Eggn Eggners Fe Ferry E Emerg rgency Rep epai air J.B .B. Wi - - PowerPoint PPT Presentation

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Eggn Eggners Fe Ferry E Emerg rgency Rep epai air J.B .B. Wi - - PowerPoint PPT Presentation

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Eggn Eggners Fe Ferry E Emerg rgency Rep epai air J.B .B. Wi . Willi liams, P P.E. E. Mike M McGre regor, r, P P.E. and KYTC, D KYT Distr trict 1 1 Mich chae ael B Baker er J Jr., Inc. Approximate Marked Main Chanel

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Eggn Eggners Fe Ferry E Emerg rgency Rep epai air

Mike M McGre regor, r, P P.E. KYT KYTC, D Distr trict 1 1 J.B .B. Wi . Willi liams, P P.E. E. Mich chae ael B Baker er J Jr., Inc. and

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57.5’ 53.9’ 46.6’ 38.4’

Clearance to low steel at mid point of span (normal pool) Approximate Marked Main Chanel

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Kentucky Lake

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The Event

  • Accident: Jan. 26, 2012, around 8:10 PM
  • UT-Chatt. Tennis Team among last to cross
  • Robert Parker, “It got close.”
  • 42 mile detour
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January 26, 2012 8:10PM

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Repair Concepts

Time is Everything!

  • Utilizing Existing Contracts

— Michael Baker — URS

  • Prefab 2 Span Bridge
  • Nickajack Bridge Reuse
  • New Single Span Truss
  • Steel Plate Girder
  • Ferry
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Nickajack Bridge

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Replacement Considerations

  • Time is Critical
  • 70’ Water Depth
  • Existing Adjacent Pier Concerns
  • Permits
  • Navigation
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The Solution

  • Design/Build Procurement
  • Single Span Steel Truss
  • Concrete or Asphalt Deck
  • 20’ Roadway Width (same as existing)
  • HS-20 Live Load
  • New DL No More Than 110% Current DL
  • New Bearings
  • Rehab Existing Pier Caps
  • No Navigation Changes
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  • Procurement thru Div. of Purchases
  • Adv. Date: February 27, 2012
  • Bid Date: March, 5, 2012
  • Open to Traffic: May 27, 2012 (Memorial

Day Weekend)

  • $50,000/Day Penalty

The Solution

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The Result

  • 3 Bids Received

– $7M – $11.2M – $11.4M

  • Contractor: Hall Contracting - $7M

– Designer: Michael Baker – Fabricators:

  • Beam/Angles – Padgett, New Albany, IN
  • Gussets – United Steel, Louisville,KY
  • Contract Executed: 03/07/2012
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Single Span Truss

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Truss Geometry - 320’ Parallel Chord Truss

10 panels@ 32’ = 320’ 32’ tall 32’ tall 23’ -8” wide CL to CL chord 21’ deck

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6 ½” Slab Minimum ½” haunch at gutter line

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The Design

  • Single Span 320’ Truss
  • 295 Tons of Steel
  • 6.5-inch Concrete Deck
  • Integral Floor System
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3D FEM using MIDAS Civil Independent check with VIRTIS

Stringer not in the model Moving Load Analysis

Design of Truss

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  • Truss – Rolled Section

Promising Rolling Schedule Contractor Preference Less Fabrication Involved

—Simplicity and Uniform Pattern Truss Design —W Section —HP Section

FINAL RESULTS- TIME AND COST SAVING!

Design of Truss

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Final Truss Member Sizes

Upper Chord - HP 16x183 Lower Chord- HP 16x121 Portal Frame – HP 16x183 Diagonal – HP 16x88 Top strut and diagonal- W12x40 Lower bracing- L5x5x3/8

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Truss Connection

  • Upper Chord Joint
  • Lower chord joint

Uniform plate thickness, bolt pattern on upper chord and lower chord joint

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Railing Design

Post spacing varies from 3’-11” to 6’ -3 ½”

Challenge: Thin Slab and anchorage detail.

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Existing Pier Retrofit

  • No jacking of the existing span
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Existing Pier Retrofit

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  • Project Awarded March 7, 2012
  • Final Engineering Drawing Completed on

April 17th

  • Quick Shop Drawing Production from

Tensor:

  • Completed for Approval - March 31st
  • Final Review of Shop Drawing – April 10th
  • Total 37 Sheets of Shop Drawing

Engineering and Shop Drawing

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Lessons Learned

  • Simple Geometry
  • Sizes All Rolled Sections

– No Shop Welding – Minimal Fabrication

  • Good Coordination Among Team
  • 3D Model
  • Hi-Tech Fabrication

– 13,000 Bolts, No Misfits

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Timeline

Mar 5th April 10th Mar, 31st Fabrication + Construction Fabrication Feb 24th Mar 9th April 17th May 25th

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Truss Assembly at Eddyville Riverport

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Truss assembly

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Loading Truss and Cranes on Barge

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Loading Truss and Cranes on Barge

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Loading truss and cranes

  • n barge
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Barge Route

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Transport

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Bearing Preparation

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Lifting Truss

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Insert truss lifting video (1 minute, time lapse)

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Lifting Truss

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Truss set down

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Stay in Place Forms and Reinforcing

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Deck Pour

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Curbs and Guide Rail

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The Opening

  • Open to Vehicles Friday May 25, 2012, at

1:00 PM

  • Open During Entire Memorial Day Weekend

with Festivities on Friday — Bridge Walk — Model A Cruise

  • 2.5 Days Before Contract Deadline
  • Incident to Opening: 17 Weeks
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Open to Traffic

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A Success Story

  • Thorough Vetting
  • Quick Decisions
  • Expedited Procurement
  • Rapid Design
  • Aggressive Fabrication Schedule
  • Opening Date Ahead of Schedule
  • A Win for All
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