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Home , Bayonne Bridge

The New Bridge - - - Into the 22nd Century

Joseph LoBuono, PE Lead Engineer, The Bayonne Bridge Project

April 26, 2016 Presentation Outline

1. Project Evolution & Development 2. Project Description 3. Computer Analysis A. Sequencing 4. Arch Strengthening 5. The New Portals 6. Temporary Braces 7. Construction of the New Arch Floor 8. Construction Update

HDR/PB, A Joint Venture 2 PROJECT EVOLUTION & DEVELOPMENT

HDR/PB, A Joint Venture 3 Bayonne Bridge History • Designed by and Cass Gilbert • Also designed George ; Triborough; Bronx - Whitestone; Throgs Neck; and Verrazano-Narrows • Opened to traffic on November 15, 1931 1652–ft., 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)

HDR/PB, A Joint Venture 4 Project Background: Existing Facility

Existing Facility: 6,974’

HDR/PB, A Joint Venture 5 Project Background: Port Authority Bridges

HDR/PB, A Joint Venture 6 Project Background: Existing Facility

BAYONNE BRIDGE

HDR/PB, A Joint Venture 7 Problem: Bayonne Bridge Air Draft Restriction

• Existing 151-foot air draft • The expansion of the will allow for newer, larger, (Post- ) ships with 151 Feet increased clearance requirements • 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 clearance of 201 feet HDR/PB, A Joint Venture 8 PROJECT DESCRIPTION

HDR/PB, A Joint Venture 9 Project Background: Container Ships

Current Future

HDR/PB, A Joint Venture 10 BBNCP: Existing vs. Proposed Roadway Profile

HDR/PB, A Joint Venture 11 “Raise the Roadway” Rehabilitate, Retrofit, and Reuse – Arch

Existing Proposed

• Rehabilitate: Strengthening the Existing Arch • Retrofit: Relocation of the Arch Portals • Reuse: Raising the Roadway within Existing Arch

HDR/PB, A Joint Venture 12 Project Description

1. Project A. 12-ft. Shared Use Path B. Median Barrier C. Shoulders D. Accel/Decel Lanes E. New Power & Communications Systems incl. CCTV F. New Tower Structures (Interface Approaches & Arch) G. M/E Buildings in NY and NJ H. Storage Building in NY I. New Tower Structures w/ New Electric Service J. Closed Drainage System

HDR/PB, A Joint Venture 13 Project Description

2. Arch A. Strengthening B. New Floor System w/ new suspenders C. Edge Girders D. Repairs E. Health Monitoring System F. Lead Paint Abatement G. Hands-On Inspection H. SMART Bridge I. Demolition

HDR/PB, A Joint Venture 14 Project Description

3. Approach Structures A. New Foundations B. New Columns (precast segmental) C. New Superstructure (precast segmental) D. Demolition

HDR/PB, A Joint Venture 15 The Project – Arch Inspection

HDR/PB, A Joint Venture 16 The Project – Arch Inspection

HDR/PB, A Joint Venture 17 APPROACH STRUCTURES

HDR/PB, A Joint Venture 18 Approach Structures: Articulation/Pier Fixity Segmental Approach Structures New York (12 spans, 272’ max, 125’ min)

New Jersey (14 spans, 252’ max, 171’ min)

