Jacking Details to Replace Expansion

Bearings For Beardstown Trusses

IL 100 over IL River

SN 009-0001

Chad Hodel, P.E., S.E.

2018 ACEC-IL / IDOT Bridge Seminar

 Introduction
• Project Description
• Jacking System & Load
Paths
• Deterioration
• Strengthening & Retrofitting
• Miscellaneous Design
Issues
• Field Issues

2018 ACEC-IL / IDOT Bridge Seminar

 Project Description
• Existing 1955 Structure:
– IL 100/US 67 w/ 2 lanes of traffic
– 2 span through-truss = 720 ft long
– 3 span through-truss = 1380 ft long
– Stringer approaches

• Contractor:
– Sangamo Construction Co.
– Emergency bearing replacement Beardstown
contract Cass Co.
IDOT Dist. 6
– Retained WHKS
2018 ACEC-IL / IDOT Bridge Seminar
 Project Description

420’
960’
360’ 360’
E F
Span 13 E
E E F
Span 9 E

• DL Bearing Reaction at Truss Ends:

– 275 kips (2 span unit)
– 310 kips (3 span unit)
2018 ACEC-IL / IDOT Bridge Seminar
 Project Description-Existing Condition

Pins for rocker bearings

appear to be seized

Bearings are rotated in

expanded state in
middle of winter

Anchor bolts are pried

over

2018 ACEC-IL / IDOT Bridge Seminar

 Project Description-Existing Condition
Constraint inducing multiple
cracks

Long cracks in horizontal

gusset plate
2018 ACEC-IL / IDOT Bridge Seminar
 Project Description-Existing Condition

2018 ACEC-IL / IDOT Bridge Seminar

Project Description-Replacement Brgs.

Pins for rocker bearings

appear to be seized

Bearings are rotated in

≈ 36” expanded state in
middle of winter

Replacement Bearing Assembly: Steel bolster

on top of High Load Multi-Rotational Bearings
2018 ACEC-IL / IDOT Bridge Seminar
 Jacking System
• Miscellaneous Notes:
– Existing Plans: Load table for End F.B. Full
D.L. Jacking  Initially designed for
jacking?
– Jacked in 1985 to refurbish bearings: no
deck & new Grade 50 floor system
– Original deck: Open steel grid
– Current deck: 7” slab = DL
2018 ACEC-IL / IDOT Bridge Seminar
 Jacking System
• Initial jacking procedure:

Maintain 1 lane of traffic

Triple HP10x42 – initially

intended as safety catch for FB
2018 ACEC-IL / IDOT Bridge Seminar
 Jacking System – Load Path
R-DL R-DL

R-Jack ≈ 1.1*R-DL

V
Potential “propped cantilever” behavior
M

2018 ACEC-IL / IDOT Bridge Seminar

 Jacking System – Load Path
Items of Interest:
• WF diaphragm btw.
gussets
• Floorbeam
V • Bolted floorbeam
M connection

2018 ACEC-IL / IDOT Bridge Seminar

 Jacking System – Load Path
Diaph. Analysis
• W14x78
web = 0.428”
• W16x88
web = 0.504”
• LARSA FEM
V analysis
• Fb = 80 ksi >>
M Fy = 33ksi
2018 ACEC-IL / IDOT Bridge Seminar
 Jacking System – Load Path
Floorbeam Connection
• At Gusset Plate:
– Combined shear & tension
– Prying action = tension
– √((fv/Fv)2+ ((ft/F’t)2) > 1 (A490-X)

• At Floorbeam Web:
V – Eccentricity = + on bolts
M – fRES > Fv (Exist. A325 bolts)

2018 ACEC-IL / IDOT Bridge Seminar

 Jacking System – Load Path
≈1” Existing Jacking Platforms
• Platforms installed
directly under FB
• 1” btw. centerlines on
subsequent inspection
• Consistent with ∆ temp

2018 ACEC-IL / IDOT Bridge Seminar

 Jacking System – Load Path
Existing Jacking Platforms
• 1” difference could grow to
≈ 2 ¼”
• Abrupt energy release once
load is removed from existing
bearings?
• How should jack be placed?
• Centered under FB = ecc. &
add’l stress on platform
2018 ACEC-IL / IDOT Bridge Seminar
 Jacking System – Load Path
Existing Jacking Platforms
• 1” difference could grow to
≈ 2 ¼”
• Centered on platform = ecc. &
add’l stress on FB

• fb (normal + torsion) >> Fy

2018 ACEC-IL / IDOT Bridge Seminar

 Jacking System
• Find a solution!!!
• Currently: February  Pending May
expansion joint replacement contract
• Feasibility  Time  Economics
• Feasibility: - No large/heavy equip.
- Access
2018 ACEC-IL / IDOT Bridge Seminar
 Alternate Jacking System
• 2-Jack Concept: Tube Stiffeners (top tube may
need located
above W30’s)
L’s bolted to
outside gusset

P-T Bars
(Relieves prying Sliding
action in gusset surfaces
plate bolts) under jacks

2018 ACEC-IL / IDOT Bridge Seminar

 Alternate Jacking System
• 2-Jack Concept: Contractor dislikes

Need to slide
existing bearing to
outside to remove

2018 ACEC-IL / IDOT Bridge Seminar

 Alternate Jacking System
• 2-Jack Concept: Concrete Quality?

