Dale Even, PE – Lunda Construction CompanyJason Block - Ames Construction, Inc.

Project Area

WisconsinMinnesota

Construction Contracts

Pile Load Test Contract – 2012 $3.5 million

Early Foundation Contract – 2013 $37 Million

Minnesota approach roadway - 2012 $55 million• Ames/Lunda Joint Venture

Superstructure Contract – 2014 to 2017 $332 million• Lunda/Ames Joint Venture

Wisconsin roadway – 2013 to 2017 $27 Million

Bridge Project Schedule

St. Croix Crossing Project Schedule

2012 2013 2014 2015 2016 2017Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

Final Design

Early Fnd Design

Pile Load Test contract

Early Fnd Contract

Superstructure Contract

Project Labor and Subcontractors

• Lunda/Ames Joint Venture Prime Contractor• Self Performed 67% of the

work• Up to 400 trades persons at peak

• Multiple Shifts• DBE Goal 15.3%• Workforce goals

• Minority 22%• Female 6%

• 25 subcontractors• Rebar/PT labor• Electrical• Painting• Stay Cables

Project Partnering

• Quarterly Partnering Meetings• Facilitator• Project Management• Executive Management

• Project Charter• Safety• Environment• Quality• Schedule• Budget• Public Relations• Issue Resolution• DBE Goal

MnOSHA Project Partnership

• 120 OSHA Site Evaluation's

• 780 Safety and Environmental Orientations

• LAJV Project Specific Site Safety Plans

• Multiple Project Safety Professionals

• All parties believe it is a Successful Program

Quality Program

• Hybrid of MnDOTDB and DBB

• Limited 3rd Party QC

• Roles of QC vs. QA• 992 Segments only

1 rejected.• National recruiting

of technical people to support the work.

St Croix Crossing Bridge

• Extradosed Bridge Design• Hybrid Cable Stay and Concrete Box Girder

• Total Bridge Length 5,079’• Total Bridge Area 13.5 Acres.• 100 Year Design Life

Major Materials

• 140,000 C.Y. of Concrete• 20 different mix designs (plastic up

to 180 minutes)• 4,000 to 9,000 PSI• 2 suppliers

• 40,000,000 pounds of Reinforcing• Epoxy Coated and Stainless

• 8,000,000 pounds of Post Tensioning Steel

• 160 Stay Cable – 76 Strands each

• 20,000 gallons of paint

Environmental Commitments

Regulatory/Oversight• MnDOT• WisDOT• USACE • USCG• MPCA • Water shed District• USFW • DNR (Mn and WI)• Over 70 site specific

plans developed• Full time ECO

Approach Bridges Construction

Minn. Mainline Approach Spans• Two parallel 1700-ft.

sections of bridge – Two units• Pre-cast balanced cantilever/

CIP on falsework

Off-Ramp – On-Ramp Spans• 960-ft. and 630-ft. structures• Pre-cast balanced cantilever/

CIP on falsework

On-site Casting Yard

On-Site Casting Yard

• Construction:• 342 pre-cast

concrete segments • 3 castings beds• Completed casting

7/13/16

• Segment dimensions:• 43 ft. wide• 10-14 ft. tall• Up to 90 tons each

Construct and Transport Rebar Cage

• 3 Pre-tie Jigs• Adjustable Jig• Cage weight approximately

7000 pounds

Match Casting

• Previously cast segment used a bulk head for casting the next segment

• Geometry of the structure controlled by rotating the match cast segment vertically and horizontally.

• As cast surveys allow for adjustments as segments are cast.

Segment Erection – Approach Structure

• Unit 1 Segments• First Segments Erected

May 2015• Balance Cantilever

Method• SPMT transport on site• Crane based erecting• 300 to 440 ton cranes

Approach Segment Erecting

Unit 1 Segments• 13 Pre-Cast Spans• Span lengths 180’ to 290’• Spans over

• Wetlands• Multiple Rail Lines• Roadways

Segment Erection -Approach Structures

Unit 1 Segments• Up to 80 above existing grade

Segment Erection -Approach Structures

Unit 1 Segments• Last Segment Erected October 2016

Approach Bridge Cast-In-Place Spans

Cast-In-Place Bridges• Br. 82048 On Ramp• Unit 2 Gore Area • Br. 82047 Off Ramp

Span 1

Cast In Place Falsework

• 80 Feet above grade• 12 Million pounds of

False-work

Cast In Place– Falsework and Formwork

• Outsourced FW Design• Pile Foundations• Pipe Columns (27,000 lf)

