Bonner Bridge Replacement Update:

Transcription

1 Bonner Bridge Replacement Update: Jerry D. Jennings, PE - NCDOT Division 1 Engineer Pablo A. Hernandez, - NCDOT Resident Engineer September 18, 2017

2 Bonner Bridge Replacement Timeline Refresher Bonner Bridge opened in Many projects to maintain & protect existing bridge. Design build contract for replacement was awarded to PCL Civil Constructors, Inc., in July HDR Engineering, Inc. of the Carolinas lead design firm. Settlement agreement reached to replace bridge in Original bid was $215.8 million. Contract adjustments due to delays & enhancements $250 million. 2

3 Bonner Bridge Replacement (B-2500 Phase I) 3

4 Comparison of Existing Bridge to the New Bridge Old New Bridge length (miles) Number of bents Number of spans in navigation zone 3 11 Navigation zone width (ft.) Navigation channel width (ft.) Design lifespan (years)

5 Design Visualization Becoming Reality Notice To Proceed: Oct 14, Onsite Activities Begin: March Substantial Completion: November Contract Completion: September Total Contract Expenditures to Date: $149.7 Million Approximately 60% Complete Design & Construction Support = $35 Million Large Percentage of Precast Concrete Members Fabricated Offsite. Construction Activities Approx. 50% Complete. 5

6 Materials & Work Activities Needed for New Bridge 20" Sq Pile 54" Cyl Pile 36" Sq Pile Footings Cast InPlace & Precast Caps Column Segments 45 Girders 96" Girders Cast In Place Decks Box Segments Plan (each) Approx. Length 18,800 FT 68,000 FT 46,711 FT 3,450 FT 6

7 Work Areas of Project Approach South Navigation Zone Approach North Approaches: 71 spans,160 ft. to 182 ft. wide. 72 bents: 2 styles of foundations: 54 cylinder pile with precast cap & 36 square pile with cast in place footing, precast columns & cap. Navigation Zone: 11 spans 200 ft. to 350 ft. wide. 11 bents: 36 square pile with cast in place footing, precast columns & cap. 7

8 Pile Driving: 36 Square Precast Prestressed Piles In Navigation Zone & Transition Approaches 338 of 532 piles installed to date. Ave Length 130ft. (weight 60 to 65 tons or approx. 1,050lbs/LF) 17 of 37 bents completed with 10 to 30 piles/bent. Three more bents with large cluster of piles should be completed in November. 8

9 Pile Driving: 54 Cylinder Precast Prestressed Piles In Approaches to High Rise. 86 of 138 piles installed to date. Weigh 55 to 62 tons, 110 to 130 ft. long. (hollow with 6 walls) 28 of 44 bents completed. 3 to 4 piles/bent. 9

10 Precast Caps: Approaches 33 of 83 caps set. Caps are voided (hollow) to engage with a rebar cage that is cast into top of cylinder piles. Once cap is set, concrete is cast into voids in top of cap make a solid connection to the piles. Largest precast cap for NCDOT. 10

11 Cast In Place Footings: Navigation Zone & Approaches 14 of 37 footings cast. Largest are 300 to 640 CY. Total 8,045 CY Smaller footings are 110 to 260 CY. Cast in place concrete is supported by a precast slab that is left in place. 11

12 Cast In Place Footings: Navigation Zone Utilize stainless steel reinforcing. Up to 8 ft. thick. Concrete delivered to existing bridge deck and discharged into 8CY bucket. Ocean water circulated inside concrete to cool the mass. Largest approx. 50ft x 50ft 6 to 16 hours to place concrete. 12

13 Cast In Place Footings: Approaches Smaller footings 36ft x 36ft and 21ft x 36ft. 6 ft. thick. 13

14 Columns: Navigation Zone & Approaches 23 of 48 sections set. Post Tensioned with 2.5 inch diameter stainless steel and plain steel bars. Grout pumped in PT ducts. 14

