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this is Matt Llewellyn and Chad Robinson they're going to do a presentation on New River Gorge rehabilitation project which is where we're going to be in a couple hours so this should tie in with our technical - where I this afternoon so please welcome Matt and check Thank You Billy typically I get a few more minutes than five to do presentations is usually at least an hour long so I'm going to blow through the first portion of this really quickly to give Matt more time for the technical side of things he did a good job of cutting out of almost all my slides but I think it's the first time you get a consultant actually listen to what your directions are say he did a good job there but the overview this is the recent projects has been going on Bridge configuration the inspection we do have a video from accidents they did a documentary which I haven't seen that area maybe mine has some more information about that the load rating some of the preservation and the one of the things we ran into last year is resetting the bearings we do have a little bit on videos on that to go into some technical details on that for us the all this is going to come up with basically we're the main arch was 1,700 feet long it's over 3,000 feet it's nearly 900 feet above the gorge it is the longest steel arch bridge in the Western Hemisphere anybody care to guess real quick how much it would cost today to rebuild this structure so you can see bridge preservation is near and dear to us on this structure so when you go out there at this afternoon we're going to have shuttle vans and you'll be able to go down to where this picture was taken from us called Fayette station jump in one of the western state bans you'd be able to go down and get the same opportunity to take the same photo as well as your being the catwalk so here's some of the some comparisons to how tall the structure is basically Eiffel Tower so the structure was built and completed in 1977 Michael Baker I did the original design on that and from the opening of the structure until recently Michael Baker did all the inspections on the Hat Miss Bob Bryar from Michael Baker here in Charleston started in 1999 on those inspections and has a lot of knowledge as well so I catch him at lunch I'm sure he has some stories about how difficult it is to do the inspections out there but the originally there reason is the ice and salts we did have corrosion starting pigeon problems you guys will probably under day like today you probably will find our Falcon out there hopefully we've got some babies down there in the arts so if you hear it start looking around build LDL attitude stay on the catwalk Hills and he'll leave you alone but he has helped our pigeon problem on that structure so we do like him but now with the Dyson thoughts we do not allow the icing salt one mile north or south of this structure we are now using the calcium magnesium acetate on this so that has helped slow down the corrosion process you can see here's some of the projects that we've done we do have a deck overlay we've done replaced a lot of holes and maps going to go into that so this is kind of a high points that we did have them do low gradient analysis and some rehabilitation plans we have done the element level inspection on this this last year and I think they're coming up on this on the second year of their six-year contract with us and you can see that the 2016 rehabilitation started last year but they're getting ready to start back up again this year with more rehabilitation this is the deck trust so these are you know typical terminology that you would see on the other trust bridges as well you can see the local kind of going through the low path that is part of the other portion that Matt had to take out of this but basically the deck trust transmits the loads into the approach fence and then the spandrel vents and then down to the arch itself and into the thrust blocks or ty bikes on the gorge below in any case definitely one of the most spectacular steel bridges in the world yet another one is located in North America 267 meters over the New River Gorge in the state of West Virginia another true steel giant the New River Gorge Bridge the New River Gorge Bridge is located in the east of the USA in West Virginia up to 20,000 vehicles rush over the steel arch bridge daily and that makes it a maintenance monster cold constant winds and it's gigantic height requires the maintenance team to give their all yeah - thirty degrees is not uncommon during West Virginia winters the river in the gorge and the remoteness of a national park means maintenance work resembles an almost logistical masterpiece every two years a maintenance team moves in Matthew Llewellyn and his men climbed the highest bridges in the country the New River Gorge is next you get more used to it as time goes on but you know the conditions are already different a lot of times you get a little bit of wind like we're getting right now that can affect how how your defend goes you can move you off the steel a little bit so the calmer the better so the more wind sometimes we sometimes we won't repel if it gets to river no easy conditions for Matt's Protege Andrew it's his turn to descend first today although he has climbing experience the New River Gorge Bridge is new to him there was yeah as much as you can no one climbs over the railing without supervision at least two colleagues keep their eyes on Andrew at all times supervisor matt has been