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I-64 Kanawha River Bridge

South Charleston & Dunbar W.V

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Contract Information

Owners: WVDOT / FHWADesigner: T.Y. Lin InternationalLet: February 2007

Contractor: Brayman Construction Corporation Finley Engineering GroupMichael Baker, Jr.

Awarded: March 2007

Start Date: May 2007Completion Date: October 2010

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Bid Results

Steel Alternative $113 Million

Concrete Alternative $83 Million

Bridge Items: $75Million 

( $379 / SF )Second Largest Contract Awarded

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Concrete

Segmental Box Girder 

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Topics of Interest

• Superstructure Concrete strength 6,500 psi• Mass Concrete• Main Piers• Balanced cantilever construction

• 167 cast-in-place segments• 760’ Main Span length longest continuous segmental

span in North America• 90 cantilever tendons 22-0.6”•

34 span tendons 19-0.6”• Post Tensioning• Grouting

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 WVDOH Class H Modified (6500 psi) concrete

Arrow Concrete

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Mix Design Requirements

Air Entrained 6500 psi

Low E modulus of elasticity, and creep

Workable mix ranging from a 4” to 8”Slump

Low Rapid Chloride Permeabilityrequirement.

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Special Provision SP601: Mass Concrete•Any Placement with Least Dimension Greater then 48.0Inches

•Maximum Allowable Temperature Difference Shall be

Limited to 35 Degrees F•Maximum Allowable Concrete Temperature Shall beLimited to 160 Degrees F

•Temperature Monitoring System to Ensure Compliance

•Thermal Control Plan Submitted Describing Methods andProcedures to Satisfy Requirements

•Temperature Monitoring System to Ensure Compliance

•Mix Design’s Conforming to SP601 Requirements

•Conforming to These Requirements will be at no Addition

(I-64 KRB) MASSCONCRETE

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Insulated Forms

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Insulated Blankets

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Method of Controlling Maximum Temperature andDifferential

(EMBEDDED COOLING PIPE)

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CL

PIER

7'-0"

15'-0"

15'-0

"

CL BOX

18'-3" 18'-3"12'-0" 12'-0"

60'-6"

18'-3"

18'-3"

12'-0"

12'-0"

60'-6"

14'-3" 9'-0" 7'-0"14'-3"

7'-0"

1

4'-3"

9'-0"

7'-0"

14'-3"

7' SHAFT (TYP.)

9'-0"

9'-0"

Main Pier Foundation

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Main Piers

Transverse View Elevation View

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Erection of the Form Traveler 

.

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Form Traveler Construction

Balanced cantilever construction method

Strukturas form travelers with DOKA

formworkCross Sections varied from 16’ to 38’ inheight created unique formwork

challenges

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Superstructure Cross-section

10'-0“SHOULDER

12'-0" AUXLANE

6'-0“OFFSET

3 TRAVEL LANES@ 12'-0" = 36'-0"

1'-6"

2" OVERLAY

NEAR MID-SPAN

1'-6"16'-0"

38'-0"

9"

1 3/8 '' VERTICALPT BAR

TRANSVERSE TENDON4-0.6'' STRANDS

5'-0"

NEAR MAIN PIER

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Cantilever Cycle

L

T 1T 1

C P I E R

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Cantilever Cycle

LC P I E R

1 W

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Cantilever Cycle

LC P I E R

1 W

T 2

T 2

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Cantilever Cycle

LC P I E R

1 W1 E

2 W

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Cantilever Cycle

LC P I E R

1 W1 E

2 W

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Cantilever Cycle

T 3

T 3

LC P I E R

1 W1 E

2 W

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Cantilever Cycle

LC P I E R

1 W2 W1 E

2 E

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Cantilever Cycle

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Post Tensioning (Stressing)

Tendons stressed to 75% of guaranteed yieldstrength

Vertical P.T. Bar Longitudinal Deck Tendons

Cantilever Tendons

Draped TendonsSpan Tendons

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Cantilever Tendons

Cantilever TendonDuctsSpare

Ducts

Anchorage

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Span Tendons

Anchorage

SpanTendonDucts

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Tendon Grouting

High Shear Colloidal Mixer 

Pre Bagged, Thixotropic, ZERO Bleed,grout supplied by BASF Chemical

Start grout from the Low Point to HighPoints

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Low Points and High Points

THANK YOU

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THANK YOU