Presentation for: 2012 NYSCHSA Summer Conference

August 28, 2012

By: Christopher Sichak, P.E.

• Introduction • Existing Conditions • Environmental Considerations • Project Needs • Development of Alternatives • Project Costs • Selection of Preferred Alternative • Construction Phase • Lessons Learned • Summary • Learning Assessment • Questions

Outline

Introduction

Project Location • NYSDOT Region 4, Orleans County, Town of Ridgeway

• Between Ridge Road (SR 104) and Oak Orchard River Road

• Oak Orchard River upstream of Waterport Pond (Lake Alice)

PROJECT

LOCATION `

Introduction Project Team

Orleans County • NYSDOT Region 4

• Town of Ridgeway

• Federal Highway Administration Ow

ner

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Clark Patterson Lee / Dewberry-Goodkind, Inc. • Ravi Engineering & Land Surveying (survey, mapping, environmental, construction inspection)

• SJB, Empire Geo Services, Inc. (geotechnical, construction material testing)

• BME Associates (wetland delineation)

• R K Hite & Co., Inc. (right of way acquisition)

Engi

nee

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Ramsey Constructors, Inc. • Clark Rigging (crane work) • G & J Contracting (reinforcement installation) • Buffalo Barricade (detour signage) • C & A Pavement Marking (pavement markings) • Villager Construction, Inc. (milling) • Elderlee, Inc. (guide-rail and signs) • Terry Tree (tree removal) • MJ Dreher Trucking (trucking) • Farrell Landscaping (seeding) • Fisher Associates (survey and ROW markers)

Co

nst

ruct

ion

Material Suppliers:

• Contech Construction Products, Inc. • Lakelands Concrete Products, Inc. • Pavilion Drainage Supply Co., Inc. • Suit-Kote • Hanson Aggregates • Vellano Bros., Inc. • Kistner Concrete Products, Inc. • Keystone Builders Supply

Introduction

• Bridge Constructed in 1930

• Steel Jack Arch Structure

• Two 40.7’ Spans (85’ total)

• 24’ curb-to-curb

• 27’ out-to-out

• No skew

• Reinforced Concrete Substructures

Existing Conditions

2006 Biennial Inspection • 31 of the 50 (62%) rated elements had poor values (4 or lower)

• NYSDOT Condition Rating = 4.015, FHWA Sufficiency Rating = 39.9, General Rec. = 4

• Structurally Deficient (Condition < 5, significant maintenance to remain in service)

Existing Conditions

• Spalling of Concrete Parapets • Hole in deck near the pier

Safety Flags • Condition presenting a clear and present danger to vehicular or

pedestrian traffic, but poses no danger of structural failure.

Existing Conditions

Approach Roadway

• 2 – 11’ travel lanes

• Variable width gravel shoulders

Two way AADT:

• 2000: 944

• 2009: 992

Existing Conditions

Geotechnical Investigations

• Shale bedrock below apparent fill soils

Boring Recovery RQD B-1 81% 51% B-2 91% 28%

RQD Rock Mass

Quality <25% very poor

25-50% poor 50-75% fair

75-90% good 90-100% excellent •Bearing capacity of 8 tons/sf

•RQD (Rock Quality Designation)

length of pieces exceeding 4” length of core run

=

x 100%

____________________

Existing Conditions

Utilities Electric (National Grid)

oRelocate aerial facilities and street light along east side of the roadway

Telephone (Verizon)

oRelocate aerial facilities along east side of the roadway

Water (Town of Ridgeway)

oCoordinate geometry with 8” Direct bored watermain along east side of the roadway

Existing Conditions

Hydraulics

• History of debris snagging on pier

• Pier erosion and scour

• Exposed pier footing

Existing Conditions

Hydraulics • 48 mile upstream length

• Initiates in Genesee County

• 192 square miles drainage area

• Upstream flow controlled

PROJECT

LOCATION

` Model

50 Year Flood Elevation (m)

Existing Structure 353.34

Replacement Option 1

353.27

Replacement Option 2

353.37

Environmental Considerations Archeological Sensitive Area

Project Location

2/9/09

SHPO Project Review Application completed detailing previous disturbance

2/24/09 SHPO concurrence with previous disturbance

FHWA concurrence no Phase I Cultural Resources neccesary

3/13/09

Environmental Considerations

Endangered Species = Stream Restriction • Longear Sunfish (Lepomis Megalotis)

• June 15 to September 15

Environmental Screenings and Permitting • USACOE Nationwide Permit #3

• NYSDEC Excavation and Fill in Navigable Waters

• NYSDEC Water Quality Certification

Project Needs Goals

• Meet current standards

• Provide structural service life of 75 years

• Minimize stream disturbance in accordance with permits

• Enhance safety

• Replace existing structure within available funding limits

3. Single Span Concrete Buried Structure

Development of Alternatives

2. Single Span Multigirder Replacement:

a. Steel

b. Spread or Adjacent Prestressed Concrete Box Beam

c. Other Prestressed Concrete Shapes (AASHTO I, New England Bulb Tee)

