Jose Rodriguez, FIGG Engineering Group and Harry A. Capers, Jr., New Jersey Department of Transportation
The new Victory Bridge on State Route 35, across the Raritan River between Perth Amboy and Sayreville, is New Jersey’s first segmental concrete box girder bridge. The bridge consists of twin parallel structures with a main span of 440 ft (134 m) — a U. S. record for fully match-cast segments, two side spans of 330 ft (101 m) each, and approach spans that vary in length from 142 to 150 ft (43 to 46 m). The main span and side spans were erected using the balanced cantilever construction method. Concurrently, the approach spans were erected using the span-by-span method. This allowed delivery of the completed bridge on an expedited schedule.
The first 3,971-ft (1.21-km) long structure was opened to traffic in June 2004, just 15 months after notice to proceed was received. The second structure was erected nine months later and opened to traffic in September 2005 — more than two months ahead of schedule.
Superstructure
The concrete segments were cast in Virginia and barged to the site for erection. Typical superstructure precast concrete segments are 9 ft 4 in. (2.84 m) long. This length was chosen to allow for ease in transportation and erection operations. Pier segments were cast in halves, each weighing 115 tons (104 metric tons), so that the same equipment could be used in the erection process. High performance 8,000 psi (55 MPa) compressive strength concrete was utilized for the superstructure segments. The segments include an additional 13/4 in. (44 mm) of concrete integral to the slab, consisting of 1¼ in. (32 mm) for a durable wearing surface and ½ in. (13 mm) for milling to meet the rideability criteria. A final profilograph measurement of 3.47 in. per mile (55 mm per km) exceeded the owner’s request of a 6 in. (95 mm) value and provides an extremely smooth riding surface. With an integral wearing surface, construction of a second course was not required; thereby shortening the construction schedule.
Substructure
The concrete substructure consists of 22 piers and two abutments for each of the twin structures. Piers in the river have foundations consisting of footings supported on drilled shafts, while those on land have rectangular footings on steel pipe piles.
The piers were constructed from precast concrete box sections. The approach pier sections are 8 by 16 ft (2.4 by 4.9 m) and weigh about 28 tons (25 metric tons) each, while the pier sections for the main span are 9 by 16 ft (2.7 by 4.9 m) with thicker walls that resulted in weights up to 32 tons (29 metric tons) each. Overall, the piers range in height from about 21 to 101 ft (6.2 to 30.8 m). Through careful scheduling and coordination, even the tallest pier was assembled in a single day, a benefit of segmental technology. High performance concrete mixes with compressive strengths of 8,000 psi (55 MPa) were used to cast the pier sections.
HPC
For freeze-thaw durability of the HPC used in the substructure and superstructure, a relative dynamic modulus of elasticity of 80 percent after 300 cycles, when tested per AASHTO T 161 or ASTM C 666 Procedure A, was specified. A maximum chloride permeability of 1000 coulombs at 56 days per AASHTO T 277 or ASTM C 1202 was also specified. In order to achieve the desired resistance to chloride penetration, fly ash was used in the concrete. For abrasion resistance of the concrete used in the water footings, an average depth of wear of 0.04 in. (1.0 mm) maximum per ASTM C 944 was required by the owner.
Bid Documents
The bid documents were significantly more detailed than usual, enabling the contractor to work directly from them rather than creating shop drawings, thereby, saving both time and money. The bid documents included details of reinforcement bends, segment geometry, and tendon stressing sequence. For certain elements, the documents included electronic files with integrated 3D color drawings. The first segment was cast just six weeks after notice to proceed, getting the project off to a quick start.
World War I
The original Victory Bridge was dedicated to New Jersey residents who served in World War I and the new bridge fulfills this same vision. Light poles are supported on concrete pilasters that showcase bronze plaques commemorating various branches of the services in World War I. Four memorial obelisks are located at the bridge abutments; two incorporating the original bronze plaques from the 1927 structure and two featuring new plaques that rededicate this important bridge for New Jersey.