HDR/PB, A Joint Venture New Precast Concrete Box Girders

HDR/PB, A Joint Venture 20 Approach Structures: Pier Types

HDR/PB, A Joint Venture 21 Replacement – Approach Structures

Existing Condition NB Approach Final

HDR/PB, A Joint Venture 22 Approach Structures: Pier Types

Single Pier Combined Pier Tall Pier

HDR/PB, A Joint Venture Approach Structures: Pier Types

Single Pier Combined Pier Tall Pier

HDR/PB, A Joint Venture Modification Of As-Bid Design Pipe Strut

HDR/PB, A Joint Venture 25 Approach Structure: New vs. Old

HDR/PB, A Joint Venture 26 THE ARCH

HDR/PB, A Joint Venture 27 Main Span Roadway Looking North

HDR/PB, A Joint Venture 28 Wider Roadway – Arch

HDR/PB, A Joint Venture 29 Design Criteria: Live Loads – Future BRT/LRT

BASE

BRT

LRT

HDR/PB, A Joint Venture 30 1930 Live Loading vs. 2011 Live Loading

HDR/PB, A Joint Venture 1930 Live Loading vs. 2011 Live Loading

HDR/PB, A Joint Venture 1930 Live Loading vs. 2011 Live Loading

HDR/PB, A Joint Venture Arch Cross-Sections ARCH Cross-Section: Non-Suspended

HDR/PB, A Joint Venture Arch Cross-Sections ARCH Cross-Section: Suspended

HDR/PB, A Joint Venture The Raised Roadway

HDR/PB, A Joint Venture 36 Arch ARCH Statical Scheme

HDR/PB, A Joint Venture Construction Staging - Main Span Arch Span – Existing

HDR/PB, A Joint Venture 38 Construction Staging - Main Span Arch Span – Stage 1 (Adjusted by Contractor)

Stage 1: Shift Traffic to the East Demolition/Prep Construction

HDR/PB, A Joint Venture 39 Construction Staging - Main Span Arch Span – Stage 2

Stage 2: Demolish ½ Arch Floor Slab; Traffic to the West Demolition/Prep Construction

HDR/PB, A Joint Venture 40 Construction Staging – Stage 2

HDR/PB, A Joint Venture 41 Demolition/Prep Construction Staging - Main Span Construction Arch Span – Stage 3

Stage 3: New Arch Floor Steel (Current Phase)

HDR/PB, A Joint Venture 42 Demolition/Prep Construction Staging - Main Span Construction Arch Span – Stage 4 Stage 4: Traffic to New Floor System; Demolish Existing Arch Floor

HDR/PB, A Joint Venture 43 Construction Staging - Main Span Arch Span – Stage 5

Stage 5: Build West Half of New Arch Floor Demolition/Prep Construction

HDR/PB, A Joint Venture 44 Construction Overview: Tower

HDR/PB, A Joint Venture 45 COMPUTER ANALYSIS

HDR/PB, A Joint Venture 46 CE: Arch Construction Sequences

1. 37 Sequence Drawings in As-Bid Set (Arch + Tower) 2. Three Revisions to As-Bid Sequence – by contractor

HDR/PB, A Joint Venture 47 Arch Analysis

HDR/PB, A Joint Venture 48 Arch Analysis

13,786 Nodes 13,872 Members 6,008 Plates 41 Springs 114 Master/Slave Nodes 296 Sections 544 Static Load Cases 38 Construction Load Cases 349 Construction Steps

HDR/PB, A Joint Venture 49 Arch Construction Sequences

1. Complete staged construction analysis tracking construction activities in this unprecedented construction process 2. Typical construction activities include: • Removal of existing components, • Construction of new components, • Installation and removal of temporary components, • Strengthening of existing components, • Replacement of suspender cables, • Shift of traffic from lower deck to upper deck during construction 3. Calibration of model geometry with survey data 4. Provide staged construction results for geometry control and determination of cambers of new members

HDR/PB, A Joint Venture 50 ARCH STRENGTHENING

HDR/PB, A Joint Venture 51 Arch Strengthening

Strengthened No. Total Lower Chords 32 80 Upper Chords 8 80 Verticals 24 82 Diagonals 8 80 Lat. Bracing 20 144 Lat. Struts 10 78

HDR/PB, A Joint Venture Arch Structures: Strengthened Member Typical Lower Chord Strengthening

HDR/PB, A Joint Venture Arch Structure: Member Strengthening Typical Gusset Plate Strengthening

