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Coatings Group
existence
Monitor
Be adaptable
Learn
Three Authorities
A - Toll Authority 1 Major structures only (9 facilities 26M square feet) Metropolitan area 100% self funded B - Toll Authority 2
Major highway (hundreds of bridges focus on 16) Urban / Metropolitan / Rural Combination funding
C - State DOT District Over 1,000 bridges (focus on overpasses) Metropolitan and Suburban area Federal / state funding
Reduce lead paint liabilities Reduce as-needed steel repairs Improve bridge appearance Define needed funding
1993 Categorizes bridge areas based on paint conditions and local environments Appropriate painting is performed in each area to minimize costs
Access costs very high = minimal contracts One contract multiple Items multiple methods
maintaining budget goals Coordinate with Capital improvement projects and biennial inspections Address highest priorities within 12 years
30%
Original Program Goal (10% by 2006)
20%
20%Deterioration Line
10%
<10% = Optimum Coating Maintenance
0% 1994
1995
1996
1997
1998
1999
2000 Year
2001
2002
2003
2004
2005
2006
50% 45% 40% 35% 30% 25% 20% 15% 10% 5% 0% 1 2 1995-1996 3 1997-1998 4 1999-2000 5 2001-2002 6 2003-2004 7 2005-2006 8 2007-2008 9 2009-2010 10 20%Deterioration Line Line representing the original program goal (10% by 2006) Trend line of actual results to date Predicted trend without program (44% by 2006) Triangles represent percentage of bridge area requiring paint repair based on biennial inspection data.
<10% = Practical goal for 12-year program 2% = Optimal / Ideal level of paint deterioration
Biennial Cycle
$24,000 $22,000 $20,000 $18,000 $ in thousands $16,000 $14,000 $12,000 $10,000 $8,000 $6,000 $4,000 $2,000 $1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006
SF in thousands
Year
2001
2002
2003
2004
2005
2006
Concurrent with some maintenance Aesthetic areas Hold until re-paint Combination / Rehabilitation Projects
Difficult projects? Some shared costs Some additional costs Maximize shop painting
population
Toll Authority - B
Program recently enacted to prioritize painting
of major structures Not an authority-wide plan (16 of several hundred structures, but the most significant 16) Works around/with major capital programs Coordination with other maintenance work Constructability a key factor
coordination, conditions Generate project specific engineers estimates for near-term painting costs
thickness, lab tests, visual survey data for paint (peeling and corrosion) Development of square footage quantities Other considerations - Deck and Joint condition, planned rehabilitations and prior painting work
evening out the workload across the program duration Coordination with other work Use of the deck condition study data, coordination with completed deck/rehabilitation projects and the capital improvement projects Prioritization factors
Condition of the existing coatings and extent of corrosion Condition of the existing deck Availability of construction staging areas Complexity of maintenance and protection of traffic Complexity of containment Environmental impacts Outside agency coordination
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Bridge ID GSP 28.0N GSP 28.0S GSP 31.0 GSP 49.0 GSP 51.9 GSP 127.2T GSP 127.2S GSP 158.2 NJT P0.00 NJT 84.24N NJT 84.24S NJT E107.88 NJT W107.87 NJT E109.83 NJT N2.01 NJT W115.36 maximum ratings
RATING
10 6 8 4 4 2 4 4 4 6 4 4
2 2 5 3 3 3 1 1 4 5 5 1
5 5 3 5 3 5 2 1 5 5 3 0
4 4 4 4 3 4 3 1 4 4 4 3
3 3 3 3 3 5 3 5 3 5 3 3
24 20 23 19 16 19 13 12 20 25 19 11
10
10
35
appropriately prioritized / sequenced Highest 2 priorities under design /construction Update survey needed
Project was a snapshot of conditions combined with other available data to make the most appropriate prioritization today Future survey will justify extending durations before painting or accelerating certain projects
budget Technical data / conditions were not always the priority driver Program is based on a snapshot survey of facilities Follow-up survey will be needed
Authority C
State Department of Transportation District 1998 project Over 1,000 bridges Majority are highway overpasses and smaller structures Semi Automated database system Used condition data, constraints, project-
environments defines degradation rates Survey characterizes exposure conditions and technical paint data Lowest cost painting option is selected using an ROI calculation
Gain from Investment - Cost of Investment ROI = Cost of Investment
Current coatings and corrosion condition ratings Exposure environment ratings Predicted life to next painting event
Cost
0.1%
1.0%
10.0% % Corrosion
100.0%
Cost
0.1%
1.0% % Corrosion
10.0%
100.0%
sorted by ROI DOT organizes projects to address priorities (human factor is required) Condition data easily attained Degradation models and cost factors were fixed Constraints were variable Does not estimate budgets
Common Threads
All prioritization programs were custom Authority constraints were custom All used existing data sources with
enhancements All need maintenance to remain accurate All provide a starting point for defendable analysis
Feedback is Needed
Programs are tools use for designated
Design
Monitor
Learn
Using Feedback
Painting Program
Square Feet per Year (actual + forecast) 2,400.000 2,200.000
Square Feet of Painting per Year (thousands)
2,000.000 1,800.000 1,600.000 1,400.000 1,200.000 1,000.000 800.000 600.000 400.000 200.000 19 92 19 94 19 96 20 00 20 02 20 04 20 06 20 08 20 10 20 12 20 14
20 16
20 20
20 22
Years
20 24
19 98
20 18
A
Justified the level of effort to secure funding Initial survey with biennial updates Living history of project data used in budget updates
Budget was pre- Program fit determined priorities to variable funds Initial survey, one planned update Engineer estimates as project schedules advance Initial survey with Authority / consultant updates N/A - program ranks need, Authority builds and estimates projects
% of Construction
10.0%
1.0% 0.4% 0.2% 0.1% Toll Authority A Toll Authority B Authority Authority C 0.2%
Planning a Project
Conclusions
Maintenance painting is needed All painting can be scheduled with the most
benefit (least cost) by evaluating structures and implementing a maintenance painting program Numerous constraints affect a program
Other work Cost trends Priorities / Goals
activities