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2 I-49 North Segment K Project 2

3 AGENDA PROJECT OVERVIEW BRIDGE DESIGN ARCHITECTURAL ENHANCEMENTS SPECIAL PROVISIONS COST ESTIMATE AND FINAL BIDS CONSTRUCTION 3

4 SITE LOCATION PROJECT SITE ARKANSAS 185 MILES TO DALLAS, TX T E X A S M I S S I S S I P P I NEW ORLEANS LAFAYETTE BATON ROUGE 4

5 I-49 NORTH CORRIDOR SEGMENTS A J ALL UNDER CONSTRUCTION OR COMPLETED SEGMENT K 5

6 PROJECT TEAM PRIME CONSULTANT - BRIDGE DESIGN: COORDINATION WITH DOTD AND TEAM MEMBERS DEVELOPMENT OF DESIGN CRITERIA & QC/QA PLAN 5 DESIGN TEAMS DESIGN OF ALL STEEL BOX GIRDER BRIDGES DESIGN OF RAMP EN (SEGMENTAL) BRIDGE DESIGN OF RAMPS SE, WN (SEGMENTAL) PEER REVIEW OF TRC S BRIDGE DESIGN. PRIME CONSULTANT - ROADWAY DESIGN. 6 NTB Associates, Inc. INTERCHANGE BRIDGE AESTHETICS VISUAL QUALITY MANUAL DESIGN OF I-220 BRIDGE WIDENING

7 PROJECT TIME LINE TIMELINE OF EVENTS DATE JUN 6, 2006 MAY 25, 2007 JUL 7, 2011 JAN 5, 2012 JAN 2, 2013 DEC 6, 2013 FEB 5, 2014 FEB 14, 2014 APR 30, 2014 EVENT NTP FOR PRELIMINARY BRIDGE DESIGN PROJECT PLACED ON-HOLD DOTD, ASBI, TRC DISCUSS POTENTIAL IMPLEMENTATION OF SEGMENTAL ALTERNATIVE DOTD/TRC STEPS TO MOVE INTO FINAL PLANS THAT INCLUDE IMPLEMENTATION OF SEGMENTAL BRIDGE DESIGN ADVANCED NTP ISSUED PHASE I PS&E SUBMITTAL PHASE I LETTING PHASE II PS&E SUBMITTAL PHASE II LETTING 7

8 CONSTRUCTION PHASES PHASE I INTERCHANGE ROADWAYS I-49 BRIDGE OVER MLK DR. (4-SPAN PPC GIRDER) PHASE II RAMP EN, SE & WN BRIDGES I-220 AT RUSSELL RD BRIDGE WIDENING 8

9 BRIDGE DESIGN RAMP BRIDGES Ramp EN: Length = 3,070 Width = Varies 42.5 to 64 Curvature = 3,500 Rad. Max. Ht. = 80 (3 rd Level) Ramp SE: Length = 3,300 Width = 35.5 Curvature = 840 Radius Max. Ht. = 105 (4 th Level) Ramp WN: Length = 700 Width = 31.5 Curvature = 550 Radius Max. Ht. = 60 9

10 BRIDGE DESIGN DUAL DESIGN ALTERNATES POST-TENSIONED SEGMENTAL CONCRETE STEEL TRAPEZOIDAL BOX GIRDERS 10

11 BRIDGE DESIGN PROJECT SPECIFIC QC/QA PLAN DEFINE ROLES AND RESPONSIBILITIES REQUIRED PROCEDURES FOR THE QC AND QA PROCESS ADHEARANCE TO CAD STANDARDS INDEPENDENT PEER REVIEW STANDARDIZE DESIGN METHODOLOGY COMPREHENSIVE DESIGN CRITERIA DESIGN DIRECTIVES SOFTWARE & DESIGN APPROACH 11

