US 35/I-64 I/C Interchange – Nitro I/C Design-Build

Brayman Construction Corporation and Trumbull Corporation, a Joint Venture (BTJV), were contracted to provide design and construction services for the $254 million U.S. 35/I-64 Interchange – Nitro Interchange Design-Build Project.  Brayman served as the lead contractor in this Joint Venture.

This multi-year improvement project consists of the design and construction of eight interstate bridges and the widening of approximately four miles of I-64 roadway from four to six lanes (eight lanes between the Saint Albans and Nitro Interchanges). The work included the complete reconstruction of two I-64 interchanges, Nitro (Exit 45) and St. Albans (Exit44), and the construction of the following structures: Rocky Step Bridge, McCloud Road ConSpan, Bill’s Creek Bridge, St. Albans Entrance and Exit Overpass Bridges, Nitro Interchange Bridge, Donald M. Legg Memorial Bridge, and Nitro WWI Memorial Bridge. The bridges on the project varied from large river crossings to structures over small rural dead-end roads, requiring the coordination of many stakeholders and significant efforts in shifting crews between the various structures.

This project had a large marine component that required installing cofferdams and large-diameter drilled shafts in the river, as well as major steel components erected and installed from the water. Instead of traditional cofferdams, a custom submerged formwork system was devised in collaboration with Doka USA, allowing underwater construction of pier walls. This innovation greatly accelerated the schedule for the challenging river-related operations.

The project worked through many challenges during both the design and construction phase dealing with multiple railroad, utility, and other agency stakeholders. It is on track for substantial completion in October 2024.

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