doing the job for 20 years he immediately notices when something is wrong yeah with this to understand the rope here it's a little harder descending for the first time dumb a New River Gorge the rookies tension is palpable today's job by design is a simple start first task superficial visual inspection every nook and cranny has to be controlled and documented and drew notes the bridges condition on his tablet [Music] and he returns what you see down Airboss looks pretty good Matt alright so while I was down there that is also moderate surface corrosion a little bit of rust initiating and some of the connections nothing major it's just something we'll monitor for the next inspection to make sure it doesn't get any worse the team's most difficult task is still ahead later they have to move two of the bridges metal plates nearly 300 feet above the canyon just below the 162 ton Road sooner or later the New River Gorge pushes each worker to the limit at most when exposed to the wind the wind is the worst always blowing here never stopping things like so that would be basically how we access the exterior portions of the vents the question I get a lot about the inspection axis is how do you guys look at the arch so far down there what do you do to access it so that works out with it with a spider basket is basically a sky climber mounted to a truck boom it hangs out over the edge of the deck we have a couple of safety backup ropes which you can see here so you can see these backup ropes that are here that's what's used for our backup safety but also gives us the ability when we're in the basket so very important part of that system so when we in-depth inspections we also we climb the lower lateral bracing with the rope access as well so that's how we access the arch so there are Falcons Chad touched on that during our inspection it's usually in August September past their normal nesting period so they weren't aggressive towards us one time we were out inspecting the bridge and the basket was about in this location which isn't quite to mid span and notice the airplane off in the distance and the operator was with me said seems like it's getting closer and I'm Kai go back to inspection about that time airplane get scoops down goes right underneath the center of the arch freak this out we were scared and especially because we had our ropes hanging way down here so my advice to you if you ever inspect this grid just don't let your roots hang low here's the bridge walk tour that you guys are going to get to take later on it is a private vendor that does that the Buena farness clipped off to a safety cable above your head so that's part of what we're going to do later so under the bridge preservation card of it you know we all know weathering steel is not good in prolonged wave conditions and when you have the pigeon nesting inside of a box member like this it results in the section loss that you see here the other problem is is the pack rust right pack brush starts to form when you have poor both sealing so we get nut loss in here this is the lower lateral bracing connection and the nuts on top of that had severe loss so in 2012 is the first rehab that WV dot did took our inspection notes and was able to determine the locations where we needed to clean up the deck truss and do some sealing inside of there so we use the attention stealer product just a pressure water pressure blast and then come in and using penetrant sealer to protect it on the inside also do a lot of caulking of those scenes so we saw some videos earlier about that penetrant sealer product that really how it works is you get the pack rust and seem like this that has the fasteners a long ways away from the edge alright so it doesn't have good sealing property so that pack dress.you you wet it with the the penetrant sealer sort of wicks back in there like wd-40 and it sets up like a sealer displaces all the water that may be in there and then we even doubled up here and talked to see some of the bolt replacements are not replacements there so that's all great you do that but you still have pigeons you know we got the falcon it's eaten some of them but we needed to find a way figure out how can we be sure that the pigeons aren't going to be back in there and do damage so that verges the knife and we brainstormed a little bit came up with a few different prototypes but ended up using the this magnetic sheet with holes drilled in it basically and it goes inside of the hand hole flexible or folds back out so it's easy to remove and you come back for the following inspection we have thousands of them out on this bridge now and continue to install some with this rehab something that we retained developed as a company and you know we'd like to like to do some other states if anybody had the application for that above to talk to you about it so we did a motivating analysis of the entire structure about five thousand different members that were low created not only for vertical live wood and deadly but also for wind and thermal force and then we have special coal trucks that we run across the structure West Virginia on certain bridges all in all is about a year and a half and man work to get this done this is just a deformed shape of from some of the wind loads yeah we don't want to see the bridge in this shape right very exaggerated we use a midas simple software to do this program we have a lot of confidence and a purchase in life for oil and use that on New River and several other structures about twelve different wind