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(CM/CI) Rapid Bridge Replacement Project Magnitude, Challenges & Technology Date: March 28, 2018

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(CM/CI) Rapid Bridge Replacement Project Magnitude, Challenges & Technology Date: March 28, 2018 Construction Management/Construction Inspection (CM/CI) Rapid Bridge Replacement Project Magnitude, Challenges & Technology Date: March 28, 2018 www.trcsolutions.com | Pittsburgh Section Presenters Scott Gallaher, PG SVP Infrastructure, CEI/CIM Practice Lead [email protected] Richard Shoemaker VP – Principle Manager – CEI, Construction Engineering Group [email protected] Colby Dressler, PE Project Manager/Construction Engineer [email protected] Robert Horwhat, PE Director Structural Materials Inspection [email protected] www.trcsolutions.com 2 Agenda TRC PA Rapid Bridge Project Relevant Projects Polyester Polymer Concrete P3 Materials Inspections Conclusions (Takeaways) www.trcsolutions.com 3 Company Fact Sheet About TRC A pioneer in groundbreaking scientific and engineering developments since the 1960s, TRC is a national engineering, environmental consulting and construction management firm providing integrated services to the power, oil and gas, environmental and infrastructure markets. From more than 120 offices throughout the U.S., our 4,100 employees serve a broad range of commercial, industrial and government clients, implementing complex projects from initial concept to operations. Employees 4,100 Headquarters Lowell, Massachusetts Locations 120 U.S. Office; U.K Office, China (Shanghai) Office, Canada Office ENR Top 500 Design Firm Rank 23 Businesses While we work in a broad range of industries our focus is on the Environmental, Power/Utility, Oil and Gas and Transportation sectors. Services span categories including: Power Oil & Gas Environment al 4 Infrastructure www.trcsolutions.com TRC Offices . 4100+ employees . 120+ U.S. offices; London and Shanghai office www.trcsolutions.com 5 Infrastructure Highways and Roadways | Bridges | Utilities, Sewers and Water Lines | Railroads | Building Structures . Roadway and Bridge Engineering Design . Building Condition Assessments . Construction Management, Engineering . Site and Civil Engineering and Inspection . Traffic Engineering . Geotechnical Engineering, Inspection and . Metallurgical Engineering Testing (field and lab) . Structural Steel Fabrication Shop Inspection . Geotechnical Test Borings . Precast/Prestressed Concrete Plant . Bridge Safety Inspection Inspection . Public Relations www.trcsolutions.co m 6 Pittsburgh Section 7 PURPOSE of project PA taking advantage of Act 88 to address the roughly 4500 structurally deficient (SD) bridges. With this Public Private Partnership (3P) approach, 558 SD bridges will be replaced more quickly; help achieve significant savings for taxpayers; and minimize the impact on the traveling public. The P3 (PWKP) will finance, design, construct and maintain the bridges for 28-year term. Construction was to be completed for all 558 bridges within 36 months. PennDOT will maintain ownership of the bridges throughout the contract. Roughly 20 % of Pennsylvania’s bridges are structurally deficient, (4506 of 22000) while the national average is 9.1 percent(2016). Unless replaced, these bridges will ultimately have to be closed, jeopardizing public safety and harming the state’s ability to grow economically and create jobs. A SD bridge is not unsafe. The designation means that one or more of its major components is deteriorating. www.trcsolutions.com 8 PADOT Rapid Bridge Replacement Project (PARBRP) 558 bridges in ~ 2 & 1/2 years 411 single Span Bridges 27 Multiple Span Bridges 120 are Culverts Prestressed, Culverts, Steel Average Structure is about 60’ in length 62 will be more than 100’ long 417 bridges will be constructed using 2,291 pre-stressed concrete beams The beams will use 6.1 million linear feet of steel strand or 1,155 miles Construct as per revised PADOT 408 Change #7 Construct as per specifications as if this were a standard design bid build 9 Role of the CQAF Construction Quality Acceptance Firm :CQAF Construction Quality Acceptance Managers: CQAM Construction Quality Acceptance Staff A quality acceptance inspection and material sampling/testing staff shall be employed by the CQAF and shall, under the direction of the CQAM, perform inspection and material sampling/testing of all Work performed and materials incorporated into the Project by any member of Development Entity’s group. The services of the CQAF shall be part of the Development Entity’s Quality Management System. perform independent quality acceptance material testing and inspection; perform quality acceptance inspection; perform audits addressing compliance with QMP; certify that the Work meets Development Entity’s acceptance criteria; 10 Role of the CQAF TRC Engineers is