Bridge over BNSF Railroad 7 km East of Windham - East Bridge Replacement Project Using Accelerated...
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![Page 1: Bridge over BNSF Railroad 7 km East of Windham - East Bridge Replacement Project Using Accelerated Bridge Construction.](https://reader036.fdocuments.us/reader036/viewer/2022062712/56649c925503460f9494d7f3/html5/thumbnails/1.jpg)
Bridge over BNSF Railroad
7 km East of Windham - East
Bridge Replacement Project Using Accelerated Bridge Construction
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Project Location
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Existing Bridgeo 3-Span Concrete Tee Beamo 123 Feet Longo 28 Feet Wide
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Approach Looking Southeast
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Profile Looking Southwest
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Design Parameterso National Highway Routeo 2500 vehicles per day (23% Trucks)o Major truck route between Great Falls and Billings o US Air Force Missile Routeo Grain Elevator in Moccasin o BNSF Railroad Crossingo Accident cluster at bridge
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New Bridge Requirements
o New width = 40 feeto Increased railroad lateral clearanceo Increased railroad vertical clearanceo Avoid existing foundations (timber piles)o Minimize grade raise to catch slopes on
existing approaches – avoid sliver fills and new R\W
o Minimize traffic disruptions
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What are our options?o New Bridge on Offset Alignment
o New Bridge on same alignment using On-site Detour
o New Bridge on same alignment using Phase Construction
o New Bridge on same alignment using Off-site detour and ABC
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Could Accelerated Construction work
here??o How long can we shut down bridge site?o How quickly can we build a new bridge?o How much building can be completed before with
existing bridge in place?o Is there a reasonable detour route?
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Possible detour route
o Secondary Highways – wide shoulders / flat slopeso Similar detour length for thru-traffico Detour through town of Hobson – school crossingo At-grade RR crossing in Hobsono Many local detours possible (County Roads)
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o Contacts with o Town of Hobson - Mayoro Hobson Schoolo County Commissionerso Trucking Industry – grain elevatoro Air Force Baseo BNSF Railroad
o Road User Cost Calculationso Preliminary ABC Ideaso Contract Time Estimateso Local Events
ABC Planning Efforts
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– Hay Days – Utica
Montana
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What can we accelerate?What portion of construction takes the most time?
o Foundation construction – 4 days/shaft or 4 piles/day
o Drilled Shaft testing – 14 days before testing / longer if problems are encountered
o Forming bent caps – 3 days eacho Curing bent caps – 15 days per projecto Deck forming – 20 days up to 300 feeto Deck curing and sealing – 28 days
Allowing for some overlap……80 days for major items
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Potential Solutionso Foundations
o What can we do while traffic is on existing bridge?o What foundation types will work?
o Forming and curing bent capso What cast-in-place can be done while traffic is on existing bridge?o Precast end and intermediate caps?
o Deck forming and curingo Full-depth precast deck panelso Partial-depth o Stay-in-place Forms
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o What could be completed before detouring traffic
o What would be accelerated while traffic is on detour route
o What work could be done after traffic is moved back on new bridge
Divided Work Into Stages
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Work Prior to Detouring Traffic
Drilled 4 shafts outside the bridge limits and behind the existing intermediate bents.
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Cast struts/crash wall on top of and between shafts
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Cast walls on top of struts
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Traffic on DetourDay 1o Removed span 2 deck and beamso Removed span 3 deck
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Day 2o Removed span 3 beamso Removed bent 3 and 4o Removed span 1 deck
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Day 3o Bent 4 – drove piles, formed and placed capo Bent 3 – Set cap and placed closureo Removed span 1 beamso Removed bents 1 and 2
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Precast Pier Cap
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Day 4o Bent 2 – Set cap o Bent 1 – drove piles
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Day 5o Bent 2 – placed closureo Bent 4 –formed and placed cap
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Day 6o Span 3 – Set girders and deck panels
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Day 7o Sunday – no work
Day 8o Span 2 – Set girders and deck panels
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Day 9o Span 1 – Set girders and half the deck panels
Day 10o Span 1 – Set remaining deck panelso Began forming closure pours
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Day 11o Bents 1 & 4 – Formed and placed backwallso Formed deck panel closure pours
Day 12o Continued forming deck panel closure pours
Day 13 and 14o Saturday and Sunday – No work
Day 15o Adjusted deck gradeso Prepare for deck closure pours
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Day 16 and 17 o UHPC Closure Pours
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Day 18 and 19o Removing form work and grinding jointso Fill low spots
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Day 20 and 21o Weekend no bridge work – building approach fills
Day 22o More grinding and approach fills
Day 23o Tying barrier steel o Test run with slip form
Day 24 o Approach work
Day 25o Slip formed barrierso Final grading along RR tracks
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Day 26 and 27o More grading worko Approach rails
Day 28o Finished approach rails
Day 29 o Opened to Traffic
One day ahead of schedule (incentive/disincentive deadline)
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Now lets see that in fast motion
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Lessons Learned
o Project scheduling was intensiveo Design details are critical – things need to fito Allow adequate tolerance on precast elementso UHPC is difficult to grind – reduce exposed area to
minimize grindingo Have an Engineer on site during construction of
critical elements – be prepared to make decisions