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DullesCorridorMetrorailProject Phase1DrilledShaftsCase HistoryPresentation

DFIADSCDRILLEDSHAFTSEMINAR SupportwithConfidence Columbus,OH July1112,2013

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PresentationOverview Thepresentationisanoverviewandcasehistorydiscussionof theDrilledShaftsfortheDullesCorridorMetrorailProject Phase1. Thisprojectincludedtheinstallationof724drilledcaissonsto supporttheelevatedguideways andstationsfortheDulles CorridorMetrorailProjectinFairfaxCounty,VA.Thedrilled caissonsrangeindiameterfrom2to10ft.Brayman ConstructionCorporationwascontractedtofurnishandinstall reinforcingcagesandconcrete,maintaincompletequality controlforallservicesandmaintain/disposeofdrillspoils..

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PresentationOverview(Continued) Thisprojectinvolvedworkingincongestedareasandhad significantenvironmentalcontrolsinplacesoasnottoharm theenvironmentofthearea.AllshaftswereMiniSID inspected forcleanlinessandCSLtestedforconcreteintegrity. Drillingmethodsincludedbothconventionaltemporarycasing anddrillingslurry.Brayman performedeight(8)staticload tests,utilizingOesterberg loadcells,andfive(5)statnamic load testsoverthecourseoftheproject. Brayman completedthescopeofworkwithin18months,six monthsaheadofschedule,workingover120,000manhours withnorecordableincidents.

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PROJECTSTRUCTURE Owner: MetropolitanWashingtonAirportsAuthority(MWAA) DesignBuildContractor: DullesTransitPartners BechtelInfrastucture /URSJointVenture DrilledShaftContractor: Brayman ConstructionCorporation

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DullesMetrorailProjectOverview TheMetropolitanWashingtonAirportsAuthority(MWAA)is constructinga23mileextensionoftheexistingMetrorailsystem, whichwillbeoperatedbytheWashingtonMetropolitanArea TransitAuthority(WMATA)fromEastFallsChurchtoWashington DullesInternationalAirportwesttoAshburn. TheextensionwillserveTysonsCorner,Virginia'slargest employmentcenter,andtheReston/Herndonarea,thestate's secondlargestemploymentconcentration.And,itwillprovidea oneseatridefromDullesInternationalAirporttodowntown Washington.ItwillbecalledtheSilverLine.

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Phase1and2 Theprojectwillinclude11newstations.Itwillbebuiltintwo phases.Phase1willrunfromEastFallsChurchtoWiehle Avenue ontheeasternedgeofReston.Itwillincludefourstationsin TysonsCornerTysonsEast,TysonsCentral123,TysonsCentral7 andTysonsWestandastationatWiehle AvenueinReston. ConstructionbeganinMarchof2009anditwillbecompletedin September2013,thentransferredtoWMATA.Theopeningdate willbescheduledbyWMATAandisanticipatedtotakeplacein late2013.

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Phase2 Phase2willrunfromWiehle AvenuetoAshburnineastern LoudounCounty.ThecontractwasawardedinJune2013forthe extensionthatwillserveRestonTownCenter,Herndon, WashingtonDullesInternationalAirport,Route606andAshburn. TheSilverLinewillprovidehighquality,highcapacitytransit serviceintheDullesCorridor.ThenewMetrorailservicewillhelp mitigatetrafficcongestion,expandthereachoftheexisting regionalrailsystem,offeraviablealternativetoautomobiletravel andsupportfuturetransitorienteddevelopmentalongthe corridor.

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MWAAandthePhase1contractorDullesTransitPartners MWAAandDullesTransitPartnersinMarch2008signedan updated$1.6billionfixedpricecontracttobuildPhase1ofthe project,keepingthecostsoftheprojectto$2.6billion. ThelowbiddesignbuildpriceforoverallPhase2construction wasapproximately$1.8billion.

