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Arrow Virginia Demonstration Project: Rapid Removal and Replacement of U.S. 15/29 Bridge Over Broad Run Near Gainesville, VA

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Final Report August 2009

Final Report August 2009

Table of Contents

List of Figures



The purpose of the Highways for LIFE (HfL) pilot program is to accelerate the use of innovations that improve highway safety and quality while reducing congestion caused by construction. LIFE is an acronym for Longer–lasting highway infrastructure using Innovations to accomplish the Fast construction of Efficient and safe highways and bridges.

Specifically, HfL focuses on speeding up the widespread adoption of proven innovations in the highway community. "Innovations" is an inclusive term used by HfL to encompass technologies, materials, tools, equipment, procedures, specifications, methodologies, processes, and practices used to finance, design, or construct highways. HfL is based on the recognition that innovations are available that, if widely and rapidly implemented, would result in significant benefits to road users and highway agencies.

Although innovations themselves are important, HfL is as much about changing the highway community's culture from one that considers innovation something that only adds to the workload, delays projects, raises costs, or increases risk to one that sees it as an opportunity to provide better highway transportation service. HfL is also an effort to change the way highway community decisionmakers and participants perceive their jobs and the service they provide.

The HfL pilot program, described in Safe, Accountable, Flexible, Efficient Transportation Equity Act: A Legacy for Users (SAFETEA–LU) Section 1502, includes funding for demonstration construction projects. By providing incentives for projects, HfL promotes improvements in safety, construction–related congestion, and quality that can be achieved through the use of performance goals and innovations. This report documents one such HfL demonstration project.

Additional information on the HfL program is at


This document is disseminated under the sponsorship of the U.S. Department of Transportation in the interest of information exchange. The U.S. Government assumes no liability for its contents or use thereof. This report does not constitute a standard, specification, or regulation.

The U.S. Government does not endorse products or manufacturers. Trade and manufacturers' names appear in this report only because they are considered essential to the object of the document.

1. Report No. 2. Government Accession No. 3. Recipient's Catalog No.
4. Title and Subtitle
Virginia Demonstration Project: Rapid Removal and Replacement of U.S. 15/29 Over Broad Run Near Gainesville, VA
5. Report Date
August 2009
6. Performing Organization Code
7. Author(s)
Rex D. Gilley, P.E., Jagannath Mallela, Gary Hoffman, P.E., R.L.S., and Gerald L. Ullman
8. Performing Organization Report No.
9. Performing Organization Name and Address
Applied Research Associates, Inc.
100 Trade Centre Drive, Suite 200
Champaign, IL 61820
10. Work Unit No.(TRAIS) C6B
11. Contract or Grant No.
12. Sponsoring Agency Name and Address
Office of Infrastructure
Federal Highway Administration
1200 New Jersey Avenue, SE
Washington, DC 20590
13. Type of Report and Period Covered
Draft Final Report
December 2007–March 2009
14. Sponsoring Agency Code
15. Supplementary Notes
Contracting Officers Technical Representatives: Byron Lord, Mary Huie
16. Abstract

As part of a national initiative sponsored by the Federal Highway Administration under the Highways for LIFE program, the Virginia Department of Transportation (VDOT) was awarded a $600,000 grant to demonstrate the use of proven, innovative technologies for accelerated bridge removal and replacement. This report documents accelerated bridge construction (ABC) techniques used to remove, widen, and replace the superstructure of the U.S. 15/29 bridge over Broad Run over three weekends.

This report describes the existing bridge and the materials and methods used to widen the three-span bridge and replace the superstructure. Prefabricated superstructure segments, four per span, were used to simplify and expedite construction. Under conventional construction, the impact of this project on the traveling public was estimated at 100 days, but with the use of accelerated construction techniques, the impact was reduced to three weekend closures.

