Precision Engineering Over NYPA’s Turbine Forebay
Not every bridge replacement happens over open water. This one happened over one of New York State’s most critical energy assets. As Engineer-of-Record for the $42 million staged superstructure replacement of three adjacent 813-foot bridges spanning the New York Power Authority powerplant turbine forebay, our team navigated one of Western New York’s most operationally sensitive infrastructure environments. The existing 12-span, post-tensioned I-girder superstructures were each replaced with three sets of four-span, continuous, galvanized steel multi-girder superstructures, improving capacity, performance, and long-term maintenance. Additional work included pier and abutment top modifications, installation of new inspection catwalks, approach highway reconstruction, relocation of bridge-mounted utilities, and mill and fill for the Military Road off-site detour route.
The deteriorated condition and limited capacity of the existing concrete I-girders demanded a detailed analysis of the structures under heavy demolition and erection loads. A custom-designed Barnhart gantry crane and multi-axle Goldhofer trailer system were engineered specifically for bridge girder removal. Working adjacent to and directly over NYPA’s powerplant and turbine intakes required a full debris containment system and work platform suspended from the existing piers, protecting active energy infrastructure throughout the process.
First in Western New York, Finished Nine Months Early
Over 50 design unit submittals were required to keep the project moving. The result spoke for itself: completion in late fall 2015, nine months ahead of the contract-required date. Our SOQ and RFP submittals earned the highest technical scores among three bidders during procurement, and the project marked a milestone as the fourth in the NYSDOT design-build program and the first delivered in Western New York. It’s the kind of project where precision, coordination, and deep technical confidence aren’t just valued. They’re the only way the work gets done.
