In 1928, a cantilever steel truss bridge (Goethals Bridge) was constructed by the Port Authority of New York and New Jersey to carry four lanes of traffic. About 90 years later, that bridge was retired and replaced by a pair of cable-stayed bridges.
Freyssinet was contracted to supply materials and equipment for the cable installation on the new bridges and to demolish the suspended span of the old structure.
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OwnerPort Authority of NY & NJ
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LocationStaten Island, NY + Elizabeth, NJ
Stay Cable System Installation
From December 2014 to July 2018, Freyssinet played a critical role in the Goethals Bridge project, supplying a range of essential materials, including specially coated strands, meticulously engineered stay ducts, advanced dampers, and specialized equipment required for the precise installation of stay cables. We were contracted by the general contractor Kiewit-Weeks-Massman to carry out this work.
Highly skilled Freyssinet technical assistants supervised the entire installation process, ensuring that all 72 stay cables were installed safely and efficiently.
In addition to their significant contributions to the construction of the new bridges, Freyssinet was also contracted by a separate subcontractor to execute the challenging task of lowering the suspended span of the old structure. This complex operation involved carefully maneuvering the span onto a barge for safe demolition, showcasing Freyssinet’s capabilities in managing intricate engineering tasks. Strand-jacks were used to lower the span from deck level to the barge over a 24-hour period.
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31Smallest Stay Unit Strands
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91Largest Stay Unit Strands
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36Number of Stays
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450Feet of the Longest Stay
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268Feet of Pylon Height
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672Feet of Main Span Length
Lowering of Goethals Bridge
With the new pair of Goethals bridges slowly taking shape, the 90-year-old span which connected Staten Island, NY to Elizabeth, NJ was to be demolished. Since the center span was structurally suspended from the steel trusses, strand-jacks were used to slowly lower the span onto a barge by 138 feet.
Freyssinet and Hebetec supplied the lifting equipment, material, and technical assistance needed to install the system and complete the lowering operation of the 1,400-Ton structure.
After about a year of engineering work and a few weeks of pre-lowering site preparation, the bridge load was taken up by the jacks, and the contractor made cuts in the columns supporting the suspended span. One Freyssinet/Hebetec technician was positioned on each side of the structure and operated the equipment while monitoring forces and displacement.
Constant radio contact and sensor monitoring ensured that the bridge maintained tight tolerances in multiple directions during the operation.
Freyssinet and Hebetec were contracted by the general contractor, R.E. Pierson, to carry out the lowering from July 2017 to February 2019.
Goethals Bridge Stay Cable Inspection
Since the bridge’s replacement in 2018, the Freyssinet team has been conducting the inspection and maintenance work for the general contractor, NYNJ Link, due to their expertise and long-standing history with the structure.
They supplied a recommended Stay Cable Inspection and Maintenance Manual that was adopted by the owners, and all inspection and maintenance work has been performed in accordance with the manual throughout the previous inspection cycles.
Freyssinet’s work includes inspecting:
- Lower steel frames
- Top/bottom anchorages
- Internal hydraulic dampers
This maintenance program increases the durability of each individual element of the stay cables. Routine maintenance and repairs are provided and facilitated by an inventory of identified “wear” parts. Freyssinet offers incorporated inspection software, resulting in a clear and concise documentation package and efficient recording and analysis of inspection findings.
From supplying and installing stay cable systems with precision to safely lowering the suspended span of the 90-year-old bridge, Freyssinet demonstrated our ability to tackle complex challenges with innovative solutions and technical excellence. In addition, our ongoing inspection and maintenance efforts ensure the durability and performance of the stay cables, reinforcing the bridge’s safety and longevity for years to come.
Freyssinet is proud to have contributed to the modernization of a vital connection between Staten Island, NY, and Elizabeth, NJ.
Heavy Lifting Solutions
Cable Systems
Heavy Lifting Solutions
Cable Systems
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