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| 2008 Bridge Repair/Rebuilding Program |
Twenty-three bridge repair/rebuild projects across the entire WSOR system were completed during the year 2008. Work has again varied from replacing pile cap bents to building entirely new bridge decks. The projects were distributed as follows: Prairie Sudivision: 5; Monroe Subdivision: 3; Fox Lake Subdivision: 4; Reedsburg Subdivision: 4; Milwaukee Subdivision: 1; Oshkosh Subdivision: 3; Madison Subdivision: 1; Waukesha Subdivision: 2. Below is a summary of the projects to give an idea of the scope of our work. Many of these repairs maintain and extend the useful life of the structures ten to twenty years before they will need to be entirely replaced. At least two bridges were entirely replaced with new structures. Total cost: $1.56 million, of which $1.01 million was paid for by WSOR. Click on photos to enlarge.
Bridge D-88 Project, MP 138.6, Milwaukee Subdivision, Horicon, WI — completed March 2008
Project consisted of: Replacing entire north and south walkway and railing system, replacing timber sub-cap on Pier 5 with pre-cast concrete cap, repairing shear cracks and bearing seat delamination on Pier 3, repairing shear cracks on north abutment, and repairing deteriorated concrete under bearings Piers 2 and 4, with polymer grout. Work performed by E-80 Plus Constructors. Total Cost: $102,445.89 (80% state funded, 20% WSOR Funded).
Installing Steel Walkway System Span 3
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Concrete Crack Polymer Injection Repair Pier 3
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Finishing Concrete Repair Bearing Riser Pier 4
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Travel Level View East, Completed Project
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Bridge D-170 Project, MP 182.6, Oshkosh Subdivision, Oshkosh, WI — completed May 2008
Project consisted of: Leveling concrete bridge seats, installing new timber bearing blocks, installing new steel bearing plates and new anchor bolts and upper backwall timbers, at East and West Abutments and replacing entire timber Tie Deck and attachment hardware. Work performed by WSOR Forces. Total Cost: $20,298 (100% WSOR Funded).
Span Jacked and Deteriorated Bearing Block Removed
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WSOR Crew Moving New Bearing Block into Position
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Installing New Timber Tie Deck
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Track Level View West, Completed Project
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Bridge B-400 Project, MP 161.55, Prairie Subdivision, Mazomanie, WI — completed August 2008
Project consisted of: Replacing missing Pile 3 Bent 4, by posting, and replacing Pile Caps, Bent 8 and Bent 9. Work performed by WSOR Forces. Total Cost: $13,076 (100% WSOR Funded).
Excavating Broken Pile 3, Bent 4, Prep for Posting Repair
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Moving Pile Post into Position over Pile 3 Cutoff
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Placing Concrete in Pile Post Collar
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Completed Pile 3 Bent 4 Pile Post
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Bridge B-278 Project, MP 189.59, Prairie Subdivision, Avoca, WI — completed August 2008
Project consisted of: Excavation and removal of 371 cubic yards of siltation debris and shaping of flow line Spans 1 through 5, north right of way line to south right of way line to restore maximum Channel opening. Work performed by WSOR Forces. Total Cost: $10,347 (100% WSOR Funded).
Bridge 388 View E. Prior to Repairs Tie Deck/E. Abutment
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Excavating Flow Line North-East Quadrant
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View North, Span 1 during Excavation
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View North West, Excavation Complete Spans 2 thru 5
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Bridge F-26 Project, MP 10.55, Monroe Subdivision, Janesville, WI — completed February 2008
Project consisted of: Replacing 14" pile caps Bents 1, 2, and 7, and replacing double 14" pile cap Bent 4 (Main Track), replacing 14" pile caps Bents 1, 6, and 7, and replacing double 10" pile cap Bents 3, 4, and 5 (Track 1), and replacing 14" pile caps Bents 1 and 2 and replacing double 10" pile cap Bent 3 (Track 2). Work performed by E-80 Plus Constructors. Total Cost: $70,072 (100% WSOR Funded).
