SCAN TEAM REPORT NCHRP Project 20-68A, Scan 07-02 Best Practices in Accelerated Construction Techniques Supported by the National Cooperative Highway Research Program The information contained in this report was prepared as part of NCHRP Project 20-68A U.S. Domestic Scan, National Cooperative Highway Research Program. SPECIAL NOTE: This report IS NOT an offi cial publication of the National Cooperative Highway Research Program, Transportation Research Board, National Research Council, or The National Academies. Acknowledgment The work described in this document was conducted as part of NCHRP Project 20-68A, the U.S. Domestic Scan program. This program was requested by the American Association of State Highway and Transportation Officials (AASHTO), with funding provided through the National Cooperative Highway Research Program (NCHRP). The NCHRP is supported by annual voluntary contributions from the state departments of transportation. Additional support for selected scans is provided by the U.S. Federal Highway Administration and other agencies. The purpose of each scan and of Project 20-68A as a whole is to accelerate beneficial innovation by facilitating information sharing and technology exchange among the states and other transportation agencies, and identifying actionable items of common interest. Experience has shown that personal contact with new ideas and their application is a particularly valuable means for such sharing and exchange. A scan entails peer-to-peer discussions between practitioners who have implemented new practices and others who are able to disseminate knowledge of these new practices and their possible benefits to a broad audience of other users. Each scan addresses a single technical topic selected by AASHTO and the NCHRP 20-68A Project Panel. Further information on the NCHRP 20-68A U.S. Domestic Scan program is available at: http://144.171.11.40/cmsfeed/TRBNetProjectDisplay.asp?ProjectID=1570. This report was prepared by the scan team for Scan 07-02, Best Practices in Accelerated Construction Techniques, whose members are listed below. Scan planning and logistics are managed by Arora and Associates, P.C.; Harry Capers is the Principal Investigator. NCHRP Project 20-68A is guided by a technical project panel and managed by Andrew C. Lemer, Ph.D., NCHRP Senior Program Officer. Brian A Blanchard, P.E., Florida DOT AASHTO Co-Chair Thomas R. Bohulav, P.E., Texas DOT AASHTO Co-Chair Christopher Schneider, FHWA Co-Chair Stuart Anderson, P.E., Texas A&M University Principal Author Cliff J. Schexnayder, P.E., Arizona State University Principal Author Steven D. DeWitt, P.E., North Carolina DOT George Raymond, P.E., Oklahoma DOT Richard Sheffield, P.E., Mississippi DOT Disclaimer The information in this document was taken directly from the submission of the authors. The opinions and conclusions expressed or implied are those of the scan team and are not necessarily those of the Transportation Research Board or its sponsoring agencies. This report has not been reviewed by and is not a report of the Transportation Research Board or the National Research Council. Scan 07-02 Best Practices In Accelerated Construction Techniques REQUESTED BY THE American Association of State Highway and Transportation Officials PREPARED BY Brian A. Blanchard, P.E., Florida DOT, Cliff J. Schexnayder, P.E., Arizona State AASHTO Co-Chair University, Principal Author Thomas R. Bohuslav, P.E., AASHTO Co-Chair Steven D. DeWitt, P.E., North Carolina DOT Christopher Schneider, FHWA, FHWA Co-Chair George Raymond, P.E., Oklahoma DOT Stuart Anderson, P.E., Texas A&M University, Richard Sheffield, P.E., Mississippi DOT Principal Author SCAN MANAGEMENT Arora and Associates, P.C. Lawrenceville, NJ November 2009 The information contained in this report was prepared as part of NCHRP Project 20-68A U.S. Domestic Scan, National Cooperative Highway Research Program. SPECIAL NOTE: This report IS NOT an official publication of the National Cooperative Highway Research Program, Transportation Research Board, National Research Council, or The National Academies. BEST PRACTICES IN ACCELERATED CONSTRUCTION TECHNIQUES 6 Table of Contents Executive Summary....................................................................................... ES-1 Background.......................................................................................................... ES-1 Summary Observations........................................................................................ ES-1 Partnering – People........................................................................................ ES-1 Design – Material Availability, Fabrication Time, and Logistics...................... ES-2 Planning – Detailed......................................................................................... ES-2 Contracting Strategy – Aligned with Requirements....................................... ES-2 New Business Model – Serve the Public........................................................ ES-2 Emergency Projects....................................................................................... ES-2 Conclusions.......................................................................................................... ES-3 1.0 Introduction............................................................................................. 1-1 Background.......................................................................................................... 1-1 Purpose and Scope.............................................................................................. 1-1 Methodology......................................................................................................... 1-2 2.0 Emergency Accelerated Construction..................................... 2-1 Introduction.......................................................................................................... 2-2 Replacement of the I-65/I-59 Interchange Bridges, Birmingham, Alabama......... 2-2 Project Description (The First Time)............................................................... 2-3 Project Execution........................................................................................... 2-3 Project Description (Déjà Vu: Same Interchange, Different Bridge)............... 2-5 Project Execution........................................................................................... 2-5 Synopsis of Acceleration Efforts.................................................................... 2-7 Underlying Fundamentals of Success............................................................ 2-9 Repair and Replacement of the I-580/880 MacArthur Maze, Oakland, California............................................................................................... 2-9 Project Description......................................................................................... 2-9 Project Execution........................................................................................... 2-9 Synopsis of Acceleration Efforts.................................................................... 2-15 Underlying Fundamentals of Success............................................................ 2-16 Replacement of the I-40 Bridge, Mojave Desert, California................................. 2-16 Project Description......................................................................................... 2-17 Project Execution........................................................................................... 2-18 Synopsis of Acceleration Efforts.................................................................... 2-21 Underlying Fundamentals of Success............................................................ 2-22 Replacement of the Russian River Bridge, Geyserville, California....................... 2-23 Project Description......................................................................................... 2-23 Project Execution........................................................................................... 2-25 Synopsis of Acceleration Efforts.................................................................... 2-26 i TABLE OF CONTENTS Underlying Fundamentals of Success............................................................ 2-27 Repair of the I-5 Tunnel, Los Angeles, California.................................................. 2-28 Project Description......................................................................................... 2-28 Project Execution........................................................................................... 2-29 Synopsis of Acceleration Efforts.................................................................... 2-31 Underlying Fundamentals of Success............................................................ 