New Press-Brake Tub Girder Steel Bridge Design Being Tested

Posted on May 8, 2013 by

In October 2011, some of the best brains in the business met in Chicago to discuss specific steel bridge system designs for the future, with a focus on economical value, innovation, and Accelerated Bridge Construction (ABC) practices. The group chose a promising shallow steel press-brake tub girder technology and gave the go-ahead to begin research on developing and testing the design.

The system consists of modular galvanized shallow trapezoidal boxes fabricated from cold-bent structural steel plate. The concrete deck is precast on the girder and the modular unit will be shipped by truck to the bridge site.

What are the economical benefits? They include:

  • A significant reduction in fabrication costs — estimated as less than half the cost of other currently available proprietary cold-formed box girder systems — due to cold-bending versus cutting and welding of the section.
  • A reduction in additional details such as stiffeners and cross frames.
  • The potential for accelerated on-site construction due to the stable modular nature of the pre-topped tub girders.
  • The ability to be used for both tangent and skewed configurations as well as simple and continuous spans.

The preliminary specimen design has been completed, resulting in modular concepts that are competitive for spans up to 60 feet. The project is now ready to begin the physical testing phase, which will determine the ultimate capacity of the systems and will serve to benchmark analytical studies.

The testing will consist of eight press-brake tub girder specimens. Nucor Corporation, SSAB Americas, and EVRAZ North America have each donated 84” x 7/16” x 480” Grade 50 steel plates, which will be cold-bent to specific dimensions. The specimens will be constructed and tested in three-point bending loading scenarios under both static and cyclic loading in the Major Structures Lab at West Virginia University. See video of the bent-plate folding process below. The testing phase of the project will be completed in early 2014.

The state of Iowa has received an Innovative Bridge Research and Deployment Program grant (IBRD) from the Federal Highway Administration to replace the Amish Sawmill Bridge on Dillon Avenue in Buchanan with this system. Construction on the bridge will begin this summer. The states of Missouri, Oregon, and West Virginia have also expressed interest in pursuing demonstration projects for this system, with the expectation that these modular systems may be competitive for longer-span lengths.

For more information on this and other short span steel bridge design innovations, click here.

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Managing Dollars and Sense in Spite of Difficult Bridge Design Challenges

How does a county engineer keep his projects moving forward while managing his budget and maintaining his sanity in today’s transportation/infrastructure environment?

Take the Sarah Mildred Long Bridge, a lift bridge connecting New Hampshire and Maine. At 73 years old, the Long Bridge was shut down in January after its center span got stuck during a routine test. But that isn’t the biggest problem – it’s the corroding floor beams and supports. The replacement bridge is scheduled for completion in 2017, but there’s a hitch—the current bridge may not last that long. Even though it’s the top red-listed bridge in New Hampshire, the funding for renovations is not yet in place. The need is obvious, but the funding isn’t there. This story, printed in “The Portland Press-Herald/Maine Sunday Telegram” on February 4, 2013, is, unfortunately, more the rule than the exception.

In Iowa, Buchanan County Engineer Brian Keierleber, P.E. talks about the scope of bridge repair challenges he faces. “I have to replace a bridge from 1870, one from 1872, and one from 1875,” he says. “General Custer fought the Battle of Little Bighorn in 1876! I’m working on bridges that predate the Model T!” But Brian has a big problem in that his 19th century bridges are facing 21st century demands, such as modern combines that measure 22 feet wide but must cross bridges that are 20 feet wide. This places extra strain on structures that should have been replaced years ago. With a huge gap between need and funding resources, Brian surmises that eventually “economics will dictate that the rural road system must be brought to more modern standards, which begins with building modern bridges.”