Using ABC techniques added approximately $260,000 to the initial construction cost of the project. However, a more comprehensive economic analysis including user cost savings shows that the project saved road users an estimated $2.16 million or about 65 percent over conventional construction practices. Because of the success of this project, VDOT plans to use ABC techniques on future projects.

17. Key Words
accelerated bridge construction, construction manager general contracting, economic analysis, full lane closure, Highways for LIFE, innovative construction, prefabricated bridge elements and systems
18. Distribution Statement

No restriction. This document is available to the public through

19. Security Classif. (of this page)
20. No. of Pages
21. Price  

Form DOT F 1700.7 (8–72) Reproduction of completed page authorized

Approximate Conversions to SI UnitsApproximate Conversions from SI Units
When you knowMultiply byTo findWhen you knowMultiply byTo find
(a) Length
(b) Area
square inches645.2square millimeterssquare millimeters0.0016square inches
square feet0.093square meterssquare meters10.764square feet
square miles2.59square kilometerssquare kilometers0.386square miles
(c) Volume
fluid ounces29.57millilitersmilliliters0.034fluid ounces
cubic feet0.028cubic meterscubic meters35.32cubic feet
cubic yards0.765cubic meterscubic meters1.308cubic yards
(d) Mass
short tons (2000 lb)0.907megagrams (tonne)megagrams (tonne)1.102short tons (2000 lb)
(e) Force
(f) Pressure, Stress, Modulus of Elasticity
pounds per square foot47.88PascalsPascals0.021pounds per square foot
pounds per square inch6.895kiloPascalskiloPascals0.145pounds per square inch
(g) Density
pounds per cubic foot16.019kilograms per cubic meterkilograms per cubic meter0.0624pounds per cubic feet
(h) Temperature
Fahrenheit temperature(°F)5/9(°F– 32)Celsius temperature(°C)Celsius temperature(°C)9/5(°C)+ 32Fahrenheit temperature(°F)
  1. The primary metric (SI) units used in civil engineering are meter (m), kilogram (kg), second(s), newton (N) and pascal (Pa=N/m2).
  2. In a "soft" conversion, an English measurement is mathematically converted to its exact metric equivalent.
  3. In a "hard" conversion, a new rounded metric number is created that is convenient to work with and remember.


The project team would like to acknowledge the invaluable insights and guidance of Federal Highway Administration (FHWA) Highways for LIFE Team Leader Byron Lord and Program Coordinators Mary Huie and Kathleen Bergeron, who served as the technical panel on this demonstration project. Their vast knowledge and experience with the various aspects of construction, technology deployment, and technology transfer helped immensely in developing both the approach and the technical matter for this document. The team also is indebted to Utah Department of Transportation engineers Jim McMinimee, Shana Lindsey, Lisa Wilson and Daniel Hsiao and FHWA Division Administrator Butch Waidelich and ITS and Structural Engineer Russ Robertson for their tireless advice, assistance, and coordination during this project.

Abbreviations and Symbols

AASHTO American Association of State Highway and Transportation Officials
ABC Accelerated Bridge Construction
ADT Average Daily Traffic
CIP Cast–in–Place
CMGC Construction Manager General Contracting
dB(A) A–Weighted Decibels
DOT Department of Transportation
FHWA Federal Highway Administration
FY Fiscal Year
HfL Highways for LIFE
Hz Hertz
IRI International Roughness Index
OBSI On–board Sound Intensity
OSHA Occupational Safety and Health Administration
PIC Public Involvement Coordinator
PIM Public Information Manager
SAFETEA–LU Safe, Accountable, Flexible, Efficient Transportation Equity Act: A Legacy for Users
SI Sound Intensity
SPMT Self–propelled Modular Transporter
SR State Route
SRTT Standard Reference Test Tire
UDOT Utah Department of Transportation
VOC Vehicle Operational Costs
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Mary Huie
Center for Accelerating Innovation

This page last modified on 04/04/11

United States Department of Transportation - Federal Highway Administration