12 BRIDGE DESIGN SUBSTRUCTURE SIMILAR FOR EACH ALTERNATE MULTI-DRILLED SHAFT (66 Φ) FOOTINGS HAMMERHEAD BENTS STRADDLE BENTS CANTILEVER BENT CANTILEVER BENT STRADDLE BENT HAMMERHEAD BENT 12

13 BRIDGE DESIGN - SEGMENTAL ALTERNATE DESIGN METHODOLOGY & CONSTRUCTIBILITY: PRECAST SEGMENTAL BALANCED CANTILEVER ERECTION TEMPORARY SHORING ERECTION BY CRANES OFFSITE CASTING YARD ONE SET OF CASTING MACHINES FOR ALL SEGMENTS 13

14 BRIDGE DESIGN - SEGMENTAL ALTERNATE DESIGN METHODOLOGY & CONSTRUCTIBILITY 732 SEGMENTS TYPICAL SEGMENT LENGTH +/-10 SPLIT PIER SEGMENTS LINEAR HAUNCH AT PIERS TYPICAL SPAN LENGTHS: +/-250 INTERIOR SPANS +/-160 END SPANS TYPICAL SECTION ELEVATION 14

15 BRIDGE DESIGN - SEGMENTAL ALTERNATE SEGMENT BOX DESIGN SAME CORE DIMENSION VARYING WING DIMENSION TO ACCOMMODATE DIFFERENT BRIDGE WIDTH RAMP EN TO 42-6 RAMP SE 35-6 RAMP WN 31-6 BOX 20-2 TYPICAL SECTION 15

16 BRIDGE DESIGN - SEGMENTAL ALTERNATE POST-TENSIONING SYSTEM CONTINUITY TENDONS CANTILEVER TENDONS TEMPORARY & PERMANENT PT BARS TRANSVERSE TENDONS CONTINUITY TENDONS CANTILEVER TENDONS BALANCED CANTILEVER ERECTION 16

17 BRIDGE DESIGN - SEGMENTAL ALTERNATE SUPERSTRUCTURE PRECAST SEG. CONTINUOUS UNITS ARRANGEMENT RAMP # OF SPANS LENGTH (FT) DESIGN BY EN EN EN SE SE WN SPAN1 UNIT1 = 803 UNIT2 = 1070 UNIT3 = 1070 GENERAL ELEVATION VIEW OF RAMP EN BRIDGE 17

18 BRIDGE DESIGN - STEEL ALTERNATE DESIGN METHODOLOGY BRIDGE GEOMETRY SIMILAR TO THE SEGMENTAL ALTERNATE TRAPEZOIDAL BOX GIRDERS WITH STANDARDIZED WEB SLOPE CONSTANT WEB HEIGHT PER BRIDGE SHOP PIECES LIMITED TO 130 & 170 KIPS CROSS FRAMES DESIGNED AS PRIMARY MEMBERS AASHTO M270 Gr. 50 STEEL PERMANENT EXTERNAL CROSS FRAMES 18

19 BRIDGE DESIGN - STEEL ALTERNATE C L GIRDER 2 EXTERNAL BRACING C L BRG BENT 1 EXTERNAL BRACING (TYP) A INTERNAL BRACING SECTION A-A C L GIRDER 1 INTERNAL K TOP FLANGE LATERAL BRACING (TYP) BRACING (TYP) C L BRG BENT 2 A TYP. SE FRAMING PLAN C L SPLICE 19

20 ARCHITECTURAL ENHANCEMENTS PIER DESIGN SHAPE AND COLOR DECORATIVE PANELS AND RUSTICATION SEGMENTAL ALTERNATIVE STEEL ALTERNATIVE 20

21 ARCHITECTURAL ENHANCEMENTS STRADDLE BENT AND C-BENT STRADDLE BENT C-BENT 21

22 ARCHITECTURAL ENHANCEMENTS DECORATIVE PANELS ARTWORK SHOWN FOR REFERENCE ONLY FINAL ARTWORK TO BE DETERMINED THROUGH CALL-TO-ARTISTS AND PROVIDED TO THE CONTRACTOR TO FABRICATE 22

