Reconstruction of the Historic BNSF Br. 482.1Temple Overman (HNTB) & Cory Duerr (KNA)

KU Structures Conference

March 7, 2019

OUTLINE

Project Overview Bridge Elements Phase Changeouts Construction Highlights and Lessons

Learned− Mass Concrete− Accelerated Bridge Construction− Construction Quantities

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PROJECT LOCATION

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PROJECT OVERVIEW

BNSF Bridge 482.1

W. Memphis, AR Memphis, TN

PROJECT TIMELINE

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November 2015 to October 2017 Historic Flooding

PROJECT OVERVIEW

FORMER LAYOUT

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Chief Engineer: George S. Morison Open for traffic on May 12, 1892 First bridge across the Lower Mississippi

PROJECT OVERVIEW

NEW LAYOUT

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PROJECT OVERVIEW

2,711’-9” Total Length With Spans From 72’-6” to 191’-0”Constructed On Alignment

OLD APPROACH

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PROJECT OVERVIEW

NEW APPROACH

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PROJECT OVERVIEW

PEDESTRIAN BRIDGE

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PROJECT OVERVIEW

HYBRID SUBSTRUCTURE

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BRIDGE ELEMENTS

Column Diameters: 7’ to 10’ Drilled Shaft Diameters: 8’ to 10’

HYBRID SUBSTRUCTURE

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BRIDGE ELEMENTS

HYBRID SUBSTRUCTURE

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Hybrid Drilled Shaft/Micropiles

BRIDGE ELEMENTS

HYBRID SUBSTRUCTURE

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BRIDGE ELEMENTS

8 Micropiles in 10’ Shafts, 4 Micropiles in 8’ Shafts. 280 total production micropiles.

SUPERSTRUCTURE

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BRIDGE ELEMENTS

DPG spans w/ steel or composite concrete deck 6 Span Lengths

− 72’-6”, 77’-2”, 88’-2”, 176’-6”, 178’-1”, 191’-0”

SUPERSTRUCTURE

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BRIDGE ELEMENTS

PHASE I CHANGEOUT November 10-11, 2016

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Spans 1 – 7 Replaced 748’

PHASE CHANGEOUTS

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Spans 8 – 15 Replaced 708’

PHASE CHANGEOUTS PHASE II CHANGEOUT

February 20-21, 2017

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Spans 16-23 Replaced 708’

PHASE III CHANGEOUT April 3-4, 2017

PHASE CHANGEOUTS

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Spans 24-27 Replaced 548’

PHASE IV CHANGEOUT August 28-30, 2017

PHASE CHANGEOUTS

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Mass ConcreteCONSTRUCTIONHIGHLIGHTS & LESSONS LEARNED

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ACI 207.1R-05 - Guide to Mass Concrete (Reapproved 2012)“Mass concrete is any volume of concrete with dimensions large enough to require that measures be taken to cope with the generation of heat from hydration of the cement and attendant volume change to minimize cracking.”

BNSF West Memphis Approach Specification defined Mass Concrete as.

“Mass concrete placement shall be defined as any pour in which the concrete being cast has dimensions greater than or equal to 6’ in three different directions.”

Mass Concrete DefinitionCONSTRUCTION Mass Concrete

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CTL Group (John Gajda) Analyzed Materials & Temperature Control Methods

− Maximum Temperature, Minimum Temperature, Temperature Differential

Time vs. Effort− Proper Preparation of Concrete = Cooling Tubes Not Required− Temperatures Needed Monitored 3x to 4x Longer Without Cooling

Tubes

PlanningCONSTRUCTION Mass Concrete

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Ready Mix Plant− Aggregate stored under canopies & sprinkled with 34°F water− Concrete was mixed using 50-75% of its water content from

ice− Remaining makeup water was added at 34°F

Concrete Preparation & CoolingCONSTRUCTIONMass Concrete

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Onsite Preparations− Decision was made to use cooling tubes

− Cooling tubes were used on all substructure placements except Pier 27 footing

− As a comparison Pier 3 with cooling tubes completed thermal cure in 5 Days; Pier 27 without cooling tubes completed thermal cure in 27 Days

− Water was cycled through Frac Tanks− Up to 5 Frac tanks were used− Water was flushed anytime it exceeded 80°F

Concrete Preparation & CoolingCONSTRUCTION Mass Concrete

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Trouble Shooting the Plan− Kraemer had to cancel the first mass concrete pour after the first 3

trucks showed up too hot to place.− Some inspection showed that some parts of our plan were not being

followed as closely as we would have liked.− We found that when temperatures and humidity was high we needed

to place all of our concrete at night.

Warmer was Better (for the Schedule)− Once the concrete was placed at an appropriate temperature it was

found that we were able to have the concrete out of thermal monitoring much sooner, because the likelihood of the temperature differential exceeding its maximum was much less apt to occur.

Trouble Shooting Mass ConcreteCONSTRUCTION Mass Concrete

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Accelerated Bridge Construction

Precast Concrete Elements Temporary Jump Spans Extended Pier Cap Beams Pier 27 Construction Deck Truss Removal Span Roll-Ins

CONSTRUCTIONHIGHLIGHTS & LESSONS LEARNED

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Precast Concrete ElementsABC

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Temporary Jump Spans

Transition from New Ballast Deck to Existing Open Tie Deck

ABC

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Extended Pier Cap BeamsABC

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Extended Pier Cap BeamsABC

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Pier 27 ConstructionABC

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Pier 27 ConstructionABC

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Pier 27 ConstructionABC

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Deck Truss RemovalABC

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Deck Truss RemovalABC

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Span 2 & 3 Roll-Ins

Phase I Changeout− 2 ~ 176.5’ Spans Rolled Transversely 17’-6.75”

ABC

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Span 2 & 3 Roll-InsABC

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ABC Span 26 & 27 Roll-Ins

Span 27 rolled transversely 23’-8” and longitudinally 3’-8” Span 26 rolled transversely 23’-8”

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ABC Span 26 & 27 Roll-Ins

CONSTRUCTION QUANTITIES

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Total Concrete Quantity ≈ 16,000 CY Total Rebar Quantity ≈ 3 million lbs Structural Steel Quantity ≈ 8.2 million lbs

CONSTRUCTIONHIGHLIGHTS

QUESTIONS?

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