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11/16/20 Bridge Update
11/16/20 Bridge Update
11/16/20 Bridge Update
11/16/20 Bridge Update
11/16/20 Bridge Update
11/16/20 Bridge Update
11/16/20
LEWALLEN BRIDGE REPLACEMENT PROJECT UPDATE
Lynn Murphy (Project Coordinator)
At month 27 of the 36-month project:


Bridge Deck Drains - Complete
The installation of deck drains along the curbs and gutters is complete.
This will allow storm water to flow off of the driving surface, into the gutters,
and then drop vertically through the drainage structures (see photos).

Epoxy Coated Steel Rebar - Complete

The required 1.5 million pounds of epoxy coated steel rebar is now installed
(see photos). Notice the vertical steel rebar pieces along the outside edges of the
bridge deck. Once the bridge deck and sidewalk are in place, these vertical
extensions will allow the concrete parapet wall to connect to the deck and sidewalk.

Concrete Bridge Deck - Concrete pouring should begin within two weeks.
Photos show the preparation of a concrete screed device that extends across the
entire width of the bridge deck. Notice that the screed structure rides on round steel
pipe rails. The screed must be adjusted to precise tolerances so the finish grade of
the new concrete surface will match the plan specifications. The screed rail will
carry several attachments to perform different functions for pouring concrete.
Once a large concrete pump is in place and begins to deliver the concrete mix,
augers attached to the screed rail will move back and forth across the bridge deck
width and will distribute the concrete. A vibrator attached to the screed rail will remove
air voids. Concrete finishing floats and surface rollers will move across the screed rail
and will smooth the concrete surface to the proper elevation.
Approximately 3,400 cubic yards of concrete mix is required for the nine-inch-thick
bridge deck (note: an average concrete truck contains 10 cubic yards).

Bridge Dimensions:

Lengths: The concrete bridge deck is 1,136 feet long.
The approach to the new bridge, traveling north bound on Clinch Avenue from
South Clinton, adds a 463 feet length of new asphalt. This approach includes a painted
median divider (11’ wide on the approach narrowing to 8’ wide on the bridge deck)
which creates a safety buffer to separate opposing traffic..
The south bound approach from State Route 61 adds a 265 feet length of new asphalt
between SR 61 and the concrete bridge deck.
Widths - north end: 102.3 feet
This width includes two parapet walls @ 14” each, two sidewalks @ 5.5’ each, two
drain gutters @ 2’ each, two bike lanes @ 4’ each, and 7 traffic lanes at 11’ each.
south end: 77.3 feet.
This width includes two parapet walls @ 14” each, two sidewalks @ 5.5’ each,
two drain gutters @ 2’ each, two bike lanes @ 4’ each, four traffic lanes @
11’ each, one painted median divider @ 8’.

Note: The TDOT Lewallen Bridge Replacement Project began on Monday September
17, 2018 and is scheduled for completion on August 31, 2021

SCROLL DOWN TO SEE ALL PREVIOUS PROGRESS REPORTS


9/24/18 - Week 1 of the 156 week project resulted in:
- Riverside Drive has been closed at South Charles G. Seivers Blvd. and at Meadowbrook Street.
- In order to better manage traffic affected by the road closure and detour, we have upgraded the traffic signal at S. Charles G. Seivers Blvd. at the Willow/Sunset intersection (at McDonald’s). It now has a protected left turn arrow in each direction, and pavement markings have been refreshed.
- The Lakefront Park Walking Trail has been closed on each end of the work zone. Along the river inlet, the metal fence and the trail lighting fixtures and poles are being removed and stored, to protect them from damage. They will be replaced when the trail re-opens.
- The TDOT contractor, Blalock Construction, began clearing and grubbing the right-of-way property on the south end of the Lewallen Bridge. The trees and brush that have been removed will be ground into mulch and spread as an erosion control blanket.
- Preliminary work for underground utility relocation is underway. A sanitary sewer line and a natural gas line are being moved to a new route, away from the work zone and beneath the existing bridge.
- Bridge and pier construction will begin on the south end of the project and proceed toward the north.

