TOTAL BRIDGE REPLACEMENT OF M13 OVER CHEBOYGANING CREEK

TOTAL BRIDGE REPLACEMENT OF M-13 OVER CHEBOYGANING CREEK DANIEL BURNS, PAUL HEBERT, AND BLAKE NICHOLS DEPARTMENT OF CIVIL & CONSTRUCTION ENGINEERING WESTERN MICHIGAN UNIVERSITY

Overview • • Background & Location Constraints Deliverables Structural Design • • • Bridge Profile Proposed Bridge Design Software Welded Steel Plate Girders Prestressed Concrete Girders Girder Material Evaluation Deck & Railing Design Column Design Pier Cap Analysis Footing Analysis Abutment Analysis • Construction Engineering • • • Preliminary Cost Estimate Quantity Takeoff Schedule of Pay Items Estimate of Cost Construction Schedule • Conclusions • • Sustainability Summary Further Recommendations Acknowledgements

Background & Location • Portsmouth Township, Bay County • Rated POOR (4) or worse • MDOT recommends total replacement

Constraints • Full Road Closure • Freeboard = 1’ minimum • Demolition and Construction = $5 million • No Construction between April 1 and July 31

Deliverables • Design Recommendations • Structural Design Calculations • Design Drawings • Schedule of Pay Items • Estimate of Cost • Construction Schedule

Structural Design

Bridge Profile 249’ 6” 61’ 90’ 61’ Existing Profile - 1927 310’ 95’ 120’ Proposed Profile 95’

Proposed Bridge Top View with Stations LEAP Concrete Rendering

Design Software Bentley LEAP Concrete & LEAP Steel Bridge Design Programs

Welded Steel Plate Girders End Cross Section Mid Cross Section

Prestressed Concrete Girders

Girder Material Evaluation Item Description Prestressed Concrete Design Prest Conc I Beam, Furn, 54 inch Prest Conc I Beam, Erect, 54 inch Welded Steel Plate Design Structural Steel, Plate, Erect Structural Steel, Plate, Furn and Fab Prestressed Concrete Design Welded Steel Plate Design Qty Unit Cost Total Cost 1, 846 ft $174. 00 /ft $21. 38 /ft Total $321, 204 $39, 467 $360, 671 882, 838 lb $0. 16 /lb $1. 31 /lb Total $141, 254 $1, 156, 517 $1, 297, 771 Cost Service Life Sustainability Total 1 2 1 2 3 6 *Lower is better

Deck & Railing Design MDOT Bridge Design Guide Aesthetic Parapet Tube (6. 29. 10) MDOT Bridge Design Guide Standard Bridge Slab (6. 41. 01)

Column Design Top View Side View

Pier Cap Analysis Rebar Layout Rebar Schedule

Pier Cap Analysis Span 3 Flexure Check Span 3 Fatigue Check

Footing Analysis 6’ 6’ Cross-Section 50’ 6’ Shear Analysis Rebar Plan

Abutment Analysis Profile Dimensions End Dimensions Rebar Plan

Abutment Analysis LEAP Moment Analysis Output

Construction Engineering

Preliminary Cost Estimate Existing Bridge Deck Proposed Bridge Deck Item Description 11, 040 ft 2 16, 130 ft 2 Unit Rate Bridge Removal ft 2 $35. 00 $386, 413 Bridge Construction (River Crossing) Traffic Control (Detour Route) ft 2 LS $220. 00 $75, 000. 00 Sub Total $3, 548, 554 $75, 000 $3, 934, 967 Cost General Provisions Mobilization 5% of Total Cost $196, 748 Miscellaneous Items 5% of Total Cost $196, 748 Preliminary Cost of Project $4, 328, 464

Quantity Takeoff Concrete Superstructure (Deck) Rebar Epoxy Coated Rebar 399. 70 yd 3 0. 00 lb 25, 742. 10 lb Abutment A Pier B 77. 40 yd 3 2, 010. 70 lb 0. 00 lb Cap 23. 20 yd 3 0. 00 lb 2, 220. 60 lb Column 15. 40 yd 3 0. 00 lb 2, 827. 60 lb Foundation Pier C 66. 70 yd 3 2, 960. 80 lb 0. 00 lb Cap 23. 20 yd 3 0. 00 lb 2, 220. 60 lb Column 16. 00 yd 3 0. 00 lb 2, 924. 40 lb Foundation 66. 70 yd 3 2, 960. 80 lb 0. 00 lb 77. 40 yd 3 2, 010. 70 lb 0. 00 lb 366. 00 yd 3 9, 943. 00 lb 10, 193. 20 lb Abutment B Substructure

