1. Albany Turnpike over CSXT Railroad
Superstructure Replacement Project
East Chatham, New York

2. Intersection
Adjacent property
Intersection
Utilities

3. Existing Conditions
 Existing Bridge: Albany Turnpike over CSXT
 Constructed in 1906
 Town of East Chatham, New York
 Berlin Construction Co., Berlin, CT
 Double Warren Through Truss
 Approx. 115’ Span x 18 ‘ Roadway Width x 17’ Deep
 Single Lane Roadway
 Vertical Clearance = 21’- 7”
 Timber Deck / Asphalt Wearing Surface

4. ASCE/APWA Summer Meeting 2014

5. Given Information
 CSXT Owner (Major Maintenance)
 Low Volume, Minor Collector (Rural)
 Original Design Load H10 (10T = 20,000 lbs. GVW)
 NYSDOT Inspection (Critical Event)
 Rated for 20T prior to inspection
 Load Posted to 4T in 2012
 Structurally Deficient, Sufficiency Rating 43.3
 Numerous Deterioration “Red Flags”
 Emergency Contract:
 Bergmann Associates, Albany Office

7. First thoughts on the Project
Repair
Rehabilitate
Replace
• Original 20 Ton
rating not
possible in only
repairing minor
item(s).
• Repair current inspection
“red flags” and also ones
predicted for next inspection
cycle (“yellow flags”).
• Restore Previous Load
Posting (20 Ton) or Greater
• Most expensive
option and one that
the Owner had not
budgeted.

8. Rehabilitation Scope
 Remove Asphalt Overlay, Timber Curb, and Timber
Deck
 Complete Steel Repairs to Trusses, Floorbeams,
and Bottom Lateral Bracing
 Remove and Replace Timber Stringers (as needed)
 Install New Timber Deck & Curb, Pave Asphalt Wear
Crs.
 Re-open to Traffic
 Restrictions: No Construction Loads except Personnel; No
Temporary Reduction in Vertical Clearance; Temporary Shoring of
Diagonals and Floorbeams required during Gusset Plate
Repair/Replacement ; One Gusset Plate Repair at a Time

9. “Sleeved” Bridge Support & Platform
WAY-CR47 (Indian Mill Bridge) Rehabilitation
over the Sandusky River
Wyandot County, Ohio
Construction: U.S. Bridge/

10. Moving Toward Bid
 A couple problems came to light about this plan …
… IT WASN’T A LONG TERM SOLUTION SO
NO ONE WAS REALLY HAPPY WITH THE
SITUATION.
… IT WAS COSTING MORE THAN
EXPECTED.

11. Novel Idea
Repair
Rehabilitate
Replace
Superstructure
Replacement
Bid Item

12. Bid Results
 Bidding (Rehabilitation Plans)
 4 Contractors Invited to Submit Bid
 Mandatory Pre-Bid Site Visit
 Base Bid: Bridge Rehabilitation
 Alternate Bid: Superstructure Replacement (late addition)
 Bid Results
 Two Bids: $300k; $677k
 Only the Low Bidder Submitted an Alternate Bid: $550k

13. One last ‘i’ and one last ‘t’
 What was it going to cost to recondition the
existing abutments?
 If a ‘GO’, would the Town of East Chatham
be willing to own the bridge?
 So Bergmann prepared schematic TS&L
type plans (30%).
 They were.

14. Loads Reactions % of CDS
Concrete Deck Slab & SIP = 120 psf
Concrete Deck Slab (Strip or Foam) = 106
psf
Asphalt Filled Steel Floor = 89 psf
Exodermic Deck = 75 psf
Timber Panels = 62 psf
DL= 216 k
DL= 191 k
DL= 142 k
DL= 135 k
DL= 112 k
100%
93%
80%
78%
72%
Floor Framing Self Wt. = 22 psf
Truss Self Wt. = 306 plf
FWS = 25 psf
DL= 40 k
DL= 70 k
DL= 45 k
Final Total (Exodermic) DL= 72.6k
Loads Reactions % of CDS&SIP
Concrete Deck Slab & SIP = 120 psf
Concrete Deck Slab (Strip or Foam) = 106
psf
Asphalt Filled Steel Floor = 89 psf
Exodermic Deck = 75 psf
Timber Panels = 62 psf
DL= 54.1 k
DL= 47.8 k
DL= 35.6 k
DL= 33.8 k
DL= 27.9 k
100%
93%
80%
78%
72%
Floor Framing Self Weight = 22 psf
Truss Self Weight = 306 plf
FWS = 25 psf
DL= 9.9 k
DL= 17.6 k
DL= 11.3 k
Final Total (Exodermic) DL= 72.6 k
Dead Load Study
Acceptable - So we have a green light
to go forward …

