Albany Turnpike over CSXT Railroad Superstructure Replacement Project

East Chatham, New York

Intersection

Adjacent property

Intersection

Alban

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rnpi

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Pohdorf Drive

NY

R295 Utilities

NORTH

Existing Conditions Existing Bridge: Albany Turnpike over CSXT Constructed in 1906 Town of East Chatham, New York Berlin Construction Co., Berlin, CT Double Warren Through Truss Approx. 115’ Span x 18 ‘ Roadway Width x 17’

Deep Single Lane Roadway Vertical Clearance = 21’- 7” Timber Deck / Asphalt Wearing Surface

ASCE/APWA Summer Meeting 2014

Given Information CSXT Owner (Major Maintenance) Low Volume, Minor Collector (Rural) Original Design Load H10 (10T = 20,000 lbs.

GVW) NYSDOT Inspection (Critical Event) Rated for 20T prior to inspection Load Posted to 4T in 2012 Structurally Deficient, Sufficiency Rating 43.3 Numerous Deterioration “Red Flags” Emergency Contract:

Bergmann Associates, Albany Office

First thoughts on the Project

Repair

Rehabilitate

Replace

• Original 20 Ton rating not possible in only repairing minor item(s).

• Repair current inspection “red flags” and also ones predicted for next inspection cycle (“yellow flags”).

• Restore Previous Load Posting (20 Ton) or Greater

• Most expensive option and one that the Owner had not budgeted.

Rehabilitation Scope Remove Asphalt Overlay, Timber Curb, and

Timber Deck Complete Steel Repairs to Trusses,

Floorbeams, and Bottom Lateral Bracing Remove and Replace Timber Stringers (as

needed) Install New Timber Deck & Curb, Pave Asphalt

Wear Crs. Re-open to Traffic Restrictions: No Construction Loads except Personnel; No

Temporary Reduction in Vertical Clearance; Temporary Shoring of Diagonals and Floorbeams required during Gusset Plate Repair/Replacement ; One Gusset Plate Repair at a Time

“Sleeved” Bridge Support & Platform

WAY-CR47 (Indian Mill Bridge) Rehabilitationover the Sandusky RiverWyandot County, OhioConstruction: U.S. Bridge/

Moving Toward Bid A couple problems came to light about this

plan …

… IT WASN’T A LONG TERM SOLUTION SO NO ONE WAS REALLY HAPPY WITH

THE SITUATION.

… IT WAS COSTING MORE THAN EXPECTED.

Novel Idea

Repair

Rehabilitate

Replace

SuperstructureReplacement Bid Item

?

Bid Results Bidding (Rehabilitation Plans)

4 Contractors Invited to Submit Bid Mandatory Pre-Bid Site Visit Base Bid: Bridge Rehabilitation Alternate Bid: Superstructure Replacement (late

addition) Bid Results

Two Bids: $300k; $677k Only the Low Bidder Submitted an Alternate Bid:

$550k

One last ‘i’ and one last ‘t’ What was it going to cost to

recondition the existing abutments? If a ‘GO’, would the Town of East

Chatham be willing to own the bridge?

So Bergmann prepared schematic TS&L type plans (30%).

They were.

Loads Reactions % of CDS

Concrete Deck Slab & SIP = 120 psfConcrete Deck Slab (Strip or Foam) =

106 psfAsphalt Filled Steel Floor = 89 psf

Exodermic Deck = 75 psfTimber Panels = 62 psf

DL= 216 kDL= 191 kDL= 142 kDL= 135 kDL= 112 k

100%93%80%78%72%

Floor Framing Self Wt. = 22 psf Truss Self Wt. = 306 plf

FWS = 25 psf

DL= 40 kDL= 70 kDL= 45 k

Final Total (Exodermic) DL= 72.6k

Loads Reactions % of CDS&SIP

Concrete Deck Slab & SIP = 120 psfConcrete Deck Slab (Strip or Foam) =

106 psfAsphalt Filled Steel Floor = 89 psf

Exodermic Deck = 75 psfTimber Panels = 62 psf

DL= 54.1 kDL= 47.8 kDL= 35.6 kDL= 33.8 kDL= 27.9 k

100%93%80%78%72%

Floor Framing Self Weight = 22 psf Truss Self Weight = 306 plf

FWS = 25 psf

DL= 9.9 kDL= 17.6 kDL= 11.3 k

Final Total (Exodermic) DL= 72.6 k

Dead Load Study

Acceptable - So we have a green light to go forward …

New Scope of Work HL93 Live Load & NYSDOT Permit Vehicle Railing Service Level TL-2 One Lane, 14’-0” Clear Match or Improve Existing Sight Distance Outboard Sidewalk for Pedestrians Improve Existing Vertical Clearance Design Reconstructed Abutment Caps Concrete Approach Slabs