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Dulles MetroRail Project Fairfax Co., Virginia ($42.7M Original)

No. of Caissons Package A 287 Package B 278 Package C 363 Total 928 Area Size Range 42 - 108 48 - 84 36 - 96 -----Volume Concrete 10,000 cy 12,300 cy 22,000 cy 44,300 cy Weight of Rebar 1,100 ton 1,352 ton 2,411 ton 4,863 ton

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Dulles MetroRail Project Fairfax Co., Virginia ($37.8M Actual)

No. of Caissons Package A 182 Package B 232 Package C 310 Total 724 Area Size Range 42 - 120 38 - 120 24 - 120 -----Volume Concrete 9,854 cy 11,910 cy 19,778 cy 41,542 cy Weight of Rebar 956 ton 953 ton 1,704 ton 3,613 ton

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DRILLED SHAFT TESTING Osterberg Load Cells (6 ea) Statnamic Load Tests (4 ea) Crosshole Sonic Logging (176 ea) Mini-SID all 724 shafts

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DRILLED SHAFT TESTING Osterberg Load Cells

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CROSSHOLE SONIC LOGGING Sample Test Report

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DRILLED SHAFT CONTRACTOR SCOPE OF WORK Drilling & Installation of Drilled Shafts Furnish, Tie & Place Reinforcing Cages Furnish & Place Concrete All required Load Testing Crosshole Sonic Log Testing Site Specific Safety Plan including all certified crane operators & a rigging engineer

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DRILLED SHAFT CONTRACTOR SCOPE OF WORK (cont.) Independent Inspection of Drilled Shaft work. Site Specific Quality Control Plan Survey and Layout of Drilled Shafts Control & Disposal of Drill Spoils Control & Disposal of Water

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Temporary Casing Temporary casing was one method used to maintain open drill holes to allow for the inspection, cage installation and concrete placement.

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Predrilling to set temporary casing in top of drill hole

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Installation of Casing

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Polymer Slurry
Polymer Slurry (CETCO or KB Industries polymers) were also used to maintain open drill excavations. Usually a top casing is set and drilling is advanced as far as practical without the use of the polymer. When caving begins the slurry is added to the bore hole and slurry is circulated from the borehole to tanks to maintain a stable excavation. The slurry is then displaced during concrete placemen and is de-sanded and re-used when practical.

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Drill Rigs
Three things governed the drill rig selection for this project, schedule, depth and diameter. With a significant variety in hole diameters (2 to 10 feet) and with depths ranging from 30 to 85 feet, drill rig options were often limited. BG-24 (Bauer) AF-240 (IMT Kelly Tractor) AF-220 (3 EA) SoilMec 518 Watson 3100 Crawler Mait 130

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Drill Rigs
Typically the larger holes (6 to 10 foot dia) were drilling using either (AF-220, AF-240 or the BG-24). While the smaller diameter shafts were drilled with the smaller/lighter drills such as the Mait 160 and the Mait 130. Schedule and on-site moves also helped in the decision making for drill rig selection. 7-Drill rigs used at one time during the construction of the drilled shafts.

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Reinforcing Cages
On-site & off-site operations were set-up to furnish, tie and handle the steel reinforcing cages.(CMC Rebar/Prince) Lifting & Placement of reinforcing cages required the qualified personnel (CCO, Signalmen & Rigging Engineer) for each pick. Heaviest Cage (w/ rigging) 68,000 lbs.

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Concrete Placement
All drilled shaft concrete was placed through the use of a concrete pump. In all over 41,500 CY of concrete was placed on this project . (DuBrook) Single largest place in a single shaft approached 250 CY. (Approx. 12 hours to place)

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TIGHT ACCESS
The project presented many challenges related to site access constraints. Much of the work was performed in the median of Route 7 & 267. Also, flyovers at I-495 & I-66 had to be managed for sequence and MPT limitation.

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HERES WHAT GOES ON TOP

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Special Thanks to goes out to MWAA and the Dulles Transit Partners for making this all happen and opening up great opportunities for the residents and visitors to the Metropolitan Washington and Northern Virginia area. Also special recognition goes at to all the men and women who delivered a quality project on time, under budget and most of all injury free (over 145,000 manhours!)

QUESTIONS ??

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THANK YOU! Brayman Construction appreciates this opportunity to share our project experience with you.