10/19/18 - After month 2 of the 36 month project:
- Traffic disrupted by the Lewallen Bridge project continues to adjust to the detours. The recent traffic signal improvements providing for left turns at Willow Street and Sunset Road appear to be very helpful to local residents.
- The TDOT contractor, Blalock Construction, continues to clear the right-of-way property on the south end of the Lewallen Bridge. Most of the trees and brush have been removed and ground into mulch, which is currently being spread across the disturbed areas as an erosion control blanket. Excavation for the first bridge pier footing is underway.
- Blalock crews are currently working at the boat launch ramp area, building two large floating work platforms. Single barge sections are hauled in by tractor-trailer truck, with the individual sections being unloaded by crane and placed into the river, where they are bolted together to form a barge. Barges will be used as a platform for workers, and to support a large crane.

11/20/18 - After month 3 of the 36 month project:
- TDOT contractor Blalock Construction continues work on the Lewallen Bridge replacement project.
- The new bridge will consist of an abutment on each end and six piers between them. Piers are numbered from north to south. Piers 4 and 5 are in the water.
- Pier 6 (the farthest south) is currently being built (see photos). One photo shows the foundation pilings (steel beams) being driven down 20-30 feet until they reach bedrock. The vertical beams shown are all contained in a single column, with the foundation for pier 6 consisting of 3 columns. A more recent photo shows the 3 rebar reinforced concrete columns sitting on top of the foundation pilings.
- Within the next few weeks, one north bound lane of Clinch Avenue will be closed, beginning at Carden Farm Drive. The slow lane will be shut down while the south abutment is prepared. The lane will re-open at mid-span of the Lewallen Bridge. Expect traffic congestion during peak hours.

12/10/18 - After month 4 of the 36 month project:
- TDOT contractor Blalock Construction continues building pier # 6 on the Lewallen Bridge replacement project.
- The attached photo shows three steel reinforced concrete columns and a foundation. Crews are building the cap that sits on top of the columns, which will support the deck. The wooden material shown in the photograph is a temporary walkway built across the structural steel.
- A sanitary sewer pipe relocation project will begin soon, beneath the existing bridge. CUB Water and Sewer will be inspecting the installation.
-The work zone speed limit on the north bound side of Clinch Avenue has been reduced from 45 mph to 35 mph, beginning at Lynncrest Street (near the Git ‘n Go Market). Speed limit signs and advance speed limit signs have been installed. The south bound speed limit continues to be 35 mph across the bridge, but it has been extended south to the Hiway Drive traffic signal.
- The north bound Clinch Avenue lane closure previously mentioned will not take place until after January 1, 2019.

1/22/19 - After month 5 of the 36 month project:
- Blasting on the south end of the project was completed on 01-10-19. No further blasting is anticipated.
- The concrete cap on Pier # 6 has been poured. Work on abutment # 2 (the farthest structure south) should begin within the next two months. This will require a north bound lane closure on Clinch Avenue.
- The sanitary sewer pipe relocation project is about 50% complete. Once it is finished, work will begin on a natural gas line relocation project.
- Piers #4 and #5 are under construction (a total of 6 piers and 2 abutments are required, numbered north to south). Piers #4 and #5 will rest on twin columns in the water. Drilling is currently in progress for these, and the first concrete pour for a column on Pier #5 is scheduled this week. It takes about one week to drill each column hole, build the rebar steel cage insert, and pour the concrete. There is minimal silt and mud on the river floor. A large diameter steel casing will sit on a shoulder 2.5 feet into the bedrock. A drill bit turns inside the steel casing to create a 9 feet wide by 25 feet deep hole into the solid bedrock, which will receive the steel rebar cage and poured concrete, to create the column.
- There has been a recent increase in curious onlookers attempting to enter the work zone on Riverside Drive, both walking and driving. The section of Riverside Drive and the adjoining sidewalks are closed to the public until the project is finished, and no entry from either direction is allowed beyond the barricades and Road Closed signs. The work zone is a very hazardous area and may not be visited by unauthorized individuals. Everyone’s cooperation in the keeping the work zone clear and safe is appreciated.

