Wall Township, New Jersey

• High performance concrete bridge decks
• Heavy Highway
• 2 new steel and concrete bridges
• Ramps, pavement, very heavy fills, curbing & sub-drainage structures
• Removal of old roadway and relocation of signs
• Highway lighting
• Traffic control and staged construction

Scope:  During this job two new steel and concrete bridges on spread footings were constructed along Route 138 spanning the North and Southbound Garden State Parkway. This job included the installation and construction of bridge abutments, piers, steel girders, decks, parapets, embankments, ramps, curbing, sub-drainage structures, pavement resurfacing, electrical and ITS conduit systems, highway lighting, beam guide rail, and striping. It also included roadway removal, and relocation of sign structures, as well as the maintenance and protection of traffic. RCC was able to decrease the project schedule through the installation of Tensar walls. By employing this material RCC was able to reduce the number of traffic staging changes the original contract plans required. Once the new bridges were completed, demolition of the four old Route 138 bridges over the Garden State Parkway was done through the use of traffic diversions off of the parkway. The new bridges were constructed with greater span lengths than the old bridges to facilitate future widening and reduce bottlenecks through this busy section of the highway.  Project Start May 2005 completion February 2007. Original Contract Amount: $10,873,893 completed contract amount: $ 10,773,547.

Unique Project Characteristics:  To expedite construction of the concrete bridge decks and reduce down time for curing, we were able to eliminate construction joints and pour each deck continuously form abutment to abutment through the use of a Telebelt 130 Conveyor.  To eliminate deflection issues, each deck pour had to be completed in less than four hours.  In the original contract drawings, demolition of the existing Route 138 Westbound bridge superstructures was depicted using panelization and crane picking methods.  With top-heavy abutments and very limited nightly working hours, we were concerned about the safety and efficiency of this method.  Instead, demolition was proposed using hydraulic hammers and breakers.  To ensure the safety of the traveling public, the top-heavy abutments were secured using a tie-rod anchor system.  Rather than performing work during the allowable four to six hour nightly work windows, each of the superstructures was removed during one twelve hour overnight weekend shift with Parkway traffic diverted around the work areas.