14" Double Pile Caps Bent 4, Main Track (foreground)
10" Double Pile Caps Bent 4, Track 1 (center)
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14" Pile Caps Bent 1
Track 1 (left), Track 2 (right)
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10" Double Pile Caps Bent 5,
Track 1 (center)
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Restored Profile of Low Chord account Pile Cap
Replacement Main Track North Side Spans 3 thru 6
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Bridge F-60 Project, MP 18.2, Monroe Subdivision, Hanover, WI — completed September 2008
Project consisted of: Replacing entire existing 3-span Timber Trestle with 2 spans, open timber deck, WSOR Standard Design Steel Trestle, and installing 115-lb Welded Rail across structure east and west approaches. Work performed by Osmose Inc. and Sub-Contractors, Radtke Construction, and Knapp RR Builders. Total Cost: $290,801 (80% State Grant, 20% WSOR Funded).
F-60 Pile Driving Set Up
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Driving Pile 4, Bent 2
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Installation of Tie Deck, and 115lb Welded Rail
On New 2 Span Superstructure
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Completed Project F-60
North Side View, Looking South
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Bridge F-80 Project, MP 26.75, Monroe Subdivision, Brodhead, WI — completed October 2008
Project consisted of: Replacing entire existing 3-span Timber Trestle with 2 spans, open timber deck, north side personnel walkway ,WSOR Standard Design Steel Trestle, and installing 115-lb Welded Rail across structure east and west approaches. Work performed by Osmose Inc. and Sub-Contractors, Radtke Construction, and Knapp RR Builders. Total Cost: $294,732 (80% State Grant, 20% WSOR Funded).
Removing Pile Equipment for Passage of Rail Traffic
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New Pile Bent 2 Driven in Place Adjacent to Existing Bent 3
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Installing North Side Personnel Walkway on
New 2 Span Superstructure
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F-80 View West, Completed Project
South Side
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Bridge B-60 Project, MP 22.36, Waukesha Sub, Waukesha, WI — completed November 2008
Project consisted of: Replacing entire open timber tie deck, adding timber personnel walkway with steel post and cable fence to south structure side, and replacing timber ballast retainers and adding timber wingwall extensions on east and west abutments. Work performed by WSOR Forces. Total Cost: $24,598 (100% WSOR Funded).
View East Prior to Repairs, Alignment Swing
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View West, Welded Rail Construction
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Tie Deck and Walkway Outrigger Ties Installation
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B-60 View East, Completed Project
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Bridge A-428 Project, MP 50.01, Fox Lake Sub, Fox Lake, IL — completed September 2008
Project consisted of: Replacing all timber tie deck blocking in E-girder Spans 4 and 7, replacing entire open timber tie deck Spans 5 and 6 (draw span) and removing deteriorated concrete under bearings Pier 3 and recasting with polymer grout. Work performed by E-80 Plus Constructors. Total Cost: $94,589.62 (100% WSOR Funded).
A-428 View East Prior to Repairs North Side
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Pier 3 Concrete and Bearing Repairs
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Span 7, E-girder Ties Installed
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Swing Span 5 and 6 Tie Deck Installed
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Bridge A-428 Project, MP 50.01, Fox Lake Sub, Fox Lake, IL — completed October 2008
Project consisted of: Replacing entire open timber tie deck East Approach Spans 1, 2, and 3, West Approach Spans 7 and 8, installing new pile cap Bents 1 and 3, raising East Approach Spans 1 through 3 maximum of 6" and adding blocking to Bents 1, 2, and 3 to offset pile settlement, installing new pile cap Bent 5, raising West Approach Spans 7 and 8 maximum of 6" and adding blocking to Bents 4 and 5 to offset pile settlement, adding 6" x 8" x 17' used headwall timber to East Headwall and adding 10" x 17 1/2" X 20' used headwall timber to West Headwall. The project also included raising the east track approach 6" and surfacing for 350 track feet and raising the west track approach 6" and surfacing for 400'. Work performed by WSOR Forces. Total Cost: $50,992 (100% WSOR Funded).