2/15/19 - After month 6 of the 36 month project:
- Construction continues on six underwater support columns drilled twenty-five feet deep within the bedrock.
- Recall that Piers # 5 and # 4 are located in the river, requiring two columns each. Both underwater columns for Pier # 5 have been poured. One column for Pier # 4 has been poured, and the second is currently being drilled.
- Piers # 3 and # 2 each require one underwater column. These will be located in the river inlet near the concrete walking trail.
- The sanitary sewer line relocation project continues. Delays were recently encountered when a natural gas line was excavated that conflicted with the required sewer line route. Powell-Clinch Utility worked with the bridge contractor for over one week performing the necessary work.

3/21/19 - At month 7 of the 36 month project:
- Drilling for six underwater shafts for bridge pier columns has been completed. Steel reinforced concrete has been poured at each shaft, and the columns must now be tested to ensure that they meet TDOT specifications and that no voids exist.
- Once testing is complete, crews will begin construction to extend the columns upward by building forms and connecting steel reinforcement. Other bridge pier column construction on dry land may now proceed, as well.
- The sanitary sewer line re-location project continues, and is awaiting connection at each end of the job. The water line and natural gas line re-location projects should begin within the next 60 days.

4/17/19 - After month 8 of the 36 month project:
- Crews are building the footings and foundation for Pier # 1 (recall that the bridge consists of 6 piers and 2 abutments, number from north to south). One of the columns for Pier # 1 is located in the parking lot adjacent to Riverside Drive.
- Pier # 1 includes three -6- feet diameter columns of steel reinforced concrete. Columns sit on individual footings. Each footing has forty-two steel beams (pilings spaced 3 feet apart) driven downward until they reach bedrock. Once the three footings are built and the columns are constructed, a steel reinforced concrete cap is built across the top of the three columns. The cap will support nine steel girder beams.
- Pier # 1 is built entirely on dry land. Piers # 2 and 3 each include one underwater column, located in the river inlet beside the concrete walking trail.
- Piers # 4 and 5 sit entirely in the river, just upstream from the two piers that support the existing bridge. Piers # 4 and 5 are each supported by twin underwater support columns. The underwater sections of the new columns are complete and will be connected to and then extended upward.
- Pier # 6, the farthest pier at the south end of the job, is complete and may be viewed for comparison. It is similar in appearance to Pier # 1.

5/20/19 - At month 9 of the 36 month project:
Underground utility relocation:
The sanitary sewer pipe relocation job is complete. Crews are currently working on a natural gas pipe and a water line installation. These should both be completed within 30 days.
Here is the current status of the eight bridge supporting structures:
Abutment # 1 - to begin after u/g utility relocation is complete.
Pier # 1 - one of three columns is under construction (see photos) with the other columns awaiting u/g utility relocation.
Pier # 2 - one of three columns is under construction (underwater) with the other columns awaiting u/g utility relocation.
Pier # 3 - two of three columns are under construction with the third column awaiting u/g utility relocation.
Pier # 4 - two of two underwater column foundations are in place with steel reinforcement being erected to extend upward (see photos).
Pier # 5 - two of two underwater column foundations are in place with steel reinforcement being erected to extend upward.
Pier # 6 - three columns and the cap across them are complete.
Abutment # 2 - should begin within 30-60 days. This one will require the lane closure for one northbound Clinch Avenue traffic lane.

6/17/19 - At month 10 of the 36 month project: 
Underground utility relocation: 
1. The sanitary sewer line and the natural gas line projects are complete. Crews are currently working on finishing the water line portion of the utility relocation (see photo). Once it is complete, construction on the remaining columns for piers # 1, # 2, and # 3 may proceed. 
Traffic Plan: 
1. On Clinch Avenue near Carden Farm Drive, one north bound lane has been closed while work begins on abutment # 2 (see photos). This lane should re-open prior to 2019 fall season school traffic beginning. 
2. On Clinch Avenue near South Seivers Blvd., a portion of the north bound right turn lane storage area has been closed and the other lanes reconfigured (see photo). This change is necessary so work on abutment # 1 may begin. The lane shift will remain in place throughout the remainder of the project.
Abutment # 2 construction:
1. Abutment # 2 construction excavation is underway to prepare a footing (see photo). Twenty-seven steel beam pilings will be driven approximately thirty feet deep (until they reach bedrock) to support the abutment.

