Rehabilitation Design and Construction for the US 190 Mississippi River Bridge Cleaning, Painting, and Repair Project

2013 Louisiana Transportation Conference Session 13

Durk Krone, P.E., TRC Engineers, Inc., Baton Rouge, LA

AGENDA
Design Team Organization

Site Location
Bridge Specifics History of Rehabilitation Projects Rehabilitation Project Phases 1 and 2

Key Areas of Deterioration

Procedures for Development of Repair Plans Non-Standard (NS) Items Constructability and Coordination

Maintenance of Traffic During Construction

Cleaning, Painting, and Containment Specifics Accelerated Schedule Bid Opening Phase 1

Construction
Conclusions & Questions
Results you can rely on

DESIGN TEAM ORGANIZATION

Louisiana DOTD Baton Rouge, LA
o Chris Guidry, P.E. Bridge Design Project Manager

TRC Engineers, Inc.

o Durk Krone, P.E. Principal o John Dallas Richard, P.E. Project Manager o Mike Paul, P.E. Project Engineer o Sage Liu, P.E. Project Engineer o Don Clayton, P.E. Maintenance of Traffic

Rahman & Associates

o o o o o Rahman Bhatti, P.E. President Paul Forte, P.E. Frank Rea Project Manager Al Fletrich, P.E. Principal Kyle Fetrich, P.E.

GPI Southeast

ENCON / CMS
Kansas City Southern (KCS) Railroad - Srikanth Honnur, P.E. Union Pacific Railroad (UPRR) Michael Freeman, P.E.
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SITE LOCATION
Between Intersections of LA 1 and US190 (west) US 61/US190/I-110 (east) River Mile 233.9 AHP

Results you can rely on

BRIDGE SPECIFICS

WEST APPROACH 5,300 FT

5,897 LF

MAIN TRUSS: 3,326 FT West Highway East Highway Approach: 1,728 FT Approach: 843 FT STRUCTURE LENGTH = 12,226 LF

EAST APPROACH 3,600 FT

BUILT 1940

4 Highway Lanes, 2 each way

ADT = 28,400 (2011)

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Results you can rely on

BRIDGE SPECIFICS

HIGHWAY APPROACH SPANS TRUSS SPANS

Highway Stringer Lower Chord Lower Lateral Bracing Floorbeam Railroad Girders

RAILROAD APPROACH SPANS

TRUSS SPAN FLOOR SYSTEM

Results you can rely on

HISTORY OF REHABILITATION PROJECTS

Bridge opened August 1940
Huey P. Long Bridge Old Mississippi River Bridge

Previous Rehabilitation Projects

Painted in mid-1960s Major Rehabilitation in 1986 Widened from 19-9 to 24-0 Deck & bridge rail repairs Structural strengthening

2005 In-depth Inspection by TRC 2010-2011 Special Inspections by TRC 2010-2013 Rehabilitation Project by TRC
Phase 1 (Highway & Railroad) Phase 2 (Railroad Approaches) Accelerated Schedule (2011)
Results you can rely on

REHABILITATION PROJECT PHASES 1 & 2

PHASE 2 = 3,572

PHASE 1 = 5,897 LF

PHASE 2 = 2,757 LF

WEST APPROACH: 5,300 FT MAIN TRUSS: 3,326 FT EAST APPROACH: 3,600 FT 100 % Railroad SHARED 50% RR 50% DOTD 100% Railroad West Highway Approach: 1,720 FT East Highway Approach: 835 FT SHARED PER STRUCTURAL ELEMENT SHARED PER STRUCTURAL ELEMENT
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KEY AREAS OF DETERIORATION

VERTICAL TRUSS MEMBERS

LATERAL & DIAGONAL MEMBERS

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KEY AREAS OF DETERIORATION

TOWER ANCHOR BOLT MEMBERS

GUSSET PLATES
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KEY AREAS OF DETERIORATION

STIRRUP BEARINGS

ROCKER BEARINGS

TRUSS LATERALS
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KEY AREAS OF DETERIORATION

TRUSS TERTIARY MEMBERS

TOWER MEMBERS
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KEY AREAS OF DETERIORATION

PIERS

HANDRAILS
Results you can rely on

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PROCEDURES FOR DEVELOPMENT OF REPAIR PLANS

EXAMPLE: DESIGN OF TRUSS VERTICAL MEMBER REPAIR
Identify the repair locations through inspection and coordination with DOTD Truss Member forces are obtained through truss analysis

