Project Overview
The Vermont Agency of Transportation (VTrans) initiated the US Route 2 bridge deck replacement project in North Hero, Vermont, to address deteriorating infrastructure while minimizing disruption to the traveling public. The scope of work included replacing the existing bridge deck, performing miscellaneous repairs to the steel superstructure, and completing related approach roadway work. Given the importance of US Route 2 as a major corridor for both local and regional traffic, the need for a fast and reliable construction method was paramount.
The primary goal of the project was to replace the aging deck quickly and efficiently while maintaining the highest level of quality. Minimizing the impact on traffic was a key concern, especially given the location of the bridge in a highly trafficked area. VTrans sought a construction method that would reduce project duration, improve safety during construction, and ensure long-term durability - all while staying within budget. To meet these goals, the project team selected a precast concrete solution utilizing the AccelBridge™ Precast Deck Panel System. This innovative system allowed the team to execute a highly coordinated and accelerated bridge construction schedule that delivered on all key project metrics.
Precast Solution
The AccelBridge™ Precast Deck Panel System is comprised of 126 (26,000 SF) precisely fabricated precast deck panels. Fort Miller Precast served as the precast concrete producer, manufacturing all panels in an environmentally controlled facility under the strict oversight of both VAOT representatives and internal quality assurance personnel. This ensured each panel met the highest quality standards and exacting tolerances necessary for the AccelBridge systems' optimal performance.
The designer chose a precast deck replacement to significantly accelerate the project timeline and minimize disruptions to the travelling public. Unlike traditional cast-in-place construction, the precast deck solution allowed the entire project to be completed within a single construction season. Construction was divided into two phases, each lasting three months from deck demolition to completion, enabling alternating traffic flow, maintaining continuous public access. Utilizing the existing steel girders, the project team was able to install the precast deck panel system in just 8 days during Phase I and 6 days during Phase II with minimal closure pours required.
One of the defining benefits of the AccelBridge™ system is its exceptional combination of speed and durability. The match-cast panels are designed for quick and accurate installation while also eliminating the need for cast-in-place joints between each panel. This system is compressed upon installation by the chosen girder system which increases durability, reduces the likelihood of cracking, and extends the service life of the bridge - all without the need for post-tensioning or reinforcement crossing the joints.
The match-casting process used by Fort Miller Precast ensures tight, accurate joints between panels, which is critical when introducing compression during installation. This precision manufacturing leads to a more durable deck and reduces future maintenance needs and costs. This process provides tighter tolerances over traditionally cast panels and eliminates the complexity and costs associated with UHPC or post-tensioned deck solutions, offering a more cost-effective and time-efficient solution.
VTrans had previously utilized Fort Miller's AccelBridge™ system in 2019 for the successful replacement of four I-89 bridges in Colchester. Drawing on that experience, the agency once again saw the advantages of choosing a proven system with reliable results. On the US Route 2 project, the team completed the deck replacement within the planned schedule and budget, all while keeping traffic disruptions to a minimum.
The engineer of record acknowledged the cost benefits of rapid installation and reduced material costs, while also recognizing the positive impact of compression on the deck's durability.
The use of precast concrete in this project significantly accelerated the construction timeline while enhancing the long-term durability and performance of the bridge. By integrating the AccelBridge™ system, the project team was able to replace the bridge deck with remarkable speed - without sacrificing quality or longevity. The advanced accelerated bridge deck construction techniques utilized in this project demonstrate the transformative power of modern infrastructure solutions, proving that rapid installation does not come at the cost of structural integrity or future performance.
Recipient of the 2025 PCINE Showcase Award
This project not only met the objectives set forth by the Vermont Agency of Transportation but also earned a 2025 PCI Northeast Showcase Award for Best in Precast - Transportation, a testament to the exceptional performance and innovation of Fort Miller Precast in utilizing precast concrete to deliver a high-quality, accelerated bridge replacement.
Receiving the PCI Northeast Showcase Award highlights the project's innovative approach and its significant impact on regional infrastructure. By incorporating advanced construction techniques and harnessing the advantages of precast concrete, this project has redefined the standards for bridge replacement projects. |