ARDOT Tests Modular Bridge Construction on Highway 77 Replacement

Unlike traditional bridge projects where most components are built on site, the new structure was assembled using prefabricated elements manufactured off site and delivered ready for installation.

According to project officials, the primary advantage of the modular bridge system is speed. Bridge components, including the abutments, are produced in advance, eliminating much of the time typically required for forming and pouring concrete structures in the field.

"If we came in here and formed up the abutments and the deck and the superstructure units, that might take two to three times as long," Kevin Weston, Assistant Division Head of Bridge Operations of ARDOT explained.

The accelerated construction process is expected to benefit motorists across northeast Arkansas by reducing the duration of road closures. Officials said the bridge can be replaced in a matter of weeks rather than the months or years often associated with conventional bridge replacement projects.

The project is also serving as a testing ground for new materials. Engineers are evaluating the use of galvanized reinforcing steel as an alternative to traditional epoxy-coated reinforcement.

Project engineers noted that when epoxy coatings are damaged, corrosion can begin at the exposed location, potentially leading to concrete deterioration and eventually potholes or structural defects. Galvanized reinforcement is expected to provide a more durable solution because the galvanizing layer can continue to protect the steel even when minor surface damage occurs.

Beyond the construction method and materials, the project marks an important milestone for ARDOT itself.

Between the 1940s and 1980s, the department constructed nearly 4,000 bridges on Arkansas's state highway system. However, after decades of relying primarily on contractors for new bridge construction, ARDOT crews are once again playing a direct role in building a bridge from the ground up.

For many employees, the project represents an opportunity to gain hands-on construction experience rather than focusing solely on bridge maintenance.

Team members involved in the project described a sense of pride in participating in every stage of the process, from initial planning through to construction, while developing a deeper understanding of what it takes to deliver a bridge project from start to finish.

ARDOT officials said the bridge replacement demonstrates more than just a faster construction schedule. They view the project as an example of innovation, efficiency and collaboration across multiple divisions within the department.

With construction progressing on Highway 77, the project is providing Arkansas transportation officials with valuable experience in modular bridge construction while potentially establishing a model for future bridge replacements across the state.