Section A1 - Bridge Replacement

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Project Description

The Section A1 project involves the replacement of the two existing bridges at the Bensalem (Route 1) Interchange with a single span bridge. The footprint of the proposed bridge is being shifted east to accommodate the new staged ramp configuration for the future widening of the PA Turnpike. Additionally the existing Westbound on ramp will be realigned to improve the current traffic flow operations.

The construction for this project also includes:

• Demolition of existing bridges over PA Turnpike mainline.
• Building of mechanically stabilized earth (MSE) wall adjacent to eastbound PA Turnpike mainline off-ramp.
• Construction of future eastbound PA Turnpike mainline off-ramp roadway.
• Placement of concrete pavement via staged ramp reconstruction.
• Upgrade of drainage measures and mast lighting installed throughout the Interchange.
• Installation of a precast slab interlocking system located at the Interchange’s roadway approach.

Project Schedule

The Notice To Proceed was August 2016. The duration of the project is over two and half (2 ½) years with construction completing by May 2019.

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Construction Information Archive

August 2019 to January 2020

• Placed rock armor under low bridges for erosion protection.
• Completed concrete roadway repairs.
• Converted Basin N2 to post-construction stormwater basin.
• Completed basin subgrade exploration/infiltration testing for Basins N4, N3, M4 and N7.

March 2019 to July 2019

• Completing punchlist items throughout project limits.
• Continued to remove excess excavation from the project.
• Continued topsoil/seeding of slopes.
• Continued excavation/conversion of stormwater basins.

December 2018 to February 2019

• Completing punchlist items throughout project limits.
• Completed cast in place concrete shoulder pavement.
• Continued applying final striping throughout project limits.
• Continued constructing/erecting redesignation sign structures (I-95 corridor).
• Continued painting sound barrier wall panels.
• Continued to remove excess excavation from the project.
• Continued placing topsoil on slopes.
• Began conversion of Storm Water Basins.

October/November 2018

• Completing punchlist items throughout project limits.
• Began applying final striping throughout project limits.
• Continued constructing/erecting redesignation sign structures (I-95 corridor).
• Began painting sound barrier wall panels.
• Continued to remove excess excavation from the project.
• Began placing topsoil on slopes.

September 2018

• Continued placing concrete pavement on southbound and northbound I-95 roadway.
• Continued placing precast single face and median concrete barrier along southbound and northbound I-95 roadway.
• Continued to erect fencing on top of bridge parapet on southbound I-95 flyover.
• Erected sound barrier posts and panels on top of concrete barrier adjacent to Bristol Plaza along northbound I-95.
• Applied anti-graffiti coating on sound barrier wall panels and bridge parapet.
• Continued placing topsoil in the median.
• Continued installing highway lighting.
• Continued constructing/erecting on-site sign structures.
• Continued constructing/erecting redesignation sign structures (I-95 corridor).
• Continued to apply paint system to southbound I-95 bridge over New Rodgers Rd and southbound I-95 Flyover structure and fascia beams.
• Began installing downspouts under southbound I-95 Flyover.
• Continued grinding/grooving of the southbound I-95 Flyover concrete deck.

August 2018

• Continued placing concrete pavement on southbound and northbound I-95 roadway.
• Continued forming, installing reinforcement steel and pouring moment slabs between southbound I-95 bridge over New Rodgers Rd and southbound I-95 flyover.
• Continued forming and pouring concrete moment slabs and single face barrier along northbound I-95.
• Continued placing precast single face and median concrete barrier along southbound and northbound I-95 roadway.
• Continued constructing approach slabs for southbound I-95 flyover and southbound I-95 bridge over New Rodgers Rd.
• Continued to erect fencing on top of bridge parapet on southbound I-95 flyover.
• Continued erecting sound barrier posts and panels on top of concrete barrier between southbound I-95 flyover and southbound I-95 bridge over New Rodgers Rd.
• Continued placing topsoil in the median. 
• Continued installing highway lighting.
• Continued constructing/erecting on-site sign structures.
• Continued constructing/erecting redesignation sign structures (I-95 corridor).
• Continued to apply paint system to southbound I-95 bridge over New Rodgers Rd and southbound I-95 Flyover structure and fascia beams.
• Began installing downspouts under southbound I-95 Flyover.
• Performed grinding/grooving of the southbound I-95 Flyover concrete deck.

