The existing CIP and steel structure of Bridge 00355 in Waterford needed a full depth deck replacement and rehabilitation. Connecticut DOT replaced the existing deck with precast concrete deck slabs manufactured by Coreslab Structures (CONN) Inc.
The project involved superstructure repairs, replacement of the existing two-span deck carrying I-395 over Route 85, as well as other associated rehabilitation work. Precast deck panels were installed and a deck membrane added to prevent water infiltration to the superstructure, followed by an asphalt overlayment and the installation of a precast concrete center median.
The project utilized Accelerated Bridge Construction (ABC) techniques to minimize the impact to the traveling public associated with conventional construction methods. The work required two 10-day traffic diversions of both I-395 and Route 85 during the summer of 2019.
Mohawk Northeast was awarded the $6 million contract and worked with Coreslab Structures on the delivery of the precast deck slabs. The northbound improvements were completed three days ahead of schedule in June.
With more than 50,000 vehicles affected in the area, the state was lucky to have a rare and simple layout for the temporary detour of I-395. Interstate traffic were temporarily detoured on and off of both north- and southbound exit and entrance ramps directly across from each other. Occasionally Mohawk Northeast, the General Contractor, had to temporarily stop traffic on Route 85 while the crane hooked up the precast bridge deck panels and swung them onto the bridge.
The ABC process temporarily inconvenienced travelers, but caused less frustration than the alternative of 12 to 18 months of bridge lane shifts and closures. In total 84 precast concrete slabs were used in the deck replacement and all related construction work was completed by the end of 2019.
The use of ABC with precast, prefabricated systems is growing. In Connecticut and the Northeast it is especially critical to cut construction time from weeks to days. An important benefit is the increased safety of both the travelling public and workers in construction zones. To document the benefits of ABC methods on this project, the CT DOT prepared a video time lapse of the full deck replacement.
For their part in the project, Mohawk Northeast and Coreslab Structures (CONN) were recognized by the Associated Builders & Contractors (CT ABC) with an Award of Merit Infrastructure-Heavy.
Click this link to watch a time lapse video of CT DOT project Full Deck
replacement on Interstate 395 over Route 85 in Waterford CT
Film Produced by Peter Venoutsos of CT DOT