United States Department of Transportation
[PDF-1.64 MB]
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Alternative Title:Deck Replacement with Precast Concrete Segments
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Abstract:The deck to be replaced in this project was on the Nemo Bridge, built in 1960 by the US Army Corps of Engineers over Pomme De Terre Lake. This 1698 ft. long steel bridge had wide flange girders with a 7 in. thick composite reinforced concrete deck only 22 ft. wide. HNTB Company, the design consultants, had originally designed the deck to be built by conventional methods one lane width at a time, which would have taken 2 years and required one-way traffic on the bridge during the whole construction. The narrow lane would not allow emergency vehicles or school busses to cross. Closing the bridge would have caused a 30-mile detour. Bridge Maintenance Engineer, David O’Connor, suggested using full thickness pre-fabricated deck panels to speed up the construction of the Nemo Bridge. MoDOT received favorable response to this idea internally and also at an on-site public hearing. The local residents and business owners were very supportive and excited about the idea of less traffic disruption, especially on busy summer weekends when tourists, campers and fisherman are visiting. HNTB then started redesigning the bridge plans. It was decided to replace the deck by only closing the bridge on Sunday through Thursday nights from 7PM to 7AM between the Memorial Day weekend and the Labor Day weekend. A precast deck system, using 10 ft. long precast sections with the barrier attached, to allow overnight replacement of at least 30 feet of bridge deck per night. To offset some of the costs of the prefabricated deck panels $160,000 of federal Innovative Bridge Research and Construction (IBRC) funds were used. The contract went smoother than expected because of the excellent work of the design group and innovative practices of the contractor. The contractor, CC&G, had to cast 162 precast sections and had only one 10-foot panel rejected. Because of forming on a long casting bed by continuous spans, the longitudinal alignment of the in place sections was almost perfect. CC&G set as many as eight sections, 80 feet of new deck, in one night. They had no problem in setting the whole deck before Labor Day 2004 saving an entire year of construction and inconvenience to the public.
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