7/16/19 - At month 11 of the 36 month project:
Underground utility relocation:
The existing natural gas, sanitary sewer, and water lines that created a conflict with proposed structures have now been replaced and relocated, and the underground utility phase is complete. This has allowed construction on the remaining five columns for piers # 1, # 2, and # 3 to begin (see photos).
Traffic plan:
The northbound lane closure on Clinch Avenue near Carden Farm Drive continues. Crews are working to complete Abutment # 2 within ten days, in hopes of re-opening the lane for upcoming school traffic (see details below).
Abutment # 1 construction:
Abutment # 1 (north end) construction is underway. Approximately one hundred steel beam pilings (twenty-five feet long) are required to be driven, and installation will begin soon.
Abutment # 2 construction:
Work on Abutment # 2 (south end) continues. A steel reinforced concrete foundation has been poured, containing steel beam pilings, installed to stabilize the footing. Additional concrete work to create the wing walls is currently underway (see photos).
Pier # 3 construction:
The attached photos of column # 3 (of 3) for Pier # 3 show a typical footing and foundation for a six feet diameter pier column. Notice that the footing contains thirty steel beam pilings that were driven twenty-five feet deep. The
concrete forms shown measure fifteen feet wide by eighteen feet long. (Recall that eight bridge structures are being built, consisting of two abutments and six piers, numbered north to south).

8/19/19 - At month 12 of the 36 month project:
Traffic plan:
The northbound lane closure on Clinch Avenue near Carden Farm Drive has been removed. Both northbound lanes are now carrying traffic.
Structures:
(Recall that eight bridge structures are being built, consisting of six piers and two abutments, numbered from north to south).
Pier # 1: Photos show the various stages of completion for the three column foundations for Pier # 1. Column #1 foundation is complete, #2 foundation is formed and ready to pour, and #3 foundation has all forty-two steel pilings installed and will be ready for reinforcement steel and concrete forms soon.
Pier # 2 photos show a good representation of how pier columns are built, once a foundation is complete. Of the three columns, one has just been poured, the second has concrete forms installed and is ready to pour, and the third has a steel cage built and is ready for forms to be applied.
Photos of Pier # 3 show that all three concrete columns are complete. Construction of a concrete cap across the top of the columns will begin soon.
Once the caps are built, girder beams will sit on the caps and will extend across the six piers, connecting to the abutments.
Pier # s 4 & 5: Both have underwater foundations complete and are awaiting concrete column forms to be set.
Pier # 6: Complete.
Abutment # 1: Construction beginning soon. Almost 200 steel pilings required.
Abutment # 2: 90% complete.

9/17/19 - At month 13 of the 36 month project:
Structures:
(Recall that eight bridge structures are being built, consisting of six piers and two abutments, numbered from north to south).
1. All concrete columns for the bridge piers have now been poured, and the construction of five steel-reinforced concrete caps across the columns is underway (see photos). This work is very labor intensive and it will take several months for the caps to be completed.
Once the caps are built, girder beams will sit on the caps and will extend across the six piers, connecting them to the abutments.
2. Abutment # 1 - Steel sheet pilings have been installed between the existing northbound traffic lanes and the site of abutment # 1 (see photos). The pilings will support the roadbed and allow both northbound lanes to remain open, while crews excavate the abutment site and begin driving steel pilings for the abutment foundation.

10/23/19 - At month 14 of the 36 month project: 
Structures:
(Recall that eight bridge structures are being built, consisting of six piers and two abutments, numbered from north to south).
Abutment # 1 - Under construction.
Pier # 1 - Columns poured, awaiting cap.
Pier # 2 - Columns poured, awaiting cap.
Pier # 3 - Columns poured, cap built, awaiting concrete cure time (see photo).
Pier # 4 - Columns poured, awaiting cap.
Pier # 5 - Columns poured, cap under construction and will be poured within the next few days (see photos).
Pier # 6 - Complete (see photo).
Abutment # 2 - Complete.
All caps are expected to be complete within the next 90 days.

