Bentley RM Bridge

Introducing CAST Tool

Marcos Beier
Technical Support Analyst
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Bentley RM Bridge CAST Tool

• Skill Level: Beginner

• Presenter: Marcos Beier, Bentley
– Balance Cantilever Concrete
– Segmental & Post Tensioned
– Integrated control of the match:
RM CAST
RM Bridge CAST tool

1. Balance Cantilever
2. RM Bridge Solutions
3. CAST tool
Balance Cantilever
Segmental precast

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 Balance Cantilever
China A.C.

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 Central span suspension
UK “demo”

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 Pre-Cast Balance Cantilever
Fort Lauderdale

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Motivation
• Advantages of Pre-casting:
– Better quality due to production in controlled environment
– Less formwork needed
– Less invasive (disturbance of traffic, environmental, …)
– Accelerated construction time

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 Precast Segment
Pier table segment

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Bentley Bridge RM – GP

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Bentley Bridge RM

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Bentley
TS&L
Bridge Seismic Analysis
RM Bridge
Problems we face and Solutions we provide

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Segmental BCB in Bentley RM
Bridge

Problems we face Solutions we provide

• PT • Cantilever Tool
• C&S • Pre-camber
• Camber
• Optimal Solution? • ADDCON
• Onsite control • Cast TOOL
• Precast factory control • Erection Control

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RM Bridge Cantilever TOOL

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Cross Section Definition of Tendon
Points

+10 +20 +30

TA0 TA10 TA20 TA30

T6...T3, T2, T1 T11, T12, T13...T16 T26...T23, T22, T21 T31, T32, T33...T36

BA10 BA20

B9...B3, B2, B1 B11, B12, B13...B19

+10

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RM Cantilever TOOL

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Cycle of construction stage
Balanced Cantilever Method basic concepts
Traveller
Traveller

Wet Concrete
e1
e2 3
γ = 25 kN/m
Step 1
Step 2 Step 3

e.g. 2 days instead of 7!!!

Traveller

C&S

Prestressing

Step 6 Step 5 Step 4

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Tendon Geometry

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 Tendon Management in RM-Tool
101-110 111-125 126-135

PIER 1
dT TIME
Stage
1 7 7 110 111
7 14 109 112 Copy tendons and modify
2
3 7 21 108 113
4
7 28 107 114
5 7 35 106 115 Copy tendon group and
7 42 105 116
6
7 49 104 117
change element numbers
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PIER 2

9 7 63 125 126
10 7 70 124 127
11 7 77 123 128
12 7 84 122 129
13 7 91 121 130
14 7 98 120 131
15 7 105 119 132

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Creep and Shrinkage
• Creep: c = e * 
– εc = plastic strain due to creep
– εe = elastic strain due to permanent load
– φ = creep factor
• Global parameters such as quality of concrete, , environment (humidity,
temperature,…)
• Section properties
• Age of concrete
e = e,i , c = e,i * 
• Load application date when using CEB-FIP model

• Shrinkage:
– Total plastic strain consists of creep + shrinkage
 =  + s
• Global parameters and section properties, similar top Creep
c

• Age of concrete

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Integral Equation


Averaging and
*
2 linearisation according
to “finite differences”
1 w1 w2 theory

Creep curve „a‟ for applied load (de-

 t2
t1 composed into increments)
a,t2
Creep curve „b‟ for stress increment
occurring during time interval (construction
b,t2
stage) under consideration

* = 1 *w2 + 2 *w1
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 Creep & Shrinkage curve

ASSHTO 1996

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Cantilever Camber and Position
Camber Line Summation Loadcase (SUMLC) · (-1)

LC 1

LC 2

LC 3

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Cantilever with 5 steps

• Fabrication shape
• Camber

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3-Span Bridge Camber Line

G2
G1

1 2 3
ADDCON: Optimization

• Preparing a structural model

• Definition of
• - Loads
• - Construction schedule
• - Corresponding ADDCON constraints
• Design criteria can be checked
• Optimisation can be started

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Constraints

• Deformation of any point on the structure

• One of the internal forces at any point on the
structure
• Stress at any cross-section at any point on the
structure

• Every constraint can be defined as a range of

values

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Optimization of the Cable Forces

