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SOUTH CASCADE DRIVE / MILLER ROAD (OLD 219) OVER CATTARAUGUS CREEKCONCORD AND ASHFORD, NY
DESIGN BUILD PROJECT – BRIDGE REPLACEMENTPIN 5101.82, CONTRACT D900024
JOSHUA T. RODEMS, PEERDMAN ANTHONY
STATEWIDE CONFERENCE ON LOCAL BRIDGESOCTOBER 26, 2017
• PROJECT BACKGROUND• DEMOLITION• DESIGN CHALLENGES
– SUBSTRUCTURES• ABUTMENTS• PIERS
– SUPERSTRUCTURE– ERECTION
• QUESTIONS
Discussion Topics
PROJECT LOCATION
Project Location
“NEW” ROUTE
219
“OLD” ROUTE
219BRIDGE
LOCATION
Project Location
4
Total Length = 175 +300 +175 = 650 ft.
Existing Bridge
Existing Bridge
• NYSDOT Design Build Procurement D900024
Winning Team Score 100%Form SP Total = $16,939,715
• Contractor: Cold Spring Construction Co. (1911)
• Designer: Erdman Anthony (1954)
• Quality: Greenman-Pedersen
• Geotechnical: Oweis Engineering (DBE)
• Independent CI: Ravi Engineering (DBE)
• Testing Lab: Atlantic Testing
Project Team
7
Close Bridge 4/25/16
Implosion 6/2/16
Complete Substructures 11/11/16
Erect Steel Framing 12/16/16
Form and Reinforce Deck 4/14/17
Cast Deck Complete 4/21/17
Approach Slabs, Joints, Railing, Open 5/12/17
Project Schedule
1. Steel Multigirder Bridge
2. Drilled Shaft Foundations at Abutments
3. Drilled Shaft Foundations at Tall Piers
4. Class HP Concrete for substructures
8
Proposal Assumptions
9
Proposal criteria for drilled shafts: • 60 psi friction• 10 tsf end bearing
Design criteria for drilled shafts after ATL borings: • 40 psi friction • 1.5 tsf end bearing
Impact on drilled shafts compared to proposal design: • Too many• Too deep • Too expensive
Back to the drawing board:• Change drilled shafts to steel piles at piers• Change to spread footing with keyway at abutments
Geotechnical Concerns
10
Total Length: 210 + 250 +160 = 620 ft.
Fix Fix
175 ft.
Proposed Bridge
Proposed Bridge – Rendering
12
Proposed Bridge – Models
43’-4” OUT-TO-OUT
Proposed Bridge
14
Demolition
16
17
Abutment Height = 42 ft. +/-Stem = 5’-6” thickService Bearing = 10 ksf
9’-6” 7’
22’
Abutment Design
19
20
21
Abutment Design
22
23
24
25
26
27
Total Height: 164 ft = Tallest in NYS
Mass Concrete
Pier Design
MASS CONCRETE• NO EXISTING STANDARD SPECIFICATION• NO NYSDOT RESTRICTION ON WHAT IS
MASS CONCRETE • NOW 54” FOR SMALLEST DIMENSION
• NEW MIX DESIGN• THERMAL CONTROL PLAN
• MAX DIFFERENTIAL TEMP.• MAX ABSOLUTE TEMP.
Pier Design
METHODS FOR TEMPERATURE CONTROL
• MIX DESIGN• COLD WATER/ICE IN MIX• INSULATE CONCRETE SURFACE AND REBAR• COOLING PIPES/VENTS
Pier Design
30
LRFDMin Dead Load and Max Wind Generates Pile Tension
• Embed Pile in Footing with studs • Embed Pile in Rock = 5 ft (+/-)
HP 14 x 117
Pier Design
31
32
Pier Design
34
35
Pier Design
37
Structural Steel
Structural Steel
92” x 5/8” WEB
24” x 1 3/4”TOP FLANGE (2” AT PIER 1)
24” x 1 3/4” BOTTOM FLANGE(2 ¾” AT PIER 1)
7” x 1/2” INT. STIFFENERS (22’-6” MAX. SPACING) 3*D = 23’-0”
FASCIA GIRDER AND 13’ AT EACH ABUTMENT WERE METALIZED
121,300 LB STEEL SAVED!
Structural Steel
40
Crane # 3
MANITOWOC 888 RINGER
• 660 Ton Capacity
• 325 Ft. Boom
• 1,395,000 LB. Counterweight
• 45 Ft. Ring
BEGIN ABUT.
PIER 2PIER 1 ENDABUT.
SPLICE SPLICE SPLICESPLICE SPLICEA B C D E F
G1
G2
G3
G4
G5
CRANE 3 LIFT – GIRDER G3D286’ RADIUS88,000 LBFACTOR OF SAFETY 1.39
NOT STABLE WITH BOTH CRANES RELEASED – NEED STIFFENING TRUSS
ONLY OK FOR WIND LESS THAN 30 MPH
Structural Steel
STIFFENING TRUSS
WT6x25, 5’ OUT-TO-OUT
Steel Erection
CONNECTED TO GIRDER AT 5’ SPACES
Steel Erection
MAX PICK = 61 TONS(includes stiffening truss, not shown)
HSS 12x12x3/8, 40’ LONG
(2) W12x65, 24’ LONG
Structural Steel
46
47
48
49
• Better Geotechnical Info. Prior to RFP.
• Identify Mass Placement Concrete Prior to RFP
• Design Build Procurement Saves $$$$$
NYSDOT Project Estimate $22,842,000
Design Build Cost $16,939,715
D/B Savings $5,902,285
Presentation Take-aways
1) WHAT METHODS ARE USED TO PREVENT HIGH TEMPERATURES AND TEMPERATURE DIFFERENTIALS IN MASS CONCRETE?
• MIX DESIGN• COLD WATER/ICE IN MIX• INSULATE CONCRETE SURFACE AND REBAR• COOLING PIPES/VENTS
PDH Questions
2) WHY WAS THE WEB THICKNESS OF THE GIRDERS ABLE TO BE REDUCED?
WEB STIFFENERS AT LESS THAN 3*D SPACING.
PDH Questions
3) WHY WERE THE WEATHERING STEEL GIRDERS METALIZED?
• EXTRA PROTECTION AT JOINTS• SPRAY ON HIGH BRIDGES• CURBLESS CROSS-SECTION WITH DEEP GIRDERS
PDH Questions
4) WHAT IS THE PURPOSE OF THE STIFFENING TRUSS DURING ERECTION
A. LIMIT VERTICAL DEFLECTION FOR LONG SPANSB. ALLOW FOR A HIGHER SAFE WIND SPEEDC. INCREASE LATERAL STIFFNESS OF THE COMPRESSION FLANGED. ALL OF THE ABOVE
PDH Questions
54
Tom Skummer, PE NYSDOT Project Manager
Tom VanSplunder, PE NYSDOT Construction Super.
John Gadja, PE CTL Mass Placement Mix
Don Streeter, PE NYSDOT Materials Guru
QA Team
Cristina Lauzon, PE HNTB
Steve Percassi, PE Bergmann Associates
Acknowledgements
RDX Explosives:• Research Development Explosive – Pre WWII• Used in depth charges to puncture German U-boats
(steel)• More “punch” than TNT
• Dynamite = slow charge for cratering earth
• Linear shaped charges – focus energy to cut steel• Primed with a non-electric blasting cap & detonating cord• Synchronized with 9ms delays to minimize over pressure• Sequence:
• Drop center span out• Cut superstructure on each side of pier• Cut superstructure at ends• Cut pier bases and kick inward
