IMUA ANNUAL PRESENTATION 2013 1
Who We Are: Founded in 1947 in Colorado Have expanded to a company of approximately 2,000 With Operations Constructing Transportation, Water and Energy Infrastructure throughout the US and Canada 2
Focus on Inland Bridge Construction I-35W - Minnesota 3
Where We Started: Glenwood Canyon Corridor (I-70) Glenwood Springs, Colorado 4
Sagadahoc Bridge over the Penobscot River 5
CAROLINA BAYS PARKWAY MYRTLE BEACH 6
Arthur Ravenal Bridge over the Cooper River 7
Alfred Zampa Memorial Bridge Over the Carquinez Straits Crockett, CA 8
San Francisco Oakland Bay Bridge Skyway 9
John James Audubon Bridge Sereno Brown, PE Deputy P.M. / Project Engineer 10
About the Project 11
Contract Details Proposal Date: January 18, 2006 NTP Date: May 4, 2006 Final Acceptance: May 5, 2011 Total Contract Value: $347,860,000 Final Contract Value: $355,901,114 12
Contract Team Flatiron Constructors, Inc. 54% Granite Construction, Inc. 25% Parsons 21% 13
Where is St. Francisville, LA 14
Bridge 3-3: Cable-Stayed Unit Bridge 3 15
Project Overview 8 Bridges Begin Bridge 3 Bridge 2 12 miles of 2-lane asphalt roadway End Bridge 3 Bridge 4 Bridge 5 1,100,000 CY of Earth Work 4 New Intersections 10+ Design Consultants Bridge 6 Bridge 7 Bridge 8 New US Hwy 61 & LA Hwy 10 Intersection Existing US Hwy 61 16
General Information First Design-Build project for Louisiana DOTD Furthest South in Mississippi River that drilled shafts are used to support superstructure. Other Notable Citations: 1. John James Audubon at 1,583 ft 1. Longest Cable Stay Bridge in Western Hemisphere! 2. 31 st Longest Cable Stay Bridge in the World 2. Cooper River at 1,546 ft (Also Constructed by FLATIRON) 1. Previous Record Holder for Longest in Western Hemisphere 2. 37 th Longest Cable Stay Bridge in the World 17
Layout of Cable Stayed Unit 18
General Arrangement 1583 ft Main Span 2866 ft Cable Stayed Portion 2.27 miles including approaches 19
Chief Obstacles to a Bridge of this Type 1. Finding an adequate foundation 1. No Rock 2. High Potential For Vessel Impact / Barge Impact 2. Contending with the Mississippi River 1. Extreme Variability in River Levels 2. Unpredictable and Potential For Rapid Change 20
Chief Obstacles to a Bridge of this Type 1. Finding an adequate foundation 1. No Rock 2. High Potential For Vessel Impact / Barge Impact 2. Contending with the Mississippi River 1. Extreme Variability in River Levels 2. Unpredictable and Potential For Rapid Change 21
Traditional Foundation Types 1. Sunken Caisson 22
Traditional Foundation Types 1. Sunken Caisson 23
Traditional Foundation Types 1. Sunken Caisson 24
Traditional Foundation Types 1. Sunken Caisson 25
Traditional Foundation Types 1. Sunken Caisson 26
Traditional Foundation Types 1. Sunken Caisson 27
Traditional Foundation Types 2. Driven Pile 28
Traditional Foundation Types 3. Drilled Shafts 29
Install Oscillator 1. Set Base 2. Set Oscillator 30
Excavate Temporary Casing Using Bottom of Permanent Casing 90 Temporary Casing Hammer Grabs West - 175 East - 180 31
32 Excavate Temporary
Lower Cage Set Rebar Cage Upper Cage 33
Pour Tremie Concrete 1 Initially, Tremie pipe is set ~ 6 above base plate while concrete is pumped. 2 Once flow is established and a seal around the Tremie is formed by the concrete, the temporary casing is oscillated up, always maintaining a 10 plug. 10 Min. Embed Note: In order for casing to be extracted, a 10 Slump must be maintained for Duration of Pour (~8 hours) 34
Chief Obstacles to a Bridge of this Type 1. Finding an adequate foundation 1. No Rock 2. High Potential For Vessel Impact / Barge Impact 2. Contending with the Mississippi River 1. Extreme Variability in River Levels 2. Unpredictable and Potential For Rapid Change 35