23 ARCHITECTURAL ENHANCEMENTS LIGHTING COMMUNITY INVOLVEMENT COLOR CHANGING OPTION 23

24 DESIGN CHALLENGES ARCHITECTURAL ENHANCEMENTS FROM CONCEPT TO CONSTRUCTION DOCUMENTS Agreement between City and State for the Incorporation of Aesthetics into the Interchange Design No Cost / Low Cost Aesthetic Methodology Shape Color Lighting Architect Produced Visual Quality Manual (VQM) NOT Part of the Contract Documents Engineer Produced Bid/Contract Documents 24

25 DESIGN CHALLENGES ARCHITECTURAL ENHANCEMENTS FROM CONCEPT TO CONSTRUCTION DOCUMENTS PIER SHAPE INITIAL SELECTION OF THEME DETERMINATION OF DIMENSIONS 25

26 DESIGN CHALLENGES ARCHITECTURAL ENHANCEMENTS FROM CONCEPT TO CONSTRUCTION DOCUMENTS COLOR PLANS IDENTIFIED LOCATIONS AND FEDERAL COLOR NUMBERS SPECIAL SURFACE FINISH FOR CONCRETE PAINT COLOR FOR STEEL 26

27 DESIGN CHALLENGES ARCHITECTURAL ENHANCEMENTS FROM CONCEPT TO CONSTRUCTION DOCUMENTS LIGHTING SELECTION OF LIGHTING SYSTEM & LOCATIONS PHOTOMETRIC & GLARE ANALYSIS 27

28 DESIGN CHALLENGES ARCHITECTURAL ENHANCEMENTS FROM CONCEPT TO CONSTRUCTION DOCUMENTS DECORATIVE PANELS CALL TO ARTISTS FOR SELECTION OF DESIGN PLANS SHOW LOCATIONS & CONCEPTUAL DETAILS SPECIAL PROVISION INDICATES QUALIFICATIONS, TYPE, ETC VECTOR FILE PROVIDED TO THE CONTRACTOR 28

29 SPECIAL PROVISIONS A SIGNIFICANT EFFORT FOR SEGMENTAL ALTERNATIVE REVIEWED OTHER STATE DOT S SPECIFICATION AND BEST-PRACTICES CONSULTED WITH ASBI & PTI, INCORPORATED LATEST TECHNOLOGY, SPECIFICATION AND PUBLICATIONS USED NON-STANDARD PAY ITEMS: PRECAST SEGMENTAL SUPERSTRUCTURE BY LN. FOOT POST-TENSIONING STEEL BY LBS. 29

30 COST ESTIMATE AND FINAL BIDS FINAL BID RESULTS-PHASE I LETTING DATE: 2/5/2014, WINNING BID: $33.2M FINAL BID RESULTS-PHASE II LETTING DATE: 4/30/2014 FINAL BIDS BID % OVER RANK BID ESTIMATE ALTERNATIVE ESTIMATE 1 SEGMENTAL $137.8M $135.9M 1.4% 2 SEGMENTAL $143.9M $135.9M 5.9% 3 STEEL $154.2M $129.4M 19.2% 4 SEGMENTAL $159.1M $135.9M 17.1% TOTAL PROJECT BID COST: $ 17I M 30

