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Engineering for Structural Stability in Bridge Construction Publication No. FHWA-NHI-15-044 NHI Course Number 130102 Reference Manual April 2015 NOTICE This document is disseminated under the sponsorship of the U.S. Department of Transportation in the interest of information exchange. The U.S. Government assumes no liability for its contents or use of the information contained in this document. This report does not constitute a standard, specification, or regulation. The U.S. Government does not endorse products or manufacturers. Trademarks or manufacturers’ names appear in this report only because they are considered essential to the objective of this document. Quality Assurance Statement The Federal Highway Administration (FHWA) provides high-quality information to serve Government, industry, and the public in a manner that promotes public understanding. Standards and policies are used to ensure and maximize the quality, objectivity, utility, and integrity of its information. FHWA periodically reviews quality issues and adjusts its programs and processes to ensure continuous quality improvement. i Technical Report Documentation Page 1. Report No. NHI-15-044 2. Government Accession No. 3. Recipient’s Catalog No. 4. Title and Subtitle 5. Report Date April 2015 Engineering for Structural Stability in Bridge Construction 6. Performing Organization Code: 7. Author(s) 8. Performing Organization Michael J. Garlich, S.E., P.E.; Thomas H. Pechillo, P.E.; Jason Report No. M. Schneider, P.E., S.E.; Todd A. Helwig, PhD., P.E.; Mary Anne O’Toole, P.E.; Stan-Lee C. Kaderbek, P.E., S.E.; Michael Grubb, P.E.; John Ashton, S.E., P.E. 9. Performing Organization on Name and Address 10. Work Unit No. (TRAIS) Collins Engineers, Inc. 11. Contract or Grant No. 123 North Wacker Drive, Suite 900 Chicago, Illinois 60606 DTFH61-09-T-70027 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered Office of Bridge Technology Federal Highway Administration 14. Sponsoring Agency Code 1200 New Jersey Avenue, S.E. Washington, DC 20590 15. Supplementary Notes 16. Abstract: This manual is intended to serve as a reference. It will provide technical information which will enable Manual users to perform the following activities: • Describe typical erection practices for girder bridge superstructures and recognize critical construction stages • Discuss typical practices for evaluating structural stability of girder bridge superstructures during early stages of erection and throughout bridge construction • Explain the basic concepts of stability and why it is important in bridge erection • Explain common techniques for performing advanced stability analysis along with their advantages and limitations • Describe how differing construction sequences effect superstructure stability • Be able to select appropriate loads, load combinations, and load factors for use in analyzing superstructure components during construction • Be able to analyze bridge members at various stages of erection • Develop erection plans that are safe and economical, and know what information is required and should be a part of those plans • Describe the differences between local, member and global (system) stability 17. Key Words 18. Distribution Statement Bridge construction, bridge erection, bridge superstructures, bridge stability 19. Security Classif. (of this 20. Security Classification (of 21. No of 22. Price report) this page) Pages Unclassified Form DOT F 1700.7 (8-72) Reproduction of completed page authorized ii iii APPROXIMATE CONVERSIONS TO SI UNITS SYMBOL WHEN YOU KNOW MULTIPLY BY TO FIND SYMBOL LENGTH in inches 25.4 millimeters mm ft feet 0.305 meters m yd yards 0.914 meters m mi miles 1.61 kilometers km AREA in2 square inches 645.2 square millimeters mm2 ft2 square feet 0.093 square meters m2 yd2 square yard 0.836 square meters m2 ac acres 0.405 hectares ha mi2 square miles 2.59 square kilometers km2 VOLUME fl oz fluid ounces 29.57 milliliters mL gal gallons 3.785 liters L ft3 cubic feet 0.028 cubic meters m3 yd3 cubic yards 0.765 cubic meters m3 NOTE: volumes greater than 1000 L shall be shown in m3 MASS oz ounces 28.35 grams g lb pounds 0.454 kilograms kg T short tons (2000 lb) 0.907 megagrams (or Mg (or "t") "metric ton") TEMPERATURE (exact degrees) oF Fahrenheit 5 (F-32)/9 Celsius oC or (F-32)/1.8 ILLUMINATION fc foot-candles 10.76 lux lx fl foot-Lamberts 3.426 candela/m2 cd/m2 FORCE and PRESSURE or STRESS lbf pound-force 4.45 newtons N iv lbf/in2 pound-force per square 6.89 kilopascals kPa inch APPROXIMATE CONVERSIONS FROM SI UNITS SYMBOL WHEN YOU KNOW MULTIPLY BY TO FIND SYMBOL LENGTH mm millimeters 0.039 inches in m meters 3.28 feet ft m meters 1.09 yards yd km kilometers 0.621 miles mi AREA mm2 square millimeters 0.0016 square inches in2 m2 square meters 10.764 square feet ft2 m2 square meters 1.195 square yards yd2 ha hectares 2.47 acres ac km2 square kilometers 0.386 square miles mi2 VOLUME mL milliliters 0.034 fluid ounces fl oz L liters 0.264 gallons gal m3 cubic meters 35.314 cubic feet ft3 m3 cubic meters 1.307 cubic yards yd3 MASS g grams 0.035 ounces oz kg kilograms 2.202 pounds lb Mg (or "t") megagrams (or "metric 1.103 short tons (2000 lb) T ton") TEMPERATURE (exact degrees) oC Celsius 1.8C+32 Fahrenheit oF ILLUMINATION lx lux 0.0929 foot-candles fc cd/m2 candela/m2 0.2919 foot-Lamberts fl FORCE and PRESSURE or STRESS N newtons 0.225 pound-force lbf kPa kilopascals 0.145 pound-force per lbf/in2 inch2 *SI is the symbol for the International System of Units. Appropriate rounding should be made to comply with Section 4 of ASTM E380. (Revised March 2003) v Engineering for Structural Stability in Bridge Construction Report No. NHI-15-044 April 2015 vi vii TABLE OF CONTENTS CHAPTER 1 INTRODUCTION .................................................................................... 