PTC Mon-Fayette Expressway

The Mon/Fayette Expressway, a critical infrastructure project with planning origins tracing back to the 1950s, continues its development toward completion. The Brayman Construction Foundations Division, was subcontracted by Trumbull Corp to execute the installation of micropile foundations for the latest section of this expansive expressway, Section 53A1.

Scope of Project

Brayman Foundations executed the installation of 9-5/8” steel-cased micropiles. Although these foundational elements remain unseen post-construction, these foundations are vital for the stability and longevity of the infrastructure, ensuring it meets and exceeds the necessary safety and performance standards.

Over nine months, Brayman Foundations deployed two dedicated drill crews to install the necessary micropiles. The project necessitated over 12,000 man-hours to install 10 miles of micropiles across six abutment structures for three new bridges. These bridges include two parallel structures traversing Route 51 and one wider bridge crossing over the Jefferson Boulevard expressway access.

In total, 667 piles were installed in both plumb and batter configurations, with drilling depths ranging from 30 feet to 105 feet. The work was conducted under challenging conditions, including tight drilling spaces and the proximity to active highway lanes, which required exceptional precision and safety measures.

Challenges and Achievements

The Brayman team faced and overcame the tight drilling conditions combined with the operational necessity of working between active north and southbound lanes of a highway. Despite this hurdle, the team’s expertise and dedication to safety and quality led to the successful completion of one of Brayman’s largest micropile projects in recent history.

The Mon-Fayette Expressway 53A1 micropile installation project is a testament to Brayman Foundations’ ability to tackle and excel in challenging confined conditions. The invisible yet crucial micropiles installed by Brayman will serve as the backbone for the expressway’s new bridge structures, ensuring their stability and durability for years to come.

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