PRESERVING LOUISIANA S INFRASTRUCTURE: US190 MISSISSIPPI RIVER BRIDGE

Overview 1. Project Objectives 2. Bridge Data 3. Timeline 4. Existing Condition 5. Sequence of Coating and Repair Operations 6. Major Repair Items 7. Environmental Monitoring 8. Special Challenges 9. Rehabilitated Condition 10. Closing / Questions

Huey P Long US-190 Mississippi River Bridge The Huey P. Long Bridge is a continuous steel cantilever truss bridge over the Mississippi River carrying US 190 (Airline Highway) and one rail line between East Baton Rouge Parish, Louisiana and West Baton Rouge Parish, Louisiana View of the bridge from the Capital Building Observatory looking South

Project Objectives 1. To clean and paint the steel bridge substructure and superstructure components 2. To evaluate and repair or replace deteriorated steel truss span and deck girder span members, as well as steel and concrete substructure components 3. To repair or replace deteriorated or damaged roadway components within the bridge right-of-way 4. To preserve the bridge for continued usage in the 21st century with minimal disruption to roadway, rail, and river traffic

Bridge / Project Data 1. Bridge Type: Continuous Steel Cantilever Truss 2. Location: Mississippi River Milepost 233.9 3. Year Completed: 1940, widened in 1985 4. Clearance: 111 feet AMSL 5. Traffic: ADT is 28,388; Rail carries 5-6 trains per day

Project Data 1. Total length of project: 5897 1 ½ from East highway abutment to West highway abutment 2. Estimated Square Feet for Cleaning and Painting: 3,675,420 from East highway abutment to West highway abutment 3. Total Original Project Cost: $74,849,999.48 4. Current Project Cost: $78,371,700.50 5. Current Project Completion: 98% 6. Current Overrun: 4.71%

Timeline

Timeline Project start: Notice to Proceed June 28, 2012. 90-Day Assembly Period. Construction began September 24, 2012. Project completion date projected for April 2016. Working Days: 858 (began as 520 before construction) Calendar days: 3 years and 8 months to date

Existing Condition Bridge was last painted in the 1980 s. Existing coating was lead containing. Extensive pack rust, crevice, and pitting corrosion, resulting in areas of significantly reduced metalwork section to member components and fasteners. General coating breakdown and surface corrosion. Significant dirt and debris accumulations within some members. Poor roadway joint conditions. Concrete was in relatively good condition in most locations.

Existing Condition

Sequence of Coating and Repair Operations 1. Containment (Class 1A) 2. Pressure washing (5,000 psi) 3. Chloride, Sulphate and Nitrate (CSN) testing for Surface Contaminants 4. Blast Cleaning to SSPC SP-10 and Hand & Power Tool Removal of Areas of Pack Rust 5. Prime Coat Application (Organic Zinc Rich) 6. Prime Coat Touch-up 7. Post-Blast Structural Inspections 8. Structural Repairs 9. Post-Structural Repairs Sequence of Painting

Project Clean & Paint Cost Breakdown Cleaning and Painting of approximately 3.6 million square feet. Lump Sum Bid Price for Painting of approximately 50 million dollars. Approximately $13.45 per square foot for painting.

Project Clean & Paint Cost Breakdown

Containments - Approaches

Girder Containments Approaches Platform Cables, Metal Decking over Roadways

Girder Containments Approaches Platform Cables, Fencing and Tarps

Tower Containments Approaches Temporary Traffic Barriers Anchored Cables for Tarps

Containment

Containment Entryway

Inside the Tower Containment

Containments - Main Bridge

Pressure Washing

Chloride, Sulphate and Nitrate (CSN) Testing

Abrasive testing Oil testing Conductivity testing

Blast Cleaning

Prime Coat Application

Post-Blast Structural Inspections Used to determine if additional repairs were required due to section losses after corrosion removal Also used to determine required deteriorated rivet replacement that was necessary (per rivet) Each was conducted jointly with the Contractor after prime coat application Quantities of items were recorded and agreed upon daily, then compared to bid items Final document was produced for record, altered quantities were captured in periodic change orders

Post-Blast Structural Inspections

Structural Repairs Clean and prime coat existing metalwork and faying surfaces to receive repairs Install or conduct repairs i.e. gusset plate clips, replace rivets, full or partial member replacement, etc. Install mechanically galvanized fasteners at repairs.

Major Repair Items

Approach Bent Anchor Bolt Replacement Boh Bros conducted concrete pedestal expansion work and anchor bolt installation, American Bridge conducted steel bracket installation and connection to the bent columns. Required 1908 CY of excavation, 585 CY of concrete, 288 anchor bolts, and 144 brackets.

