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8/30/2017 1 PATTULLO BRIDGE Concrete Deck Rehabilitation

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8/30/2017 1 PATTULLO BRIDGE Concrete Deck Rehabilitation 8/30/2017 HISTORY PATTULLO BRIDGE • Originally opened in 1937; Concrete Deck • First toll bridge in British Columbia. Rehabilitation & Service Life Extension Scott R. Cumming, M.E., P. Eng . WSP Canada Inc. Technical Discipline Manager, Group Leader, Concrete Technology Materials Discipline, Western Canada 2016 ICRI Kick‐Off Party | February 1, 2016 2016 ICRI Kick‐Off Party | February 1, 2016 LOCATION CONFIGURATION • Four lane arterial • Four narrow lanes connection between (3.0 m each); Surrey and New Westminster, BC; • Limited by width of truss • First major river crossing opening (12.04 m); for vehicles to connect Metro Vancouver to • Centre two lanes closed Fraser Valley; each night from 10pm to • Originally built by the 5am; Province of British (provides additional Columbia as part of separation for impaired Highway 1A; drivers). 2016 ICRI Kick‐Off Party | February 1, 2016 2016 ICRI Kick‐Off Party | February 1, 2016 1 8/30/2017 CONFIGURATION REINFORCED CONCRETE BRIDGE DECK • North and South approach spans supported by concrete‐ encapsulated steel trusses; • Main river crossing spans • Nominally 200 mm thick; • Waterproofing supported by structural membrane was originally steel spans; • 50 mm asphalt pavement installed; • Camel back truss spans overlay; navigable channel; • Removed in 1982 and • Spans supported by steel asbestos‐modified trusses are FAR more asphalt overlay placed; dynamic than approach spans. 2016 ICRI Kick‐Off Party | February 1, 2016 2016 ICRI Kick‐Off Party | February 1, 2016 REINFORCED CONCRETE BRIDGE DECK PROVINCE OF BC CREATES • Issues related to concrete • Bridge operations limped deterioration were known to along through 1980s and BC MoTI in 1982; 1990s as concrete • Deferred rehabilitation until deterioration worsened with 1985 until construction of a time; new 6‐lane crossing was • South Coast Regional completed downstream; transportation Authority • With new crossing came (TransLink) created by population explosion south of Province of BC in 1998. the Fraser River; • In 1999, Province of BC “gifts” • Unable to undertake Rapid three bridges to TransLink; rehabilitation due to population • Downloaded responsibility perceived major impact on growth traffic flow; for operation and • Average traffic volume is maintenance onto the regional 70,000 vehicles per day. transportation authority. 2016 ICRI Kick‐Off Party | February 1, 2016 2016 ICRI Kick‐Off Party | February 1, 2016 2 8/30/2017 TransLink FIRST NOTICES DECK CONDITION IS POOR TransLink FIRST NOTICES DECK CONDITION IS POOR • Extent of deterioration not fully • Widespread condition assessment understood until 2003 when re‐ undertaken in 2006; coating of the below‐deck portion • Bridge closed for a weekend; of steel truss span is undertaken; Leakage through • Top surface of deck exposed by milling full thickness cracks • Scaffolding installed beneath deck at transverse floor of asphalt overlay to expose reinforced for re‐painting work; beams concrete bridge deck at select locations; • Confused as to why brand new • Condition Assessment included: blue paint is being stained rust • Delamination survey; brown; • Cover depth measurement; • Scaffold provides close‐up access • Half‐cell corrosion potentials; to deck soffit for first time; • Chloride profiles; • Identified full‐thickness cracks • pH profiles; and major water leakage through • Corrosion rate measurements; deck; • Condition of superstructure and • First limited condition assessment substructure elements also reviewed; undertaken at soffit; 2016 ICRI Kick‐Off Party | February 1, 2016 2016 ICRI Kick‐Off Party | February 1, 2016 TransLink STARTS TO REALIZE HOW BAD IT IS… TransLink STARTS TO REALIZE HOW BAD IT IS… • In 2009, a fire started by • Signage installed beneath bridge homeless people destroyed the deck to warn of risk of falling timber superstructure supporting concrete. the final span of the South Approach; • Nets are installed to catch falling • Extended deck closure while concrete at areas of bridge repairs are undertaken; spanning: • Access provided to remaining • Roads; area of deck; • Railroad tracks; and • All asphalt pavement overlay • Navigable river channel. removed and replaced; • Deck condition assessed in detail; • RESULTS ARE HORRIFYING 2016 ICRI Kick‐Off Party | February 1, 2016 2016 ICRI Kick‐Off Party | February 1, 2016 3 8/30/2017 EXTENT OF DETERIORATION IMPACTS RIDEABILITY EXTENT OF DETERIORATION IMPACTS RIDEABILITY • Widespread spalling of concrete • Weekend closures undertaken two deck caused by chloride‐induced to three times annually from 2009 to corrosion begins to disrupt asphalt 2015; pavement overlay; • Not enough time for proper repairs, • Major potholes frequently result; cleaning rebar, substrate preparation, patching, etc.; • Periodic weekend closures implemented to target problem • Only had sufficient time to patch areas; spalls and re‐pave in order to minimize traffic disruption; • Select areas exposed by milling; • No time allowed for efforts to arrest • Spalls removed by chipping; or mitigate corrosion. 