Michigan Governor Announces First Steel Bridge in Bundling Project Open to Traffic

Photo Credit: Valmont Structures (Fabrication of the Bentley Street Bridge – Lapeer, Michigan)

In a press release, Michigan Governor Gretchen Whitmer announced that the first bridge in a major bundling project has been replaced and reopened to traffic in Lapeer.

The Bentley Street bridge in Lapeer opened to traffic on April 29, 2022. The bridge is the first structure repaired under the Michigan Department of Transportation bridge bundling program. (Photo by OHM Engineers)

The Bentley Street Bridge, fabricated by Valmont Structures, is a press-brake-formed steel tub girder (PBTG) bridge and is the first of 19 PBTG bridges included in the bundling project. By bundling bridge projects under one contract, states can save costs by streamlining coordination and permitting, increasing economies of scale, and improving bridge conditions on local routes.

Through the Short Span Steel Bridge Alliance (SSSBA), AISI kicked off the PBTG initiative in response to a challenge from the Federal Highway Administration to provide a cost-effective and rapid installation steel bridge solution for repairing the nation’s infrastructure.

Dr. Karl Barth of West Virginia University led a team organized by the SSSBA that initiated the PBTG system. Dr. Barth and Dr. Greg Michaelson, P.E. of Marshall University conducted extensive research on this new bridge technology, which was funded by members of the American Iron and Steel Institute.

The first PBTG bridge was built in 2015. Today, PBTG bridges have been installed in 12 states and Michigan DOT took it to the next level by using the PBTG system for its 19-bridge replacement project.

Dr. Barth said, “We are honored to see how rapidly this system has progressed from concept to commercial implementation. It is truly a testament to the strength of the team comprised of members of all facets of steel production and bridge delivery that were integrally involved in advancing this system.”

The Amish Sawmill Bridge was the first press-brake tub girder bridge installed in the U.S. and considered by experts to be the future of short span steel bridge design.

Project Moved Quickly, Met Timelines Efficiently

Steel met the challenge to provide a cost-effective solution that could be fabricated, delivered, and installed efficiently.

“Major repairs are ongoing on bridges across Michigan as we are continuing to fix the damn roads to keep drivers safe and save them time and money,” said Governor Whitmer. “We’re fixing our roads and bridges with the right mix and material, so they stay fixed.”

“We’re very happy with the bridge,” said Jeff Graham, Lapeer’s director of public works. “I drove across it every day before it was closed for repairs, and it looks great now compared to what it did before.”

Graham said the project moved along quickly once it started and the contractors met their timelines efficiently. Overall, he’s enthusiastic about the program going forward.

Matthew Chynoweth, P.E., Chief Bridge Engineer of the Michigan DOT, credited the entire design-build team for their work on the project. This includes the contractor (C.A. Hull), consultant (Alfred Benesch & Company), and fabricator (Valmont Structures).

“I extend my sincerest thanks to you, and the partnership we’ve forged to ensure the success of our pilot bundle program,” said Chynoweth. “You guys really delivered, keep it up.”

Follow the Progress of the Project

Six bridge bundling projects started in March and April. All of the bridges encompassed by the program will be completed and reopened to traffic within 60 or 90 days from the start of repairs.

The project is funded by Federal Highway Improvement Program (HIP) dollars. MDOT bridge staff and consultants are doing preliminary design and construction administration work for the bridge bundling program.

Follow the progress of the project in real-time with MDOT’s ArcGIS Online

MDOT’s ArcGIS Online provides an interactive mapping platform that helps visualize department data, analyze patterns, track assets, and strengthen transportation planning efforts across the state. See updated map.

Phase II to Address 59 More Bridges

$196 million in federal COVID relief funds appropriated by Governor Whitmer and the Legislature will allow the state to execute Phase II of the bridge bundling program, beginning later in 2022, to address 59 more bridges.

MDOT expects bridge bundling, which covers several bridge locations under one contract, to streamline coordination and permitting, increase economies of scale, and improve bridge conditions on local routes around the state. MDOT is working to expand the approach, already in use on state trunkline projects, to address locally owned bridges.

Hot-dip galvanized press-brake tub girders provide over 75 years of maintenance-free protection. (Photo Credit: Valmont Structures)

PBTG Bridges Provide Over 75 Years of Maintenance-Free Protection

Press-brake formed steel tub girders have been independently researched and tested to deliver proven performance. The bridge system allows for a variety of installation and superstructure options, reduces time in the field, and comes hot-dip galvanized to provide over 75 years of maintenance-free protection.

The girders meet all AASHTO and LRFD requirements and have been used and approved for both state DOT- and FHWA-funded projects. In fact, press-brake formed tub girders were selected for the 2021 AASHTO Innovation Initiative, which will be helping to implement this market-ready product nationwide.

In 2023, Guy Nelson and Jeff Simkins (Valmont) presented an overview of press-brake tub girders to members of the Colorado LTAP
(video provided courtesy of Colorado LTAP)

For more information about Valmont Structures, contact Guy Nelson:

Guy Nelson, PE, SE
Business Development Director – North American Structures
Valmont Industries, Inc
28800 Ida Street
Valley, NE 68064
Tel: (616) 813-8514
Guy.Nelson@valmont.com