31 CONSTRUCTION SUBMITTALS TYPES RFI S SHOP DRAWINGS: SEGMENT DRAWINGS FOR PRECAST SUPERSTRUCTURE (PIER, HAUNCHED, TYPICAL, EXPANSION & CLOSURE) DISC BEARING ASSEMBLIES EXPANSION JOINTS DECK DRAINAGE DECORATIVE PANELS TEMPORARY WORKS: LIFTING BEAMS, STRONGBACKS/CLOSURE BEAMS, STRESSING/ACCESS PLATFORMS, SHORING TOWERS FOR BALANCE CANTILEVER SUPERSTRUCTURE/STRADDLE BENTS/RAMP EN SPAN 1 CIP SPAN, FORMWORK FOR HAMMERHEAD, CANTILEVER AND STRADDLE BENTS, RAMP EN SPAN 1 CIP SPAN AND SEGMENTAL SUPERSTRUCTURE CLOSURE POURS CONSTRUCTION ANALYSIS: LONGITUDINAL CONSTRUCTION ANALYSIS CONTRACTOR S SCHEDULE, MEANS AND METHODS AND SEQUENCE WITH RESULTING COMPUTER MODELS TO DETERMINE CAMBER TRANSVERSE CONSTRUCTION ANALYSIS CALCULATIONS SUPPORTING CONTRACTOR S MEANS AND METHODS FOR TEMPORARY WORKS, JACKING, TIE-DOWNS, ETC POST-TENSIONING: POST-TENSIONING SYSTEM DRAWINGS POST-TENSIONING LAYOUT DRAWINGS FOR SEGMENTAL SUPERSTRUCTURE, RAMP EN SPAN 1, STRADDLE BENTS TENDON ELONGATIONS/STRESSING DATA (LONGITUDINAL AND TRANSVERSE) POST-TENSIONING PLAN/MANUAL FRICTION AND WOBBLE TEST DATA CASTING YARD SUBMITTALS (PER SPECIAL PROVISIONS) INCLUDES DETAILS OF SEGMENT CASTING FORMS AND CELLS GEOMETRY CONTROL: CASTING MANUAL (SEE ATTACHED EXCERPT FROM SPECIAL PROVISIONS) UNCAMBERED & CAMBERED SEGMENT GEOMETRY AS-CAST SEGMENT GEOMETRY AND CORRECTIONS AS-ERECTED SEGMENT GEOMETRY AND CORRECTIONS ERECTION MANUAL (SEE ATTACHED EXCERPT FROM SPECIAL PROVISIONS) FULL SCALE GROUTING MOCK-UP PLAN GROUTING OPERATIONS MANUAL/PLAN JACKING PLAN FOR FUTURE BEARING REPLACEMENT MATERIAL, VENDOR & PERSONNEL QUALIFICATIONS ELECTRICAL/LIGHTING: SHOP DRAWINGS, EQUIPMENT SUBMITTALS AND O&M MANUALS ETC TRACKING & DOCUMENTATION 31

32 CONSTRUCTION VALUE ENGINEERING PROPOSALS CONTRACTOR PROPOSAL FOR REPLACEMENT OF 60 KSI REINFORCEMENT WITH 75 KSI RE-GRADING POND AND RAISE FOOTINGS AT EN & WN REPLACE RAMP WN BRIDGE WITH FILL 32

33 CONSTRUCTION 33

34 CONSTRUCTION 34

35 CONSTRUCTION 35

36 CONSTRUCTION 36

37 CONSTRUCTION 37

38 CONSTRUCTION 38

39 CONSTRUCTION 39

40 CONSTRUCTION 40

41 CONSTRUCTION 41

42 CONSTRUCTION 42

43 CONSTRUCTION 43

44 CONSTRUCTION GROUTING MOCK-UP SPECIAL PROVISIONS REQUIRED THE GROUTING MOCK-UP OF AN ENTIRE CONTINUITY TENDON RAMP EN TENDON D1-1 (400 LENGTH, 13 HEIGHT) 44

45 CONSTRUCTION 45

46 CONSTRUCTION 46

47 CONSTRUCTION 47

48 CONSTRUCTION RAMP SE BENT 2 48

49 CONSTRUCTION RAMP SE BENT 2 49

50 CONSTRUCTION 50

51 Construction Decorative Panels 51

52 CONSTRUCTION RAMP EN 52

53 QUESTIONS / ANSWERS Durk Krone, P.E., Principal TRC Engineers, Inc United Plaza Boulevard, Suite 502 Baton Rouge, LA DKrone@trcsolutions.com T: Follow us LinkedIn Twitter Mike Paul, P.E., Project Manager TRC Engineers, Inc United Plaza Boulevard, Suite 502 Baton Rouge, LA MPaul@trcsolutions.com T: Follow us LinkedIn Twitter 53

