THE CONCRETE BRIDGE MAGAZINE

SUMMER 2011

ASPIRE is a quarterly magazine published by PCI in cooperation with the associations of the National Concrete Bridge Council. The editorial content focuses on the latest technology and key issues in the Concrete Bridge Industry.

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52 | ASPIRE , Summer 2011 CBP Concrete Bridge Preservation Burned Bridge Returns in 22 Days Emphasis on constructability rehabilitates precast concrete bridge quickly by H. Simon Hagedoorn, FINLEY Engineering Group, and Chris DuBois, Lane Construction Corporation On January 21, 2011, a fatal accident involving an 8200-gal. gaso- line tanker badly damaged the Beachline Expressway/SR 528 overpass at Courtenay Parkway/SR 3 in Brevard County, Fla. Re- storing the bridge to service required only 22 days, thanks to close cooperation and a focus on constructability. Florida Department of Transportation (FDOT) offcials concluded that the two easternmost of three spans on each of the side-by-side bridges were beyond repair. Because the overpass provides critical access to the Kennedy Space Center and nearby towns, the bridge had to reopen quickly. Within 24 hours, FDOT summoned three contractors to a prebid conference at the site. The FDOT emergency-response team de- veloped the project's scope, acquired the original plans, and es- tablished a maintenance-of-traffc plan. The job was awarded to Lane Construction Corporation in Maitland, Fla., with a bid of $2,191,000 and a schedule of 25 days. "The ability to meet our schedule was the most important factor in our selection of subconsultants and suppliers," said Gary F. Jera- bek, district manager for Lane Construction Corporation. FinLEy Engineering Group in Orlando was selected to design the repair and reconstruction work. FinLEy submitted the initial precast, prestressed concrete AAS- HTO i-beam design to Lane within 12 hours after receiving the contract. The frst beam was cast within 24 hours of the notice to proceed by Standard Concrete Products, Tampa, Fla. Final beam designs were complete within 36 hours. The original design was adhered to as closely as possible while updating to current construction practices. For example, the origi- nal AASHTO i-beams had harped strands, but local precast plants were not equipped to fabricate beams that way. Straight strands with end debonding were specifed instead. The bridge features two multi-column piers on driven pile founda- tions—one on each bridge—including column and cap. The piers were reconstructed to the top of the footing elevation, while the existing footings and piles were reused. Demolition crews took only 2 days to remove the damaged portions. Lane saved 3 days by using monolithic placements for the columns and pier caps, fnishing in 4 days. The crew took 1 day to set the beams, which occurred 2 days after they placed the substructure. Seven days after the beams were erected, the bridge deck concrete was cast replacing a total area of 9,628 ft. 2 Two days after the decks were placed, barrier walls were slip- formed. Simultaneously, crews milled the pavement. Milling of SR 3 and paving of both roadways followed. The bridge was completed 3 days ahead of schedule, providing welcome news to a community hit hard by the tragedy. "Fast-track projects require exceptional coordination, cooperation, and under- standing," says FinLEy's Managing Principal Craig Finley. "Ev- eryone accepted the responsibility to do what it took." CBP CONCRETE BRIDGE PRESERVATION A fatal accident involving an 8200-gal. gasoline tanker badly damaged the Beachline Expressway/SR 528 overpass in Brevard County, Fla. The bridge was repaired with precast concrete girders in approximately 3 weeks. All photos: Lane Construction Corp. CBP_sum11.indd 52 7/1/11 10:32 AM

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