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Rehabilitation of the I-81 Bridges
over
Oneida Lake & Erie Canal
Sam Anthony P.E., F.ASCE,
Erdman Anthony, Rochester, NY
Project Location
• 15 Miles North of
Syracuse
Bridge History
• 1958 Construction Begins
• 1961 Opened to traffic
• Longest Prestressed Concrete Superstructure
(at time of construction)
• Summers, Munniger and Molke, Consulting Engineers
• Terry Contracting, Inc., Long Island City, NY
• 2000 Major Rehabilitation – concrete overlay
• 2011 Emergency Repair – external post tensioning added
• 2012 NYSDOT retains Erdman Anthony to perform in-depth structural
evaluation
• NYSDOT video documentary of design and construction:
3
Unique Bridge Features
• 70ft – 320 ft – 70 ft span configuration
• Cantilever girders extend 70ft beyond piers
• 232 ft Drop-In girders
• 38 ft solid counterweight in each flank span
• Longitudinal & transverse post-tensioning
Interlocking “finger” connection
5
Plan View of Girders
Plan View of Girders with Diaphragms
ABUT PIER MIDSPAN
6
Cantilever Girders
Counterweight
8
Drop-in Girders
Bearings-on-diaphragms
9
Longitudinal post tension
10
Cantilever – Interior Girder
Cantilever – Exterior Girder
Drop-In Girder
Typical Post Tensioning Detail
11
External post tension
12
External post tension
13
Erdman Anthony Scope of Work
1. In-depth Inspection
a. Phase 1: 100% Hands On
b. Phase 2: Non Destructive Inspection
c. Phase 3: Localized Destructive
2. Structural Analysis
3. Rehabilitation Plans, Specs and Estimate
14
15
Erdman Anthony – Phase 1 - Visual Inspection
• 100% Hands-on Inspection
• Regions of concrete deterioration
• Exposed & broken tendons
16
Phase 1 - Scupper Inventory
Bridge Girder Span Scpr Notes
Likely
Tendon
Corrsn
NB 1 1 1 Cracks in web, delams in chamfer and soffit yes
2 No Delams noted no
2 3 Delam soffit only no
4 Delam soffit only no
10 Cracks and Delam in Web yes
11 Delam in Web yes
3 12 Wet concrete no
13 Major delams, possible broken tendon yes
6 1 1 Small Delam in web no
2 Delam soffit only no
2 3 Delams in Deck Soffit no
4 No Significant Delams noted no
10 Crack in chamfer, minor web delam, exposed stirrup no
11 No Delams noted no
3 12 Minor Delam in web no
13 Web delams, spalled concrete over tendon yes
SB 1 1 1 Cracks and Delam in Web yes
2 Some Delam in Web and Chamfer yes
2 3 Minor Delam in Deck Soffit no
4 Cracks and Delams in web and chamf. yes
10 No Delams noted no
11 No Delams noted no
3 12 Web delams, exposed stirrup yes
13 Major delams, broken tendon yes
6 1 1 Crack and Delam in Web - Imm. Spall yes
2 Minor Delam in Deck Soffit only no
2 3 No Delams noted no
4 Spall and Broken tendons yes
10 Delams in Web - top and bot. yes
11 Delams in Web yes
3 12 Start of web delams yes
13 Crack in web no
Phase 1 - Added wearing surface
17
18
Phase 2: Half Cell Potential [HCP]
RESULTS: Northbound – G1 – Inside Face – near scupper 12
Pier 2
(north)
Tendon (Typ)
Chamfer
Bottom of Deck Slab (unrolled)
> 90% probability
corrosion occurring
> 90% probability NO
corrosion occurring
corrosion uncertain
2 - Ultrasonic Shear Wave Tomography [UST]
• Completed by CTL Group
• Low frequency (20 to 100 kHz)
multifunctional phased array
ultrasonic system
• Used to evaluate grout integrity
for select longitudinal and
transverse tendons.
