LAKE CHAMPLAIN BRIDGEERECTION
Presented By: Stephen Percassi, PE
Brief Project History
• August 26, 1929 - Pre-existing bridge opened to traffic($1.1 million)
• October 16, 2009 – Bridge closed due to structural deterioration• October 24-25, 2009 –Public information meeting• December 28, 2009 – Bridge demolished• February 5, 2010 – Bridge replacement design approval• March 17, 2010 – Project advertised• April 15, 2010 – Bid opening • May 27, 2010 – Project awarded to Flatiron ($69.6 million)
– Erdman Anthony retained as Flatiron’s erection engineer
• June 11, 2010 – Groundbreaking ceremony• More project and bridge history:
www.nysdot.gov/lakechamplainbridge/history
• 4 New York approach spans• 3 Vermont approach spans• “Rigid Frame” flank each side of main span• Modified Network Tied Arch main span
• 3180 Tons – Approach steel• 950 Tons – Arch steel• Fabricated by High Steel Structures
New Bridge Structure
• 240’ or 250’ span lengths• Composite plate girder design• Plan bracing in each fascia bay• Construction Wind analysis• Pier girder – drop-in sequence• Angel wing falsework
Approach Span Erection
• Manitowoc 888 Series 2 (land) – 180 ft boom• Manitowoc 2250 S3 (land & barge) – 180 ft boom
Approach Span Erection
• Manitowoc 4100W S1 Ringer S3 (barge) –220 & 180 ft boom
Approach Span Erection
Photo courtesy of Flatiron
Vermont & New York Causeway
Angel Wing Falsework
Photo courtesy of Flatiron
Angel Wing Falsework
Photo courtesy of Flatiron
Angel Wing Falsework
Photo courtesy of Flatiron
Angel Wing Falsework
Span 8 Falsework
Span 1 Falsework
Photo courtesy of Flatiron
Approach Span Erection
Delta Frame Erection• 485 Ton each approach (970 Ton total)• Composite plate girder design• Heavy diagonal bracing in each bay• Construction Wind analysis
Rigid Frame Erection Sequence
Rigid Frame Erection Sequence
Rigid Frame Erection Sequence
Rigid Frame Erection Sequence
Rigid Frame Erection Sequence
Rigid Frame Falsework
Photo courtesy of Flatiron
Rigid Frame Falsework
Photo courtesy of Flatiron
Rigid Frame Falsework
Photo courtesy of Flatiron
Rigid Frame Falsework
Photo courtesy of Flatiron
Rigid Frame Falsework
Photo courtesy of Flatiron
Rigid Frame Falsework
Photo courtesy of Flatiron
Rigid Frame Falsework
Photo courtesy of Flatiron
Rigid Frame Falsework
Photo courtesy of Flatiron
Rigid Frame Falsework
Photo courtesy of Flatiron
Rigid Frame Falsework
Photo courtesy of Flatiron
Rigid Frame Falsework
Photo courtesy of Flatiron
Rigid Frame Falsework
Photo courtesy of Flatiron
Rigid Frame Falsework
Photo courtesy of Flatiron
Rigid Frame Falsework
Photo courtesy of Flatiron
Rigid Frame Falsework
Photo courtesy of Flatiron
Rigid Frame Falsework
Photo courtesy of Flatiron
Rigid Frame Falsework
Photo courtesy of Flatiron
Arch Span Erection• 402 ft span length• Modified network tied arch• Construction Wind analysis• Transfer Beams across slips• Conventional falsework for deck system• Tall tower bents for arch members
Arch Staging Area
Photo courtesy of Flatiron
Arch Span Erection
Arch Span Erection• Liebherr 1400 Series 2 (land) – 184 ft boom
Photo courtesy of Flatiron
Arch Span Erection• Manitowoc 888 Series 2 (land) – 200 ft boom
Arch Falsework
Photo courtesy of Flatiron
Arch Falsework
Photo courtesy of Flatiron
Arch Span Erection
Arch Span Erection
Arch Span Erection
Arch Span Erection
Arch Span Erection
Arch Span Erection
Photo courtesy of Flatiron
Arch Span Erection
Photo courtesy of Flatiron
Arch Span Erection
Photo courtesy of Flatiron
Arch Span Erection
Photo courtesy of Flatiron
Arch Span Erection
Arch Span Erection
Arch Span Erection
Arch Span Erection
Arch Span Erection
Arch Span Erection
Arch / Barge Transfer Beams
Arch / Barge Transfer Beams
Arch / Barge Transfer Beams
Arch / Barge Transfer Beams
Arch / Barge Transfer Beams
• Arch span positioned on barges beneath rigid frames• Actual centerline dimensions field verified• Strand jack positions adjusted to accommodate
temperature• 4 Strand jacks operated from single location
continuously monitoring stroke and force• Provided allowable operating envelope of arch knuckle
elevations
Arch Heavy Lift
Heavy Lift Falsework
Heavy Lift Falsework
Heavy Lift Falsework
CROSSBEAM
ARCHKNUCKLE
STRAND JACK
STRAND JACK
Heavy Lift Falsework
Heavy Lift Falsework
Heavy Lift Falsework
Heavy Lift Falsework
Heavy Lift Falsework
Strand Jack
• Hydrospex Strand Jack provided by Bigge Crane and Rigging Co.
• 365 Ton SWL Capacity
Lifting Jewel
• Hydrospex Lifting “jewel” provided by Bigge Crane and Rigging Co.
• 365 Ton SWL Capacity
Strand Jack
Courtesy of Flatiron
Strand Jack
Courtesy of Flatiron
Strand Jack
Courtesy of Flatiron
Strand Jack
Courtesy of Flatiron
Strand Jack
Courtesy of Flatiron
Arch Lifting Hitch
Arch Lifting Hitch
Arch Lifting Hitch
Photo courtesy of Flatiron
Arch Float Procedure
Arch Float Procedure
Arch Float Procedure
Arch Float Procedure
Arch Float Procedure
Arch Float Procedure
Arch Float Procedure
Arch Float Procedure
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Arch Float / Lift
Time Lapse
Time lapse courtesy of HNTBhttp://www.youtube.com/watch?v=pLY5_Fdtgyg
Acknowledgements
• Flatiron Construction Corporation– Mark Mallett – Project Manager– Paul Rudloff – Project Engineer– Cody Hix – Field Engineer– Chris Daigle – Field Engineer
• Erdman Anthony – Project Staff (Rochester, Buffalo, Albany, Harrisburg, Pittsburgh)– John Gast – Erection Consultant
• Glosten Associates (naval architects)• HNTB Structural Engineering Staff
– Ted Zoli– JoAnna Billings – Gregor Wollmann
• NYSDOT– Main Office Metals & Construction– Region 1 Construction
PDH Quiz
1. What construction wind speed was used to check stability of the structure in its temporary condition?
2. What was the primary function of the angel wings?
3. For the rigid frame falsework system, what was the primary function of the “tension” tower?
4. How many tons did the barge float / arch heavy lift weight?
5. What was each strand jack safe working capacity?
6. How many strands used at each jack location?
65 mph (15 year return period)
Stability of pier girders
Lateral wind resistance
950 ton
365 ton
31
Thank you…. www.nysdot.gov/lakechamplainbridge