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1/16/2012

Topics

I 35W P t 2
I 35W Part 2

Mn/DOT Decision to Utilize Design Build


Procurement Process and RFP Development
Challenges We Faced
Scoring Process
Mn/DOTs Approach to Design Build Projects
Design and Construction of the Bridge

Building the I35W St. Anthony Falls Bridge


Dan Dorgan
State Bridge Engineer
Minnesota Department of Transportation

February 15, 2010

Previous I-35W Bridge


I35W A Team Success

The Major North-South route through Minneapolis

Owner

Minnesota Department of Transportation

Contractor

Flatiron Constructors, Inc.


Manson Construction Co. Johnson Bros.

Designers

FIGG Bridge Engineers TKDA

Owners Oversight Consultant


Parsons Transportation Group

Partner
FHWA

Planning for Replacement Begins Early


Morning Hours of August 2
Previous Bridge Emergency Replacement Plans
Inadequate
q
Replacement Team Begins to Form
Discussion Begins on Fastest Delivery Method

August 1, 2007

1/16/2012

New Bridge is Needed Fast


141,000 Cars a Day Used the
Bridge
One of the Busiest Bridges in
Minnesota

Serves major traffic areas of:


U of M
Downtown Minneapolis

$400K a day estimated in road


users costs
Mn/DOT needs to Demonstrate
Abilities and Begin Rebuilding
Public Confidence

How Do We Do It?

August 2nd Design-Build Best-Value


Procurement Method Selected
Core Team Identified

Three experienced Design Build Project


Managers on Team
Bridge Office personnel
Three bridge designers
Two construction engineers with bridge
experience
Empowered to be decision makers

Mn/DOT Design Build Process


Why Best Value?
Considers Quality and Cost
7th Design Build Best Value Project
35W Utilized Previous Lessons Learned
Mn/DOT Design Build Specifications Well
Developed
Past Design Build Projects Successful
Geometric Improvements Desired
Public Input / Communication and
Visual Quality Important
Utilize Expertise of DB Teams
Allows Construction to Begin Quickly

Challenges of I-35W Site


Utility Coordination
R/W Acquisition (13 Parcels)
Environmental Permitting (10)
Contaminated
Materials
C t i t dM
t i l
Demolition Contract
24/7 Work Necessary
Hydraulic Scour
Context Sensitive Design Site
Winter was Coming

National Response
We are from Washington and are Here to Help.They Did!
August 2nd Secretary Peters and
FHWA Administrator Capka on Site
August 4th President Bush Visits
and Pledges to Expedite Assistance
Congress authorizes $250 million
in Emergency Relief money to
replace bridge and restore
highway facilities to pre-disaster
conditions
Total Federal Emergency Relief
$373.5M
FHWA Division Bridge Engineer
Assigned Full-Time to Project
Team

1/16/2012

Procurement Process

RFP Development & Challenges


Slow Down, You are Moving Too Fast

Established Mn/DOT Design Build Team on August


2nd
Issued Statement of Qualification on Saturday,
August 4th
Short listed 5 teams August 8th
Held daily confidential meeting with each
proposing team

A Landmark Bridge Should be Considered


You Dont Know Whyy the Previous Bridge
g
Collapsed
No Ugly Freeway-Style Bridge
Design Bridge for a Future Light Rail Line
Minnesota Politics

M, W, F : Phone Conferences, T, TH: Face to Face


Purpose: develop relationships with contractor, increase
their comfort level, explain project expectations

Held public meetings, DBE and Utility


coordination meetings
Addressed Media and Public Questions
Developed Request for Proposals in Three Weeks
Responded to Clarifications and Issued Addenda

RFP Development & Challenges


Defined Allowable Bridge

Types

Concrete Box or Concrete Beams


Steel Box or I-girder
Redundant Designs Required
No Hinges

Project Visual Quality

RFP Development & Challenges

Advisory Group Goals and Oversight

Alternate Technical Concepts


Allowed

Established an Aggressive Procurement Timeline


August 1, 2007 Collapse Occurs
August 4 Issue Request for Qualifications
August 8 Short Listed Teams
August 23 Request For Proposals Released
September
S t b 14 - Technical
T h i l Proposals
P
l R
Received
i d
September 18

