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:

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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

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Plan View of Girders

Plan View of Girders with Diaphragms

ABUT PIER MIDSPAN

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Cantilever Girders

Counterweight

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Drop-in Girders

Bearings-on-diaphragms

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Longitudinal post tension

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Cantilever – Interior Girder

Cantilever – Exterior Girder

Drop-In Girder

Typical Post Tensioning Detail

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External post tension

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External post tension

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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

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Erdman Anthony – Phase 1 - Visual Inspection

• 100% Hands-on Inspection

• Regions of concrete deterioration

• Exposed & broken tendons

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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

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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.

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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

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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

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Phase 3 - Videoscope

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Phase 3 - Videoscope – Drill 2B

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Phase 3 - Videoscope Results – Drill 2B

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Phase 3 - Videoscope Results – Drill 3B

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Phase 3 - Videoscope - Anchor

• Inspected 108 transverse tendon anchorages at diaphragm(s) A & D

• Conditions ranged from fair to poor

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Phase 3 - Videoscope Results – Anchor 1

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Phase 3 – Videoscope Results – Anchor 1

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Phase 3 - Window 7

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Phase 3 - Window 7 – Row 1

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Phase 3 - Window 7 – Row 2 - Interior

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Structural Analysis

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• 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

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Cantilever PT Removals

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Drop In PT Removals

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Drop In PT Removals

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Good News

No viable offsite

detours!

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Completed Bridge

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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

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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.