THE CONCRETE BRIDGE MAGAZINE

WINTER 2008

ASPIRE is a quarterly magazine published by PCI in cooperation with the associations of the National Concrete Bridge Council. The editorial content focuses on the latest technology and key issues in the Concrete Bridge Industry.

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36 | ASPIRE , Winter 2008 In July of 2003, PCL Civil Constructors Inc. (PCL) was the low bidder on a $ 4 6 m i l l i o n l u m p s u m d e s i g n - build contract for the Ernest F. Lyons Bridge Replacement project in Stuart, Florida. The main scope of this Florida Department of Transportation (FDOT) project was the construction of a new high-level segmental bridge over the Intracoastal Waterway in Martin County, Florida. The project site is located on Florida's East Coast, approximately 45 miles north of West Palm Beach. The new Ernest F. Lyons Bridge is a 4600-ft-long, 31-span, two-lane, precast segmental bridge built using the span- by-span method of construction. With the exception of the first span, which is 100 ft long, all spans are 152 ft in length. Typical segments were 10 ft long, 10 ft deep and 61 ft wide and weighed approximately 80 tons. Pier segments were split into two half-segments, each 5 ft long, to reduce their weight for handling. A typical span consisted of 15 precast segments that were post- tensioned together using ten 19-strand tendons. Five tendons ran along each web wall. The spans were subsequently made continuous into six-span units. The 32 foundation units for the segmental bridge used between ten profile ErnEsT F. Lyons BridgE rEpLacEmEnT / StuARt, Flo RIdA DESIGN E NGINEER : Parsons transportation Group, Jacksonville, Fla. P EER R E vIE w E NGINEER: Corven Engineering, tallahassee, Fla. P RIME CONTRACTOR: PCl Civil Constructors Inc., tampa, Fla. R EADy MIx CONCRETE: tarmac, West Palm Beach, Fla. P OST-T ENSIONING: VSl, Springfield, Va. SUBSTRUCTURE FORMwORK: Symons Corporation, des Plaines, Ill. AwArds: Florida Transportation Builder's Association "Best in Construction" award in the Major Bridge Category and an award of excellence from the Design-Build Institute of America (DBIA) ERNEST F. LYONS BRIDGE The Ernest F. Lyons replacement bridge is a 4600-ft-long, 31-span, precast segmental bridge built using the span-by-span method of construction. Photos: Jim Schneiderman, PCL. The project was completed within budget and more than 8 months ahead of schedule. 10973_ASPIRE_win08.indb 36 12/12/07 3:32:04 PM

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