Olmsted Dam Project - U.S. Army
Olmsted Dam Project - U.S. Army
Olmsted Dam Project - U.S. Army
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<strong>Olmsted</strong> <strong>Dam</strong> <strong>Project</strong><br />
2012 USACE Locks<br />
Maintenance Workshop<br />
February 29, 2012<br />
Paducah, KY<br />
US <strong>Army</strong> Corps of Engineers<br />
Louisville<br />
District<br />
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1
<strong>Olmsted</strong> Locks & <strong>Dam</strong> <strong>Project</strong><br />
Rendering of completed project<br />
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T<br />
T<br />
Ohio River Main Stem<br />
US <strong>Army</strong> Corps<br />
of Engineers<br />
Ohio River & Great Lakes Division<br />
Locks & <strong>Dam</strong><br />
MONTGOMERY ISLAND<br />
NEW CUMBERLAND<br />
T<br />
T<br />
DASHIELDS<br />
EMSWORTH<br />
T<br />
T<br />
T<br />
TT T<br />
T<br />
T<br />
Pittsburgh<br />
ALLEGHENY R.<br />
PA<br />
MISSISSIPPI R.<br />
MISSOURI<br />
OLMSTED<br />
ILLINOIS<br />
JOHN T. MYERS<br />
Cairo<br />
53<br />
T<br />
T<br />
T<br />
52<br />
L&D 53<br />
T<br />
TENNESSEE<br />
OLMSTED<br />
T<br />
T<br />
NEWBURGH<br />
T<br />
SMITHLAND<br />
SMITHLAND<br />
L&D 52<br />
WABASH<br />
T<br />
CUMBERLAND<br />
T<br />
GREEN<br />
T<br />
JOHN T. MYERS<br />
T<br />
INDIANA<br />
McALPINE<br />
CANNELTON<br />
T<br />
KENTUCKY<br />
NEWBURGH<br />
MARKLAND<br />
CANNELTON<br />
T<br />
T<br />
T<br />
Louisville<br />
T<br />
T<br />
Cincinnati<br />
KENTUCKY<br />
T<br />
T<br />
T<br />
McALPINE<br />
T<br />
OHIO<br />
CAPT. A. MELDAHL<br />
TT<br />
T<br />
T<br />
MARKLAND<br />
LOUISVILLE DISTRICT<br />
P.O. Box 59<br />
Louisville, KY 40201-0059<br />
(502) 582-5736<br />
GREENUP<br />
T<br />
R. C. BYRD<br />
T<br />
BIG SANDY<br />
WILLOW ISLAND<br />
BELLEVILLE<br />
RACINE<br />
CAPT. A. MELDAHL<br />
T<br />
PIKE ISLAND<br />
T<br />
T<br />
T<br />
Huntington<br />
GREENUP<br />
HANNIBAL<br />
KANAWHA<br />
T<br />
T<br />
T<br />
T<br />
T<br />
WVA<br />
R. C. BYRD<br />
LEGEND<br />
RACINE<br />
WILLOW ISLAND<br />
BELLEVILLE<br />
EXISTING STRUCTURE<br />
AND POOL<br />
UNDER CONSTRUCTION<br />
T<br />
TT<br />
TT<br />
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T<br />
HUNTINGTON DISTRICT<br />
502 8th St.<br />
Huntingotn, WVA 25701-2070<br />
(304) 529-5452<br />
MONONGAHELA R.<br />
NEW CUMBERLAND<br />
PIKE ISLAND<br />
HANNIBAL<br />
DASHIELDS<br />
MONTGOMERY ISLAND<br />
PITTSBURGH<br />
DISTRICT<br />
1000 Liberty Ave.<br />
Pittsburgh, PA<br />
15222-4186<br />
(412) 644-4130<br />
EMSWORTH<br />
700<br />
650<br />
600<br />
550<br />
500<br />
450<br />
400<br />
350<br />
300<br />
ELEVATION IN FEET (M.S.L.)<br />
981<br />
950 900 850 800 750 700 650 600 550 500 450 400 350 300 250 200 150 100 50 0<br />
250<br />
RIVER MILES BELOW PITTSBURGH<br />
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<strong>Olmsted</strong> Locks & <strong>Dam</strong> <strong>Project</strong><br />
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<strong>Olmsted</strong> <strong>Dam</strong><br />
<strong>Project</strong><br />
November 2010<br />
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<strong>Olmsted</strong> <strong>Dam</strong> <strong>Project</strong><br />
May 4 2011 Aerial<br />
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The Biggest Uncontrollable Challenge<br />
The Ohio River<br />
Flood of 2011 high is 335.5’ @ 7.5 fps on May<br />
3<br />
120 Day River Velocity Plot<br />
Shell SS2 Set and Tremied<br />
Shell LP2 Set and Tremied<br />
Birds Point Levee Blown<br />
6 Month River Elevation Plot<br />
120 Day River Elevation Plot<br />
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Flood 2011, Ohio River is 3.6 miles<br />
wide at <strong>Olmsted</strong><br />
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Specialized Tools to Build <strong>Olmsted</strong> <strong>Dam</strong><br />
Cat Barge w/ Lifting Frame.<br />
Lifting Frame<br />
Tremie Rebar Template on<br />
Cradle being moved by CTE<br />
Gantry w/ Lifting Frame.<br />
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Super Gantry Crane<br />
Facts & Figures:<br />
-Cost:<br />
$9.5 million<br />
-Lifting System:<br />
12 Strand Jacks<br />
-Design Lifting Capacity:<br />
5,100 tons<br />
-Travel Speed:<br />
20’ per minute (unloaded)<br />
10’ per minute (loaded)<br />
-Interior Dimensions:<br />
100’ tall by 130’ wide<br />
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Catamaran Barge Construction<br />
Facts & Figures:<br />
Cost:<br />
$19 million.<br />
Propulsion Source:<br />
The barge will be moved by two<br />
4,500 HP push boats.<br />
Dimensions:<br />
310’ Wide, 200’ Long, 115’ High.<br />
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Strand Jack Heavy Lift Equipment<br />
Facts & Figures:<br />
Cost: $238,232 per jack<br />
Lifting Speed: 20’ per<br />
hour<br />
Capacity: 1100 Tons<br />
depending on number of<br />
strands<br />
