Tuesday, January 17, 2017

I-87+287 Tappan Zee Bridge over Hudson River

(Bridge Hunter, Satellite plus 152 photos)

The 1952-1955 cantilever truss bridge is being replaced by a $4-5 (depending on source) billion cable stay bridge.

Old bridge:
By The original uploader was Nrbelex at English Wikipedia - Transferred from en.wikipedia to Commons by Matthiasb., CC BY-SA 2.5, Link
New York State Thruway Authority
 from NYCroads
The old bridge was built at the second-widest point on the Hudson , 3 miles, so that it would be just north of the Port Authority of New York and New Jersey so that the toll revenue would go to the newly created New York State Thruway Authority instead of the Port Authority. "A unique aspect of the design of the bridge is that the main span is supported by eight hollow concrete caissons. Their buoyancy supports some of the loads and helps reduce costs." It's 138' height above water is high enough to commit suicide. It has been referred to as the "Golden Gate Bridge of the East" because of the number of suicides. Several efforts have been implemented to reduce suicide attempts. [Wikipedia]

The buoyant caissons rest on steel piles driven to bedrock. The caissons were constructed on land and barged to the site. Some of the piles are 270' long because the bedrock was 300' below river bottom. The 30" steel piles were cleaned out and filled with concrete.  [NYCroads]

New York State Thruway Authority from NYCroads
The main cantilever span is 1,212' and the total length is 16,013'. Avoiding the Port Authority was not the only reason for choosing the Tappan Zee location. The location was a crossroads of existing and planned expressways connecting New Jersey, New York State, New York City, and Connecticut. The 1,212' main span consists of 340' cantilevered spans and a suspended span of 531'. Each side span is 602' At the time of construction, it was the widest of its type. The 19 approach spans were 235-250' long, 93' wide, and 28' deep and weighed up to 900 tons. They were built on shore and then jacked up from a barge using four 500-ton jacks. [NYCroads]

It was designed to carry 100,000 vehicles on a peak day. During 1956 it carried 18,000 vehicles per day. Now it carries 135,000vpd over seven lanes, the middle one of which changes directions twice a day. It takes 45 minutes to change the lane. The projection for 2025 is 175,000vpd. [NYCroads]

None of the heavy rail (commuter), light rail, HOV+bus lane ideas considered during the design phase were incorporated in the final design. But it does have a dedicated bicycle and pedestrian span on the north side with scenic overlooks. [NYCroads, hdrinc]

I can't find where I read it, but since the demolition cost of the old bridge would be $140 million, leaving it as a walkway is being studied. A seven lane highway would certainly be wide enough for bicycles and pedestrians. In fact, they could add bus and HOV lanes on the north side.

New Bridge:
New York State Thruway Authority from hdrinc
Tappan Zee Constructors

By Jim.henderson - Own work, CC BY 4.0, Link
It is being built by Tappan Zee Constructors.

In June, 2015, the first prefabricated section of three 12' tall and 400' long girders was lifted into place by the Left Coast Lifter. (video) This is the first of 31 miles of girders to build the first 4-lane, 3.1-mile bridge. A second bridge is being built in parallel so that each direction of travel will have its own 4-lane bridge. The girders are placed on pedestals on top of the pier cap. The pedestals "contain structures called 'seismic isolation bearings,' made of steel and a rubberlike material designed to offer some flexible movement (in case of earthquakes) and also to withstand the day-to-day pounding from trucks. The three-girder assemblages will soon be joined by twin-girder assemblages that will carry prefabricated electrical, plumbing and communications lines and complete the width of the span."

The 328'x100' Left Coast Lifter can lift 1,900 tons, and it came to this site through the Panama Canal. The Tappan Zee prefabricated sections weigh between 900 and 1,100 tons. The previous job for this "world's largest floating crane" was to help build the replacement of the earthquake-damaged eastern span of the San Francisco-Oakland Bay Bridge. The crane has three 806hp diesel powered generators to drive the cable winches. The 6,750 ton crane was built in 2009 near Shanghai.

In July, 2016, a crane boom collapsed across all of the lanes of the old bridge. Fortunately, no one was hurt. It was one of the 28 cranes working on the bridge. It was doing the routine task of installing piling using a vibratory hammer. Investigations did not have much to report three days later.  (Most pictures show the crumpled boom laying over the old bridge. This link shows the crumpled boom at the crawler base.) The crane was working on one of the 1000 piles needed by the bridge. A pile is a steel tube up to 6' in diameter and 300' long. But Jeff J. Loughlin, the business manager of International Union of Operating Engineers Local 137, had a theory. The Manitowoc MLC 300 crawler crane with a 256' boom was operating from the deck of the new bridge. Jeff's theory is "the pile had struck a very soft spot of river mud and had begun to sink rapidly, jolting the 60-ton hammer into a rapid drop and putting a particular strain on the boom, which buckled." He explained that with an old crane, the operator could take his foot off the break and allow the hammer to free fall and avoid stressing the boom. But modern cranes have a hydraulic braking system that limits the descent rate to 800 feet per minute. The operator had 30 years of experience manipulating cranes. I assume a drug test can be done within three days so that issue has been ruled out.