4. Two-Span Bridge Replacement (Steel or Concrete Superstructure)

Conceptual Alternatives:

1. Rehabilitation

5. Multi-Span Concrete Buried Structure

3. Single Span Concrete Buried Structure

Development of Alternatives

2. Single Span Multigirder Replacement:

a. Steel

b. Spread or Adjacent Prestressed Concrete Box Beam

c. Other Prestressed Concrete Shapes (AASHTO I, New England Bulb Tee)

4. Two-Span Bridge Replacement (Steel or Concrete Superstructure)

Conceptual Alternatives:

1. Rehabilitation

5. Multi-Span Concrete Buried Structure

Dropped due to Hydraulic Characteristics

Development of Alternatives

1. Rehabilitation • Replace the superstructure

• Repair and reuse the existing substructures

• Retained existing features would continue to deteriorate

• Initial construction cost

• Anticipated future maintenance costs

• Continued stream obstruction from pier

3. Single Span Concrete Buried Structure

Development of Alternatives

2. Single Span Multigirder Replacement:

a. Steel

b. Spread or Adjacent Prestressed Concrete Box Beam

c. Other Prestressed Concrete Shapes (AASHTO I, New England Bulb Tee)

Conceptual Alternatives:

1. Rehabilitation

Dropped due to Anticipated Costs

Development of Alternatives

2. Adjacent Prestressed Concrete Box Beam Replacement

Proposed Elevation

100’ (+/-)

• Lower initial construction cost than steel multigirder

• deck forming and thickness

• Tall Concrete Abutments and Wingwalls with spread footings on bedrock (25’ – 30’)

Development of Alternatives

3. Single Span Concrete Buried Structure

• Arch:

o Geometry fits well with site topography

o Structurally sound and efficient shape

o Most economical foundation size

• Lower maintenance costs

o Absence of features requiring maintenance:

Joints

Bearings

Deck

Primary Members

• Lower construction costs

o Limited field construction (precast)

o Limited field specialty work

Development of Alternatives

• Detailed as a precast structure o Twin leaf structure, headwalls, and wingwalls o E78T/0: Contech BEBO (77’ -9” Span x 21’ –10” Rise)

Proposed Elevation

77’-9”

21

’-1

0”

3. Single Span Concrete Buried Structure (Precast Arch)

Development of Alternatives

Design Criteria Standard Value Existing Value Proposed Value Structural Capacity

HL-93 and NYS Design Permit Vehicle (LRFD Replacement Min.) MS-23 (AASHTO Replacement Min.) MS-18 (AASHTO Rehabilitation Min.)

N/A MS-23

EI 05-003 •LRFD Specifications mandated for bridge design by October 1, 2007 •Exception: LRFD implementation for design of buried structures in 2010

EI 07-014

EI 07-030

EI 08 -042

•Release of 2007 (Metric and US) and 2008 (US) LRFD Specifications

•Release of 2010 US Customary LRFD Specifications •Implementation for buried structures if the project’s preliminary engineering design phase begins after October 1, 2010

EI 10-013

Maintenance and Protection of Traffic

• Traffic maintained via offsite detour

• NYSDOT Highway Work Permit (PERM 33)

Development of Alternatives

Right of Way

• 66’ ROW width

• Single property owner (Erie Boulevard Hydropower) adjacent to structure

• Temporary easements taken at the four corners of the bridge

o Constructing wingwalls

o Placing stone filling

• Donation streamlined the ROW process and minimized project costs

Project Costs

Work Item Precast Concrete Arch

Replacement Single-Span Multigirder

Replacement

Right-of-Way $ 14,000 $ 14,000

Structure Removal $ 225,000 $ 170,000

Bridge Construction $ 755,800 $ 1,074,400

Highway $ 211,000 $ 176,500

M&PT $ 21,300 $ 21,300

Mobilization (4%) $ 40,100 $ 51,200

Contingency (10%) $ 126,800 $ 150,800

Total $ 1,394,000 $ 1,658,500

Preliminary Engineer’s Estimates

Selection of Preferred Alternative

Preferred Alternative: Precast Concrete Arch Replacement

• Lowest Initial Construction Cost

• Precast Components

o Quality Control During Fabrication

o Expedited Installation

o Minimal Environmental Impacts

• Lowest Maintenance Costs

• Aesthetics - recreational area during summer months

oForm liner considered but dropped due to:

Cost (not federally reimbursable)