1.1 SECTION 1. MANUAL SCOPE 1.1 SECTION 2. SURVEY OF STATE DEPARTMENTS OF TRANSPORTATION 1.6 1.2.1 Survey Description ..................................................................... 1.6 1.2.2 Summary of Responses ............................................................. 1.6 CHAPTER 2 CONSTRUCTION FAILURE CASE STUDIES ....................................... 2.1 SECTION 1. INTRODUCTION 2.1 SECTION 2. ROUTE 17 (FUTURE I-86), NEW YORK (2010) 2.1 SECTION 3. MARCY BRIDGE, NEW YORK (2002) 2.2 SECTION 4. RED MOUNTAIN FREEWAY, ARIZONA (2007) 2.5 SECTION 5. EAST BOUND I-80/94 TO NORTH BOUND IL 394, RAMP J 2.7 2.5.1 General Description ................................................................... 2.7 2.5.2 Ramifications of Collapse ........................................................ 2.12 SECTION 6. I-70 BRIDGE, COLORADO (2004) 2.12 SECTION 7. SR69 OVER THE TENNESSEE RIVER (1995) 2.15 SECTION 8. SOUVENIR BOULEVARD BRIDGE, QUEBEC (2000) 2.18 SECTION 9. QUEBEC BRIDGE OVER ST. LAWRENCE (1907) 2.19 SECTION 10. I-80 GIRDER FAILURE (2005) 2.23 SECTION 11. CASE STUDIES – STEEL BOX-GIRDER BRIDGE FAILURES DURING ERECTION OUTSIDE OF NORTH AMERICA 2.25 2.11.1 Introduction .............................................................................. 2.25 2.11.2 Fourth Danube Bridge .............................................................. 2.26 2.11.3 Cleddau Bridge ........................................................................ 2.27 2.11.4 West Gate Bridge ..................................................................... 2.28 2.11.5 Rhine Bridge ............................................................................ 2.30 2.11.6 Zeulenroda Bridge ................................................................... 2.32 SECTION 12. SUMMARY AND CONCLUSIONS 2.32 CHAPTER 3 TYPICAL BRIDGE CONSTRUCTION PRACTICE ................................. 3.1 SECTION 1. INTRODUCTION 3.1 SECTION 2. ERECTION SEQUENCING 3.1 3.2.1 Site Conditions ........................................................................... 3.1 3.2.2 Girder Shipping .......................................................................... 3.1 viii 3.2.3 Erection Sequence ..................................................................... 3.3 3.2.3.1 Initial Preparation ..................................................................3 .3 3.2.3.2 Steel Girder Bridges ..............................................................3 .5 3.2.3.3 Concrete Girder Bridges ........................................................3 .7 SECTION 3. GIRDER HANDLING 3.10 3.3.1 Center of Gravity ...................................................................... 3.10 3.3.2 Rigging for Straight and Curved Steel Girders ......................... 3.11 3.3.3 Rigging for Concrete Girders ................................................... 3.12 3.3.4 Local Stresses from Beam Clamps .......................................... 3.13 3.3.5 Lifting Beams & Spreader Beams ............................................ 3.14 3.3.7 Bolting Procedures ................................................................... 3.17 3.3.8 Field Welding Considerations .................................................. 3.18 3.3.9 Concrete Girders ...................................................................... 3.18 SECTION 4. CRANES 3.19 3.4.1 Typical Crane Data .................................................................. 3.19 3.4.2 Holding Cranes ........................................................................ 3.25 3.4.3 Soil Pressures and Structures Influenced by Crane Location .. 3.26 SECTION 5. BRACING 3.27 3.5.1 Girder Bracing .......................................................................... 3.27 3.5.2 Temporary Bracing and Hold Downs ....................................... 3.29 3.5.2.1 Chain Down to Standard Bearings ...................................... 3.30 3.5.2.2 Erecting on Multi-Rotational Bearings ................................. 3.36 3.5.2.3 Bracing to Adjacent Structures – Phased Construction ....... 3.37 3.5.2.4 Uplift Hold-Down ................................................................. 3.38 SECTION 6. SHORING TOWERS 3.39 SECTION 7. DECK CONSTRUCTION 3.42 3.7.1 Placing Sequence .................................................................... 3.42 3.7.2 Overhang Brackets .................................................................. 3.43 SECTION 8. BRIDGE DEMOLITION 3.48 SECTION 9. SUMMARY 3.49 CHAPTER 4 STABILITY FUNDAMENTALS ............................................................... 4.2 SECTION 1. INTRODUCTION 4.2 SECTION 2. GEOMETRICAL IMPERFECTIONS AND RESIDUAL STRESSES 4.3 SECTION 3. COLUMN BUCKLING 4.8 4.3.1 Flexural Buckling ........................................................................ 4.9 4.3.2 Torsional Buckling .................................................................... 4.13 ix