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Crane Bridge Design STJ Engineering Matt Albert AJ Chandler Noah Fehrenbacher Jake Gennicks Jake Wilhoit Rose-Hulman Institute of Technology.

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Presentation on theme: "Crane Bridge Design STJ Engineering Matt Albert AJ Chandler Noah Fehrenbacher Jake Gennicks Jake Wilhoit Rose-Hulman Institute of Technology."— Presentation transcript:

1 Crane Bridge Design STJ Engineering Matt Albert AJ Chandler Noah Fehrenbacher Jake Gennicks Jake Wilhoit Rose-Hulman Institute of Technology

2 Presentation Overview Project Description Project Description Design Requirements Design Requirements Preliminary Design Preliminary Design Decision Matrix Decision Matrix Final Design Final Design Summary Summary

3 Naval Surface Warfare Center Crane Division Located in Martin County, Indiana Located in Martin County, Indiana Constructed during WWII Constructed during WWII Purpose of base: Purpose of base: –Weapons development –Ammunition storage –Ammunition distribution

4 Design Requirements Environmental permitting Environmental permitting Traffic control plan Traffic control plan Topographic map Topographic map Geotechnical subsurface investigation Geotechnical subsurface investigation Hydraulic analysis Hydraulic analysis Complete bridge design Complete bridge design

5 Environmental Permitting United States Army Corps of Engineers United States Army Corps of Engineers –Letter of Permission Indiana Department of Environmental Management Indiana Department of Environmental Management –Regional General Permit –Demolition Notification Indiana Department of Natural Resources, Division of Water Indiana Department of Natural Resources, Division of Water –No permit required

6 Codes and Regulations Indiana Department of Transportation Codes Indiana Department of Transportation Codes American Association of State Highway Transportation Officials (AASHTO) Load and Resistance Factor Design American Association of State Highway Transportation Officials (AASHTO) Load and Resistance Factor Design Manual of Uniform Traffic Control Devices Manual of Uniform Traffic Control Devices Environmental Permits Environmental Permits

7 Bridge 1926 Current Condition Constructed in 1941 Constructed in 1941 Deck rehabilitated in 1956 Deck rehabilitated in 1956 Timber foundation and superstructure Timber foundation and superstructure Four spans totaling 80 feet Four spans totaling 80 feet Two lane highway Two lane highway

8 Traffic Control Bridge

9 Topographic Map

10 Soil Borings

11 Hydrology Study Q 100 = 181*DA 0.799 *Sl 0.466 *(I-2.5) 0.831 Bridge Drainage Area = 1.1 mi 2 85% Point Slope = 54.2 ft/mi 10% Point Q 100 = 932 cfs

12 Hydraulic Analysis Bottom existing beams @ 93.3’ 100 year peak flood level @ 85.5’ Creek bed @ 82’ Existing road surface @ 95.5’

13 Decision Matrix Initial Cost (35%) Lifespan (35%) Maintenance (20%) Constructability (10%) Average Single Span Prestressed Concrete Beams 45544.55 Steel Beams 53343.80 Double Span Cast-in-Place Concrete Beams 14512.85 Precast Nonprestressed Concrete Beams 34533.75 Prestressed Concrete Beams 24533.40 Steel Beams 43333.35 Multiple Span Prefabricated Multiple Span 14453.05 Design Options

14 Decision Matrix Initial Cost (35%) Lifespan (35%) Maintenance (20%) Constructability (10%) Average Single Span Prestressed Concrete Beams 45544.55 Steel Beams 53343.80 Double Span Cast-in-Place Concrete Beams 14512.85 Precast Nonprestressed Concrete Beams 34533.75 Prestressed Concrete Beams 24533.40 Steel Beams 43333.35 Multiple Span Prefabricated Multiple Span 14453.05 Design Criteria

15 Decision Matrix Initial Cost (35%) Lifespan (35%) Maintenance (20%) Constructability (10%) Average Single Span Prestressed Concrete Beams 45544.55 Steel Beams 5 3343.80 Double Span Cast-in-Place Concrete Beams 14512.85 Precast Nonprestressed Concrete Beams 34533.75 Prestressed Concrete Beams 24533.40 Steel Beams 43333.35 Multiple Span Prefabricated Multiple Span 14453.05

