LA 1 Phase 2 Leeville to Golden

Meadow

Louisiana Transportation Conference James Gregg, PE

1

LA 1 Phase 2

Existing highway is sinking and floods with storm surge

Levee is 28 miles North of Port Fourchon

Port Fourchon services 90% of the Gulf of Mexico deep water oil and gas production

Construct two lane elevated structure between Golden Meadow and Port Fourchon

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LA 1 Phase 2

Project broken into 4 Phases Phase 1 – Leeville to Port Fourchon (Completed 2011)

– 8.8 miles of elevated structure (2 – 12 ft lanes with 8 ft shoulder) – $371,600,000

Phase 2 – Golden Meadow to Port Fourchon

– 8.3 miles of elevated structure (2 – 12 ft lanes with 8 ft shoulders) – Upgrades to LA 1 from Port Fourchon to Grande Isle – Estimated cost: $346,000,000

Phase 3 – US 90 to Larose

– 4 lanes of at-grade highway from Larose, LA to US 90 (19.5 miles) – Estimated Cost: $346,000,000

Phase 4 – Additional lanes, Golden Meadow to Fourchon

– 15.1 miles of elevated structure – Estimated cost: $660,000,000

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LA 1 Phase 2

Funding Source

Phase 1 – Leeville to Port Fourchon (Completed 2011) – $70.4M Revenue Bonds – $66M (TIFIA Loan) – $81.6M Federal ear marks – Tolls (round trip)

• $3.00 / car • $12.50/ 5-axle truck

Phase 2 – Golden Meadow to Port Fourchon

– $46.6M State funds plus private donors – Gulf of Mexico Energy Security Act (GOMESA) Phase II (2017)

Phase 3 – US 90 to Larose

– None

Phase 4 – Additional lanes, Golden Meadow to Fourchon

– None

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LA 1 Phase 2

Phase 1

• Opened to traffic in December 2011

• Project Cost: $371.6M

• 8.8 miles of two lane elevated structure

• Project advertised in 4 phases

– Phase 1A – 5.3 miles constructed top down (Fourchon – Leeville)

– Phase 1B – 3.5 miles of approaches and connectors

– Phase 1C – Leeville Bridge replacement

– Phase 1D – Customer service center and ITS

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LA 1 Phase 2

Phase 2

• Phase 2A – Southern Segment – 1 mile of bridge from existing Phase

1A bridge

– Crosses Bollinger Canal

– Design to be completed by February 2017 (Sub-consultant: GEC)

6 Dredged access

LA 1 Phase 2

Phase 2

• Phase 2B – Middle Segment – 7 miles of elevated structure

– Top down construction

– Design to be completed by 2017/2018

– Crosses two main pipelines

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LA 1 Phase 2

Phase 2

• Phase 2C – Northern Segment – 3,835 ft of elevated structure

– Crosses existing levee

– Design completed awaiting 408 permit

– Letting date: 6/8/2016

– Estimated cost: $30M-$50M

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LA 1 Phase 2

Phase 2

• Phase 2D – Northern Segment – 280 ft of elevated structure

– 1,500 ft of roadway tying in relocated LA 1 with existing LA 3235

– New at grade toll facility

– Final phase to be constructed

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LA 1 Phase 2

Phase 2

• Phase 2E – Widening of Existing LA 1 Bridge at North Connector – 1,889 ft of widening

– Crosses Bollinger Canal

– Design to be completed by March 2016 (Sub-consultant: GEC)

– 2nd to be advertised for construction

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LA 1 Phase 2

PHASE 2C – Northern Segment

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LA 1 Phase 2C

Phase 2C

Elevated structure • 80’-0” LG-54 spans

• 150’-0” LG-78 spans – Pipeline crossing

– Levee crossing

• 60’-0” LG-36 spans

• 20’-0” slab spans

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Slab spans LG-36

LG-54 LG-54 LG-78

LG-54 LG-78

T-Wall

Levee improvements (at bridge

crossing)

• 300 ft of T-Wall

• Raise flood protection to elevation 21.0 ft

• Existing elevation 16.0 ft

• Increased toe of levee F.S.

LA 1 Phase 2C

Phase 2C

• Design Criteria – New Bridge Design Manual

– Louisiana Girders

– LADV-11

– Wind Loading

– AASHTO Guide Specs for Bridge Vulnerable to Coastal Storms

• Wave Loading

– Pile to cap fixity/ no battered piles

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LA 1 Phase 2C

Soil Conditions

• Unconsolidated soils

• Top 30 ft of soil has minimal to no lateral resistance

• Piles will continue to settle during installation under their own weight

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Pile Size

Recommended

Factored Pile

Capacity (Tons)

Max Factored

Pile Capacity

(Tons)

Tip Elevation (Ft)

24”x24” voided 270 300 -130

30”x30” voided 375 420 -140

LA 1 Phase 2C

Intermediate Diaphragms • BDEM requires intermediate diaphragms for bridges subjected to

extreme high winds • Phase 1A construction debrief suggested intermediate

diaphragms be removed as a cost saving measure (material and labor)