15. New Scope of Work
 HL93 Live Load & NYSDOT Permit Vehicle
 Railing Service Level TL-2
 One Lane, 14’-0” Clear
 Match or Improve Existing Sight Distance
 Outboard Sidewalk for Pedestrians
 Improve Existing Vertical Clearance
 Design Reconstructed Abutment Caps
 Concrete Approach Slabs

16. Proposed Section
 Single Lane
 Outboard Sidewalk
 Curbed Roadway
 Vandal Protective
Fencing

17. Proposed Site Plan
 Guardrail upgrades or extensions (red)
 Gabion retaining walls (maroon)
 Pavement transitions (green)

18. Proposed Profile
 Maintain SSD
 Improve rail vertical
clearance to 21’-9”
 Recondition existing
abutments

19. Schedule
PO
issued
USB
8/6/13
Initial
Submittal
9/2513
Release
for Fab
10/3/13
Shipped
to Site
11/12/13
Begin
Shipments
to Site
11/18/1
3
Steel
Erected
11/26/1
3
Concrete
Slab Pour
01/14/1
4
Opened to
Traffic
01/31/1
4
50 days 8 days 46 days
8 days 49 days 17 days
Total = 178 days

20. Steel Bridge Design
 Early Coordination of Final Loads & Reactions
 Different skews caused different truss spans
 Left =112’-5 ¾”; Right Truss = 114’-11 ¾”
 AASHTO DL & LL Loads, Wind Loads
 Strength, Service, Fatigue & Extreme Event Load Comb.
 Top Chord/U-Frame Stability Check
 Gusset Plate Check (per 2009 FHWA Guidance Report)

21. Steel Bridge Design
 Extreme Profile Change/Unusual Framing
 Exodermic Deck Layout, Slab Reinforcing &
Coordination
 Bearing Pad Design: Fixed & Sliding CDB (Cotton
Duck)
 Armored Expansion Joint: Wabo WA300
Compression Seal
 Vandal Protection Fencing Coordination
 NYSDOT Level 1 Load Rating (LRFR)

22. Exodermic® Deck Details
Courtesy of the Bridge Grid Flooring Manufacturers Association (BGFMA) www.bgfma.org
For this project:
• WT4x5 Bearing Bars at 12” o.c.
• 1 ½” x 1/4” Distribution Bars at 6” o.c.
• 20 Ga. Haunch & Flat Pans
• Longitudinal: #3 bars at 6” o.c.
• Transverse: #5 bars at 8” o.c.

23. Steel Bridge Design
Looking South at the Forward Abutment

24. Steel Bridge Design
Looking South at the Forward Abutment

25. Steel Statistics
 Truss Girder Weight = 34,810 lbs.
 Heaviest Segment = 12,070 lbs.
 Floor Framing Weight = 40,443 lbs.
 Unique Floor Beams = 7; Unique Stringers = 18
 Heaviest Section (Truss): W14x82
 Heaviest Section (Framing): W18x50
 Total Weight Steel & Hardware = 136,754 lbs.
 Total Fasteners: 5,462 Bolts
 Most Common Size: 7/8” dia. x 2 ½” (2,012 Bolts)
 Shipped in 4 Truck Loads

26. Superstructure Replacement Cost
 Mobilization $50.0k
 WZTC $5.0k
 Remove Existing Bridge $80.0k
 Furnish New Truss $450.0k
 Install New Truss $130.0k
 Earthwork $100.0k
 Concrete Work $210.0k
 Approach Work $175.0k
 Total $1,200.0k ($1.2M)

27. Project Participants
 Owner: CSXT Railroad, Jacksonville, FL
 Ross White, Territory Manager
 Contractor: CP Ward, Inc. of Scottsville, NY
 Steve Phillips, Vice President
 Design Consultant: Bergmann Associates, Albany,
NY
 Michael Cooper, P.E., Project Manager
 Superstructure Design: Contech & U.S. Bridge
 Dave Morgan, P.E., Project Engineer
 Exodermic Deck Design: LB Foster, Pittsburgh, PA
 Ed Coholich, Project Manager
 Town of Chatham
 Mr. Jesse DeGroodt, Town Supervisor

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40. Model to Reality
Looking West at the Left Truss Girder

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49. What made this project work?
 Collaborative Partnership
 Innovative Thinking
 Non-binding alternate bid proposal
 Exodermic Deck
 Steel framing (both at the south abutment and sidewalk).
 Deck installation and pour sequence
- Leaving us with a unique project that was
successful for the Town and the Owner -
Questions?

50. Thank you