& schoharie county& schoharie county department of public ... · • erosion of the stream...

Engineering Architecture & Surveying P CEngineering, Architecture, & Surveying, P.C.

& Schoharie County& Schoharie County Department of Public Works

Re-Use of a Bridge Superstructure at Stone Store Road BridgeStone Store Road Bridge

November, 2014

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Table of ContentsStone Store Road Bridge

1. Background of the steel beams 1. Originally used on Schell Road Bridge

2. Re-used on Bush Road Bridge

2. Use of Beams on Stone Store Road Bridge1. Bridge condition before inspection

2. Design of a new bridge

3. Construction photos, timeline, costs

4. Total project savings

3. Learning Assessment Questions

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Prior to ConstructionStone Store Road Bridge

Why this project is unique:

Bridge superstructure was recycled.

Schoharie County forces constructed this project.

Thi d th C t b t ti l t fThis saved the County a substantial amount of money.

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BackgroundSchell Road Bridge

Steel was originally placed on Schell Road Bridge• Two span bridge over Fox Creek.

• Built c.1930.

B id l d d i 1996 fl di• Bridge was severely damaged in 1996 flooding.

• Saved all the steel bridge beams from the bridge.

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Background Bush Road Bridge

• Bush Road Bridge• Town of Conesville

• Built 1902

• 40 foot, single-span, rolled steel pony truss, timber deck, and rub rail

• Abutments are concrete with spread footings on earth cut (no piles)g ( p )

• Asphalt wearing surface, W-beam railing

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• Issued Red Structural Flags in 2007Background Bush Road Bridge

• Issued Red Structural Flags in 2007

• Cracking of the left and right trusses

• Issued Red Structural Flags in 2006

• Abutment footings were undermined

• Cracking of second floorbeam

• Cracking of the top flange cover plate

• End truss bearings were overextended

• End stringers were in contact with end backwall

• Computed condition rating of 3.677

• Truss bottom chords were bowing

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BackgroundBush Road Bridge

Steel superstructure was then re-used on Bush Road Bridge

• The steel superstructure was placed on Bush Roadwas placed on Bush Road Bridge in 2007

• 2008 Bridge Inspection reportInspection report issued no red flags.

• Computed condition

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rating of 6.129


Hurricane Irene DamageAugust 28, 2011

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• In a report to FEMA in December 2011C k b d d b t 6 t 7 f t• Creek bed scoured by up to 6 to 7 feet

• Undermining of both abutments

• Splayed wingwalls at the east abutment became detachedSplayed wingwalls at the east abutment became detached

• West abutment was undermined

• Erosion of the stream bank occurred at all four corners of the bridge

• Preliminary cost estimates for replacement with a new pre-cast concrete three-sided frame structure was $844,000 (including design, construction, ROW acquisition, construction inspection)

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, q , p )

Prior to ConstructionRe-using Beams on Bush Road Bridge

• Due to flooding from Hurricane Irene, Bush Road h d l d t b l dwas scheduled to be replaced

• The steel beams, wooden deck, and rail system, which were still in noticeably good shape, were salvaged.were still in noticeably good shape, were salvaged.

• The County worked with engineers to find a good use for the bridge

• Decided to re-use the bridge on the replacement of Stone Store Road Bridge

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Prior to ConstructionRemoving Beams on Bush Road Bridge

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Prior to ConstructionStone Store Road Bridge: BIN 3354770

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• Stone Store Road BridgeB ilt i th 1930• Built in the 1930s

• 22’ span, 19’10” width

• 2013 computed condition rating of 3 796• 2013 computed condition rating of 3.796

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Stone Store Road HistoryStone Store Road Bridge: BIN 3354770

GUIDE RAIL1978 – Comment in report that “both approaches need guide rail.” 1992 S f t fl f b k i ili th b id1992 – Safety flag for broken pipe railings on the bridge1995 – No approach railing safety flag 2001 – Timber posts installed to remove safety flag p y g2002 – Timber posts bent and hit2004 – Safety flag for failed timber posts2006 Two safety flags for cracks and weakness in bridge pipe2006 - Two safety flags for cracks and weakness in bridge pipe

railings2007 - Safety flags removed as pipe railing cracks repaired

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A h R iliApproach RailingStone Store Road Bridge: BIN 3354770

1995 2012

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PRIMARY MEMBER1986 Primary member section loss to flanges was 20%1986 – Primary member, section loss to flanges was 20% 2003 – Section loss to girders reported at 40% 2005 – Red flag for section loss to girders of 52% max2007 - Red flag removed by NYSDOT as load rating indicates section loss did not reduce capacity2014 – Yellow flag issued for section loss on the bottom flanges2014 Yellow flag issued for section loss on the bottom flanges of the girder at G4 (57%)

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The jack arch deck is spalled away, exposing section loss of girders. Two red flags issued in August 2011. Section

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g g gloss progresses from 20% in 1986 to 57% in 2014.


FLOOD DAMAGE1987 Emergency flood inspection wingwall washout1987 – Emergency flood inspection, wingwall washout 2011 (April) – Two yellow flags are issued for erosion underneath

the wingwalls2011 (August) – Post-flood inspection determined cracks in the

abutments due to erosion after Hurricane Irene.

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Flood DamageStone Store Road Bridge: BIN 3354770

Both footings are undermined and have vertical cracks. Two yellow flags issued in April 2011.