By Ramlogue - Own work, CC BY-SA 4.0, Link
In August, 2016 the "halfway done" milestone was reached. This posting includes a slide show of eight pictures. The sixth picture shows how the roadway concrete is pumped from barges. Concrete plants were built on barges so that they did not have to run a lot of trucks through the adjoining communities. They also avoided long truck runs to build a 3-mile long bridge. The eighth photo shows the cranes and the blue form blocks that are raised after each of the 26 segments of a tower is built and cured. The cables vary in size from 11" to 24" in diameter with some of the biggest being 800 feet long.

In December, 2016 it hit the milestone of all eight 419' high towers being completed.

NYC CBS News has a list of its articles concerning the Tappan Zee.
Satellite image captured Jan, 2017 is probably at least two years old.
I learned about this construction from some Facebook postings.

Tito Arevalo posted
Manitowoc 4600 ringer Crane
Peter Cerniglia posted six photos with the comment: "Tappan Zee bridge in New York." The comments on the photos are my own.

2

3: This is probably one of the 60-ton hammers mentioned above that the crane crash described above was using.

5

1

4: During off hours they raise the tugboat assigned to the barge out of the water. I assume this is done to make it more difficult to steal or vandalize it. I've seen cranes around here hoist an air compressor in the air during off hours for the same reason.

6
Screenshot from the video on the referenced page.

Update: OSHA finds faulty equipment caused the Tappan Zee Manitowoc MLC300 crane collapse. It seems like a $13,000 fine for a $4 billion contract is barely a slap on the pinkie.
Chris Spence posted
93 ton edge girder... 4100 tappen zee bridge ny yesterday
Chris Spence posted
30 ton floor beam. 4100 tappen zee bridge ny stretched out getting that Sunday $$ local 417
Stephen Collins Never seen a cab relocated like that
Chris Spence Was trying to get a good pic but I'm the signal man didn't have time to.
Ben Stalvey several 4100 have moved relocated cabs.
Shane Strickland I ran this crane on the Biloxi Bay Bridge around 10 years ago! Traylor Brothers right?Chris Spence Yea traylor bros.

Aaron Brown posted two photos with just the comment: "New York." Fortunately, the comments confirmed these were of the Tappan Zee accident.

1

2
Chris Spence posted two photos with the comment:
got a Saturday in on new tappen zee bridge in ny, they added a 100' jib onto the 4600. She's got 400' of stick now
1
2
While looking for another bridge project in NY State, I found a highlights page with explanations of the various phases of construction and photos. One phase of note is that the 750 ton crossbeam between the towers was prebuilt and lifted as a unit by the "I Lift NY" barge crane.

NYDOT
The final girder assembly was placed in October, 2016.

NYDOT

The towers were completed Dec 2016 and the main span was connected to the approaches Feb 2017.

NYDOT
It is interesting how pictures float around the web and show up months later.

Kevin Downey posted
Peter Cerniglia posted two photos with the comment: "Here are a couple of pictures of the 4600 ringer at the Tappanzee Bridge in New York we have been running with 300 for the bone and we just added 100 foot of jib."
Ben Stalvey wow 400 ft sweet
Mike Irish That runs a # 27 boom for the jib. Same boom as what's in a 4100W ringer. That thing is an animal!!

1

2
Robert LaChappelle posted
4100 ringer erecting MR 608 Tappan Zee bridge NY
Ben Stalvey Wow must ave alot boom on that 4100 RingerChris Spence that's the Bob hill 4100 it's got 240 or 260
Bob Dahringer posted ten photos with the comment: "Passed by the new Tappan Zee Bridge this morning, still lots going on."
Aaron Hartlaub I think that is the MLC 300 that came down last year.


1

2

3

4

5

6

7

8

9

10

Bob Dahringer commented on a posting
West towers on the Tappan Zee.
[A couple of Potain tower cranes. There are currently (May, 2017) four working on the bridge]
Robert LaChapelle posted
Getting ready to jack down and dismantle MR608's Tappan Zee Bridge New York
Blane Tidwell posted five photos with the comment: "MLC 300 manitowic didn't make it but a few months on this job."

1

2

3

4

5
Ben Stalvey commented on the above posting

John T. Collinson commented on the above posting

John T. Collinson commented on the above posting
Rich Reiter posted
Dismantle of the first MR608 at the Tappan Zee Bridge.
Rich Reither commented on his posting

No comments:

Post a Comment