Padelford Street over Rt. 24

Project Details
Owner: Massachusetts Department of Transportation (MassDOT)
Contractor: MAS Building & Bridge, Inc., WSP
Project Completion: 2014
Scope: 8 PBUs, 46 precast substructure units 

Project Overview

To meet a six-week bridge-closure limitation, the Massachusetts Department of Transportation (MassDOT) utilized performance-based specifications to allow the design-build team more flexibility, innovation, and creativity. This project marked the state’s first use of performance-based specifications, setting a new standard for future infrastructure projects.

Fort Miller played a crucial role by fabricating all the prefabricated bridge units (PBUs) and precast substructure components at our state-of-the-art plant. We also pre-assembled these elements to ensure precise alignment in the field. 

Our ability to deliver high-quality, precast units allowed the design-build team to meet MassDOT’s aggressive schedule without compromising on quality or safety, reducing the roadway closure from two years to just six weeks.

Scope and Details 

The replacement of this key overpass in the town of Berkley, Massachusetts was originally proposed with cast-in-place concrete and steel girders, requiring a projected closure time of two years.

Concerned about the time frame, community and town leaders requested MassDOT investigate alternatives–resulting in an accelerated bridge construction (ABC) solution led by our construction partners, MAS Building & Bridge, Inc. and WSP. 

Fort Miller fabricated a total of 46 substructure units for this project, which helped accelerate the construction timeline while ensuring long-lasting structural integrity. Additionally, eight PBUs were fabricated for this 204-foot-long overpass.

Because the connection of the units relied heavily upon protruding reinforcing and splice sleeves cast at very tight tolerances, the entire bridge was pre-assembled at our Easton, NY plant to ensure proper alignment in the field.

This pre-assembly process allowed us to mitigate potential erection concerns and ensure rapid installation once on location. 

Precast Substructure Features:

• The entire substructure, including pier caps, pier columns, abutment and wingwall stems, footings, and backwalls was composed of precast concrete elements.
• To address potential fit-up conflicts, Fort Miller employed innovative gap-splice details in the PBUs’ closure pours and relied on grouted splice sleeves to streamline the connection of substructure units.
• Using tight tolerances, templating techniques, and preassembly at our plant, we ensured the field installation was smooth and efficient, minimizing disruptions on-site.

Impact and Innovation 

The Padelford Street Bridge replacement highlights Fort Miller’s expertise in delivering high-performance precast substructure solutions for accelerated bridge construction projects. 

By implementing prefabricated components, the project successfully met the community’s demand for an accelerated construction schedule without sacrificing quality or safety.

Our work on this overpass also showcased the flexibility and performance of precast substructure elements, which MassDOT now encourages for similar projects across the state. 

Precision manufacturing, innovative design techniques, and commitment to project success demonstrate why Fort Miller is a trusted partner for infrastructure projects that require speed, efficiency, and durability.