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The Bayonne Bridge: Reconstruction of a 1931 Steel Arch

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The Bayonne Bridge: Reconstruction of a 1931 Steel Arch The Bayonne Bridge: Reconstruction of a 1931 Steel Arch Joseph LoBuono, PE (HDR/WSP) Engineering Symposium Rochester 2018 April 24, 2018 Project Development The Project Challenges Innovation Construction Status Project Development The Port of New York and New Jersey NEW JERSEY BAYONN E BRIDGE NEW YORK Bayonne Bridge History • Designed by Othmar Ammann and Cass Gilbert Also Designed The George Washington Bridge; Triborough Bridge; Bronx - Whitestone; Throgs Neck; and Verrazano- Narrows • Opened to Traffic on November 15, 1931 1,675-foot, Steel Arch Span was the Longest in the World at the Time, and Remained so for 46 years • 1985 Designated a National Historic Civil Engineering Landmark • 2001 National and NJ State Historic Register Eligible (2003 NY Eligible) Existing Main Arch Span Problem: Bayonne Bridge Air Draft Restriction • Existing 151-foot Air Draft • The Expansion of the Panama Canal will Allow for New, Larger, (Post-Panamax) Ships with Increased Clearance Requirements 151 Feet • Taller Ships (up to 200-ft), will not be able to Navigate Beneath the Bayonne Bridge • The Bridge of the Americas (Pacific Approach to Panama Canal), has a 201-foot Clearance • Trends in Shipping (shown in photo) • 8,000 TEU Regina Maersk • 13,000 TEU Emma Maersk Problem: Bayonne Bridge Air Draft Restriction Raise the Roadway Rehabilitate, Retrofit, and Reuse - Arch Full Replacement of Approach Structures The Project Approach Structures: Articulation/Pier Fixity New York (12 spans, 272’ max, 125’ min) New Jersey (14 spans, 252’ max, 171’ min) Approach Structures: Piers Single Pier Combined Pier Tall Pier Main Span Roadway Looking North Existing & New Arch Floor System Challenges Challenges Upgrade 81 Year Old Structure to 2012 Code Cross-Sections: Arch Span – Original Design Cross-Section Comparison Wider Roadway 1930 Live Loading vs. 2011 Live Loading 1930 Live Loading vs. 2011 Live Loading 1930 Live Loading vs. 2011 Live Loading 1930 Live Loading vs. 2011 Live Loading Challenge - Arch Structures: Strengthened Member Typical Lower Chord Strengthening Challenge - Arch Structures: Strengthened Member Composite Final Member: Existing Steel + New Steel Traffic Existing Unload Strengthen Reload Unload Reload Switch Sidewalk New Steel 1/2 Deck Upper Rdwy 1/2 Deck 1/2 Deck 1/2 Deck Framing Arch – Loading Cycles Arch – Loading Cycles Challenges Maintain 2 Lanes of Traffic During Construction Challenges Construct New Structure Within Existing Structure Challenges Raise the Profile 65’ at Center Challenges Construct New Portals Innovation Challenges Construct New Arch Floor Arch - New Floor Construction 01 Arch - New Floor Construction 02 Arch - New Floor Construction 03 Arch - New Floor Construction 04 Arch - New Floor Construction 05 Arch - New Floor Construction 06 Arch - New Floor Construction 07 Arch - New Floor Construction 08 Arch - New Floor Construction 09 Arch - New Floor Construction 10 Arch - New Floor Construction 11 Arch - New Floor Construction 12 Arch - New Floor Construction 13 Arch - New Floor Construction As-Built Transfer Girder Arch New Floor - Transfer Truss Girders Approach Structures: NB Type 1 Pier Construction AS-Bid NB Pier Redesigned NB Pier Approach Structures: NB Type 1 Pier Construction Approach Structures: NB Type 1 Pier Approach Structures: NB Type 1 Pier Construction Status Construction - Approaches Drilled Shafts Construction - Approaches Precast Concrete Pier Segments Construction - Approaches Precast Concrete Superstructure Segments Construction: Approaches Northbound NY Approach Superstructure September 2016 Construction Status: Segmental Complete, Back-launch Gantries Construction Status: NB Lanes (2) Opened February 2017 Construction Construction Existing Arch Floor Demolition Existing Arch Floor: Demolition of Suspended Span Complete September 7, 2017 14,400 TEUs vs. 5,000 TEUs Vessel Height at 185 feet (actual) The End.
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