15 Columns: Navigation Zone & Approaches Cast in Place Column Stub Precast sections: 11ft x16ft 4ft to 12 ft. tall 18inch thick walls Smaller sizes in approaches: 5ft x 5ft. 15

16 Columns: Navigation Zone & Approaches 16

17 Girders: Approaches Prestressed Precast Concrete Girders: 106 of 303 girders set. 26 of 71 spans set. 96 tall. 160 to 182 ft. long. 100 tons (approx. 50 CY of concrete per girder). Delivered by truck and barge. Truck has 13 to 16 axels 17

18 Girders: Approaches Two cranes to erect. Largest precast girders in NCDOT. Very large & heavy hardware for temporary bracing. 18

19 Girders: Approaches Girders span land, marsh & water. Access for setting girders is challenging due to narrow work site and adjacent traffic. Braced for 110mph to 140mph until deck is cast. 19

20 Cast In Place Decks: Approaches 23 of 71 Decks cast. 160ft to 182 ft. long. 42 ft. wide. Stainless steel reinforcing. 20

21 Cast In Place Decks: Approaches Approx. 225CY per deck. (Total 18,000 CY) Lightweight Concrete weighs 20% less than normal concrete. Cast In Place Deck Area = 480,950 SF or acres. 21

22 Cast In Place Decks: Approaches Finished with burlap drag and covered with felt lined plastic for wet cure. Formwork for bridge rail that is cast in place. 22

23 Cast In Place Decks: Approaches Clear deck is 40ft wide: Two 12ft lanes and two 8ft shoulders. Deck will be ground and/or grooved for skid texture. 23

24 Cast In Place Decks: Approaches Clear deck is 40ft wide: Two 12ft lanes and two 8ft shoulders. Bridge rail is bicycle safe: 54 tall. 24

25 Box Segments: Navigation Zone 90 of 264 box segments set. Segments cast in Chesapeake VA. Shoring Tower needed for temporary support of the box segments. Two bearings assemblies per bent i.e. 22 bearings (approx. 5ft x 5ft) 25

26 Box Segments: Navigation Zone Barge strategically loaded for unloading. Segments are large & match cast. 8 to 19 ft. tall. 5 to 14 ft. long. 100 tons Pier segments set against frame on shore tower. Bolted and epoxy for the connection to each other. 26

27 Box Segments: Navigation Zone Set additional segments with crane for form Pier Table. Jacks and tie downs position and secure Pier Table. 27

28 Box Segments: Navigation Zone Segment lifters positioned on Pier Table. Shuttle Barge spudded below lifter, segment is lifted & connected to alternating sides. Balanced Cantilever Erection. 28

29 Box Segments: Navigation Zone Segments temporarily post tensioned to previous segments in upper corners and floor. Permanent threaded rods and cables (i.e. Tendons) installed at each pair of segments. Continue erecting cantilevers. 29

30 Box Segments: Navigation Zone Tendons installed though all each stage (12 stages i.e. 12 segments each side of the pier segments). 18 to 22 5/8 diameter strand bundled into a Tendon. Tendons are stressed to approx. 900,000 lbs. 30

31 Box Segments: Navigation Zone Construct two adjoining cantilevers with an approx. 4ft gap for cast in place Closure Pour. Once Closure Pour gains strength, stress interior Tendons. 31

32 Box Segments: Navigation Zone Interior accessible at ends of the navigation zone and underside doors. Also provides access to hollow columns for inspection. 32

33 Channel Width: Navigation Zone ~80 ft. ~70 ft. ~300 ft. Seven spans with horizontal & vertical clearances for navigation. 33

34 Box Segments: Navigation Zone 34

35 Under Construction Stay Tuned 35

36 Under Construction Stay Tuned 36

37 Under Construction Stay Tuned 37

38 Under Construction Stay Tuned 38

39 Under Construction Stay Tuned Questions? 39