Route 36 Bridge, New Jersey

SEGMENTS, SPRING 2010, VOL. 55

Segmental construction of the new RT36 eastbound bridge superstructure is completed and open to traffic. New Jersey’s second precast segmental bridge, when fully completed, will serve as a gateway to the shore towns of Highland and Sea Bright in Monmouth County, NJ. The structure crosses the Shrewsbury River and will ultimately replace the functionally obsolete and structurally deficient 75 year-old, double-leaf bascule bridge.

The new 8-span bridge, being constructed by J.H. Reid General Contractor, boasts a modest main span of approximately 232' over the navigational channel and will provide a minimum vertical clearance of 65' above mean high water elevation (Fig. 1 and 2). When completed, the sister bridges (eastbound and westbound) will be approximately 1,611' long with a deck width of approximately 46' each.

J.H. Reid is using a Manitowoc 4100 Ringer Crane to erect the precast girder segments which are being manufactured by Unistress Corporation in addition to precast pier columns. Unistress began casting segments at their Pittsfield, MA production facility in September 2008 with the eastbound pier column segments and completed them in December of the same year. Westbound pier casting began in May 2009 and was completed in December 2009 bringing a close to production of 98 substructure segments required for the project.

Casting of the 384 superstructure segments began in October 2008 and will continue through June 2010. Production of the eastbound superstructure segments were competed August 2009 (Fig. 3). J.H. Reid is currently constructing westbound land piers and has begun driving piles for westbound river piers. Segment erection of the westbound river piers is scheduled to begin mid-March 2010 with superstructure erection following closely behind in April. Superstructure and substructure segment erection will occur concurrently. Anticipated project completion is end of year 2010. Demolition of the existing bridge is also being performed at this time.

DYWIDAG-Systems International U.S.A., Inc. (DSI) is working closely with J.H.Reid to supply post-tensioning material, engineering services and long-term field technical assistance during segment erection and post-tensioning installation (Fig. 4). DSI is supplying over 615 tons of 0.6" diameter strand (120 tons is epoxy coated for use in the precast piers), as well over 163,000 lbs. of 1-3/8" diameter GR150 Threadbar®. The project specification requires the tendons have a substantially high level of corrosion protection and in response to this requirement; DSI is supplying their System 100 Multi-Plane Anchorage System designed for extended service life structures. The multi-strand tendon sizes used on the project are 4-0.6", 12-0.6", 15-0.6", 19-0.6" and 27-0.6".

When completed, the project will include architectural features that will reflect the historic setting and character of the existing bridge, including two monuments located at the bridge abutments. As defined by NJDOT, the new bridge’s historic features include:
• Decorative fish tiles replicated from the existing bridge to be located on the pylons and light pole pilasters.
• A five-bar open steel rectangular railing to enhance the openness of the bridge and provide unobstructed views of the Atlantic Ocean.
• Rustications/reveals in the pier columns and form liners on the waterline footings.

Project Details

State:

New Jersey
 

Designer:

Jacobs Civil Inc.
 

Owner:

New Jersey Department of Transportation
 

Contractor:

J.H. Reid General Contractor
 

Construction Engineer:

 

Construction Engineering Inspection:

GRL Engineers Inc.
 

Formwork for Precast Segments:

 

Post-Tensioning Materials:

 

Bearings:

Seismic Energy Products
 

Epoxy Supplier:

 

Prepackaged Grout:

 

Precast Producer:

 

Bridge Resources