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Saving the last remaining piece of the Catskill Mountain Railway
The Black Bridge Rehabilitation
Outline
• History of the Catskill Mountain Railway & Bridge
• Overview of Existing Bridge & Condition
• Design Process and Challenges
• Construction
• Assessment of Learning
• Questions
Catskill Mountain Railway Background
Constructed in the late 1800’s to transport NYC residents to the Catskills
Catskill Mountain Railway Background
• 15.7Mile Railway Running from Catskill to Palenville
• Narrow gage (3 ft ) rail way vs 4’-8 ½”
• Primarily for passenger use that run seasonally for tourists
• The last surviving usable element of what was an elaborate network of track
• Developed by Charles Beach family for rich NYC residents
• Was closed to RR in 1918
• Converted to Pedestrian use shortly after
• Mainly carried utilities
• Closed to Pedestrian Use in 2010
Overview of Existing Bridge & Conditions
Overview of Existing Bridge & Conditions
Four span – 440 ft modified Pratt Through Truss
Overview of Existing Bridge & Conditions
Flooding during Irene
Project Funding & Goals
• Obtain Transportation Enhancement Program (TEP) funding in 2013
• Bridge is owned by the Village. Greene County Highway Department agreed to sponsor.
• Total Project Funding = $2.8M
(Inclusive of Design, Const & CI)
• Approximately $2.3M for Construction
• Funding is capped
• Village had a 20% match (nearly $600K)
Project Funding & Goals
• Rehabilitate the bridge for pedestrian and bicycle use
• Provide connectivity for the Catskill Walking Loop
• Provide a new deck system
• Maintain utilities & provide upgrades
• Repair Structural deficiencies
• Replace bearings
• Paint the bridge
• Aesthetic Improvement
• Substructure repairs completed in 2013 from Hurricane Irene damage
Overview of Existing Bridge & Conditions
Narrow bridge – Skewed Structure
Overview of Existing Bridge & Conditions
Utility Hangers Through the Deck
Overview of Existing Bridge & Conditions
Water Line along walkway
Overview of Existing Bridge & Conditions
16” diameter suspended Sewer line
Overview of Existing Bridge & Conditions
Floorbeam deterioration
Overview of Existing Bridge & Conditions
Floorbeam deterioration
Overview of Existing Bridge & Conditions
Overview of Existing Bridge & Conditions
Hanger deterioration
Overview of Existing Bridge & Conditions
Hanger deterioration
Overview of Existing Bridge & Conditions
Pin Condition
Overview of Existing Bridge & Conditions
Bearing Condition
Design Process
• Preliminary Design Begins in 2014
• Bridge Inspection & Load Rating to determine repairs
• Design for 90 psf Pedestrian LL & H-5 Truck Loading
• Required Structural Repairs included:• Hanger Plates
• Floorbeam webs
• Top chord connection plates
• End post repairs
• Stringer replacement
Design Process
• On the National Register for Historic Places
• Maintaining the sewer line a must
• No issues with SHPO….They were pleased the bridge would be saved.
• Public was easy to work with. They just wanted to be able to walk across the bridge.
Design Process
BIG QUESTION?What color do you paint the Black Bridge?
Brick
Design Process
Design Process
Design Process
Design Process
QUESTION?How do you replace the hanger plates without taking the eyebars or pin out or shoring the bridge?
Design Process
QUESTION?How do you replace the hanger plates without taking the eyebars or pin out or shoring the bridge?
Analysis of truss indicated all verticals are in compression. Generally smaller forces in verticals.
Design Process
QUESTION?How do you replace the hanger plates without taking the eyebars or pin out or shoring the bridge?
Forces were redistributed amongst other truss members and remained within stress levels
Forces redistributed to other members
Design Process
Removal Line
Design Process
Design Process
Design Process
• Complete the design and advertise the project in March 2016
• Knew our budget was going to be tough
• Started getting questions from contractors regarding the painting
• Only one bidder at $4.40M
• Engineer’s Estimate $2.48M
Design Process
What happened???• The painting was an issue
• NYSDOT Std Specs - Value of work subcontracted out can
not exceed 50% of the project cost.
Design Process
Now What???• Section 108-05 Subletting Or Assigning the Contract –
Specialty Items do not count in the calculation for the subcontracting.
• Obtained approval from NYSDOT for paint as a Specialty Item
• Obtained another $200K in Flex funds from NYSDOT
• Rebid the project in June 2016. Also included some bid alternates to help with the costs
Design Process
Second Letting
• Low Bid was $2.42M including Bid Alternate #1
• Harrison Burrows Contracting – Glenmont, NY
• Clark Patterson Lee performed Construction Inspection
Construction Photos
Construction Photos
Construction Photos
Construction Photos
Construction Photos
Construction Photos
Construction Photos
Construction Photos
Construction Photos
Construction Photos
Construction Photos
Construction Photos
Construction Photos
Construction Photos
Construction Photos
Construction Photos
Construction Photos
Construction Photos
Construction Photos
Completed Project
Completed Project
Completed Project
Completed Project
Completed Project
Completed Project
Completed Project
Project Summary
• Construction began Fall 2016
• Mostly minor demolition
• Major construction resumed Spring 2017
• Bridge was completed and opens Oct 2017
• Total Final Construction Cost = $2,382,874
• Original Budget = $2,489,000 (with Bid Alt #1)
Assessment of Learning
Question 1
What was needed to be done to allow the Subcontractor to be allowed to have greater than
50% of the contract value?
Assessment of Learning
Answer 1
Identify the Painting work as a Specialty Item
Assessment of Learning
Question 2
Why were we allowed to remove the hanger plates and channels at the panel points of the
truss.
Assessment of Learning
Answer 2
Force redistributed to diagonals and bottom chord members without overstressing
Assessment of Learning
Question 3
A narrow gage railroad has a rail spacing less than?
Assessment of Learning
Answer 3
4’-8 ½”
