IBC ROUTE 139 June 9, 2006

Innovative Design Concepts used to

Widen The Notoriously Congested

Route 139,14th Street Viaduct

By

Stewart Willis

and

Manuj Ray

Route 139 New Jersey Approach to

Holland Tunnel

Overview

Project Background

12th Street Viaduct

14th Street Viaduct

Widening of 14th Street Viaduct

Superstructure Alternates

Substructure Alternates

Selected Alternate, Design Concepts and Lessons Learned

Questions and Answers

Existing Structures Condition

Deteriorating and Deficient Structure

Deck and Concrete Encasement

Severely Deteriorating

Low Live Load Capacity

Physical Condition of Structural Steel

Superstructure and Substructure

Seismic Susceptibility and

Vulnerability

Deteriorating Structure

Existing Structures Condition

Project Objectives

Deck Slabs Replacement

Structural Steel Repairs & Retrofits

Maintain Traffic during Rehabilitation

Increase Live Load Capacity to HS25

Seismic Retrofit

Replicate Original Light Fixtures and Poles

Provide Architectural Treatments That Replicate Original Balustrade

Maintenance and Protection of

Traffic

14th Street Viaduct shares Turnpike

traffic

12th Street Viaduct carries one lane of

NB Turnpike Ramp traffic

Six traffic stages

Maintenance and Protection

of Traffic

Maintenance and Protection of

Traffic

Existing 12th Street Viaduct


(Jersey Ave. to Palisade Ave )

Viaduct Length – 519 m (1,705 ft.)

Width - 17 m (56 ft.) with 4 lanes

46 Spans

Concrete Deck with Asphalt Overlay, Steel Girders and Steel Piers

12 Concrete Arch Spans – 69 m (226 ft.)

Timber Pile and Caisson Foundations

Constructed in 1925

Existing 14th Street Viaduct Jersey Ave. to Palisade Ave.

Viaduct Length – 442 m (1,451 ft.)

Width - 17.8 m (58 ft.) with 4 lanes

26 Spans

Concrete Deck with asphalt overlay, Steel Girders and Steel Piers

Timber Pile and Steel Pile Foundations

Constructed in 1948

Site Conditions

Soil Profile

Fill of silty sand with brick, gravel, ash

and cinders contaminated with heavy

metals

Bedrock (Sandstone and Diabase) at 17

m to 32 m below grade

Area of oil contaminated soil under 14th

Street Viaduct near Monmouth Street

Area of lead hazardous soil at 14th Street

Viaduct at Pier 23


Rehabilitation

Remove asphalt deck overlay

Replace deck with CIP HPC deck

Repair or replace various deteriorated

steel pier members

Strengthen various pier cap beams,

columns, column base plates and pier

knee brackets

Repair various deteriorated transverse

truss diagonals

Existing 14th Street Viaduct Rehabilitation

Replace deck with CIP HPC deck

Replace stringers in Spans 1 to 14

Strengthen floorbeams, pier columns knee brackets, foundation pedestals and column base plates

Add micropiles to strengthen existing foundations

Remove two existing OHSS and Construct new OHSS on individual foundations

SHPO Commitments

SHPO Commitments

Route 139 is part of the Route 1 & 9 Historic District from Pulaski Skyway to Holland Tunnel

Light poles and fixtures replicate the original

Barrier curb architectural treatment replicates the original balustrade

Facade on the 12th Street Span 1 to 9 walls replicate the buried columns

Color of paint for steel replicates concrete color

SHPO Commitments

Span Arrangement Studies

SUPERSTRUCTURE ALTERNATE 1

AASHTO M270, Grade 345 (ASTM A709, Grade 50) steel

Continuous welded plate girders and an alternate rolled beams option

19-span configuration consisting of one simple span and 6 continuous span units

Shear locks and longitudinal expansion joint

Span Arrangement Studies SUPERSTRUCTURE ALTERNATE 2

AASHTO M270, Grade 345 (ASTM A709, Grade 50W) steel

10-span unit of continuous welded plate girders

3 Units, two 4-span straight and curved girders and one 2-span curved unit



SUPERSTRUCTURE ALTERNATE 3

AASHTO M270, Grade 485 (ASTM A709, Grade HPS 70W) and Grade 345 (HPS 50 W) steel

9 spans continuous welded plate girders

3 Units, one 4-span straight and one 3 span curved girders and one 2-span curved unit



SUBSTRUCTURE OPTION 1

Hammerhead pier cap with a rectangular tapered column

The foundation is to be comprised of a concrete pile cap straddled over existing battered timber piles supported by four 610 mm (24 in.) diameter concrete filled steel pipe piles

Match Existing Pier locations



Hammerhead pier cap supported with a 60 inch diameter column

The column will be supported on a 6 feet diameter drilled shaft foundation with permanent steel casing

