PA Turnpike A57.66 Bridge Replacements with ABC...

PA TURNPIKE A57.66 SLIDE – IN BRIDGE

REPLACEMENTS

Phil Carper – Road-Con Inc

APC / PENNDOT FALL SEMINAR NOVEMBER 16, 2017

Quentin D Rissler, PE – Larson Design Group

PROJECT PARTNERS

• Pennsylvania Turnpike Commission -Owner

• Road-Con Inc. – Construction Contractor

• Larson Design Group – Contractor’s Engineer

• HDR Inc. – Design Engineer

• STV Inc. – Construction Management and Inspection

PROJECT NEEDS AND DESCRIPTION – EXISTING STRUCTURE

3 Span Steel Plate Girder Bridge-Overall Rating of 5 - Deck and Pier Issues

CHALLENGES• Two Narrow Bridges

• 30,000 ADT

• Location

Bridge NB-355 – PTC Northeast Extension over Crackersport Road, Lehigh County, PA

ACCELERATED BRIDGE CONSTRUCTION• 12 months

• 55 hours

• $55,000 / hour

Bridge NB-355 – PTC Northeast Extension over Crackersport Road, Lehigh County, PA

NEW STRUCTURE• Single Span Steel Plate Girder • Replace substructure with stub

abutments on micropiles

ADD A SLIDE TITLE - 4

WEEKEND CLOSURE (10/13 – 10/16)

• Duration: 9:30pm Friday evening to 2:00am Monday morning

• No serious traffic problems. Traffic counts are being reviewed.

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RISING TO THE CHALLENGE…….

• Brainstorming• Many discarded ideas• Contractor – Engineer Teamwork• Owner Flexibility • Goal – Plan for Contingencies

- Efficiency on 55 hour closure- Simplify the Process

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THE SOLUTION…….

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TEMPORARY SUPPORT STRUCTURES | Piles

TEMPORARY SUPPORT STRUCTURES | Lateral Forces

TEMPORARY SUPPORT STRUCTURES | Lateral Forces

TEMPORARY SUPPORT STRUCTURES | Jacking Contingencies

• Soil Nail Wall

• 30’ Average Nail Depth

• 4’ Spacing

• Excavation Height = 9’6”

• Concrete Whaler System

TEMPORARY EXCAVATION & SUPPORT

TEMPORARY EXCAVATION & SUPPORT

• 9.625” Diameter

• Depth = 85’

• 10’ Into Rock

• 16’ Overhead Clearance

• Installed in 5’ lengths

MICRO-PILES

MICRO-PILES

• 77’ 6” length

• 9’ 6” height

• Class A Sulfate Resistant Concrete

• Jacking Ledge

ABUTMENTS

• Abutments & Wings Backfilled with Class A Concrete

• Prevent Approach Settlement

ABUTMENTS

• Anchor Bolts Cored and Placed Prior to Slide

ABUTMENTS

• Tight Quarters

• 5 Girder/Bridge

• Length = 117 LF

• 9/16 in. X 63 in. Web

• Weight = 30,000 EA

• 75 Ton Hydraulic Crawler

CONSTRUCTING THE SUPERSTRUCTURE

• Slide Beam Elevation = New Abutment Elevation

• Constructed on Bearing Pads

CONSTRUCTING THE SUPERSTRUCTURE

• End Diaphragms

• Pull Rod Conduit

CONSTRUCTING THE SUPERSTRUCTURE

• End Diaphragms

• Anchor Block Block-out

CONSTRUCTING THE SUPERSTRUCTURE

• 170 CY AAAP Concrete Per Deck

CONSTRUCTING THE SUPERSTRUCTURE

LATERAL BRIDGE SLIDE - OVERVIEW

SLIDING CONSIDERATIONS

• Rollers vs. Teflon Pads?• Rollers = Guided and Less Friction

• Push vs. Pull – Lateral Forces?• Push/Pull System Used With Rod and Hollow

Core Jacks• Conduit/Pull Rod Placement?• How do we travel in reverse?• Modifications to As-Designed Plans

LATERAL BRIDGE SLIDE

• Center-point Anchor block on Abutments

MODIFICATIONS TO AS-DESIGNED PLANS

• Conduit Through End Diaphragm for Pull Rod

MODIFICATIONS TO AS-DESIGNED PLANS

• Falsework to Abutment Connection

PREPARING FOR THE SLIDE

TEST SLIDE

• Jacking

• Channel Placement

• Roller Placement

• Forward – Min. 6”, per Contract Specifications

TEST SLIDE

• Reverse Slide System

• 20 Minutes to Switch the Sliding Components

TEST SLIDE

THE BIG WEEKEND

THE BIG WEEKEND

• 55 Hour Closure of the PA Turnpike – Exit 74 to 56• 60 Mile Detour Implementation• 2 Bridges to Demolish• 2 Bridges to Slide/Jack/Set Down • 400 Ton of Stone To Place• Median Barrier and Transitions• 1600 sy of Milling• 500 Tons of Asphalt• $55,000 per hour after 55 hours

DEMOLITION

• Saw-cutting vs. Hammers

• Non-composite deck

• 4 Excavators

• 9 Hours

DEMOLITION

• Anchor Block on New Abutment; Modified Diaphragms

• 100 Ton Hollow Core Jack

• 100 Ton Hilman Rollers

• 1 ¼” Threaded Rod

• 1.1 Million Pounds per Bridge

• Sliding Load on Rollers = 15 Ton/Hollow Core Jack

• Slide Distance = 42’

• Max Speed = 11 in. Every 3 Minutes (0.003 mph; 0.30 ft/min)

LATERAL BRIDGE SLIDE

BIG SIGH OF RELIEF – SLIDE COMPLETED

COMPLETED STRUCTURES

Questions?

THANK YOU