Rural Location

Selection of Preferred Alternative

Bid, Letting, and Award

• Advertised on April 14, 2010

o Delayed due to federal fund availability

o 75 calendar days from anticipated NTP to completion date

32 calendar days prior to stream restriction

51 calendar days post stream restriction

• Bid opening on May 5, 2010

o Low Bidder: Ramsey Constructor's, Inc. (4 bidders)

o 92% Engineers Estimate

Preferred Alternative: Precast Concrete Arch Replacement

Construction Phase

Notice to Proceed

May 13, 2010

Existing Bridge Demolition June 3 through June 15, 2010

Construction Phase

Precast Arch Concrete Footing Placement

Completed July 30, 2010

Construction Phase

Precast Concrete Shop Drawings

Submitted July 2, 2010

Approvals: Foundation Layout: July 12, 2010 Arch Units: July 27, 2010 Wingwalls/Headwalls: August 11, 2010

Construction Phase

Arch Placement

September 22, 2010

Construction Phase Arch

Erection 9/22/10

Construction Phase Arch

Erection 9/22/10

Construction Phase Arch

Erection 9/22/10

Construction Phase Arch

Erection 9/22/10

Construction Phase

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Arch Erection 9/22/10

Construction Phase Crown Closure

Pour 9/27/10

Construction Phase

Headwall and Wingwall Placement

October 7 and 8, 2010

Construction Phase

Headwall and Wingwall Bracing

Construction Phase Headwall

and Wingwall Bracing

Construction Phase

Headwall and Wingwall

Installation

“Everyone is OK”

Construction Phase

Headwall and Wingwall Installation

Construction Phase Rock

Outcrop Removal 10/9/10

to 10/13/10

Construction Phase

Backfill and Geotextile Installation

Bodkin Bar Connection

Construction Phase Backfill and Geotextile Installation Commences

10/13/10

Construction Phase Precast

Headwall Installation Complete 10/19/10

Construction Phase Nearing Backfill Completion

October 23, 2010

Construction Phase

New Bridge opened on November 5, 2010

• 60 working days utilized to complete project

Construction Phase

• Average of 9.5 hours per working day

• Appropriate Geotechnical Explorations • Pay attention to surrounding existing features

Lessons Learned

• Permitting / Stream Restrictions • May impact the preferred alternative

• Constructability • Utilize input from others to understand the process

Summary

Learning Assessment

Q: What NYSDOT bridge rating typically constitutes a “poor” rating?: a) 5: Minor deterioration, but functioning as originally designed. b) 4: Between a 5 and a 3 rating. c) 3: Serious deterioration, or not functioning as originally designed. d) 2: Between a 3 and a 1 rating. e) 1: Totally deteriorated, or in failed condition.

A: b) 4

Learning Assessment

Q: Which statement(s) is/are true of a structurally deficient bridge: The bridge a) doesn't meet current standards for managing traffic volumes. b) has a condition rating < 5. c) has narrow lanes, no shoulders, or low clearances. d) requires significant maintenance to remain in service. e) is unsafe or likely to collapse.

A: b) has a condition rating < 5

and

d) requires significant maintenance to remain in service

Learning Assessment

Q: Which statement is true of a Safety Flag: a) Reports a condition presenting a clear and present danger to vehicular or

pedestrian traffic, but poses no danger of structural failure.

b) Reports a potentially hazardous structural condition, which if left unattended could become a clear and present danger before the next scheduled inspection.

c) Reports the failure or potential failure of a primary structural component that is likely to occur before the next schedule biennial inspection.

A: a) Reports a condition presenting a clear and present danger to vehicular or pedestrian traffic, but poses no danger of structural failure.

Q: In geotechnical exploration, what does RQD stand for?

A: Rock Quality Designation

Learning Assessment

Q: (True/False) Meeting the freeboard recommendation is the primary concern on all bridge replacement projects over water.

A: False, while true for most projects, other considerations such as recurring scour or stream obstacles (pier) need to be taken into consideration.

Learning Assessment

Q: (True/False) Structural design criteria currently requires the use of AASHTO Standard Specifications (Allowable Stress Design) for Buried Structures.

A: False, LRFD specifications are required if the project’s preliminary engineering design phase began after October 1, 2010.

Learning Assessment

Q: Identify four conventional bridge elements not contained as part of precast concrete buried structures which account for lower maintenance costs.

A: 1. Joints

2. Bearings

3. Deck

4. Conventional Primary Members

Learning Assessment

Q: What benefits can be realized during the construction of a precast concrete buried structure resulting in minimized construction costs and an enhanced finished product?

A: 1. Increased quality control during fabrication.

2. Expedited installation (lack of forming, pouring, cure times)

3. Minimization of environmental impacts.

Learning Assessment

Q: What is the name Contech gives to the mechanism which connects the geotextile “tabs” cast into the back face of the MSE style walls and the Tesar geotextile within the backfill zone?

A: Bodkin Bar

Learning Assessment

Q: (True/False) It is possible to construct a bridge over a stream with a restriction during the prime construction season.

A: True.

Learning Assessment

Questions