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A M E R I C A N S E G M E N T A L B R I D G E I N S T I T U T E
Editorial by Cliff Freyermuth
Manager, ASBI
S E G M E N T S
A M E R I C A N
S E G M E N T A L
B R I D G E
I N S T I T U T E
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Volume 45

Summer 2004
I N S I D E
COMMUNICATION NEWS
New ASBI Members ...........................2
Address Change ...................................2
Come Celebrate Segmental! ................2
San Francisco Oakland
Skyway Bridge Tour ............................2
Construction Practices Handbook .......2
2004 Grouting Certification Training .3
Grouting Test Tendons Using
Transparent Sheathing in Japan ...........3
Steel Price Volatility ............................3
PROJECT NEWS
The Panama Canal Second Crossing,
Paraiso, Panama ..............................4, 5
San Francisco Oakland
Skyway Bridge .....................................5
Wakota Bridge, Minnesota ..................6
Southbound Victory Bridge
Opened, New Jersey ............................7
Dallas High Five Segmental Ramps ........8
Ernest Lyons Bridge, Florida ...........8, 9
Woodrow Wilson Bridge
Replacement .......................................9
US 17 Wilmington Bypass, NC ....9, 10
I-95/Palm Beach International Airport
Interchange .......................................10
Ft. Lauderdale/Hollywood International
Airport Interchange ...........................11
RESEARCH NEWS
UCSD Bridge System Test ..........11, 12
MILESTONES
Editorial
This edition of the newsletter contains
a number of significant milestones
marking progress on major segmental
projects as well as research activities, as
follows:
The second crossing of the Panama
Canal, a 1,378 ft. main span concrete
cable-stayed bridge was completed in
August 2004 in accordance with a very
aggressive 27 month schedule. The use
of four form travelers on a four-day cycle
resulted in completion of about 2,200
sq. ft. cast-in-place bridge per day. The
Centennial Bridge has the longest
main span for a concrete cable-stayed
bridge in the Western Hemisphere, and
the third longest in the world.
The southbound Victory Bridge
in New Jersey was opened to traffic on
June 8, 2004. The new bridge is 3,971
ft. long, has a 440 ft. fully match-cast
main span, and has precast piers as tall
as 135 ft. The bridge was constructed in
just 15 months.
The segmental ramps of the Dallas
High Five Interchange with spans
ranging to 300 ft. were completed on
schedule at the end of July. This project
featured the first use of a mobile rubber-
tired segment erection device.
The first segment was erected
July 26 in the San Francisco-Oakland
Skyway Bridge which features typical
spans of 550 ft. and segments weighing
up to 800 tons. These are the longest
precast segmental spans and the heaviest
precast segments used to date in the U.S.
Construction of the largest
segmental substructure project thus far
in the U.S. is progressing by three joint
ventures working on the new Woodrow
Wilson Bridge in Washington, D.C.
Two major South Florida airport
interchange projects featuring 4.3 miles
of segmental ramps will be completed in
2004.
A segmental balanced cantilever
bridge system seismic test was completed
June 11 at the University of California
at San Diego (UCSD). There was no
cracking in the segmental superstructure
under the design seismic loading.
The above projects and the UCSD
seismic research clearly illustrate the
advantages of segmental construction for
major bridges. The November 7-9 ASBI
Convention at the Grand Hyatt Tampa
Bay will provide a comprehensive view
of current developments in segmental
design and construction technology.
We hope to see many of you at the
Convention.
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9/3/04 12:25:32 PM 2
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C O M M U N I C A T I O N N E W S
New ASBI Members
We are very pleased to welcome
APAC, Inc., ENERPAC, and PCL
Civil Constructors, Inc. as new
ASBI Organizational Members. The
addresses and contact persons are as
follows:
APAC, Inc.
900 Ashwood Parkway, Suite 700
Atlanta, GA 30338-4780
(770) 392-5300
FAX: (770) 392-5393
email: jdarmeni@ashland.com
John Armeni
ENERPAC
6100 N. Baker Rd., Bldg. B
Milwaukee, WI 53209
(414) 247-5462
FAX: (262) 781-1089
e-mail: paul.hohensee@enerpac.com
Paul Hohensee
PCL Civil Constructors, Inc.
3810 Northfield Blvd., Suite 200
Tampa, Florida 33810
(813) 235-2021
FAX: (813) 264-6689
email: DWhaley@pcl.com
Dave Whaley
Address Change
T.Y. Lin Internationals corporate
headquarters moved June 28, 2004.