• Data assembled and plotted
graphically to allow 3D
interpretation.
20
2 - Ultrasonic Shear Wave Tomography [UST]
RESULTS: SB/G6/P2 @ possible tendon void
UST SCANNER
Web: 21” (533mm)
Cover
2.5”
(65mm)
Depth into Girder
Possible
Tendon Void
21
2 - Ultrasonic Shear Wave Tomography [UST]
RESULTS: Southbound – G6 (East Fascia) @ North Pier
C/L North Pier
Main Span
Foam Void (Typ)
Tendon (Typ)
Possible Void Location
22
Phase 3 - Videoscope
23
Phase 3 - Videoscope – Drill 2B
24
Phase 3 - Videoscope Results – Drill 2B
25
Phase 3 - Videoscope Results – Drill 3B
26
Phase 3 - Videoscope - Anchor
• Inspected 108 transverse tendon anchorages at diaphragm(s) A & D
• Conditions ranged from fair to poor
27
Phase 3 - Videoscope Results – Anchor 1
28
Phase 3 – Videoscope Results – Anchor 1
29
Phase 3 - Window 7
30
Phase 3 - Window 7 – Row 1
31
Phase 3 - Window 7 – Row 2 - Interior
32
Structural Analysis
33
• 72 Steps in
Analysis
• All stress states
predicated on
previous step
• After 57 years,
pt losses are
close to
exhausted
• CSI Program
Updates
Problematic
Cantilever PT Removals
34
Cantilever PT Removals
35
Drop In PT Removals
36
Drop In PT Removals
37
38
39
40
41
Good News
No viable offsite
detours!
42
43
44
45
46
Completed Bridge
47
SB Bridge SB Bridge NB Bridge NB Bridge
W Fascia E Fascia W Fascia E Fascia
Elevation
Elevation
Deflection
Elevation
Deflection
Elevation
Deflection
Elevation
Deflection
Elevation
Deflection
Elevation
Deflection
Elevation
Deflection
Elevation
Deflection
Elevation
Deflection
Elevation
Deflection
Elevation
Deflection
Elevation
Deflection
Elevation
Deflection
Elevation
Deflection
Elevation
Deflection
*Deflection = Recorded Elevation - Baseline Elevation
Survey Deflection Monitoring Record Table
Outside
Temp, °FDate
Baseline Elevation
Recorded Elevations & Calculated Deflections*
Elevations (ft) and Deflections (in)
Measurement
Type
Owner’s Manual – Instrumentation – MISTRAS
Scenario Prestressing Wire Status Required Action
1Less than 21 breaks in the east fascia drop-in girder and
less than 21 breaks in the west fascia drop-in girder.No Action Required
222 or more wire breaks in the east or west fascia drop-in girder
(but not both).
Reduce Number of Lanes
to Two as per Figure 1
3 22 or more wire breaks in the east and west fascia drop-in girders. Close Bridge
Action Plan Summary
PDH Questions1. “AS IS” condition, what girder controlled
the load rating?
The drop in fascia girder = 20 tons
2. What was the primary strategy to improve
rating?
Remove the 8” overlay weight. Put back
1.5” overlay. New rating = 38 tons.
3. How many wires need to break before
you have to worry?
2148
49
Credits
NYSDOT Region 3 Nick DeCirce, PE Project Manager
NYSDOT Region 3 John Sexton, PE Regional Bridge
NYSDOT Main Office Matthew Royce, PE Emergency Repair
NYSDOT EIC Eric Sczerbaniewicz
Erdman Anthony Sam Anthony, PE Lead Structural
Erdman Anthony Bob Farrell, PE Sr. Structural
Steve Percassi, PE Sr. Structural
Joe Bechel, PE Sr. Structural
Erdman Anthony Drew Schwingel, EIT Structural
KPFF / CTL Chris Ligozio, PE Sr. Structural
Corven Engineering John Corven, PE Sr. Structural
Crane Hogan Frank Fisher Superintendent
Thanks for your attention.