• LAJV Formwork Design

Cast-In-Place Box Girder Construction

• Variable Depth• Variable Width

Cast In Place – Falsework and Formwork

• No standardized shapes

• Hand formed in place• VE to simply shapes

denied due to aesthetic concerns

Cast-In-Place Box Girder Construction

• Cold Weather Work

Cast in Place on Falsework

River Bridge Construction

Cold Weather Construction

Pier Blades

Aesthetic Construction Details

Crossbeam Falsework and Formwork

Rebar, PT Duct and Headed Rebar Installation – Crossbeams

3D Model of Knuckle Joint

• The owner developed a 3D Model Pre-Bid• Contactor developed ISD’s• Bid Item to Build a Mock up to sort out

Constructability Issues• Mock-Up and ISD’s identified several conflicts in

the design

Crossbeam Construction - Concrete

Crossbeam Construction

Pier Tower Construction

Pier Tower Climbing Formwork • Custom Forms• Poured in 22 Foot Lifts• Tower Boxes • 67’ above deck

Pier Tower Construction

Tower Construction

Typical River Span Deck Section

• 18‘ deep twin three cell box

• CIP center closure link

• 4-0.6“ φ transverse PT tendons at approx 2-6" c/c

30 m

6 m

Grey Cloud Casting Yard

Grey Cloud Segment Casting

• 5 casting beds• 3 OH Cranes• 5 Pre-tie beds• Storage for up to 400

Segments• Cast 650 segments

Grey Cloud Island Casting Yard

River bridge segments

• 18 ft. deep

• 10 ft. long

• 48 ft. wide

• 180 tons

• Casting September 2014 to August 2016

Pre-Fab of Rebar

• 35,000Lbs

Segment Transport

• Barged 33 miles on Mississippi and St. Croix rivers to project site

• Up to 10 Segments per barge

• Pass through Lock and Dam #2

• 96 Hours outside the St Croix pool.

River Bridge Construction Staging

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Geometry Control

• Methods to control Geometry

• Wet joints

• Shims

• Adjust PT bar forces

Erecting Equipment

Segment Lifters• Design, Fabrication,

Procurement 10 months• Load Test to 125%• 3 Pairs of lifters

Segment Erection

Segment Erection

Segment Erection

Piers 8 and 12• Hoist off of Barge• Walking Frame to

transport

Erecting Equipment

660 Ton Ringer Cranes• 1- Barge Mounted• 1 – Land Based

Segment Erection - Segment Epoxy

• 3 temperature ranges

• 40°F - 115°F • Revised to

28°F - 115°F for cold weather then Rescinded.

Segment Erecting – Post Tensioning

Post-tensioning steel bars

Post-tensioning stressing 25 strands 0.6” φ

Segment Erecting -Longitudinal Closure Link

Closure Link• Connects EB and WB• Install Rebar/PT• Pour Concrete• Stress PT• Completed to advance

erection

Typical Deck SegmentAt Stay Anchorage

• External transverse tendons at stays

• Hoist Strut into place

• Install Rebar/Cast Concrete

• PT Transverse Tendon Before Stays

Transverse Struts

Stay Cables

• 32 Cables/Pier• 76 Strands/each• 2.4 Million Lbs of

force• Installed Strand by

Strand• 400 miles of cable

Stay Cables

Each of the 76 strands is installed and stressed separately in a 10” diameter duct

Stay Cables – Inside Anchor Box

Stay Cables

After each strand is installed, crews pull it tight using a hydraulic jack. It applies 33,000 lbs of force.

Span 14 Trestle

• Top Down Construction• Tree Clearing Allowed 10 feet

beyond drip line• Highly Erodible soils• Steep Terrain

Span 14 Erecting

• Hoist segments onto cart

• Winch segments into place

• Install Temporary PT Bars

• Repeat

Span 14 Erection

Span 14 Erection

Segment Construction Update

Completed Erecting October 5th, 2016• 2015 – 282 segments erected• 2016 – 710 segments erected

Questions