11 feet deep Rock Sockets

Cut through the existing timber piles of several existing foundations of the 14th Street



Hammerhead pier cap with a rectangular column with rounded ends

The foundation is to be comprised of a concrete pile cap supported by steel H-piles

The steel piles are driven to the top of rock between the existing battered piles. Hammerhead pier cap with a 60 inch diameter column


SELECTED (Based on Decision Matrix)

Alternate 3 Superstructure

AASHTO M270, Grade HPS 485

(ASTM A709, Grade HPS 70W and

Grade HPS 345 (HPS 50 W) steel

Option 2 Substructure

Drilled Shaft Foundation

Economical ($6 Million less)

Selected Span Arrangement

14th Street Widening


Reinforcement


Design Features

Cut existing timber piles

28 # 18 Bundled Bars with #5 Spiral

Mechanical splices

No splices permitted in Plastic

Hinging areas

Constant diameter Permanent Steel

Casing


Features

4000 psi Flowable Concrete (3/8 inch

diameter aggregates)

Cross Hole Sonic Logging (CSL) tests

Osterberg Load Cell Test

Rock sockets

Lessons Learned

Design

Interference with existing timber piles

Proposed pre-cutting timber piles prior to driving

Sheeting and excavation

Monitor existing substructure for distress

Lessons Learned

Contractor’s Method

Proposed special

teeth attached to

permanent casing

No temporary

sheeting or

foundation

excavation

required


Permanent Casing

CSL Testing

High quality drilled shaft installation

Tests can find multiple defects and

their quadrant

Not sensitive to pile length or soil

CSL finds defects between (steel)

access tubes

Allows low cost testing access if

problems occur during installation

Design versus Construction Cross Sonic Logging (CSL) Tubes

CSL tubes to be

located between

bundled bars

Contractor

proposed tubes

to be attached to

the bundled bars

CSL tests were

OK

Lesson Learned

Permanent Steel Casing

Constant Diameter

Proposed

Telescopic casing used by

Contractor (VE or redesign)

Theoretical Concrete

Volume 121, 123 and 90 CY

vs. Actual 206, 170 & 128

CY(40 to 70 percent more)

Concrete Escaped thru

overlap of casing

CSL test were Ok

General View of Piers

Modified Elastomeric Bearings

Stainless Steel Sliding and PTFE mating surface

No Masonry Plates

Concrete Keeper Blocks

Steel Guide Bars

Can accommodate movements and rotations for curved girders

Modified Elastomeric Bearings

Structural Steel

3800 LF Girder length for widening

1.3 Million pounds (600,000 kg) of

Weathering Steel

HPS 70 W for girder flanges

HPS 50 W webs and bearing stiffeners

Grade 50 W for Cross Frames (Rolled)

Structural Steel

Structural Steel ECONOMICAL FABRICATION GUIDELINES

Only four different flange plate thickness

One location of flange butt weld

Two field splice details for 33 splices

Blast clean and use Class B Bolt Faying Surfaces for Field splices Bolt design

One Interior Cross Frame detail used for the entire bridge (104 total)

No less than Category C Fatigue Detail

Longitudinal Deck Joint

Silicone Sealed armored joint between existing and widened structure

Economical

Easy maintenance

1 inch recess to prevent damage from snow plows

Deck Slabs

4000 PSI High Performance Concrete deck slabs (LRFD Method)

Centrifugal forces for curved spans are significant

Developed In-house spreadsheets

Pouring sequence

Full Continuous

Conventional 3 day interval between pours

Deck Slabs

Parapets

Provided Architectural Treatments That

Replicate Original Balustrade year 1925

Coordination and Partnering

The Route 139 Team


Contract Awarded to D’Annunzio & Sons for $ 72 M

Three milestones with $2.7M bonus

Local Community, Businesses and Commuters to benefit from early completion

Maintain traffic during rehabilitation

Keeping Public and numerous agencies informed

Project website is maintained by NJDOT http://www.state.nj.us/transportation/commuter/roads/jcviaducts/


NJDOT Project website includes:

Progress

Current and upcoming lane closures

Traffic cameras and Traffic information

Two week anticipated construction schedule

Construction photographs

Route 139 New Jersey Approach to

Holland Tunnel

Conclusion

Estimated completion ahead of schedule

Team effort on the part of Contractor, Engineer and the Owner, NJDOT

Low future maintenance thru Innovative Design Concepts

Longer spans, less piers saves money and construction duration

Innovative Design Concepts used to Widen The

Notoriously Congested Route 139,14th Street

Viaduct

The End Questions and Answers

Stewart Willis and Manuj Ray

June 14, 2006

IBC ROUTE 139 June 9, 2006

Documents

Transcript of IBC ROUTE 139 June 9, 2006