Approach Bent Anchor Bolt Replacement

Rivet Removal and HS Bolt Replacement 106,000 projected, 47,346 conducted Replacement criteria was agreed upon prior to work beginning (MM created, all parties consented) American Bridge conducted this work. Required reconsideration once approach work was complete (differing conditions on main truss) Tracked and agreed upon daily between AB and MM Savings was used to pay for fabrication and installation of bottom chord perforation covers to mitigate future section loss

Rivet Removal and HS Bolt Replacement

RR Stringer Stirrup Bearing Repairs 40 projected, 40 conducted American Bridge conducted this work Required evaluation after railroad closure, stringer jacking, and dismantling to determine if all repair types would be conducted Faying surfaces had to be prepped and coated during closure 14-hour rail closure agreed upon in advance, none went over 13 Final closure only lasted 7 hours

RR Stringer Stirrup Bearing Repairs

Power tool cleaning of faying surfaces and prime coating

RR Stringer Stirrup Bearing Repairs

RR Tower Bent Member Replacement 201 projected, 237 conducted American Bridge conducted this work Most required temporary bracing and had to be completed during the RR closure (members not allowed to be removed during rail traffic)

RR Tower Bent Member Replacement

Post Structural Repairs Clean primed steel of dust, dirt and debris from repair activities Solvent clean to remove any oil, grease or grime deposits and solvent and hand tool clean mechanically galvanized fasteners to roughen the surface Prime coat touch-up areas of damaged primer and galvanizing of the installed fasteners.

Post Structural Repairs Sequence of Painting Clean and apply penetrating sealer to any areas of irremovable crevice corrosion Apply red tinted prime stripe coat Apply grey tinted epoxy intermediate stripe coat Apply white epoxy intermediate coat and touch-up Apply caulking to all gaps between plates ½ or less Apply Louisiana Grey polyurethane topcoat and touch-up

Penetrating Sealer Application

Cleaning of Galvanized Fasteners

Prime Stripe Coat Application

Intermediate Stripe Coat

Intermediate Coat Application

Topcoat Application Main Bridge

Topcoat Application - Approaches

Touch-up of Containment Contact Points

Environmental Monitoring

KGC Environmental Services Inc. Scope of Services Perform TSP-Lead high volume air monitoring during lead emission generating activities. Conduct visible emission and visible accumulation assessments in order to measure the containment system efficacy. Mitigate environmental risk by identifying potential issues before they occur. Ensure compliance with all laws, regulations and contract specifications pertaining to hazardous waste management, ambient air quality and protection of the environment. Conduct pre-job and post-job soil sampling. Provide detailed and legally defensible environmental data.

TSP-Lead Ambient Air Monitoring

KGC Summary of Environmental Data Suspected Cause of (TSP-Lead)Air Quality Project Limit Exceedance Structural Repairs, Rivet Busting, Plate Clipping & Grinding Number of Exceedances 40 Blowing Down Without Full Containment & Ventilation Abrasive Blasting, Vacuuming & Recycling 14 Containment Dismantling 4 Site Clean-Up & Moving Equipment 2 17

Hazardous Waste Management

Hazardous Waste Management Number of Hazardous Waste Shipments 25 Number of 55 Gallon Waste Drums Used 1,085 Pounds of Hazardous Waste Recycled/Disposed 837,135 pounds

Challenges & Lessons Learned Sensitive Receptor Areas- multiple businesses and residences were extremely close to the bridge. In order to mitigate the risk associated with abrasive blasting a coating system that contained lead and chromium next to sensitive receptors, the contractor instituted special containment and housekeeping procedures. KGC performed 24 hour high volume sampling to confirm that the sensitive receptors were not being negatively impacted as a result of the contractor s activities. Structural Repairs including rivet busting, plate clipping and grinding disturbed lead coated faying surfaces. The majority of the TSP-lead air samples that were over the project limit were a result of the aforementioned activities. Engineering controls and high volume air monitoring should be considered when LADOTD performs repairs and maintenance on other projects where the existing coating system contains heavy metals. Housekeeping is Paramount - thorough vacuuming of lead dust and abrasives from steel members and containment tarps prior to containment dismantling is essential to keeping a safe work environment. As the blasting and painting crews progressed down the bridge, iron workers moved in to perform the necessary structural repairs. At times they worked in less than ideal work conditions.

Challenges & Lessons Learned Equipment Storage Yards Require the contractor to store all blasting and painting equipment and materials used on the project on state property. Otherwise, heavy metals that are invariably present on these items could be released onto public property opening the LADOTD to potential litigation and remedial efforts.

Special Challenges Water Ponding in Past Pitting Corrosion Lower Chord Horizontal Diaphragms

Special Challenges Slurry Blasting Tower Column Base Repairs

Special Challenges Slurry Blasting Outboard Roadway Railings

Containments- Bridge Rail

Special Challenges Slurry Blasting and Painting Outboard Roadway Railings

Special Challenges RR Coordination

Special Challenges Steel Repair and Inspection Access

Special Challenges - Snooper used for Final Touch-up of Platform Contact Points

Rehabilitated Condition

Closing / Questions