The SSSBA is helping to turn that eventually into now with a new, easy-to-use, web-based design tool called eSPAN140. Engineers (or non-engineers) can obtain cost-effective designs for short span steel bridges in five minutes or less in just three easy steps. The only data required is the project’s length, width and number of striped traffic lanes. eSPAN140 prints out a Steel Solutions book that’s tailor-made for the project and includes the names/phone numbers/emails of manufacturers and fabricators who can provide pricing information and deliver the completed bridge to the site. And the best news of all – eSPAN140 is FREE to use and can be used multiple times for additional projects. It was developed by the steel bridge industry, with more than 30 organizations collaborating on the project.

County engineers (and non-engineers) have everything to gain and nothing to lose with eSPAN140. Try it today.

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FHWA Awards IBRD Grant to Construct Steel Bridge in Iowa

Posted on November 16, 2012 by

The Amish Sawmill Bridge on Dillon Avenue in Buchanan, Iowa, is about to get a new look and a lot of attention from the bridge design community, the steel industry and the Federal Highway Administration (FHWA).

Buchanan County Engineer Brian Keierleber submitted a proposal to replace the bridge with funding from the FHWA’s Innovative Bridge Research and Deployment (IBRD) program. The $350,000 grant was awarded on the basis of using a trapezoidal bent steel girder section supported on Geosynthetic Reinforced Soil (GRS), technology endorsed by the members of the Steel Market Development Institute’s (SMDI) Modular Steel Bridge Technical Working Group.*

The project will include the construction of GRS abutments with a sheetpiling face and the placement of trapezoidal bent plate beams on the GRS abutments. Stay-in-place forms will be utilized prior to casting a deck in place. The project will meet the stated goals of the IBRD program and the “Every Day Counts” initiative.“

With construction slated to begin in June 2013, this project will prove of particular interest to researchers at West Virginia University who are currently testing shallow steel press-brake tub girders to obtain data on the ultimate capacity of this system. The Amish Sawmill Bridge project will provide an opportunity to conduct field testing on the bent plate system in order to validate design assumptions and evaluate performance over the long term.

The payout for bridge designers, the steel industry and the FHWA is an economical, innovative new system that could significantly impact future best design practices.

* The members of the Modular Steel Bridge Technical Working Group include representatives from the Short Span Steel Bridge Alliance, Steel Market Development Institute, National Steel Bridge Alliance, National Association of County Engineers, steel bridge fabricators, university faculty members, steel manufacturers, government organizations and bridge owners.

Posted in Abutments, County Bridges, FHWA, Short Span Bridges, Steel Bridges, Uncategorized | Tagged , , , , | Leave a comment

A Short Span Steel Bridge Saves a Local Community

Posted on August 14, 2012 by

According to the American Society for Civil Engineers, more than 26% (one in four) of the nation’s bridges are either structurally deficient or functionally obsolete (see http://www.infrastructurereportcard.org/fact-sheet/bridges).  Over half of these bridges are in rural locations, and essential to the lifeline of many small towns throughout the United States.

These short span bridges (typically 140 feet or less) connected families with their family, community, local businesses, and emergency essentials.  In some locations, one bridge out of service can disrupt an entire community.  This is exactly what happened in Mt. Olive Township, N.J.

An article that appeared in RAI Magazine (June 2012)  detailed how Hurricane Irene washed away a local bridge in 2011, causing not only logistical problems, but also an emergency medical situation. A family with a special needs child required regular medical care – they relied on the bridge for access to a local medical facility.  Thanks to the assistance of a local steel bridge fabricator, a 30-foot-long by 12-foot-wide, simple steel beam bridge designed to carry HS20 loads, was quickly installed.

Short span steel bridges have been used to connect communities for over a century.  Steel bridges can be quickly fabricated and installed which saves communities, such as Mt. Olive, time and money and in some cases, fast access to emergency services.

The Short Span Steel Bridge Alliance recently made it very easy to develop — at no cost — designs, standards, and prefabricated solutions for crossing uneSPAN140der 140 feet through the development of eSPAN140.  In 3 simple steps, a bridge owner or designer can get the information needed to design a short span steel bridge or culvert.