load combinations here one of the things worked out really well was the data collection using a visual basic macro inside of Excel for to the section loss and as we enter that section wall saying what this is what this macro does is it it builds up a plot of the section loss here so we're very quickly able to tell if we had the right side or the right y bar or x bar on that to get it in the correct location sort of its self checking [Music] guess it plays very large complex load rating you can see this is a this is a man's head sticking out of that hole this is the bottom of the article and upper area - we had to find a way with 870 gusset plates we needed to find a way to standardize the data collection and we were fortunate to have shop drawings on this project and we were able to scan those and scale them into CAD and use those as a basis for getting our whitmore section dimensions and all of those properties and so there was a few locations where we didn't have good shot growing data where we went out and did feel collection of that took some head-on photographs and just got the measurements that we needed so the results were the low gradient came in pretty good we've got a deck trust diagonals that came in under inventory so we did repairs for those and this most recent rehab --it overall is pretty good pretty good news this is just that member of strengthening detail for some of those Dec trust diagonals just amateur and couple angles around here to increase the radius of gyration in the week axis because compression members so I like to say that is this rehab projects kind of like the spaghetti sauce commercial that you know all the ingredients are in there for a good rehab rate we do a little bit of everything you know down to Clarion and grubbing clear up the major structural repairs Chad mentioned the bearing reset we'll talk about that let's so let's just dig into some of these repairs that that we did starting out with the clearing and rubbing is kind of like a Indiana Jones and the Temple of Doom when you drop down and the sky basket they're just all these trees were growing up through the orange so we needed to clean that up and make it more accessible for inspection and for the rehabilitation work one of the interesting things that happened is this crew found the remains of the body when they were doing the clearing and robbing and there was like there was a Virginia Tech student that back about 20 years ago was going to a mountaineer game about the Morgantown and his car ended up at the end of the bridge and they would never did find his body said as a result of this project it was kind of an unsolved mystery including just before the contractor started his work we went out and did what we call just-in-time inspection a lot of times when you do a concrete inspection we're developing plans it could be a few years maybe before it goes to construction we all know that concrete changes over time so we wanted to do this just in time and have a defined quantity here that the contractor could use and know that we have everything worked out just right so we use orange or pink paint to delineate the patches that were needed this falls into B lambs and then we use the green tank for the cracks the contractor provided us with some spiders to use in addition we use some of our rappelling techniques to get on all phases of these sub structural units and do a hundred percent hammer sounding some of the thermal imaging may come in you know useful in applications like this that was how we did doing this job and then we provided hit the head-on photographs for each face of these piers they provided those to the contractor kit so you can see exactly where you need to get and quantified all that this is the finished product of Isildur cracks with a two-part hybrid urethane mender mender and then patches were Justin on shelf knowledge grant ice cap early strength patching material and then that was all irrigated with a with an epoxy coating it just noticed in this photograph kinda looks like a ride aways been cleared up through there that's that's really good we couldn't clear all the trees but just the bigger ones so it will need to be done again if you is an environment a sensitive area where we could just do what we want so in 2012 we took care of messages the Dec trust issues so this most recent rehab is focusing more on the arch locations and trying to do more down in arts and events like what we did in the Dec trends previously so you can see looking down inside of one of these diagonals here what that looks like so there's an internal diaphragm and it's just the perfect little bird box for pigeons to get in there and nest and make a big mess so we know we need to clean that up but not only we're going to clean it up we're going to follow up with trying to seal that off so the pigeons can get back in there and use some of those magnets but the good news is is the section locks on this bridge did not control the load rating so that was a positive result so we learn from the previous rehabilitation is you need to have good criteria we're doing boat replacement for the contractor to know I mean you're going to quantify it and give them an amount at each connection but it needs to be a le to figure it out when he's in the field and the destruction inspectors what is the criteria so what we ended up using was just a flat to flat dimension if he can find a flat to flat dimension that was in this case for 7/8 bold down to one and eighth across the flats then it would