I-80 North Fork Bridge

Pennsylvania Bridges P3 Project Will Improve Multiple Structures and Safety at a Key I-80 Location

Project Highlights

• Main features are replacement of dual four-span continuous composite weathering steel plate girder structures with spans totaling over 1,100 lf
• Replacement of dual single-span bridges over Jenks Street
• Replacement of two current bridges over Richardsville Road with a single structure
• Replacement of approximately two miles of I-80 roadway
• Realignment of approach to the eastbound bridge to run parallel to the westbound bridge to address a substandard curve for improved safety
• 24,000 cy of ready-mix concrete
• 4.6 million lbs of reinforcement steel
• 4,800 lf of H-pile
• Extension of three culverts, including the North Fork Park Culvert, which carries I-80 traffic over the tributary to North Fork Redbank Creek
• Demolish the existing five structures
• Follow time-of-year restrictions to protect stocked trout in North Fork Redbank Creek

Fay, S&B USA Construction (Fay) is acting as a subcontractor to Bridging Pennsylvania Constructors (BPC), a joint venture between S&B USA Construction and FCC Construction on the I-80 North Fork Bridges project. This project is one part of the PennDOT Major Bridge P3, a megaproject to address interstate highway infrastructure in critical need of replacement across the Commonwealth of Pennsylvania. BPC is the general contractor for the entirety of this project.

The mainline I-80 North Fork Bridges are dual structures (one eastbound and one westbound) most recently rehabilitated in 2013. They cross over North Fork Redbank Creek and Water Plant Road in Brookville Borough and Pine Creek Township in Jefferson County. Two additional pairs of nearby smaller bridges also carry I-80 over local roads. Combined, these bridges are expected to carry annual daily traffic of approximately 31,000 vehicles by 2026, of which approximately 44 percent is truck traffic.

 

Challenge

According to PennDOT, both North Fork bridges have problematic fatigue details, which have received multiple retrofits during the structure’s service lives. The main spans of the existing bridges are steel two-girder systems with floor beams and stringers. Both bridges are reaching the end of their serviceable lifespan. The current bridges are separated by approximately 1,100 ft, with a public park located between and below the two bridges.

The purpose of the project is to provide safe, efficient and effective crossings of I-80 over North Fork Redbank Creek and Water Plant Road that appropriately accommodates interstate traffic with respect to connectivity, mobility, loading and geometry.

 

Solutions

Working with BPC, Fay is realigning and reconstructing approximately two miles of roadway and five bridge structures. In a key goal, this project will minimize the distance between the I-80 North Fork Bridges over North Fork Redbank Creek and Water Plant Road with spans totaling over 1,100 ft in length by eliminating a curve on the eastbound bridge and realigning the bridges to run parallel. These structures are dual four-span continuous composite weathering steel plate girder structures with spans totaling over 1,100 ft in length.

Fay will also construct two bridges to carry I-80 over Jenks Street and replace two existing I-80 structures over Richardsville Road with a single structure spanning both eastbound and westbound lanes. Fay added temporary pavement to widen the inside of I-80 eastbound and westbound lanes to enable the I-80 bridges over Jenks Street to occur in two phases while maintaining two travel lanes in each direction.

Additional work will include extending three culverts, including the North Fork Park Culvert, which carries I-80 traffic over the tributary to North Fork Redbank Creek. Activities including steel erection for the new structures and demolition of the existing bridges will be performed from temporary causeways in North Fork Redbank Creek. Because this is a stocked trout creek annually protected from Feb. 15 until June 1, all work in the waterways will be scheduled prior to or after this restriction period.

Construction

The North Fork project consists of four overall phases:

In Pre-Phase 1, Fay is widening the temporary median on the west side of the project and shifting traffic. Once traffic is shifted into the temporary median, the outside portions of the existing I-80 structures over Jenks St. will be demolished, which will be closed for approximately 18 months while Fay builds the new structures. Temporary earthwork and widening on the east side of the project are also being performed as part of this phase.

During Phase 1, Fay will begin constructing the outside portions of the I-80 structures over Jenks St. and the mainline new I-80 eastbound bridge. Additional temporary earthwork will be performed, and the outside shoulders of both eastbound and westbound lanes on the west side of the project.

Fay will also begin building the temporary westbound road that will be used in conjunction with the final mainline I-80 eastbound structure as a temporary traffic configuration while the existing westbound is under construction in Phase 2. At the end of Phase 1, Fay will switch westbound traffic to the temporary roadway.

In Phase 2, Fay will perform a full-depth reconstruction of the existing westbound roadway, demolish the existing I-80 westbound bridge, construct the new I-80 westbound bridge, and construct the new I-80 eastbound roadway. After all this work is completed, the westbound and eastbound traffic will be redirected onto its permanent configuration.

In Phase 3, Fay will finish the project by demolishing the original I-80 eastbound bridge, demo the existing I-80 eastbound pavement, and restore the pavement area to return to the original private owners.

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