Precast Concrete Bridge Construction Projects

Design and fabrication of various types of bridge elements. These include precast box and arch culverts, abutment walls and foundations, wing walls and parapets. Unique solutions are also designed the incorporate a blend of engineering and production techniques.

Review the example projects listed below:

Oldmans Creek Road Bridge Reconstruction

Route 206 Crusers Brook Bridge

oldmans-culvert-being-rolled-to-orient-for-installation
oldmans-culvert-being-rolled-to-orient-for-installation

press to zoom
oldmans-culvert-headwall-section-being-installed
oldmans-culvert-headwall-section-being-installed

press to zoom
oldmans-bridge-2
oldmans-bridge-2

press to zoom
oldmans-culvert-being-rolled-to-orient-for-installation
oldmans-culvert-being-rolled-to-orient-for-installation

press to zoom
1/7

Oldmans Creek Road Bridge Reconstruction

Garden State Precast Project #:# 19-48967

Project Name: BRIDGE 5-B-5 RECON - OLDMANS CREEK RD

Location:: Woolwich Township, NJ

Project start date: September 17, 2019

Project end date: May 2020

Synopsis of Development:

Design, and fabrication of a modified arch bridge in (6) sections. Design and fabrication of matching precast headwalls (2) and wing wall sections (11).

Technical challenges and project constraints:

  • Match existing HEC 3 design cross section

  • Design modified bin wall/deadmen wing wall anchors

  • Design and outsource fabrication of specialty formwork

  • Overhead electrical wires reduced available area for crane set up, section weight was restricted

  • Development of shipping, rigging and handling for odd shaped units.

Fabrication and Testing Activities:

  • Development of Safety protocol for wing wall fabrication with new bin wall/deadmen anchors

  • Development of supports for bin wall/deadmen anchors

  • Test fitting of all sections in yard prior to shipment

  • Change in fabrication due to Covid-19 pandemic.

  • Modeling bin wall/deadmen anchor system for use on projects on a national level.

Fabrication

  • Production commenced on 3-5-20 and completed on 4-27-20

 
bridge-4
bridge-4

press to zoom
bridge-3
bridge-3

press to zoom
bridge-1
bridge-1

press to zoom
bridge-4
bridge-4

press to zoom
1/4

Crusers Brook Bridge Project

Garden State Precast Project #: 17-42643

Project Name: NJ ROUTE 206 CRUSERS BROOK BRIDGE DP 17102

Location: HILLSBOROUGH TWP NJ

Project start date: NOVEMBER 2018

Project end date: SPRING 2019

Synopsis of Development:

This is a design-build project that Garden State Precast participated in during a four-year period. The project consisted of twenty-four, large, three-sided frames in a dual run configuration. GSP was involved in the design, production and shipment of the units.

Design Challenges and Project Constraints:

This project was designed and deployed over a four-year period. Challenges included project geometry, barrier HL4 ratings, phase construction, special high-strength concrete, shipment to project site, rigging and handling for a 90 degree roll from form to shipment then another 90 degree roll from shipment to installation. All units also required manufacturing on a 30 degree skew.

Fabrication and Testing Activities:

  • Design, purchase of specific formwork, and production of (24) 33’ x 11’-2 frames

  • Validation on NJDOT Class P2 concrete – 6500 psi.