2016 ICRI Kick‐Off Party | February 1, 2016 2016 ICRI Kick‐Off Party | February 1, 2016 EXTENT OF DETERIORATION IMPACTS RIDEABILITY MULTIPLE DECK CONDITION ASSESSMENTS UNDERTAKEN • Periodic repairs actually made things Halo Patch • Findings: worse due to the ring‐anode effect Material • Widespread delaminations; and forced anodic corrosion into • Up to 32% in some spans; concrete surrounding patch repairs; • Major soffit spalling at steel truss spans; • Deterioration accelerated and worsened with time. 2016 ICRI Kick‐Off Party | February 1, 2016 2016 ICRI Kick‐Off Party | February 1, 2016 4 8/30/2017 MULTIPLE DECK CONDITION ASSESSMENTS UNDERTAKEN MULTIPLE DECK CONDITION ASSESSMENTS UNDERTAKEN • Findings: • Findings: • Extreme chloride • Major rebar section‐loss concentrations occurring; • > 10x threshold • Complete rebar section‐loss at concentration isolated areas; required to initiate and support corrosion at depth of rebar; • Surprisingly minimal alkalinity depression due to carbonation at top and soffit surfaces; 2016 ICRI Kick‐Off Party | February 1, 2016 2016 ICRI Kick‐Off Party | February 1, 2016 MULTIPLE DECK CONDITION ASSESSMENTS UNDERTAKEN OTHER CHALLENGES • Findings: • Extreme half‐cell potentials (more • The deck is not this bridge’s only issue… electronegative than ‐350 mVCSE at widespread areas); • Widespread full thickness SUBSTRUCTURE cracking. IS EXHIBITING WIDESPREAD CRACKING DUE TO ALKALI‐SILICA REACTIVITY; 2016 ICRI Kick‐Off Party | February 1, 2016 2016 ICRI Kick‐Off Party | February 1, 2016 5 8/30/2017 OTHER CHALLENGES OTHER CHALLENGES • The deck is not this bridge’s only • The deck is not this bridge’s only issue… issue… WIDESPREAD CRACKING AND SPALLING IS PRESENT STEEL SUPERSTRUCTURE AT APPROACH SPAN EXHIBITS COMPLETE SUPERSTRUCTURE SECTION LOSS AT SOME AREAS DUE TO CORROSION; CORROSION JACKING OCCURRING AT UPPER FLANGES. 2016 ICRI Kick‐Off Party | February 1, 2016 2016 ICRI Kick‐Off Party | February 1, 2016 OTHER CHALLENGES OTHER CHALLENGES • The deck is not this bridge’s only • The deck is not this bridge’s only issue… issue… BEARINGS ARE PIER NO. 5 SEISMICALLY ALMOST DEFICIENT COMPLETELY UNDERMINED BY SCOUR 2016 ICRI Kick‐Off Party | February 1, 2016 2016 ICRI Kick‐Off Party | February 1, 2016 6 8/30/2017 OTHER CHALLENGES OTHER CHALLENGES • The deck is not this bridge’s only • The deck is not this bridge’s issue… only issue… BRIDGE DECK IS TOO NARROW DUE TO PILES DO NOT WIDTH OF TRUSS EXTEND THROUGH 12.0 m ÷4 lanes = 3.0 m each OPENING; FULL‐DEPTH OF LIQUIFIABLE SOILS WIDTH OF EACH LANE INTO SOLID IS LESS THAN CURRENT GROUND DESIGN CODE OF ≥ 3.6 metres 2016 ICRI Kick‐Off Party | February 1, 2016 2016 ICRI Kick‐Off Party | February 1, 2016 SEISMIC RETROFIT & REHABILITATION PROJECT SEISMIC RETROFIT & REHABILITATION PROJECT • TransLink issues an RFP for Seismic Retrofit and Rehabilitation Project in 2013; • Winning team lead by Buckland & Taylor (now COWI Bridge North America) • Preliminary Design Requirements: • Extend service life by 30 years; • Widen deck to current design requirements (i.e. widen truss opening); • Must mitigate impact of work on traffic flow (so… widen truss while bridge is open to traffic); • Bearing replacement; • Determined that list of deliverables cannot be completed for • Deck rehabilitation; TransLink’s maximum allowable budget of $299M (surprise!); • Substructure repairs and strengthening; • TransLink removes various scope items; • Seismic retrofit for 1‐in‐2,475 year return period earthquake; • Reduce seismic requirements to 1‐in‐475 return period earthquake; • Ground densification for foundations; • Armouring of in‐river piers with riprap; • Requests design team to evaluate second option to extend service life • Consultation with six First Nations bands claiming land rights; of bridge deck for an additional 10 years; • Archaeological assessment; • A 10 year rehab is VERY different than a 30 year rehab; • Preliminary cost estimate and construction schedule; • • Capital budget for construction is $299M (Maximum); Project now requires two parallel designs. 2016 ICRI Kick‐Off Party | February 1, 2016 2016 ICRI Kick‐Off Party | February 1, 2016 7 8/30/2017 OPTIONS CONSIDERED FOR REHABILITATION PROJECT TransLink Governance 10 year Service Life Extension: 30 year Service Life Extension: • Governed by Mayors of 14 cities and • Remove asphalt overlay; • Complete removal and replacement of municipalities that comprise Metro • Remove top 50 mm of concrete two worst spans with precast units; Vancouver;
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