Concrete Products

SEP 2015

Concrete Products covers the issues that attract producers of ready mixed and manufactured concrete focusing on equipment and material technology, market development and management topics.

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32 • September 2015 www.concreteproducts.com In the second and concluding part of "In With The New" (Concrete Products, August cover feature), visits to two Chesapeake Bay pre- cast/prestressed operations underscore the astute engineering and colossal concrete schedule behind the Empire State's largest bridge contract to date. The 3.1-mile, cable-stayed, double span New NY Bridge, linking Rochester and Westchester Counties across the Hud- son River, will replace the Tappan Zee Bridge in 2017-2018 phases. Work proceeds under Tappan Zee Constructors LLC (TZC), a design- build joint venture of American Bridge Co., Fluor Enterprises, Granite Construction Northeast, and Traylor Bros. TZC is running the project from a Tarrytown, N.Y., field office about 15 miles upriver from New York City. TWO BRIDGES REPLACE ONE The New NY Bridge is actually two parallel bridges connected by emergency crossovers and designed to accommodate a future, cen- trally-located light rail transit deck with no additional reinforce- ment. The twin spans will provide eight full-time traffic lanes at least 12 ft. wide with full shoulders, two express/emergency lanes, and a 12-ft.-wide bicycle and pedestrian path. While the project calls for abundant use of steel girders on approach and main spans, the most impressive horizontal load-bear- ing members are precast concrete. Bayshore Concrete Products Corp. and Coastal Precast Systems LLC are producing massive tubs for 60 pile caps and 59 pier caps, respectively, in their Virginia operations. The caps are designed as stay-in-place formwork and will greatly cur- tail the need for forming crews to work at the water line, far from shore, or at high elevations above the pier foundations. Although operating with a "lighter" load than Bayshore Concrete and Coastal Precast, Massachusetts-based Unistress Corp. holds TZC's largest pre- cast contract: A $70 million order for 6,000 prestressed deck panels measuring 40- x 12-ft. FEATURE BY KEN STADDEN Heavy Lifting Bayshore Concrete, Coastal Precast ship near-record scale members that prove instrumental in New NY Bridge scheduling, economy and site safety plan Bayshore Concrete Products built the pile cap tub forms at its Cape Charles steel fabrication shop. The producer enlisted a rebar subcon- tractor for the pile cap tub cages, fabricated mainly with galvanized steel, but some stainless steel for conditions with the potential for exposure to Hudson River fows. The 340- to 490-ton tubs were cast in half sections and designed as stay-in-place forms for the fnished pile caps. The products have been tandem-towed, four at a time, two per barge, to the Hudson River project site.

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