11/20/19 - At month 15 of the 36 month project: 
Structures:
(Recall that eight bridge structures are being built, consisting of six piers and two abutments, numbered from north to south)
Abutment # 1 - Extensive excavation to prepare the abutment footing is underway (see photos). Soon, steel pilings will be driven to reinforce the concrete foundation.
Pier # 1 - Columns poured, concrete forms are currently being built for the cap.
Pier # 2 - Columns poured, concrete forms for the cap are complete, concrete cap to be poured this week (see photos).
Pier # 3 - Complete.
Pier # 4 - Columns poured, concrete forms are currently being built for the cap.
Pier # 5 - Complete (see photos).
Pier # 6 - Complete.
Abutment # 2 - Complete.
All caps should be complete within the next 60 days. The next phase has nine girder beams extending across the caps.

12/16/19 - At month 16 of the 36 month project:
Crews continue to work on stabilizing a slide that occurred after a heavy rain event, adjacent to the proposed location of abutment # 1. This work requires Clinch Avenue to be narrowed down to only one traffic lane flowing in each direction. We have adjusted our traffic signals to help accommodate the current traffic plan, and we hope to have at least one additional traffic lane available soon. Photos of the stabilization work are attached. Notice the soil anchors (long bolts) that have been drilled through the steel retaining wall
Structures:
(Recall that eight bridge structures are being built, consisting of six piers and two abutments, numbered from north to south).
Abutment # 1 - Construction is on hold while the adjacent slide is stabilized.                    
Pier # 1 - Columns poured, concrete forms are currently being built for the cap.
Pier # 2 - Complete.
Pier # 3 - Complete (see photo).
Pier # 4 - Columns poured, concrete forms are built for the cap, and the cap is to be poured this week (see photo).
Pier # 5 - Complete.
Pier # 6 - Complete.
Abutment # 2 - Complete.

1/21/20 - At month 17 of the 36 month project:
At the previous slide near abutment # 1, three traffic lanes are now in use after crews have stabilized the site. More than fifty soil anchors (each fifty feet long) were horizontally drilled through a steel retaining wall and secured with a concrete grout.
The current traffic plan using one northbound lane and two southbound lanes should remain in place throughout the remainder of the project.
Structures:
(Recall that eight bridge structures are being built, consisting of six piers and two abutments, numbered from north to south).
Abutment # 1 - Excavation is currently in progress. The installation of almost 200 steel beam pilings within the foundation will begin soon.    
Pier # 1 - Cap to be poured this week (see photo)
Pier # 2 - Complete.
Pier # 3 - Complete.
Pier # 4 - Complete.
Pier # 5 - Complete.
Pier # 6 - Complete.
Abutment # 2 - Complete.
Nine girder beams will sit on top of the structures. The longest span (between piers 4 and 5, over the river channel) is approximately 190 feet long. The first shipment of girder beams will arrive within the next few weeks. The beams will be erected starting on the south end of the project.

2/17/20 - At month 18 of the 36 month project:
Structures:
(Recall that eight bridge structures are being built, consisting of six piers and two abutments, numbered from north to south).
Abutment # 1 - Due to the previously reported problems with a slide, additional engineering/design work is required before construction on this abutment may begin. Work should commence within the next 30 days.            
Pier # 1 - Complete.
Pier # 2 - Complete.
Pier # 3 - Complete.
Pier # 4 - Complete.
Pier # 5 - Complete.
Pier # 6 - Complete.
Abutment # 2 - Complete.
Twelve steel girder beams have been delivered (see photos), and their installation is currently underway. The first beams being installed are on the south end of the project, between piers 5 and 6 (see photos).
Each span (the space between two piers) will have nine girder beams sitting on the piers. Installing the girder beams is a very technical and labor intensive operation, and will take several months to complete (the first individual girder beam installed weighed 52,000 pounds).
Once all the girder beams are in place, crews will begin installing bridge decking and reinforcement steel across the girder beams, in preparation for concrete pours.

3/16/20 - At month 19 of the 36 month project:
Girder Beam Installation:
As of March 17, 2020.. eighteen steel girder beams and their cross braces have been installed across piers 5 and 6 (see photos). The project requires forty-five additional steel beams. Girder beam installation will continue for the next several months.
Nine concrete girder beams are to be installed between pier 6 and abutment 2 (the southernmost structures). Two concrete beams were installed on Monday, March 16th. The remaining seven should be delivered and installed this week.
9 more steel beams will be delivered this week and are to be installed across the river channel (between piers 4 and 5) during the week of March 23rd.
Abutment # 1: TDOT Nashville continues with the new design and engineering work for the construction of abutment # 1 (the northernmost structure located at the temporary retaining wall).

