TXDOT IH635 Accelerated Bridge Construction

In August 2020, SEMA Construction proudly delivered the I-635 Accelerated Bridge Construction (ABC) project over Seagoville Road in Balch Springs, Texas. This innovative endeavor marked the TXDOT’s first implementation of the ABC method, revolutionizing efficiency and construction standards in the state. The project’s primary goal was to replace two aging 50-year-old bridges on I-635 while minimizing traffic disruptions on this critical corridor, which serves an estimated 142,000 to 154,000 daily drivers, including 11% large truck traffic.

Utilizing the ABC approach, bridge components were fabricated offsite, significantly expediting the construction process. Each bridge was constructed using 15 prefabricated sections, with dimensions of up to 105 feet in length, 70 feet in width, and weighing approximately 250,000 pounds with railing included. Over two weekends, one direction of the highway was fully closed to allow for the demolition of the existing structures and installation of the new sections. This process minimized onsite construction time from months to mere days, greatly reducing public inconvenience.

The project was completed on schedule within the $9.2 million budget, with early finish incentives raising the total value to $9.4 million. By successfully delivering Texas’s first ABC project, SEMA Construction set a precedent for future infrastructure improvements in Texas, showcasing expertise in advanced construction methods, commitment to public safety, and reliability in meeting critical timelines.

Selling Points

• First ABC project implemented by TxDOT.
• Reduced onsite construction time from months to days.
• Traffic disruptions were strategically minimized on a major urban highway corridor.

Major Achievements

• Successful delivery of Texas’s first Accelerated Bridge Construction project.
• Completion within budget and ahead of schedule, achieving early finish incentives.
• Effective coordination of full highway closures and rapid bridge installation over two weekends.