Sponsored by United States Steel, this film examines a major deck replacement project on the George Washington Bridge undertaken by the Port Authority of New York and New Jersey in 1977-78. The bridge is described as the world’s most heavily traveled bridge, and opened in 1931, with over 1.6 billion vehicles having crossed it through 1977. It documents a $37 million project necessitated by wear, and to accommodate the significant traffic volume. The replacement process involved a lot of innovation, with new orthotropic steel panels and segmented construction employed to maintain traffic flow. Significant coordination was required between day and night work routines to minimize disruption; in the end the bridge remained functional for both local commuters and the broader metropolitan area.

00:00 The George Washington Bridge is maintained by the Port Authority of New York and New Jersey to enhance commerce in the Port District. 0:52 – The bridge serves as a northern bypass around Manhattan, crucial for metropolitan transport. 1:00 – A $37 million project was initiated to replace the upper level deck. 1:13 – Originally built with six lanes, the bridge now accommodates 14 lanes, with 80 million vehicles annually. 1:30 – The upper level deck replacement was a significant challenge to maintain traffic flow. 1:41 – The bridge’s original design anticipated traffic increases. 2:02 – Historical footage shows the daring work of original steel workers, though safety has since improved. 2:19 – The construction process includes erecting towers, spinning cables, and installing the roadway. 2:31 – Coordinated work between land and river teams was necessary for installing main floor beams. 2:50 – The deck replacement plan allowed for traffic during peak hours using segmented construction. 3:16 – The original deck withstood heavy use and weather effects for 46 years but deteriorated significantly by the 1970s. 3:32 – Major repairs since 1961 led to the decision for a full deck replacement. 4:02 – New criteria for the deck included improved wear, longevity, and minimal maintenance. 4:43 – A test program in 1974 tested pre-fabricated orthotropic steel panels for replacement. 5:02 – Delamination issues were discovered during these tests. 5:11 – Orthotropic panels were stiffened with ribs and various asphalt surfaces tested. 5:26 – The final design used prepped orthotropic modules for quick installation. 5:43 – Each module could replace a 160x44t bay overnight, maintaining traffic flow. 6:05 – Modules were sealed with neoprene compression seals to manage expansion and contraction. 7:05 – Fabrication was handled by Carl Kotch Erecting Company in Carteret, New Jersey. 7:19 – Fabrication involved high-strength, maintenance-free A588 weathering steel. 7:41 – Assembly line fabrication included lifting plates with vacuum pads and automatic welding. 9:49 – Over 200 miles of welding and thousands of holes punched were part of the process. 10:43 – Milling ensured precise panel dimensions. 11:05 – Panels were modified for drainage and pavement constraints. 12:10 – Quality checks included deflection tests and surface preparation for pavement adhesion. 13:15 – A special asphalt concrete was chosen 14:15 – Nightly operations involved removing old deck sections and installing new modules. 15:06 – Installation was split into day and night routines 17:11 – Nighttime work included traffic rerouting and actual deck replacement in phases. 18:09 – Traffic control was crucial for safe two-way flow during construction. 19:01 – The deck replacement was executed in four phases: saw cutting, removal, temporary support, and new panel installation. 21:00 – Steel cleaning and painting were critical for new installations. 23:45 – The process ensured minimal disruption, with the new deck installed within schedule. 26:16 – This project showcased an effective method for bridge deck replacement.

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This film is part of the Periscope Film LLC archive, one of the largest historic military, transportation, and aviation stock footage collections in the USA. Entirely film backed, this material is available for licensing in 24p HD, 2k and 4k. For more information visit http://www.PeriscopeFilm.com