Construction of the Route 460 Connector Phase 1 Breaks, Virginia Timothy Barry, PE Robert Bennett, EI June 10-13, 2012 Pittsburgh, PA

Location of Buchanan Co. Virginia 460 Connector Rendering

 Project Team ◦ Owner:  Virginia Department of Transportation ◦ Design Build Firm:  Bizzack Construction LLC – Prime Contractor  CJ Mahan Const. Co. – Bridge Sub-Contractor  Stantec - EOR  Jansen Spaans Engineering Inc – EOR  VSL, Inc – PT and Form Traveler Supplier ◦ Inspection & Contract Management:  Amec Engineering – QA/QC  AMT Engineering - QA/QC  RS&H CS – CEI Oversight

 Project Details ◦ Design-Build Project Delivery Method ◦ Twin Structures 1700 feet long each ◦ Spread Footing and Micro-Pile Foundations ◦ Cast-in-place balanced cantilever segmental superstructure ◦ Total Project Cost:  $100,000,000.00

 Project Details ◦ Maximum height over Grassy Creek: 250 feet  Tallest Bridge in Virginia ◦ Longest Span: 489 feet ◦ Width of Each Bridge: 43 feet ◦ Each Bridge carries 2 lanes of traffic ◦ West portion of the project ends at the Kentucky State Line. ◦ Connector to the Coalfields Expressway Project

 Project Details ◦ Maximum height over Grassy Creek: 250 feet  Tallest Bridge in Virginia ◦ Longest Span: 489 feet ◦ Width of Each Bridge: 43 feet ◦ Each Bridge carries 2 lanes of traffic

 Massive Transportation Improvement Plan for the Appalachian Region  Designated a Congressional High Priority Corridor by the United States Congress-1995 ◦ Authorized 80% federal funding

 Intended to modernize the transportation system in this area  Help boost commerce and tourism for the region  Public Private Partnership (PPP) ◦ Coal Companies ◦ VDOT

 PPP Highlights ◦ Partnership between VDOT and the Local Coal Companies ◦ Land Clearing/Mining of the Right-Of-Way ◦ Road Bed Preparation  Removal of Deficit Material ◦ Significant Savings to VDOT

 51 miles of 4-lane highway (Virginia)  From Pound, VA to West Virginia Border  West Virginia section of Coalfields  Eventually will connect I-77 in WV to RT 23 in Virginia Pound, VA Paynesville, WV

 Structure Details ◦ Length– 1700’ ◦ Height- 250’ ◦ Longest Span- 489’  Material Quantities ◦ Concrete– 16,000 C.Y. ◦ Reinforcing Steel- 2.6 M lbs. ◦ Post-Tensioning Strand- 150 Miles

Cast-in-Place Balanced Cantilever Segmental Bridge

 Remote Location ◦ Breaks, Virginia  Dickerson, Buchanan, Pike Counties ◦ Population under 100,000 ◦ Approx. 63 persons/ Sq Mile  Topography ◦ 400 feet of elevation differential ◦ Unstable terrain

 Labor Force ◦ Local labor ◦ Housing ◦ Commuting Difficulties ◦ Added Costs  Infrastructure ◦ Basic Utilities  Water, Electric ◦ Communications

 Communications ◦ Internet Service ◦ No Telephone Service ◦ Limited or No Cell Service  Material Deliveries ◦ Concrete Plant on Site ◦ Delivery Service ◦ Careful Planning ◦ No Overnight Deliveries

 High Strength Concrete ◦ 8000 psi for superstructure ◦ Mass Concrete ◦ Low Permeability Concrete  Maximum of 2,000 coulombs  Corrosion Resistant Rebar ◦ Low Carbon/Chromium ◦ Long-Term Durability ◦ Epoxy Coated Bar Supports ◦ 75 ksi tensile strength

 Segmental Bridge Specifications ◦ Issues Nationwide with Segmental Bridge Durability ◦ Post-Tensioning and Grouting ◦ VDOT re-writing their segmental specifications ◦ Instituted for this project  Added Cost

 Project Webcam

 On-Site Weather Station