THE ROCKS ROAD THE ROCKS ROAD CULVERTSCULVERTS

A PRECAST CONCRETE BOX CULVERT A PRECAST CONCRETE BOX CULVERT AND CORRUGATED METAL PIPEAND CORRUGATED METAL PIPE

By Joe Wisinski and Brad NewmanBy Joe Wisinski and Brad Newman

Introduction to Madison CountyIntroduction to Madison County

►►Geographic Center of New YorkGeographic Center of New York►►There are a total of 312 bridges and There are a total of 312 bridges and

culverts located within Madison Countyculverts located within Madison County►►188 of the those structures have a span less 188 of the those structures have a span less

then 20 feetthen 20 feet►►Two divisions in Morrisville and Wampsville Two divisions in Morrisville and Wampsville

with approximately 70 employeeswith approximately 70 employees

REASONS AGAINST INREASONS AGAINST IN--HOUSE HOUSE CONSTRUCTIONCONSTRUCTION

►►Engineering staff of 3 peopleEngineering staff of 3 people►►Survey equipment with no Electronic Survey equipment with no Electronic

Distance Measurer or Data CollectorDistance Measurer or Data Collector►►No CADDNo CADD►►Board of Supervisors lacked confidence in Board of Supervisors lacked confidence in

the Highway Departmentthe Highway Department►►Over ten years had lapse since the last Over ten years had lapse since the last

precast concrete box had been installed by precast concrete box had been installed by County workersCounty workers

WHY WE DID ITWHY WE DID IT

►►Large cost savings, that would result in Large cost savings, that would result in the County being able to replace more the County being able to replace more culverts in the futureculverts in the future

►►Bridge Crew would gain experienceBridge Crew would gain experience►►Increase morale among County workers, Increase morale among County workers,

by constructing something that they could by constructing something that they could take pride intake pride in

►►Justify additional funds for the Highway Justify additional funds for the Highway DepartmentDepartment

HOW WE DID ITHOW WE DID IT►►Looked to other counties (e.g. Chenango Looked to other counties (e.g. Chenango

County) for guidanceCounty) for guidance►► Surveyed the Surveyed the ““old fashion wayold fashion way”” with the with the

transit, rod, and tape.transit, rod, and tape.►►Prepared the plans by hand, plotted over Prepared the plans by hand, plotted over

400 points, then interpolated between 400 points, then interpolated between points to create topographic map points to create topographic map

►►Total time for survey and drafting = 4 Total time for survey and drafting = 4 monthsmonths

HOW WE DID ITHOW WE DID IT

►►Cleared project w/ NYS DEC, SHPO and US Cleared project w/ NYS DEC, SHPO and US Fish & WildlifeFish & Wildlife

►►Had Construction Release Forms signed by Had Construction Release Forms signed by surrounding neighbors for work preformed surrounding neighbors for work preformed outside of rightoutside of right--ofof--wayway

►►Hired D.H. Smith for the actual installation Hired D.H. Smith for the actual installation and placement of the precast box culvertand placement of the precast box culvert

EXISTING 8 FT. DIA. CULVERT EXISTING 8 FT. DIA. CULVERT CONDITIONSCONDITIONS

►►Both structures were located within 500 feet Both structures were located within 500 feet of each otherof each other

►►The end of the 8 ft. The end of the 8 ft. diadia. culvert began to . culvert began to unravel and deformunravel and deform

►►3 ft. deep scour hole present on the outlet 3 ft. deep scour hole present on the outlet end of the pipeend of the pipe

►►Non standard Non standard guiderailguiderail

CORRUGATED METAL PIPECORRUGATED METAL PIPE

EXISTING BRIDGE CONDITIONSEXISTING BRIDGE CONDITIONS

►► The concrete slab bridge had significant cracks in The concrete slab bridge had significant cracks in the abutment wallsthe abutment walls

►► The existing stream alignment had resulted in a 4 The existing stream alignment had resulted in a 4 ft. to 6 ft. undermining of the southeast wingwall ft. to 6 ft. undermining of the southeast wingwall footingfooting

►► Knoll at the intersection of Rocks Road and Knoll at the intersection of Rocks Road and Cramer Road located between the two structures Cramer Road located between the two structures resulted in poor intersection sight distanceresulted in poor intersection sight distance

►► Non standard bridge railNon standard bridge rail

NEW CORRUGATED METAL PIPENEW CORRUGATED METAL PIPE

►►8 ft. diameter, 60 ft. long8 ft. diameter, 60 ft. long►►10 gauge, galvanized steel 10 gauge, galvanized steel ►►CastCast--inin--place concrete headwall/cutplace concrete headwall/cut--off walloff wall►►ReRe--use of existing stone headwall for stone use of existing stone headwall for stone

apronsaprons►►Gabion basket wingwallsGabion basket wingwalls

NEW PRECAST CONCRETE BOX NEW PRECAST CONCRETE BOX CULVERTCULVERT

►►10 feet by 6 feet 10 feet by 6 feet –– 60 ft. length, new skew60 ft. length, new skew►►Used standard NYSDOT specificationsUsed standard NYSDOT specifications►►CutCut--off wallsoff walls►►Post tensioningPost tensioning►►Gabion basket Gabion basket wingwallswingwalls►►Buried cars removed from embankmentBuried cars removed from embankment►►Utility coordination w/ NYSEG and Utility coordination w/ NYSEG and WindstreamWindstream►►Sediment and Erosion Control (e.g. Sediment and Erosion Control (e.g. SedimatsSedimats & &

Erosion Control Blankets)Erosion Control Blankets)

CONSTRUCTION BEGINSCONSTRUCTION BEGINSON JULY 25ON JULY 25

PROJECT COMPLETEDPROJECT COMPLETEDON OCTOBER 13ON OCTOBER 13

CONCLUSIONCONCLUSION►►Final Cost = approx. 200K Final Cost = approx. 200K ►►LESSONS LEARNEDLESSONS LEARNED

Coordination of both County Highway Coordination of both County Highway DivisionsDivisionsConstruction techniquesConstruction techniquesNew engineering tools requiredNew engineering tools requiredCost effective for in house Cost effective for in house design/constructiondesign/construction