Bridge projects with deep foundations like the Key Bridge Rebuild use various types of testing. Engineers first conducted dynamic testing on the piles using strain gauges and accel- erometers. Each time the yellow impact hammer strikes, the sensors collect real-time data. The devices measure how much load the pile can handle, how the pile holds up under pressure, and how the driving equipment performs. The data collected can also be used to adjust the driving depth and pile length. In late October, six more steel test piles arrived at the project site so engineers could continue driving. By late November, crews had driven all 12 test piles into the river.
“Every element of the design has been engineered with the highest safety standards.,” Harkness said. “There will be six piers that will have a rigid fender constructed around the foundation of the piers to meet and exceed the current stan- dards for federal requirements.” STATIC LOAD TESTING BEGINS In late November, the static load testing process kicked off. Static load testing is done to ensure a strong foundation for the new Key Bridge. Crews lifted a metal load test frame, weighing about 550,000 pounds on top of the test piles. The load test frame applies 10 million pounds of pressure on the main axial pile. During this process, crews set the load test frame on four reaction piles and test one pile at a time. “That information will inform our geotechnical engineers as to whether the pile is performing as we have assumed in the design,” said MDTA Director of Project Development Brian Wolfe. “It will confirm that we’ve got the load that we need to move ahead with the design and begin installing the piles.” LOOKING AHEAD TO 2026 The Key Bridge Rebuild team is achieving significant mile- stones with each passing month. The MDTA looks forward to completing demolition on land in early 2026 and and moving into the construction phase of the rebuild. “We are working day and night to expedite the delivery of a new bridge and we understand the impact the loss of the Key Bridge has had on the Baltimore region – including longer commute times,” Gartner said. “We’re in this together and we ask for your patience while we safely reconnect our communities.”
Rendering of new Key Bridge.
DESIGN MILESTONE In November, project engineers reached 70% on the new bridge design. At that point the MDTA Board was able to up- date their financial forecast to include the updated cost range and schedule estimates for the bridge project.
“The Key Bridge Rebuild achieved 70% design in 14 months compared to other projects that have averaged seven years, while also progressing construction,” said MDTA Exec- utive Director Bruce Gartner. “Typical transportation projects of this magnitude take years of planning before even beginning design and pre-construc-
“The Key Bridge Rebuild achieved 70% design in 14 months compared to other projects that have averaged seven years, while also progressing construction.”
tion activities – something that Maryland and MDTA has compressed down to months.” The updated cost estimate range and
schedule are tied to a robust pier protection system, designed to comply with federal guidelines and modern construction standards.
—MDTA EXECUTIVE DIRECTOR BRUCE GARTNER
MARYLAND TRANSPORTATION AUTHORITY 2025 ANNUAL REPORT 15
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