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AddCon Method

• Provides a solution for finding the optimal

tensioning strategy for the construction of cable-
stayed bridges
• Include non-linear structural behaviour and time-
dependent effects
• Computes the correct tensioning forces for the
stay cables which lead exactly to a predetermined
moment distribution and also to the intended
geometry

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Choosing Constraints

Defined boundary condition

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After optimisation

Defined boundary condition

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RM Bridge Erection Control
• Expected position is not achieved during the
construction of bridge:
– Current position should be taken into account

• Compensation is made with pre-camber and

fabrication shapes
optimization of internal forces under
permanent loads
X
choice of erections situations

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Solution
• deformed structure is the start position:
– full account of location in space is taken into account
– implemented procedure is repeated interactively until
convergence criteria

• fabrication shape is applied as loading:

– control and optimization of forces and displacements

• kink correction for structural assembly:

– control or simulation of construction in face-to-face
connections

• kink correction for structural assembly:

– control or simulation of construction in face-to-face
connections

novel solution: based on displacement constraints

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Fabrication Shape
• Definition of the bridge segment stress free
geometry WITHOUT rigid body part
• There is only one fabrication shape per bridge
segment

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Kink Correction

• How does it work?

 corr   Node
 Element

Iteration

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RM CAST Tool
In Factory: control points

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Short Line Match Casting

Idea of Short Line Match Casting

• Perfect match at segment joints

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 Short Line Match Casting
Casting sequence

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 Bentley Bridge RM - GP
Geometric
Preprocessor

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 Short Line
Match Casting

Casting sequence

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Short Line Match Casting

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Preparation in GP
Definitions for
 Rivet positions
 Segmentation
 Casting sequence

 Four geometry points

• Name1(co) center, offset
• Name2(el), Name3(el) elevation,
lentgh
• Name4(b) bottom
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 Short Line Match Casting
Measuring the segments

 Aluminium bolts for elevation

and length
 Horizontal stirrups

 Distance from joint (a, c)

 Distance from centerline (W)

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Short Line Match Casting

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Short Line Match Casting

Casting sequence

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Short Line Match Casting

Casting sequence

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Effects

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Geometry coordinates

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Preparation in GP
Definitions for
 Rivet positions
 Segmentation
 Casting sequence

 Four geometry points

• Name1(co) center, offset
• Name2(el), Name3(el) elevation,
lentgh
• Name4(b) bottom
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Preparation in GP
Definitions for
 Rivet positions
 Segmentation
 Casting sequence

 Casting direction
 Segment type
 Segment length

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RM2006 - GP

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Preparation in RM
 Preparation following the principles of camber calculation
 Final export to RMCast with module “DoCast”

Elements for casting are define in RM-Set:

 First element must be starter
 Side where next element joins
must be given

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 High 5 - Dallas

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RM Cast

RM Cast is a tool to help casting segments in the casting yard.

Small inaccuracies which may occur during casting can be
corrected and the setup of other segments is changed.

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RM Cast

Typical casting steps:

 Setup match cast segment
 Setup wet cast rivets/stirrups
 Pour segment
 Survey rivets/stirrups
 Correct casting curve

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RM Cast

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RM Cast

Report generation

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Prepare starting segment

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Survey segment

• Survey rivets after casting segment

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Writing surveyed values

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• RM-cast will then
correct the
coordinates of
next segments
depending on the
errors in
surveyed
segment.

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Prepare match-cast segment

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Survey segment

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Writing surveyed values

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• Repeat this procedure until you complete whole
casting set.

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Bentley RM Bridge
CAST Tool
Conclusions

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 RM 3D structural model
bridge over the Kanawha River

(Courtesy of Finley Engineering Group, Inc.)

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RM Bridge CAST tool

• Balance Cantilever + ABC = Segmental

• Bentley RM Bridge solutions
– PT, C&S, camber, onsite and shape factory control
– Cantilever, Pre-camber, ADDCON and Erection Control

• RM Bridge CAST tool

– updating analysis
– connecting site modifications to design
 Kanawha River
West Virginia

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RM Bridge & BrIM Benefits

• Bentley BrIM vision

• Bentley portfolio
• Enhanced GUI
• Intuitive cast-by-cast calculation
• One tool for all
 Big I - URS

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Bentley RM Bridge
Introducing CAST Tool
Questions

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Thank you for your attention!
marcos.beier@bentley.com