2019 Midwest Geotechnical Conference The New Champ Clark Bridge US 54 over the Mississippi River at Louisiana, Missouri Don Hammond, PE HNTB Corporation
Louisiana (Missouri) • 1 of 4 vehicular bridges connecting Missouri and Illinois north of St. Louis (Alton, Hannibal & Quincy) • One way detour of 77 miles via Hannibal
Aerial Looking West
Key Topics • History of Original Bridge & Geologic Profile • Design/Build • Foundations – with focus on large OE pipe pile • East Approach Embankment on Soft Ground
Original Champ Clark Bridge
Original Champ Clark Bridge: Timeline • February 1926 – Chamber of Commerce initiated formal planning. Within 3 days, legislation was moving through Congress. • March 1926 – Harrington, Howard & Ash staff were on site. • October 1926 – Substructure work begun • May 1928 – Bridge completed and open
Original Champ Clark Bridge: Bid
Geologic Profile
Original Champ Clark Bridge: Foundations 30 ton timber piles driven no less than 35 feet below bottom of pier.
Original Champ Clark Bridge: Struggles
Original Champ Clark Bridge: Recent Issues • 20 foot clearance for 2 lanes • Required closure for wide loads • Frequent closures for emergency maintenance
Original Champ Clark Bridge: Recent Issues
Another Issue • Frequent closures for flooding of Illinois approach
Design/Build in Missouri • Design/Build became legal in Missouri in 2005 • Chose Design/Build to expose IDOT to method • Missouri is the lead state with Illinois as a partner
Project Goals • Construct project on budget ($62.5M) • Safe, reliable, low maintenance structure that provides at least 100 years of service life • 405 foot navigation clearance • Minimize and mitigate construction impacts • Deliver project using a diverse workforce
Additional Unspecified Objectives • Two 12-foot lanes with 10-foot shoulders • Improve traffic flow at US 54 / Rte 79 intersection • Engage community
Risk Mitigation Ahead of Award • Permits: 404, 408, Coast Guard, etc. • Right of Way (Army Corps and Sny Levee) • Some hydraulic modeling • PreAward Geotech
Pre-Award Geotechnical Investigation 10 River Borings 13 Land Borings 2 CPTs
Geologic Profile
4/17/17 Supplemental Pre-Award Geo Report Issued
Contract Awarded to Massman/HNTB in June 2017 5 Spans on four 12-foot Deep Steel Plate Girders 3 Spans on Prestressed Concrete Girders (NU)
Contract Awarded to Massman/HNTB in June 2017 July - Completed 8 Water Borings (1 at each shaft) Aug. - Completed 20 Land Borings Sept. - Issued Memo for River Pier Foundations Oct. - Issued Memo for Approach Piers and Abutments Nov. - Began Inspection of Drilled Shaft Construction Jan. - Issued Memo for Block Wall and Embankment
Post-Award Geotechnical Investigation 8 River Pier Borings 3 Approach Pier Borings 2 Abutment Borings 6 Wall Borings 9 Embankment Borings Total = 28
New Champ Clark Bridge: Spans and Foundations Spread Footing on Rock 48” Open Ended Pipe Piles to Rock H-Piles to Rock 11.5’ Dia. Drilled Shafts with 11.0’ Dia. Rock Sockets
New Champ Clark Bridge: Spans and Foundations
West Abutment & Retaining Wall
West Abutment & Retaining Wall
West Abutment & Retaining Wall Factored Bearing Pressure = 13 ksf Factored Bearing Resistance = 32 ksf Cut was Line Drilled
River Piers 11.5 ft Shafts with 11.0 ft Sockets: 5/8” Wall Permanent Casing 20 to 60 ft Long Shafts 22 ft Long Sockets 8 CSL Tubes 60 #18 bars Factored Axial Load = 8100 kips / Shaft
River Piers Confidentially, pre- award samples of Maquoketa Shale were tested for Slake Durability (ASTM D4644) Results confirmed that of Maquoketa Shale was actually shaley, silty dolomite along rock sockets, that would not rapidly degrade during construction.
River Piers Determination that slurry was not needed resulted in significant cost savings and shortened construction schedule by 2 weeks.
