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Aaron L. Stover, PE, SEMichael Baker Jr., Inc.
Milton Madison Bridge Slide
Kentucky Society of Professional EngineersMay 23rd, 2014 – Lexington KY
Project Partners
Milton, KY
Madison, IN
The Challenge
Existing Bridge
80+ year old bridge
Structurally Deficient
Functionally Obsolete
Sufficiency Rating of 6.5
Remaining life <10 years
Constructible Affordable Replacement Bridge
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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
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Markland Dam
Project Site
I-275
I-65
Cincinnati
Louisville
LocationOne of two Ohio River bridges between Cincinnati and Louisville
I-65 Bridge - 46 milesMarkland Dam - 26 milesI-275 Bridge – 65 miles
Project Location Map
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Superstructure Replacement
Milton Approach Re‐construction
STR 1 Replace KY Approaches
STR 2 Truss Replacement
Pier Strengthening And Scour Mitigation
Superstructure Replacement
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Milton, KY
Madison, IN
• STR 3 – Replace IN Approaches
• STR 4 – Pedestrian Access
No Right-of-Way required
1 2 3
4
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Pier Strengthening
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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
SECTION A-A
A A
12’-0”LANE
8’-0”SHOULDER
5’-0” 12’-0”LANE
8’-0”SHOULDER
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Typical Section
Existing Bridge is 20 ft curb to curb
5 ft pedestrian walkway
Selected Alternative
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Existing Bridge
Proposed Bridge
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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
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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 ($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)
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$103.7 M
10 Days
Sept 2012
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Maintenance of Traffic
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Existing Existing Bridge
New Bridge
during 1Tie In Ramps
during 1st Closure
Slide Truss during Closure
Slide Truss during 2nd Closure
Maintenance of Traffic
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Sliding
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Pulling Strands
Bearing Pulling Bracket
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Temporary Towers
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Sliding Girders
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Sliding Girder Pedestal
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Sliding Girder and Pedestal
Slide 19
KY Approach Span D
Slide 20
Rebuild Common Pier
Rebuild Common Pier
N
Span DSpan D
Span D Sliding Girder Support
Slide 21
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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
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Polishing Sliding Plates
Slide 25
Restraint Configuration
Slide 26
H H H H H
H
H
LongitudinalRestraint (TYP)
LongitudinalRestraint (TYP)
TransverseRestraint (TYP)
TransverseRestraint (TYP)
Restraints during Slide
Lateral Restraint was provided by pulling system
Pier 4 Bearings were restrained longitudinally
Unguided Bearing (TYP)
Unguided Bearing (TYP)
Transverse Restraints
Slide 27
TransverseRestraint
TransverseRestraint
Stowed for Transit
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Longitudinal Restraint for Slide
Slide 28
Installed At Pier 4Guided Angles
Installed At Pier 4
Pier 4 Bearing Harness
Disc Bearings
Slide 29
Sole PL
Permanent Slide PL
Bearing PL
Disc Bearing
SS Sliding Surface
Base PL
Erection Slide PL
Sliding Surface
Bearing Pulling Harnesses
Slide 30
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Bearing Pulling Harness
Slide 31
Lead Bearing
Trailing Bearing
Pulling Strands
Clamping Rods
Pulling Rod from Lead Bearing
Push PL
Push PL
Lead Bearing Harness
Slide 32
Push PL
Pulling Rods to Trailing BearingPulling Rods to Trailing Bearing
StrandsRestraint PL
Push PL
Trailing Bearing Harness
Slide 33
Pulling Rods From Lead Bearing
Pulling Rods From Lead Bearing
Upper Sliding Surface
Upper Sliding Surface
Pulls Bearing during the slide
Locks Upper Slide PL wrt. Upper Bearing PL
Permits Lower sliding surface movement
Lower Sliding Surface
Lower Sliding Surface
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Then, a Problem
Slide 34
Dislodged Bearing
Slide 35
10” Drop
Dislodged Bearing
Slide 36
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Upper Lateral Bracing
Slide 37
Slippage at Upper Chord Bracing
Slide 38
Analysis of Drop
Slide 39
Analysis of Drop
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Jacking to Replace Bearing
Slide 40
Additional Lateral Restraint
Slide 41
Additional Longitudinal Restraint
Slide 42
Pier 2 and 6
Stuffers Installed
Prevent bearing from moving during slide
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Harness Vertical Support
Slide 43
Added Pipe Sliders to keep Harnesses AlignedAdded Pipe Sliders to
keep Harnesses Aligned
Span D Slide Process
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Jack Completed Bridge
Remove Permanent Bearings
Attach Strands
Slide Bridge / Jack Bridge
Reinstall Bearings
Elastomeric Bearing Elastomeric Bearing
Pier 2 PedestalPier 2 Pedestal
Jack AssemblyJack Assembly
Sliding GirderSliding Girder
Span D DiaphragmSpan D DiaphragmSliding Bearing Sliding Bearing
Span D Sliding Bearing
Slide 45
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Span D Slide
Slide 46
Sliding Plates
Slide 47
Pier 2 (Below)
Pier 3 / Pier 5 (Rt)
Slide Lubricant
Slide 48
Atypical Use: Bridge Sliding Grease
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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
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VSL Strand Setup
Slide 52
VSL Command Center
Slide 53
Bumper System
Slide 54
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Truss Slide Video
Slide 55
Needs Brakes
Slide 56
Sliding from Girder onto Pier
Slide 57
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Playing “Chicken”
Slide 58
Expansion Joint Installation
Slide 59
Open to Unrestricted Traffic
Slide 60
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By the Numbers – Questions?
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Wt. for Slide 15,260 tons
Slide Distance 55 feet
Length of Truss 2427 feet
Height of Truss180 feet above
water
Wt. of Truss Members
8000 tons
Truss Members 2200 pieces
Bolts 145,000 pieces
Length of Concrete Beam
3462 feet
Wt. of Asphalt 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