54 BASEMENT 54

55 Sa (g) DESIGN CHALLENGES SEISMIC DESIGN (2012 AASHTO LRFD) SEISMIC ZONE 1 (SECTION ) A s = 0.06 CONECTION FORCE = 0.25 x TRIB VERT LOAD ADDRESS CONNECTION FORCE FROM POINT OF APPLICATION TO THE FOUNDATION OPTIMIZED DESIGN WITH SEISMIC ANALYSIS DESIGN RESPONSE SPECTRUM (Tributary Vertical Load = 0.25) S DS = 0.15 SD1 = PERIOD, T (SEC) 55

56 DESIGN CHALLENGES BEARING TYPE SELECTION POLYETHER URETHANE DISK BEARINGS WITH PTFE SLIDING SURFACES FIXED UNI DIR. MULTI DIR. BEARING CONFIGURATION & ORIENTATION SHORT CHORD MOVEMENT 56

57 DESIGN CHALLENGES RAMP EN/ES GORE AREA GEOMETRIC CONSTRICTIONS CANTILEVERED APPROACH SLAB TAPERED RAMP EN BRIDGE GEOTECH. CONSIDERATIONS FOR MSEw 57

58 DESIGN CHALLENGES BRIDGE ABUTMENT ON MSE WALL 40 TALL MSEw ABUTMENT SPREAD FOOTING (20 x55 x4 ) LOAD TRANSFER PLATFORM (113 x54 x3 ) 58

59 CONSTRUCTION POND NEAR RAMPS EN & WN 59

60 CONSTRUCTION SEGMENT CASTING YARD 60

61 BRIDGE DESIGN - SEGMENTAL ALTERNATE CONSTRUCTION DETAILS FORMS TO ACCOMMODATE VARIABLE DEPTH FORMS TO ACCOMMODATE VARIABLE WIDTH 61

62 CONSTRUCTION FLOODING 62

63 6 C 6 A B A DESIGN CHALLENGES EXPANSION JOINTS SELECTION TYPE - FINGER JOINTS DETAILS CONSIDERATION OF LONGIT & LATERAL MOVEMENT F 63

64 BRIDGE DESIGN - SEGMENTAL ALTERNATE SEGMENT BOX DESIGN PIER SEG. SECTION DEPTH = 13FT TYP. SEG. SECTION DEPTH = 9FT LINEAR TRANSITION - 5 HAUNCH SEGMENTS EACH SIDE OF PIER SEGMENT VARIABLE DEPTH SECTION 64

65 BRIDGE DESIGN CONCEPTUAL STAGE INTERACTION BETWEEN ROADWAY & BRIDGE DESIGNERS CONCEPTUAL BRIDGE GEOMETRY FINAL ROADWAY GEOMETRY 65

66 BRIDGE DESIGN - SEGMENTAL ALTERNATE RAMP EN SPAN 1 - C.I.P CONCRETE BOX VARYING BRIDGE WIDTH, TOO WIDE FOR THE TYPICAL SEGEMENT DESIGN CANTILEVER TO WINGS MATCH SEGMENTAL BRIDGE FOR AESTHETICS PLAN VIEW - SPAN 1 TYPICAL SECTION SPAN 1 66

67 BRIDGE DESIGN - SEGMENTAL ALTERNATE SEGMENTAL DESIGN LONGITUDINAL DESIGN COMMERCIALLY AVAILABLE SOFTWARE PACKAGE TIME DEPENDENT STAGED CONSTRUCTION TENDON GEOMETRY AND STRESSING SCHEDULE TRANSVERSE DESIGN 3-D FEM MODEL SHELL ELEMENTS SEGMENT DESIGN 3D FEM & STM MODELS LONGITUDINAL MODEL Loadcase: 4:LL: Cantilever Tandem Results file: Transverse_46Width_Final.mys Entity: Force/Moment - Thick Shell Component: Mx Y Z X Maximum at node 2767 Minimum at node 2953 TRANSVERSE-MODEL 67