July 2018

• Continued placing concrete pavement on southbound and northbound I-95 roadway.
• Continued forming, installing reinforcement steel and pouring moment slabs between southbound I-95 bridge over New Rodgers Rd and southbound I-95 flyover.
• Began forming and pouring concrete moment slabs and single face barrier along northbound I-95.
• Continued placing precast single face and median concrete barrier along southbound and northbound I-95 roadway.
• Continued placing concrete for bridge deck on southbound I-95 flyover (Unit 1).
• Continued placing concrete for bridge parapet on southbound I-95 flyover (Unit 3).
• Continued constructing approach slabs for southbound I-95 flyover and southbound I-95 bridge over New Rodgers Rd.
• Continued to erect fencing on top of bridge parapet on southbound I-95 flyover.
• Began erecting sound barrier posts and panels on top of concrete barrier between southbound I-95 flyover and southbound I-95 bridge over New Rodgers Rd.
• Continued placing topsoil in the median.
• Continued installing highway lighting.
• Continued constructing/erecting on-site sign structures.
• Continued constructing/erecting redesignation sign structures (I-95 corridor).
• Applied paint system to southbound I-95 bridge over New Rodgers Rd and southbound I-95 Flyover structure and fascia beams.

June 2018

• Completed paving asphalt treatment base course on northbound I-95 roadway.
• Continued placing concrete pavement on southbound and northbound I-95 roadway.
• Placed topsoil in the median.
• Started installing highway lighting.
• Began constructing/erecting on-site sign structures.
• Started constructing/erecting redesignation sign structures (I-95 corridor).
• Placed precast single face and median concrete barrier along southbound and northbound I-95 roadway.
• Formed and poured moment slabs adjacent to post/panel wall and MSE Wall along northbound I-95 roadway.
• Formed, installed reinforcement steel and poured moment slabs between southbound I-95 bridge over New Rodgers Rd and southbound I-95 flyover.
• Poured concrete at tooth expansion dam at pier on southbound I-95 Flyover.
• Started installing deck reinforcement steel on southbound I-95 (Unit 1).
• Placed concrete for bridge deck on southbound I-95 flyover (Unit 1 and Unit 3).
• Placed concrete for bridge parapet on southbound I-95 flyover (Unit 3).
• Constructed approach slabs for southbound I-95 flyover and southbound I-95 bridge over New Rodgers Rd.
• Applied paint system to sound barrier wall panels and bridge structure wall along northbound I-95.
• Started to erect fencing on top of bridge parapet on southbound I-95 flyover.

April/May 2018

• Excavated, graded & placed subbase along southbound and northbound I-95 roadway.
• Continued placing underdrain stone along southbound I-95 roadway.
• Paved asphalt permeable base course along southbound and northbound I-95 roadway.
• Continued placing concrete roadway on southbound I-95 roadway.
• Began placing subbase and adjacent embankment fill along retaining wall for northbound I-95.
• Began paving asphalt permeable base course along retaining wall for northbound I-95.
• Continued installing drainage pipe and Inlets along northbound I-95 roadway.
• Placed concrete for bridge parapet on southbound I-95 flyover (Unit 2).
• Installed overhangs and stay-in-place forms on southbound I-95 flyover (Unit 1).
• Continued setting tooth expansion dam at pier on southbound I-95 flyover.
• Installed deck reinforcement steel on southbound I-95 (Unit 3).
• Started placing concrete deck on southbound I-95 (Unit 3).
• Started placing concrete for bridge parapet on southbound I-95 (Unit 3).
• Began installing highway lighting conduit on southbound I-95 (Unit 3).
• Completed concrete deck placement on southbound I-95 bridge over New Rodgers Road.
• Continued placing structural backfill at abutments for southbound I-95 bridge over New Rodgers Road.
• Applied paint system to sound barrier wall panels and soldier pile wall along northbound I-95.
• Continued placing embankment fill between PA Turnpike and New Rodgers Road.
• Started constructing approach slabs for southbound I-95 bridge over New Rodgers Road.

