Design For Efficient Fabrication,

Shipping & Erection

Scott Krause
May 10, 2007
 Topics

General Information
„ G1.4, S2.1, S10.1, G12.1
Fabrication
Shipping
Erection
 General Information

Savings Impact

Labor and
equipment cost
per hour

Design Detailing Fabrication Erection

Lifecycle of Structure
 Economic Fabrication

Consistency / Repeatability
„ Materials
„ Details
Learning Curve
 Economic Fabrication
Girder Spacing
„ Maximize girder spacing (11’-14’) to eliminate a
girder line
Example: 4 girder lines instead of 5
„ 20% less girders
„ 25% less cross frames
„ Keep spacing constant for as much of the
structure as possible
 Economic Fabrication
Girder Depths
„ Keep constant depth across structure
Minimizes diaphragm and stiffener variation
Simplifies detailing and fabrication
„ Exception: If girder weights vary dramatically
(+/- 15 tons) from inside girder to outside
girder, consider varying depth to keep erection
costs down
 Economic Fabrication
Haunched girder
„ Avoid steep transitions
(45’ +/-)
Allow radius at bearing
area to enable bending
of flange – at a
minimum, allow
substitution of bending
or welding (fabricator’s
option)
„ If bridge is skewed,
keep diaphragm lines
parallel to bearing
lines (similar depths)
 Economic Fabrication
Minimize Diaphragm Variations
„ Stiffener sizes
Any change in size or configuration is a chance for
error
„ Quantity and Diameter of bolts
Minimize variation in diameter (retooling, multiple
wrenches in field)
Minimize quantity changes
„ Cross frame member sizes
Use “Common” sizes, combine where practical
Heavy sections are an issue right now
 Economic Fabrication
Cross frame details
 Economic Fabrication
Slab Welding
„ Vary thickness, not
width
„ Eliminates excess run-
off tabs
„ Minimum slab width is
48”, preferably 72-96”
 Economic Fabrication
Stiffener fitting
„ Bearing Stiffeners
Use “Fit to Bear” and fillet welds in lieu of CJP
„ Connection Stiffeners
Use fillet welds in lieu of “Tight Fit”
„ Intermediate Stiffeners
Consider increasing web thickness to eliminate
stiffeners
„ Use standard cope size per structure
 Economic Fabrication
NJ End Diaphragm Details
„ Expansion joints connected to structure
Slots in top flange of end diaphragms
„ Must be burned or machined
½”ø bars welded to end diaphragms
„ Prefabrication steps prior to fabrication of
diaphragm
 Economic Fabrication
Avoid “tab” plate connection to flange
„ Expensive detail
Drill flange
Fit stiffener and plate
Tack weld stiffener to plate
Pull out of assembly, weld
Re-fit assembly, bolt assembly to flange
„ If painted, grind and prime prior to bolting
Weld stiffener to web, flange
 Economic Fabrication
Avoid placing stiffeners too close to each
other
„ Rule of thumb – for each inch of stiffener width,
allow same clearance face to face of stiffeners,
with a minimum of 6”
Drip bars
„ Weld in lieu of bolting
 Assembly
Assembly requirements (main members)
„ Most specifications require 3 contiguous sections
to be set up (minimum)
„ Current measuring technology will allow 2
sections to be assembled with no decrease in
accuracy
Increases fabricator’s flexibility
Decreases cycle time of fabrication
 Assembly
Cross frames are not required in set-up,
unless specifically required by contract
documents
Cross frames are accurately fabricated to
calculated dimensions
Girders are next…
 Curved Structures
Curved girders deflect different amounts due
to varying span lengths of each girder
Curved girders have a tendency to “roll”
during deflection
„ Top flange away from center of curve
„ Bottom flange towards center of curve
 Skewed Structures
Skewed girders deflect similar amounts per
girder line
Due to the skew and associated framing,
skewed girders will deflect vertically, and
rotate transversely during deflection
 Curved/Skewed Structures
Define expectations of erected and final
position on the plans
Sample note:
 Curved/Skewed Structures
Use welded cross frames instead of knock
down cross frames
„ Hold geometry better
„ Quicker to erect (1 vs. 3 crane picks)
 Shipping
Generally, shipping is biggest constraint on
member size
Rule of thumb shipping envelope (member)
„ Length: 130’-0
„ Height: 9’-0
„ Width: 10’-0
Includes mid-ordinate for curved girders
„ When members start pushing envelope, contact
fabricator or NSBA for guidance
Shipping Procedures
 Shipping
Weight is generally not an issue, unless
piece is short
„ Need to be able to put enough axles under piece
to stay within axle load limits
 Shipping
If piece is too large to ship via land, water is
an option for delivery
Water delivery limits competition, price may
be affected
 Erection
Minimize time spent in field erecting
structure
Minimize variations in framing members
„ Less marks, less sorting, less chance for errors
Define expectations on designs
Provide a method for erection of structure in
contract package
„ Allow substitutions with acceptable calculations
 Erection
Specify an AISC Certified Erector for complex
structures
Time spent on erection procedures is worth
the effort – minimize problems in field
 Summary
Minimize variations in superstructure design
When in doubt, ask a fabricator, shipper or
erector for advice
Design stage is where all parties have the
biggest impact on structure