5 minute read

Tappan Zee Constructors, LLC

from NACJ Summer 2021 Magazine

by North American Constructors Journal

from NACJ Summer 2021 Magazine, page 56

Ledcor Group of Companies

Tappan Zee Constructors, LLC: An All-Star Collaboration

Joint venture of Fluor Enterprises, Inc., American Bridge Company, Granite Construction Northeast, Inc., and Traylor Bros, Inc. takes on $3.98bn Tappan Zee Bridge project

Written by Kevin Doyle Produced by Stephen Marino

WWhen taking on the largest bridge construction project in New York State’s history, a consortium of companies was required to execute the $3.98bn Tappan Zee Bridge endeavor.

Tappan Zee Constructors, LLC, a joint venture incorporated in 2012, is made up of Fluor Enterprises, Inc. (30%), American Bridge Company (23.3%),

Granite Construction Northeast,

Inc.(23.3%), and Traylor Bros, Inc. (23.3%). The powerhouse companies combine local, national and international expertise under a single banner and received a notice to proceed in January 2013.

The cable-stayed bridge owned by The New York State Thruway Authority is a Design/Build marvel that has made extensive use of Building Information Modeling (BIM). The 3.1-mile span across the Hudson River is formally named the Governor Mario M. Cuomo Bridge and links Rockland and Westchester counties. It replaces the 61-year-old Governor Malcolm Wilson Tappan Zee Bridge that opened in 1955.

The bridge will have an anticipated lifespan of 100 years and will be fully operational by June 2018. The north span opened to traffic in August 2017 and will eventually carry the northbound and westbound traffic of Routes I-87 and I-287 and incorporates a shared use path for bicycles and pedestrians. Upon completion, the south span will carry the southbound and eastbound traffic of the two highways.

The Collaborators

Fluor Corporation (NYSE: FLR): This global engineering, procurement, fabrication, construction and maintenance giant designs, builds and maintains facilities for clients on six continents. Headquartered in Irving, TX it ranks No. 149 on the Forbes 500 list and had revenue of $19bn in 2016.

American Bridge Company: Based in Coraopolis, PA, American Bridge’s projects include a significant proportion of the world’s large bridges, marine installations, and

cutting-edge construction of complex bridges for more than 60 years, completing more than 135 major bridge projects across the nation. The company manufactures pre-stressed concrete structural elements in its precast yards and has developed some of the most innovative construction techniques in the industry.

All told, the project has utilized more than 1,700 sub-contractors and suppliers while employing more than 7,000 individuals.

Site Safety

other complex structures. It is renowned for its project experience, safety leadership, reputation for integrity and competence, commitment to in-house development of human talent, equipment fleet, and its advanced engineering technology.

Granite Construction Northeast, Inc: This division of California-based Granite Construction operates as a civil contractor and is based in Tarrytown, NY. Its projects include highways and bridges, marine, airports, mass transit, and Design/ Build projects. Granite Construction offers airport construction services in New York and New Jersey.

Traylor Bros. Inc.: The company has self-performed highly technical, When major players join forces on projects of such scope, they bring with them industry standard safety protocols developed and refined through decades of shared experience.

According to a fact sheet posted to the www.newnybridge.com site, TZC workers are required to:

• Wear hard hats at all times in work areas • Wear hearing protection in the vicinity of operations that produce high levels of sound • Wear high-impact safety glasses with rigid side shields at all times • Wear thick work gloves at all times • Wear safety-toed footwear

with ankle support at all times • Wear U.S. Coast Guard approved life vests when working on barges, boats and temporary trestles • Wear water-activated beacons that flash when submerged in water • Carry rust-proof whistles for long-distance emergency warning • Wear high-visibility vests and pants • Wear safety harnesses when working at heights of six feet or more

Project Highlights

The numbers associated with the massive undertaking are staggering – 14 miles of main span cables, 50 miles of foundation piling, 300,000 cubic yards of concrete and 220 million pounds of steel. When completed, the bridge will have eight general traffic lanes, wide shoulders and Emergency/Express bus lanes, and six scenic overlook locations.

To enhance the collaborative effort and facilitate the sharing of information, members of the TZC team and Thruway Authority personnel are working out of the same office.

The bridge’s signature characteristic are its eight main span towers, which were topped off in December 2016. Each stands 419 feet tall, each slopes at a five-degree angle, and each includes internal maintenance

elevators engineered to match the slope. A key component throughout the project has been the use of the I Lift New York super crane, one of the world’s largest. Owned by TZC and officially registered with the Coast Guard as the Left Coast Lifter, the crane sits on a 384-foot marine barge with a 328-foot boom with a lifting capacity of more than 1,900 tons – greater than the combined weight of 12 Statues of Liberty. The crane has allowed TZC to pre-fabricate huge sections of the bridge weighing up to 1,100 tons off site at Coeymans Yard before shipping them downriver for placement. All told, the crane set more than 100 assemblies of steel girders and multiple concrete pier caps. It is also assisting in removal of the existing bridge and the crane’s use throughout the project is estimated to save the state approximately $1bn. TZC has continually monitored environmental impact on the Lower Hudson Valley, placing data stations at each landing on either side of the river and other key locations to gather information on noise, vibration and air quality. Of particular concern is protecting the region’s endangered peregrine falcon population. Once the bridge is completed, more than six million man hours of construction time will have been accumulated.