Develop repair scheme:

o For members with dominating dead load the dead load stress should be minimize thru jacking or posttension before new steel for repair is integrated into the member o For members with significant live loads live loads need to be restricted during the repair

Repairs are grouped into a Type based upon similar repair details Each repair type is then assigned a Non-standard (NS) item number and given a unique item name for bidding purposes
TEMPORARY JACKING SCHEMATIC FOR VERTICAL REPAIRS TYPE I, II, III-A AND III-B

Example:
ITEM NO. NS-805-00016 NS-805-00016 SUMMARY OF ESTIMATED QUANTITIES ITEM NS BRIDGE SUPERSTRUCTURE REPAIR (TRUSS VERTICAL MEMBER REPAIR, TYPE I) NS BRIDGE SUPERSTRUCTURE REPAIR (TRUSS VERTICAL MEMBER REPAIR, TYPE II) UNIT EACH EACH QUANTITY 9 1

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PROCEDURES FOR DEVELOPMENT OF REPAIR PLANS

Key Plan of Repair Locations

Details for Each Repair Location

Temporary Jacking Scheme

Notes to Clarify Intent of Repairs

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PROCEDURES FOR DEVELOPMENT OF REPAIR PLANS

Temporary PostTension scheme

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NON-STANDARD (NS) ITEMS

Phase 1: 127 Non-standard Items Used for Needed Repairs Phase 2: 57 Non-standard Items Used for Needed Repairs Pay Unit = Each Total Number of Repairs = 4175 (2480 Phase 1,1695 Phase - 2) Reasoning/Benefits - Provides a unit bid price for each repair type - Provides a unit price for additional similar repairs found during construction Bridge Superstructure/Substructure Non-standard Item includes all labor, equipment, materials, and incidentals required to complete the work.

Results you can rely on

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CONSTRUCTABILITY AND COORDINATION

JACKING FRAME SYSTEM FOR STIRRUP BEARING REPAIRS

COORDINATION REQUIRED
ENCON (internal to design team) DOTD RAILROADS

Results you can rely on

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MAINTENANCE OF TRAFFIC DURING CONSTRUCTION

Phased Construction Highway Traffic
Commuter and Trucks Detour route for evacuations Lane Closures

Railroad Traffic (KCS & UPRR) Track Fouling

Results you can rely on

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CLEANING, PAINTING, & CONTAINMENT SPECIFICS

Total Surface Area 4,266,000 SF Pressure Wash and Solvent Clean to SSPC-SP1/SP12 NV2 Abrasive Blast to SSPC-SP10 Documents Specified an Organic Zinc, Epoxy Urethane Paint System Environmental Requirements

SSPC Guide 6, Level 1A Containment Pre- and Post-Project Soil and Water Sampling Air Quality Monitoring Visible Emissions Assessment - EPA Method 22 Waste Management SSPC Guide 7, 40 CFR (Collection, Storage, Transportation, Disposal)

Red Lead in Existing Paint Cleaning must be fully contained OSHA (29 CFR 1926.62, Lead in Construction PPE)

Respirators, Tyvex Suits, Fall Protection, Safety Glasses

Results you can rely on

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ACCELERATED SCHEDULE

May 2011 TRC met with DOTD and set a date for submission of final plans for late March 2012 DOTD contacted TRC on June 15, 2011 Surplus Federal Funds TRC submitted accelerated fee proposal to DOTD June 17, 2011 DOTD Issued Advanced Notice-to-Proceed June 20, 2011 August 31, 2011 TRC submitted 158 stamped and signed drawings (297 total sheets Phase 1)

Results you can rely on

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BID OPENING PHASE 1

BID OPENING DATE January 11, 2012 ENGINEER ESTIMATE = $ 85,460,813.70 HIGH BID = $ 118,288,888.88 LOW BID = $ 74,849,999.48 AWARDED TO - LIBERTY / ALPHA
DOTD Project No.: H.000343.6
RANK
1 2 3 4 5 6 Bidder Number 28182050 00271000 54683000 HER01000 47347000 24429000 Bidder Name Construction Bid (Items Total) $74,849,999.48 $82,258,373.20 $91,377,777.00 $92,345,632.31 $111,446,919.80 $118,288,888.88

Liberty Main.-Alpha Paint. A Jt Vt. Massman Construction Co. Conti Enterprises, Inc. Hercules Painting Co., Inc Kiewit Louisiana Co Abhe & Svoboda, Inc.

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CONSTRUCTION

CONTAINMENT SYSTEM

INSIDE CONTAINMENT
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CONSTRUCTION

BLASTING

RESULTS FROM BLASTING

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QUESTIONS

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