Johnson Street Bridge Replacement Project

Technical Briefing

April 8, 2015

New IntersectionHarbour & Esquimalt Road

Delta Hotel Access

Rest Pier Completion

Rest Pier Completion

West Abutment

West Abutment

Bascule Pier Big Pour

Intermediate Pier

New Project Schedule Key Milestones

Steel Fabrication & Shipping March 1, 2015 – June 5, 2016 (66 weeks)

Bridge Machinery Fabrication Feb. 23, 2015 – Nov. 23, 2015 (39 weeks)

Bridge Decks – East June 26, 2015 – Oct. 23, 2015 (17 weeks)

Bridge Decks – West June 26, 2015 – Sept. 18, 2015 (12 weeks)

Bridge Machinery Installation Nov. 23, 2015 – Feb 1, 2016 (10 weeks)

Site Shut Down Feb. 23, 2016 – June 5, 2016 (15 weeks)

Steel Bridge Erection June 5, 2016 – Sept. 18, 2016 (15 weeks)

Bascule Span (Miscellaneous): Sept. 18, 2016 – Nov 27, 2016 (10 weeks)

Traffic shift/bridge ready for traffic Jan. 15, 2017

Demolition Jan. 15, 2017 – April 16, 2017 (13 weeks)

Project completion June 25, 2017

Project Contingency

Item Amount

Initial Contingency

$2,515,000

Value Engineering Savings

$ 300,000

Current Contingency Commitments

-$1,344,573

Projected Contingency items

-$1,870,500

Contingency Shortfall

-$ 400,000

Financial Impact

Description of Costs Amount

Insurance $ 280,000

Additional city costs $ 420,000

Professional consulting services

$1,800,000

Current contingency shortfall

$ 400,000

Legal costs for mediation $ 400,000

Unallocated contingency to completion

$1,500,000

Total $4,800,000

Project Budget – Costs Presented to Council in March

• These costs were recently presented Council and an additional $4.8 million was requested for the project

• $1.5 million was granted by Council

• This brings the total budget for the Johnson Street Bridge Project to $94.3 million

Steel Fabrication

Steel Fabrication

• Steel fabrication restarted in March

• New quality control oversight program now in place in the steel fabrication plant

• Work done to improve Quality Management Plan and Inspection and Testing Plan

Steel Fabrication Non-destructive examination of Orthotropic Steel Deck mockup to inspect quality of welds

Steel Fabrication Truss web plates after plasma cutting. Quality Control verifying traceability of material

Steel Fabrication

• Regular inspections by the fabricator and the contractor’s quality control consultants

• Ensures the bridge is constructed to the highest standard of the design – any steel not meeting the highest quality and safety specifications will be not be accepted by the City

Steel Fabrication Overhead robotic gantry welding equipment used in the production of orthotropic deck panels

Steel Fabrication Ring flange plates cut and beveled, prior to bending to the radius of the rings

How the Bridge is Constructed

• The steel bridge has six main components: two rings, two forward trusses, a counterweight and the steel deck

• The counterweight and steel deck connect the ring and truss structures together to form the complete bridge

How the Bridge is Constructed

How the Bridge is Constructed

• Fabrication begins with the rings

• Starts with cutting, rolling, and splicing together of curved plates that form the ring

• The sides and middle areas of the rings are made by splicing together sections of steel plate to create three complete web-like elements per ring

How the Bridge is Constructed Robotic welding of the orthotropic steel deck test panel

How the Bridge is Constructed

• After the pieces are complete and inspected, they are aligned and the ring is progressively welded together

• The trusses are fabricated in a similar fashion to the rings by creating long, slender pieces of steel, which are then progressively assembled into a fully welded structure

How the Bridge is Constructed

How the Bridge is Constructed

• The deck is constructed with a series of orthotropic panels (a steel plate with welded ribs for added support) that are spliced together and connected with the floor beams

• The deck and floor beams are later connected to each truss to create a fully welded structure

How the Bridge is Constructed

How the Bridge is Constructed

• When the components are complete, inside the steel fabrication factory there are a number of trial assemblies and tests to ensure the bridge performs as it is designed to

• After the bridge has been assembled, tested and measured in position, the machinery responsible for the raising and lowering of the bridge will be installed

How the Bridge is Constructed

How the Bridge is Constructed

• The various bridge components will then be painted and packaged for shipping to Victoria on an ocean freight vessel

• The estimated timelines are:– Fabrication – 7-9 months– Trial erection – 2-3 months– Painting – 1-2 months– Travel time from China to Victoria – 2 months

Seismic Design

Seismic Design

• Presentation in March to explain the seismic design to Council

• The design standards for the Johnson Street Bridge that the H&H final design are based on are the most comprehensive and relevant design requirements for bascule bridges in North America

Seismic Design

• The new JSB has been designed as a “Critical Bridge” – the equivalent to the definition of “Lifeline Bridge”, the performance required by the City

• The design of new JSB will allow the bridge to be available to all traffic after a design earthquake of 1/1000 years.

Seismic Design

• The JSB is being designed and constructed to a very high seismic standard meeting the most stringent current codes in North America

• The JSB will “be usable by emergency vehicles and for security/defense purposes immediately after a large earthquake, e.g. a 2500-yr return period event”

Machinery Fabrication

Mediation

Next Steps

• Next Quarterly Update to Council in May

• Continued onsite work by PCL

• Arrival of the steel bridge span in June 2016

• Updates to Council as needed on contingency and possible project cost savings

Thank You

Questions