Evaluation and Scoring Completed


Financial Proposals Received

No piers in river due to scour and variable


rock elevations

Other Agencies Demanded the Design


Accommodate Future LRT addition

Drilled Shafts Would be Needed


Upper layer of soft sandstone

Added a week before RFP could be released


Developed Criteria for LRFD Methodology

One Team Withdraws

New St. Anthony Falls Bridge


PROJECT GOALS
Safety
Quality
Aesthetics
h
Public Relations

September 19 Project Letting

Enhancements

September 20 City of Minneapolis Grants


Municipal Consent

Maintain Time and Budget

Project Award October 8, 2007


Construction Begins November 15, 2007

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RFP Evaluation/Scoring Criteria


Quality (50 percent)
Experience and authority of key individuals
Extent of quality control/quality assurance
Safety
Measures to evaluate performance in construction
Aesthetics/Visual
A h i /Vi
lQ
Quality
li (20 percent))
Visual enhancements to the structure
Involvement of the public after letting
Enhancements (15 percent)
Roadway and Long-Term I-35W Plans
Structural Enhancements
Public Outreach/Involvement (15 percent)
Impacts to the public
Approach to communication

Best Value Selection Process


Score Technical Proposal with Proposal Evaluations Received
from Twenty-Seven Individuals From Six Agencies
Associated General Contractors

FHWA
National Park Service
Minnesota Department of Administration
Minnesota Department of Transportation
City of Minneapolis

Methodology:

Criteria was provided to teams when RFP was issued


Time and Cost components unknown during evaluation of proposal
Best Value Selection

Best Value Selection Process

Incentive Included to Manage Schedule

Based on Cost plus Time Divided by Technical Score


$200,000 per day for each day bid

Formula

(Cost + (Time in days * $200,000))/Technical Score

Locked Incentive Date (LID) Payment

Payment of LID Payment is intended to ensure Mn/DOT and the public


benefits of early completion

Payments based on Substantial Completion

$7 million
illi ffor meeting
i LID completion
l i d
date 12/24/08

$2 million for every 10 days earlier, capped at $20 million

December 24, 2008 Deadline

Early Completion Bonus for up to 100 Days early

Provisions to Contain Costs

LID Payment of $7 Million Must be accepted by Contractor 30 days


after notification of reaching Substantial Completion

Project Selection Results

Acceptance of LID means acceptance of:

Waiver of any delays, Owner or Contractor caused

Full and final settlement for any claims or time extension.

Waiver of all claims covers all unknown costs and use of


dispute resolution process

Design Build on Accelerated Schedule


August 1 - Collapse occurs
August 4 - Issue Request for Qualifications

Proposer

Technical
Proposal
Score

Price Proposal
'A'

Time
(Days)

Time
(Days x $200K)
'B'

Adjusted Score
(A+B) / Technical Score

Ames / Lunda

55.98
55 98

$ 178,489,561
178 489 561

392

$ 78,400,000
78 400 000

4 588 952 50
4,588,952.50

C.S. McCrossan

65.91

$ 176,938,000

367

$ 73,400,000

3,798,179.34

Walsh / American
Bridge

67.88

$ 219,000,000

437

$ 87,400,000

4,513,847.97

Flatiron / Manson

91.47

$ 233,763,000

437

$ 87,400,000

3,511,129.33

August 8 - Short listed teams

AUGUST 2007

Low Score = Best Value!