2-31 Repair of the I-10 Bridge over Escambia Bay, Pensacola, Florida....................... 2-32 Project Description......................................................................................... 2-32 Project Execution........................................................................................... 2-34 Synopsis of Acceleration Efforts.................................................................... 2-36 Underlying Fundamentals of Success............................................................ 2-37 Replacement of the Queen Isabella Causeway to South Padre Island, Texas..... 2-37 Project Description......................................................................................... 2-38 Project Execution........................................................................................... 2-39 Synopsis of Acceleration Efforts.................................................................... 2-42 Underlying Fundamentals of Success............................................................ 2-42 Conclusions: Emergency Accelerated Construction............................................ 2-43 Recommendations......................................................................................... 2-43 3.0 Planned Accelerated Construction............................................ 3-1 Rebuild of the I-15 Devore Corridor, Devore, California....................................... 3-1 Project Description......................................................................................... 3-1 Project Execution........................................................................................... 3-3 Synopsis of Acceleration Efforts.................................................................... 3-4 Underlying Fundamentals of Success............................................................ 3-5 Yerba Buena Island Bay Bridge, San Francisco, California.................................. 3-6 Viaduct Roll-In................................................................................................ 3-6 Detour and Transistion Structures.................................................................. 3-9 Replacement of the Duval Street Bridge, Jacksonville, Florida............................ 3-12 Project Description......................................................................................... 3-12 Project Execution........................................................................................... 3-13 Synopsis of Acceleration Efforts.................................................................... 3-13 Underlying Fundamentals of Success............................................................ 3-15 Improvements to the SR 9A/I-295 Corridor, Jacksonville, Florida........................ 3-15 Project Description......................................................................................... 3-15 Project Execution........................................................................................... 3-16 Synopsis of Acceleration Efforts.................................................................... 3-16 Underlying Fundamentals of Success............................................................ 3-17 Replacement of the I-10 Bridges Over Escambia Bay, Pensacola, Florida.......... 3-18 Project Description......................................................................................... 3-18 Project Execution........................................................................................... 3-21 Synopsis of Acceleration Efforts.................................................................... 3-21 BEST PRACTICES IN ACCELERATED CONSTRUCTION TECHNIQUES ii TABLE OF CONTENTS Underlying Fundamentals of Success............................................................ 3-22 Reconstruction of Interstate 10, Houston, Texas.................................................. 3-23 Project Description......................................................................................... 3-23 Project Execution........................................................................................... 3-24 Synopsis of Acceleration Efforts.................................................................... 3-26 Underlying Fundamentals of Success............................................................ 3-27 Conclusions: Emergency Accelerated Construction............................................ 3-28 Recommendations......................................................................................... 3-29 4.0 Program Approach to Acceleration........................................... 4-1 Introduction........................................................................................................... 4-1 Philosophy............................................................................................................. 4-1 Focus Areas.......................................................................................................... 4-2 Enabling Accelerated Project Completion............................................................ 4-3 Innovative Contracting................................................................................... 4-3 Partnering....................................................................................................... 4-3 Cultural Change.............................................................................................. 4-4 Accelerated Bridge Construction.......................................................................... 4-5 Contractor’s Perspective of Accelerated Construction........................................ 4-13 General Issues................................................................................................ 4-14 Contracting Strategies.................................................................................... 4-14 Planning and Scheduling................................................................................ 4-15 Construction Practices................................................................................... 4-15 Program Acceleration: The Future........................................................................ 4-16 Emergency Construction...................................................................................... 4-17 Keys to Successful Program Implementation....................................................... 4-20 5.0 Observations, Recommendations, and Implementation............................................................................5-1 Introduction........................................................................................................... 5-1 Observations......................................................................................................... 5-1 Partnering – People........................................................................................ 5-1 Design – Material Availability and Logistics................................................... 5-2 Planning – Detailed......................................................................................... 5-2 Contracting Strategy – Aligned with Requirements....................................... 5-2 New Business Model – Serve the Public........................................................ 5-2 Recommendations................................................................................................ 5-2 Emergency Projects....................................................................................... 5-3 Planned Project Acceleration......................................................................... 5-3 Program Project Acceleration......................................................................... 5-4 Implementation..................................................................................................... 5-5 Conclusions.......................................................................................................... 5-6 iii Appendix A Scan Team Biographical Information..................... A-1 Appendix B Scan Team Contact Information................................. B-1 Appendix C Practitioners Contacted During the Data-Gathering Phase........................................................ C-1 Appendix D Bibliography........................................................................... D-1 Appendix E Host Agency Contact Information............................. E-1 Appendix F Amplifying Questions........................................................ F-1 Appendix G I-10 Escambia Bay Bridge Natural Disaster Emergency Contract................................................................. G-1 BEST PRACTICES IN ACCELERATED CONSTRUCTION TECHNIQUES iv LIST OF TABLES v