be replaced the real defined criteria and worked out well so in those top ends of the diagonals and posts we wanted to solve the problem that we solved some of the earlier presentations where you have debris accumulation right we don't want to breed in here and we don't want wet debris most of all so looking in here during our inspections we saw them water when it would rain it runs down the underside of the arch and then gets into the connection so we wanted to put in a drip Marv right to keep that from happening normally drip marks are welded to the steel but this in this situation we thought well it's going to be hard to get welding leads down there we don't like to weld the bridge of members unless we have to what about user magnet so that's what we ended up doing got with magnet manufacturers and figured out the best way to do this and caulk them into place and sealed there as well so they wouldn't have a chance of pack rust issues with the weathering still seems to be working really well so as another part of the same issue is there's a gap here at the top and then the ends of these are open you know I've been in a boxes so we wanted to seal those off and make sure that the pigeons and the moisture couldn't get back in there so looked at different products and up settling on an HDPE plastic plate that is really easy lightweight to work with in the field you can use standard woodworking tools and fabricate these things either in place or on the deck with us and here's an example of one of those and got some pretty good shapes to them cut out and the contractor would be able to build this take them down put them in and then he them into place and there's also a mechanical connection on the inside to the end of some of the bolt heads there in there so works out pretty well and he's actually using that in different places than what we had specified and found some locations where there's water ponding and was able to seal that off too so using the same technology and client this is the section loss I was talking about the internal diaphragm here and then some of the loss to the to the main plates of the diagonals and post and something we notice is that these weep holes are just a little bit too high and it allows the water but build up on the inside so pretty simple repair just extend that we pulled down to the top of the diaphragm here's that finished product just a hole drilled in this location I don't know how many credit kids fans we have in the room I always like the partner misty mr. Miyagi tells Daniel Danielson locks on wax off right well this is what we're doing on the gorge bridge we're waxing on there's a the penetrance healers not good for UV so there's some locations where we have debris that accumulates on some of these gusset plates that we needed to seal that so that it wouldn't continue to corrode we couldn't just use the Ventris sealer and we had to topcoat that so materials division did several tests and weather auditor and figured out that this wax would be a good material to used as a topcoat there one wouldn't hurt the environment in the future if we have to take it back off compared to some other products so that's what they did there several approved products on the list that they were allowed to use the the penetrate sealer goes on and you wipe it off and then you apply the wax because will maybe be able to see that from the catwalk as we go across so here's the finished product in this location inside of the box is just finishin sealer and then in place where it's disposed UV it has the top coat of the wax it was just talking around the gusset plate with tantric sealer and most of these locations worked out really low at the base of the bench we also put the wax coating that blue tape will go off but you can see how it matches up really well in the sunlight and then in the bottom of the base the vents that we also just put sufficient sealer down there there was a few locations that weren't weathering steel that we just had to use more conventional paint system epoxy with the urethane topcoat one of the things that surprised this was the way the contractor decided to access all these locations it really does it similar to how we do the inspection on spiders except for he doesn't mounted one at he has frames that are up on the deck at each location didn't want the cost of the truck there the whole time and he also anchors them to the catwalk the challenge that this made was that you know as inspectors construction spectres would have to be right on site as that basket would come up they have to go back down and inspect the completed work so there's kind of a continual process if you were there in the right time and it you know it's working out but it is a little bit of a coordination issue we've supplemented some of the construction inspection working with the district 9 team to be on site there when some of the access gets extreme hard to get to we've been able to team with them and provide a little assistance there and sort of a QA QC inspection as well to back up on top of the deck we do have expansion joint problems like we have on every bridge the compression seals from strain relief joints were leaking and we need to replace those so this is just showing the effects of that the pack rust at the bearings then sealed those up and this is a mentalizing process we've metallized these angles and in particular in between where the where the new joint system would have to go we wanted that to be very well protected so we didn't get the