October 8 Project award to


Flatiron / Manson and FIGG

August 23 Request
For Proposals
released
l
d

SEPTEMBER

September 14
Technical proposals
received and
evaluation begins

OCTOBER 2007

September 19 - Project letting

DECEMBER 2008
December 24
Anticipated
open to traffic
(15 Month
Construction
Schedule)

September 18 - Financial proposals received

1/16/2012

Bridge Description
Variable depth superstructure 25 to 11
Concrete piers supported by footings and drilled shafts socketed into
rock
Cast-in-Place approach spans and Precast Segmental River span (120
segments)

Bridge Description
Two parallel bridges, each with two box girders
Striped for 5 lanes each direction (10 total) with 13 and 14
shoulders
Future configuration of 4 lanes each direction plus light rail
line or bus transit lane (lane drop for ramps)

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904

35W Public Involvement


Stakeholder Involvement
Design Charette
Communication

October 24, 2007


7:30 AM 5:00 PM

FIGG Bridge Design CharetteTM

88 People
Residents, Businesses,
Cultural/Arts,
University of Minnesota,
Government Officials
Voted on Bridge Features

Photos Courtesy of Figg Bridge

A Sculptural Bridge: Arches. Water . Reflections

CURVED PIER OPTION A

CURVED PIER OPTION B

Photos Courtesy of Figg Bridge

Option 1

Native stone in gabion wall

Photos Courtesy of Figg Bridge

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Option 2

Native Stone
Photos Courtesy of Figg Bridge

Native Kasota Stone

Vetterstone
Photos Courtesy of Figg Bridge

Rectangular MSE wall panels

Inscriptions of famous quotes about the


Mississippi River and other river icons
embossed in rectangular panels
Photos Courtesy of Figg Bridge

Option 1
Fully Open Rail

Photos Courtesy of Figg Bridge

View from north shore near St. Anthony Falls

Mn/DOTs Project Approach


Co-housed with Contractors Design
Build Team
Important to Establish a
Partnership Relation

Utilize past DB expertise

Well Developed Quality


Management Template

Staffed project with experienced,


experienced
decisive staff empowered to act
Supplement with consultants as
needed

Independent Review by Oversight


Team

Mn/DOT and Parsons Transportation


Group

OTS reviews early and often

Bridge Color

White - Modern or
Sandstone - Color from local rock

Reviewed all submittals within 7


days
Averaged 2 days

Photos Courtesy of Figg Bridge

1/16/2012

Mn/DOTs Project Approach


(Continued)

Environmental Management

Project Memorandum (Categorical Exclusion)


Strong Relationships with permitting agencies
Project was a Priority of Permitting Agencies
Use Good Will & Sense of Mission of Permitting
Agencies

Make & Keep Reasonable Commitments

Partnership

Mn/DOT
Flatiron Manson
Flatiron-Manson
Mn/OSHA on Site and part of team

Training of all workers assigned to project

Required escorts for visitors

Large Safety Team


Audits performed weekly
No Serious Injuries on Project

FHWAs Participation
Full-time Bridge Engineer On Site
Gathered expertise from national experts on any
issue
g in experts
p
to share ideas from p
past DB
Brought
projects
- Silica Fume
- Health Monitoring
- Quality Programs
- Drilled Shafts

Mn/DOT used previously developed Quality Management


Template

Do Not Exploit

Safety Management

Quality Management

Establishes minimum expectations


Expect teams to expand and enhance
Eliminated lag between development and start of
construction

Quality Procedures

Identifies
Identifies
Identifies
Identifies

task
pertinent specifications
responsibilities for all involved
documentation needed

Construction Inspections
Field Revisions

Involvement of Engineer of Record (Figg Bridge Engineers)

Other Actions Led to Project Success


Labor Agreement with the Building trades
Efficient Labor force over 600 at peak
Unaffected by cold weather
Construction continued 24/7

Communication by Flatiron and Figg Engineers


Saturday Sidewalk Superintendent Talks
Educational Outreach to City Schools

Bridge Removal
Removal was a Separate Force Account
Contract
Coordination with NTSB required
DB Contractor Aware of Removal Time
Constraints

Aug. 20
Navy Divers recover 13th victim, site turned over to Mn/DOT
Sept. 6
Navigation channel opened to commercial traffic
Sept. 27
Final steel removed from river

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44

Site was Cleared by October 11, 2007

Goal:
Goal:
Work
Everywhere
Possible
W kE
Work
Everywhere
h
P
Possible
ibl
at
the
Same
Time
at the Same Time