Here’s a short video about eSPAN140.

Brian P. Keierleber, P.E., County Engineer, Buchanan County Iowa, says that eSpan140 has provided him with a fast and cost-effective way to a professionally rendered short span steel bridge design. “I have confidence in these designs and details as they were developed by university researchers who are national experts in bridge design and construction.” The payoff for Keierleber? “After I put in my specific bridge information, I get a design that I can take to a fabricator.  This saves time for me and precious funds for our county.  It is one more tool in the tool box providing for economical options.”

Go to http://www.eSPAN140.com to set up a free account. It’s your first step to start on a short span steel bridge design.

Posted in Accelerated Bridge Design and Construction, Bridge Design Economics, eSPAN140, short span bridge design tools, Short Span Bridges, Short Span Steel Bridge Alliance, Uncategorized | Tagged , , , , , , , | Leave a comment

Weathering Steel – New River Gorge Bridge 25 Years Later

Posted on June 5, 2012 by

The New River Gorge Bridge is a steel arch bridge 3,030 feet (924 m) long over the New River Gorge near Fayetteville, West Virginia, in the Appalachian Mountains of the eastern United States. With an arch 1,700 feet (518 m) long, the bridge is now the third longest in the US.

See historic footage of the construction of the bridge in this video:

Tours of the bridge are now available.  The “Bridge Walk” tours – launched in Sept. 2010 — allow guests an up-close look at the workings of the bridge and its engineering highlights and to experience the massive structure that connects the banks of the New River National River.  One of the more remarkable features is that the bridge was constructed with weathering steel – it is the largest arch bridge constructed using this material.  The bridge was built in 1977 and is still performing well, according to a study conducted by West Virginia University.

Bridge engineers choose weathering steel for its performance, economical and environmental benefits. Weathering steels contain elements that allow them to form a protective coating patina or coating when properly exposed to the atmosphere. The use of uncoated weathering steel typically provides initial cost savings of 10 percent or more, and life cycle cost savings of at least 30 percent over the life of the structure. Initial cost savings are realized because weathering steels do not need to be painted. Life cycle cost savings are realized by the material’s durability. Inspections of bridges in service between 18 and 30 years show that weathering steel performs well in most environments.

Weathering steels provide environmental benefits as well. They do not require initial painting, thereby reducing emissions of volatile organic compounds (VOC) when oil-based coatings are used. They do not require coating removal or disposal of contaminated blast debris over the life span of the structure, providing another significant environmental benefit.

For more information on weathering steel, also see a collection of videos on the Short Span Steel Bridge Alliance’s website.

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Instant Steel Bridge: Accelerated Bridge Construction With Steel

Posted on April 23, 2012 by

A remarkable feat took place recently in Boston, MA.  A bridge, owned by the The Massachusetts Department of Transportation, that would “normally involve two years of detours and frustration for local drivers” (according to an article in the New York Times) was replaced in one weekend. See a time-lapsed video and more information here.

The article highlights the fact that by using “accelerated bridge construction” techniques, a collection of technologies and methods that can shave months if not years off the process of building and replacing critical infrastructure, Massachusetts is at the forefront of a national effort that is aimed at putting drivers first.

Victor M. Mendez, the head of the Federal Highway Administration, said “This will be the new normal,”

In order to achieve these feats, many engineers and DOTs are utilizing steel for the projects which required accelerated construction. Short span steel bridges provide many advantages for accelerated construction.  In 2010, The Utah Department of Transportation decided to install a pre-fabricated steel bridge in order to save time and money.  According to Tom Christensen, P.E., project engineer with Jones & DeMille Engineering, “We specified prefabricated steel on this project for several reasons. One reason was that steel beams are typically shallower than pre-fabricated, pre-stressed concrete systems, which allowed us to keep a low bridge profile height. The second factor was cost. The pre-fabricated steel beams were less expensive than comparable pre-fabricated concrete systems.”

