Design and Construction of

the Bronco Bridge

in Denver, CO

Downtown
Denver
IH25
Mile Hi
Stadium
Bronco Bridge

Platte
River

Colfax Avenue

Aerial View of Denver Colorado

Mile Hi Stadium

IH25
Bronco Bridge

Colfax Avenue

Platte River

Hike and
Bike Path

Aerial View of Bronco Bridge

Bronco Arches Bridge

Traffic Volume greater than 200,000 vehicles/day

Existing Bridge to be replaced in 6 phases.
Maintenance of Traffic was number one priority
for project.

Bronco Arches Bridge

IH25 over the Platte River

Original Bridge was built in 1951.

Bronco Arches Bridge May 2011

The bridge is a local landmark along the Platte River.

Came to be known as the Bronco Arches after the Broncos
came to Denver in the 1960s.

Bronco Arches Bridge

Bridge framing and foundations repeatedly in

need of repair.
Deck degradation was accelerating
Sufficiency and Load Ratings poor.

Bronco Arches Bridge

CDOT feasibility study determined that

Replacement with a new structure was desirable.
Restoration and additional widening would be too
expensive and disruptive to existing traffic.

New Bronco Bridge March 2013.

Project bid in March 2011.

Lawrence Construction was low bidder at $14.2M.
Awarded May 2011.
Project Schedule of 550 working days.
Completion anticipated in August 2013.

Bronco Bridge Value Engineering

Summit Engineering retained by LCCO for VE in May of 2011.

Project redesigned as a Value Engineering Proposal.
Design included bridge and all retaining walls.
Significant use of precast / prebuilt elements to speed construction

Features of VE Design

No cost savings
Value in Reducing Construction Time and
Traffic Disruption
Walls and Abutments built under existing
bridge

Heavy Use of Precast Elements

Precast Piers
Integral Connections / No caps or bearings.

Spliced / Continuous U Girder Superstructure

Steel Piling at Abutments

CIP Retaining Walls

40% Reduction in Number of Girders

Significant reduction in Pre-stressing
Simplified girder erection / No shoring

Enhanced Aesthetics.

Bronco Bridge Design

New Bridge is shorter and wider than existing.

Bridge:371 long x 197 wide, (Old Bridge: 384 long x 158.5 wide)
3 Span Layout, 88 148 134
Extensive Retaining Wall Structures at Abutments.

Bronco Bridge Design

Eight girder lines, Piers under each girder line.

New bridge increases lane capacity by two lanes in both directions.
VE combined Phases 2 & 3.

Bronco Bridge Foundation Design

54 Drilled Shafts at each Interior Pier

Steel Piling at Abutments

Bronco Bridge Abutment Design

Integral Abutments on flexible steel piling foundation.

Continuous Abutment Cap. Girders set on cap, no bearings.
Existing Abutment left in backfill. No demolition.

Bronco Bridge Abutment Foundation

Abutment caps supported on steel piling foundation.

Pile driving commences in August 2011.
Piling driven under existing bridge.
No disruption to traffic above.

Bronco Bridge Abutment Foundation

Abutment Piling encased in 30 corrugated pipe

Retaining Wall footing cast around piling

Bronco Bridge Retaining Walls

Redesigned from MSE to traditional CIP Cantilever walls on footings.

Max wall height 29
Reduced excavation and allowed construction to commence earlier.
Construction significantly complete prior to commencement of demolition.

Bronco Bridge Retaining Walls

Walls formed and cast under and alongside existing

bridge.
No traffic disruption.

Bronco Bridge Abutment and Retaining Walls

Walls backfilled and compacted around piling under existing bridge

Bronco Bridge Abutment and Retaining Walls

Abutment Cap formed and cast under existing bridge

Bronco Bridge Phase I Demolition

Demolition Commences 11/22/2013

Deck and Upper Framing Removal

Bronco Bridge Phase I Demolition

Steel Arch Demolition

Demolition Complete on 12/15/2011

Bronco Bridge Pier Design

Precast, Twin Wall Piers.

Arched Pier Shafts with Connecting Strut
Reinforcing Extended from base and top of pier shafts to connect to foundation and
precast girder superstructure.

Bronco Bridge Precast Pier Casting

All 16 Piers precast in Contractors yard at jobsite.

