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Structures Projects

Some of our recent and major structural engineering projects include the following:

I-95 Scotch Road Interchange, Mercer County

When Merrill Lynch proposed to relocate their corporate headquarters to Ewing, NJ, Arora and Associates was up to the challenge to meet the demanding schedule for a major I-95 Interchange reconstruction dictated by both Merrill Lynch and New Jersey Department of Transportation.

Arora went to work immediately to identify roadway design issues, projected traffic volumes, utility, right-of-way, environmental, community and traffic issues. In a remarkably short time frame, Arora proposed conversion of this diamond interchange to a full cloverleaf. Arora also recommended the addition of two collector-distributor (CD) roadways on Route I-95, superelevating over one mile of interstate roadway to eliminate substandard geometry and replacing the functionally obsolete bridge.

Arora's structural engineers found innovative solutions to reduce the project costs. Among them was NJDOT's first use of high performance weathering steel (HPS70W). The use of this material reduced costs by eliminating an entire girder line and provided greater flexibility in staging the replacement of the bridge. Construction time and costs were shortened by the design of prefabricated wall systems. Integral abutments eliminated deck joints and simplified construction details. Instrumentation of the high performance steel girders and the abutments were incorporated into the contract to assist NJDOT in evaluating the performance of this new material and preparing future design standards. During design, Arora used the bridge as a test case to evaluate the cost impacts of implementing the draft NCHRP 12-49 seismic specifications for NJDOT.

Other challeges that Arora handled were wetlands mitigation and numerous utilities that required relocation or protection including multiple gas pipelines and a sewer pump station. Maintenance and protection of traffic during construction was a concern due to the high volume of commuter traffic through the interchange. Arora provided complete MPT plans and developed contract durations and incentives for lane outages and detours.

The project was named Project of the Year by the Professional Engineer's Society of Mercer County and Outstanding Enginering Acheivement by the New Jersey Society of Professional Engineers.

The project was completed on schedule at a cost of $24.3 million.

D&R Canal Pedestrian Bridge Over Route US 1, Mercer County

Arora and Associates was retained to create a signature bridge for the Delaware and Raritan Canal State Park, which is on the National Register of Historic Places and a key element of the East Coast Greenway between Maine and Florida. The bridge unifies the Delaware and Raritan Canal's towpath that was split by Route US 1.

Although the bridge looks as if it predates the highway, Arora used state-of-the-art engineering and materials to meet project objectives of a durable, low-maintenance structure. The choice of a curved-chord Pratt truss was inspired by railroad bridges constructed during the period in which the D&R Canal was in operation. To further complement the park and the main truss span, steel through-trusses were selected for the approach ramps and substructures were detailed with coursed-rubble, gray sandstone masonry. The structure has been cited by NJDOT and environmentalists as a prime example of Context Sensitive Design.

The project was nominated by NJDOT for New Jersey's 2004 Historic Preservation Awards Program and FHWA's 2004 Excellence in Highway Design. It received the Engineering Excellence award from the American Concrete Institute and Distiguished Award from the American Consulting Engineers Council of New Jersey. The project was complete on schedule at a cost of $3 million.

Whitehead Road Over AMTRAK, Mercer County

Arora designed a 116-meter long, three-span continuous multiple girder bridge to replace an 82-year old existing through-girder bridge over AMTRAK's Northeast Corridor, the heaviest traveled electrified rail corridor in the USA. The difficult project site placed many constraints on the project solution. Raising the bridge to obtain minimum clearances over the railroad dictated raising the roadway. The proximity of the intersection with East State Street and adjacent buildings further constrained the horizontal and vertical geometry. An abandoned recycling facility had to be avoided and on-site contaminated soil required a cleanup plan.

In addition to working over an active electrified rail line, AMTRAK's NE Corridor communications duct bank and AT&T and MCI trunklines were located immediately adjacent to the existing abutment. A new water main was jacked under the railroad tracks and a Conrail freight track was relocated.

