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ACCELERATED BRIDGE
CONSTRUCTION
THE CLAYTON STREET BRIDGE
REPLACEMENT
Malek Al-Khatib, P.E.,Vice President , Project Manager | Louis Berger
ASCE & SEAM January 15, 2015
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Background
History of the Clayton Street Bridge
• First Massachusetts Bay Transportation Authority (MBTA) transit bridge built using Accelerated Bridge Construction (ABC) methods
• Built in 1911 and modified in 1926
• Deteriorated three-span steel structure with steel bents
• Replaced in 2013 with a single-span steel structure, thus opening up the street and the sidewalks below
• Design completed September 2012
• New structure erected November 2013
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• Located in the Dorchester
neighborhood of Boston,
Massachusetts
• Mix of residential industrial
neighborhoods
• Part of the MBTA Ashmont
Red Line
• Frequent truck route
Location MapDorchester, Massachusetts
Clayton St. Bridge
Quick Facts
Field
Corner
Station
Braintree
Branch
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• Steel elements showed
signs of deterioration
• Original 13’-10”
clearance was not
sufficient for current
truck traffic
• Steel bents blocking the
roadway caused hazards
for motorists and
obstructed sidewalks for
pedestrians
Old StructureCondition
steel bents
Through Girder Deck
Structure
obstructed sidewalks
13’-10” clearance
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Challenges
Structure
• Low Clearance
• Truck collision damage
proved that low clearance
was an ongoing issue that
had to be fixed
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Community and MBTA Red Line Operation
• Residential abutters cross the street from the bridge
• MBTA Red Line trains could not be shut down on
weekdays
• Limited number of possible Red Line weekend
shutdowns
• Coordination with other MBTA construction projects
Notice for public information meeting
Challenges
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Challenges
Structure
500 ft. radius track curve
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Challenges
Structure
50 degree bridge skew angle
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Challenges
Structure
• Converting 3 span
structure to a single span
• Existing abutments
couldn’t sustain the load
increase
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Challenges
Structure
• Framing Configuration
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Challenges
MBTA System
• Traction power lines run
through the bridge
• Third rail and heater cables
run through the bridge and
were in poor condition
• Signal and communication
system was outdated and
not well plotted
• Rail sprinkler system runs
through the bridge and was
in poor condition
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Challenges
MBTA System
• Conduct testing and tagging of signal and communication cable.
• Replace antiquated signal system and reducing the number of conductor cables from 500 to around 80
• Replace several manholes and junction boxes.
• Cannot combine power and signal cable conduits
• Maintain MBTA System operational.
Rendering for temporary bridge
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Construction Site Constraints
• Limited ROW
• Heavy traffic on Clayton Street during rush hours
• City ordinance regarding noise and work hours
• Limited number of possible streets shutdowns
• Coordination with the utility companies
Challenges
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• Clayton Street Bridge
clearance is the highest in
the area.
• Narrow residential one way
streets
• Main streets are congested
weekdays.
