Overview

A new three-mile long twin bridge, Governor Mario M. Cuomo Bridge (new Tappan Zee Bridge/ New NY Bridge), was the largest design-build project in North America during its recent construction. LiRo provided construction quality control (CQC) services as part of the Tappan Zee Bridge Constructors design-build team (TZC), providing on- and off-site quality control inspection services, including pile foundations, structural steel, concrete, sub and superstructure construction, and civil and geotechnical disciplines. In addition, LiRo developed ITPs (Inspection and Test Plans) and Quality Control Plans for construction activities and managed construction materials documentation. Services also included periodic off-site fabrication facility audits and, in conjunction with subcontractors, specialty testing and inspection services as requested by the client.

About the Project

The bridge structure features 1,200 ft long dual composite cable-stayed main spans, combined with 515 ft long span steel girder back spans. The four main towers are outwardly inclined, and the entire structure is supported on 50 miles of foundation piling, 220,000 cy of concrete and 220 million pounds of U.S. steel. All construction material used and every process employed during installation are in accordance with a 100-year design.

Project Challenges & Solutions

Managing and staffing the largest design-build project in North America with skilled personnel was extremely challenging for the Design Builder. LiRo provided discipline experts and focused the quality control efforts where they were needed most to support the Design Build Team. This included providing welding technical expertise, assisting the Design Builder in managing their labor, subcontractors, and fabricators, as well as trouble shooting and resolving construction and fabrication issues.

Communication is another challenge on a project of this size. LiRo facilitated dialogue and ensured that technical issues were addressed immediately to avoid interruption and avert delays.

The LiRo Group has been an integral part of the Quality Program for the New Tappan Zee Bridge and has been the primary support to the Project Quality Manager.

Outcome

The new bridge is currently in service providing reliable and safe passage as well as increased capacity to the traveling public. Punch-list and close-out activities are ongoing.