Serving as the main connection between I-87 and Ticonderoga in Essex County, NY, the Route 74 Bridge over Eagle Lake was in dire need of replacement.
The nearly 100-year-old culvert presented a unique opportunity to explore innovative construction methods instead of traditional staged construction.
Long-term closure for traditional repair and replacement would have resulted in a detour of over 30 miles. As the route serves as the main connection for commuters, trucking, and local traffic, closure would have imposed a substantial economic burden on the local community.
Instead, Fort Miller’s innovative use of precast concrete bridge components significantly reduced downtime, meeting Accelerated Bridge Construction (ABC) methods as requested by the New York Department of Transportation.
Our project team utilized several methods to limit route closure to one single weekend, preventing undue stress on vehicle traffic patterns while providing a time and cost-saving solution.
Construction Timeline and Process
The project timeline was meticulously planned to ensure completion within a tight schedule:
- January 10: Micropile installation commenced.
- April 3 & 17: Precast abutments set in two phases.
- April 25: Demolition of the north side of the existing deck and abutments.
- Friday, May 5 (6 PM): Existing bridge shut down.
- May 5-8: Removal of the old bridge and installation of new superstructure units over the weekend.
- Monday, May 8 (5 AM): Bridge reopened.
- May 23: Installation of the thin polymer overlay.
Key Challenges and Solutions
The primary challenge was minimizing the impact of the bridge replacement on the local community and economy. Prolonged closure would have disrupted daily commutes and local businesses.
A key factor in completing the bridge replacement within the closure window was our prefabrication process and staging at our plant location 70 miles south of the project site.
Additionally, piles and other substructure components were installed before the closure, with traffic reduced to a single lane regulated by a temporary signal.
Fort Miller’s use of advanced precast technology to deliver precise, high-quality components was instrumental in meeting the tight project timeline.
Precast Abutments
Fort Miller designed and fabricated the precast abutments off-site in a controlled environment, ensuring quality and precision. The use of precast abutments allowed for rapid installation, significantly reducing on-site construction time.
Precast Approach Slabs
The company also supplied precast approach slabs, which form the transition between the bridge deck and the roadway. These slabs were designed to fit perfectly with the prefabricated bridge units, ensuring a smooth and durable connection.
Prefabricated Bridge Units
Perhaps the most crucial contribution was the prefabricated bridge units themselves.
These units were preassembled, including the necessary reinforcements and structural elements, in Fort Miller’s facility. This preassembly meant that the bridge could be erected on-site in a fraction of the time required for traditional construction methods. Each unit was meticulously engineered to meet the project’s specifications, ensuring both strength and longevity.
Project Outcome and Impact
The successful completion of this $2.6 million project within a weekend demonstrated the effectiveness of ABC methods and the strength of the partnerships between all stakeholders. Eagle Lake Bridge was reopened to traffic at 5 AM on May 8, just as planned.
The local community benefited from minimal disruption, preserving economic stability and ensuring continued connectivity.
Collaboration among various stakeholders allowed for the project to remain on schedule and under budget.
- Fort Miller Co., Inc. provided the precast abutments, approach slabs, and prefabricated bridge units, forming the backbone of the new structure.
- STS Steel supplied the structural steel necessary for the prefabricated bridge units.
- JN Giamarino Construction Inc. handled the installation of micropiles, essential for the foundation of the new bridge.
- Rozell Industries, Inc. provided crane services to maneuver heavy components into place.
- Elderlee, Inc. was responsible for the bridge rail and guiderail installations, ensuring safety and compliance.
- Transpo Industries, Inc. supplied the polymer concrete used in the closure pours, providing durability and strength to the new bridge structure.
Conclusion
The Eagle Lake project resolved a critical infrastructure issue as well as set a benchmark for future projects, proving that with the right approach, even the most challenging projects can be completed efficiently and effectively.
Fort Miller’s expertise in precast concrete solutions, dedication to innovation, and commitment to excellence ensured all project timelines and requirements were met. This project received the 2023 Bridge Award from the Eastern New York Chapter of the Association for Bridge Construction and Design (ABCD).