additional corrosion there and this is just that foam joint installation there's a few manufacturers of that type of drink system here this week it's a expanded polyurethane firms wipe it's pre compressed goes into the opening and then expands silicone impregnated is it's really easy to install goes them fast the contractor on this job really liked them there are some guys here if you guys want to talk to him about that I like to say the deck repairs are easy is one two three right this is from last week we were just out there we're working in the fast lanes now sounding out the deck with the rotary percussion fool and gamer's is how we did it in delineating those areas and then then the contractor will come in and song cut talk at some of the areas on the outline on the outlines that we've made and we've got all this quantified for them they'll verify the quantities once this puts the final song captures down there and then jackhammer it out and come back in but the attaches material real quick view their Bachelor Philadelphia culture most of you are familiar with so let's talk more about this varying slide and I said kind of early email out to most of you some of you might have seen this video already this was one of the most significant research that we made bridge is extremely maintenance intensive and different teams are regularly deployed Matt and his engineers get ready for the main task of the day under the name directly over the canyon the only safeguard a loose rope attached to the foot of the bridge after several visual inspections the day's biggest challenges up a support element of the bridge must be shifted without disrupting traffic sounds impossible but it is not three and three quarters of an inch yeah I agree with your mark okay so so we'll just get that mark to come over and line up with that and we should be good over the middle part of the bridge expands or contracts depending on the temperature one of the gears that insures the necessary clearance is stuck and must be brought into position you yeah that's what we want we want to see it move that mean it's broke loose event I wish an alien frog slide on over 51 drugs do you want $8 the pressure from the compressor supports the men and takes weight off the plate that's how the bridge bearing is able to move and can be put back in place again the amount of pressure the selection and positioning of the devices are the true test of whether Andrews calculations are correct yeah I'm happy with it all right well good dry reverse needs to be yeah everything went right according to plan moved it about three and a quarter inches you can see our two marks are lined up now so it's in the right place everything fits perfectly the bridge bearing and the supporting element are positioned perfectly again while maintenance work what's happening under the bridge the four-lane traffic flowed smoothly above daily routine I'm a New River Gorge Bridge one of the most spectacular steel bridges in the world [Music] okay so that video is completely technically correct right the coverage due in the expanding tract there like this right we feel like this right so a little bit of Hollywood type of errors in there so we know better than that so the issue was what we just watched the issue was the soleplate doesn't line up with the base plane can you guys see my point yes okay and see this is a retainer plate on the outside the retainer plate is not connected appropriately to this roller okay so if we look at it in a different view you can see there's three independent pieces here so gears on each side with just the center pin connecting through here the original design called for this retainer plate to be bolted to the bolster but somehow during fabrication and construction that was changed to just have the center pen which is allowed the bolster to move around the roller to move around inside of there independently so that was really the issue when it got to extreme temperatures 120 degrees it would be approaching the safety limits of its rotation so we knew we needed to repair it looked at first vertical jacking right I mean that's what we do a lot of vertical jack put it right back place this is about 400 feet off of the ground so you're not going to build a temporary clinic very easily and to attach something to the face of a steel vent we know that it's going to put at centricity into it and with the kind of loads we were looking at was it really that good of an idea to start looking at words ology acting and thought that would be a good idea here we've done it before probably not on this scale but we thought we could make it work out so just the closer schematic looking at this we have a fixed fairing that's here from the approach spans that's welded onto the top of the cap and then this base plate is welded to the top of the cap as well so the first thing we needed to do to do this horizontal slide was install what we call the jackin assembly it's basically some post tensioning bars that are drilled through the cap and then we have a pushin beam that's on the backside and a bumper here and then the jack is applied over here so the first step is to detach this base plate right we can't move it unless it's detach the error the welds off all the way around the base plate and then we have to remove those retainer plates so they don't restrict the the free rotation of the bearing and then simply apply the force that bumpers they're calibrated based on the temperature of the day at this field and it's there to stop us