• Analyze Louisiana Girders based on 155 mph wind speed – 150 ft - LG-78 – 80 ft - LG-54 – 65 ft - LG-36 – Placement of an intermediate diaphragm at midspan does not reduce

tendency of the web to flex about longitudinal axis – Significant revers moment forces in bottom flange observed

• Intermediate diaphragms not used for LG’s

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LA 1 Phase 2C

Piles

• Phase 1A construction debrief suggested not to batter piles laterally due constructability associated with poor soil conditions

• Used FB-Multi Pier to model unit with soil layers to calculate lateral and longitudinal distribution

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65%-85% 10%-15% 5%-10% 5%-10%

LA 1 Phase 2C

Bent Cap

• Pile/ cap was assumed to be fixed

• Piles embedded in cap 2’-6”

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4’-

0”

4’-

6”

2’-6” pile embedment 30” piles (typ.)

LA 1 Phase 2C

T-Wall

• 5 – 60 ft monoliths (300 ft)

• Top of wall = Elev. 21.0’

• Top of existing levee = Elev 16.0’

• 7’-6” x 2’-3” stem

• 91’ H-Piles

• 3’-10” vertical clearance from top of wall to low chord of bridge

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LA 1 Phase 2C

T-Wall

• Existing toe of levee does not meet Corps factor of safety

• 10,000 yd3 fill required in drainage canal at T-Wall

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LA 1 Phase 2C

Independent Contractors Style Bid Estimate

• Armeni Consulting – Former chief estimator for Traylor Brothers

• Contractors-style estimate which includes a breakdown on labor, equipment, permanent materials and subcontractors

• Address means and methods and schedule

• Construction estimate used in-lieu of engineers estimate or using DOTD estimating tool with historical prices

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LA 1 Phase 2C

Means and Methods

• Fill not allowed on south side of levee – Additional fill will reduce F.S. of levee and

potentially damage pipelines

• Haul road to access T-wall and bridge south of levee

• Barge access north of levee

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Temporary Trestle

Drainage canal (barge access)

Temporary Haul road (levee)

LA 1 Phase 2

PHASE 2B – Middle Segment

(Top Down Segment)

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LA 1 Phase 2B

Top Down Construction

• Top down required similar to Phase 1A – Contractor allowed to install temporary piles and trestle

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LA 1 Phase 2C

Soil Conditions/ Piles

• No pile test program due to top down

• F = 0.7

• PDA testing during construction, however, must project pile capacity

• Soils are consistent between Phase 1 and Phase 2

• Phase 1A serves as test pile program for 24” piles

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Pile Size

Recommended

Factored Pile

Capacity (Tons)

Max Factored

Pile Capacity

(Tons)

Tip Elevation (Ft)

24”x24” voided 270 300 -130

30”x30” voided 375 420 -140

LA 1 Phase 2B

Value Engineering

• Required due to project size

• 19 recommendations

• 4 recommendations required further investigation

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ID VE Recommendation

ST1 Construct Segmental Bridge

ST27 Set up onsite casting plant

ST31 Use LG-54 in lieu of LG-36

GT22 Increase 24” Pile to 30” (Voided Center)

LA 1 Phase 2

LA 1 Phase IA – 4.5 miles (1,151,323 ft2 of bridge deck) requiring top down construction.

Bids (2007)

• James Construction Group: $137,479,548 (B3)

• Traylor/ Massman: $138,287,218 (B3)

• $119/sqft

Alternative Span Arrangement Substructure

B1 40’ Slab Spans 24” P.P.C. long piles

B2 40’ Slab Spans 24” P.P.C. short piles

B3 65’ AASHTO Type III

Girder Spans 24” P.P.C. long piles

B4 65’ AASHTO Type III

Girder Spans 24” P.P.C. short piles

B5 95’ AASHTO BT-63

Girder Spans 30” P.P.C. long piles

B6 95’ AASHTO BT-63

Girder Spans 30” P.P.C. short piles

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LA 1 Phase 2B: Bid Alternatives

Based on Value Engineering workshop bid alternatives were investigated

• HNTB – PPC Girder Alternatives (A1 & A2)

• Corven Engineering – Segmental Alternatives (A3, A4, & A5)

• Armeni Consulting – Construction means and methods and contractors style bid estimate with detailed primavera schedule

VE Alternative Report

Alternative Span Arrangement Substructure

PPC Girder Alternative

ST 31 A1

65’-0” span, 4- LG-36

4 or 6 - 24” Square P.P.C. Piles

A2 108’-0”span, 4- LG-

63 6 - 24” Square

P.P.C. Piles

Segmental Bridge

Alternative ST 1

A3 65’-0”

Trapezoidal Box Segmental Spans

4 - 24” Square P.P.C. Piles

A4 100’-0”

Trapezoidal Box Segmental Spans

4 - 30” Square P.P.C. Piles

A5 136’-0”

Trapezoidal Box Segmental Spans

6 - 30” Square P.P.C. Piles

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LA 1 Phase 2B: Bid Alternative A1 (65’-0” span)

