A Backstage Tour of Charleroi Lock and Dam

From blank-sheet concept to finished product, the I-77 over Route 606 South Gap Bridge Replacement sprinted from proposal kickoff in November 2022 to substantial completion in June 2025, a full five months ahead of the November 6 contract completion date. The early delivery secured 100% of VDOT’s “no-excuses” early-completion incentive, marking a major milestone for Brayman’s first VDOT design-build.

How we beat the deadline:

Relentless scheduling. From day one, the Team operated with urgency, completing proposal development, conceptual design, and pricing in just three months. Key design decisions were made to avoid long-lead environmental permitting, and utility coordination was fast-tracked to accelerate the start of construction. The NTP was issued in March 2023, and construction commenced by October.

Phased for speed. Strategic sequencing allowed the Team to demo and rebuild the bridge in two major phases, keeping traffic moving while maintaining production momentum. Phase 1 cleared the way for half of the new, wider structure to be erected quickly, while Phase 2 carried the project through to its final completion. Alongside the bridge work, the Team widened 1,600 LF of I-77 and constructed Brayman’s first-ever reinforced soil slope, a critical structural element that now supports the expanded roadway and showcases our growing in-house design-build capabilities.

Creative access planning. The sharp interstate curve made traditional overhead access at the abutments unsafe and unworkable during Phase 2. Nearly all materials, equipment, and personnel had to be brought in from below, a challenge met with resourceful planning and precise field execution. The Team engineered a custom below-deck access and work plan that enabled the safe and efficient construction of structural steel, deck, and MSE walls, all from underneath, without disrupting live interstate traffic.

Execution under pressure. From unforgiving weather to unexpected site conditions, the Team faced pressure from every angle—and delivered. Challenging subsurface conditions impacted driven foundation piling. Flooding disrupted work during the box culvert wingwall replacement. And a mid-project change in concrete supplier threatened to derail critical path operations. Through it all, the Team responded with real-time adjustments and relentless tenacity, reworking sequences, maintaining momentum, and never giving back a day.

South Gap isn’t just another bridge; it’s proof that Brayman is a serious player in VDOT’s alternative-delivery arena. With the early-finish bonus in the bank and a strong relationship built with the owner, the playbook forged here is already fueling momentum on our Bristol-Salem Bridge Bundle Design-Build and setting the tone for future success across Virginia.

Stay tuned—Team Brayman’s just getting started.

‍

We are honored to be recognized by the Engineers' Society of Western Pennsylvania with the 2024 Project of the Year Award for Alternative Delivery for our work on the I-64 Kanawha Bridge.

The U.S. Army Corps of Engineers awarded a $769.9-million contract to a joint venture of Trumbull Corp. and Brayman Construction Corp. to build a new lock chamber at the Montgomery Locks and Dam on the Ohio River in Monaca, PA.

Brayman Construction and Trumbull Corporation are proud to announce a five-year Occupational Safety and Health Administration (OSHA) Strategic Partnership for the Bayfront Parkway Improvement Project in Erie, PA. This is the longest OSHA Partnership in Erie’s history, reflecting a strong commitment to workplace safety and health.

The goals of this partnership include reducing the total number of days away from work injury and illness cases by 3%, controlling workplace hazards by assisting contractors with the implementation of an effective safety and health management system, conduct weekly self-inspections to reduce exposure of workers to safety and health hazards, and to maintain a continuous dialog that support various safety and health campaigns/initiatives.

“At Brayman, safety is not just a policy; it’s our way of life. This partnership with OSHA and Trumbull Corporation reinforces our long-standing dedication to ensuring the highest safety standards,” said Stephen Muck, Chairman and CEO of Brayman Construction.

Mark Gentile, President of Trumbull Corporation, added, “Our partnership with Brayman Construction has been built over several successful projects, each reinforcing our shared commitment to delivering a safe project. This partnership with OSHA, is another step in our collaborative journey, reflecting Safety as a shared core value, in every aspect of our work.”

“Securing an OSHA Strategic Partnership reflects our continual efforts to lead the industry in safety practices,” stated Angela Ravenscroft, Corporate Safety Director at Brayman Construction. “This achievement is another milestone in our ongoing mission to provide a safe working environment for everyone.”

Christopher Snedden, Assistant Area Director for OSHA stated, “Anytime OSHA and responsible contractors from the private sector can work together to minimize hazards in the workplace and decrease the number of injuries, the result is always positive. We commend Brayman Construction and Trumbull Corporation for taking a proactive approach in prioritizing safety and committing to ensuring safe working conditions.”

The Bayfront Parkway Improvement Project, valued at $111.7 million, aims to strengthen the connectivity within the city of Erie by enhancing accessibility and safety for all its users. This project is not just an infrastructural development; it’s a step towards a safer, more connected community.

‍‍

About Trumbull Corporation:

Trumbull Corporation is an award-winning industry leader in heavy civil construction, having built hundreds of bridges, highway projects, tunnels, excavation, locks, dams, well pad construction, pipeline installation, and utilities throughout the Mid-Atlantic region. Our world-class team is known for taking extra measures to ensure our work is thorough and accurate.

‍

About OSHA:

In 1970, the United States Congress and President Richard Nixon created the Occupational Safety and Health Administration (OSHA), a national public health agency dedicated to the basic proposition that no worker should have to choose between their life and their job. The OSHA law makes it clear that the right to a safe workplace is a basic human right. Together with our state  partners, OSHA has tackled fatal safety hazards and health risks. We have established common sense standards and enforced the law against those who put workers at risk. Our standards, enforcement actions, compliance assistance and cooperative programs have saved thousands of lives and prevented countless injuries and illnesses.

Although our task is far from complete, our progress gives us hope and confidence that OSHA will continue to make a lasting difference in the lives of our nation’s workers, their families and their communities.

A Brayman and Trumbull joint venture project just celebrated the start of our Bayfront Parkway Improvement Project in Erie, PA.

“Construction will be completed in six phases over approximately four years. It will start at the Sassafras Street Extension intersection before the end of September and is expected to conclude with the construction of the pedestrian bridge at Holland Street.”

Brayman Construction & Trumbull, A Joint Venture, is making headway on I-64 for West Virginia Department of Transportation. This project includes widening 5 miles of highway from two lanes into three lanes as well as constructing a new bridge over the Kanawha River.

Have you ever wondered what goes on behind the scenes of a jobsite? One of our projects Charleroi Locks and Dam got a backstage tour. Check out the feature on how the operations of this unique dam work.