Ironton Russell Bridge Project...Ironton Russell Bridge Project Construction Update July 1, 2015 Responsible for Construction Inspection & Engineering Prepared by: Brian Davidson,

Ironton Russell Bridge Project

Construction Update July 1, 2015

Responsible for Construction Inspection & Engineering

Prepared by: Brian Davidson, P.E.

Rendering by URS

Ironton Russell Bridge Project Law 93-0.00 Project Summary: July 1, 2015 ______________________________________________________________________________________________________________________________________

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Project Overview The Ironton Russell Bridge Project entails the construction of a cast in place concrete cable stayed bridge over the Ohio River with structural steel approaches connecting the towns of Ironton, Ohio and Russell, Kentucky. The bridge will provide two 12-ft driving lanes and two 4–ft shoulders; a driving lane and shoulder in each direction. Span lengths for the approaches vary widely as they cross numerous (6) rail lines, the Ohio River levee and city streets. On the Kentucky side the spans are 140-ft and 235-ft; in Ohio the spans are 110-ft, 144-ft, 186-ft and 144-ft. The approach bridges are founded on small diameter drilled shafts (Kentucky) or steel pile (Ohio). The main span unit consists of three spans; two flanking spans at 370-ft and the center span of 900-ft. The main span unit is supported by two CIP, 316-ft tall, diamond shaped towers, founded on large diameter drilled shafts with rock sockets. When completed, the 900-ft main span will be the longest span the Ohio DOT has built. The contract value for construction of the new structure and removal of the existing is $81,266,742.05, with Brayman Construction Corporation the low bidder. Recent Construction Highlights - Main Span

Tower 3 (KY): The Peri form system used for casting the Tower 3 legs has been removed from segment 18. Pier table false work has also been removed. Crews there now prepare for raising the form traveler from a barge at river level to the pier table.


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Main Span Cantilever-Form Traveler: During the month of June form traveler assembly continued as forms were secured to the traveler and hydraulic systems were installed (above). This work is currently taking place on barges adjacent to Tower 4. When the traveler is ready to be raised, the floating platform will be moved to a location underneath the Tower 3 pier table in the river channel.


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Ohio Back Span: Rebar for the Ohio backspan deck is currently being placed and installed over the recently completed stay-in-place formwork (above). Six edge girder and deck placements will connect the integral Pier 5 cap to the Ohio pier table (left).To date five of the six edge girder sections and two of the six deck sections have been cast. Each of the reaming deck sections are 56’-6” long. The contractor may elect to eliminate construction joints combining individual deck sections into fewer than six concrete placements.


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Tower 4 (OH): Peri formwork from Tower 3 was moved to Tower 4 and tower leg construction has resumed beginning at segment 7. Rebar for this segment was pre-fabricated on a barge, picked with a crane (left), and then set into the Peri formwork (below).


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Scheduled Actual Select Milestone Events (Schedule Update 33) Date Date Notice to Proceed 3Feb12 Open Bridge to Traffic 25Apr17 End Project 30Jan18 Ohio Approach Set Structural Steel Ohio Approach 18Apr14 18Mar14 Complete Deck Concrete Ohio Approach 15Oct14 22Oct14** Main Span Cast KY Tower Footing 10May13 10May13 Cast OH Tower Footing 21Jan14 21Feb14 Cast First KY Tower Section 27June13 14June13 Cast Last KY Tower Section 03Jun15 03Jun15 Cast First OH Tower Section 05Mar14 27Mar14** Cast Last OH Tower Section 16Dec15 Complete KY Back span 06Aug14 15Aug14 Complete OH Back span 15Jul15 Set form traveler KY Tower 23Ju115 Set form traveler OH Tower 02Mar16 Main span Closure Pour 12Sept16 Kentucky Approach Set Structural Steel Kentucky Approach 13Sept13 6Sept13 Complete Deck Concrete KY Approach 10Dec13 20Nov13 % Complete ($) Paid $56.2M/Total $82.8M 67.9% % Complete (Time) Day 1213 of 1803 67.3%

**Non critical path activity. Bridge and Roadway Summary At Tower 3 (KY), Segment 18 was cast on May 29, 2015. This completes the casting of concrete for Tower 3. The Peri formwork system has been removed from the tower. Crews are preparing the tower and pier table for raising the form traveler. At Tower 4 (OH), The Peri formwork has been set at Tower 4 to resume construction of the Tower 4 segments. Segment 7 right (upstream) was cast on June 18, 2015. Segment 7 left (downstream) is currently being formed. Two of the six Ohio back span deck pours are complete. One section of the Ohio back span edge girder connections remain to be cast. The form traveler for the main span cantilever is currently being assembled on a barge adjacent to Tower 4.


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Tower 3 (KY) Progress thru 7/1/15


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Tower 4 (OH) Progress thru 7/1/15


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Substructure Progress Chart thru 7/1/15

Kentucky Approach Ohio Approach Rear (KY) Abutment % complete Pier 6 % complete Drilled shafts 12 of 12 100 Pile Installed 24 of 24 100 Footing 7 of 7 100 Footing 100 Backwall 2 of 2 100 Stem 100 Wing walls 6 of 6 100 Cap 100

Pier 1 Pier 7 Drilled shafts 3 of 3 100 Pile Installed 24 of 24 100 Footing 100 Footing 100 Stem 100 Stem 100 Cap 100 Cap 100

Main Span Pier 2 Pier 8 Drilled shafts 6 of 6 100 Pile Installed 27 of 27 100 Footing 100 Footing 100 Pier Segment 3 of 3 100 Stem 100 Diaphragm Segment 4 of 4 100 Cap 100

Pier 3 (Ky Tower) Forward (OH) Abutment Drilled shafts 6 of 6 100 Pile Installed 22 of 22 100 Footing 100 Footing 100 Tower Segments 18 of 18 100 Backwall 2 of 2 100 Wingwalls 2 of 2 100 Pier 4 (OH Tower) Drilled shafts 6 of 6 100 Footing 100 Tower Segments 6.5 of 18 36

Pier 5 Drilled shafts 4 of 4 100 Footing 100 Pier Segments 2 of 2 100 Diaphragm Segment 3 of 3 100


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Superstructure Progress Chart thru 7/1/15

Precast Floor beams # cast % cast 52 pieces total 52 of 52 100

Precast Anchor blocks # cast % cast

108 pieces total 107 of 108 99

Main Span Unit % complete Kentucky Back span Segments 12 of 12 100 Ohio Back span Segments 3 of 12 25 Kentucky Cantilever Segments 0 of 15 0 Ohio Cantilever Segments 0 of 15 0

Kentucky Approach % complete Girders Fabricated 24 of 24 100 Girders Erected 24 of 24 100 Deck Castings 3 of 3 100

Ohio Approach % complete Girders Fabricated 35 of 35 100 Girders Erected 35 of 35 100 Deck Castings 4 of 4 100

Documents

Ironton Russell Bridge Project...Ironton Russell Bridge Project Construction Update July 1, 2015 Responsible for Construction Inspection & Engineering Prepared by: Brian Davidson,