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PA Chemical FacilityDesign and Construction of Heavy Haul Bridge

November 17, 2016

Presented by: David J. Phelan, PEDaniel Noecker, PE

Agenda

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1. Project Overview2. Design Phase3. Construction Phase4. Lessons Learned5. Question and Answer

Project Overview

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Project Overview

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I-376PROPOSED

PA CHEMICAL FACILITY

Project Overview• Relocate portion of SR 0018 south by 950 feet• New alignment cuts through mountainous terrain• Move 7M CY of excavated material to cap site• Aggressive design & construction schedule

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Project Overview (con’t)• Road/bridge necessary across existing SR 0018,

relocated CSX Railroad, and future Rail Lines– Coordination with PennDOT 11-0 (HOP) and CSX– Temporary condition – hauling operation– Permanent condition – site access road

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Project Overview

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West Haul Bridge East Bridge

PROPOSED PA CHEMICAL FACILITY

Ohio River

Project Overview

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West Haul Bridge

Design Phase

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Design Phase• Challenges

– Compressed design schedule– Short construction duration over Western PA winter– Heavy vehicular load– Impact load

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Design Phase• Design Criteria

– 75 year permanent design life– 2 year temporary design life (Hauling Operation)– Heavy Haul Considerations Alternatives

• Prefabricated temporary haul bridge• Permanent bridge• At-grade crossing• Conveyor belts

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Design Phase

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• Design Criteria (con’t)– Bridge Geometry

• No skew• Three (3) – 115 ft Spans

• Two (2) – 30 ft Lanes• 66 ft Overall Width

Design Phase• Design Criteria (con’t)

– Design Loads• Standard PennDOT/AASHTO Highway Loads• Caterpillar 777G (360 k GVW)

– Use of Standard PennDOT Details to the extent possible

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Design Phase

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CAT 777G (360,000 lbs GVW) PHL-93 (72,000 lbs GVW)

Design Phase• Proposed Bridge Superstructure

– P/S Concrete PA Bulb-Tee Beams 33x71.5• Simple Spans made Continuous for Live Load• Cost effective• Low future maintenance• Common bridge beam type in PA for these spans• Quicker fabrication turn-around time compared to steel

beams

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Design Phase• Proposed Bridge Superstructure (con’t)

– 10 Beams– 6.5’ Spacing– 10,000 psi concrete– 0.6” diameter strands

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Design Phase• Proposed Bridge Superstructure (con’t)

– Reinforced Concrete Deck & Approach Slabs• Special designs for heavier loads• 12” thick concrete deck with future LMC overlay• 30” thick approach slabs• Steel plate over neoprene strip seal

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Design Phase

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Design Phase• Proposed Bridge Superstructure (con’t)

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– Enhanced AASHTO yield line analysis using assumed impact loads from design haul vehicle.• 8’-8” barrier and rail

combination• 14’-0” debris shield

Design Phase• Proposed Bridge Superstructure (con’t)

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– 3D Finite Element Analysis for Deck and Approach Slab Design• 12” Class AAAP

Concrete Deck• 30” Class AAAP

Concrete Approach Slab

Design Phase• STAAD – Concrete Stress Output

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Design Phase• Proposed Bridge Substructure

– Pile Stub Abutments behind MSE Walls (BC-799M)• Cost effective• Quick construction• Minimize concrete pours in winter• Integral CIP concrete crash wall for adjacent railroad• Predrilling to eliminate pile downdrag

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Design Phase• Proposed Bridge Substructure (con’t)

– Wall Piers• Simple construction• Integral crash wall for adjacent railroad

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Design Phase• Structural Design Considerations

– Two 30-0” bi-directional loaded lanes, limiting only one CAT 777G in each lane.

– Pile design (S.O.L. 483-13-12) • 50 ksi pile capacity• Temporary haul condition – Full pile section• Permanent condition – Reduced section accounting for

1/16” loss due to corrosive soils

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Construction Phase

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Construction Phase• MSE Wall Embankment Fill

– Contract drawings specified AASHTO NO. 57– Standard PennDOT Special Provisions allow for varying

types of fill materials with up to 15% fines– Special provisions take precedence in hierarchy of

contract documents in case of a discrepancy– Contractor’s bid based on sand

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Construction Phase

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Construction Phase• Request to run larger equipment across bridge

– CAT 785C• 550 k GVW (compared to 360 k GVW for CAT 777G)• 50% heavier than CAT 777G design• Bridge did not rate

– Various additional equipment loads evaluated– Signs installed at bridge approaches

• One vehicle in each direction at a time (200’ spacing)• Limit equipment on bridge & speed to 15 MPH

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Construction Phase• Future Pipe Rack

– Additional 1.5 k/ft– Evaluate for final condition– Design modifications to accommodate

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Construction Phase

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January 2016 Field Visit

West Haul BridgeOhio River I-376

Construction Phase

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January 2016 Field Visit

Construction Phase

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January 2016 Field Visit

Construction Phase

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March 2016 West Haul Bridge in Use

Lessons Learned

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Lessons Learned• Review special requirements closely against

contract documents (MSE Fill)• Ensure design limitations are clear on plans• Consider modifying design criteria for temporary

conditions• Consider future potential uses and loadings

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Questions and Answer