lake champlain bridge erection · heavy lift weight? 5. what was each strand jack safe working...

LAKE CHAMPLAIN BRIDGEERECTION

Presented By: Stephen Percassi, PE

Brief Project History

• August 26, 1929 - Pre-existing bridge opened to traffic($1.1 million)

• October 16, 2009 – Bridge closed due to structural deterioration• October 24-25, 2009 –Public information meeting• December 28, 2009 – Bridge demolished• February 5, 2010 – Bridge replacement design approval• March 17, 2010 – Project advertised• April 15, 2010 – Bid opening • May 27, 2010 – Project awarded to Flatiron ($69.6 million)

– Erdman Anthony retained as Flatiron’s erection engineer

• June 11, 2010 – Groundbreaking ceremony• More project and bridge history:

www.nysdot.gov/lakechamplainbridge/history

• 4 New York approach spans• 3 Vermont approach spans• “Rigid Frame” flank each side of main span• Modified Network Tied Arch main span

• 3180 Tons – Approach steel• 950 Tons – Arch steel• Fabricated by High Steel Structures

New Bridge Structure

• 240’ or 250’ span lengths• Composite plate girder design• Plan bracing in each fascia bay• Construction Wind analysis• Pier girder – drop-in sequence• Angel wing falsework

Approach Span Erection

• Manitowoc 888 Series 2 (land) – 180 ft boom• Manitowoc 2250 S3 (land & barge) – 180 ft boom

Approach Span Erection

• Manitowoc 4100W S1 Ringer S3 (barge) –220 & 180 ft boom

Approach Span Erection

Photo courtesy of Flatiron

Vermont & New York Causeway

Angel Wing Falsework

Photo courtesy of Flatiron

Angel Wing Falsework

Photo courtesy of Flatiron

Angel Wing Falsework

Photo courtesy of Flatiron

Angel Wing Falsework

Span 8 Falsework

Span 1 Falsework

Photo courtesy of Flatiron

Approach Span Erection

Delta Frame Erection• 485 Ton each approach (970 Ton total)• Composite plate girder design• Heavy diagonal bracing in each bay• Construction Wind analysis

Rigid Frame Erection Sequence

Rigid Frame Erection Sequence

Rigid Frame Erection Sequence

Rigid Frame Erection Sequence

Rigid Frame Erection Sequence

Rigid Frame Falsework

Photo courtesy of Flatiron

Rigid Frame Falsework

Photo courtesy of Flatiron

Rigid Frame Falsework

Photo courtesy of Flatiron

Rigid Frame Falsework

Photo courtesy of Flatiron

Rigid Frame Falsework

Photo courtesy of Flatiron

Rigid Frame Falsework

Photo courtesy of Flatiron

Rigid Frame Falsework

Photo courtesy of Flatiron

Rigid Frame Falsework

Photo courtesy of Flatiron

Rigid Frame Falsework

Photo courtesy of Flatiron

Rigid Frame Falsework

Photo courtesy of Flatiron

Rigid Frame Falsework

Photo courtesy of Flatiron

Rigid Frame Falsework

Photo courtesy of Flatiron

Rigid Frame Falsework

Photo courtesy of Flatiron

Rigid Frame Falsework

Photo courtesy of Flatiron

Rigid Frame Falsework

Photo courtesy of Flatiron

Rigid Frame Falsework

Photo courtesy of Flatiron

Rigid Frame Falsework

Photo courtesy of Flatiron

Arch Span Erection• 402 ft span length• Modified network tied arch• Construction Wind analysis• Transfer Beams across slips• Conventional falsework for deck system• Tall tower bents for arch members

Arch Staging Area

Photo courtesy of Flatiron

Arch Span Erection

Arch Span Erection• Liebherr 1400 Series 2 (land) – 184 ft boom

Photo courtesy of Flatiron

Arch Span Erection• Manitowoc 888 Series 2 (land) – 200 ft boom

Arch Falsework

Photo courtesy of Flatiron

Arch Falsework

Photo courtesy of Flatiron

Arch Span Erection

Arch Span Erection

Arch Span Erection

Arch Span Erection

Arch Span Erection

Arch Span Erection

Photo courtesy of Flatiron

Arch Span Erection

Photo courtesy of Flatiron

Arch Span Erection

Photo courtesy of Flatiron

Arch Span Erection

Photo courtesy of Flatiron

Arch Span Erection

Arch Span Erection

Arch Span Erection

Arch Span Erection

Arch Span Erection

Arch Span Erection

Arch / Barge Transfer Beams

Arch / Barge Transfer Beams

Arch / Barge Transfer Beams

Arch / Barge Transfer Beams

Arch / Barge Transfer Beams

• Arch span positioned on barges beneath rigid frames• Actual centerline dimensions field verified• Strand jack positions adjusted to accommodate

temperature• 4 Strand jacks operated from single location

continuously monitoring stroke and force• Provided allowable operating envelope of arch knuckle

elevations

Arch Heavy Lift

Heavy Lift Falsework

Heavy Lift Falsework

Heavy Lift Falsework

CROSSBEAM

ARCHKNUCKLE

STRAND JACK

STRAND JACK

Heavy Lift Falsework

Heavy Lift Falsework

Heavy Lift Falsework

Heavy Lift Falsework

Heavy Lift Falsework

Strand Jack

• Hydrospex Strand Jack provided by Bigge Crane and Rigging Co.

• 365 Ton SWL Capacity

Lifting Jewel

• Hydrospex Lifting “jewel” provided by Bigge Crane and Rigging Co.

• 365 Ton SWL Capacity

Strand Jack

Courtesy of Flatiron

Strand Jack

Courtesy of Flatiron

Strand Jack

Courtesy of Flatiron

Strand Jack

Courtesy of Flatiron

Strand Jack

Courtesy of Flatiron

Arch Lifting Hitch

Arch Lifting Hitch

Arch Lifting Hitch

Photo courtesy of Flatiron

Arch Float Procedure

Arch Float Procedure

Arch Float Procedure

Arch Float Procedure

Arch Float Procedure

Arch Float Procedure

Arch Float Procedure

Arch Float Procedure

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Arch Float / Lift

Time Lapse

Time lapse courtesy of HNTBhttp://www.youtube.com/watch?v=pLY5_Fdtgyg

Acknowledgements

• Flatiron Construction Corporation– Mark Mallett – Project Manager– Paul Rudloff – Project Engineer– Cody Hix – Field Engineer– Chris Daigle – Field Engineer

• Erdman Anthony – Project Staff (Rochester, Buffalo, Albany, Harrisburg, Pittsburgh)– John Gast – Erection Consultant

• Glosten Associates (naval architects)• HNTB Structural Engineering Staff

– Ted Zoli– JoAnna Billings – Gregor Wollmann

• NYSDOT– Main Office Metals & Construction– Region 1 Construction

PDH Quiz

1. What construction wind speed was used to check stability of the structure in its temporary condition?

2. What was the primary function of the angel wings?

3. For the rigid frame falsework system, what was the primary function of the “tension” tower?

4. How many tons did the barge float / arch heavy lift weight?

5. What was each strand jack safe working capacity?

6. How many strands used at each jack location?

65 mph (15 year return period)

Stability of pier girders

Lateral wind resistance

950 ton

365 ton

31

Thank you…. www.nysdot.gov/lakechamplainbridge