Arora and Associates, P.C. delivered all contract deliverables before the accelerated submission dates.

During Design and Construction, partnering was embraced by the NJDOT, the contractor, Arora, AMTRAK and the utility companies. Project issues were resolved collaboratively without resorting to formal contract resolution procedures. As a result, the bridge was opened 10 months ahead of schedule.

The project was nominated for the American Society of Highway Engineers Project of the Year award and the New Jersey Department of Transportation submitted the project to the FHWA for an Excellence in Highway Design as an outstanding example of an urban highway reconstruction project.

The project was completed on schedule at a cost of $18 million.

Amwell Road over Neshanic River, Somerset County

Replacement of the existing two-span arch bridge over the Neshanic River that is deteriorated and structurally deficient. The project consists of replacing the bridge and improving roadway geometrics on an alignment that minimizes right-of-way acquisitions and environmental impacts. Within the project limits, the proposed vertical and horizontal alignment of Amwell Road will be improved to satisfy minimum design criteria.

Route 130 Over Crafts Creek, Burlington County

Replacement of the Route 130 Bridge over Crafts Creek. The bridge will be widened to provide for an auxiliary right-turn lane onto Hornberger Avenue. The proposed structure type will be able to accommodate traffic staging that allows for two lanes of traffic in each direction. Aesthetic consideration will be given to accommodate the existing curved west fascia of the bridge and the visual appearance of the bridge barrier.

Route 70 over Manasquan River, Monmouth and Ocean Counties

The Route 70 Bridge over the Manasquan River Bridge is considered a gateway to both Monmouth and Ocean Counties and serves vehicular, pedestrian and marine traffic. Constructed in 1936, the existing bridge is 625 feet long with a single leaf bascule span over a navigation channel. Due to the bridge's deteriorated condition and functional obsolescence, the NJDOT asked Arora and Associates, P.C. to design a replacement structure.

Arora performed an alternatives analysis and a vessel height survey to determine the best alignment for Route 70, height of the structure and the optimum structural solution for this site. Based on Arora's study, the roadway alignment was revised to minimize right-of-way impacts, the bridge height was set to provide a 25-foot vertical underclearance for marine traffic and the navigation channel opening was shifted and widened to 75 feet. The bridge will carry a 12-foot median, two 12-foot lanes and one 10-foot shoulder in each direction. Sidewalks and parapets are included on each side of the bridge resulting in an overall bridge width of 95 feet.

The twin eastbound and westbound structures will each be 724 feet long and consist of two three-span continuous superstructure units. The superstructure utilizes 8,000 psi AASHTO Bulb Tee Girders spaced at eight feet on center. Architecturally treated pier columns and caps will be constructed utilizing precast concrete components connected through post-tensioning. Pier foundations consisting of 24-inch concrete filled pipe piles will be constructed at the waterline within precast concrete cofferdam shells providing both driving templates for the concrete-filled pipe piles and architecturally treated formwork for the footings.

During September 2004, the bridge was designated as the September 11 Memorial Bridge in remembrance of the 170 people from Monmouth and Ocean Counties who died in the 911 terrorist attacks. The project scope was enhanced to include architectural treatments to the piers and parapets, monuments, signage, plantings and a Public Access Platform. The project also involves the widening and reconstruction of Route 70, a bridge fender system, noise walls, retaining walls, bulkheads, traffic signals, ramps, stormwater management water quality retention basins and manufactured treatment devices, highway lighting, ITS improvements and utility relocations. A project website was developed as part of Arora's Community Outreach Program Project. The project should be completed over a year ahead of schedule and at a cost of $52 million.

