The process of a bridge repair

U.S. 81 over Kyle Railroad in Ottawa County is in the process of being repaired.
The project is expected to wrap up next spring. 

By Ashley Tammen

North Central Kansas Public Affairs Manager

We often receive comments and questions about how long it takes to repair bridges. To properly explain the repair process, we must explain what makes up a bridge.

Bridges are composed of three basic elements: the foundation, the substructure that holds up the bridge deck and the superstructure or bridge deck. The superstructure is made up of several layers of reinforced steel with steel girders throughout. Bridge repairs can encompass repairing one of those elements or even up to all three — including the concrete surface and guardrails can break down over time.

One example of a bridge repair is on U.S. 81 over Kyle Railroad in Ottawa County. The superstructure needs repaired due to the wear and tear of concrete.

“Where there is damage on the bottom side of a bridge, you risk moisture coming in underneath. When maintenance staff goes to patch potholes on top, it doesn’t last long due to the moisture and the movement of the bridge,” said Phillip Nelson, Engineering Technician Senior in Salina. 

There are several steps that must be taken so the bridge deck can be replaced, which occur in multiple phases.

During the first phase, two temporary median crossovers are installed with drainage structures and inside shoulders so traffic can be rerouted to the opposite bridge while one bridge is being repaired.

Next, the existing U.S. 81 bridge will get an temporary asphalt overlay to help prevent damage while the two-way traffic is driving on the bridge and temporary guardrails will be installed.

During phase two, traffic will be reduced to one lane and temporarily detoured to the southbound U.S 81 bridge using both crossovers. Once traffic has been rerouted off the bridge under construction, the contractor will remove all the old concrete leaving only the steel girders.

The steel girders will then be repainted, and new concrete will be replaced above them. After repairing the bridge, permanent guardrails will be installed on the south ends with temporary guardrails on the north ends for two-way traffic.

Finally, during the last phase, traffic will be moved over to the newly-repaired south bridge using median crossovers. Once traffic has been rerouted, the last bridge will get repaired. 

The last step is to repaint the stripes on the repaired bridge, and U.S. 81 will be open for traffic. It is expected to be completed next spring.

We urge all motorists to slow down in work zones and give our crews room to work. 

Hot News: Damaged steel bridge girders can be repaired

By Tom Hein, Wichita Public Affairs Manager

In December 2018, a large load struck the underside of a KDOT bridge on K-96 near Maize.

 Extensive damage to steel girders was obvious but the distortions were deemed repairable.

In December 2018, damage to the underside of a bridge on K-96 near Maize occurred.  

In January, a contractor was hired to use a heat straightening process to repair the damaged girders. Steel has a memory and generally wants to go back to its original shape. 

Contractors were hired to repair the underside of the bridge by using a heat straightening process. 

By heating in the right place and at the right temperature, as the steel cools from brief heating process, the metal shrinks and pushes back to its original shape.

Along with using the heat straightening process, other tools like clamps and hydraulic jacks are used to fix the bridge. 

Besides judiciously placed heatings, clamps and hydraulic jacks are used to help influence the return of the steel to its former shape.

The bridge on K-96 is now repaired. 

After seven days of the heat straightening process, the bridge damage has been reversed. 

In a 2008 report, The Federal Highway Administration cited that heat straightening can be traced to the early days of welding. Experiments to reverse distortions by heating steel in specific patterns were successful. Originally considered more art form than a scientific process, the techniques eventually generated wide-spread acceptance through engineering evaluation and research. Today, heat straightening is considered an accepted science and will continue to be used when necessary.

Work Zone Wednesday: Multi-phase bridge project along I-70

Work continues on the multi-phase bridge project along I-70 in Ellis County. The project is expected to be completely finished in December, weather permitting. 

Work is progressing on a multi-phase bridge project along I-70 in eastern Ellis County.

Both the east and westbound bridges carrying I-70 over Old Highway 40 and the Union Pacific railroad near Walker have undergone major renovations. The project started in fall 2016 with the installation of temporary crossovers in preparation for the bridge deck replacements and concrete patching and overlays that have taken place this spring and summer.

The eastbound portion was completed at the end of July and work is currently taking place on the westbound structures. Work is expected to be finished by the end of October. The temporary crossovers will then be removed and the project completely finished in December.

Bridges Inc. of Newton is the primary contractor with a total project cost of approximately $2 million.

Work Zone Wednesday: Bridge Repairs on K-196 in Butler County

Work is underway on K-196 to upgrade and replace bridges in Butler County. 

On Feb. 27, the Kansas Department of Transportation began to upgrade/replace Dry Creek Bridge, Whitewater River Bridge and Diamond Creek on K-196 in Butler County. The bridges are located between Northwest Diamond Road/K-196 Intersection and Northwest Tawakoni Road/K-196 Intersection between the City of Potwin and the City of Whitewater.

All three original bridges have been torn down and pouring of the bridge deck for the eastern bridge began last week. 

 

Currently, all three original bridges have been torn down and removed. Project grading and seeding has been completed on each of the bridges and crews are focusing construction efforts from the east bridge to the western bridges. Pouring of the bridge deck for the eastern bridge began last week. On the western bridges, the contractor is driving piles and working on pier construction. Despite the early spring rains, the bridge replacement project is still scheduled to be completed and reopen the highway to unrestricted traffic by late November 2017, depending on delays due to adverse weather conditions.

The bridge replacement project is expected to be be completed and reopen to traffic by late November 2017.

 Until the highway is reopened, through traffic will continued to be affected by the bridge replacement project with the closure of K-196 and will be routed on an official state detour which will direct traffic through K-254 to I-135 instead of K-196.

King Construction Company from Hesston is the prime contractor for this $2,726,000 project, which is funded by T-WORKS, the transportation program passed by the Kansas Legislature.

U.S. 83 Bridge repair let

KDOT’s November letting included 24 projects across the state totaling approximately $24.6 million.

One of the projects will repair the U.S. 83 bridge located at the I-70/U.S. 83 junction in Thomas County. The repairs consist of removal of concrete and deck patching, followed by placement of a new concrete overlay and railing. Plans also include installation of galvanic nodes, which will help protect the reinforcing steel from corrosion.

To see all of the projects in the November letting, click here.