6/19/2014. Milton Madison Bridge Slide. Project Partners. The Challenge. Aaron L. Stover, PE, SE Michael Baker Jr., Inc.

Transcription

1 Kentucky Society of Professional Engineers May 23 rd, 2014 Lexington KY Milton Madison Bridge Slide Aaron L. Stover, PE, SE Michael Baker Jr., Inc. Project Partners The Challenge Milton, KY Existing Bridge 80+ year old bridge Structurally Deficient Functionally Obsolete Sufficiency Rating of 6.5 Remaining life <10 years Constructible Affordable Replacement Bridge Madison, IN 1

2 Presentation Outline Project Overview Maintenance of Traffic Temporary Piers Truss Restraints Bearings and Slide Harnesses Dislodged Bearing Span D Slide Truss Slide Open to Traffic 4 Project Location Map I-275 Cincinnati Project Site I-65 Louisville Markland Dam Location One of two Ohio River bridges between Cincinnati and Louisville I-65 Bridge - 46 miles Markland Dam - 26 miles I-275 Bridge 65 miles 5 Superstructure Replacement Milton, KY Madison, IN 3 Milton Approach Re construction STR 1 Replace KY Approaches STR 2 Truss Replacement Pier Strengthening And Scour Mitigation Superstructure Replacement STR 3 ReplaceIN Approaches STR 4 Pedestrian Access No Right-of-Way required 6 2

3 Pier Strengthening 1. Drill holes into ex. caisson 2. Grout Rebar into Caisson 3. Add Stem Reinforcement 4. 2 thick encapsulation 5. Pier Cap Reinforcement 6. Cast new Pier cap 7. Scour Countermeasure A A SECTION A-A 7 Typical Section Existing Bridge is 20 ft curb to curb 5 ft pedestrian walkway SHOULDER LANE LANE 8-0 SHOULDER 8 Selected Alternative Existing Bridge Proposed Bridge 9 3

4 12 Month Closure Design Build Letting Summary September 22, 2010 Five Contractors submitted bids Formula for Effective Bid Price lowest effective bid wins [A + B Adjustment] A = construction cost B = closure days x $25,000/day. Adjustment = $3.75 million for early opening 11 Design Build Letting Summary $103.7 M 10 Days Sept 2012 September 22, 2010 Five Contractors submitted bids Formula for Effective Bid Price lowest effective bid wins [A + B Adjustment] A = construction cost ($102 $127 million) B = closure days x $25,000/day. (365 days max) Adjustment = $3.75 million for early opening (Sept 2012 or May 2013) 12 4

5 Maintenance of Traffic Slide Truss during 2 nd Closure New Bridge Existing Bridge Tie In Ramps during 1 st Closure 13 Maintenance of Traffic 14 Sliding Pulling Strands Bearing Pulling Bracket 15 5

6 Temporary Towers 16 Sliding Girders 17 Sliding Girder Pedestal 18 6

7 Sliding Girder and Pedestal Slide 19 KY Approach Span D Rebuild Common Pier N Span D Slide 20 Span D Sliding Girder Support Slide 21 7

8 Preparing Pier Caps Slide 22 Pier 2 Sliding Plates for Both Slides Span D SS Slide PL GR 36 PL Stainless Steel Sliding Surface Slide 24 8

9 Polishing Sliding Plates Slide 25 Restraint Configuration Transverse Restraint (TYP) Longitudinal Restraint (TYP) H H H H H H H Restraints during Slide Unguided Bearing (TYP) Lateral Restraint was provided by pulling system Pier 4 Bearings were restrained longitudinally Slide 26 Transverse Restraints Transverse Restraint Stowed for Transit Slide 27 9

10 Longitudinal Restraint for Slide Pier 4 Bearing Harness Guided Angles Installed At Pier 4 Slide 28 Disc Bearings Sole PL Permanent Slide PL Bearing PL Disc Bearing SS Sliding Surface Base PL Erection Slide PL Sliding Surface Slide 29 Bearing Pulling Harnesses Slide 30 10

11 Bearing Pulling Harness Push PL Clamping Rods Push PL Lead Bearing Pulling Strands Trailing Bearing Pulling Rod from Lead Bearing Slide 31 Lead Bearing Harness Push PL Push PL Pulling Rods to Trailing Bearing Strands Restraint PL Slide 32 Trailing Bearing Harness Pulls Bearing during the slide Locks Upper Slide PL wrt. Upper Bearing PL Permits Lower sliding surface movement Upper Sliding Surface Lower Sliding Surface Pulling Rods From Lead Bearing Slide 33 11

12 Then, a Problem Slide 34 Dislodged Bearing 10 Drop Slide 35 Dislodged Bearing Slide 36 12

13 Upper Lateral Bracing Slide 37 Slippage at Upper Chord Bracing Slide 38 Analysis of of Drop Slide 39 13

14 Jacking to Replace Bearing Slide 40 Additional Lateral Restraint Slide 41 Additional Longitudinal Restraint Pier 2 and 6 Stuffers Installed Prevent bearing from moving during slide Slide 42 14

15 Harness Vertical Support Added Pipe Sliders to keep Harnesses Aligned Slide 43 Span D Slide Process Jack Completed Bridge Remove Permanent Bearings Attach Strands Slide Bridge / Jack Bridge Reinstall Bearings Sliding Bearing Span D Diaphragm Jack Assembly Pier 2 Pedestal Elastomeric Bearing Sliding Girder 44 Span D Sliding Bearing Slide 45 15

16 Span D Slide Slide 46 Sliding Plates Pier 2 (Below) Pier 3 / Pier 5 (Rt) Slide 47 Slide Lubricant Atypical Use: Bridge Sliding Grease Slide 48 16

17 VSL Strand Jacks Slide 49 VSL Heavy Lifting Equipment Slide 50 Strand Jacking Design Load (10% Friction) Reserve Capacity Observed Friction was much less Slide 51 17

18 VSL Strand Setup Slide 52 VSL Command Center Slide 53 Bumper System Slide 54 18

19 Truss Slide Video Slide 55 Needs Brakes Slide 56 Sliding from Girder onto Pier Slide 57 19

20 Playing Chicken Slide 58 Expansion Joint Installation Slide 59 Open to Unrestricted Traffic Slide 60 20

21 By the Numbers Questions? Wt. for Slide Slide Distance Length of Truss Height of Truss Wt. of Truss Members Truss Members Bolts Length of Concrete Beam Wt. of Asphalt 15,260 tons 55 feet 2427 feet 180 feet above water 8000 tons 2200 pieces 145,000 pieces 3462 feet 4000 tons Wt. of Stone 46,000 tons Concrete Poured 12,730 cu yds Wt. of Rebar 1,907,000 lbs Workers (Peak) 135 Workers (Average) 50 Equipment 300 pieces Explosives 124 charges ADT 11,000 Project Cost $ 104 Million 61 21