The New Champ Clark Bridge US 54 over the Mississippi River at - - PowerPoint PPT Presentation

The New Champ Clark Bridge

US 54 over the Mississippi River at Louisiana, Missouri

2019 Midwest Geotechnical Conference

Don Hammond, PE HNTB Corporation

Louisiana (Missouri)

• 1 of 4 vehicular

bridges connecting Missouri and Illinois north of St. Louis

(Alton, Hannibal & Quincy)

• One way detour of 77

miles via Hannibal

Aerial Looking West

Key Topics

• History of Original Bridge & Geologic Profile
• Design/Build
• Foundations – with focus on large OE pipe pile
• East Approach Embankment on Soft Ground

Original Champ Clark Bridge

Original Champ Clark Bridge: Timeline

• February 1926 – Chamber of Commerce

initiated formal planning. Within 3 days, legislation was moving through Congress.

• March 1926 – Harrington, Howard & Ash

staff were on site.

• October 1926 – Substructure work begun
• May 1928 – Bridge completed and open

Original Champ Clark Bridge: Bid

Geologic Profile

Original Champ Clark Bridge: Foundations

30 ton timber piles driven no less than 35 feet below bottom of pier.

Original Champ Clark Bridge: Struggles

• 20 foot clearance

for 2 lanes

• Required closure

for wide loads

• Frequent closures

for emergency maintenance

Original Champ Clark Bridge: Recent Issues

Original Champ Clark Bridge: Recent Issues

• Frequent closures for

flooding of Illinois approach

Another Issue

• Design/Build became legal in Missouri in 2005
• Chose Design/Build to expose IDOT to method
• Missouri is the lead state with Illinois as a partner

Design/Build in Missouri

• Construct project on budget ($62.5M)
• Safe, reliable, low maintenance structure that provides at

least 100 years of service life

• 405 foot navigation clearance
• Minimize and mitigate construction impacts
• Deliver project using a diverse workforce

Project Goals

• Two 12-foot lanes with 10-foot shoulders
• Improve traffic flow at US 54 / Rte 79 intersection
• Engage community

Additional Unspecified Objectives

• Permits: 404, 408, Coast Guard, etc.
• Right of Way (Army Corps and Sny Levee)
• Some hydraulic modeling
• PreAward Geotech

Risk Mitigation Ahead of Award

Pre-Award Geotechnical Investigation

• 10 River Borings
• 13 Land Borings
• 2 CPTs

Geologic Profile

4/17/17 Supplemental Pre-Award Geo Report Issued

Contract Awarded to Massman/HNTB in June 2017

5 Spans on four 12-foot Deep Steel Plate Girders 3 Spans on Prestressed Concrete Girders (NU)

Contract Awarded to Massman/HNTB in June 2017

July

• Completed 8 Water Borings (1 at each shaft)

Aug.

• Completed 20 Land Borings

Sept.

• Issued Memo for River Pier Foundations

Oct.

• Issued Memo for Approach Piers and Abutments

Nov.

• Began Inspection of Drilled Shaft Construction

Jan.

• Issued Memo for Block Wall and Embankment

Post-Award Geotechnical Investigation

• 8 River Pier Borings
• 3 Approach Pier Borings
• 2 Abutment Borings
• 6 Wall Borings
• 9 Embankment Borings

Total = 28

New Champ Clark Bridge: Spans and Foundations

Spread Footing on Rock 11.5’ Dia. Drilled Shafts with 11.0’ Dia. Rock Sockets H-Piles to Rock 48” Open Ended Pipe Piles to Rock

New Champ Clark Bridge: Spans and Foundations

West Abutment & Retaining Wall

West Abutment & Retaining Wall

West Abutment & Retaining Wall Factored Bearing Pressure = 13 ksf Factored Bearing Resistance = 32 ksf Cut was Line Drilled

River Piers

11.5 ft Shafts with 11.0 ft Sockets:

• 5/8” Wall Permanent Casing
• 20 to 60 ft Long Shafts
• 22 ft Long Sockets
• 8 CSL Tubes
• 60 #18 bars
• Factored Axial Load = 8100 kips / Shaft

River Piers

Confidentially, pre- award samples of Maquoketa Shale were tested for Slake Durability (ASTM D4644) Results confirmed that of Maquoketa Shale was actually shaley, silty dolomite along rock sockets, that would not rapidly degrade during construction.

