever overturning moment Custom design to suit conditions

40
2012 CISC Alberta Steel Workshop

5) Launch Equipment Nose

Nose is lighter using truss - but more detailed fabrication required

41
2012 CISC Alberta Steel Workshop

5) Launch Equipment Nose

Hinged nose to accommodate large cantilever deflection for long spans

42
2012 CISC Alberta Steel Workshop

5) Launch Equipment Nose

Simple temporary nose using rolled beam sections

43
2012 CISC Alberta Steel Workshop

5) Launch Equipment Nose

Can accomplish with no nose in the right situation

44
2012 CISC Alberta Steel Workshop

5) Launch Equipment On Piers

Nose about to touchdown on rollers

45
2012 CISC Alberta Steel Workshop

5) Launch Equipment On Piers

Close-up of roller nests (green) and guide wheel

46
2012 CISC Alberta Steel Workshop

5) Launch Equipment On Piers

Roller assembly with integral guide system. Can also side on greased plates or teflon/stainless systems
47
2012 CISC Alberta Steel Workshop

5) Launch Equipment On Piers

Roller assemblies need certain amount of space on pier top for equipment and temporary anchor bolts

48
2012 CISC Alberta Steel Workshop

5) Launch Equipment Moving

Friction system for Park Bridge - hydraulic rams with clamping jaws All pushing force goes into concrete abutment
49
2012 CISC Alberta Steel Workshop

5) Launch Equipment Animation

Courtesy of BC MoT and Focus Corp.

50
WBES 2011 Phoenix, AZ

5) Launch Equipment Moving

Friction system for CMOP girder clamp rides on bottom flange

51
2012 CISC Alberta Steel Workshop

5) Launch Equipment Moving

Winching with tackle pulling from abutment to equalizer beam at back end

52
2012 CISC Alberta Steel Workshop

5) Launch Equipment Moving

Winching by pull directly from front

53
2012 CISC Alberta Steel Workshop

5) Launch Equipment Moving

Launch system using two linked strand jacks pulling from abutment
54
2012 CISC Alberta Steel Workshop

5) Launch Equipment Moving

Using multiple linked strand jacks on steel rails behind abutment

55
2012 CISC Alberta Steel Workshop

Presentation Outline
1) Overview of Launching and how can it be used for construction of steel structures bridges or other. 2) Site Constraints for Launching - Reviewing the suitability of the site. Two projects Park Bridge & Coast Meridian. 3) Bridge Design for Launching - Adequacy of permanent bridge superstructure for temporary launching demands 4) Fabrication and Assembly for Launching - Unique aspects 5) Launch Equipment - Function of systems typically used 6) "Jack Down" after Launching - Transfer of bridge superstructure from temporary supports to permanent bearings 7) Summary and Conclusion
56
2012 CISC Alberta Steel Workshop

6) Jack Down at Piers

1200mm (4-ft) Jack Down with 700 tons load

57
2012 CISC Alberta Steel Workshop

6) Jack Down at Piers

Remove temporary rollers

Slide-in permanent bearing

58
2012 CISC Alberta Steel Workshop

6) Jack Down at Piers

Bearing in position

Bearing installed
59
2012 CISC Alberta Steel Workshop

Presentation Outline
1) Overview of Launching and how can it be used for construction of steel structures bridges or other. 2) Site Constraints for Launching - Reviewing the suitability of the site. Two projects Park Bridge & Coast Meridian. 3) Bridge Design for Launching - Adequacy of permanent bridge superstructure for temporary launching demands 4) Fabrication and Assembly for Launching - Unique aspects 5) Launch Equipment - Function of systems typically used 6) "Jack Down" after Launching - Transfer of bridge superstructure from temporary supports to permanent bearings 7) Summary and Conclusion
60
2012 CISC Alberta Steel Workshop

7) Summary What to Remember

Launching can be used for many types of structures, but should be straight or constant curve. Launching is a viable option for regions of: Steep or inaccessible terrain or obstacles below, or heavy vehicle traffic below. Design girders for permanent loads and temporary launch loads. Check elements of superstructure for launching (splices, bottom flange, plan bracing, jacking stiffeners). May need re-design. Require an assembly bed that is wide enough for crane access and long enough to assemble girders to safely cantilever out. Launching may not be cost effective if traditional construction methods are available (Need to manage all girders throughout work).

61
2012 CISC Alberta Steel Workshop

7) Summary - Additional Information

Incremental Launching of Steel Girders in British Columbia Two Case Studies Structural Engineering International (SEI) magazine, November 2011 Issue
62
2012 CISC Alberta Steel Workshop

Acknowledgements
General Contractors Park Bridge: Flatiron Construction Corp (Richmond, BC) CMO: SNC Lavalin Constructors Pacific (Vancouver, BC) Erector KWH Constructors & Somerset Engineering (Burnaby, BC) Fabricators Park Bridge: Rapid-Span (Armstrong, BC) Park Bridge: Structal-Bridges (Quebec) CMO: Geo. Third & Son (Burnaby, BC) CMO: Dynamic Structures (Port Coquitlam, BC)
63
2012 CISC Alberta Steel Workshop

Thank-you !!

Questions?

64
2012 CISC Alberta Steel Workshop