March 2018

• Excavated, graded & placed subbase along southbound I-95 roadway.
• Began placing underdrain stone along southbound I-95 roadway.
• Paved asphalt permeable base course along southbound I-95 roadway.
• Installed drainage pipe and Inlets along northbound I-95 roadway.
• Placed concrete for bridge parapet on southbound I-95 flyover.
• Started installing overhangs and stay-in-place forms on southbound I-95 flyover and southbound I-95 bridge over New Rodgers Road.
• Set tooth expansion dam at pier on southbound I-95 flyover.
• Began constructing end diaphragms at abutment on southbound I-95 flyover.
• Started installing deck reinforcement steel on southbound I-95 bridge over New Rodgers Road.
• Began placing structural backfill at abutments for southbound I-95 bridge over New Rodgers Road.
• Applied paint system to sound barrier wall panels adjacent to Rt. 413 exit ramps.
• Placed embankment fill between PA Turnpike and New Rodgers Road.
• Placed embankment for northbound I-95 along MSE Wall adjacent to Bristol Plaza.

February 2018

• Continued deck construction of southbound I-95 flyover from south of I-276 to Durham Road (Unit 3).
• Began placing post tensioning ducts and grouting of integral pier cap.
• Continued erecting structural steel girders over I-95 southbound (Unit 1).
• Started deck construction of southbound I-95 bridge over New Rodgers Road.
• Began constructing moment slab along CD roadway.
• Poured sleeper slab for southbound I-95 flyover.
• Milled existing asphalt along northbound I-95 roadway.
• Rubbilized and removed existing southbound I-95 concrete pavement.
• Started excavating and grading of subbase along I-95 southbound/northbound roadway.
• Began forming and installing reinforcement steel for barrier on top of post/panel wall adjacent to northbound I-95 in front of storage facility.
• Continued erecting concrete panels for sound barrier wall adjacent to Rt. 413.
• Continued installing median drainage pipe and inlets.
• Started installing pavement crossover for Stage 2/3 modified along northbound I-95.

January 2018

• Continued construction of the abutments for the southbound I-95 bridge over New Rodgers Road.
• Continued deck construction of southbound I-95 flyover from south of I-276 to Durham Road (Unit 3).
• Formed/poured integral pier cap.
• Continued placing post tensioning ducts in integral pier cap.
• Began erecting straddle bent on Pier 2.
• Started erecting structural steel girders over I-95 southbound (Unit 1).
• Erected precast beams over New Rodgers Road.
• Removed existing southbound I-95 concrete pavement.
• Continued slipforming concrete pavement for northbound I-95 roadway.
• Continued building post/panel wall adjacent to northbound I-95 in front of storage facility.
• Continued erecting concrete panels for sound barrier wall adjacent to Rt. 413.
• Started installing median drainage pipe and inlets.
• Prepared crossover along northbound I-95 roadway.
• Switched southbound traffic from southbound I-95 to CD Roadway.

December 2017

• Began driving piles at abutments for the southbound I-95 bridge over New Rodgers Road.
• Continued construction of the abutments for the southbound I-95 bridge over New Rodgers Road.
• Started deck construction of southbound I-95 flyover from south of I-276 to Durham Road (Unit 3).
• Formed integral pier cap.
• Placed post tensioning ducts in integral pier cap.
• Applied painting and penetrating sealer on barrier and moment slab.
• Continued placing precast single face barrier and corresponding form/pour of moment slabs for MSE Walls adjacent to the Collector Distributor (CD) roadway north and south of southbound I-95 flyover.
• Installed new sign structure and removed existing sign structure.
• Continued building post/panel wall adjacent to northbound I-95 in front of storage facility.
• Continued erecting concrete panels for sound barrier wall adjacent to Rt. 413.
• Continued placement of subbase and paving of asphalt treated base course on CD and northbound I-95 roadway.
• Continued slipforming concrete pavement along northbound I-95 roadway and Rt. 413 ramps.
• Continued slipforming concrete pavement along CD roadway and Rt. 413 ramps.
• Switched southbound traffic from southbound I-95 to CD Roadway.

