Transportation: Bridges

In 1972, O’Connell had provided electrical construction services on the former Troup-Howell Bridge for a major lane expansion initiative. Thirty-five years later we were back on location providing electrical construction services for lighting the new bridge. O’Connell aided field engineers in interpreting the electrical plans for the bridge’s innovative accent lighting system and worked closely with the general contractor and New York State DOT to satisfy all electrical objectives. The final results speak for themselves.

Under a $5 million sub-contract from Crane-Hogan Structural Systems, O’Connell Electric provided all electrical construction and data communications work for the new bridge’s power and control systems, highway approach lighting, bridge accent lighting, security systems, and area traffic control signals.

O’Connell’s electrical work for bridge power and control systems was critical for operational reliability.  The drive in each of the bridge’s bascule leaves consists of interconnected dual electric motors.  Standby power for all bridge systems was supplied by an auto-start diesel generator.  The control system allows semi-automatic operation of the drive system via a programmable logic computer.

O’Connell’s fiber optics work included design and installation of two-72 strand submarine cables installed under the river bed, alongside the electric, which linked bridge and highway CCTV systems, several traffic signal controls, a local water and wastewater plant, and controls for future area needs.

The computer controlled accent lighting system O’Connell installed incorporates several service levels spanning “Standard” to “Full Ornamental” for special events.

O’Connell is no stranger to large-scale international bridge rehabilitation projects. Our portfolio includes the Thousand Islands Bridge and The Peace Bridge, which is the second busiest boarder crossing between the U.S. and Canada. Under a $3 million contract from the American Bridge Company, O’Connell was tasked with replacement and upgrade of all bridge electrical and communications infrastructure. The new two-conduit raceway system we installed spans the full 7385 foot length of the bridge, one conduit carrying wire and cable for bridge functionality, the other for future international communications. O’Connell installed newly engineered dehumidification systems into sealed vaults, where the bridge stay cables are anchored, as part of the bridge’s comprehensive corrosion protection system. We also installed all new street, bridge, and navigational lighting for the project.

The majority of electrical work and installations needed to be accomplished underneath the bridge’s surface. Demonstrating versatility and adaptability in a challenging construction environment, O’Connell researched, rented, purchased, and modified specialized equipment that enabled our technicians, and other trades, to access work areas from the topside of the bridge. With workmen suspended 100 feet, or more, over water and land during the construction period, job site safety and worker fall protection were an utmost priority. O’Connell demonstrated exceptional safety performance throughout the eighteen-month duration of the project with no reported safety incidents or injuries.

On a project of this magnitude, numerous obstacles and challenges present themselves that could not have been anticipated when bidding the work. O’Connell exhibited both the character and industry leadership qualities we are known for by managing each issue that arose and meeting all project completion schedules.

O’Connell Electric is one of a select few electrical contractors in the country qualified to bid on this type of work. Norfolk Southern awarded our Transportation Division contracts totaling $5.9 million to rehabilitate the electrical and operating systems of the four bridges—rail and waterway—and upgrade them for remote control operation from a central site. O’Connell coordinated and supervised all machinery replacements for the bridges including new motors, brakes, span locks, and switches as well as installation of new generator platforms and numerous structural repairs.

Innovative project management and construction measures were key to O’Connell’s success and efficiency across the four remote bridge sites. A combination of well-planned prefabrication measures and deployment of custom fabrication trailers fully outfitted with tools and office communications greatly reduced lost job site time. O’Connell ingenuity was responsible for onsite rigging and hoisting systems as well as machinery and equipment replacement practices that eliminated the need for employing barges and cranes or for necessitating marine and rail traffic interruptions. In one instance we were able to place a 4000-pound 125KW generator through a machine room floor hatch more than 100 feet off the ground and rig it over the top of existing equipment within a one-hour rail traffic window.

When centralization of bridge remote operational systems was changed from Norfolk Southern’s Birmingham control center to the Decatur, Alabama, Norfolk Southern Tennessee River Bridge site, O’Connell designed and implemented all necessary modifications and additions for the site including new buildings and building amenities, service and power generation systems, and expanded electrical and communications infrastructures. Working closely with our IT subcontractor, O’Connell developed data logging systems across the four bridge network with remote access capabilities, via Norfolk Southern’s intranet, allowing instant review of all bridge operational data for  diagnosing potential faults and to determine override measures in emergency situations.

Norfolk Southern’s Signals and Communications divisions contracted with O’Connell later in the project to design and construct a series of new signal and communications buildings, electrical and data wiring, and camera, intercom, and antennae systems.

All work for the four bridge project was completed on time and without disruption to marine or rail traffic. O’Connell has also worked on Norfolk Southern projects in Ohio and Chicago.