Max No. of Strands: 66<br />
Stoke Distance: 18”<br />
http://www.dormanlongtechnology.com/<br />
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Marine Skidway<br />
1562’ long - 12:1 Slope<br />
Top El. 370 Lower El. 240<br />
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Cradle Transport System<br />
(Push-Pull Skid System)<br />
Facts Figures:<br />
-Cost: $4 million<br />
-Power Source: Electric over<br />
Hydraulics.<br />
-Travel Speed: 64’ per hour<br />
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Aquadigger<br />
Facts & Figures:<br />
Barge:<br />
-Cost: $14 million<br />
-Barge Dimensions: 180’ Long by<br />
50’ wide by 11’ deep<br />
Excavator:<br />
-Cost: $3,500,000<br />
-Bucket Size: 5 cubic yards<br />
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Pile Driving Equipment<br />
Features:<br />
Template has multiple cylinders<br />
to allow it to be moved in nearly<br />
any direction to fit the<br />
requirements<br />
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2007 Downstream Riprap Activities<br />
270’ El. Riprap visible in May 19,<br />
2011 river survey<br />
Green spots are approx. El. 250’<br />
17<br />
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River Survey Time Lapse<br />
January<br />
February October December<br />
September February 16,<br />
November June July June<br />
23, 12, 15,<br />
9, 5, 24, 16, 23, 2010<br />
2010<br />
February October July<br />
August April 1,<br />
2012<br />
2012 21, 24, 20, 7, before 28, 29, 2011<br />
2011<br />
after 2010<br />
2009<br />
2011<br />
2009 LF<br />
LF<br />
removal<br />
removal<br />
December January 7, 2012 2011<br />
Deep Red - 236 and below<br />
Orange - 236 – 240<br />
Yellow - 240 - 244<br />
Green - 244 - 248<br />
Light Blue - 248 - 252<br />
Blue - 252 - 256<br />
BUILDING<br />
Dark Blue - 256 - 260<br />
18<br />
BUILDING Dark Purple STRONG - 260 - ®<br />
264<br />
Light Purple - 264 and higher
Aerial View of Grout Mat Facility<br />
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Grout Mat Roll-Up Machine w/ Spool<br />
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Grout Mat Installation<br />
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Grout mat<br />
placement<br />
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2009 Master / Sheet Pile Installation<br />
As builter, slides over<br />
and self centers on<br />
master pile and self<br />
leveling optical laser<br />
plumb shots beam to<br />
surface in pipe<br />
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Current Pipe Pile Installation<br />
Surveying<br />
As-built<br />
pile head<br />
location w/<br />
As-Builter<br />
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Foundation Pile Installation<br />
2010 Quantity<br />
384 Piles<br />
Planned 45 days or 8.5 per day<br />
Took 66 days or 5.8 per day<br />
2 - 10 hr. shifts / day<br />
Started July 16, 2010<br />
Finished Nov 15, 2010<br />
2011 Quantity<br />
424 Piles<br />
Planned 45 days or 10 per day<br />
Took 41 days or 10.4 per day<br />
2 – 12 hr. shifts / day<br />
Started August 12, 2011<br />
Finished Nov 11, 2011<br />
2012 Quantity<br />
346 Piles<br />
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Precast Yard / Shell<br />
Work<br />
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Late May 2010 Versus Aug 2010<br />
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Isometric Views of LP-1 Shown on Base Structure<br />
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LP-1 Status Sept 2009<br />
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LP-2<br />
Support<br />
Structure<br />
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Bearing Walls<br />
SBS-2 Walls<br />
SS-1 Walls<br />
31<br />
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SS-1<br />
Construction of Shells<br />
SS-2<br />
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Typical Concrete Placements<br />
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Typical Concrete Placements<br />
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Typical Concrete Placements<br />
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SBS Shell<br />
to Shell<br />
Joint<br />
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Shell Outfitting Work<br />
Flat Shells<br />
Typical Sill Shell (SS2-5)<br />
Typical Stilling Basin<br />
Shell (SS2-5)<br />
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Shell Preparation Activities<br />
Master Pile Brackets<br />
<br />
Both Below<br />
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Shell Preparation Activities<br />
Flat Jacks & Hydraulic Piping<br />
Support the shells on<br />
landing/bearing piles<br />
Hydraulic<br />
Hose Cutter<br />
Flat jack Control Panel -><br />
Mounted on lift frame<br />
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Shell Preparation Activities<br />
Shell Support Posts<br />
Support for the shell on “A”<br />
& “D” lines of the tremie mat<br />
template and cradle right<br />
above rails<br />