River Piers: Drilled Shaft Design
River Piers: Drilled Shaft Design Factored Side Resistance = 0.40 (q s ) = 8.7 ksf Similarly… Factored Tip Resistance = 0.36 (q t ) = 269 ksf
River Piers: Drilled Shaft Construction
River Piers: Drilled Shaft Construction
River Piers: Drilled Shaft Construction
Approach Piers Originally designed as traditional H-pile supported footings. Length 38 ft At MoDOT’s suggestion, Unbraced Massman switched to 48” diam. open ended pipe pile bents. 16 ft of Eliminated footing excavations in scour saturated, flood-prone overbank
Approach Piers: 48” Dia. Open Ended Pipe Piles ASTM A-252 Grade 3 (Fy = 45 ksi) Galvanized to 20 ft below scour Top Half 1-inch Wall / Bottom Half ¾-inch Wall Filled with concrete above scour
Approach Piers: 48” Dia. Open Ended Pipe Piles Want to drive through 10-ft layer of cobbles & boulders to seat on rock. Hard Rock or Soft Rock? Shaley DOLOMITE or Calcareous SHALE? Since Qu > 4000psi, decided it is hard rock. Cutting Shoe Point Reinforcement Required
Approach Piers: 48” Dia. OEP (3/4” Wall) Nominal bearing resistance shall not exceed maximum factored axial structural resistance for severe driving. [AASHTO 10.7.3.2.3] Max. Factored Axial Str. Resistance = 0.6 (45) 111.4 = 3006 kips Let Nominal Bearing Resistance = 3006 kips
Approach Piers: 48” Dia. OEP (3/4” Wall) Decided to PDA each pile & use a geotechnical resistance factor of 0.65 Max. Factored Axial Geo. Resistance = (0.65) 3006 = 1954 kips Max. Factored Axial Load (from Br. Engr.) = 1860 kips < 1954 kips OK Req’d Nom. Driving Resistance, R ndr = 1860/0.65 = 2865 kips (57% Fy)
Approach Piers: 48” Dia. OEP ...but Massman’s PDA Consultant, FTC, still worried about damaging pile based on recent events. Since: Source: NCHRP Synthesis • Driving to end bearing 478 • With known, consistent top of rock • PDA/CAPWAP on every pile HNTB (with MoDOT acceptance) raised resistance factor to 0.9 with 0.8 preferred. R ndr = 1860/0.9 = 2070 kips (41% Fy)
Approach Piers: 48” Dia. OEP Massman Submitted: Delmag D62-22 164.6 kip-ft rated energy 13.7 kip ram weight HNTB Review Comments
Approach Piers: 48” Dia. OEP -- WEAP
Approach Piers: 48” Dia. OEP -- PDA
Approach Piers: 48” Dia. OEP - CAPWAP • 10 to 15 bpi at EOD • Stopped 1 to 4 feet above est. top of rock CAPWAP Results Capacities: 2100 to 2800 k > 2070 k (ok) 30% to 60% side friction Max Stress: 20 to 25 ksi < 40.5 ksi (ok)
East Abutment: HP-12x53 Delmag D30-32 R ndr = 485 kips 75.4 kip-ft rated energy R PDA = 492 kips 6.6 kip ram weight Pile Tip 135.5 ft below grade
East Approach Embankment
East Approach Embankment
East Approach Embankment – Stage Raise
East Approach Embankment – Settlement Plates
East Approach Embankment - OK to Pave? From Trend Line: Bo = 2.0929 B 1 = 0.8789 Smax = Bo/(1-B 1 ) Smax =17.282 inches Remaining Settlement = 17.3-15.3 = 2 inches
Approach Piers
Steel Erection
Steel Erection
Flood Stage
Deck Construction
Deck and West Approach
Opened August 3, 2019 3 mo. ahead of schedule
Your Original Champ Clark Bridge Questions… $1.0 M in 1926 = $14.3 M in 2018 New Champ Clark Bridge Winning Bid of $60 M in 2017 More Traffic / Heavier Traffic Unrestricted Vehicle Height Above 500 yr Flood Wider Deck
Construction Timelapse
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