contracted to the By the Technical Provisions, CQAF Development Entity, Plenary Walsh worked with Development Entity Keystone Partners, LLC (PWKP) to produce the acceptance scope; The owner did review contract TRC Engineers by contract has joint and Throughout development of equal reporting responsibilities to both Inspection and Test Plans (ITP’s), PWKP, and PADOT. issues arose where the Owner TRC is the only entity contractually tied to preferred more involvement from both the owner (DOT) and the developer. the CQAF Even without disagreements to extended scope, because contract terms were set out up front, this still created contractual/financial challenges Dual Reporting presents challenges for the CQAF 11 Role of the CQAF Inspection process for CQAF in 2015 and 2016 was designed Inspection process for CQAF in 2017 was converted to 100% as a “HOLD POINTS” inspection relative to items that are Full Time CQAF along with removal of most Contractor QC defined as an acceptance test, or activity that required full staff. time witness: CQAF is “full time” with exception of activities that Foundations do not require inspection in an effort to conserve Test piles resources and provide for quality of life Production piles Rebar tying Concrete placement Job site Clean up Acceptance breaks Etc. Hold points that were required in past years, still Backfill required Bituminous Paving In addition to the field inspection element TRC Engineers, is also responsible for: Full time inspection in fabrication facilities for prestressed, precast, structural steel elements 30 facilities to date in multiple states. Project documentation review- Source of Supply, certifications, QC plans, etc. 12 Role of the CQAM The CQAM shall review, approve, authorize, examine, and confirm any methods or procedures requiring the “Engineers’ review, approval, authorization, examination, confirmation, etc.” which are contained in Publication 408. (Ex Dot: Structures control Engineer) is part of the three part dispute resolution team consisting of TRC, PADOT, HDR Issue Recommendation Letter for substantial completion Issue Recommendation letter for final acceptance. 13 Structure of CQAF Developed a structure in CQAF, Construction Managers, Area Field Managers and Field staff, Auditors. Parallel Unit for fabrication shop inspection. This structure is loosely matched on the QC side with WGCJV 3 regions across state typical pyramid structure Created a matrix of communication in quality management units and PADOT Intent is to push down decisions making levels, and establish escalation processes if needed. Final say goes to dispute resolution team 14 Challenges 15 Challenges Understanding the differences in roles between CQAF, Quality control, Quality assurance Qualified Inspectors Same certifications as standard delivery Available resources Different approach to acceptance with CQAF Hold Point inspection Substantial on-boarding effort Extensive winter school Fully integrated sub consultants 16 Challenges Matching manpower to Contractors schedule General schedule is on a continuous two day look ahead Real schedule is hourly Work force fatigue High stress job everyone is watching Extensive travel – 4,672,643 miles driven thru Feb 2018 OT hours, routinely OT running at the equivalent of 19 FTE’s/ month Contractor delays Paperless project 17 P3 Multi Asset Challenges In many cases, design-build projects nearing $1 billion are usually single assets or localized to a general area. The project team is located in/around the project. With 558 assets, resolving project and technical issues becomes exponentially more difficult; for example: You can’t “look out your window” and see your project Many of the assets chosen for replacement are small, single-span bridges in remote areas Lack of cell service THE HUMAN FACTOR== At any point in time, there is always two entities involved in a project issues- CQAF and Lead Contractor. Many times, the statements of the exact problem do not match. Must utilize common tools to truly resolve- conference calls, FaceTime/Skype, real time pictures, etc. 18 “The Learning Experience” Some fundamental changes in normal requirements Experienced “fit up” issues with precast culverts- this subsequently led to requiring fabricators to “fit up” adjoining pieces Contract required CQAF to work with labs that were AMRL accredited- upon searching it was found that no labs existed in the state which led to accreditations being received Fundamental changes in how prestress strand is tested/accepted- now takes into account failures due to testing operation, grip, etc. Clarified some items for ease of construction Use of aluminum instead of Masonite when setting culverts Use of a protective asphaltic board in place of an asphalt mix for culvert protection Clarification of grouting requirements for culverts (50 psi)
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