October/November 2017

• Placed deck concrete for the middle portion of the southbound I-95 bridge over I-276.
• Erected structural steel for the end portion of the southbound I-95 bridge over I-276.
• Constructed the abutment and pier substructures for the southbound I-95 bridge over New Rodgers Road.
• Placement of precast single face barrier and corresponding form/pour of moment slabs for MSE Walls adjacent to the Collector Distributor (CD) roadway north and south of southbound I-95 flyover.
• Continued backfilling for MSE wall adjacent to Bristol Plaza.
• Continued building post/panel wall adjacent to northbound I-95 in front of storage facility.
• Erected steel posts and concrete panels for sound barrier wall adjacent to Rt. 413.
• Installed drainage pipe on I-95 northbound/southbound lanes.
• Started placement of subbase and paving of asphalt treated base course on CD and northbound I-95 roadway.
• Continued slipforming concrete pavement along northbound I-95 roadway and Rt. 413 ramps.
• Continued slipforming concrete pavement along CD roadway and Rt. 413 ramps.
• Painted MSE Walls.
• Installed structural sign caissons.

August/September 2017

• Started driving piles at Abutment No. 2 footing for the southbound I-95 flyover.
• Constructed the substructure for the southbound I-95 bridge over New Rodgers Road.
• Completed backfilling and coping for MSE Walls adjacent to the Collector Distributor (CD) roadway north of southbound I-95 flyover.
• Completed backfilling and coping for MSE Walls adjacent to the Collector Distributor (CD) roadway south of southbound I-95 flyover.
• Set precast panels and backfill for MSE wall adjacent to Bristol Plaza.
• Began building post/panel wall adjacent to northbound I-95 in front of storage facility.
• Drilled and poured concrete caissons for sound barrier wall adjacent to Rt. 413.
• Started slipforming concrete pavement along northbound I-95 roadway and CD roadway.
• Began grading the off-ramp from southbound I-95 to Rt. 413 and southbound I-95 roadway.
• Excavated and graded southbound I-95 roadway south of Ford Road.
• Installed guiderail along on-ramp from southbound 413 to southbound I-95.
• Excavated Basin M4.

June/July 2017

• Installed reinforcement deck steel and deck forms for southbound I-95 flyover bridge Unit 2.
• Continued construction of intermediate diaphragms for southbound I-95 flyover bridge Unit 2.
• Continued drilling and installing soldier pile retaining wall for northbound I-95.
• Continued installing MSE wall panels and stone backfill along CD roadway, east/west walls, north of Abutment 1.
• Continued setting precast panels and backfill for MSE wall along CD roadway, south of Abutment 1.
• Continued placing embankment for northbound I-95 MSE wall adjacent to Bristol Plaza.
• Continued installing drainage pipe along southbound I-95, northbound I-95 and CD Roadway.
• Continued placing subbase and asphalt treated base course northbound/southbound I-95 south of Ford Road.
• Placed concrete pavement northbound/southbound I-95 from Ford Road to southbound off-ramp to Route 413.

