i-95 bridge restoration project - virginia department of ......casting yard 25-acre site mi-jack...
TRANSCRIPT
![Page 1: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/1.jpg)
I-95 Bridge Restoration Project
Scott J. Fisher, P.E. Jorge M. Suarez, P.E.
Virginia Concrete Conference Richmond, VA March 7, 2013
![Page 2: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/2.jpg)
Project Background
Restore 11 bridges Richmond I-95 Corridor Concrete: 9,500 cy
or…17 football fields 4” deep
Total of 234 PCUs Update: 157 PCUs Cast 99 PCUs Installed
![Page 3: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/3.jpg)
Casting Yard
25-acre site Mi-jack gantry cranes Casting beds Actual field
substructure geometry
PCU storage
![Page 4: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/4.jpg)
Preconstructed Composite Units (PCUs)
LW concrete 9 inch slab Fabricated plate girders 2 or 3 girder components Transverse PT bars Cast-in-place closure pours Continuity bars
![Page 5: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/5.jpg)
Concrete Challenges
LW Concrete Aggregate Moisture
Finishing lightweight concrete PT Grouting Work time for closure pours SCC wet weight and effects
on formwork Shotcrete
![Page 6: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/6.jpg)
Substructure Concrete Work
Surface Repairs/Shotcrete Crack Injection Repairs Drilled Shafts Footing Extensions Abutments
Pier Caps In-Fill Walls (SCC) Electrochemical Chloride
Extraction (ECE) Sacrificial Cathodic
Protection (CP)
![Page 7: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/7.jpg)
Substructure: Challenges
![Page 8: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/8.jpg)
Substructure: Drilled Shafts
![Page 9: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/9.jpg)
Substructure: Surface Repairs
![Page 10: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/10.jpg)
Substructure: Shotcrete
![Page 11: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/11.jpg)
Substructure: Pedestal Repairs
![Page 12: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/12.jpg)
Existing Bridge: Joint Repairs
![Page 13: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/13.jpg)
Substructure: New Pier Caps
![Page 14: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/14.jpg)
Substructure: Self-Consolidating Concrete
![Page 15: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/15.jpg)
Substructure: Infill Walls - Lombardy
![Page 16: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/16.jpg)
Superstructure Concrete Work
Lightweight concrete decks Grout PT ducts Closure Pours Continuity Joints Parapets/Median Barrier
![Page 17: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/17.jpg)
Superstructure: Test Slabs
![Page 18: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/18.jpg)
Superstructure: Deck Pours
![Page 19: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/19.jpg)
Superstructure: Pump or Dump
![Page 20: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/20.jpg)
Superstructure: Moving PCUs
![Page 21: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/21.jpg)
Superstructure: On Site
![Page 22: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/22.jpg)
Superstructure: Closure Pours
![Page 23: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/23.jpg)
Superstructure: Grouting Continuity Bars
![Page 24: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/24.jpg)
Roadway Walls – RW3 CIP Wall
![Page 25: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/25.jpg)
Roadway Walls – MSE Wall
![Page 26: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/26.jpg)
Lessons Learned
Non-production Test Slabs are Important!!!
LW Concrete Aggregates – Moisture LW Concrete Finishing – Fogging LW Concrete Finishing – Bunyon Screed
Speed Avoid unreinforced “knife edges” for
skewed bridges Multiple Concrete Suppliers
![Page 27: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/27.jpg)
Lessons Learned
Cones make for great temporary supports!!!
![Page 28: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/28.jpg)
Acknowledgements
Owner: Virginia Department of Transportation (Richmond District)
CEI Consultant: Michael Baker Jr., Inc.
Engineer: URS Corporation
General Contractor: Archer Western Constructors, LLC
![Page 29: I-95 Bridge Restoration Project - Virginia Department of ......Casting Yard 25-acre site Mi-jack gantry cranes Casting beds Actual field substructure geometry PCU storage](https://reader034.vdocument.in/reader034/viewer/2022042917/5f597a43a1888f79cb09af65/html5/thumbnails/29.jpg)
I-95 Bridge Restoration Project
Scott J. Fisher, P.E. Jorge M. Suarez, P.E.
Virginia Concrete Conference Richmond, VA March 7, 2013