16 Decision Matrix Initial Cost (35%) Lifespan (35%) Maintenance (20%) Constructability (10%) Average Single Span Prestressed Concrete Beams 4 5 544.55 Steel Beams 53343.80 Double Span Cast-in-Place Concrete Beams 14512.85 Precast Nonprestressed Concrete Beams 34533.75 Prestressed Concrete Beams 24533.40 Steel Beams 43333.35 Multiple Span Prefabricated Multiple Span 14453.05

17 Decision Matrix Initial Cost (35%) Lifespan (35%) Maintenance (20%) Constructability (10%) Average Single Span Prestressed Concrete Beams 45 5 44.55 Steel Beams 53343.80 Double Span Cast-in-Place Concrete Beams 14 5 12.85 Precast Nonprestressed Concrete Beams 34 5 33.75 Prestressed Concrete Beams 24 5 33.40 Steel Beams 43333.35 Multiple Span Prefabricated Multiple Span 14453.05

18 Decision Matrix Initial Cost (35%) Lifespan (35%) Maintenance (20%) Constructability (10%) Average Single Span Prestressed Concrete Beams 45544.55 Steel Beams 53343.80 Double Span Cast-in-Place Concrete Beams 14512.85 Precast Nonprestressed Concrete Beams 34533.75 Prestressed Concrete Beams 24533.40 Steel Beams 43333.35 Multiple Span Prefabricated Multiple Span 144 5 3.05

19 Decision Matrix Initial Cost (35%) Lifespan (35%) Maintenance (20%) Constructability (10%) Average Single Span Prestressed Concrete Beams 4554 4.55 Steel Beams 53343.80 Double Span Cast-in-Place Concrete Beams 14512.85 Precast Nonprestressed Concrete Beams 34533.75 Prestressed Concrete Beams 24533.40 Steel Beams 43333.35 Multiple Span Prefabricated Multiple Span 14453.05

20 Structural Design Deck Design Beam Design Wind LoadLive LoadDead Load 387 lbs 640 lbs/ft100 lbs/ft 16 kips 3 kips8 in Thickness 33 ft

21 Beam Design Dead LoadLive Load 640 lbs/ft 1183 lbs/ft 32 kips8 kips32 kips

22 Beam Design Foundation Design Design 80 ft 45 in

23 Foundation Design Load from Beams 75 k H-Piles 20 ft 36 in Design 33 ft Bedrock

24 Cost Estimate for Construction Cost Per Unit# of UnitsTotal Cost Deck Cast-in-Place Deck, 4500 psi, Type C $461.67/CYD65.5$30,239 Reinforcement Steel, #8 bars $0.61/LBS56,390$34,398 Asphalt for Tack Coat $313.40/TON2.7$846 HMA Surface, Type A $72.42/TON8.0$579 Concrete Barrier Walls, 4500 psi, Type A $484.34/CYD15.3$7,430 Subtotal$73,492 Beams Concrete Bulb-T Beams, 22”x45”, 80’ $98.30/LF400$39,320 Subtotal$39,320 Foundation Foundation Excavation $16.69/CYD20.0$334 Pile, Steel H, HP 12”x53” $31.80/LF100$3,180 Pile, Steel H, HP 12”x74” $44.40/LF100$4,440 Substructure Concrete, 4500 psi, Type A $433.55/CYD18.3$7,951 Subtotal$15,905 GRAND TOTAL $128,700

25 Cost Estimate for Construction Cost Per Unit# of UnitsTotal Cost Deck Cast-in-Place Deck, 4500 psi, Type C $461.67/CYD65.5$30,239 Reinforcement Steel, #8 bars $0.61/LBS56,390$34,398 Asphalt for Tack Coat $313.40/TON2.7$846 HMA Surface, Type A $72.42/TON8.0$579 Concrete Barrier Walls, 4500 psi, Type A $484.34/CYD15.3$7,430 Subtotal$73,492 Beams Concrete Bulb-T Beams, 22”x45”, 80’ $98.30/LF400$39,320 Subtotal$39,320 Foundation Foundation Excavation $16.69/CYD20.0$334 Pile, Steel H, HP 12”x53” $31.80/LF100$3,180 Pile, Steel H, HP 12”x74” $44.40/LF100$4,440 Substructure Concrete, 4500 psi, Type A $433.55/CYD18.3$7,951 Subtotal$15,905 GRAND TOTAL $128,700

