NEWARK BAY BRIDGE RECONSTRUCTION New Jersey Turnpike Authority Contract: T100.034 Newark Bay Bridge Deck Reconstruction and Miscellaneous Structural, Roadway, and Lighting Improvements Overview of Project • Officially Named the “Vincent R. Casciano Memorial Bridge” • Opened to Traffic April 4, 1956 • Three Span Thru Arch Truss Main Span • Girder/Floor Beam Approaches • Total Length = 9,560 ft • Main Span = 1,270 ft • Re-decking Limits = 7,357 ft • AADT = 65,000 • Additional Traffic Due to Pulaski Skyway = ORGANIZATION CHART New Jersey Turnpike Authority Ammann & Whitney URS Ferreira/Tutor-Perini Construction Oversight Design Engineer Joint Venture (FTP JV) Fort Miller Co, Inc. Precast Supplier SEQUENCE OF OPERATIONS • Constructability Review – RFI Process • Demolition of Existing Structure • Miscellaneous Steel Repairs Throughout Structure • Painting & Prep of Existing Steel • Installation of Shear Studs and Haunch Angles • Receive and Set Panels/Grout Panels • Installation of New Scuppers • Installation of New Expansion Joints/Joint Closure Pours with HPC • Installation of New HPC Cast in Place Parapet/Precast HPC Median Barrier • Installation of New LED Lighting • Milling/Diamond Grinding of New Deck • Transverse Sawcut Grooving • Installation of the Lane Control System due to the Pulaski Skyway Reconstruction • Return Traffic back to Pre-Construction Conditions SCHEDULE • Original Milestone Dates • Pre-Stage – October 27, 2010 • Stage I – July 15, 2011 • Stage II – June 1, 2012 • Stage III – June 3, 2013 • Stage IV – August 26, 2013 – Final Completion • Revised Milestone Dates as of CPM Update #10 • Pre-Stage – December 8, 2010 (Expanded Scope) • Stage I – December 29, 2011 • Stage II – September 12, 2012 • Stage III – September 30, 2013 • Stage IV – November 1, 2013 • Completion of LCS – January 14, 2014 – Additional Work • Completion of Security Fence – May 2014 – Additional Work STAGED CONSTRUCTION DEMOLITION • The JV Milled the Existing Roadway to Separate Asphalt from the Concrete • Concrete Deck Sawcut into Sections and Removed by Excavator • Slabs Placed Directly into Dumpsters and Properly Disposed • Concrete Median Barrier was Munched by Machine and Debris Removed by Hand • Scuppers and Joints Removed and Disposed of • Protection of Fiber Optic Line CONSTRUCTABILITY REVIEW – RFI PROCESS • Constructability Issues Arose During Shop Drawing Submittal Process for the Precast Panels • The Design Attempted to Minimize Joint Widths & Grout Pocket Size Due to the Excessive Cost of the MMA Grout • During a Meeting with the NJTA Designers and the NJTA Construction Teams, Fort Miller Demonstrated the Difficulty in Working with the Proposed Connections • The Design was More Stringent that Allowable PCI Standards CONSTRUCTABILITY REVIEW • Mock-ups – Very Important to the Process – Included Full Size Panel Assembly – FTP JV was Required to Grout One Transverse Joint and One Longitudinal Joint – Cores Were Taken to Evaluate Consolidation • Design Changes – Pocket Size Increased – Elimination of Pre-Stress Tension Bars – Maximum Extension of Pea Gravel Reduced STEEL REPAIRS • Lateral Bracing was Severely Damaged by Corrosion and Vibration of Bridge – Bolts were Worn Down to Nubs • East Abutment Bearings were Corroded and Extended • Gusset Plates from Floor Beams to Girders were Cracked and Severely Corroded • Tie Chord Plates in the Navigable Water Way are Corroded and Require Replacement STEEL REPAIRS REMOVE AND REPAINT TOP FLANGE • The Joint Venture Removed the Lead Based Paint within Full Containment • The Joint Venture Placed One Coat of Epoxy Primer, a Minimum of 4 mils SHEAR STUDS • Over 200,000 Shear Studs to Layout and Coordinate with the Precast Panel Pockets • There is a Minimum of 1” Penetration Embedment Length and a Maximum of 3” Into the Shear Stud Pocket RECEIVE AND SET PANELS • The Joint Venture is using a Gantry System for Stage I Erection of the Precast Panels • The Precast Panels are Shipped from Saratoga, NY with the Understanding that the Supplier Meets the Necessary Height and Width Restrictions to Travel Without an Escort TYPICAL JOINT POCKETS GROUT PANELS • The Specified Grout is a Two Component System, a Powder Mixture and a Liquid Polymer. • BASF Allows a Clean, Dry 3/8 inch Pea Gravel as an Extender. The Pea Gravel Does Not Affect the Chemical Reaction Between the Two Components. GROUT OPERATIONS • Grout Installation was Performed Mainly at Night Due to Lane Closing Restrictions and Access • Labor Intensive Operation • Grout Had to be Placed Under Pressure, the Product was not Free-flowing as Specified ADDITIONAL HIGHLIGHTS • Two Spans Used Exclusively Stainless Steel Reinforcing • 202 New Scupper/Fiberglass Downspouts – Openings cast into the precast panels – Lesson Learned, Minor Cracking in the Corner Openings, Better Result in Stage III with Corners Skewed • Installation of New Expansion Joints – Three Types of Joints Installed, Standard, Modular & Relief • Closure Pours at Joint Locations – Cast in Place HPC Between the Expansion Joints and the Precast Panels • Cast In Place HPC Parapets • Precast Median Barrier – Bolted and Grouted into Place for Removal for Next Contract LED LIGHTING • Original Bid Luminaire Was HP Sodium • Issued by NJTA in March 2012 • One of the First Projects to Use LED Lighting • Hapco Light Pole – New Dampener Designed due to Excessive Vibrations on NJTA Structures MICRO-MILLING OF PRECAST DECK • Fort Miller Manufactured the Precast Slabs with an Additional ¼” of HPC Concrete • The Micro-milling Leveled the Longitudinal and Transverse Joints Along with Imperfections with the Precasting TRANSVERSE SAWCUT • Transverse Saw Cutting is Difficult Using Staged Construction • Longitudinal Saw Cutting May Have Been More Appropriate for a Quieter Ride NEW LANE CONTROL SYSTEM • Due to the Reconstruction of the Pulaski Skyway, Additional Roadway Repair Work was Completed • Also, a Lane Control System was Developed for the Eastbound Right Shoulder of the Hudson County Extension Allowing Traffic to Utilize the Area • There will be an Expected Increase of 2000 Vehicles per Peak Hour NEW LANE CONTROL SYSTEM • NEW LCS Included – Eleven New LED Signs that will Display • Down, Green Arrow – Displayed When Patrons can Legally Travel Shoulder • 45 Degree Down, Yellow Arrow – Utilized while Closing the Shoulder to Patrons • A Red “X” when not in use, Except for Emergencies – Two Static Informational Signs – To Be Used During Morning and Afternoon Peak Periods RETURN TRAFFIC TO ORIGINAL CONFIGURATION • Remove LCS System and Return Traffic to Two Lanes in Each Direction for the Entire Length of the Hudson County Extension .