PDCA Project of the Year Awards

Land: Less than $500,000 

Peter Courtney Minto Island Bridge, Legacy Contracting, Inc. 

The new Peter Courtney Minto Island Bridge is a steel arch bridge spanning the Willamette Slough, connecting the downtown Riverfront Park to the park on Minto-Brown Island. The new bridge provides access to over 1,300 acres of parks on both sides of the Willamette River for the community while also linking more than 30 miles of off-street trails. 
The main span of the bridge is a 304.5-foot tied-arch span with four total approach spans, three at 50 feet and one at 35 feet. Combined, the bridge is a five-span bridge totalling 489.5 feet long. The deck consists of cast-in-place components as well as precast panels for the main span. The supports are made up of cast-in-place tapered columns that used a form liner for aesthetics. 
The Minto Island Bridge is a one-of-a-kind structure, from the foundation up. Although there are only 12 permanent piles in the finished product, many more were required in order to build this beautiful bridge. Driving the work bridge, support tower and falsework piling in a very sensitive area and completing the work within the in-water work window was challenging. Legacy Contracting was able to use a vibratory hammer and impact hammer to drive the pile through the difficult subsurface conditions.
Read about the Peter Courtney Minto Island Bridge by Legacy Contracting, Inc. on page 48.
Land: $500,000 to $2 Million

Silver Sands State Park Phase 1B Improvements, Blakeslee Arpaia Chapman, Inc.

Blakeslee Arpaia Chapman, Inc. (BAC) was contracted by the Connecticut State DOT to provide the foundation work for Silver Sands State Park phase 1B improvements. The improvements consisted of the installation of raised, pile supported, bathhouses and concession area, several handicap accessible ramps to and from parking areas, boardwalks along the beach and a walkway across wetlands connecting to an existing boardwalk.
One challenge in the project was how to install an eight-foot wide timber pile supported walkway through 290 feet of wetlands to meet and attach to another existing walkway. The walkway consisted of two pile bents every 14 feet with a split cap and cross bracing. The specifications precluded any equipment from entering or bearing upon the wetlands.
Because the walkway connected to an existing walkway, BAC worked their way out two bents at a time. Once all the piles, caps and braces were in, they backed our way out, removing the temporary piles and cutting the extended split caps back to the eight-foot permanent walkway width.
Read about Silver Sands State Park Phase 1B Improvements by Blakeslee Arpaia Chapman, Inc. on page 52.

Land: $2 Million to $5 Million

Naval Academy Cyber Securities Studies Building, Corman Kokosing Construction

The overall scope of this project is to deliver the latest addition to the campus of the United States Naval Academy. This $114 million Center was a design-build of a 206,400 square-foot academic building, dedicated to the education of midshipmen in all areas of cyber warfare, and will include classrooms and lecture halls, teaching and research laboratories, a research and testing tank to support the engineering and weapons laboratories, an observatory, offices and multi-purpose collaborative space for students and faculty. Situated between Nimitz Library and Rickover Hall, the Center will be surrounded by elevated hardscape terraces continuous with those of the adjacent buildings.
Corman Kokosing Pile's experience and Atlantic Metrocast's SlickCoat piles process was the perfect combination to provide the pile foundation to build the premier educational and research facilities for the government's unique project. The design began immediately and construction on the Center for Cyber Security Studies began in late 2016 with an anticipated completion in the third quarter of 2019.
The presence of bulkheads, seawall, piles, slope instability and miscellaneous buildings previously constructed at the site impacted the construction of the foundations. Available historical design documents from past construction projects did not accurately show actual conditions. Corman Kokosing Construction prepared for many types of buried obstructions to be excavated and removed to make way for new construction work.
Read about the Naval Academy Cyber Security Building by Corman Kokosing Construction on page 56.

Marine: Less than $500,000

Terminal 3 Headline Dolphin, Legacy Contracting, Inc.

The new Terminal 3 Headline Dolphin is a concrete structure supported by steel piling with a mechanical capstan for vessels to use for their headline mooring line. A new 200-foot-long, two-span gangway was installed on the new dolphin to the existing terminal with one intermediate concrete cap supported by steel piling. Logging vessels that load on Terminal 3 can now utilize the new headline dolphin to keep the forward part of their vessel against the dock during loading operations. With the location of the dolphin being more than 200 feet from the existing terminal, Legacy Contracting was required to preform the work on a modular float barge.
Eight 24- by 0.625- by 123-foot piles painted with a marine grade coating system supports the concrete dolphin. These piles were driven full length at a 3:1 batter slope out from the center of the dolphin. With the steep batter, Legacy Contracting fabricated a driving template that was supported by one center pile and used to achieve correct spacing and batter to meet the tight tolerance required. The template also had to be designed so it could be easily disassembled to remove it after all the piles were driven. The piles were PDA tested to ensure they met specified bearing capacities of 600 kips in compression and 440 kips in tension.
Legacy Contracting, Inc. was able to overcome challenges and deliver the owner a great end product. 
Read about the Terminal 3 Headline Dolphine by Legacy Contracting, Inc. on page 60.

Marine: $500,000 to $2 Million

Topsail Island Bridge Replacement, Balfour Beatty

Balfour Beatty US is the general contractor responsible for the delivery of the Topsail Island Bridge Replacement project on NC 50/210, which is on schedule for completion 300 days ahead of contractual requirements. The high-profile bridge project involves the complete replacement of the existing steel truss swing-span bridge with a two-lane, fixed-span, high-rise bridge over the Intracoastal Waterway (ICW) and associated approaches at beach end.
Because the shallow depths of the wetlands and adjacent waters of the ICW prohibit the use of barges for material deliveries to the project area, the team had to put the trestle in place in its entirety to access the 3,700-foot bridge deck. By using driven piles, Balfour Beatty was able to complete the 4,000-foot-long trestle within the in-water work window of October 1, 2016, to March 31, 2017, to begin construction on the bridge structure. If the team did not complete the trestle prior to the start of the fish moratorium on April 1, 2017, the delivery of the entire bridge could have been delayed by a year. 
Balfour Beatty made creative adjustments to the schedule to drive the piles and complete the trestle while meeting in-water work limitations. To start, the team worked double shifts seven days each week to drive approximately six 30-inch steel pipe piles per shift and installed the trestle structure to gain access to the next pile locations. With limited storage on-site, the team scheduled pile deliveries for on-time delivery staggering the deliveries of piles sourced from existing projects in Wilmington, N.C., Savannah, Ga. and Milledgeville, Ga. to exactly the right the amount of pile needed each day. 
Originally contracted for completion by 2020, Balfour Beatty is on schedule to open the Topsail Island Bridge to traffic in 2018 300 days ahead of the contractual schedule. This extraordinary feat would not be possible without the use of driven piles. 
Read about the Topsail Island Bridge Replacement by Balfour Beatty on page 64.

Posted in PileDriver Magazine. Tagged as Issue 5, 2018.

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