Rt. 8 – New Hartford, NY

Project Details

• Owner: New York State Department of Transportation, Region 2
• Contractor: Vector Construction Corporation
• Engineer of Record: STV, Incorporated
• Completed: 2018

Project Overview

The New York State Department of Transportation (NYSDOT) undertook an accelerated bridge deck replacement on the Route 8 bridge over Genesee Street in New Hartford, NY. 

Traditional staged construction for a bridge of this width could have required multiple phases over 1–2 full construction seasons. Instead, this project leveraged Accelerated Bridge Construction (ABC) techniques to replace the aging bridge deck in a single weekend closure, dramatically reducing the bridge construction schedule compared to conventional methods. 

By using prefabricated components like precast concrete bridge deck panels, the team was able to minimize traffic disruption on this well-traveled route to just 4.5 days, in line with NYSDOT’s “Driver’s First” initiative, prioritizing reduced congestion during construction.

Scope and Details

This project entailed a full replacement of the bridge’s deck and related components using precast elements and fast-track construction methods. All construction activities were compressed into one continuous timeline:

The Route 8 bridge was closed to traffic at 6 PM on a Friday and reopened by approximately 6 AM the following Wednesday, totaling about 95 hours of around-the-clock work. By performing the deck replacement over a weekend, the project avoided disrupting weekday rush-hour traffic, clearly minimizing traffic disruption for commuters. 

To meet this aggressive schedule, all crews and subcontractors were on standby to step in as soon as each preceding task finished. Meticulous coordination ensured that even with small delays or adjustments, the critical work stayed on track to meet the reopening deadline.

Working closely with Fort Miller early in the planning process, the project team was able to front-load production and stage components near the site for just-in-time delivery. Using heavy-duty cranes at multiple positions, crews removed old deck sections and placed each full-depth precast panel onto the bridge girders in a precisely coordinated sequence. 

This approach eliminated the need for on-site concrete curing and allowed all panels to be set in a single day, exemplifying key ABC techniques and maintaining a tight bridge construction schedule.

Impact and Innovation

In the case of Route 8, investing in an accelerated schedule paid clear dividends in public convenience and safety. Much of the effort was front-loaded (design, fabrication, and planning were completed before the road closure), allowing on-site operations to run like clockwork during the brief construction window. 

The accelerated bridge deck replacement approach greatly reduced impacts on the traveling public. What could have been a prolonged, multi-year construction process was instead condensed into a single long-weekend closure. 

From an engineering perspective, the project showcased innovative construction techniques and NYSDOT’s strategic commitment to improving project delivery. Precasting the deck in a controlled plant environment produced high-quality concrete components with low permeability and excellent durability, which will translate into a longer service life and lower maintenance costs for the bridge. 

Additionally, the jointless deck design (integral with the abutments) eliminates expansion joints on the bridge,  improving long-term performance by eliminating hardware that often leaks or fails, an innovative choice that reduces future maintenance and creates a smoother ride for traffic.

The success of this project has validated ABC techniques as a powerful tool in NYSDOT’s arsenal for bridge rehabilitation. The Route 8 bridge was the first accelerated deck replacement of its kind in NYSDOT’s Region 2, and it proved that with careful planning and modern methods, an entire bridge deck can be replaced in a matter of days rather than months. 

This achievement is now serving as a model for future bridge construction schedules aimed at minimizing traffic disruption while delivering high-quality, long-lasting infrastructure improvements.