Schedule of Pay Items Item ID Item Description 7060001 Bridge Ltg, Furnish and Remove QTY Units 1 LS 7060002 Bridge Ltg, Operate and Maintain 400 yd 3 7060020 Concrete, Low Temperature Protection 766 yd 3 7060090 Reinforcement, Steel 7060091 Reinforcement, Steel, Epoxy Coated 7060100 Substructure Concrete 9943 lb 35935 lb 366 yd 3 7060111 Superstructure Concrete, Form, Finish, and Cure 1 LS 7060112 Superstructure Concrete, Form, Finish, and Cure, Night Casting 1 LS 7060113 Superstructure Concrete, Night Casting, Deck 400 yd 3 7080033 Prestressed Concrete I Beam, Furnish, 54 inch 1846 ft 7080034 Prestressed Concrete I Beam, Erect, 54 inch 1846 ft 7110005 Bridge Railing, Aesthetic Parapet Tube 620 ft

Detailed Cost Estimate Division 01 General Provisions 02 Earthwork 03 Bases 04 Drainage Features 05 HMA Pavements 06 PCC Pavements 07 Structures 08 Incidental Construction 09 Materials TOTAL 2016 Award $420, 000 $882, 765 $100, 495 $44, 792 $7, 858 $213, 353 $1, 889, 712 Avg Award $420, 000 $843, 637 $111, 813 $42, 726 $7, 722 $206, 497 $1, 884, 071 2016 Low 3 $420, 000 $901, 186 $109, 218 $46, 213 $8, 039 $247, 174 $1, 992, 858 Avg Low 3 $420, 000 $871, 872 $118, 137 $44, 486 $7, 916 $242, 533 $1, 963, 286 $404, 227 N/A $3, 963, 202 $391, 924 N/A $3, 908, 389 $425, 466 N/A $4, 150, 154 $417, 043 N/A $4, 085, 274

Construction Schedule • Begin August 1, 2017 • End January 23, 2018 • Total Duration is 121 Days • Sitework (17 Days) • Substructure (30 Days) • Superstructure (46 Days)

Conclusions

Sustainability • Girder Material Selection • Service Life • Maintenance Impact • Construction Schedule • DNR Restrictions • Recycle Demolished Materials

Summary • 3 -Span, 310’ Bridge • Prestressed Concrete Girders • Demolition & Construction = $4. 2 million • Construction Duration = 121 days

Further Recommendations • Traffic Impact Verification • Pile Design • Quantity Updates • Demolition Planning

Acknowledgements • MDOT Sponsor • Dina Tarazi, PE • James Ranger, PE • Advisor • Dr. Yufeng Hu, PE • Senior Design Faculty • Dr. Decker Hains, PE, PMP • Timothy Schnell

Questions?

Item Cofferdam Installation (Pier B) Cofferdam Installation (Pier C) Cofferdam Excavation (Pier B) Cofferdam Excavation (Pier C) Substructure Excavation (Abutment A) Piles (Pier B) Piles (Pier C) Piles (Abutment D) Pier B Construction Pier C Construction Abutment A Construction Abutment D Construction Production Rate 2000 200 1 1 10 10 10 5 5 ft 2/day yd 3/day unit/day piles/day days/unit QTY 4576 883 1 1 16 12 12 16 1 1 Duration sq ft cyd units piles units 3 3 5 5 1 1 2 2 10 10 5 5 days days days days Girder Erection (Bay A-B) 6 girders/day 8 girders 2 days Girder Erection (Bay B-C) Girder Erection (Bay C-D) 6 6 girders/day 8 8 girders 2 days 15 2 7 2 2 200 days/span days ft/day Bridge Deck - Form, Place Rebar Bridge Deck - Pour Bridge Deck - Cure Structural Approach (Abutment A) Structural Approach (Abutment D) Parapet Barrier 3 spans 620 feet 15 2 7 2 2 4 4 days days

Cofferdam Calculations Cofferdam Height Above OHWM Ordinary High Water Mark (OHWM) 1 foot Width of Existing Footing 8 feet 6 feet Center to Center Distance 15 feet Work Space Width 8 feet 50 feet Single Pier Surface Area to Retain = 4576 sq. ft. Single Pier Riverbed to Excavate = 883 cyd 581. 61 feet Width of Proposed Footing Riverbed Elevation 571 Bottom of Footing 561. 5 Length of Proposed Footing Excavation Height = 9. 5 feet Cofferdam Height = 22 feet Width = 38 feet Length = 66 feet