26 Cost Estimate for Construction Cost Per Unit# of UnitsTotal Cost Deck Cast-in-Place Deck, 4500 psi, Type C $461.67/CYD65.5$30,239 Reinforcement Steel, #8 bars $0.61/LBS56,390$34,398 Asphalt for Tack Coat $313.40/TON2.7$846 HMA Surface, Type A $72.42/TON8.0$579 Concrete Barrier Walls, 4500 psi, Type A $484.34/CYD15.3$7,430 Subtotal$73,492 Beams Concrete Bulb-T Beams, 22”x45”, 80’ $98.30/LF400$39,320 Subtotal$39,320 Foundation Foundation Excavation $16.69/CYD20.0$334 Pile, Steel H, HP 12”x53” $31.80/LF100$3,180 Pile, Steel H, HP 12”x74” $44.40/LF100$4,440 Substructure Concrete, 4500 psi, Type A $433.55/CYD18.3$7,951 Subtotal$15,905 GRAND TOTAL $128,700

27 Cost Estimate for Construction Cost Per Unit# of UnitsTotal Cost Deck Cast-in-Place Deck, 4500 psi, Type C $461.67/CYD65.5$30,239 Reinforcement Steel, #8 bars $0.61/LBS56,390$34,398 Asphalt for Tack Coat $313.40/TON2.7$846 HMA Surface, Type A $72.42/TON8.0$579 Concrete Barrier Walls, 4500 psi, Type A $484.34/CYD15.3$7,430 Subtotal$73,492 Beams Concrete Bulb-T Beams, 22”x45”, 80’ $98.30/LF400$39,320 Subtotal$39,320 Foundation Foundation Excavation $16.69/CYD20.0$334 Pile, Steel H, HP 12”x53” $31.80/LF100$3,180 Pile, Steel H, HP 12”x74” $44.40/LF100$4,440 Substructure Concrete, 4500 psi, Type A $433.55/CYD18.3$7,951 Subtotal$15,905 GRAND TOTAL $128,700

28 Bridge 3175 Current Condition Located on south perimeter Located on south perimeter Steel superstructure with concrete deck Steel superstructure with concrete deck Limestone block abutments Limestone block abutments Single lane security road Single lane security road Single span of 24 feet Single span of 24 feet

29 Topographic Map

30 Soil Borings Topographic Map

31 Hydrology Study Q 100 = 181*DA 0.799 *Sl 0.466 *(I-2.5) 0.831 Q 100 = 2530 cfs Bridge

32 Hydraulic Analysis Bottom existing beams @ 101.5’ Creek bed @ 91’ Existing road surface @ 103.5’ 100 year peak flood level @ 103.75’

33 Decision Matrix Initial Cost (35%) Lifespan (30%) Maintenance (20%) Constructability (15%) Average Cast-in-Place Concrete Superstructure 33333.5 Precast Concrete Plank Superstructure 25443.9 Three-Sided Concrete Box Culvert 35534.5 Preengineered Bridge System 25544.1 Design Options

34 Decision Matrix Initial Cost (35%) Lifespan (30%) Maintenance (20%) Constructability (15%) Average Cast-in-Place Concrete Superstructure 33333.5 Precast Concrete Plank Superstructure 25443.9 Three-Sided Concrete Box Culvert 35534.5 Preengineered Bridge System 25544.1 Design Criteria

35 Decision Matrix Initial Cost (35%) Lifespan (30%) Maintenance (20%) Constructability (15%) Average Cast-in-Place Concrete Superstructure 3 3333.5 Precast Concrete Plank Superstructure 25443.9 Three-Sided Concrete Box Culvert 3 5534.5 Preengineered Bridge System 25544.1

36 Decision Matrix Initial Cost (35%) Lifespan (30%) Maintenance (20%) Constructability (15%) Average Cast-in-Place Concrete Superstructure 33333.5 Precast Concrete Plank Superstructure 2 5 443.9 Three-Sided Concrete Box Culvert 3 5 534.5 Preengineered Bridge System 2 5 544.1

37 Decision Matrix Initial Cost (35%) Lifespan (30%) Maintenance (20%) Constructability (15%) Average Cast-in-Place Concrete Superstructure 33333.5 Precast Concrete Plank Superstructure 25443.9 Three-Sided Concrete Box Culvert 35 5 34.5 Preengineered Bridge System 25 5 44.1

38 Decision Matrix Initial Cost (35%) Lifespan (30%) Maintenance (20%) Constructability (15%) Average Cast-in-Place Concrete Superstructure 33333.5 Precast Concrete Plank Superstructure 254 4 3.9 Three-Sided Concrete Box Culvert 35534.5 Preengineered Bridge System 255 4 4.1