right at the right position so works out great we've got the base plate and the sole plate are lined up to strike but the roller is still tilted what we're going to do now you know that work good what we're going to do now no.10 concept just a smaller assembly anchored along to the sole plate and the base plate and then use a pushing beam behind the roller to pull it into place with the proper that's there so apply that force toward over and we have the bottom of the lined up so the bottom of the bolster and the base plate are lined up still killed it or take the same thing turn it upside down the same jackal assembly turn it upside down apply the force now we're back in position everybody's happy we put the retainer back go on we go all right we're done probably ought to do something make sure we don't get in this same boat again right so we we put the 1 by 3 bars connected with some tabs here to make sure we don't have this problem in the future one of the big benefits of this type of assembly versus vertical jacking is that you can do it at multiple locations so that same assembly there's four of these bearings on the bridge that same assembly was used four different times where when you vertical Jack you have to have multiple jacking assemblies so that your uniform lifting in the bridge a QC inspection that we've been doing is it's part of the post design services contract that we have and in combination with our routine inspections we generated a punch list report last fall that we gave to the project so that they could work with the contractor and go back at some of these locations touched up and also it just is a good service to be able to get a second opinion we have construction personnel that are there every day but when we go through we do a sweep of the whole bridge we're seeing a lot more of it hands-on through our inspection just a different kind of service that we've been providing on this project and we'll do it again at the end of this construction period and form another punch list of the items before the contractor leaves the site which is important to make sure you get all that touched up just as a way to help the personnel at district 9 make sure they get good quality project so in summary the New River Gorge Bridge is one of the most significant unique structures in the world just its sheer size and complexity presents many technical challenges and we like to think it was a successful partnership with West Virginia UT and us just brainstorming ideas using innovative materials to come up with practical solution and be proactive in a bridge preservation since and not wait till we get to that worst first kind of mentality before the load rating goes bad we're out there sealing things up so it should help protect the public investment that 300 million dollars that we saw earlier well into the future so with that like that open up any questions this is the team that works on it Chad who was up here earlier Adrienne les is the district 9r engineer sitting in the back row David whited is the project manager that work with us in the development of the plant and then Travis is here with me today and Burgess and Michael who he designed the bearing retrofit and big delivery April so do you have any questions for any other side we went off to that I'd like to know if you're using some of those preservation details on your new design right yeah if we were designing a bridge like this yeah the if we if we had a truss bridge that was going in that was weathering steel I would really think about you know painting or having some coating where you know that debris is going to accumulate and that would be an important part of you steel companion downline you got any other thoughts on that Billy it was a new design that we've been using this magnetic back panels that you're using those being used by new design I don't think we've designed the truss bridge like this that would have hand holes like that in our state and recent history that would need that type of details probably more for for bridges there are an service and yes we are using them on a few other bridges in West Virginia one in Parkersburg West Virginia where we we had some fatigue very details in a 514 steel and a tension top cord that was hard to access with the bolted cover plate so those cover plates were removed and we use the magnets over top of that top cord so that every year you can get back in there and look at that partial length weld in that traffic roof how much total thermal movement that you have in the horizontal direction but also in the verdict vertical direction with our trip if you remember Travis you got an answer for that I know in the 1700 fee that we had it splits two different ways horizontally so an inch on one hundred plus you get the approach band expansion so it's it's going to be like 12 inches of footer so maybe let us put the foot 1/2 the vertical I don't know whe e most of the section laws were at the connection of throughout the arches yeah the section loss is really concentrated at the connections and mostly inside the boxes where there was debris accumulation and voice debris that caused that very long related condition but the rest of the bridge the patina is holding up pretty good we do some ultrasonic thickness gates measurements we have monitoring stations that Michael Baker started years ago we've continued those and really haven't seen much progression and the thickness change of the bridge just in open spaces thank you very much that's vinegar thanks man you