Route I-78 Connector, Essex County

The project area is located along the I-78 Connector, a major access route to Newark Liberty Airport in the City of Newark, Essex County, New Jersey. Improvements include the widening and raising of the existing northbound roadway over US Route 1 & 9, Route I-78 and Route I-78 ramps. Three lanes were provided for westbound traffic while two lanes were provided for eastbound traffic. To achieve this proposed lane configuration, existing ramps and structures were widened and raised as follows:

  • Route I-78 Connector over Ramps B & C (Structure No. 0725-154)
  • Route I-78 Connector Ramps A & B over Route 1 & 9 (Structure No. 0725-155)
  • Route I-78 Connector Ramps C, QP & D over Route 1 & 9 (Structure No. 0725-170)
  • Route I-78 Connector Ramps B & C over Route I-78 (Structure No. 0725-156)
  • Route I-78 Connector Ramps QP & R over Route I-78 (Structure No. 0725-157)
All of the bridge and ramp construction was staged to maintain the existing flow of traffic. Maintenance of traffic was a major consideration in the development of the project. Structural framing plans were designed to facilitate future deck replacements. All bridge roker bearings were replaced with elastometric bearing pads or pot bearings. Existing superstructures were raised increasing minimum underclearances to 5.1 meters (16'-9") over Route I-78 and Route I-78 Ramps and to 4.75 meters (15'-7") over US Route 1 & 9. Substructures of the existing bridges were evaluated for increased earth pressure, new superstructure loads, HS-25 live load, and Seismic Performance Category B requirements. Some of the strategies used to mitigate the increased abutment loading included lightweight concrete bridge decks, lightweight concrete abutment seat and backwall extensions and lightweight fill behind the abutment walls. The project also included eight retaining walls and eleven sign structures.

Chesterfield-Sykesville Road over Black's Creek, Burlington Co.

Replacement of the bridge with a new 40-foot long single-span, 31-foot wide prestressed concrete voided slab beam structure. The new bridge carries an 11-foot lane and a three-foot shoulder in each direction. Chesterfield-Sykesville Road was realigned to improve reverse curve radii.

The bridge is not individually eligible, but contributes to the eligible historic elements. Design included unique architectural features to reflect the historic context of the structure. The bridge parapet and fascia have aesthetic treatments and color that give it an aged look. Wingwalls have wood cladding to mimic the existing mill pond dam. A fish ladder was provided to allow fish to migrate past the spillway.

Construction cost was $3.3 million.

Ewingville Road Over Shabakunk Creek, Mercer County

Replacement of the existing 30-foot span, steel-stringer bridge. Arora is performing preliminary and final design of the replacement bridge including survey, hydraulic analysis, geotechnical investigation, cultural resources and bridge design. Arora also prepared applications for stream encroachment, freshwater wetlands and soil erosion permits required for construction.

South Salem Street Bridge Over NJTransit, Morris County

Replacement of the existing three-span, through-girder bridge over an active railroad with a 115-foot long, single-span, 58-foot wide, steel multi-beam structure. It will accommodate an additional track planned by NJ Transit. The new bridge will carry a 12-foot lane and a 10-foot shoulder in each direction and a 6-foot sidewalk on both sides. The proposed alignment of Salem Street eliminates the existing reverse curve. The Railroad Corridor is eligible for the National Register of Historic Places. The bridge is not individually eligible, but contributes to the eligible historic railroad district. Architectural treatments will be provided on the parapets, substructure and wingwalls to maintain compatability with the historic corridor.

Prospect Street Bridge Over NJTransit, Morris County

This project involves replacement of the Prospect Street Bridge superstructure and capping the existing abutments. Prospect Street will be re-profiled from the intersection of Prospect Street and Elliott Street to the intersection of Prospect Street and Blackwell Street. Extensive utilities will require accommodation or relocation to accomplish the project. Coordination with NJ Transit will be required for designing catenary structures to detach the wires from the bridge, re-profiling catenary wires, and relocating railroad signal and communication lines. The project also includes survey in the active track bed, cultural resources study, drainage, highway lighting and traffic engineering. Traffic will be detoured during construction to facilitate the accelerated construction of the replacement bridge.