ChallengesTraffic Management Plan
(Clayton Closed & Dickens Closed
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Weekend Hourly Schedule
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Temporary BridgeUsed to re-route MBTA
systems off bridge during
construction
• Temporary bridge built in
Spring 2013 to re-route
cables off existing
structure
• Minimized interference
with train service during
construction
• (Left) temporary bridge
completed with utility
ducts re-routing utilities
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System Work
System work without
interrupting service
• Systems were
replaced, re-routed
and/or upgraded
• New manholes were
installed
• New cables and
junction boxes
improved service
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Strengthening Existing Abutments
40ft deep minipiles
85ft long tieback soil
anchors
Installation of tiebacks and mini piles
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Strengthening Existing Abutments
40ft deep minipiles
85ft long tieback soil
anchors
Installation of tiebacks and mini piles
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Strengthening Existing Abutments
Proposed Bridge
Existing BridgeInstallation of tiebacks and mini piles
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Strengthening Existing
Abutments
Installation of Tiebacks
• 85-foot-long tiebacks
installed at design
angle while avoiding
existing steel bents
• Installed during two
weekend street
shutdowns while trains
were operational over
the bridge
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Installation of Mini Piles
• 40-foot-long mini piles
cored through top of
existing abutment
• Installed during three
weekend Red Line
shutdowns while
keeping the streets
open below
Strengthening
Existing Abutments
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New Bridge
Constructed on site
• New superstructure was
pre-assembled in the shop
• New superstructure
arrived in five panels and
was fully assembled onsite
• New superstructure was
assembled in yard
adjacent to existing
structure
• New structure was erected
on scaffolding
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SPMT Units – ABC Construction
Self Propelled Modular Transit Units
• Two SPMT Units were used to transport bridge
• SPMT Units moved simultaneously and were controlled
by one operator
• Tires of SPMT Unit had 360º rotation capabilities for
ease of mobility and precision when placing new
structure on bearings
• Steel plates were placed along the path of the SPMT to
ensure proper load bearing capacity
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Veteran’s Day
Weekend
• Friday Nov. 8, 2013:
Demolition; preparation
began after last train
• Saturday Nov. 9, 2013 at
noon: Clayton Street was
cleared of debris
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Veteran’s Day Weekend
Preparing the Substructure
• Saturday 10 p.m.: Bearings and backwalls were
installed
• Existing backwalls were sawn off and cleaned along
with the existing bridge seats
• New backwalls were installed
• Lesson learned: Place down new bridge prior to
installing backwalls
• New bearings were installed and locations were
confirmed by surveyor
• Lesson learned: Ensure bearings and bearing
plates are level prior to placing down bridge
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Veteran’s Day Weekend
Moving the Superstructure
• Saturday 5:30 p.m.: Bridge started to move
• SPMT Units lifted the bridge off the scaffolding at 5:30 p.m. on November 9th
• Media and residents gathered to watch the 500,000lb structure slowly roll into place
• Saturday 10:30 p.m.: Substructure modifications were completed, and the bridge began moving to its final position, and lowered on the new bearings.
• Bridge was successfully placed on the bearings and the track and ballast were replaced
• Sunday Nov. 10, 2013: bridge was completed.
• Monday 12:05: Track work completed for Monday morning service
• Service resumed for Monday morning commuters on schedule
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ABC Planning/Design/Construction
Basic Elements
• Detailed planning, design, and constructability reviews.
• Proposed means and methods included in the bid documents.
• Attention to all details that affect schedule.
• Risk assessment and minimize unforeseen conditions.
• Detailed construction scheduling during the design phase, including hourly schedules and assignment of responsibilities, were necessary for success of weekend installation
• Detailed scheduling and dry-runs with the contractor to ensure smooth delivery
• Collaboration and open communication between owner, contractor and designer ensured a smooth weekend
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ABC Planning/Design/Construction
Benefits of Accelerated Bridge Construction
• By conventional techniques, the replacement would
have taken an additional 10 months and $2 million to
complete
• Conventional methods would have resulted in several
weeks of Red Line and street closure
• Community engagement drove the project schedule
and ultimate success
• Due to proper preparation, work that was initially
scheduled for a 3-day weekend was successfully
completed in a 2-day weekend with no injuries or
accidents
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Replacement Sequence 3D Animation
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• The bridge was painted a light grey color to match surroundings
• Formliner was added to the face of the abutment walls
• New sidewalks were constructed and the roadway was paved and cleared
• New street lighting under the bridge
Finishing Touches
formliner
sidewalks
14’-0” clearance
lightings
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Before & After
• Clearance was increased from 13’-10” to 14’-0”
• Sidewalks were widened
• Steel bents were removed
• Bird netting was installed to protect bridge seats
• Formliner was added for esthetics
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Planning, attention to details, and partnering = Success