68 BRIDGE DESIGN - SEGMENTAL ALTERNATE POST-TENSIONING DETAILS DIABOLOS zzzz DIABOLOS LOCATIONS CONTINUITY TENDONS 68

69 BRIDGE DESIGN - SEGMENTAL ALTERNATE POST-TENSIONING SYSTEM CONTINUITY TENDONS WITH DIABOLOS CANTILEVER TENDONS 69

70 /4 BRIDGE DESIGN - STEEL ALTERNATE VARIES ½ TO 64-0 VARIES /4 TO /8 VARIES /4 TO /8 C L GIRDER 3 C L GIRDER 2 BRIDGE SECTION - RAMP EN - UNIT 1 C L GIRDER 1 70

71 BRIDGE DESIGN - STEEL ALTERNATE DESIGN SOFTWARE COMMERCIALLY AVAILABLE GRILLAGE ANALYSIS SOFTWARE PACKAGE FOR DESIGN PRODUCTION VERIFIED GRILLAGE RESULTS WITH 3D FEM MODELS 71

72 BRIDGE DESIGN - STEEL ALTERNATE S2 W RW S1 RAMP EN SE WN W (FT) RW (FT) D (FT) S1 (FT) S2 (FT) C L GIRDER 2 C L GIRDER 1 TYPICAL BOX GIRDER SECTION 72

73 BRIDGE DESIGN - STEEL ALTERNATE RAMP EN SE WN TOTAL LENGTH (FT) 3,070 3, UNITS SPANS MAX. SPAN (FT) WIDTH VARIES (FT)

74 CONSTRUCTION PROPOSED DESIGN MODIFICATIONS SEGMENTAL ERECTION SCHEME DESIGN DOCUMENTS INDICATE GROUTING BEARINGS AFTER CLOSURE POURS CONTRACTOR PROPOSED TO GROUT BEARINGS AFTER ERECTION OF 1D/1U SEGMENTS 74

75 CONSTRUCTION VALUE ENGINEERING PROPOSALS RE-GRADING POND AND RAISE FOOTINGS AT SE & WN INITIAL PROPOSAL ABANDONED DUE TO GEOTECHNICAL AND SCHEDULE ISSUES SUBSEQUENT PROPOSAL HAD LESSER FOOTING ELEVATION INCREASES REQUIRED RE-DESIGN BY EOR S IMPLICATIONS FOR SEISMIC & POST TENSIONING 75

76 CONSTRUCTION VALUE ENGINEERING PROPOSALS REPLACE RAMP WN BRIDGE WITH FILL PROPOSAL ABANDONED DUE TO LARGE MAGNITUDES OF REQUIRED FILL AND UNKNOWN SOIL IMPROVEMENT REQUIREMENTS 76

77 PROJECT TIME LINE TIMELINE OF EVENTS DATE EVENT JAN 2, 2013 ADVANCED NTP ISSUED FOR FINAL DESIGN DEC 6, 2013 PHASE I - PS&E SUBMITTAL FEB 5, 2014 PHASE I - LETTING FEB 14, 2014 PHASE II - PS&E SUBMITTAL APR 30, 2014 PHASE II - LETTING APR 28, 2014 PHASE I - NTP FOR CONSTRUCTION SEP 15, 2014 PHASE II - NTP FOR CONSTRUCTION JUN 1, 2014 PHASE I - BEGIN CONSTRUCTION NOV 3, 2014 PHASE II - BEGIN CONSTRUCTION FEB 1, 2017 PHASE I - ESTIMATED COMPLETION DATE APR 4, 2017 PHASE II - ESTIMATED COMPLETION DATE 77