john james audugon bridge - main span bridges

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John James Audubon Bridge Cost: $348 million Client: Louisiana Department of Transportation and Infrastructure Location: St. Francisville, LA Markets: Bridges Flatiron is designing and building a new cable-stayed bridge across the Mississippi River. The bridge, to be formally called the John James Audubon Bridge, will replace the ferry system currently in place and will connect St. Francisville with New Roads just north of Baton Rouge, Louisiana.

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John James Audubon Bridge:

John James Audubon Bridge Main Span

Main Span:

Main Span

Materials and Equipment:

Materials and Equipment Cement from Thailand Structural Steel from Japan Oscillator from Germany Wind tunnel analysis from Ontario, Canada

Main Span:

Main Span General From Pier 2E to pier 2W 3186 LF of deck 75’-10” wide 40 Drilled Shafts 136 Cable Stays

Main Span:

Main Span Towers 500’ high 136 cable stays 2 Crossbeams Top of tower is elevation 520’ Deck Elevation is 130’

Main Span:

Main Span Deck 241,600 SF of deck 30 ton precast panel pieces 5668 CY of concrete 1656 tons of resteel 38 tons of post tensioning 1263 CY of latex overlay 2 breather joints 2 expansion joints

Main Span:

Main Span

Tower Foundations 1W & 1E:

Tower Foundations 1W & 1E 160’ x 64’ x 15’ Cap 7 by 3 pile group – 1 test pile 8’-0” diameter shafts

Tower Shafts:

Tower Shafts 8 ft shaft to 7’-6” approx 180-ft deep Pile tips @ Elev. -185’ to -180’ Tip grouting

Trestle and Work Platform:

Trestle and Work Platform

Trestle and Work Platform:

Trestle and Work Platform Build a trestle to create a work platform from which to install drilled shafts

Trestle:

Trestle

Trestle and Work Platform:

Trestle and Work Platform

Set Shaft Template:

Set Shaft Template Secondary Template Upper Template Lower Template Spud Pile

Shaft Template:

Shaft Template

Drive Permanent Casing:

Drive Permanent Casing APE 400B Vibratory Hammer Paint markings at each foot verify depth of casing as it is being installed. River bottom EL approx. -40’ East, 5’ West

Drive Permanent Casing:

A vibratory hammer is used to vibrate the casing down into the ground Drive Permanent Casing

Drive Permanent Casing:

Drive Permanent Casing Vibratory hammer driving the casing into the ground

Drive Temporary Casing:

Drive Temporary Casing Temporary casing is driven inside the permanent casing with an Oscillator Speed has been accelerated An oscillator works like someone is opening and closing a jar (back and forth)

Oscillator:

Oscillator

Oscillator at Work:

Oscillator at Work

Oscillator Extracting a Casing:

Oscillator Extracting a Casing

Excavate Temporary Casing :

Excavate Temporary Casing Bottom of Permanent Casing 90” Temporary Casing Hammer Grabs West - 175 East - 180

Excavate Drilled Shaft:

Excavate Drilled Shaft

Shaft E5 Excavation:

Shaft E5 Excavation

Install Reinforcing Cage:

Install Reinforcing Cage

Pour Tremie Concrete:

Pour Tremie Concrete 41.8’ 10’ Min. Embed 30’ of temp. casing removed Maintain 4” Slump for Duration of Pour (~8 hours)

Pour Tremie Concrete:

Pour Tremie Concrete

Base Grouting:

Base Grouting

The Tip Grouting Process:

The Tip Grouting Process 1. Shaft Constructed 2. Base Grout Pressure Applied 3. Some Relaxation Occurs 4. Structural Load Applied

Base Grouting - Verification:

Base Grouting - Verification Pressure Volume Movement of Shaft

Base Grouting:

Base Grouting

Base Grouting:

Base Grouting

Footing Cofferdam Structure:

Footing Cofferdam Structure Piles and trestle are installed

Footing Cofferdam Structure:

Footing Cofferdam Structure Piles and trestle are installed

Install Soffit Panels:

Install Soffit Panels Top View

Install Soffit Panels:

Install Soffit Panels

Installed Soffit Panels:

Installed Soffit Panels

Soffit Panels with Bracing Frame:

Soffit Panels with Bracing Frame

Install Bracing Frame:

Install Bracing Frame Install first tier of brace frame Top View

Erect Pre-Cast Wall:

Erect Pre-Cast Wall Install pre-cast walls Connect to soffit panels and first tier brace frame

Install Precast Wall:

Install Precast Wall

Install Precast Wall:

Install Precast Wall

Install Jacking System:

Install Jacking System Install jacking system with permanent hangers

Install Additional Brace Frames:

Install Additional Brace Frames Install 2 nd and 3 rd tier brace frame.

