Proj Overview

PROJECT OVERVIEW

West Virginia Parkway Authority project BDR-3-24 replaced the north and southbound bridge decks over Cabin Creek Road, Cabin Creek, and a CSX Railroad utilizing precast deck panels with Accelerated Bridge Construction (ABC) techniques. This project was part of the West Virginia Parkways Authority’s ongoing effort to replace the 116 bridge decks on the Parkway’s nearly 40-year-old bridge infrastructure in a safe and efficient way before the bridge deck deterioration reached a critical stage.

PRECAST SOLUTION

The HNTB designed project replaced 4 spans and over 56,500 SF of bridge deck using ABC construction. The contractor was Orders Construction Company and the precast deck panels were produced by PennStress, a PCI certified manufacturer. The existing bridge decks on the steel beams were removed, the beams prepared, and new precast bridge deck panels were set in place with UHPC being used to connect the superstructure system. The existing bridges were built on a radius with significant cross slopes and elevation changes, which added complexities to each piece of precast. PennStress utilized 3D modeling software, TEKLA to ensure coordinated piece geometry, shear pockets, projection steel, leveling assemblies, headed studs, consideration of existing conditions and to eliminate precast to precast interference for a complete bridge deck system.

Using HNTB’s design, the contractor developed their plan to execute the deck replacement project. Traffic was diverted and the bridge decks were efficiently replaced during reduced traffic flow periods. This minimized the disruptions to the traveling public and completed the work prior to winter conditions. PennStress produced the deck panels in accordance with the DOT tolerances within a climate-controlled manufacturing facility. Each piece was reviewed by internal PCI certified quality control professionals and DOT third party quality assurance. The 3D modeling, manufacturing conditions, quality assurance, and casting well in advance of needing the precast pieces on site helped reduce the risk of the project.

The traveling public and Orders Construction Company benefited by being separated from the construction workers’ area, the reduced traffic zone duration and a long-term improvement to these structures on the West Virigina Parkway Authority’s infrastructure.

 

Project Team

Owner

West Virginia Parkways Authority

PCI-Certified Precast Producer

PennStress

Engineer-of-Record

HNTB Corporation

General Contractor 

Orders Construction Company, Inc.

Photo Credit

Andy Ryan

Key Project Attributes

  • West Virigina Parkways Authority commitment to planning for upgrades as part of their long-term bridge deck replacement program.
  •  HNTB’s robust design included ABC techniques that allowed the contractor to safely separate their workers from the traveling public while efficiently completing the project for minimal disruptions to the public.
  • Precast deck panels are adaptable to meet existing site layouts and needs.
  • Coordination between the owner, design engineer, contractor, and precast manufacturer allowed for successful ABC projects.
  • Ultra-high-performance concrete joints and precast concrete resulted in a durable riding surface built for decades of service.

Project/Precast Scope

  • Installed during designated windows between Labor Day and winter, these panels replaced deteriorating decks on both northbound and southbound spans over Cabin Creek.
  • As part of a long-term bridge deck replacement program, these precast components helped forestall reactive maintenance and avoided the pitfalls of aging infrastructure buildup.
  • 4 Spans and 56,000+ square feet of precast concrete.