39 Decision Matrix Initial Cost (35%) Lifespan (30%) Maintenance (20%) Constructability (15%) Average Cast-in-Place Concrete Superstructure 33333.5 Precast Concrete Plank Superstructure 25443.9 Three-Sided Concrete Box Culvert 3553 4.5 Preengineered Bridge System 25544.1

40 Culvert Design 24 ft 10 ft 8 ft x 2 Backfill Design 675 Cubic Yards 2 ft 8 ft 8 ft x 2 Foundation Design

41 Cost Estimate for Construction Cost Per Unit# of UnitsTotal Cost Foundation Construction Foundation Excavation $16.69/CYD25$417 Reinforcement Steel (#7 bars) $0.61/LBS5,500$3,355 Substructure Concrete, 4500 psi, Type A $433.55/CYD19$8,237 Subtotal$12,009 Superstructure Construction Three Sided Box Culvert $1,657.23/LF16$26,516 Precast Wing Wall Section $425.25/EA4$1,701 Compacted Aggregate Base, #53 $23.21/TON110$2,553 Dry Excavation $9.32/CYD725$6,757 Structure Backfill $12.37/CYD680$8,412 Subtotal$45,939 Barriers and Railing Guardrail Type CF-1 $77.44/LF53$4,104 End Section, Galvanized, Flared $74.20/EA4$297 Subtotal$4,401 GRAND TOTAL $62,500

42 Cost Estimate for Construction Cost Per Unit# of UnitsTotal Cost Foundation Construction Foundation Excavation $16.69/CYD25$417 Reinforcement Steel (#7 bars) $0.61/LBS5,500$3,355 Substructure Concrete, 4500 psi, Type A $433.55/CYD19$8,237 Subtotal$12,009 Superstructure Construction Three Sided Box Culvert $1,657.23/LF16$26,516 Precast Wing Wall Section $425.25/EA4$1,701 Compacted Aggregate Base, #53 $23.21/TON110$2,553 Dry Excavation $9.32/CYD725$6,757 Structure Backfill $12.37/CYD680$8,412 Subtotal$45,939 Barriers and Railing Guardrail Type CF-1 $77.44/LF53$4,104 End Section, Galvanized, Flared $74.20/EA4$297 Subtotal$4,401 GRAND TOTAL $62,500

43 Cost Estimate for Construction Cost Per Unit# of UnitsTotal Cost Foundation Construction Foundation Excavation $16.69/CYD25$417 Reinforcement Steel (#7 bars) $0.61/LBS5,500$3,355 Substructure Concrete, 4500 psi, Type A $433.55/CYD19$8,237 Subtotal$12,009 Superstructure Construction Three Sided Box Culvert $1,657.23/LF16$26,516 Precast Wing Wall Section $425.25/EA4$1,701 Compacted Aggregate Base, #53 $23.21/TON110$2,553 Dry Excavation $9.32/CYD725$6,757 Structure Backfill $12.37/CYD680$8,412 Subtotal$45,939 Barriers and Railing Guardrail Type CF-1 $77.44/LF53$4,104 End Section, Galvanized, Flared $74.20/EA4$297 Subtotal$4,401 GRAND TOTAL $62,500

44 Cost Estimate for Construction Cost Per Unit# of UnitsTotal Cost Foundation Construction Foundation Excavation $16.69/CYD25$417 Reinforcement Steel (#7 bars) $0.61/LBS5,500$3,355 Substructure Concrete, 4500 psi, Type A $433.55/CYD19$8,237 Subtotal$12,009 Superstructure Construction Three Sided Box Culvert $1,657.23/LF16$26,516 Precast Wing Wall Section $425.25/EA4$1,701 Compacted Aggregate Base, #53 $23.21/TON110$2,553 Dry Excavation $9.32/CYD725$6,757 Structure Backfill $12.37/CYD680$8,412 Subtotal$45,939 Barriers and Railing Guardrail Type CF-1 $77.44/LF53$4,104 End Section, Galvanized, Flared $74.20/EA4$297 Subtotal$4,401 GRAND TOTAL $62,500

45 Summary Project Description Project Description Design Requirements Design Requirements Preliminary Design Preliminary Design Decision Matrix Decision Matrix Final Design Process Final Design Process Cost Estimate Cost Estimate

46 Any Questions?

47

48

49

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