Piers cast horizontally on mud slab.
Conventional Wall Forms used.

Bronco Bridge Precast Pier Casting

Piers cast continually until complete.

All piers are identical.
Stacked and stored in Contractors yard until ready for erection.

Bronco Bridge Pier Foundation Construction

54 Caissons drilled and cast following demolition.

12 Footing for Pier shoring cast over top of caisson.
CIP Pier Base reinforcing placed and footing cast prior to erecting piers

Bronco Bridge Precast Pier Erection

Piers shipped on flatbed trailer

Lifted and set vertical with two cranes
Set into shoring tower on cip footing

Bronco Bridge Precast Pier Erection

Piers supported on inverted jacks

Line and grade set prior to releasing crane
Base formed and cast next after erection

Bronco Bridge Precast Girder Design

CDOT U72 base cross section

Draped and straight P/S for service and construction loadings
Highly modified to accommodate design for continuity

Bronco Bridge Precast Girder Post Tensioning

Girder Top Flange Notched to accommodate PT Anchor Block

CIP Block cast at jobsite
Detailed to accommodate stressing jacks

Bronco Bridge Precast Girder Erection

Girders shipped with PT anchor blocks formed.

Girders set on Neoprene level pads on pedestal at top of piers
Pier shafts reinforced with temporary PT bars.

Bronco Bridge Precast Girder Erection

Erected with 240 ton, 300 ton and 500 ton Hydraulic Cranes
Girders set on abutments on leveling pads
Girders set in one or two shifts depending on crane placement.

Field Cast Splices and Diaphragms

All field cast concrete was conventional 4500 psi Class D.

Diaphragms and thickened Bottom Slab over piers
PT End Blocks
Abutment Diaphragms.

Field Cast Splices and Diaphragms

Reinforcing at Pier Diaphragms over Piers and PT Anchor Blocks

Field Cast Splices and Diaphragms

Diaphragms formed over Piers and at Abutments

Field Cast Splices and Diaphragms

Diaphragms and PT Anchor Blocks cast

PT over Piers stressed.
Girders ready for Precast Panel Erection

Precast Panel Erection

Five widths of precast panels cast for differnent phases

Panels are transversely prestressed, longitudinally post tensioned.
Panel ends butted together at transverse joints

Precast Deck Panel Erection

Panels graded on Leveling Bolts

Panels set with pockets over shear reinforcing in girder top flange

Precast Deck Panel Erection

Panels set from abutment to abutment

Ready for haunch and transverse joint casting

Precast Deck Haunch and Joint Concrete Cast

Haunches, Pockets and Joints filled with same mix as Panels.

Batched at precast plant and shipped to jobsite and pumped into place.
15 CY of 7200 psi concrete per flange.
Deck Panel PT stressed.

Precast Deck Haunch and Joint Concrete Cast

4 strand, 0.6 Diameter strand tendons at 36 o/c

Stressed at both ends from Abutments

Final Operations for Phase I Construction

Approach pavement and Barrier Rail Cast

Expansion Joints installed at end of approach slabs
Deck ground smooth and asphalt overlay applied
Traffic switched and Phase II Demolition started.

Phase I Construction Complete

Demolition Started
Construction Complete / Traffic Switch
Total Duration =

November 22, 2011

May 4, 2012
164 Calendar Days

Phase II/III Construction

Demolition Started
Construction Complete / Traffic Switch
Total Duration =

May 7, 2012
August 19, 2012
104 Calendar Days

Phase IV Construction

Demolition Started
Construction Complete / Traffic Switch
Total Duration

August 23, 2011

December 3, 2012
102 Calendar Days

Phase V Construction

Demolition Started
Construction Complete / Traffic Switch
Total Duration =

December 4, 2012
April 4, 2013
121 Calendar Days

Summary

Completion in early June 2013

Under budget and ahead of schedule

Design based on Constructibility

Prebuilt Abutments and Walls minimized traffic

disruption

Innovative use of Precast Concrete reduced

construction time.

Innovations made possible by cooperative effort of

DOT, Engineer and Contractor

Thank You.

Designer:
Contractor:
Precaster:
Owner:

Summit Engineering Group

Lawrence Construction Co.
Plum Creek Precast
Colorado Department of Transportation