I-80 Reconstruction Rolling Along

Accelerated Bridge Construction process in full swing

‘Bridge Farm’ at 1300 East exit has captivated the public’s attention. The first of seven bridge structures (out of 17 total on the project) was slated to be moved into place beginning the final week of June. The mammoth $137 million reconstruction project will continue through December 2009.

Contractor Ralph L. Wadsworth Construction of Draper, Utah, and the various subs on the on the $137 million I-80 Reconstruction project in Salt Lake City are employing unique construction innovations to ensure minimal traffic delays and keep workers out of harm’s way.

“We’ve been successful keeping upwards of 100,000 cars a day rolling through our jobsite,” says John Montoya, project manager for the Utah Department of Transportation.

The project is employing a number of innovative Accelerated Bridge Construction techniques, highlighted by the Bridge Farm site off the 1300 East exit. That’s where seven bridges were being constructed at once and then will be moved into place via giant self-propelled modular transporters similar to what was done in October on the 4500 South bridge replacement project.

Wayne Bowden, project manager of the I-80 Reconstruction for RLWC, says the lessons learned by the design and construction team on the 4500 South project have been applied to this project.

“(4500 South) actually helped develop the relationship with Mammoet (the Holland-based company that specializes in moving massive structures), what their capacity is, how they design their components and how we can assist in the design of the components we’re required to provide,” Bowden adds. “There is a big learning curve there. Also, there were a lot of ‘what if’ scenarios that were encountered on 4500 South, and we were able to implement those into our (I-80) design.”

Bowden says that the first of the seven initial bridge replacements were slated to begin in late June with an expected six-week schedule duration. He says that each of the seven bridges will be moved into place differently than the 4500 South bridge.

“On this particular project there is an added component with launching the (bridge) structures across the spans,” Bowden says. “On 4500 South, we just moved the bridge in from the side and set it on the foundations.

“On this one, we’ll pick it up from the bridge staging area, drive it up a loop ramp, across cross streets, down on ramps, drive it to the location and launch it out with a rail system across the hole. From there it will be lowered into position with a series of 600-ton jacks and climbing towers.”

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Loet Schartman, a project manager for Mammoet’s U.S. office in Houston, says his crews have to find a way to scoot the bridge over the hole and then lower it using climbing jacks. “It is a much bigger operation than other projects,” he adds. “4500 South was technically more challenging because of the different slopes. This project is more challenging because of more equipment, the type of equipment and the short time span to get all the bridges moved into place.”

Montoya agrees that a lot of work still needs to happen in the initial bridge moving phase. “Every move is synchronized and engineered and every single one is unique in some aspect,” he adds. “No two bridges have the same dimensions or the same engineering.”

Safety Priority No. 1

UDOT officials have been emphasizing safety – to both the traveling public and highway contractors – for many years, and the push to minimize potential accident risks is evident on I-80. One key for this is the Barrier Moving Machine, which allows the construction team to add or subtract a lane in about 30 or 40 minutes.

In addition to reducing traffic delays, the moveable barrier provides a much more permanent and safer separation between moving cars and construction workers.

“It’s a great safety advantage for our guys,” Bowden says. “During off-peak hours we can take a lane, and during peak hours we add the lane back. On a past median widening project on I-15 from Alpine to Provo, we didn’t have a moveable barrier. Guys were literally working within 6 inches of 75-mph traffic. It was a nightmare.”

Montoya adds that people are more productive when they’re safe. “From our perspective we want everybody safe, including workers and the traveling public,” he says. Bowden says ABC construction innovations like the Bridge Farm are done primarily to reduce overall traffic disruptions, which UDOT officials point to as one of the most important intangibles in justifying the cost and time for any major road or highway construction project.

Bowden says that’s why his crews are building seven bridges at the Bridge Farm location at once.

“A lot of UDOT’s concern is to not impact the traveling public,” Bowden adds. “We ran several scenarios – one being building a temporary structure off the side of each bridge. We looked at properties throughout the corridor that these structures could be built at. We determined that building them in one location was going to be more cost-effective and quicker.”

Once the seven initial bridge structures are moved into place, crews will continue with other aspects of the project, including replacing all utilities, MSE walls and noise walls. Bowden says another unique construction aspect is that the existing road surface concrete will be left in place, with a 3- to 7-in. separation layer of asphalt placed on top of that, then another 12 in. of concrete placed on top of that. He says leaving the existing surface in place will save a considerable amount of time and money.

“We have a very talented team of engineers and contractors,” Montoya says. “We’ve really set the bar high for getting projects done fast, and in good quality, while keeping the public safe. I think everybody that’s involved is proud of that.”

Bowden says complicated, high-risk construction projects like the I-80 Reconstruction are right up his alley.

“This project is unique in the sense that we’re developing some new techniques and methods that UDOT can use in the future,” he adds. “We try to come up with innovative ideas, implement them and see the project come to life. I like it a lot more than just taking a set of plans and building a bridge.”

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