Phase 2B

• Similar to Phase 1A and I-269 D/B

• AASHTO Type III vs. LG-36 – 4 - LG-36 (8,500 psi)

(Most cost effective)

– 5 - AASHTO Type III (8,500 psi)

– 4 – AASHTO Type III (10,000 psi)

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Comparison between projects

Phase 1A Phase 2B

Design Load HS-20 LADV-11 Span 65’-0” 65’-0”

Piles 3 - 24”

(2 transverse battered per bent) 4 – 24”

(no transverse batter)

Girder 3 – Type III 4 – LG-36 Deck 7.5” 8”

Intermediate Diaphragm

Yes No

LA 1 Phase 2B: Bid Alternative A2

(108’-0”, LG-63, 24” Piles)

Balanced Alternative

• Started with 100’-0” to compare with alternate A4 (100’ segmental)

• Increased to 108’-0” based on balancing superstructure and substructure construction

• Use of LG-54 vs. LG-63 girders – 5 lines of LG-54 (8,500 psi)

– 4 lines of LG-63 (8,500 psi)

• 24” vs. 30” piles – 6 – 24” piles

– 4 – 30” piles

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LA 1 Phase 2B: Bid Alternative A1 & A2

(65’-0” or 108’ spans)

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LA 1 Phase 2B: Bid Alternative A3 (65’-0” span)

Segmental Alternative A3 (short span)

• Simple Span

• 7 ft deep box

• 5” long expansion joint segments

• 9’-4” segmental units

• Segments cast in casting yard

• Longitudinal tendons – fully bonded

– placed internally to the concrete webs

– 19 x 0.6” strands

• Transverse tendons – 3 – 4 strand tendons

– 3’-2” spacing

• 4 – 24” piles

• 14 acre on-site casting yard

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LA 1 Phase 2B: Bid Alternative A3 (65’-0” span)

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LA 1 Phase 2B: Bid Alternative A4 (100’-0” span)

Segmental Alternative A4 (medium span)

• 5 span continuous

• 7 ft deep box

• 10’-0” segmental units

• 6” CIP closure pours

• Segments cast in casting yard

• Longitudinal tendons – Unbonded

– external but inside box

– 22 x 0.6” strands

• Transverse tendons – 3 – 4 strand tendons

– 3’ - 4” spacing

• 4 – 30” piles

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LA 1 Phase 2B: Bid Alternative A5 (136’-0” span)

Segmental Alternative A5 (long span)

• 5 span continuous

• 8 ft deep box

• 10’-4” segmental units

• 6” CIP closure pours

• Segments cast in casting yard

• Longitudinal tendons – Unbonded

– external but inside box

– 22 x 0.6” strands

• Transverse tendons – 3 – 4 strand tendons

– 3’ - 6” spacing

• 6 – 30” piles

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LA 1 Phase 2B: Bid Alternative Cost Estimate

Alternative Difference in Cost Duration

Alternative A1 – 65’ Span Concrete Girder Bridge: = 0% (base) (71 Months)

Alternative A2 – 108’ Span Concrete Girder Bridge: = -5% (70 Months)

Alternative A3 – 65’ Span Precast Segmental Bridge: = +24% (73 Months)

Alternative A4 – 100’ Span Precast Segmental Bridge: = +10% (60 Months)

Alternative A5 – 136’ Span Precast Segmental Bridge: = +10% (56 Months)

• Alternative A2 appears to yield lowest total cost – Alternative A2 was the 2nd place bid on I-269 D/B which required top down

• Cost to build trestle can fluctuate

• Segmental yields shortest duration

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LA 1 Phase 2B: Bid Alternative On Site Casting Yard

Evaluate on site casting yard for PPC piles and PPC girders

• Project has 500,000 linear ft. of PPC elements

• Requires PCI Plant Certificate must be waived

• Saves on sales tax and freight

• Requires local labor and prevailing wages

• Requires 18 acres for casting yard – LA 1 coalition believes they can have space donated by Port

• Study found potential cost savings

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LA 1 Phase 2B: Bid Alternatives Recommendations

ST 31 – Use longer PPC girder spans & ST 1 – Segmental Alternatives

Alternative A1 (65’-0” span)

• Winning alternate on LA 1 Phase 2B and I-269 Coldwater River D/B

Alternate advanced to final design

Alternate A2 (108’-0” span)

• 5% cheaper than 65’-0” spans

Alternate advanced to final design

Alternate A3, A4 & A5

Alternate not advanced to final design

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Bid Alternatives Recommendations

GT 22– 30” piles

Alternate A1 (65’-0”)

• 4 – 24” piles are adequate

Not recommended

Alternate A2 (108’-0”)

• 6 - 24” piles

• 4 – 30” piles

Advanced as sub-alternate for A2

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LA 1 Phase 2

Phase 2 Lettings

Phase Estimated Construction Letting

• Phase 2C June 2016*

• Phase 2E Q1 – 2017 (depending on funding)

• Phase 2A 2018

• Phase 2B 2018/2019

• Phase 2D 2022

* Waiting 408 permit approval.

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LA 1 Phase 2: HNTB Team

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LA 1 Phase 2

Questions

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