A-428 View West Prior to Repairs
Note Settlement of Approach in Foreground
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Timber Tie Deck Replacement,
West Approach
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Bent 5 Pile Cap Installation,
West Approach
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A-428 View West, Completed Project
Profile Settlement of East & West Approaches Corrected
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Bridge A-540 Project, MP 98.13, Fox Lake Subdivision, Janesville, WI — completed June 2008
Project consisted of: Replacing entire Timber Block and Rail Clip floor system with Direct Fixation Pandrol Plate floor system, resetting superelevation of main and Saw Tooth Beam Bearing Shoes with Concrete Risers, replacing deteriorated concrete Wing Walls and Back Walls in East and West Abutments and installing 115-lb Welded Rail across Structure. Work performed by E-80 Plus Constructors. Total Cost: $102,547 (100% WSOR Funded).
A-540 View West Prior to Repairs
Deteriorated Rail Fixation System in Foreground
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Installing Pandrol Direct Fixation Plates
and Welded Rail
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Concrete Repairs, End Wall (Foreground),
Bearing Superelevation Corretion Pad (Upper Center)
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A-540 View West,
Completed Project
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Bridge A-542 Project, MP 98.16, Fox Lake Subdivision, Janesville, WI — completed June 2008
Project consisted of: Replacing entire Timber Block and Rail Clip floor system with Direct Fixation Pandrol Plate floor system, resetting superelevation of main and Saw Tooth Beam Bearing Shoes with Concrete Risers, replacing deteriorated concrete Wing Walls and Back Walls in East and West Abutments and installing 115-lb Welded Rail across Structure. Work performed by E-80 Plus Constructors. Total Cost: $92,547 (100% WSOR Funded).
A-540 View West Prior to Repairs
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Drilling Floor Beams for Pandrol Direct Fixation Plates
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Recast Concrete East Headwall
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A-542 View East, Completed Project
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Bridge 369 Project, MP 174.88, Reedsburg Subdivision, Baraboo, WI — completed October 2008
Project consisted of: Replacing entire timber Tie Deck and north and south timber Walkways, installing 42 each #8 x 24" steel tension rods at east and west Abutment Parapet and Return Walls (top course to second stone course) to unitize Back Walls, placing cast reinforced concrete Back Wall and Return Wall risers (60 lineal feet) to correct elevation, replacing timber Ballast Retainers on east and west Abutments, and tuck pointing open masonry joints on Back Walls and Bridge Seat. The project also included raising the East Track Approach 6" and surfacing for 600 track feet and raising the West Track Approach 6" and surfacing for 400'. Work performed by WSOR Forces. Total Cost: $44,647 (100% WSOR Funded).