Install Jacking System:

Install Jacking System Install jacking system with permanent hangers Lower structure to facilitate 2 nd & 3 rd tier bracing installation

Install Additional Brace Frames:

Install 2 nd and 3 rd tier brace frame. Install Additional Brace Frames

Cofferdam Structure Bracing:

Cofferdam Structure Bracing

Cofferdam Structure Bracing:

Cofferdam Structure Bracing

Cofferdam Structure with Bracing:

Cofferdam Structure with Bracing

Install Follower Sheeting:

Install Follower Sheeting Install sheet pile

Lower Structure:

Lower Structure Lower structure to final elevation Lock off hangers

Lower Cofferdam Structure:

Lower Cofferdam Structure

Cofferdam Lowering:

Cofferdam Lowering

Slide 56:

Lower Structure

Lowered Cofferdam:

Lowered Cofferdam

Cofferdam Lowering:

Cofferdam Lowering

Base of Main Span Towers:

Base of Main Span Towers

Pour Concrete Seal:

Pour Concrete Seal Install 8 foot concrete seal

Dewater Structure:

Dewater Structure Install pump Remove water

Remove Hangers and Cut Casing:

Remove Hangers and Cut Casing Remove hangers Cut casing

Place Reinforced Pile Cap:

Place reinforced pile cap concrete Place Reinforced Pile Cap

Place Pedestal Concrete:

Place Pedestal Concrete Place pedestal reinforcing and concrete lift 1 Restrut as required

Place Pedestal Concrete Lift 2:

Place Pedestal Concrete Lift 2 Place pedestal concrete lift 2

Remove Cofferdam:

Remove Cofferdam Remove sheeting Remove bracing Patch blockouts

Past Project Experience:

Past Project Experience Bath, Maine - 2000 Bath, Maine - 2000

Main Span Towers:

Main Span Towers

Main Span Towers:

Main Span Towers

Tower Cross Section:

Tower Cross Section Box sections for simple jump forming Cable anchorage on inside tower wall

Tower Cable Anchorages:

Tower Cable Anchorages Steel anchorage trays for upper stays Concrete corbels for lower steep cables Crossbeams connected clear of anchorage zone

Tower Form System:

Tower Form System

Tower Form System:

Tower Form System

Tower Form System:

Tower Form System

Tower Form System:

Tower Form System Main Span Towers

Tower Form System:

Tower Form System

Tower Form System:

Tower Form System

Tower Form System:

Tower Form System

Tower Form System:

Tower Form System

Tower Form System:

Tower Form System

Tower Form System:

Tower Form System

Tower Form System:

Tower Form System with Crossbeam Form

Tower Form System:

Tower Form System

Tower Form System:

Tower Form System Insert Rebar into form then pour concrete

Tower Form System:

Tower Form System

Tower Form System:

Tower Form System Animation

Build Main Span Towers:

Install formwork & rebar Pour concrete Raise formwork Repeat process Build Main Span Towers

Composite Deck Cross-Section:

Composite Deck Cross-Section Economy, simplicity and constructability Durability Accessibility Low maintenance

Deck Anchorage:

Deck Anchorage

Deck Anchorage Prefab:

Deck Anchorage Prefab

Deck Anchorage:

Deck Anchorage Cable anchorage is prefabricated on the girders before installation

Deck Anchorage:

Deck Anchorage

Stay System:

Stay System 7-Wire parallel strand Monostrand Jacking State-of-the-Art Corrosion Protection Galvanizing Grease Strand PE Coextruded HDPE Pipe Vibration suppression

Begin Deck Work:

Begin Deck Work

Begin Deck Work:

Begin Deck Work

Bridge Construction:

Bridge Construction

Bridge Construction:

Bridge Construction

Bridge Construction:

Bridge Construction

Bridge Construction:

Bridge Construction

Begin Deck Work:

Begin Deck Work

Deck Work:

Deck Work

Install Girders:

Install Girders

Install Girders:

Install Girders

Install Girders:

Install Girders Install edge girders

Install Girders:

Install Girders Install edge girders

Install Girders:

Install Girders Install edge girders Install cross girders

Build Bridge Deck:

Build Bridge Deck Truck precast deck panels onto bridge

Build Bridge Deck:

Build Bridge Deck Truck precast deck panels onto bridge Set panels with derrick crane

Build Bridge Deck:

Build Bridge Deck Truck precast deck panels onto bridge Set panels with derrick crane

Install Segmental Sections:

Install Segmental Sections

Bridge Segments:

Bridge Segments Cable anchorage is pre-attached to girders Segments are installed in sections Cable stays are installed for support Process is repeated

Bridge Segments:

Bridge Segments Segments are installed in sections Cable anchorage is added Cable stays are installed for support Process is repeated

Bridge Segments:

Bridge Segments

Bridge Segments:

Bridge Segments

Bridge Segments:

Bridge Segments

Lift Deck Panels:

Each panel weighs approximately 61,500 lbs. Lift Deck Panels

Install Deck Panels:

Install Deck Panels

Install Deck Panels:

Install Deck Panels

Install Deck Panels:

Install Deck Panels

Install Deck Panels:

Install Deck Panels

Install Deck Panels:

Install Deck Panels

Install Deck Panels:

Install Cable Stays as the bridge is extended Install Deck Panels

Main Span:

Main Span

Main Span:

Main Span

Main Span:

Main Span

Main Span:

(Time Lapse Camera) Main Span

Overall Method of Construction:

Build bridge in segments Install Cable Stays to support bridge Overall Method of Construction

The Finished Bridge:

The Finished Bridge

The Finished Bridge:

The Finished Bridge

The Finished Bridge:

The Finished Bridge

Future Appearance - Video:

Future Appearance - Video

The End:

The End