Verrazano-Narrows Bridge

The Verrazano Narrows Bridge Deck Replacement consisted of replacing 545,000 SF of existing concrete-filled steel grid decking with steel orthotropic deck and adding a reversible HOV lane, increasing the total traffic lanes to 13. The bridge has a 4,260-foot main span that is the longest in the Americas, a 6690’ total suspended length, and carries over 175,000 vehicles daily on I-278 between Staten Island and Brooklyn. The 938 new orthotropic deck panels were 49-foot-6-inch long and varied from 6-foot-6-inch to 14-foot-6-inch wide, and required extensive field welding of longitudinal and transverse joints, and are then covered with an elastomeric acrylic resin waterproofing membrane and 2-inch waterproofed asphalt course to extend the design life of the deck. The deck replacement was completed in four stages over 23 months, 13 months earlier than the 36 months allowed per the contract, and 4 months earlier than the maximum available project bonuses. Removal and replacement of deck panels was performed at night to minimize traffic impacts. The project also required extensive temporary works, including over 630,000 square feet of temporary shielding over the lower level, which remained active throughout the work; four 35-ton capacity overhead gantry cranes and a steel-girder runway system spanning the length of the bridge; and temporary roadway lighting on both Upper and Lower Level roadways. TPC also operated and maintained a reversible traffic lane system throughout the duration of the deck replacement. Other work includes demolition of the existing 18-lane toll plaza and replacement with “open-road” toll collection gantries, complete replacement of bridge roadway lighting with LED lighting, new roadway drainage, extensive reconstruction of expansion joints at the bridge towers, new roadway barrier, and painting.