May 2017

• Continued installing overhangs and stay in place forms for southbound I-95 flyover bridge Unit 2.
• Began installing deck reinforcement steel for southbound I-95 flyover bridge Unit 2.
• Continued construction of intermediate diaphragms for southbound I-95 flyover bridge Unit 2.
• Continued drilling/installation of soldier pile retaining wall for northbound I-95.
• Continued installing MSE wall panels and stone backfill along CD roadway, east/west walls, north of Abutment 1.
• Continued excavating and setting of precast panels for MSE wall along CD roadway, south of Abutment 1.
• Continued placing embankment for northbound I-95 MSE wall adjacent to Bristol Plaza.
• Continued installing drainage pipe along southbound I-95, northbound I-95 and CD Roadway.
• Started placing subbase and asphalt treated base course northbound/southbound I-95 south of Ford Road.
• Began placing concrete pavement southbound I-95 from Ford Road to southbound off-ramp to Route 413.

April 2017

• Erected structural steel girders for southbound I-95 flyover bridge Unit 1.
• Installed overhangs and stay in place forms for southbound I-95 flyover bridge Unit 2.
• Constructed intermediate diaphragms for southbound I-95 flyover bridge Unit 2.
• Continued drilling/installation of soldier pile retaining wall for northbound I-95.
• Continued installing MSE wall panels and stone backfill along CD roadway, east/west walls, north of abutment.
• Continued excavating and setting of precast panels for MSE wall along CD roadway, south of abutment.
• Continued placing embankment for northbound I-95 MSE wall adjacent to Bristol Plaza.
• Continued installing MSE panels for northbound I-95 MSE wall adjacent to Bristol Plaza.
• Continued excavating and grading storm water basins adjacent to northbound I-95.
• Continued installation of drainage pipe along southbound I-95, northbound I-95 and CD Roadway.
• Excavated and graded northbound roadway from on ramp to northbound I-95.

March 2017

• Erected precast bulb tee beams for southbound I-95 flyover bridge Unit 2.
• Began erection of structural steel girders for southbound I-95 flyover bridge Unit 1.
• Started drilling/installation of soldier pile retaining wall for northbound I-95.
• Installed MSE wall panels and stone backfill along CD roadway, east/west walls, north of abutment.
• Excavated MSE wall foundation along CD roadway, south of abutment.
• Continued placing embankment for northbound I-95 MSE wall adjacent to Bristol Plaza.
• Continued installing MSE panels for northbound I-95 MSE wall adjacent to Bristol Plaza.
• Continued excavating and grading storm water basins adjacent to northbound I-95.
• Continued installation of drainage pipe along southbound I-95, northbound I-95 and CD Roadway.
• Graded and paved remaining northbound I-95 roadway.

January/February 2017

• Continued construction of pier substructures for southbound I-95 flyover bridge.
• Began foundation excavation of MSE wall, north.
• Installed MSE wall panels and stone backfill along CD Roadway, north.
• Placed MSE wall foundation along CD roadway, south.
• Placed embankment for northbound I-95 MSE wall adjacent to Bristol Plaza.
• Installed MSE panels for northbound I-95 MSE wall adjacent to Bristol Plaza.
• Excavated and graded storm water basins adjacent to northbound I-95.
• Started clearing/grubbing and corresponding E&S measures for northbound I-95.
• Continued installation of drainage pipe along southbound I-95, northbound I-95 and CD Roadway.
• Rubblized northbound I-95 roadway.

November/December 2016

• Completed construction of abutment substructure for southbound I-95 flyover bridge.
• Continued construction of pier substructures for southbound I-95 flyover bridge.
• Started building MSE Wall panels along northbound I-95 adjacent to the Bristol Plaza.
• Started building MSE Wall panels along CD Roadway.
• Began grading subbase along southbound I-95.
• Placed concrete pavement of southbound I-95 off-ramp to PA 413.
• Continued installation of drainage pipe along southbound I-95, northbound I-95 and CD Roadway.
• Began placing embankment and backfill adjacent to MSE Walls.
• Installed High Mast Lighting.
• Implemented Stage 2 modified traffic switch and traffic switch at PA 413 ramps.

