Location: Lawrence County, OH
Owner: ODOT, District 9
General Contractor: Brayman Construction Corp.
Value: $83 Million
Date Complete: June 2016
Brayman was contracted to replace the existing Ironton-Russell Bridge, which is a major crossing of the Ohio River between the towns of Ironton, OH and Russell, KY.
The project entails construction of a cast-in-place concrete, cable-stayed bridge with structural steel approaches and reinforced concrete edge girder superstructure on the main span.
The main unit consists of three spans; two flanking spans at 370' each and the center span of 900' -- the longest span ODOT has ever constructed. The main span will be supported by 2ea, 316' tall cast-in-place delta-shaped towers, founded on large diameter drilled shafts with rock sockets.
Span lengths for the approaches vary widely since they cross numerous rail lines, the Ohio River levee, and city streets. On the Kentucky side, the spans are 140' and 235'. In Ohio, the spans are 110';144'; 186'; and 144'. The approach bridges are founded on drilled shafts (Kentucky) or steel pile (Ohio).
The main structure of the bridge will have 120 cables. There will be 15 pairs in the Ohio back span, 30 pairs in the main span, and 15 pairs in the Kentucky back span. The strands are made of steel, and the number of strands varies from a minimum of 14 located in the cables nearest both towers to a maximum of 35 in the cables farthest from the towers on the back span sides. The cables at the mid-span contain 31-strands each.
There are two piers and one abutment on the Kentucky approach. The Ohio approach has two towers in the river; and four piers, and one abutment. All abutments, piers, and towers will be cast-in-place, reinforced concrete.
Pier 2 on the Kentucky approach is located in the river and is the tallest pier at 80'. The widest pier is Pier 1 at 60'. The foundations for Towers 3 and 4, as well as Piers 2 and 5, are cast-in-place, reinforced concrete footings on drilled shafts.
Total foundation units consist of 43ea large diameter drilled shafts ranging in size from 42" to 96" diameter. Working from barge-mounted equipment, in water averaging 45' deep, pre-cast cofferdams are being used for Towers 3 and 4, and a conventional cofferdam aided installation at Pier 2.
The two-lane structure will provide two, 12' driving lanes and two, 4' shoulders for a total width of 32'. The navigational clearance for the bridge will be 805'. Once the newly constructed bridge is open to vehicular traffic, Brayman will perform removal of the existing structure.