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Before ConstructionStone Store Road Bridge: BIN 3354770

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Stone Store Road Bridge before

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construction


Previous Bridge New Bridge

• Centerline to centerline bearings 22’-0”

O t t t idth 22’ 3”

• Centerline to centerline bearings 37’-7 9/16”

O t t t idth 23’ 3”• Out to out width 22’-3”

• Clear roadway width 18’-6”

• Out to out width 23’-3”

• Clear roadway width 20’-6”

• Bridge designed for HS22 loading

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AADTStone Store Road Bridge: BIN 3354770

• Schell Road Bridge – 30/1987

• Bush Road Bridge – 50/2006

• Stone Store Bridge – 200/2006Stone Store Bridge 200/2006

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DesignStone Store Road Bridge: BIN 3354770

Design included:

• Relocation of existing roadway alignment to maintainRelocation of existing roadway alignment to maintain existing bridge location during construction.

• Improvements to vertical and horizontal geometryImprovements to vertical and horizontal geometry.

• Improvements to sight distance at the bridge.

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Design included:

• Design of new cast-in-place concrete abutments and wingwalls. g p gConcrete abutments were designed to accommodate the recycled superstructure. This was changed to stone strong walls by the County in order to reduce construction time; the walls have by e Cou y o de o educe co s uc o e; e a s a ethe same configuration.

• Keep existing bridge substructure to protect the new bridge with li ht i t f th h d li islight improvement of the hydraulic opening.

• All steel superstructure members were removed from Bush

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Road Bridge, sand blasted, and hot-dipped galvanized.

Design – Proposed AlignmentStone Store Road Bridge: BIN 3354770

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Property acquisitionProperty acquisition

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During ConstructionStone Store Road Bridge: BIN 3354770

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C t ti Ti liConstruction Timeline Stone Store Road Bridge: BIN 3354770

Date Project Milestone2001 Removal of beams from Schell Road Bridge2001 Removal of beams from Schell Road Bridge

Summer/Fall of 2007 Superstructure Placed on Bush Road Bridge

August 29, 2011 HURRICANE IRENEFall 2013 Deck and superstructure removedFall 2013 Deck and superstructure removed

Summer 2014 Superstructure sandblasted and galvanized

Fall 2014 Stone Store Bridge constructed

Fall 2014 (proposed) Bridge re openedFall 2014 (proposed) Bridge re-opened

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Post ConstructionStone Store Road Bridge: BIN 3354770

What problems were faced during construction?• Property acquisition• Excavation adjacent to the road to 12 feet deep• Maintaining traffic on Stone Store Road during construction

What was done to rectify the problem?• Bought property

Shift d b id 5’ d t d d h i b t t l t• Shifted bridge 5’ downstream and used shoring box to excavate close to the roadway • Road reduced to one lane with a Jersey barrier

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Construction Cost BreakdownConstruction Cost Breakdown Stone Store Road Bridge: BIN 3354770

Task Contractor/Suppliers Price

Materials

Sand blasting and trucking Sowle’s Auto Body $4,995

Rebar Steel Sales, Inc. $5,860

G l i i H bb ll $6 000Galvanization Hubbell $6,000

Concrete Cranesville Concrete $19,900

Stone strong blocks LHV Pre-Cast $34,556

Asphalt (approx., based on bid price) Cobleskill Stone $20,000Asphalt (approx., based on bid price) Cobleskill Stone $20,000

Miscellaneous Hardware $3,850

SUPERSTRUCTURE TOTAL $95,161

Outside Labor/Consulting

Design services Spectra Engineering $35,000

Removal of existing superstructure W.M. Schultz Construction $45,000

Property acquisition $5,000

Shoring & excavator rental $18 000

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Shoring & excavator rental $18,000

TOTAL $103,000


Work to be completed by Schoharie County forces included:

• Property acquisition

• Construction stakeout

Construct concrete formwork

• Install the deck & rail system

• Box out and build new bridge

approaches• Construct concrete formwork

• Install and tie the steel

• Pour the concrete

approaches

• Pave the deck & approaches

• Install the guiderail• Pour the concrete

• Install beams and diaphragms

• Install the guiderail

• Install top soil and seed

• Install rip rap

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sta p ap


Estimated bridge replacement cost: $519,555(Winbolts 2014 estimate)(Winbolts 2014 estimate)

All work completed for less than $225,000 (approx.)

Total savings: $294,555 (approx.)

Savings for re-using the steel beams:

Savings: $15,000 (approx.)

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Project Objective

To provide the replacement of Stone Store Road Bridge in an expeditious and cost-ffeffective manner.

This objective was achieved. The structure was replaced within two years at an out ofwas replaced within two years at an out of pocket cost of less than $225,000.

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Learning Assessment

Can you flag a condition that was never designed into the structure?designed into the structure?

Yes, even though it still rates as an 8.

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Learning Assessment

What are some issues to consider when re-using bridge beams?re using bridge beams?

Fatigue cycles, section loss.

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Learning Assessment

In addition to re-using the steel beams, whatIn addition to re using the steel beams, what cost-savings measures were employed with this project?

Project was undertaken with County forces. O i i l b t t l ft i lOriginal abutments were left in place as scour protection.

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Question and Answers

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& schoharie county& schoharie county department of public ... · • erosion of the stream...

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