September/October 2016

• Paved bituminous permeable base course and paved concrete of southbound I-95 SB widening and Route 413 entrance ramp.
• Built stormwater basins and sediment traps.
• Completed placement of embankment behind Bristol Plaza.
• Continued installation of drainage pipe along southbound I-95 and CD Roadway.
• Continued construction of pier substructures for southbound I-95 Flyover Bridge.
• Built south abutment foundation and wall substructure for southbound I-95 Flyover Bridge.
• Started excavation of foundation and construction of concrete leveling pads for west MSE Wall.
• Completed temporary shoulder widening for southbound I-95 roadway.

August 2016

• Continued driving piles at pier foundations for southbound I-95 flyover bridge.
• Continued construction of abutment and pier substructures for southbound I-95 flyover bridge.
• Continued excavation and preparation of foundation for MSE Wall for CD Roadway.
• Started excavation of E&S Basins behind Bristol Plaza and adjacent to northbound I-95 roadway.
• Continued installation of drainage pipe along southbound I-95 and CD Roadway.
• Continued placement of embankment fill for retaining wall and under southbound I-95 flyover bridge behind Bristol Plaza for northbound I-95.
• Continued constructing remaining portion of new pavement for Route 413 on-ramp.
• Removed existing concrete pavement along southbound I-95 and Route 413 on-ramp.
• Installed High Mast foundations and pulling wire for high mast lighting.

July 2016

• Continued driving piles at pier foundations for southbound I-95 flyover bridge.
• Started construction of abutment and pier substructures for southbound I-95 flyover bridge.
• Continued excavation of E&S Basins and installation of drainage pipe.
• Continued placement of embankment fill for retaining wall along northbound I-95.
• Began constructing second half of concrete pavement for Route 413 on-ramp.
• Extended sanitary sewer pipe under south and north sides of I-95 widening and tested sewer.
• Started slope excavation for CD Roadway.

June 2016

• Started driving piles at pier foundations for southbound I-95 flyover bridge.
• Continued building pier substructures for southbound I-95 flyover bridge.
• Continued excavation of E&S Basins and installation of drainage pipe.
• Began placement of embankment fill for retaining wall.
• Began placement of concrete pavement for Rt. 413 on-ramp.
• Started by-pass pumping and extension of sanitary sewer pipe under I-95 widening.

May 2016

• Continued building pier substructures for southbound I-95 flyover bridge.
• Initiated clearing and grubbing of southbound I-95/CD roadway widening.
• Shifted northbound/southbound I-95 traffic onto temporary bituminous median widening.
• Started building of E&S Basins and installation of drainage pipe.
• Started placement of embankment fill for CD roadway
• Started placement of asphalt treated base course in preparation of concrete pavement for Route 413 on-ramp.
• Continued jacking operation for extending sanitary sewer pipe under I-95.

April 2016

• Completed installation of temporary pavement and shifted traffic to Stage 1 northbound and southbound I-95.
• Continued building pier substructures for southbound I-95 flyover bridge.
• Initiated clearing along southbound I-95 to provide for widening work zone.
• Started placement of new storm water drainage pipe along southbound Route 413 on ramp.
• Completed jack/bore of 72” and 54” drainage pipe under I-95.

January/February/March 2016

• Completing installation of Intelligent Transportation System (ITS) fiber/electrical conduit under the I-95 median.
• Started building pier substructures for the southbound I-95 flyover bridge.
• Placed temporary barrier and temporary paving for left side widening on northbound I-95 roadway.
• Placed temporary barrier and temporary paving for left side widening on southbound I95 roadway.
• Used jack/bore method to install drainage pipe under I-95.
• Completed open cut drainage pipe adjacent to southbound I-95.

November/December 2015

• Maintenance and Protection of Traffic (MPT) initiated for Pre-Stage 1.
• Completed clearing and grubbing for work behind Bristol Plaza.
• Started installation of bridge foundation piles for the new southbound flyover structure.
• Started installation of new drainage facilities along I95 southbound at the Route 413 on-ramp.
• Started installation of new ITS fiber in the median of I95.

September/October 2015

• Maintenance and Protection of Traffic (MPT) initiated for Pre-Stage 1.
• Started clearing and grubbing for work behind Bristol Plaza.