Working with Lee Construction Company of the Carolinas, KCI performed more than 25 engineering tasks associated with seven bridges as part of the construction of the Fayetteville Bypass interchange with the All-American Freeway, which provides a critical link to access the Fort Bragg Army Base. KCI worked with the contractor and provided all the necessary construction engineering including:
- Design of multiple falsework and formwork for deck overhangs to support screed equipment
- Design of multiple steel girder erection plans for curved girder bridges
- Design of temporary towers to support girder erection loads
- Design of unique temporary supports for tri-level integral bent
- Design of work trestles supporting up to 275 ton cranes and associated picks
- Design of shoring walls and tiebacks
- Load rating bridge for anticipated crane loads
- Design of hanging platforms for construction access and formwork
- Design of post tensioning operations for integral pier caps
- Mass concrete analysis
- Design of specialty equipment such as sand jacks and overhang buggy
- Modify footings and caps to alleviate construction tolerances
To assist the contractor in meeting their tight construction schedule, KCI first initiated design of items that were on the critical path. Our team also provided additional engineering services to the contractor on short notice for critical items that arose during construction.
The project had a lot of unique features—a number of curved girder bridges, integral bents, unique falsework and complicated construction—that needed a high technical level of engineering support.
James D. Fitz Morris, PEPractice Leader
Many tasks required out-of-the-box strategies to overcome site-specific challenges. The multiple integral bents supporting curved steel girders for the tri-level bridge over All-American Freeway required an innovative solution to supporting the girders and concrete cap with multiple obstructions below and adjacent to the bridge. Structural engineers designed a unique support system with arms that were braced back to the integral bent column to fit within tight space requirements. Additionally, KCI provided innovative internal bracing details to secure the falsework to the column and a system of sand jacks and other support brackets that allowed easy lowering of the falsework system under loads in excess of 200,000 pounds per jack.
All design and plans met detailed requirements established by the contractor or NCDOT specifications. This project was performed within the established schedule and budget constraints and met or achieved the expectations of the contractor.