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Dale Even, PE – Lunda Construction CompanyJason Block - Ames Construction, Inc.
Construction Contracts
Pile Load Test Contract – 2012 $3.5 million
Early Foundation Contract – 2013 $37 Million
Minnesota approach roadway - 2012 $55 million• Ames/Lunda Joint Venture
Superstructure Contract – 2014 to 2017 $332 million• Lunda/Ames Joint Venture
Wisconsin roadway – 2013 to 2017 $27 Million
Bridge Project Schedule
St. Croix Crossing Project Schedule
2012 2013 2014 2015 2016 2017Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
Final Design
Early Fnd Design
Pile Load Test contract
Early Fnd Contract
Superstructure Contract
Project Labor and Subcontractors
• Lunda/Ames Joint Venture Prime Contractor• Self Performed 67% of the
work• Up to 400 trades persons at peak
• Multiple Shifts• DBE Goal 15.3%• Workforce goals
• Minority 22%• Female 6%
• 25 subcontractors• Rebar/PT labor• Electrical• Painting• Stay Cables
Project Partnering
• Quarterly Partnering Meetings• Facilitator• Project Management• Executive Management
• Project Charter• Safety• Environment• Quality• Schedule• Budget• Public Relations• Issue Resolution• DBE Goal
MnOSHA Project Partnership
• 120 OSHA Site Evaluation's
• 780 Safety and Environmental Orientations
• LAJV Project Specific Site Safety Plans
• Multiple Project Safety Professionals
• All parties believe it is a Successful Program
Quality Program
• Hybrid of MnDOTDB and DBB
• Limited 3rd Party QC
• Roles of QC vs. QA• 992 Segments only
1 rejected.• National recruiting
of technical people to support the work.
St Croix Crossing Bridge
• Extradosed Bridge Design• Hybrid Cable Stay and Concrete Box Girder
• Total Bridge Length 5,079’• Total Bridge Area 13.5 Acres.• 100 Year Design Life
Major Materials
• 140,000 C.Y. of Concrete• 20 different mix designs (plastic up
to 180 minutes)• 4,000 to 9,000 PSI• 2 suppliers
• 40,000,000 pounds of Reinforcing• Epoxy Coated and Stainless
• 8,000,000 pounds of Post Tensioning Steel
• 160 Stay Cable – 76 Strands each
• 20,000 gallons of paint
Environmental Commitments
Regulatory/Oversight• MnDOT• WisDOT• USACE • USCG• MPCA • Water shed District• USFW • DNR (Mn and WI)• Over 70 site specific
plans developed• Full time ECO
Approach Bridges Construction
Minn. Mainline Approach Spans• Two parallel 1700-ft.
sections of bridge – Two units• Pre-cast balanced cantilever/
CIP on falsework
Off-Ramp – On-Ramp Spans• 960-ft. and 630-ft. structures• Pre-cast balanced cantilever/
CIP on falsework
On-Site Casting Yard
• Construction:• 342 pre-cast
concrete segments • 3 castings beds• Completed casting
7/13/16
• Segment dimensions:• 43 ft. wide• 10-14 ft. tall• Up to 90 tons each
Construct and Transport Rebar Cage
• 3 Pre-tie Jigs• Adjustable Jig• Cage weight approximately
7000 pounds
Match Casting
• Previously cast segment used a bulk head for casting the next segment
• Geometry of the structure controlled by rotating the match cast segment vertically and horizontally.
• As cast surveys allow for adjustments as segments are cast.
Segment Erection – Approach Structure
• Unit 1 Segments• First Segments Erected
May 2015• Balance Cantilever
Method• SPMT transport on site• Crane based erecting• 300 to 440 ton cranes
Approach Segment Erecting
Unit 1 Segments• 13 Pre-Cast Spans• Span lengths 180’ to 290’• Spans over
• Wetlands• Multiple Rail Lines• Roadways
Approach Bridge Cast-In-Place Spans
Cast-In-Place Bridges• Br. 82048 On Ramp• Unit 2 Gore Area • Br. 82047 Off Ramp
Span 1
Cast In Place– Falsework and Formwork
• Outsourced FW Design• Pile Foundations• Pipe Columns (27,000 lf)
• LAJV Formwork Design
Cast In Place – Falsework and Formwork
• No standardized shapes
• Hand formed in place• VE to simply shapes
denied due to aesthetic concerns
3D Model of Knuckle Joint
• The owner developed a 3D Model Pre-Bid• Contactor developed ISD’s• Bid Item to Build a Mock up to sort out
Constructability Issues• Mock-Up and ISD’s identified several conflicts in
the design
Pier Tower Construction
Pier Tower Climbing Formwork • Custom Forms• Poured in 22 Foot Lifts• Tower Boxes • 67’ above deck
Typical River Span Deck Section
• 18‘ deep twin three cell box
• CIP center closure link
• 4-0.6“ φ transverse PT tendons at approx 2-6" c/c
30 m
6 m
Grey Cloud Segment Casting
• 5 casting beds• 3 OH Cranes• 5 Pre-tie beds• Storage for up to 400
Segments• Cast 650 segments
Grey Cloud Island Casting Yard
River bridge segments
• 18 ft. deep
• 10 ft. long
• 48 ft. wide
• 180 tons
• Casting September 2014 to August 2016
Segment Transport
• Barged 33 miles on Mississippi and St. Croix rivers to project site
• Up to 10 Segments per barge
• Pass through Lock and Dam #2
• 96 Hours outside the St Croix pool.
Erecting Equipment
Segment Lifters• Design, Fabrication,
Procurement 10 months• Load Test to 125%• 3 Pairs of lifters
Segment Erection - Segment Epoxy
• 3 temperature ranges
• 40°F - 115°F • Revised to
28°F - 115°F for cold weather then Rescinded.
Segment Erecting – Post Tensioning
Post-tensioning steel bars
Post-tensioning stressing 25 strands 0.6” φ
Segment Erecting -Longitudinal Closure Link
Closure Link• Connects EB and WB• Install Rebar/PT• Pour Concrete• Stress PT• Completed to advance
erection
Typical Deck SegmentAt Stay Anchorage
• External transverse tendons at stays
• Hoist Strut into place
• Install Rebar/Cast Concrete
• PT Transverse Tendon Before Stays
Stay Cables
• 32 Cables/Pier• 76 Strands/each• 2.4 Million Lbs of
force• Installed Strand by
Strand• 400 miles of cable
Stay Cables
After each strand is installed, crews pull it tight using a hydraulic jack. It applies 33,000 lbs of force.
Span 14 Trestle
• Top Down Construction• Tree Clearing Allowed 10 feet
beyond drip line• Highly Erodible soils• Steep Terrain
Span 14 Erecting
• Hoist segments onto cart
• Winch segments into place
• Install Temporary PT Bars
• Repeat
Segment Construction Update
Completed Erecting October 5th, 2016• 2015 – 282 segments erected• 2016 – 710 segments erected