River Piers

Determination that slurry was not needed resulted in significant cost savings and shortened construction schedule by 2 weeks.

River Piers: Drilled Shaft Design

River Piers: Drilled Shaft Design

Factored Side Resistance = 0.40 (qs) = 8.7 ksf Similarly… Factored Tip Resistance = 0.36 (qt) = 269 ksf

River Piers: Drilled Shaft Construction

River Piers: Drilled Shaft Construction

River Piers: Drilled Shaft Construction

Approach Piers

Originally designed as traditional H-pile supported footings. At MoDOT’s suggestion, Massman switched to 48” diam.

• pen ended pipe pile bents.

Eliminated footing excavations in saturated, flood-prone overbank 16 ft of scour Unbraced Length 38 ft

Approach Piers: 48” Dia. Open Ended Pipe Piles

ASTM A-252 Grade 3 (Fy = 45 ksi) Galvanized to 20 ft below scour Top Half 1-inch Wall / Bottom Half ¾-inch Wall Filled with concrete above scour

Approach Piers: 48” Dia. Open Ended Pipe Piles

Want to drive through 10-ft layer of cobbles & boulders to seat on rock. Hard Rock or Soft Rock? Shaley DOLOMITE or Calcareous SHALE? Since Qu > 4000psi, decided it is hard rock.  Cutting Shoe Point Reinforcement Required

Approach Piers: 48” Dia. OEP (3/4” Wall)

Nominal bearing resistance shall not exceed maximum factored axial structural resistance for severe driving. [AASHTO 10.7.3.2.3]

• Max. Factored Axial Str. Resistance = 0.6 (45) 111.4 = 3006 kips

Let Nominal Bearing Resistance = 3006 kips

Approach Piers: 48” Dia. OEP (3/4” Wall)

Decided to PDA each pile & use a geotechnical resistance factor of 0.65

• Max. Factored Axial Geo. Resistance = (0.65) 3006 = 1954 kips
• Max. Factored Axial Load (from Br. Engr.) = 1860 kips < 1954 kips OK

Req’d Nom. Driving Resistance, Rndr = 1860/0.65 = 2865 kips (57% Fy)

Source: NCHRP Synthesis 478

Approach Piers: 48” Dia. OEP

...but Massman’s PDA Consultant, FTC, still worried about damaging pile based on recent events. Since:

• Driving to end bearing
• With known, consistent top of rock
• PDA/CAPWAP on every pile

HNTB (with MoDOT acceptance) raised resistance factor to 0.9 with 0.8 preferred.

Rndr = 1860/0.9 = 2070 kips (41% Fy)

Approach Piers: 48” Dia. OEP

Massman Submitted: Delmag D62-22 164.6 kip-ft rated energy 13.7 kip ram weight HNTB Review Comments 

Approach Piers: 48” Dia. OEP -- WEAP

Approach Piers: 48” Dia. OEP -- PDA

Approach Piers: 48” Dia. OEP - CAPWAP

• 10 to 15 bpi at EOD
• Stopped 1 to 4 feet above est. top of rock

CAPWAP Results Capacities: 2100 to 2800 k > 2070 k (ok)

30% to 60% side friction

Max Stress: 20 to 25 ksi < 40.5 ksi (ok)

East Abutment: HP-12x53

Delmag D30-32 75.4 kip-ft rated energy 6.6 kip ram weight Rndr = 485 kips RPDA = 492 kips Pile Tip 135.5 ft below grade

East Approach Embankment

East Approach Embankment

East Approach Embankment – Stage Raise

East Approach Embankment – Settlement Plates

East Approach Embankment - OK to Pave?

From Trend Line: Bo = 2.0929 B1 = 0.8789 Smax = Bo/(1-B1) Smax =17.282 inches Remaining Settlement = 17.3-15.3 = 2 inches

Approach Piers

Steel Erection

Steel Erection

Flood Stage

Deck Construction

Deck and West Approach

Opened August 3, 2019

3 mo. ahead of schedule

Your Questions…

Original Champ Clark Bridge $1.0 M in 1926 = $14.3 M in 2018 New Champ Clark Bridge Winning Bid of $60 M in 2017

More Traffic / Heavier Traffic Unrestricted Vehicle Height Above 500 yr Flood Wider Deck

Construction Timelapse