The new address is:
T.Y. Lin International
Two Harrison Street, Suite 500
San Francisco, CA 94105
(415) 291-3700
www.tylin.com
Come Celebrate Segmental!
You are cordially invited to the 2004 ASBI Convention scheduled November
7-9 at the Grand Hyatt Tampa Bay! Complete details on the Convention are
provided in the program included with the newsletter. Some of the major features
of this years Convention are:
A Sunday (Nov. 7) evening dinner cruise to the Sunshine Skyway Bridge on
the Lady Tampa Bay
Accompanying persons tour on Monday, Nov. 8 to the John and Mable
Ringling Museum of Art and the Ca dZan Mansion in Sarasota, Florida
Latest results of segmental seismic research at the University of California at
San Diego
Design and Construction reports on major segmental projects in the U.S. and
around the world
Awards Luncheon presentation of the 2004 ASBI Leadership Awards
Michel Virlogeuxs luncheon talk Extremely Slender Concrete Cable-Stayed
Bridges
Panel on the Residual Effects of the Steel Price Crisis
Tuesday afternoon tour of the Lee Roy Selmon Cross-town Expressway
construction site and casting yard
We believe that combining the above events and more in the ambiance of the
Grand Hyatt Tampa Bay will make the 2004 ASBI Convention one of our best.
San Francisco Oakland Skyway Bridge Tour
A bus and boat tour of the San Francisco Oakland East Bay Skyway Bridge
casting yard and construction site will be held October 4, 2004. The tour schedule
is as follows:
6:00 a.m. - 7:00 a.m.
Continental Breakfast
7:00 a.m.
Charter Bus Departs for Casting Yard
9:00 a.m. - 11:00 a.m.
Tour Casting Yard (approximately)
11:00 a.m. - 1:00 p.m.
Bus Returns to Jack London Square
1:00 p.m. - 5:00 p.m.
Harbour King Tour of Construction
Lunch on the Harbour King
5:00 p.m.
End of Tour and Return to Jack London Square
At the time it was bid, the San Francisco Oakland East Bay Skyway Bridge
represented the largest contract awarded by Caltrans at $1,047 billion. The 6,900
ft. long twin segmental structures feature segments 88 ft. wide and up to 28 ft. deep
with a maximum weight of about 800 tons. Duplicate copies of the tour brochure
are available on request to the ASBI office, and tour information is also posted on
the ASBI website.
Construction Practices Handbook
A 26-member ASBI Committee, Chaired by John Armeni, APAC, Inc. is at
work on the development of a comprehensive handbook on Construction of
Segmental Concrete Bridges. The first draft of the Handbook was distributed for
review on August 6. The target date for publication of the handbook is May 31,
2005. Seminars on segmental construction practices based on the handbook will
be scheduled in the Fall of 2005, and will continue in the following years.
San Francisco -
Oakland East Bay Skyway Bridge.
7673 ASBI News Sum 04.indd 2
9/3/04 12:25:34 PM Figure 3 - Transparent Sheathing Shows Grout Flow
Figure 1 -
2004 Grouting
Certification
Training
Figure 2 - 117m long Mock-up Tendons with Two Crests for Test Grouting
in Japan
Figure 4 -
April Producer Price
Index, Bureau of
Labor Statistics
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2004 Grouting Certification
Training
The 2004 Grouting Certification
Training held April 5-6 at the Adams
Mark Hotel, Jacksonville, Florida
was attended by 133 engineers and
construction personnel. A view of the
training class during the examination
is shown in Fig. 1. A total of 737 have
now participated in this training.
The next Grouting Certification
Training will be held April 4-5, 2005
at the J.J. Pickle Research Campus at
the University of Texas at Austin. This
training event will be co-sponsored
by the Texas Department of
Transportation.
Grouting Test Tendons Using
Transparent Sheathing in
Japan
Fig. 2 illustrates falsework
supporting two 117m (384 ft.) long
continuous mock-up tendons using
Himilan transparent sheathing which
simulates almost half of an actual 250m
(820 ft.) long internal tendon for the
5-span box girder. The tendon consists
of 12-15.2mm (0.6 in.) strands and the
sheathing of i.d. 80mm (3.15 in.). The
sheathing is stiff enough against lateral
pressure and friction due to tensioning
strands when it is used for an external
tendon and maintains its circular shape
at crest of the tendon.
Fig. 3 shows downstream grout flow
in the lower portion in the section
area inside the transparent sheathing
which has light transmittance of 85%.
One tendon was grouted by pressure
injection only, and the other was
by simul