Access to the Work 36
Access to the Work 37
Chief Obstacles to a Bridge of this Type 1. Finding an adequate foundation 1. No Rock 2. High Potential For Vessel Impact / Barge Impact 2. Contending with the Mississippi River 1. Extreme Variability in River Levels 2. Unpredictable and Potential For Rapid Change 38
Trestle and Work Platform Built to feed all stages of construction from drilled shafts to deck erection. East Trestle 342 ft long West Trestle 870 ft long Provided some relief from annual flood waters. 39
Annual Fluctuation of Mississippi River 2011 2008 36 Max River Level 2010 28 2009 2006 2007 Min River Level 7.4 40
Working on the River (Or Trying ) HIGHEST RIVER LEVEL RECORDED OVER LAST 85 YEARS NEW $2M CRANE 41
Working on the River (Or Trying ) 42
Working On the River (Or Trying ) 43
Foundation Construction Design & Construction of Pier Footings 44
Foundation Construction Design & Construction of Pier Footings THE CHALLENGE: How to construct a reinforced concrete monolith, approximately half the size of a football field, underwater. In depths that can vary from 4 to 45 below water? THE PLAN: Construct the shell of the pier, above water, then carefully submerge it into position create a waterproof seal and then remove all the water leaving a rigid empty shell to construct your pier within. BEHOLD: The Modular Cofferdam For an idea that does not first seem insane, there is no hope. Albert Einstein 45
Past Project Experience Bath, Maine - 2000 Bath, Maine - 2000 46
Past Project Experience John s Pass, FLORIDA 2007 47
Vetting the Design: We Built Models 48
Vetting the Design: We Built Models Lots of Models 49
Lowering Mock-Up Employee Training Even Full Scale! 50
Peer Design Review (Global Marketplace) Concept Peer Review Final Peer Review Project Design Check Cofferdam Design Project Locale Project Design Check 51
Cofferdam Erection Sequence Piles and trestle are installed 52
Install Soffit Panels Top View 53
Tower Foundations 1W & 1E 160 x 64 x 15 Cap 7 x 3 pile group 8-0 diameter shafts 54
Casting of Cofferdam Panels On-Site 55
Install Soffit Panels 56
Walk Through of Construction Sequence Install jacking system with permanent hangers 57
Install Bracing Frame Install first tier of brace frame Top View 58
Erect Pre-Cast Wall Install pre-cast walls Connect to soffit panels and first tier brace frame 59
Install Precast Wall Panels 60
Install Precast Wall Panels 61
Install Additional Brace Frames Install 2 nd and 3 rd tier brace frame. 62
Install Additional Brace Frames 63
stall Sheet iles 64
Finished Cofferdam Prior to Lowering 65
Lower Structure Synchronously lower dam from elev. +44ft to -3ft (47ft Total) 66
Field Jacking Arrangement 67
Nut Spinners At Work 68
Jacking Load Frames & Lowering Control Center 69
Lowering Control Console 70
Field Jack Pressure Monitoring / Digital Inclinometer M 71
Lower Cofferdam Structure 72
Lower Structure 73
A View From Inside the Dam 74
A View From Inside the Dam 75
Tracking Progress 76
Pour Concrete Seal Install 8 foot concrete seal 77
Dewater Structure Install pump Remove water 78
Remove Hangers and Cut Casing Remove hangers Cut casing 79
Place Reinforced Pile Cap Place reinforced pile cap concrete 80
Place Pedestal Concrete Place pedestal reinforcing and concrete lift 1 Restrut as required 81
Place Pedestal Concrete Lift 2 Place pedestal concrete lift 2 82
Remove Cofferdam Remove sheeting Remove bracing Patch blockouts 83
Lowered Cofferdam 84
Lowered Cofferdam BEACON 85
Inside Cofferdam 86
87 Inside Cofferdam
Constructing Tower Base 88
Designer Rendering 89
How Did We Do? (Actual Photo) 90