HDR/PB, A Joint Venture 54 Strengthening Steel Erection Strengthening Plates

HDR/PB, A Joint Venture 55 Strengthening Steel Erection Strengthening Plates

HDR/PB, A Joint Venture 56 NEW PORTALS

HDR/PB, A Joint Venture 57 BBNCP: Proposed New Arch Portal

New Portal

Existing Portal

HDR/PB, A Joint Venture 58 Arch - New Portals

HDR/PB, A Joint Venture 59 TEMPORARY BRACES

HDR/PB, A Joint Venture 60 Arch Structure: New Temporary Bracing Scheme U5U6 – Upper Chord

HDR/PB, A Joint Venture 61 Arch Structure: New Temporary Bracing Scheme U7U8 – Upper Chord

HDR/PB, A Joint Venture 62 Arch Structure: New Temporary Bracing Scheme PP0-3 “Banana Gusset” - Temporary

HDR/PB, A Joint Venture 63 Arch Structure: Temporary Bracing Scheme PP0-3 “Banana Gusset” – 3D FEM Analysis

HDR/PB, A Joint Venture 64 Arch Rehabilitation: New Temporary Bracing Scheme

PP0-3 “Banana Gusset” - Temporary

HDR/PB, A Joint Venture CONSTRUCTION of the NEW ARCH FLOOR

HDR/PB, A Joint Venture 66 Arch - New Floor Construction 01

HDR/PB, A Joint Venture 67 Arch - New Floor Construction 02

HDR/PB, A Joint Venture 68 Arch - New Floor Construction 03

HDR/PB, A Joint Venture 69 Arch - New Floor Construction 04

HDR/PB, A Joint Venture 70 Arch - New Floor Construction 05

HDR/PB, A Joint Venture 71 Arch - New Floor Construction 06

HDR/PB, A Joint Venture 72 Arch - New Floor Construction 07

HDR/PB, A Joint Venture 73 Arch - New Floor Construction 08

HDR/PB, A Joint Venture 74 Arch - New Floor Construction 09

HDR/PB, A Joint Venture 75 Arch - New Floor Construction 10

HDR/PB, A Joint Venture 76 Arch - New Floor Construction 11

HDR/PB, A Joint Venture 77 Arch - New Floor Construction 12

HDR/PB, A Joint Venture 78 Arch - New Floor Construction 13

HDR/PB, A Joint Venture 79 Arch - New Floor Construction As-Built Transfer Girder

HDR/PB, A Joint Venture 80 CONSTRUCTION UPDATE

HDR/PB, A Joint Venture 81 Bayonne Bridge Summary Overall • Approximately $700M spent to date (December 2015) – Program Costs • $495M construction in place Northbound Roadway • Foundations – 100% complete • Pier Columns – 95% complete • NY&NJ Abutments – 100% complete • Steel Fabrication – 90% complete • Arch Strengthening – 80% complete • Tower Construction – 95% complete • Approach Spans – 50% complete

HDR/PB, A Joint Venture 82 Construction – Approaches Drilled Shafts

HDR/PB, A Joint Venture 83 Construction – Approaches Approach Superstructure/Pier

HDR/PB, A Joint Venture 84 Construction – Approaches Precast Concrete Pier Segments

HDR/PB, A Joint Venture 85 Construction – Approaches Precast Concrete Superstructure Segments

HDR/PB, A Joint Venture 86 Steel Fabrication Towers

HDR/PB, A Joint Venture 87 Steel Fabrication Towers

HDR/PB, A Joint Venture 88 Steel Fabrication Strengthening Plates

HDR/PB, A Joint Venture 89 Construction – Tower Tower Columns

HDR/PB, A Joint Venture 90 Construction – Tower Tower Columns

HDR/PB, A Joint Venture 91 Construction – Tower Tower Construction

HDR/PB, A Joint Venture 92 Steel Erection Column Extensions

HDR/PB, A Joint Venture 93 Steel Erection Column Extensions

HDR/PB, A Joint Venture 94 Steel Erection Column Extensions

HDR/PB, A Joint Venture 95 Rendering of the Completed Project The Arch

HDR/PB, A Joint Venture 96 The Bayonne Bridge – circa 1931 Thank You!

HDR/PB, A Joint Venture 97