Department of Transportation


This view is a close up of the formwork installed for the concrete pier caps. The formwork is temporarily anchored to the pier and must support the concrete while it's still in its fluid form. After the concrete for the pier cap hardens and develops sufficient strength, the forms and anchors are removed.

This view is of the end of a completed pier showing the pointed edges of the column. The similarity to the existing bridge pier columns geometry and size can be seen in the background.

This view is looking towards the mainland on the westernly end of the bridge. It was taken from the top of Pier 11 which is two spans away from the navigation channel and the center of the bridge. It shows the on-going pier construction.

This view is of the completed pier columns and pier caps near the easterly end of the bridge (taken from the top of Pier 11). The similarity to the existing bridge pier column geometry and size can be seen on the left.

Galvanized reinforcement steel for the pier column previously assembled on the temporary trestle bridge is lifted into place by a crane. Once all the reinforcement steel is installed and tied together, concrete formwork is installed and the concrete for the piers is poured.

The reinforcement steel and formwork is all set for the pier shown and a concrete pumping truck is on site to pour the concrete needed to create the pier cap. After the concrete is poured, hardens and reaches an acceptable strength, the forms can be removed revealing the concrete structure.

The footing for the westerly abutment has been formed out and concrete is in the process of being poured. Reinforcement steel for the abutment's bridge seat and wall elements can be seen extending above the concrete forms to create the connection to the footing.

The bridge seat for the westerly abutment has been formed and poured. The northern portion of the abutment bridge seat has gained the strength needed so that the forms can be removed. The rest of the forms will remain in place until the concrete reaches the strength and age required to be self-supporting.

This view shows the interior of a steel cofferdam for a water pier. Tremie seal concrete was placed within the cofferdam to keep the work zone dry and stable. Six steel pipe pile casings are the formwork for the reinforced concrete caissons and extend above the concrete seal. Crosshole sonic logging tubes extend out of the steel casings and verify the structural integrity of the concrete caissons at depths of more than 80 feet below ground. Sonic pulses are generated and received throughout the length of the caissons to provide the concrete caissons condition.

Workers erect the galvanized reinforcement steel cage before pouring concrete for the pier columns. The columns are founded on the pier's footing below which is inside the water-tight steel sheet pile cofferdam. The steel rebar cage conforms to the shape of the pier columns and adds strength and ductility to the column.

The construction of the pier cap reinforcement steel cage is on the right of the temporary construction bridge near the top of the photo. The pier cap is assembled on a barge independent from the primary construction structure so that large cranes can travel along the path. After each pier cap reinforcement steel cage is complete, a crane will place it on top of the pier column. After all the reinforcement steel is secured in place, forms will be installed to hold the shape of the columns and the concrete can then be poured.

This view is of a completed galvanized reinforcement steel cage for the pier cap which was assembled on a barge adjacent to the pier. Crews check for proper alignment of the reinforcement steel prior to lifting the cage into place. After the top of the pier column concrete is poured and gains the appropriate strength, the beams and bearings will be mounted on top of the pier cap..

This is a top-down view taken from the existing Route 72 bridge of the reinforcement steel cage for a pier column. The pier columns range from 26 to 72 feet measured from the top of the footing to the top of the pier cap. The reinforcement steel for each pier must be carefully detailed and fabricated to ensure the column is built to the appropriate dimensions.

The interior of a steel cofferdam for one of the water piers with the tremie seal concrete bottom to keep the work zone dry and stable. Crews flame-cut a portion of the steel casing that was required for the construction of the concrete caisson foundations, but is not needed for the final structure.

After the casing for the concrete caissons have been removed to the proper elevation, crews place the bottom level of galvanized reinforcement for the concrete pile caps.

This view shows the completed galvanized reinforcement steel cages for one of the water piers placed within a steel cofferdam prior to pouring the concrete pile cap. The horizontal bars will extend out of the footing and into the column of the finished pier.

This view shows the contractor's temporary construction trestle bridge used a s a construction platform on the south side of the existing Route 72 Manahawkin Bay Bridge. Concrete is being delivered and placed for the concrete pile caps at one of the water piers.

A vibratory hammer is used to drive the steel casing through the upper layers of soil to faciltate the concrete caisson foundations. This casing is installed to help keep the soil out of the excavated areas which are cleared using a drill; the drilled holes will be filled with concrete to complete the caisson construction.

This view is of a reinforcement steel cage being delivered and prepared for installation into a concrete caisson. Work continues during adverse weather conditions to keep the project on schedule.

This view shows a drill in use. The drill is being lifted so that the excavated material can be cleaned, removed and work can progress effectively.

A reinforcement steel cage is being lifted into place and prepared for installation into a concrete caisson. The reinforcement steel increases the strength of the caisson and extends to the bottom of the element, approximately 80 feet below ground.

Last updated date: November 10, 2020 7:36 AM