I-64/I-77 Accelerated Bridge Deck Replacement

ORDERS Construction served as Lead Contractor for the West Virginia Parkways Authority’s (WVPA) accelerated bridge deck replacement on I-64/I-77 in Chelyan, West Virginia — the full-depth replacement of four mainline interstate bridge decks along a corridor carrying approximately 70,000 vehicles per day. The $46.9 million contract required all four decks to be replaced within 45-calendar-day windows using precast panels with parapets pre-placed, followed by ultra-high performance concrete (UHPC) for the haunch build-up and the transverse and longitudinal closure pours, all while maintaining two lanes of traffic in each direction.

All four structures fell within both a vertical and a horizontal curve. Working with the precast supplier, ORDERS reengineered the panel layout to follow the curvature while minimizing the number of unique panel sizes required — reducing fabrication complexity and protecting the accelerated placement schedule. The UHPC haunch build-up and closure pours allowed the precast system to be set, connected, and opened to traffic within the compressed windows the contract allowed. The project also included replacing 9,096 LF of concrete median wall with FHWA’s newer constant-slope barrier.

The site combined three concurrent third-party constraints that rarely occur together. Bridges 3074S and 3074N spanned Cabin Creek Road and Cabin Creek, requiring a temporary creek crossing and flagging of Cabin Creek Road throughout construction, while bridges 3073S and 3073N crossed a CSX Transportation spur line on which CSX permitted work only during six twelve-hour shifts per week. Reconciling the CSX and WVPA requirements demanded close coordination with the Owner and its engineering representative, HNTB, Inc., and drove the decision to split the work by season — the 3074 structures in the fall of 2024 and the 3073 structures in the spring of 2025.

ORDERS outperformed the schedule on both phases. The 3074 structures carried a 45-calendar-day requirement and were completed in 40 days, and the CSX-constrained 3073 structures, due June 10, 2025, were completed June 6, 2025. The full project — four interstate bridge decks and 9,096 LF of median barrier — finished days ahead of the contract completion date. With structures crossing a public road, an active CSXT rail line, and a major tributary of the Kanawha River, every operation required extensive coordination; managing all three conditions at once, on a high-volume interstate corridor, demonstrates the team’s ability to sequence complex bridge and roadway work while preserving mainline capacity.

Project Highlights

• Client: West Virginia Parkways Authority (WVPA)

• Engineering Representative: HNTB, Inc.

• Completion Date: August 2025

• Scope: Full-depth replacement of four mainline interstate bridge decks using precast panels with pre-placed parapets and UHPC closure pours; 9,096 LF of constant-slope median barrier

• Challenges:45-calendar-day deck replacement windows, CSX Transportation coordination limited to six twelve-hour shifts per week, creek and roadway crossings, vertical and horizontal curve geometry, and two lanes of traffic maintained in each direction on a 70,000 vpd corridor

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