Receiver<br />
on template<br />
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Shell Preparation Activities<br />
Containment structures & wire brushes<br />
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Shell Preparation Activities<br />
Lift Frame Bolts<br />
Extension to top of lift frame -><br />
Inside lift frame leg<br />
Under<br />
Shell Nut<br />
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Shell Preparation Activities<br />
SBS Tremie Mat Rebar<br />
A & D Line<br />
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Shell Outfitting Work<br />
Vertical Lower Pier Shells<br />
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Cat Barge with Lower Pier Shell<br />
Setting difficulties included<br />
lining up the keyway with the<br />
training wall that had approx.<br />
1” clearance and the 2<br />
pintles that had ½” clearance<br />
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Shell Preparation Activities<br />
Horizontal Positioning Systems<br />
One of 2 male pintles<br />
installed on SS Shells &<br />
Female Receiver on LP<br />
Shells<br />
Horizontal Flat Jacks<br />
and bearing plate on<br />
curb<br />
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Shell Preparation Activities<br />
Vertical Positioning Systems<br />
Flat Jacks support the 2600 ton shell<br />
(4 Total)<br />
Sheer Key grouted w/ Cradle<br />
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Shell Preparation Activities<br />
Grout Sealing Systems<br />
Post tremie Grout fill<br />
lines<br />
Male Keyway mates<br />
w/ training wall<br />
Horizontal Grout Bags used<br />
to seal between LP and SS<br />
shell<br />
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Duration of Shell Movement<br />
• It will take approximately a 3 week duration<br />
to:<br />
►Set onto the Cradle<br />
►Lift with the Cat Barge<br />
►Haul and Set at It's Final Position<br />
►Fill with Tremie Concrete<br />
►Return to Pick another Shell<br />
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Super Gantry Transporting Shell<br />
Gantry Gantry<br />
Gantry sets sets Gantry moves Tremie picks<br />
shell disconnects picks moves<br />
up<br />
& to rebar lift<br />
Tremie pickup frame load shell frame<br />
and over shell rebar<br />
on && tremie lift backs cradle & mat frame<br />
frame lift on frame rebar away<br />
& Cradle mat<br />
frame<br />
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Super Gantry Moving SBS Shells to Cradle<br />
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SS2 Tremie Mat Rebar<br />
- Tremie mat<br />
support frames are<br />
welded to plates<br />
embedded in shell<br />
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CTE Lowers Cradle and SBS1 into River<br />
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Catamaran Barge Picking Shell off Cradle<br />
Cradle reaches the bottom of the MSW<br />
Cradle Cat moves Barge picks back Cat Barge up lift frame MSW moves for & shell removal over and cradle of moves tremie / shell away rebar leaving template<br />
Cradle comes down the marine skidway (MSW)<br />
cradle & tremie rebar template<br />
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Hookup and Move of SBS1 <strong>Dam</strong> Station<br />
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Cat Barge Setting Shell into Final Position at Bottom of<br />
River<br />
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Shell Positioning Control Room View<br />
Both videos made from screen shots taken every 5 minutes over 10-12 hours<br />
SBS2 Shell Positioning<br />
Screen Shots in 36 sec<br />
video<br />
SS2 Shell Positioning<br />
Screen Shots in 36 sec<br />
video<br />
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Shell Tremie Concrete<br />
Filling Work<br />
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Tremie Instrumentation<br />
System<br />
Approximately 500+/-<br />
Pneumatic Tubes are<br />
installed per shell and<br />
piped back to control<br />
cabinets on lift frame<br />
System converts pneumatic<br />
air pulses into electronic<br />
signals controlled and<br />
displayed by computer<br />
1 of 6 Tremie Control Cabinets w/ 96 sensors<br />
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2011 - LP1 & LP2 Infill Concrete<br />
8 Lifts<br />
above<br />
elevation<br />
268.5<br />
with most<br />
involving<br />
trunion<br />
anchor<br />
rods<br />
1 Lift below<br />
268.5<br />
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Navigable Pass Shell Installation using Cat Barge<br />
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Additional Updates<br />
Louisville District Internet Pages<br />
http://www.lrl.usace.army.mil/poi/default.asp?mycategory=297<br />
Youtube Video Updates<br />
http://www.youtube.com/louisvilleusace<br />
Flickr Photo Updates<br />
http://www.flickr.com/photos/louisvilleusace/<br />
Canadian Discovery Channel Feature<br />
http://watch.discoverychannel.ca/#clip438573<br />
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