Sellwood Replacement Bridge Perched Box Caisson · Elevated cofferdam constructed above water then...
Transcript of Sellwood Replacement Bridge Perched Box Caisson · Elevated cofferdam constructed above water then...
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Sellwood Replacement Bridge Perched Box Caisson
Design & Construction
…a cofferdam alternative
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Sellwood Replacement Bridge
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Project Information
• Location: Portland, Oregon• Budget: $307.5 Million• Three span steel deck arch (Design by TYLin)• Contractor: Slayden/Sundt, A Joint Venture
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Perched Box CaissonElevated cofferdam constructed above water thenlowered down using hydraulic jacks. A voided baseslab sleeves over foundation shafts as the box issubmerged and secured using anchoring collars toseal and resist vertical forces.
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Why?
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Key Constraints
• Alluvial gravel with numerous cobbles and boulders up to 5 feet in diameter
• Long sheet pile length • Scour up to 65 feet (CH2M Hill estimate)• Stay-in-place falsework not to exceed 35ft2
relative to stream flow • In-water work restricted to July 1st - Oct 31st
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Design Development
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Buried Pier - Option 1 Typical Cofferdam
Constructability Limitations• 90ft sheet piles driven into
cobbles & boulders. • In-water work
NOT CONSTRUCTIBLE Conclusion:
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Elevated Pier - Option 2A Above Grade Seal
Constructability Limitations• Abandoned concrete seal
exceeds permit allowance• Removal of concrete seal
not reasonable.
NOT ALLOWEDConclusion:
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Elevated Pier - Option 2BCofferdam with Shored Pier
Constructability Limitations• Piles driveability issues. • Limited removal access of
heavy falsework shoring. • Mid depth concrete seal
could negatively influence the structural behavior of the permanent foundations (i.e. Seismic Response)
NOT RECOMMENDED Conclusion:
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Elevated Pier - Option 2CPerched Box Caisson
Constructability Limitations• Fabrication Intensive• Requires “Birds Mouth”
Forms
SELECTED OPTIONConclusion:
Area ≤ 35ft2
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Construction Sequence
1,2,3,4,5
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Drive Pile
Use pile template when driving
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Construct Drilling Reaction Frame
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Install Drilled Shafts
Pile to support oscillator lateral and vertical extraction forces
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Disassemble Reaction Frame
Use steel crossbeams to form Box Caisson base slab
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Pour Elevated Base Slab
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Construct Wales, Walls & Topping Slab
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Construct Bird Mouth Forms
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Construct Jack-Down Frame
Reuse steel beams from drilling reaction frame
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Lower Assembly (Jack-down)
Total Weight = 1,016,000 lbs
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Install Tie-down Collars
Anchor tie-down collars and seal to shaft casing
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Dewater, Remove Frame, Cut-off Casing
Resist buoyant uplift force
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Pour Bottom Lift of Pier
Support pier concrete weight
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Pour Upper Pier and Angel Wings
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Disassemble Walls, Slab to Remain
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Analysis & Design
1+1=2
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Analysis & Design Steps
• LUSAS 3D Finite Element Analysis Software• Check loading for:
– Oscillator drilling forces– Base slab pour– Jack-down distribution– Bouyant uplift – Pier concrete weight
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Voided Slab Design
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Construction Photos
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Inside Box Prior to Jack-down
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Tie-Down Collar
Design
Fabrication
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…or Flying Saucer
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Aerial View
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Elevated Position
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Jack-down Frame
High Tension Rods
(8) Cylinder Jacks
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EFCO Pier Forms
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High Water
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Completed Pier
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Time-Lapse Video
November 2013 – February 2014
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Contractor Feedback
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Construction Benefits
• Quantities saved:
• Reduced environmental liability • Easy access for materials
Structure Steel Concrete Dredging
Traditional Cofferdam 1,170 Tons 6,130 yd3 13,100 yd3
Perched Box Caisson 390 Tons 380 yd3 0 yd3
Savings 780 Tons 5,750 yd3 13,100 yd3
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Additional Benefits
• Easier permitting with lower total pile count. Reused 3800LF temporary pile.
• No tremie concrete = no contaminated water. Dewater directly back into river.
• Construction schedule not limited to in-water work restrictions.
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Challenges and Lessons Learned
• Synchronizing jacks to maintain slab tolerance during Jack-down was difficult.
• Creating a water-tight seal at the sheet to concrete interface was costly and time consuming.
• Joints at birds mouth forms to sheet pile are difficult to achieve water-tightness.
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Suggestions for Improvements
• Negotiate larger allowable stay-in-place falsework• Avoid birds mouth forms when possible• Improve sealing methods prior to jack-down• Improve control during jack-down• Increase pumping rate during dewatering• Modify tie-down collar to reduce underwater
construction• More robust pile for shaft drilling
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Questions?