Mr. Pozotrigo was a Resident Engineer for a highly complex project that included the demolition of the middle deck section of a three-deck structure under live traffic. It was scheduled to be completed in nine stages, including construction of a temporary outboard detour road (ODR) in the East River.
The ODR included the installation of large drilled caissons with temporary casing tubes, pile cap girders, four million pounds of structural steel frame, one kilometer of precast concrete deck slab, new parapet walls, asphalt overlay, a noise shield for the adjacent residents, lighting, and the modification of two entrance ramps. In addition, the ODR required the installation of a tubular fender system that was built for the first time in the USA. It consisted of a one-kilometer-long tubing structure, 11 feet in diameter. The system was held by 13 floating dolphins anchored to the river bottom by a system of large iron chains for flexibility to the fender in case of a collision. On completion of the ODR, northbound traffic was transferred to the new structure during one weekend stage.
This complex undertaking required complete closure of the FDR with extensive coordination with all city agencies. This was completed in record time and received the praise of NYSDOT for execution, timing, and savings to NYC motorists. The demolition of the main structure on the FDR called for construction of a protection shield made of 3.5 million pounds of steel that also served as a support mechanism for the various structures built on top of the FDR, including the southbound traffic, the roof structure of the FDR, and several buildings erected directly on top of the FDR Drive.
The rehabilitation of the main structure (southbound) consisted of demolition of the 27-inch concrete deck slab sandwiched between live traffic underneath and the building structures on top. The entire structure underwent extensive seismic retrofit. Special features included the installation of moment connection plates with full penetration welds, strengthening of columns with additional plates and bolts, and wrapping existing columns and girders with reinforced fiber polymer and cement lining. Construction experience gained on this project included deep foundations; structural steel erection; drilled shafts; footings; reinforcing steel; and concrete work. Construction cost: $147 million