Bridge 369 Tie Deck Replacement View East
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Concrete Reinforcement of Back and Return Walls
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Installing Walkway Plank on South Walkway
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Bridge 369 View East, Completed Project
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Bridge 236 Project, MP 137.5, Reedsburg Sub, Madison, WI — completed November 2008
Project consisted of: East Timber Pile Trestle Approach: Replace timber Back Wall and Return Walls, and place 30 tons riprap around Wall base; Replace 100% of the open timber tie deck and 100% north and south 4-ply timber Stringer Packs Spans 1 and 2 with larger dimension material to offset pile settlement; Raise East Approach Spans 1 and 2 6"; Cut existing piles and double pile cap Bents 1 and 2, to offset pile settlement, and restore track profile and alignment; Replace frame cap Bent 3, Pier 1 and repair south Personnel Walkway. Beam Spans 2, 3, & 4: Replace pile cap and sub cap Row 1, Pier 1; Replace steel Bearing Shoe 1, Pier 1 with steel and precast concrete fabricated Beam Shoe to correct span settlement and proper superelevation; Replace steel Bearing Shoes 2 and 3, pier 2, with steel and precast concrete fabricated Beam Shoes to correct pile settlement and proper superelevation; Replace pile cap Row 1 and pile cap and sub cap Row 2, Pier 4; Replace steel Bearing Shoe 6, Pier 4, with steel and precast concrete fabricated Beam Shoe to correct span settlement and proper superelevation; and Repair south Personnel Walkway. West Timber Pile Trestle Approach: Repair timber Back Wall and Return Walls, and place 40 tons riprap around Wall base; Replace 50% open timber tie deck and 100% north and south 4-ply Stringer Packs Spans 6 and 7; Raise West Approach Spans 6 and 7 6" and cut existing piles and double pile cap Bents 5 and 6 to offset pile settlement, and restore track profile and alignment; Replace frame cap Bent 4, Pier 4; and Repair south Personnel Walkway. The project also included WSOR Forces raising the East Track Approach 6" and surfacing for 225 track feet and raising the West Track Approach 6" and surfacing for 150 track feet. Work performed by E-80 Plus Constructors. Total Cost: $127,472.20 (100% WSOR Funded).
Bridge 236 View West Prior to Repairs
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South Side View Bent 2 & Pier 1 Double Capping Complete
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Pier 2, Pile Cap and Steel & Concrete Beam Shoes Detail
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Bridge 236 View East, Completed Project
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Bridge 237 Project, MP 137.55, Reedsburg Sub, Madison, WI — completed November 2008
Project consisted of: East Timber Pile Trestle Approach: Replace timber Back Wall and Return Walls, and place 40 tons riprap around Wall base; Replace 70% of the open timber tie deck and 100% north and south 4-ply timber Stringer Packs Spans 1, 2, and 3 with larger dimension material to offset pile settlement; Raise East Approach Spans 1, 2, and 3 6"; Cut existing piles and triple cap Bent 1, double pile cap Bents 2 and 3 and install longitudinal bracing, to offset pile settlement, and restore track profile and alignment; Replace frame cap Bent 4, Pier 1; and Repair south Personnel Walkway. Beam Spans 3, 4, and 5: Replace steel Bearing Shoe 1, Pier 1 with steel and precast concrete fabricated Beam Shoe to correct span settlement and proper superelevation; Replace steel Bearing Shoes 2 and 3, pier 2, with steel and precast concrete fabricated beam shoes to correct pile settlement and proper superelevation; Replace steel Bearing shoes 3 and 4, Pier 3, with steel and precast concrete fabricated Beam Shoes to correct pile settlement and proper superelevation; Replace pile cap Row 1 and pile cap and sub cap Row 2, Pier 4; Replace steel Bearing Shoe 6, Pier 4, with steel and precast concrete fabricated Beam Shoe to correct span settlement and proper superelevation; and Repair south Personnel Walkway. West Timber Pile Trestle Approach: Repair timber Back Wall and Return Walls, and place 40 tons riprap around Wall base; Replace 65% open timber tie deck and 100% north and south 4-ply Stringer Packs Spans 6, 7 & 8; Raise West Approach Spans 6, 7, and 8 6"; and Cut existing piles and double pile cap Bents 6, 7, and 8 to offset pile settlement; Restore track profile and alignment; Replace frame cap Bent 5, Pier 4; and Repair south Personnel Walkway. The project also included WSOR Forces raising the East Track Approach 6" and surfacing for 150 track feet and raising the West Track Approach 6" and surfacing for 65'. Work performed by E-80 Plus Constructors. Total Cost: $149,472.21 (100% WSOR Funded).
Bridge 237 View West Prior to Repairs,
(note poor alignment)
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E-80 Crew Replacing Stringers,
Spans 1 through 3
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Pile Cap and Sub Cap Repair, Pier 4 (center) Bent 6 (right)
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Bridge 237 View East, Completed Project
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