Proposed Section Single Lane Outboard Sidewalk Curbed Roadway Vandal Protective

Fencing

Proposed Site Plan Guardrail upgrades or extensions (red) Gabion retaining walls (maroon) Pavement transitions (green)

Proposed Profile Maintain SSD Improve rail

vertical clearance to 21’-9”

Recondition existing abutments

Schedule

PO issued USB

8/6/13Initial

Submittal

9/2513 Release for Fab

10/3/13

Shipped to Site

11/12/13

Begin Shipments to Site

11/18/13

Steel Erected

11/26/13

Concrete Slab Pour

01/14/14

Opened to Traffic

01/31/14

50 days 8 days 46 days

8 days 49 days 17 days

Total = 178 days

Steel Bridge Design Early Coordination of Final Loads & Reactions Different skews caused different truss spans Left =112’-5 ¾”; Right Truss = 114’-11 ¾” AASHTO DL & LL Loads, Wind Loads Strength, Service, Fatigue & Extreme Event Load

Comb. Top Chord/U-Frame Stability Check Gusset Plate Check (per 2009 FHWA Guidance

Report)

Steel Bridge Design Extreme Profile Change/Unusual Framing Exodermic Deck Layout, Slab Reinforcing &

Coordination Bearing Pad Design: Fixed & Sliding CDB

(Cotton Duck) Armored Expansion Joint: Wabo WA300

Compression Seal Vandal Protection Fencing Coordination NYSDOT Level 1 Load Rating (LRFR)

Exodermic® Deck DetailsCourtesy of the Bridge Grid Flooring Manufacturers Association (BGFMA) www.bgfma.org

For this project:

• WT4x5 Bearing Bars at 12” o.c.

• 1 ½” x 1/4” Distribution Bars at 6” o.c.

• 20 Ga. Haunch & Flat Pans

• Longitudinal: #3 bars at 6” o.c.

• Transverse: #5 bars at 8” o.c.

Steel Bridge Design

Looking South at the Forward Abutment

Steel Bridge Design

Looking South at the Forward Abutment

Steel Statistics Truss Girder Weight = 34,810 lbs. Heaviest Segment = 12,070 lbs. Floor Framing Weight = 40,443 lbs. Unique Floor Beams = 7; Unique Stringers =

18 Heaviest Section (Truss): W14x82 Heaviest Section (Framing): W18x50 Total Weight Steel & Hardware = 136,754 lbs. Total Fasteners: 5,462 Bolts Most Common Size: 7/8” dia. x 2 ½” (2,012

Bolts) Shipped in 4 Truck Loads

Superstructure Replacement Cost Mobilization $50.0k WZTC $5.0k Remove Existing Bridge $80.0k Furnish New Truss $450.0k Install New Truss $130.0k Earthwork $100.0k Concrete Work $210.0k Approach Work $175.0k Total $1,200.0k ($1.2M)

Project Participants Owner: CSXT Railroad, Jacksonville, FL

Ross White, Territory Manager Contractor: CP Ward, Inc. of Scottsville, NY

Steve Phillips, Vice President Design Consultant: Bergmann Associates,

Albany, NY Michael Cooper, P.E., Project Manager

Superstructure Design: Contech & U.S. Bridge Dave Morgan, P.E., Project Engineer

Exodermic Deck Design: LB Foster, Pittsburgh, PA Ed Coholich, Project Manager

Town of Chatham Mr. Jesse DeGroodt, Town Supervisor

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Model to Reality

Looking West at the Left Truss Girder

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What made this project work? Collaborative Partnership Innovative Thinking

Non-binding alternate bid proposal Exodermic Deck Steel framing (both at the south abutment and

sidewalk). Deck installation and pour sequence

- Leaving us with a unique project that was successful for the Town and the Owner -

Questions?

Thank you