Jack Brg. Area

2018 ACEC-IL / IDOT Bridge Seminar
 Deterioration
• Possible extent of
concrete repairs?

2018 ACEC-IL / IDOT Bridge Seminar

 Deterioration
• Diaphragm
corrosion

2018 ACEC-IL / IDOT Bridge Seminar

 Deterioration
• Floorbeam Corrosion
1/8” +/- flange thickness

Prior Inspection
Report Sketch

Harness lanyard

Span 9 FB - West

2018 ACEC-IL / IDOT Bridge Seminar

 Deterioration
• Potential deterioration issues discovered with
2-18-15 cursory site visit
• Concerns with existing conditions/member cap.
on non-redundant load path
• WHKS: How do we determine a solution w/o
knowing existing conditions?
 2-24-15 damage inspection to record S.L.
 Sig. deterioration  Strengthen/retrofit for
1-jack option
2018 ACEC-IL / IDOT Bridge Seminar
 Strengthening & Retrofitting
• Bolted diaphragm retro:
• Plates and L’s on each
side of diaphragm
• Field drilled to match
gusset holes

• Detailed procedure
req’d to protect gusset
connection integrity

2018 ACEC-IL / IDOT Bridge Seminar

 Strengthening & Retrofitting
• Floorbeam strengthening:
• Top / bot. flange
cover plates
• Flange to web
L’s
• Brg. stiffener
• Web plate
• P-T rods

2018 ACEC-IL / IDOT Bridge Seminar

 Strengthening & Retrofitting
• P-T rods: transfer tension at top of FB & limit
prying action on FB/gusset conn.
• 1” dia. – 150 ksi by Williams Form Eng. Corp in
oversize hole to prevent shear loading
• Tensioned to 75 kips w/ impact wrench/DTI washer

2018 ACEC-IL / IDOT Bridge Seminar

 Strengthening & Retrofitting
Jack
recessed into
top & bot brg.
Plates

Lubricated
SS/TFE
sliding
surface (2-3
days for brg.
replacement)
2018 ACEC-IL / IDOT Bridge Seminar
 Miscellaneous Design Issues
• RDL = 310 kips (Unit 1), 275 kips (Unit 2)
– From AASHTO rating software
– Agrees with exist. plan loading diagram
– But how much does it really weigh?!?
– Increased RDL 10% to account for misc.
weight (utilities, rust, etc….)
– JackDL ≈ 1.2*RDL (including propped cantilever
behavior)

2018 ACEC-IL / IDOT Bridge Seminar

 Miscellaneous Design Issues
• Encouraged to use AASHTO Operating Load
Factors
– Inventory: 1.3*DL + 2.17 (LL+IM)
– Operating: 1.3*(DL + (LL+IM))
– LL+IM ≈ 30 to 40 kips
– Small benefit for using Operating Factor
Increased 1.3 to 1.5 due to non-
redundant load path and poor condition
2018 ACEC-IL / IDOT Bridge Seminar
 Field Issues
• 1st Jacking Attempt = Unsuccessful
– Max. Span 9 Plan Jack DL = 329 kips
– Span 9 Jack Load Req’d = 360 kips
– “Popped up” when bearing released
– Existing bearings appeared “stuck down”
• 2nd Jacking Attempt = Success
– Span 10 Jack DL = Max. Plan Jack DL = 311 kips
• Remaining Jacking Attempts = Mixed Results
– Generally had to allow nom. higher jacking loads
– Allowing structure to sit overnight on jacks helped
“break bearings loose”
2018 ACEC-IL / IDOT Bridge Seminar
 Field Issues
Wrong Weld

?
Shop
Drawings

WHKS Plans: Back Gouge/Field Weld

2018 ACEC-IL / IDOT Bridge Seminar

 Field Issues
Wrong Weld

?
Shop
Don’t be afraid to inquire and Drawings

ask questions!!!!
WHKS Plans: Back Gouge/Field Weld

2018 ACEC-IL / IDOT Bridge Seminar

Questions