south cascade drive / miller road (old 219) over

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

QUESTIONS?

THANK YOU

JOSHUA T. RODEMS, PEERDMAN ANTHONY

rodemsj@erdmananthony.com

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