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Copano Bridge Location
Located in Aransas County 45 miles North of Corpus Christi Upgrade a 2 mile bridge over
Copano Bay from a two lane roadway to a four lane roadway.
Cost $98,162,587 Contractor Williams Brothers
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Existing Bridge
9,232 ft. 229 spans 40 ft. average span length 2-13 ft. lanes with 2 ft. shoulders Outdated bridge rail 46 year old bridge
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2001 94 piles encased. October 2009 Emergency Structure
repair.
Proposed Project
Construction began August 2011 4 years to complete Project Length 16,129 ft. or 3.054 mi. Bridge Length 11,010 ft. or 2.085 mi. Center Line of new bridge 40 ft. east of existing 93 Spans
– 92 spans of Tx54 in 120’ and 100’ lengths – 1 span of Tx70 at 150’ channel crossing
Girder Type TX54 (129,785 LF), TX70 (1,794 LF) 94 bents 460 round piles 54 in. (50,591 LF) 330 square piles 24 in. (27,844 LF) TY T223 Rail (22,665 LF) 42 in. Single Slope Concrete Barrier Type 1 (10655 LF) 42 in. Single Slope Concrete Barrier Type 4 (510 LF) 3% bridge grade over channel Maximum vertical clearance at channel 75 ft.
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Construction Phasing and Time Line
Phase I – 62 ft. – 3 years Demo Existing Bridge – 3 months Phase II – 18 ft. – 1 year
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Curing the Piles
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54 in. cylindrical pile 46 – ½ in dia prestressing
strands W11 spiral wrap CL “H” Concrete (HPC) Compressive Strength 7000 psi
6 in. wall thickness 2 ⅜ in. clear cover
Test Pile Program
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13 test piles Dynamic Monitoring and Analysis of Driven Piling
Special Spec 4586 – Conduct the Dynamic Pile Monitoring during initial
driving and any restrikes. – Use the Case Pile Wave Analysis Program and Wave
Equation analysis program to determine • Ultimate Pile Bearing Capacity • Pile stresses • Pile integrity • Pile driving system efficiency • Pile length
High Performance Concrete
Type C HPC – Design Strength Min 28 day 3600 psi – Used for
• Bridge abutments • Bridge bents • Bridge footings
Type S HPC – Design Strength Min 28 day 4000 psi – Used for
• Bridge slab
Type H HPC – Design Strength Min 28 day 7000 psi – Used for
• Beams • Piles
Corrosion inhibiting admixtures – Calcium nitrate 3 gals/cy
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Epoxy-Coated Reinforcing (ECR) Steel
Used in – Deck – Rail – Abutments – Bent caps and tie-beams – Columns
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Stainless Reinforcing Steel
“Splash Zone” below El 13 ft. – MHW = El 1 ft. – Plus 12 ft. wave height
Cost stainless $2.47/lb compare to black $0.35/ lb Use stainless reinforcing steel
in CIP elements – Columns – Footings – Pile-footing connections
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