The Rodney Staton Memorial Bridge project involved the design/build rehabilitation of a 630-LF, three span structure spanning R.D. Bailey Lake. The approved design comprises new approaches, substantial structural steel upgrades and repairs, as well as complete deck replacement utilizing 152-each full depth, post-tensioned precast panels. This alternative design provided the state of West Virginia with a cost savings in excess of one million dollars.
Now gaining popularity within the construction industry, precast deck panels offer benefits such as quality control and an expedited construction process. Although no longer an uncommon practice, the Rodney Staton Memorial Bridge project marks two firsts in West Virginia: the replacement of a concrete deck with precast panels and the use of an epoxy overlay on the bridge deck. Six blockouts were cast in each panel to act as pockets to accept all new welded shear connector studs installed on the bridge girders.
After panel installation and adjustment to grade, transverse joints were pressure grouted. To maintain joints in compression for both live and dead loads, post-tensioning ducts which allow for longitudinal stressing were also cast in the slabs. Ducts, shear stud pockets and haunch were grouted after post-tensioning occurred. Finally, a cast in place center strip provided full width deck continuity.
The structural system of the bridge was substantially changed. Girders were modified into a continuous span by replacing the hinged section with a bolted splice. Expansion joints and approach slabs were also replaced and the locations were moved into the new semi-integral type abutments; all of the bearings were also replaced. To accommodate the new design of the girders with the removal of the hinge, stiffeners were added to the girders as appropriate to increase capacity of the bridge. Additional work items included slip-formed parapets, a new paint system, and utility relocation. Affording the community minimal disruption, operations were half width, allowing an 11-foot live lane throughout construction. Ultimately, the project was completed seven months ahead of schedule with zero injuries.