Utah DOT, Axtell,UT, Sevier River Bridge

Utah DOT prefabricated steel bridge, Axtell, UT. Bridge was built using accelerated bridge design and construction guidelines. Fabricated by Wheeler Bridge.

You can learn more about the advantages of steel in accelerated construction by viewing several case studies at the Short Span Steel Bridge Alliance web site.

Also see:

Posted in Accelerated Bridge Design and Construction, Bridge Design Economics, Installation, Prefabricated Bridges, Short Span Steel Bridge Alliance | Tagged , , | Leave a comment

Three Myths.. and the Reality… of Steel Bridges

Posted on March 30, 2012 by

There are a lot of “myths”or misconceptions surrounding the use of steel in bridge construction. These myths often arise out of past experience and don’t take into account changes in technology, improvements in materials and products or updated design and construction practices.

MYTH # 1: Steel Is Not Recommended For Short Spans.

REALITY: Due to changing designs and prices for both steel and concrete members, the relative economics of span and cost of each material has also changed. In many cases, the most economical steel span may be close to or the same as for the concrete design.  The Short Span Steel Bridge Alliance has developed standard designs and details to further simplify the process.  In addition, they have created a program called eSPAN140 which provides economical customized solutions for bridges under 140’

MYTH # 2: Optimization by weight is the best approach to economical design.

REALITY: Although this may be true in some cases, savings in material may sometimes be more than offset by increases in fabrication cost; in certain instances, adding weight may provide the least cost solution.

MYTH # 3: Modular prefabricated short-span steel bridges are only temporary structures.

REALITY: Modular prefabricated short-span bridges, as compared with so-called panel bridges, are typically permanent structures.

For more information on these and other myths, visit www.ShortSpanSteelBridges.org

Posted in Bridge Design Economics, Modular Bridges, Prefabricated Bridges, Short Span Bridges, Steel Bridges, Uncategorized | Tagged , , , | Leave a comment

Sustainability in Steel Bridge Construction

Posted on March 30, 2012 by

Today’s bridges are being designed to last 30 to 80 years before major maintenance or replacement is required (CE News, Sept. 2011).  Therefore, today’s infrastructure planning and design decisions will impact us far into the future – these decisions must be made with the application of sound sustainability practices.  Many different rating systems are currently being developd by various public and private organizations to evaluate the level of “sustainability” in a given project.  But, makes a project sustainable?  Some practices which can improve the sustainability of a project include:

Stormwater Management, including underground detention systems.
Onsite Material Recycling, including metal recovering & processing
Preservation / Reuse of current structures

Steel provides solutions in these three areas.

  • Corrugated Steel Pipe provides a cost-effective solution to stormwater management requirements and saves valuable space. These durable subsurface structures serve as detention, infiltration and filtration systems for site development.
  • Steel is North America’s Number #1 Recycled Material. Each year, more steel is recycled than aluminum, paper, glass and plastic combined! Scrap has become the steel industry’s single largest source of raw material because it is economically advantageous to recycle old steel into new steel.
  • Steel bridge are unique in the fact that many times, they can be preserved or even reused. In some cases, bridges over 100 years old have been rehabbed to allow traffic to travel over them once again.  For example High Steel Structures recently rehabbed the Gerloff Road Truss Rehabilitation in Montgomery County, PA.  Originally constructed in 1888, this wrought iron Phoenix Pratt truss is listed on the National Register of Historic Places. When PennDOT found it to be in need of rehabilitation, they faced a major challenge in determining how to rehab the bridge without distracting from or disrupting the historic truss. High Steel stepped in – with an end result is a completely independent arch structure that enables traffic to cross a previously closed bridge.

More information about sustainability and short span steel bridges can be found at www.ShortSpanSteelBridges.org

Posted in Corrugated Steel Pipe, Historic Bridges, Material Recycling, Short Span Bridges, Steel Bridges, Sustainability, Uncategorized | Tagged , , , , | 1 Comment