4/21/20 - At month 20 of the 36 month project:
Lewallen Bridge construction has continued as an essential transportation project and goes un-interrupted by Covid-19 health concerns.
Girder Beam Installation:
Crews continue making good progress on installing the seventy-two girder beams needed for this project, with more than 60% in place (see girder beam photos).
Structures:
Of the eight bridge structures, seven are complete, and abutment # 1 (the northernmost structure located at the temporary retaining wall) is now under construction, after months of delays. Crews are currently driving steel beam pilings to create a foundation, and will soon be building forms for placing steel reinforced concrete. Once the abutment is complete, nine girder beams will sit on top to connect it to Pier # 1 (see pile-driving photo).

5/11/20 - At month 21 of the 36 month project:
Girder Beam Installation:
Girder beam work continues, and twenty-seven additional beams are arriving this week. Once these are installed, only nine more are needed, and will be set once abutment # 1 is ready.
Structures:
Abutment # 1: Steel beam pilings to create a foundation are now in place and crews are ready to build concrete forms. It will take several weeks to complete the abutment # 1 construction.
Engineering will soon begin to determine the exact elevation of the tops of all the newly installed girder beams. Once these elevations are mapped, plans for the construction of overhangs and decking will be prepared, and installation can begin. Several hundred pieces of galvanized steel deck pan have been delivered and are in storage.

6/23/20 - At month 22 of the 36 month project:
Structures:
Abutment # 1:
After several months of delays, construction will proceed this week on the north abutment. Precast concrete sections will be installed around the existing steel beam pilings to create the structure (as opposed to building forms, pouring concrete, and then removing forms). The use of the precast materials should result in a much faster process.
Girder Beam Installation:
Girder beam installation is complete, except for the last nine beams, which will be set once abutment # 1 is ready. After the abutment is built, installing the final nine beams should take less than one week (see girder beam photos).
Bridge Decking and Overhangs:
Work will begin soon to install the bridge decking. This consists of laying down galvanized steel deck pans across the girder beams, then placing tons of rebar steel across the pans, then pouring concrete in sections. This is a major portion of the project and will take several months to complete.


7/20/20 - At month 23 of the 36 month project:
Structures:
Abutment # 1:
Good progress has been made during the past four weeks. A visiting crew was assigned to this structure alone and they have installed the engineered walls and the compacted crushed stone backfill (see photos). Work will now begin on building forms for a concrete cap, which will be poured across the exposed tops of the steel beam pilings. This cap will bear the weight for the last nine steel girder beams.
Bridge Decking and Overhangs:
Galvanized steel deck pans have been installed across about 65% of the bridge. Crews are building overhangs, using temporary metal brackets that support wooden concrete forms (see photos). The overhangs will support a five-feet wide sidewalk on each side of the bridge, along with a parapet wall with railings. Epoxy coated steel rebar will extend from the main bridge deck onto the overhangs, then concrete will be poured to create a continuous slab.

Recent Inquiries:
Question # 1: What color will the new bridge be painted?
Answer: Unlike the old bridge, the new bridge will not have steel trusses exposed over the road surface, so no protective coating (paint) is required. The driving surface, the sidewalks, and the parapet walls will all have a concrete finish. To commemorate the old bridge color, there will be thirty-eight new decorative styled light fixtures and poles, painted green.

The steel girder support beams will be visible only from beneath the bridge. These steel surfaces are referred to as “weathered steel”, meaning that they are built to oxidize to a pre-determined depth, which will form a protective rust surface coating. This eliminates the need to initially paint them, as well as long-term maintenance requiring paint removal (sandblasting) and then new painting. The only paint protection required on the girder beams will be beneath any expansion joints, where rain water (and road salt) will flow onto the steel.

Question # 2: What will be the name of the new bridge?
Answer: TDOT construction plans show signs to be installed on the new bridge approaches, keeping the same name as the existing bridge: “Hon. William Everett Lewallen Memorial Bridge”, more commonly referred to simply as the “Lewallen Bridge”.


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