January 1, 2016
FINLEY provided pre-bid engineering services which included the development of a construction sequence that cast the back spans on falsework. This modification resulted in a savings of time, simplified construction and reduced the equipment required for the cable-stayed portion of the project by allowing land access to build the main span.
The falsework system along with precast concrete girders for floor beams on side spans, allowed Brayman to have land access to build the main span area. The falsework supported all construction equipment required for the pylons and deck, eliminated the need for marine operations and provided a much safer work environment.
The falsework was designed as a modular system, allowing it to be used for both the Kentucky and Ohio approaches and reduced the number of travelers from two to one. The modifications allowed the main span to be cast in place in a segmental, one-directional cantilever method.
FINLEY’s design modifications included the first known use in the USA of precast stay anchor blocks. The use of these blocks allowed Brayman to immediately install the cable stay and simplified the traveler design, reducing the pouring cycle by a week.
Brayman decided to use precast concrete cofferdams rather than the typical sheet pile style to speed up the construction process and save on costs. The use of precast cofferdams allowed us to greatly reduce the amount of tremie concrete required, as well as provide a sacrificial form for the tower footing.
“We took a close look at the changes proposed by the contractor to ensure that the bid met our requirements. The changes were very innovative, kept to our high standards, and resulted in less cost to our taxpayers. Preliminary approval was provided in 2 months, with final approvals complete in 6 months. After years of hard work, patience and diligence, the residents of Ironton and Russell and other travelers will soon enjoy a reliable, safe crossing to enhance commerce and quality of life in the area.” David Bame, PE, Project Engineer, Ohio Department of Transportation
Firms providing a significant role in the project include:
Owner: Ohio Department of Transportation
Contractor: Brayman Construction Corporation
Value Engineering Redesign & Construction Engineering: FINLEY Engineering Group, Inc.
Form Travelers, Post-Tensioning Materials, Stay Cable Materials: VSL
Precast Producer: Car Concrete/Brayman Precast, LLC
Formwork: tower legs: PERI Formwork Systems, Inc.
Bearings: D.S. Brown Company
Expansion Joints: Watson Bowman Acme
Project Designer & Owner’s Engineer: URS Corporation