NJ Route 440 Multi-Span Bridge Construction

Complex deck replacement and rehabilitation of multi-span bridges in New Jersey

Our Client’s Challenge

NJ 440 is an expressway connecting the Garden State Parkway (GSP), U.S. Route 9, and Interstate 287 to the Outerbridge Crossing at the New York-New Jersey state line. NJ 440 is a critical transportation link in one of the nation’s most extensive roadway corridors, connecting vehicular traffic for more than 20 million residents of the New York City metropolitan area.

In 1972, a massive interchange between NJ 440, I-287, the New Jersey Turnpike, and GSP—locally known as “Spaghetti Junction”—was opened to traffic. However, in the half-century since its opening, the interchange’s decks were in poor condition, and many bearings showed signs of corrosion.

Our Solution

Gannett Fleming’s services included final engineering design and construction services to the New Jersey Department of Transportation (NJDOT) for bridge deck replacement and rehabilitation of several multi-span bridges of the NJ 440 interchange in Woodbridge Township, Middlesex County, New Jersey.

During the construction phase, we provided additional engineering design services. As the project’s magnitude grew, structural elements of the bridge spans presented new challenges. For example, changing the maintenance of traffic requirements needed deft handling of the prime contractor’s plan to keep timelines intact.

Initially scoped as requiring some bearing resetting and a few bearing replacements, water penetration through the deck joints on the NJ 440 bridges necessitated replacing all 140 bearings. Our team employed phased, accurate prediction models of lead times required by the manufacturers to maintain the project schedule.

Gannett Fleming also coordinated and performed:

Surveying/mapping.
Highway/traffic engineering.
Maintenance.
Protection of traffic plan.
Highway lighting.
ITS elements.
Community relations.
Construction cost estimates.

NJDOT required adequate traffic flows through the high-volume corridor by minimizing lane and road closures, especially during workday hours. The congested interchange required innovative approaches to minimize traffic impact and maintain control of the work area.

Through on-site visual inspections and detailed traffic analysis, our team determined that most of the NJ 440 traffic exits to the GSP southbound ramp just prior to the construction area, thereby requiring the closure of only two lanes in this short segment. This “extra” space allowed the contractor to efficiently build more structure while allowing commuters to move easily and safely throughout the work zone.

Key Features

Replaced deficient bridge deck.
Replaced deteriorated bearings.
Rehabilitated aged substructure units.
Replaced collision-damaged steel superstructure components.
Replaced bridge railing and approach guide rail attachments.
Replaced and upgraded under-bridge lighting.
Relocated intelligent transportation system (ITS) conduits.
Milling/resurfacing within the project limits.

Outcomes

Extends service life of the bridge by at least 50 years.
Maintains adequate levels of traffic flows by minimizing lane and road closures.
New bridge deck, bearings, substructure units, railings, lighting, and approach slabs.