Prefabricated Bridge Elements and Systems in Japan and Europe

Abstract

In April 2004, a scanning tour of Japan, the Netherlands, Belgium, Germany, and France was made to obtain information about bridge construction methods being used to minimize traffic disruption, improve work zone safety, minimize environmental impact, improve constructibility, increase quality, and lower life-cycle costs. From information obtained from the tour, 10 technologies were identified for further consideration and possible implementation into U.S. practices. These included two technologies that allow bridges to be built off site and then moved to their final location in a short time, three superstructure systems and four deck systems that facilitate faster and safer construction, and one substructure system. The two technologies for moving bridges were self-propelled modular transporters and other moving systems, including skidding or sliding, incremental launching, floating, rotating, and lifting of bridges into place. The superstructure systems included a precast concrete deck system known as the Poutre Dalle system, the use of partial-depth concrete decks prefabricated on steel or concrete beams, and U-shaped precast concrete segments with transverse ribs. The deck systems involved full-depth prefabricated concrete decks, special cast-in-place closure joint details, hybrid steel–concrete deck systems, and a multiple-level corrosion protection system. The substructure system consisted of stay-in-place precast concrete panels that serve as both formwork and structural elements for solid and hollow bridge piers.

Laboratory and field testing and evaluation of precast bridge elements

“…Due to increasing traffic volume, there is an expanding need to construct and rehabilitate bridges with minimal impact to traffic. In April 2004, a team from the U.S. toured Japan, the Netherlands, Belgium, Germany, and France to observe rapid construction bridge technologies being used in these countries and to identify technologies that may be implemented in the U.S. (Russell et al, 2005). Rapid construction has several advantages over traditional construction methods.…”

“…Certain disadvantages need to be considered when determining if using rapid construction technologies are appropriate for a given project. These disadvantages include an increase in construction cost, size and weight limitations of precast members, availability, and contractor familiarity (Russell et al, 2005)…”

Laboratory testing of precast bridge elements, verification of post-tensioning forces and construction documentation of the Boone County IBRC accelerated bridge replacement project

“…Constructing and rehabilitating bridges with minimal impact to traffic has become a priority with the increase in traffic volume. In April 2004, an 11-person team from the U.S. took a tour of Japan, the Netherlands, Belgium, Germany, and France to observe rapid construction bridge technologies being used in these countries and to identify technologies that may be implemented in the U.S. (Russell et al, 2005). Renewal of the infrastructure in the U.S. is necessary for several reasons, including increases in population, projected increase in vehicle miles traveled, obsolete or deficient structures, impact of road construction, and injuries and fatalities related to work zones (NCHRP, 2003).…”

“…The disadvantages of rapid construction include an increase in construction cost, size and weight limitations of precast members, availability, and contractor familiarity (Russell et al, 2005). These disadvantages need to be considered when determining if using rapid construction technologies are appropriate for a given project.…”

“…The most common bridge superstructure in the U.S. consists of erecting steel, reinforced concrete, or prestressed concrete girders, and using formwork to place a cast-inplace (CIP) concrete deck. Eliminating the deck formwork reduces construction time and lane closure time, and improves worker safety (Russell et al, 2005). There are several different types of deck systems that are used in rapid construction projects.…”