Urgent bridge replacement: from site prep to first train in 120 days.
July 11th, 2010
The AIL Group of Companies was very excited to be a partner in an urgent mine site infrastructure project to replace a 197-foot span steel girder bridge that had been damaged during severe “once-in-500-year” flooding. The bridge replacement needed to take place within a 12-month window and, thanks to the concerted efforts of all project partners, it was up and running within eight months (six months from awarding of contract). Here’s how quickly it rolled out.
View Time-Lapse Video, 3:20 min >
April 2009 – Scoping, Proposals
We were initially contacted by Consulting Engineers, BG&E, in early April, investigating the possibility of using Super•Cor®Arches for this project. We had worked with BG&E on several projects over the last four years. BG&E were, in-turn working for Calibre Engenium, Project Managers of the bridge replacement for a large Australian mining company. Whatever design solution was to be chosen, it had to be completed by December 1. After various options were looked at, twin Super•Cor® SC74 Arch Structures were chosen for the proposal due to very favorable cost, completion time and performance / maintenance factors. The 87-foot-long Arches had a span of 65.6 feet, a rise of 32.8 feet and were spaced 13 feet apart.
Late June 2009 – Project Awarded
After commercial negotiations took place, an order was placed in late June. Delivery of required Super•Cor® product was by late August or early September – about eight weeks to get to site including trial erection. According to Tony Douglass, Project Manager, at Calibre Engenium, we were awarded the project primarily due to our engineering and design ability, the professionalism of our team, and our local manufacturing expertise. These “ticks in the boxes” gave Calibre and their customer added confidence that the project would be done on time and on budget. At this point, the Stabilized Earth Wall hadn’t been ordered, as the final design was not complete.
July, August, 2009 – Manufacture Super•Cor®, Prepare Site
Detailed design and manufacturing of Super•Cor® components at our facility and site preparation by the contractor occurred during this window. To keep the rail line on the damaged span bridge open, Calibre had to put an earth embankment across the river and with five 7.8-foot-diameter pipes to handle flow during the dry season. The Principal Contractor NRW, due to rock, encountered early civil problems on site. This made footing locations more difficult and the project fell slightly behind schedule. With a very tight timeline, even one week behind was critical. Wall design and commercials went well into July and the order was placed on July 24 for a mid-September delivery. As an extra to the Wire Wall, Calibre required a steel face to be put at the base of the wall for added protection against major impacts due to debris etc. We came up with a structural plate fascia for both sides.
September, 2009 – Construct Super•Cor® Arches
Super•Cor® plates and base channels arrived to site on time. Fortunately for all concerned, Calibre followed Atlantic Civil Products’ suggestion and used a dedicated plate erection company, APE Erections. Andy Reilly, founder and co-owner of APE Erections, took the bull by the horns and built both structures in less than three weeks, including grouting the ribs. This brought the project back on schedule.
October, November, 2009 – Walls, Engineered Backfill, Railway Construction
Wall panels arrived on site, mid September on schedule. An AIL Group Technical Sales Representative was on site for the duration of the wall erection to ensure all went well. NRW, even worked around the clock toward the end to ensure the wall was in place and the rail formation complete and on schedule to the day. Track laying crews connected the line on schedule and the first loaded train went across on time.
December 1, 2009 – Project Completed
If a conventional bridge had been chosen instead of the Super•Cor® structures, the estimated completion time was April, 2010.
P.O. Box 1290
Greeley, Colorado
80632-1290
Physical address:
19060 WCR 66
Greeley, CO 80631
1-800-234-0734
1-970-356-9600
1-970-356-9621 fax
bigrbridge.com
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