Main Pier Foundations

7' and 8' diameter drilled shafts


100' long with socket into bedrock

Drilled Shaft Issues


First Shaft Struck on Artesian
Drilled Second Test Shaft above
artesian
Used 4 O-cells for skin friction and
only one to estimate end bearing
Used self-consolidating concrete
Test Shaft exceeded design by 20%
1st Production shaft on December 4
at Contract Day 50
Final Shaft for Piers Installed
January 12

January 27, 2008

Aerial view of south


side

1/16/2012

Shaft Drilling
Abutment 5

January 14, 2008

Pouring footing
at Pier 3

January 14-15, 2008

February 20, 2008

Inside footing
enclosure
at Pier 3

January 14-15, 2008


First Pier Column January 23rd

Temp -9 to 3 Fahrenheit

Mass Concrete

Piers 2, 3, and 4

March 5, 2008

1/16/2012

Cold Weather Protection

1st

Precast Segment Pour Day 107 January 30 Temp -14 to -2 Fahrenheit

Superstructure
(main span precast segments)
(casting yard longline casting)

All headings cast simultaneously


Heated enclosures
Last Segment Cast June 6th

Corrosion Resistant
Design Details
Integral Wearing Surface monolithic application of additional
concrete above what is required
structurally
Additional concrete precompressed
both directions with deck PT. 250
psi compression longitudinal, 0 psi
tension transverse
4.5" clear cover to top deck
reinforcing and prestressing
Top 0.5" reserved for deck milling
and profiling
Falsework Began Jan 28
Final Concrete Placed May 31

Approach Spans on Falsework

South Side Approach Span Precast Yard in Background

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Sidewalk Talks every Saturday


With Peter Sanderson

WEBSITE

More than 100 people


showed up routinely

www.mndot.gov

Signs mounted on 10th Avenue Bridge for selfguided tours

WEBCAM

www.mndot.gov

Sponsored
S
d by:
b
Flatiron Manson JV (contractor)
FIGG (Bridge Designer)
Cemstone (Concrete Supplier)
North Central States Regional Council of Carpenters
(Carpenters Union)
American Engineering Testing
Bulach Custom Rock

Casting the Future


1800 Area Students

Each day 60 students attended 4


hour course and site tour
Photos Courtesy of Figg Bridge

11

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Casting the Future

1,800 students created a


glass mosaic concrete tile
Photos Courtesy of Figg Bridge

Casting the Future

Students proudly display their works of


art made of concrete and recycled glass.

Casting the Future

Students filled molds with concrete


and recycled glass aggregate.

2nd Street Overpass

Photos Courtesy of Figg Bridge

Precast Segments Moved to River Staging Area

Photos Courtesy of Figg Bridge

Photos Courtesy of Figg Bridge

Segments Placed May 25 to July 10

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1/16/2012

Segment lengths - 13.5' to 16.5'


Weights - 380 kips to 216 kips
15 segments per cantilever

Superstructure Span 2 Precast

Span 2 North Side

Segment Installation - July 3, 2008

Span 2
(precast main span)

Span 2

Precasting is complete
120 precast segments were placed in 47
days
Placed up to 6 per day

Cantilever Erection

Preparing for closure pour

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Closure Pours on July 16 and 24

North Approach Span 4 Cast in Place

Open to Traffic September 18, 2008

Smart Bridge System


Integrated Bridge Sensor Monitoring System covering four areas:

Support of Construction Process

Support construction processes

Record of structural behavior (structure monitoring)

Control of the automated anti-icing system

Intelligent Transportation System (ITS)

Structural Behavior and Monitoring

Sensors are used to assist in


making construction decisions
Concrete maturity sensors are
embedded in the concrete
when it is poured
p
when the
Sensors report
concrete has achieved the
required strength before the
next operation can begin
Temperature gauges are also
used to monitor the core heat
of large concrete elements
This helps to prevent cracking
due to differential
temperatures
(outer surface vs. core)

Concerted effort by Mn/DOT, FHWA, and University of Minnesota


Sensors embedded or mounted to the bridge provide information
to engineers about the structural behavior of the bridge

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